Wacker Neuson DT25 Track Dumper Service Manual - PDF DOWNLOAD

Service manual

Track dumper

Vehicle model

DT25

Edition

1.4

Language

en

Article number

1000279465

Documentation Title

Language

Order no.

Service manual

en

1000279465

Operator’s manual

en

1000268390

Spare parts list DT25

de/en/fr

1000273051

Spare parts list DT25

de/it/es

1000273052

Legend Issue

Published

1.0

08 / 2013

1.1

09/2013

1.2

06/2015

1.3

01/2017

1.4

04/2017

Copyright - 2017 Wacker Neuson Linz GmbH, Hörsching Printed in Austria All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.

This document may be used by the receiver only for the designated purpose. It may in no way be duplicated or translated into any other language, in whole or in part, without prior permission in writing from the manufacturer.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH. Violations of legal regulations, in particular of the copyright protection, will be subject to civil and criminal prosecution.

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 figures and descriptions in this documentation that do not reflect products that have already been delivered and that will not be implemented on these machines.

Technical data, dimensions and weights are only given as an indication. Responsibility for errors or omissions not accepted.

The cover features the machine with possible optional equipment.

Wacker Neuson Linz GmbH Flughafenstr. 7 A-4063 Hörsching Phone: +43 (0) 7221 63000 Fax: +43 (0) 7221 63000-2200 E-mail: office.linz@wackerneuson.com www.wackerneuson.com

Table of Contents

Table of Contents

Table of Contents I

Operation Information on this service manual ..........................................................................

Identification of warnings and dangers ....................................................................

Designated use and exemption from liability ...........................................................

Overall view of vehicle .............................................................................................

Brief description .......................................................................................................

Type labels and component numbers ......................................................................

Maintenance prop ....................................................................................................

1-1 1-2 1-3 1-4 1-5 1-6 1-8

Technical data Chassis .................................................................................................................... 2-1 Diesel engine ........................................................................................................... 2-1 Hydraulic system ..................................................................................................... 2-1 Chassis .................................................................................................................... 2-2 Operating hydraulics ................................................................................................ 2-2 Electrical system ...................................................................................................... 2-2 Swivel skip ............................................................................................................... 2-2 Front skip (option) .................................................................................................... 2-2 Noise levels ............................................................................................................. 2-3 Vibration ................................................................................................................... 2-3 Fuses ....................................................................................................................... 2-4 Dimensions model DT25 with swivel skip ................................................................ 2-5 Dimensions model DT25 with swivel skip and stabilizer blade (option) ................... 2-6 Dimensions model DT25 with front skip (option) ..................................................... 2-7 General tightening torques ...................................................................................... 2-8 Tightening torques for hydraulic screw connections (dry assembly) ................. 2-8 Tightening torques for high-resistance threaded fittings .................................. 2-10 Maintenance Fluids and lubricants ............................................................................................... 3-1 Maintenance plan DT25 ........................................................................................... 3-2 Introduction .............................................................................................................. 3-5 fuel system ............................................................................................................... 3-6 Specific safety instructions ................................................................................ 3-6 Refueling ........................................................................................................... 3-6 Drain fuel ........................................................................................................... 3-7 Stationary fuel pumps ........................................................................................ 3-7 Diesel fuel specification ..................................................................................... 3-7 Cleaning the filter cup/replacing the filter cartridge ........................................... 3-8 Bleeding the fuel system ................................................................................... 3-9 Engine lubrication system ...................................................................................... 3-10 Checking the oil level ....................................................................................... 3-10 Adding engine oil ............................................................................................ 3-11 Drain engine oil ................................................................................................ 3-11 Replacing the oil filter cartridge ....................................................................... 3-12 Engine and hydraulics cooling system ................................................................... 3-13 Specific safety instructions .............................................................................. 3-13 Checking the coolant level/adding coolant ...................................................... 3-14 Draining coolant ............................................................................................... 3-16 Cleaning the radiator ....................................................................................... 3-16 Air filter ................................................................................................................... 3-17 Replacing the filter ........................................................................................... 3-18 Hydraulic system ................................................................................................... 3-19 Specific safety instructions .............................................................................. 3-19 Checking the hydraulic oil level ....................................................................... 3-20

SHB DT25 en - Edition 1.4 * ShDT25en1_4IVZ.fm

I-1

Table of Contents Adding hydraulic oil .......................................................................................... 3-21 Drain hydraulic oil ............................................................................................ 3-21 Replacing the hydraulic oil filter cartridge ........................................................ 3-22 Replacing the cartridge of hydraulic oil intake filter ......................................... 3-23 Checking hydraulic pressure lines ................................................................... 3-25 Tracks .................................................................................................................... 3-26 Checking track tension .................................................................................... 3-26 Tightening the tracks ....................................................................................... 3-26 Decreasing track tension ................................................................................. 3-27 Traveling drive ....................................................................................................... 3-28 Checking the oil level and adding oil ............................................................... 3-28 Draining oil ....................................................................................................... 3-28 Electrical system .................................................................................................... 3-29 Specific safety instructions .............................................................................. 3-29 Servicing and maintenance at regular intervals ............................................... 3-29 Instructions concerning specific components .................................................. 3-30 Alternator ......................................................................................................... 3-30 Battery ............................................................................................................. 3-31 Battery master switch ...................................................................................... 3-32 Flashing headlight ............................................................................................ 3-32 General maintenance ............................................................................................. 3-33 Cleaning ........................................................................................................... 3-33 General instructions for all areas of the vehicle ............................................... 3-33 Exterior of the vehicle ...................................................................................... 3-34 Engine compartment ........................................................................................ 3-34 Threaded fittings and attachments .................................................................. 3-34 Pivots and hinges ............................................................................................ 3-34 Overview of grease nipples DT25 with swivel skip ................................................ 3-35 Overview of grease nipples DT25 with front skip (option) ...................................... 3-36 Test report DT25 .................................................................................................... 3-38 Engine Engine overview ....................................................................................................... 4-1 Checking and adjusting valve clearance .................................................................. 4-2 Checking and adjusting maximum engine speed .................................................... 4-4 Fan belts: checking tension and replacement .......................................................... 4-5 Checking the tension of the fan belt .................................................................. 4-5 Fan belt damage and wear and tear .................................................................. 4-6 Fan belt replacement ......................................................................................... 4-7 Engine malfunctions ................................................................................................. 4-8 Traveling drive Travelling drive pump DT25 ..................................................................................... 5-1 Legend: traveling drive pump DT25 ......................................................................... 5-2 Automotive valve DT25 ............................................................................................ 5-3 Pump diagram with variable displacement with automotive valve ..................... 5-4 Hydraulic motor ........................................................................................................ 5-5 Left control lever ...................................................................................................... 5-6 Solenoid valve for changeover of Drive control ....................................................... 5-7 Test instructions ....................................................................................................... 5-8 Checking travel pressure DT25 ......................................................................... 5-8 Checking straight-ahead vehicle travel .............................................................. 5-9 Checking: automotive valve DT25 ................................................................... 5-11

I-2

SHB DT25 en - Edition 1.4 * ShDT25en1_4IVZ.fm

Table of Contents Hydraulic system Gear pump for functions DT25 ................................................................................ 6-1 Right-hand control lever ........................................................................................... 6-2 Hydraulic control valve DT25 with swivel skip, front skip (option) ........................... 6-3 Check valve DT25 with swivel skip .......................................................................... 6-4 Solenoid valve for hydraulic PTO shaft (option) ...................................................... 6-5 Test instructions ....................................................................................................... 6-6 Checking the operating pressure of the operating hydraulics DT25 with swivel skip, front skip (option) ............................................................................................... 6-6 Checking boost pressure DT25 ......................................................................... 6-7 Hydraulics diagram DT25 with swivel skip and front skip (option) ........................... 6-8 Legend: hydraulics diagram DT25 with swivel skip and front skip (option) ............. 6-9 Hydraulics diagram DT25 with swivel skip, front skip and hydraulic PTO shaft (option) 6-10 Legend: hydraulics diagram DT25 with swivel skip, front skip and hydraulic PTO shaft (option) ................................................................................................................... 6-11 Hydraulics diagram DT25 with swivel skip and dozer blade (option) ..................... 6-12 Legend: hydraulics diagram DT25 with swivel skip and dozer blade (option) ....... 6-13 Electrical system Ohmic law (current, voltage, resistance); Power ..................................................... 7-1 Measuring equipment, measuring methods ............................................................. 7-1 Electric units ............................................................................................................ 7-2 Fuses ....................................................................................................................... 7-3 Instrument panel overview ....................................................................................... 7-4 DT25 diagram .......................................................................................................... 7-5 DT25 diagram (legend) ............................................................................................ 7-6 Engine wiring harness DT25 .................................................................................. 7-10 Instrument panel wiring harness DT25 (right) ........................................................ 7-11 Instrument panel wiring harness DT 25 (left) ......................................................... 7-12 Control unit wiring harness DT25 .......................................................................... 7-13 Chassis wiring harness DT25 ................................................................................ 7-14 Table of conductors DT25 ..................................................................................... 7-15

SHB DT25 en - Edition 1.4 * ShDT25en1_4IVZ.fm

I-3

Index

Index I

B

M

Biodegradable oil .................................................................................3-24

Maintenance Adding coolant .............................................................................. 3-14 Adding engine oil .......................................................................... 3-11 Adding hydraulic oil ...................................................................... 3-21 Air filter ......................................................................................... 3-18 Biodegradable oil .......................................................................... 3-24 Check the coolant level ................................................................ 3-14 Check the hydraulic oil level ......................................................... 3-20 Checking the engine-oil level ....................................................... 3-10 Cleaning ....................................................................................... 3-33 Engine lubrication system ............................................................ 3-10 Fluids and lubricants ...................................................................... 3-1 General maintenance ................................................................... 3-33 Hydraulic pressure lines ............................................................... 3-25 Hydraulic system .......................................................................... 3-19 Instructions concerning specific components ............................... 3-30 Maintenance plan ........................................................................... 3-2 Pivots and hinges ................................................................ 3-34, 3-35 Servicing and maintenance at regular intervals ........................... 3-29 Test report .................................................................................... 3-38 Threaded fittings ........................................................................... 3-34 Maintenance prop ................................................................................. 1-8 Manipulators .......................................................................................... 5-6 Maximum engine speed ........................................................................ 4-4

C Check valve DT25 with swivel skip ........................................................6-4 Checking Boost pressure DT25 ......................................................................6-7 Operating pressure for operating hydraulics DT25 .........................6-6 Straight-ahead vehicle travel ..........................................................5-9 Travel pressure DT25 ........................................................... 5-8, 5-11 Clean the filter cup .................................................................................3-8 Clean the fuel filter .................................................................................3-8 Cleaning the radiator ...........................................................................3-16 Control lever on the right .......................................................................6-2

D DT25 diagram ........................................................................................7-5

E Electrical components ............................................................................7-2 Electrical system ....................................................................................7-1 Engine overview ....................................................................................4-1 Engine wiring harness DT25 ................................................................7-10

F Flashing headlight ................................................................................3-32 Fuses .....................................................................................................7-3

G Gear pump for work operation DT25 .....................................................6-1

H Hydraulic distributor ...............................................................................6-3 Hydraulic motor ......................................................................................5-5 Hydraulics diagram DT25 with swivel skip and front skip (option) 6-8, 6-12

R Refueling ............................................................................................... 3-6 Replacing the cartridge of hydraulic oil intake filter ............................. 3-23 Replacing the filter cartridge ................................................................. 3-8 Replacing the hydraulic oil filter cartridge ........................................... 3-22 Replacing the oil filter cartridge ........................................................... 3-12

S

I

Solenoid valve for changeover of Drive control ..................................... 5-7

Indications On this service manual ...................................................................1-1 Instrument panel wiring harness DT25 ................................................7-11

T Technical data Noise level ...................................................................................... 7-5 Working hydraulics ......................................................................... 2-2 Traveling drive pump DT25 ................................................................... 5-1

V Valve clearance Checking and adjusting .................................................................. 4-2 Vehicle Overview ........................................................................................ 1-4

I-4

SHB DT25 en - Edition 1.4 * ShDT25en1_4SIX.fm

Operation

Operation

1 1.1

Operation Information on this service manual This service manual contains important information on how to work safely, correctly, and economically with the machine. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones. It helps to avoid hazardous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the Operator’s Manual.

Careful and prudent working is the best way to avoid accidents!

Operational safety and readiness of the vehicle do not only depend on your skill, but also on maintenance and servicing of the vehicle.

Insist on using original spare parts when performing maintenance and repair work. This ensures operational safety and readiness of your vehicle, and maintains its value.

Your Neuson dealer will be pleased to answer any further questions regarding the machine or the service manual.

Abbreviations/symbols • Identifies a list • Subdivision within lists or an activity. Follow the steps in the recommended order.

☞ Identifies an activity ➥ Description of the effects or results of an activity s. fig. (w/o. fig.) = without figure "Opt." = Optional Stated whenever controls or other components of the vehicle are installed as an option.

A combination of digits, or a combination of digits and letters, for example 40/18 or 40/A used to designate the control elements, means: Figure no. 40/control element no. 18 and/or position A in figure no. 40 Figures carry no numbers if they are placed to the left of the text.

SHB DT25 en - Edition 1.4* dt25b110.fm

1-1

Operation 1. 2

Identification of warnings and dangers Important indications regarding the safety of the personnel 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 cause injury or death for the operator or other persons.

☞ Measures for avoiding danger

Caution!

Failure to observe the instructions identified by this symbol can cause damage to the machine.

☞ Measures for avoiding danger for the vehicle

Notice!

This symbol identifies instructions for a more efficient and economical use of the vehicle.

Environment!

Failure to observe the instructions identified by this symbol can cause damage to the environment. The environment is in danger if environmentally hazardous material (waste oil, for example) is not subject to proper use or disposal.

1-2

SHB DT25 en - Edition 1.4 * * dt25b110.fm

Operation 1. 3

Designated use and exemption from liability • The vehicle is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble • Every other application is regarded as not designated. Wacker Neuson shall not be liable for damage resulting from this and the risk shall be fully borne by the user.

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 vehicle can be negatively affected by performing vehicle modifications without proper authority and by using spare parts, accessories and special equipment that have not been tested and released by Wacker Neuson. Wacker Neuson will not be liable for damage resulting from this.

• Wacker Neuson Linz 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: • Maneuvering operation • Operation • servicing and performing maintenance 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 vehicle. Observe all safety instructions!

• The vehicle may not be used for transport jobs on public roads.

SHB DT25 en - Edition 1.4* dt25b110.fm

1-3

Operation 1.4

Overall view of vehicle 1

Skip

2

Operator seat

3

Engine cover

4

Travel drive

5

Lifting eye/tie-down point

6

Chassis

7

Tracks

8

Rollbar

9

Document box

10

Control stand

11

Hydraulic PTO shaft (HPTO) (option)

12

Trailer coupling (option)

13

Stabilizer blade (option)

3

1

2

10

11

8

5

6

5

4

10 9

1

13

7

5 Fig. 1:

1-4

6

5

4

12

Vehicle outside views

SHB DT25 en - Edition 1.4 * * dt25b110.fm

Operation 1.5

Brief description The model DT25 dumper is a self-propelled work machine.

Get informed on and follow the legal regulations of your country.

This machine is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere. The main components of the vehicle are: • Rollbar • Swivel skip • Front skip (option) • Stabilizer blade (option) • Water-cooled 4-cylinder engine • Sturdy steel sheet chassis

SHB DT25 en - Edition 1.4* dt25b110.fm

1-5

Operation 1.6

Type labels and component numbers Serial number The number is located on the type label.

The type label is located on the seat mount.

The vehicles built at the Hörsching/Austria plant have 17-digit numbers.

Please refer to the Operator’ Manual of the vehicle for more information.

Fig. 1:

Position of the type label

COMPACT DUMPER

Fig. 2:

Type label

Engine number The type label (arrow) is located on the cylinder-head cover of the engine.

Fig. 3:

Engine number

Number of hydraulic pump for drive operation The type label (arrow) is located on the right side of the pump.

Fig. 4:

1-6

Hydraulic pump number

SHB DT25 en - Edition 1.4 * * dt25b110.fm

Operation Number of hydraulic pump for work operation The type label (arrow) is located on the lower side of the pump.

Fig. 5:

Hydraulic pump number

Spool number The type label (arrow) is located on the spool housing.

Fig. 6:

Spool number

Hydraulic motor numbers The type label (arrow) is located at the front of the hydraulic motor.

Fig. 7:

Number of drive model

Hydraulic pilot control number The type label (arrow) is located on the pilot control housing.

Fig. 8:

Pilot control number

SHB DT25 en - Edition 1.4* dt25b110.fm

1-7

Operation 1.7

Maintenance prop Danger!

Careful when performing maintenance on or under the skip, and in general when performing maintenance with the skip tilted out –

Accident hazard! ☞ Use the maintenance prop Proceed as follows to attach the maintenance prop: ☞ Remove the maintenance prop A from the transport bracket

A

☞ The maintenance prop is fastened with lock pins C and pins D ☞ Insert the maintenance prop A on the tipping cylinder B ☞ Secure maintenance prop A with lock pins C and pins D

C

During transport fit maintenance point A in the seat as shown in Fig. 9.

D

Fig. 9:

Transport bracket

B C D A

Fig. 9:

1-8

Maintenance prop

SHB DT25 en - Edition 1.4 * * dt25b110.fm

Technical data

Technical data

2 2.1

Technical data Chassis Sturdy steel-sheet chassis, engine on vibration-proof rubber mounts

2.2

Diesel engine Hydraulic motor Product Type Version Number of cylinders Displacement Nominal bore and stroke

Kubota diesel engine V2403-M-EU3 Water-cooled 4-stroke engine 4 2434 cm³ 87 x 102.4 mm

Power

33.0 kW at 2350 min-1

Max. torque

163 Nm at 1600 min-1

Max. engine speed without load

2350 +/- 50 min-1

Idling speed

1150 +/- 50 min-1

fuel injection system Starting aid Battery Max. inclined position (engine no longer supplied with oil): Comply with the emission level Direction of rotation Adjustment Injection pressure

2.3

Model DT25

Bosch type MD mini-pump Glow plug (preheating time about 15 seconds) 12 V/105 Ah 20° in all directions 97/68/EC EPA3 Anticlockwise (as seen from the flywheel) 16.25° before top dead center 13.73 MPa

Compression ratio

23.2 : 1

Oil sump capacity

9.50 Liters

Valve clearance

0.20 ± 0.02 mm

Hydraulic system

Model DT25 2 pumps with variable displacement + 1 gear pump 66 + 66 + 40 l/min 172 l/min at 2350 rpm-1

Hydraulic system Pump Displacement

SHB DT25 en - Edition 1.4* dt25b210.fm

Operating pressure for operating hydraulics

175 bar

Operating pressure for drive hydraulics

350 bar

Hydraulic oil radiator

Standard

Hydraulic reservoir capacity

30 liters

2-1

Technical data 2.4

Chassis Chassis 2 speed ranges Theoretical climbing ability

2.5

2.8

2-2

20° 320 mm

No. of track rollers on either side

6 pieces

Ground clearance

350 mm

Ground pressure

0.24 to 0.49 kg/cm3

Operating hydraulics Model DT25 40 l/min at 2350 rpm 2 sections 175±5bar Suction and return filter 30 liters

Electrical system Electrical system

2.7

5.0 and 11 km/h

Track width

Working hydraulics Hydraulic pump flow rate Directional valve Max. operating pressure Filter Hydraulic oil reservoir

2.6

Model DT25

Model DT25

Dynamo

12 V 480 W

Starter

12 V 2.0 kW

Battery

12 V 105 Ah

Skip Struck Heaped Liquid capacity Skip length Skip width Skip height Swivel range

Model DT25 1120 liters 1503 liters 769 liters 2128 mm 1532 mm 603 mm −90°/+90°

Skip Struck Heaped Liquid capacity Skip length Skip width Skip height

Model DT25 923 liters 1281 Liters 923 liters 1775 mm 1450 mm 490 mm

Swivel skip

Front skip (option)

SHB DT25 en - Edition 1.4 * * dt25b210.fm

Technical data 2.9

Noise levels Model DT25

Sound power level )1

101 dB(A)

Sound power level (LWA Operator-perceived sound pressure level (LPA)2

82 dB (A)

Uncertainty (KPA)3

1.

2.

3.

0.9 dB (A)

According to ISO 6395 According to ISO 6396 According to EN ISO 4871

Notice!

Sound power level measurement based on Directive 2000/14/EC. Operator-perceived noise level measured in compliance with EU Directives 84/532/EEC, 89/ 514/EEC and 95/27/EEC. Measurements performed on asphalted surface.

2.10 Vibration Model DT25

Vibration 1

Effective acceleration value of the limbs

< 2.5

Effective acceleration value for the body 1

< 0.5

1.

SHB DT25 en - Edition 1.4* dt25b210.fm

m -----s2 m -----s2

Measurements as per 2002/44/EC, ISO EN 20643 and ISO/TR 25398 (measurement under the following conditions: excavating, driving). Vehicle and attachment operation and maintenance as per Operator’s Manual. Uncertainty of measurement: measurements as per EN 12096:1997 standard Value of vibrations transmitted to human body specified under special operational and ground conditions. Therefore it does not apply to a large number of applications. Therefore, the value of the vibrations transmitted to the human body (indicated by the vehicle manufacturer in accordance with European standards) must not be used as a reference for specifying vehicle operator exposure to vibrations

2-3

Technical data 2.11 Fuses Fuse box A is located under the operator seat. The 3 power fuses B are located under the engine cover

Description

Rated current (A)

Fuse

A

8

7 10

11

3

4

5

6 9

2

1

12 13

14

1

1-pole socket 12 V

10 A

2

Lights switch

15 A1

3

Armrest microswitch

4

Switch supply depending on speed and seat rotation

5

Not used

6

Electro-stop

7

Not used

8

Rotating beacon switch

10 A

9

Switch lights

3A

10

Alternator excitation

5A

11

Horn relay

7.5 A

12

Diesel engine glow plug preheating

40 A

13

Main supply

60 A

14

Alternator

50 A

5A 7.5 A 5A -

B

Fig. 10: Fuses

2-4

SHB DT25 en - Edition 1.4 * * dt25b210.fm

Technical data 2.12 Dimensions model DT25 with swivel skip

2128

2500 350

1370 850

1870

603

3000

90

°

1606

320 1044

1550

1303

1532

1319

1610

2166

590

Fig. 11: Machine dimensions (model DT25 with swivel skip)

Main data

SHB DT25 en - Edition 1.4* dt25b210.fm

Model DT25

Payload

2500 kg

Dead weight incl. skip

2800 kg

Length indications

3666 mm

Width

1610 mm

Height

2500 mm

Track width

320 mm

Skip height

1370 mm

Skip length

2128 mm

Skip width

1532 mm

Skip depth

603 mm

2-5

Technical data 2.13 Dimensions model DT25 with swivel skip and stabilizer blade (option)

590

2500 320

1319

1550 1620

1303

1610

1532

1580

2166

3004 350

328 480

1370 850

1870

603

3000

90

°

2128

Fig. 12: Vehicle dimensions (model DT25 with swivel skip and stabilizer blade)

Main data

2-6

Model DT25

Payload

2500 kg

Dead weight incl. skip

2800 kg

Length indications

4202 mm

Width

1610 mm

Height

2500 mm

Track width

320 mm

Skip height

1370 mm

Skip length

2128 mm

Skip width

1532 mm

Skip depth

603 mm

Stabilizer blade width

1620 mm

Max. stabilizer blade height

480 mm

Max. stabilizer blade depth

328 mm

SHB DT25 en - Edition 1.4 * * dt25b210.fm

Technical data 2.14 Dimensions model DT25 with front skip (option)

2500

2344 1210

490 468

1473

1870

60 °

1775

349

320 932

1550

1610

1550

1319

1485

1044

Fig. 13: Machine dimensions (model DT25 with front skip)

Main data

SHB DT25 en - Edition 1.4* dt25b210.fm

Model DT25

Payload

2500 kg

Dead weight incl. skip

2700 kg

Length indications

3295 mm

Width

1610 mm

Height

2500 mm

Track width

320 mm

Skip height

1210 mm

Skip length

1775 mm

Skip width

1485 mm

Skip depth

490 mm

2-7

Technical data 2.15 General tightening torques Tightening torques for hydraulic screw connections (dry assembly) Metric hose fittings for hydraulic applications (light execution, DKOL) Nominal Ø Outer Ø Thread Wrench size Torque 05 6L M12X1.5 WS 14 15 Nm 06 8L M14X1.5 WS 17 20 Nm 08 10L M16X1.5 WS19 40 Nm 10 12L M18X1.5 WS 22 50 Nm 12 15L M22X1.5 WS 27 75 Nm 16 18L M26X1.5 WS 32 85 Nm 20 22L M30X2 WS 36 100 Nm 25 28L M36X2 WS 41 180 Nm 32 35L M45X2 WS 55 220 Nm Galvanized 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) Nominal Ø Outer Ø Thread Wrench size Torque 05 8S M16X1.5 WS19 40 Nm 06 10S M18X1.5 WS 22 50 Nm 08 12S M20X1.5 WS 24 60 Nm 10 14S M22X1.5 WS 27 75 Nm 12 16S M24X1.5 WS 30 90 Nm 16 20S M30X2 WS 36 100 Nm 20 25S M36X2 WS 41 180 Nm 25 30S M42X2 WS 50 270 Nm 32 38S M52X2 WS 60 400 Nm Galvanized and dry surface (O-ring slightly oiled). Torque tolerance: −10 % Values determined empirically and to be applied as approximate figures.

Screw connections with various seals for hydraulic applications (light execution) Straight pipe fitting with thread and Non-return screwed plug Identification Thread valve with aid outside Ø Sealing elastic seal Elastic seal O-ring washer M10X1.0 9 Nm 18 Nm 15 Nm 18 Nm 10 mm M12X1.5 20 Nm 25 Nm 25 Nm 25 Nm 12 mm M14X1.5 35 Nm 45 Nm 35 Nm 35 Nm 14 mm M16X1.5 45 Nm 55 Nm 40 Nm 50 Nm 16 mm M18X1.5 55 Nm 70 Nm 45 Nm 70 Nm 18 mm M22X1.5 65 Nm 125 Nm 60 Nm 125 Nm 22 mm M27X2.0 90 Nm 180 Nm 100 Nm 145 Nm 27 mm M33X2.0 150 Nm 310 Nm 160 Nm 210 Nm 33 mm

2-8

SHB DT25 en - Edition 1.4 * * dt25b210.fm

Technical data Screw connections with various seals for hydraulic applications (light execution) M42X2.0 240 Nm 450 Nm 210 Nm 360 Nm 42 mm M48X2.0 290 Nm 540 Nm 260 Nm 540 Nm 48 mm G1/8A 9 Nm 18 Nm 15 Nm 18 Nm 9.73 mm G1/4A 35 Nm 35 Nm 30 Nm 35 Nm 13.16 mm G3/8A 45 Nm 70 Nm 45 Nm 50 Nm 16.66 mm G1/2A 65 Nm 90 Nm 55 Nm 65 Nm 20.96 mm G3/4A 90 Nm 180 Nm 100 Nm 140 Nm 26.44 mm G1A 150 Nm 310 Nm 160 Nm 190 Nm 33.25 mm G1 1/4A 240 Nm 450 Nm 210 Nm 360 Nm 41.91 mm G1 1/2A 290 Nm 540 Nm 260 Nm 540 Nm 47.80 mm Torque tolerance: - 10%; Countermaterial: steel/aluminum

Screw connections with various seals for hydraulic applications (heavy execution) Straight pipe fitting with thread and Non-return screwed plug Identification Thread valve with aid outside Ø Sealing elastic seal Elastic seal O-ring washer M12X1.5 20 Nm 35 Nm 35 Nm 35 Nm 12 mm M14X1.5 35 Nm 55 Nm 45 Nm 45 Nm 14 mm M16X1.5 45 Nm 70 Nm 55 Nm 55 Nm 16 mm M18X1.5 55 Nm 90 Nm 70 Nm 70 Nm 18 mm M20X1.5 55 Nm 125 Nm 80 Nm 100 Nm 20 mm M22X1.5 65 Nm 135 Nm 100 Nm 125 Nm 22 mm M27X2.0 90 Nm 180 Nm 170 Nm 135 Nm 27 mm M33X2.0 150 Nm 310 Nm 310 Nm 210 Nm 33 mm M42X2.0 240 Nm 450 Nm 330 Nm 360 Nm 42 mm M48X2.0 290 Nm 540 Nm 420 Nm 540 Nm 48 mm G1/8A 35 Nm 55 Nm 45 Nm 45 Nm 13.16 mm G1/4A 45 Nm 80 Nm 60 Nm 60 Nm 16.66 mm G3/8A 65 Nm 115 Nm 75 Nm 100 Nm 20.96 mm G1/2A 90 Nm 180 Nm 170 Nm 145 Nm 26.44 mm G3/4A 150 Nm 310 Nm 310 Nm 260 Nm 33.25 mm G1A 240 Nm 450 Nm 330 Nm 360 Nm 41.91 mm G1 1/4A 290 Nm 540 Nm 420 Nm 540 Nm 47.80 mm Torque tolerance: - 10%; Countermaterial: steel/aluminum

SHB DT25 en - Edition 1.4* dt25b210.fm

2-9

Technical data Tightening torques for high-resistance threaded fittings

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

with adjustment threads Screws according to DIN 912, DIN Screws according to DIN 931, DIN 933, etc.

7984 8.8 10.9 12.9 8.8 10.9 5.5 Nm 8 Nm 10 Nm 5 Nm 7 Nm 10 Nm 14 Nm 17 Nm 8.5 Nm 12 Nm 25 Nm 35 Nm 42 Nm 20 Nm 30 Nm 45 Nm 65 Nm 80 Nm 40 Nm 59 Nm 87 Nm 110 Nm 147 Nm 69 Nm 100 Nm 135 Nm 180 Nm 230 Nm 110 Nm 160 Nm 210 Nm 275 Nm 350 Nm 170 Nm 250 Nm 280 Nm 410 Nm 480 Nm 245 Nm 345 Nm 410 Nm 570 Nm 690 Nm 340 Nm 490 Nm 550 Nm 780 Nm 930 Nm 460 Nm 660 Nm 710 Nm 1000 Nm 1190 Nm 590 Nm 840 Nm 1040 Nm 1480 Nm 1770 Nm 870 Nm 1250 Nm 1420 Nm 2010 Nm 2400 Nm 1200 Nm 1700 Nm

DIN 912 - hexagon socket head cap screws; DIN 931/DIN 933 - hexagon bolts 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.

Thread M8X1.0 M10X1.0 M10X1.25 M12X1.25 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M24X2.0 M27X2.0 M30X2.0

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

7984 8.8 10.9 12.9 8.8 10.9 25 Nm 37 Nm 43 Nm 22 Nm 32 Nm 50 Nm 75 Nm 88 Nm 43 Nm 65 Nm 49 Nm 71 Nm 83 Nm 42 Nm 62 Nm 87 Nm 130 Nm 150 Nm 75 Nm 110 Nm 83 Nm 125 Nm 145 Nm 72 Nm 105 Nm 135 Nm 200 Nm 235 Nm 120 Nm 175 Nm 210 Nm 310 Nm 360 Nm 180 Nm 265 Nm 315 Nm 450 Nm 530 Nm 270 Nm 385 Nm 440 Nm 630 Nm 730 Nm 375 Nm 530 Nm 590 Nm 840 Nm 980 Nm 500 Nm 710 Nm 740 Nm 1070 Nm 1250 Nm 630 Nm 900 Nm 1100 Nm 1550 Nm 1800 Nm 920 Nm 1300 Nm 1500 Nm 2150 Nm 2500 Nm 1300 Nm 1850 Nm

DIN 912 - hexagon socket head cap screws; DIN 931/DIN 933 - hexagon bolts 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.

2-10

SHB DT25 en - Edition 1.4 * * dt25b210.fm

Maintenance

Maintenance

Maintenance

3

Maintenance

3.1

Fluids and lubricants

Component/application

Fluid/lubricant

Specified

Season/temperature

Capacity1

Diesel engine

Engine oil

AGIP SIGMA S SAE2 30

Year-round

9.5 l

Travel drive

Gearbox oil SAE 85W-90 TOTAL EP SAE 85W 90

Year-round

0.7 l

Year-round

30 l

AGIP GR SM

Year-round

As required

AGIP GR SM

Year-round

As required

No. 2-D, DIN 51601 grade

Over 4 °C

No. 1-D, DIN 51601 grade

Below 4 °C

AGIP ARNICA 463

Hydraulic oil Hydraulic oil radiator

PANOLIN HLP Synth 46 Biodegradable oil

4

FINA BIOHYDRAN SE 46 BP BIOHYD SE-46

Grease

Roller and friction bearings

Grease zerks

Multipurpose grease 6

Fuel tank

Diesel fuel 7

5

54 l

Soft water + antifreeze ASTM D4985 Radiator 1.

2.

3.

4.

5.

6.

7.

3-1

Coolant

Distilled water + antifreeze ASTM D4985

Year-round

About 6 l

Capacities indicated are no system fills According to DIN 51511 According to DIN 51524 section 3 Biodegradable hydraulic oils based on saturated synthetic esters with an iodine value of < 10 according to DIN 51524, section 3, HVLP, HEES KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive Sulfur content below 0.05 %, cetane number over 45

SHB DT25 en - Edition 1.4 * * dt25b320.fm

Maintenance

SHB DT25 en - Edition 1.4* dt25b320.fm3-2

Maintenance

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Service center

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service center

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Customer

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):

Perform the following oil and filter changes (check oil levels after test run): • Engine oil1 • Clean the engine oil filter2 • Replace the fuel filter element3 • Replace the air filter insert • Hydraulic oil filter insert 4 • Cartridge of hydraulic oil intake filter • Hydraulic oil • Traveling drive oil • Coolant • Replacing fan belts Inspection work (

Every 3 years and/or after 1000 o/h

Fluid and filter changes (

Every 12 months or after 500 o/h

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

Every 6 months or after 250 o/h

Work description

Once a month or after 50 o/h

Maintenance plan DT25

Service work (daily)

SHB DT25 en<> - Edition 1.4 * * dt25b321.fm<>

3.2

Maintenance plan/operating hours (o/h)

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):

Check the following material. Refill if necessary: • Check the fuel level, add fuel • Engine oil • Hydraulic oil • Coolant

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Check hydraulic oil radiator for dirt, clean if necessary

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

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Air filter (damage)

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Clean the filter cup

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3-2

Check injection condition of fuel injection nozzle

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Check injection setting

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Check the fuel injection pump

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Maintenance

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Check the automotive valve setting

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Check/set the maximum engine speed

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Check the exhaust system for damage and condition

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Check intake and exhaust valve clearance Check battery electrolyte. Add distilled water if necessary

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Check alternator, starter and electric connections, bearing play and function Pressure check of primary pressure limiting valves

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Check the tracks for cracks and cuts

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Check track tension and adjust it if necessary

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

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Check screws for tightness

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Pin lock

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Line fixtures

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Labels and Operator’s Manual

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Coolant

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Clean the fan blades

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V-belt tension SHB DT25 en – Edition 1.4 * * dt25b321.fm

Lubrication service (

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):

Lubricate the following assemblies/components: – see Overview of grease nipples DT25 with swivel skip on page 3-35 and – see Overview of grease nipples DT25 with front skip (option) on page 3-36 • Skip • Tilt cylinder

●

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Service center

service center

Customer

Every 3 years and/or after 1000 o/h

Every 12 months or after 500 o/h

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

Service work (daily)

Work description

Every 6 months or after 250 o/h

Maintenance plan DT25

Once a month or after 50 o/h

3.2

Maintenance

3-3

Maintenance plan/operating hours (o/h)

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Service center

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service center

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):

Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Repair if necessary: ● • Visual check ● ☞ Engine and hydraulic system ● ☞ Cooling circuit ● ☞ Travel drive 1.

2.

3.

4.

Customer

Leakage check (

Every 3 years and/or after 1000 o/h

• Track tension • Swivel cylinder • Lifting cylinder

Every 12 months or after 500 o/h

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

Every 6 months or after 250 o/h

Work description

Maintenance plan/operating hours (o/h) Once a month or after 50 o/h

Maintenance plan DT25

Service work (daily)

SHB DT25 en<> - Edition 1.4 * * dt25b321.fm<>

3.2

● ● ● ●

Replace the engine oil for the first time after 50 o/h or the first month, then every 250 o/h or after 6 months at the latest Replace the engine oil filter for the first time after 50 o/h or the first month, then every 250 o/h or after 6 months at the latest Replace the fuel filter for the first time after 50 o/h or the first month, then every 250 o/h or after 6 months at the latest Replace the hydraulic oil filter for the first time after 50 hours run or the first month, then every 250 hours run or after 6 months at the latest

Maintenance

3-4

Maintenance

3-5

SHB DT25 en – Edition 1.4 * * dt25b321.fm

Maintenance

Maintenance 3.3 Introduction The working order and the service life of vehicles are heavily dependent on maintenance.

Before performing servicing and maintenance, 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 serious injury when using compressed air. Always wear safety glasses, protective masks and clothing.

Daily and weekly service and maintenance work must be performed by a specifically trained operator in accordance with the maintenance plan “A”; all additional maintenance work may only be performed by technically trained and qualified personnel.

The maintenance plans indicate when the maintenance work mentioned below must be performed (– see Maintenance plan DT25 on page 3-2).

3-5

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance 3.4

fuel system

Specific safety instructions • Extreme caution is essential when handling fuel – increased fire hazard!

• Never perform work on the fuel system near open flames or sparks!

• Do not smoke when working on the fuel supply system and while refueling!

• Before refueling, stop the engine and remove the starting key!

• Do not refuel in closed rooms!

• Wipe away fuel spills immediately!

• Keep the vehicle clean to reduce the fire hazard!

Refueling Fuel filler neck A is located under the engine cover.

A

Danger!

When using the fuel there is high

fire and poisoning risk!

Fig. 14: Fuel filler inlet

☞ Do not refuel in closed rooms. ☞ Never perform work on the fuel system near open flames or sparks. ☞ No smoking, no fire!

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 3-9.

Notice!

Fill up the tank with the correct fuel type at the end of each working day. This prevents condensation water from forming in the fuel tank over night. Do not fill the tank completely but leave some space for the fuel to expand.

SHB DT25 en - Edition 1.4* dt25b323.fm

3-6

Maintenance Drain fuel B

For emptying the fuel tank, we recommend using a pump for extracting the fuel via cover B on the upper tank wall.

☞ Proceed as follows: • Clean the area around cover B with a lint-free cloth • Open filler cap B • Install the pump for extracting fluids from the tank • Extract all the fuel until the tank is completely empty • Close filler cap B

Environment!

Ensure that no fluid escapes!

Fig. 15: Drain fuel

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.

Refueling from barrels If refueling from barrels is unavoidable, please note the following (see Fig. 16): Incorrect

• Barrels must neither be rolled nor tilted before refueling • Protect the suction pipe opening of the barrel pump with a fine-mesh screen • Immerse it down to a max. 15 cm above the floor of the barrel • Only fill the tank using refueling aids (funnels or filler pipes) with integral micro-filter

Correct

• Keep all refueling containers clean.

Fig. 16: Refueling from a barrel

Diesel fuel specification Use only high-grade fuels Grade • No. 2-D according to DIN 51601 • No. 1-D according to DIN 51601

3-7

Cetane number

Usage: 4°C to 45°C

Min. 45

For outside temperatures below 4 °C or for operation above 1500 m altitude

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance Cleaning the filter cup/replacing the filter cartridge

Danger!

Fuel is extremely flammable, and explosive under certain circumstances.

Accident hazard! ☞ No smoking in the job site, no open flames or sparks. ☞ Once the filter cup is back in position, check for leaks and ensure that all gasoline spills have been wiped away before starting the engine.

O

S A

E D B C

☞ Set fuel cock A to S (OFF) ☞ Unscrew filter cup B with a suitable tool by loosening ring C ☞ Remove filter cup B and O-ring D, and wash with a nonflammable solvent. ☞ Allow filter cup B to dry thoroughly ☞ Take out filter element E and rinse it with diesel fuel or replace it ☞ Re-install filter element E once cleaning is over, and protect it against dust and dirt ☞ Screw filter cup B back on again with a suitable tool by tightening ring C ☞ Set fuel cock A to O (ON) and check for leaks ☞ Bleeding the fuel system

Environment!

Dispose of the drained fuel in an environmentally friendly manner.

Fig. 17: Filter cup

SHB DT25 en - Edition 1.4* dt25b323.fm

3-8

Maintenance Bleeding the fuel system

Danger!

If fuel comes into contact with hot engine parts or the muffler, there is an increased

Fire hazard! ☞ Never bleed the fuel system if the engine is hot!

Bleed the fuel system in the following cases: • After removing and fitting the fuel filter, prefilter or the fuel lines back on again

O

A

• After running the fuel tank empty

C

• After running the engine again, after it has been out of service for a longer period of time.

C

B

☞ Bleed the fuel system as follows: ☞ Park the vehicle on level and horizontal ground ☞ Stop the engine ☞ Fill the fuel tank ☞ Open fuel filter valve A by turning the lever to the bottom onto O ☞ Actuate suction lever B of the fuel pump to pump fuel ➥ until fuel comes out of the filter without any air ☞ Unscrew screw C with a suitable tool ☞ Actuate suction lever F of the fuel pump to pump fuel ➥ until fuel comes out of the prefilter without any air ☞ Tighten screw C again with a suitable tool ☞ Starts the engine ➥ If the engine runs smoothly for a while and then stops, or if it does not run smoothly: ☞ Stop the engine ☞ Bleed the fuel system again as described above ☞ Have a check performed by authorized personnel if necessary.

Fig. 18: Bleeding the fuel system

3-9

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance 3.5

Engine lubrication system Caution!

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

Engine damage and loss of output! ☞ Have the oil changed by an authorized service center – see chapter 3.2 Maintenance plan DT25 on page 3-2 Checking the oil level

Notice!

Check the oil level once a day.

We recommend checking it before starting the engine. After stopping a warm engine, wait at least 5 minutes before checking.

☞ Proceed as follows: • Park the vehicle on level ground A max min

• Stop the engine!

• 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 ☞ 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 need be add oil when the oil level has reached the MIN mark on the oil dipFig. 19: Checking the oil level

SHB DT25 en - Edition 1.4* dt25b323.fm

stick A

3-10

Maintenance Adding engine oil

Caution!

Too much or incorrect engine oil can cause engine damage! Therefore:

☞ Do not add engine oil above the MAX mark of oil dipstick 19/A ☞ Use only the specified engine oil

Environment!

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

☞ Proceed as follows: B

• Clean the area around cover of the closure screw B with a clean lint-free cloth OIL

• Open filler cap B • Raise oil dipstick A slightly to allow any trapped air to escape • Adding 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 3-10 • Add oil if necessary and check the oil level again • Close filler cap B • Push oil dipstick A back in as far as the stop • Completely remove all oil spills from the engine.

Fig. 20: Filler cap

Drain engine oil

☞ Proceed as follows: • Clean the area around filler cap C with a lint-free cloth • Place a sufficiently large container under the place where the oil is drained • Open filler cap C • Wait for a short while (appr. 3 minutes), until the oil has drained completely from the sump • Close filler cap C

Environment!

C Fig. 21: Oil drain plug

3-11

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

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance Replacing the oil filter cartridge

Danger!

Replace the oil filter cartridge only if the engine is stopped.

Caustic injury hazard! ☞ Wait at least 15 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Remove filter cartridge A with key B ☞ Apply a thin coat of oil to the seal of the new cartridge ☞ Tighten the new filter cartridge A by hand ☞ Do not tighten the cartridge too much! Do not use a key! ☞ Check the engine oil level and add oil if necessary B A

Environment!

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

Fig. 22: Engine oil filter cartridge

SHB DT25 en - Edition 1.4* dt25b323.fm

3-12

Maintenance 3.6

Engine and hydraulics cooling system The oil and water radiator is located in the engine compartment, in front of the engine. It cools the diesel engine, and the hydraulic oil of the drive and operating hydraulics.

The coolant reservoir is also located in the engine compartment, in front of and above the oil cooler.

Specific safety instructions • Dirt on the radiator fins reduces the radiator’s cooling capacity! To avoid this:

☞ Clean the outside of the radiator at regular intervals. Use oil-free compressed air (max 2 bar) for cleaning; thus, keep a reasonable distance from the radiator so that the cooling fins are not damaged. Refer to the maintenance plans 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 cooling capacity as well and can cause 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 add cold water/coolant if the engine is warm! ☞ After filling the coolant reservoir, make a test run with the engine and check the coolant level again after stopping the engine • The use of the wrong coolant can destroy the engine and the radiator. Therefore:

☞ Add enough antifreeze compound to the coolant – but never more than 50 %. If possible, use brand-name antifreeze agents since they already contain anti-corrosion agents.

☞ Observe the coolant compound table – see chapter 3.1 Fluids and lubricants on page 3-1

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

• Once you have filled the coolant reservoir:

☞ Test run the engine ☞ Stop the engine ☞ Let the engine cool down ☞ Check the coolant level again

Environment!

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

3-13

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance Checking the coolant level/adding coolant

Danger!

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

Burn hazard! ☞ Wait at least 15 minutes after stopping the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap B to the first notch and allow the pressure to drop ☞ Ensure that the coolant temperature is sufficiently low so you can touch the radiator plug with your hands

Danger!

Antifreeze is flammable and toxic.

Accident hazard! ☞ 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

SHB DT25 en - Edition 1.4* dt25b323.fm

3-14

Maintenance Checking the coolant level

☞ Proceed as follows: A

• Park the vehicle on level ground • Stop the engine!

• Remove the key and carry it with you • Let the engine and the coolant cool down • Open the engine cover • Check the coolant level on the transparent coolant reservoir A and on the radiator B

☞ If the coolant level is below the LOW mark or the filler inlet of the radiator: • Adding coolant

Notice!

FULL LOW

Check the coolant level once a day.

We recommend checking it before starting the engine.

Fig. 23: Coolant reservoir

B

Adding coolant After the engine has cooled down:

Fig. 23: Radiator

☞ Release overpressure in the radiator ☞ Carefully open the cap to the first notch and fully release the pressure ☞ Open filler cap B ☞ Add coolant to the lower edge of the filler inlet (radiator) ☞ Close filler cap B ☞ Start the engine and let it warm up for about 5 – 10 minutes. ☞ Stop 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 marks ☞ If necessary, add coolant and repeat the procedure until the coolant level remains constant

Notice!

Check the antifreeze every year before the cold season sets in

3-15

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance Draining coolant The radiator is located at the front of the machine under the engine cover. Drain plug C for draining the coolant is located at the bottom on the side facing the engine.

☞ Proceed as follows: • Clean the area around filler cap C with a lint-free cloth • Place a sufficiently large container under the place where the coolant is drained • Open filler cap C • Wait a moment (approx. 3 minutes) until the coolant from the radiator and engine has drained off • Close filler cap C C Fig. 24: Coolant drain plug

Environment!

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

Cleaning the radiator If there is dust on radiator D between the fins and the pipes, clean it under running water.

Caution!

D

Do not clean the radiator with tools, such as a spatula or screwdriver. They can damage the fins and pipes, causing coolant to escape or the heat dissipation capacity to be reduced.

Fig. 25: Cleaning the radiator

SHB DT25 en - Edition 1.4* dt25b323.fm

3-16

Maintenance 3.7

Air filter Caution!

The filter cartridge will be damaged if it is washed or brushed out!

Bear in mind the following to avoid premature engine wear!

☞ Do not clean the filter cartridge ☞ Replace the filter cartridge when the indicator light illuminates ☞ Never reuse a damaged filter cartridge ☞ Ensure cleanliness when replacing the filter cartridge!

A device on the air filter monitors the filter cartridge.

☞ Replace filter B if: • If telltale 18 comes on • According to the maintenance plan

Notice!

For applications in especially dusty environment, replace or clean the air filter more frequently.

18

Caution!

Fig. 26: Indicator for air filter contamination

B

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 aluminum mills, chemical plants and other nonferrous-metal plants.

☞ Replace filter B after 50 operating hours at the latest!

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

Fig. 26: Air filter

• Check air filter attachments, air intake hoses and air filters for damage, and immediately repair or replace if necessary • Check the screws at the induction manifold and the clamps for tightness.

3-17

SHB DT25 en - Edition 1.4 * * dt25b323.fm

Maintenance Replacing the filter • Replace filter B as follows:

D

E

Fig. 27: Removing the lower housing section

B

☞ Stop the engine ☞ Remove the key and carry it with you ☞ Let the engine cool down ☞ Switch off the vehicle ☞ Remove dirt and dust from the air filter and the area around the air filter ☞ Bend both hooks D on the lower housing section E outward ☞ Remove lower housing section E ☞ Carefully remove filter B with slightly turning movements ☞ Ensure that all dirt (dust) inside the air filter housing 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 ☞ Insert the new filter B in the air filter housing ☞ Position the lower housing section E (ensuring that it is correctly positioned) ☞ Close both hooks D

Fig. 28: Removing the filter element

SHB DT25 en - Edition 1.4* dt25b323.fm

3-18

Maintenance

Maintenance 3.8

Hydraulic system

Specific safety instructions • Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this: • Check whether the operator seat is correctly locked in one of the final positions • Lower both armrests • Insert the starting key in preheating start switch 28 • Turn the ignition key to position “1” • Move the control lever a few times • Turn the ignition key to position “0” • Raise the armrest of the operator seat • Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injury. Always consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in!

• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This can cause damage to the hydraulic pump!

• Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and serious injury or damage to property. Interrupt work immediately in case of loose nuts or damaged lines.

☞ Contact your Wacker Neuson dealer immediately • Replace the hose or line if one of the problems mentioned below is detected.

☞ Damaged or leaky hydraulic seals. ☞ Worn or torn shells or uncovered reinforcement branches ☞ Expanded shells in several positions. ☞ Entangled or crushed movable parts. ☞ Foreign bodies jammed or stuck in protective layers.

Caution!

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

Risk of serious damage to the hydraulic system! ☞ Take care to avoid dirt when working! ☞ Always add hydraulic oil using the filling screen! ☞ Only use authorized oils of the same type – see chapter 3.1 Fluids and lubricants on page 3-1

☞ Always add hydraulic oil before the level gets too low – see Adding hydraulic oil on page 3-21

☞ If the hydraulic system is filled with biodegradable oil, then use only biodegradable oil of the same type for adding oil – observe the sticker on the hydraulic oil reservoir!

☞ Contact customer service if the hydraulic system filter is contaminated with metal chippings. Otherwise, follow-on damage can result!

3-19

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance 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.

Checking the hydraulic oil level

Caution!

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

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

A

☞ Proceed as follows: • Park the vehicle on level ground • Retract all hydraulic cylinders

☞ Fully tilt in the skip • Stop the engine • Open the engine cover • Sight glass B is located on hydraulic oil tank A

FULL

• Check the oil level by means of level indicator B

LOW

• The oil level must be at the FULL level • A gage element in the sight glass B indicates the oil level

B Fig. 29: Oil level indicator on the hydraulic oil reservoir

If the oil level is lower • Adding hydraulic oil The oil level varies according to the machine’s operating temperature: Machine condition • Before putting into operation • Normal operation

Temperature

Oil level

Between 10 and 30°C

LOW mark

between 50 and 90°C

FULL mark

Notice!

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

1

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3-20

Maintenance Adding hydraulic oil

Danger!

Removing the filler plug can cause oil to escape –

Accident hazard! ☞ Carefully unscrew the plug to slowly reduce the pressure inside the reservoir.

Do not add hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil will overflow at the filler opening on the hydraulic oil reservoir.

☞ Add as follows: • Park the vehicle on level ground • Retract all hydraulic cylinders • Stop the engine • Clean the area around filler inlet C with a clean cloth • Open filler inlet C C

With the filter insert in place: • Adding hydraulic oil • Check the hydraulic oil level on sight glass B • Add if necessary and check again • Firmly close filler cap C

Fig. 30: Hydraulic oil tank

Drain hydraulic oil D

For emptying the hydraulic oil tank, we recommend using a pump for extracting the hydraulic oil via inspection flange D on the upper tank wall.

☞ Proceed as follows: • Clean the area around inspection flange D with a lint-free cloth • Remove inspection flange D by unscrewing all fastening screws • Install the pump for extracting fluids from the tank • Extract all the hydraulic oil until the tank is completely empty • Screw inspection flange D back on again

Environment!

Ensure that no fluid escapes!

Fig. 31: Drain hydraulic oil

3-21

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance Replacing the hydraulic oil filter cartridge Exchange filter cartridge A as follows:

☞ Stop the engine ☞ Open the engine cover ☞ Ensure that all dirt (dust) has been removed ☞ Remove filter A by unscrewing it ☞ Insert the new filter cartridge A

A

Environment!

Collect the drained oil in a suitable container and dispose of it by an environmentally safe manner!

Environment!

A

Dispose of filter cartridge A in an environmentally friendly manner.

Fig. 32: Replacing the oil filter cartridge

SHB DT25 en - Edition 1.4* dt25b324.fm

3-22

Maintenance Replacing the cartridge of hydraulic oil intake filter Exchange filter cartridge A as follows:

☞ Stop the engine ☞ Open the engine cover ☞ Remove the inspection flange by unscrewing screws B ☞ Ensure that all dirt (dust) has been removed ☞ Remove filter A by unscrewing it ☞ Insert the new filter cartridge A ☞ Retighten the inspection flange by screwing screws B

A

Environment!

B

Collect the drained oil in a suitable container and dispose of it by an environmentally safe manner!

Environment!

Dispose of filter cartridge A in an environmentally friendly manner.

A

Fig. 33: Replace the oil intake filter cartridge

3-23

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance Important notices on the use of biodegradable oil • Use only the biodegradable hydraulic fluids which have been tested and approved by Wacker Neuson. Always contact Wacker Neuson for the use of other products that have not been recommended. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components that can be proved to be due to the hydraulic fluid • Use only biodegradable oil of the same type for adding oil. In order to avoid misunderstandings, a label providing clear information is located on the hydraulic oil reservoir (next to the filler inlet) regarding the type of oil currently used! Replace missing labels!

Mixing two different biodegradable oils can worsen the quality of one of the oil types.

Therefore, ensure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 % when changing biodegradable oil (manufacturer indications) • Do not add mineral oil – the content of mineral oil should not exceed 2% by weight in order to avoid foaming problems and to ensure biological degradability • When operating the vehicle with biodegradable oil, the same oil and filter replacement intervals are valid as for mineral oil – see chapter 3.2 Maintenance plan DT25 on page 3-2 • Always have the condensation water in the hydraulic oil tank drained by an authorized service centre before the cold season. The water content must not exceed 0.1 % by weight.

• The instructions in this Operator’s Manual concerning environmental protection are also valid for the use of biodegradable oil.

• If additional hydraulic attachments are installed or operated, use the same type of biodegradable oil for these attachments to avoid mixtures in the hydraulic system.

Subsequent change from mineral oil to biodegradable oil must be performed by an authorized service center or by your Wacker Neuson partner

SHB DT25 en - Edition 1.4* dt25b324.fm

3-24

Maintenance Checking hydraulic pressure lines Specific safety instructions

Danger!

Use caution when checking the hydraulic lines; Especially when searching for leaks.

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injury.

Injury hazard ☞ Always consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in!

☞ Always observe the following instructions: • Retighten leaking screw connections and hose connections only when the system is not under pressure. In other words, release the pressure before working on pressurized 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 bare hands, but wear protective gloves!

• Use paper or wood to check for minor leaks. Never use an unprotected light or open flame!

• Damaged flexible lines may be replaced by an authorized service centre only!

• Leakages and damaged pressure lines must be immediately repaired or replaced by an authorized service center or after-sales personnel.

This not only increases the operating safety of the vehicle 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 20066, part Tl. 5.

1 Q/04

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

Example: The indication "1 Q/04" means manufactured in the 1st quarter of 2004.

3-25

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance 3.9

Tracks Danger!

Careful when working on the tracks –

Accident hazard! ☞ Use suitable means to support and secure the vehicle ☞ In addition, ensure that the vehicle cannot overturn Checking track tension

15 mm

Check track tension as follows:

☞ Park the dumper on firm and level ground ☞ Raise the dumper with suitable means ☞ Tracks should be raised off the ground ☞ Stop the engine ☞ Use additional supports for the dumper and ensure that it cannot overturn ☞ Measure the distance between the middle of the track and the horizontal line ➥ The rubber track should not sag more than 15 mm when tight

Notice!

Fig. 34: Checking track tension

If possible, the distance from the rollers should be the same for both tracks.

Tightening the tracks B

Fig. 35: Increasing track tension

A

☞ Park the dumper on firm and level ground ☞ Raise the dumper with suitable means ☞ Tracks should be raised off the ground ☞ Stop the engine ☞ Use additional supports for the dumper and ensure that it cannot overturn ☞ Take the lubrication pump supplied with the machine ☞ Insert the tube of the pump in grease nipple A ☞ Pump grease into the track tensioner (distance 10 – 15 mm as above) ➥ Ram B is extended ➥ The track is tensioned ☞ Check track tension ➥ Repeat the procedure if the tracks are not tight enough

Notice!

Check track tension once a day since excessive or insufficient track tension can damage the tracks and the rams.

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3-26

Maintenance Decreasing track tension B

Fig. 36: Loosen the chain

A

☞ Park the dumper on firm and level ground ☞ Raise the dumper with suitable means ☞ Tracks should be raised off the ground ☞ Stop the engine ☞ Use additional supports for the dumper and ensure that it cannot overturn ☞ Unscrew lubricating valve A with a suitable tool ☞ Slide back ram B ➥ Ram B is retracted ➥ The track is loosened ➥ Grease comes out of valve A ☞ Check track tension ➥ Repeat the procedure if the tracks are too tight

Environment!

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

3-27

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance 3.10 Traveling drive Danger!

Immediately after stopping 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.

Burn and injury hazard! ☞ Wait until the engine has cooled down before taking up work. ☞ Slowly open the plug to release the pressure inside.

Checking the oil level and adding oil A

B

Fig. 37: Check the oil level

☞ Park the vehicle on level and horizontal ground ☞ Position the vehicle so that filler plug A is at the top ☞ Stop the engine ☞ Let the engine cool down ☞ Unscrew screws A and B with a suitable tool ☞ The oil must slowly flow out of the opening B ➥ If the oil does not flow out of opening B, add oil: ☞ Add 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 vehicle a few meters ☞ Check the oil level again ➥ If the oil level is not correct: ☞ Repeat the procedure

Draining oil

B A

Fig. 38: Draining oil

☞ Park the vehicle on level and horizontal ground ☞ Position the vehicle so that filler plug B is at the bottom ☞ Stop the engine ☞ Let the engine cool down ☞ 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.

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3-28

Maintenance 3.11 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 safety glasses and protective clothing with long sleeves.

If acid is spilled:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once!

• Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells – explosion hazard!

• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is low. The battery can burst or explode!

☞ Replace the battery immediately • Never work with an open flame, avoid sparks and do not smoke near open battery cells.

The gas that forms during normal battery operation can ignite!

• Use only 12 V power sources. Higher voltages will damage the electrical components • When connecting the battery leads, ensure that the poles +/− are not inverted, otherwise sensitive electrical components will be damaged.

• Do not interrupt voltage-carrying circuits at the battery terminals because of the sparking hazard!

• Never place tools or other conductive articles on the battery – risk of short circuit!

• Always disconnect the battery terminal before starting repair work on the electrical system (-).

• Dispose of used batteries properly.

Servicing and maintenance at regular intervals Every week

☞ Check once a week: • Electric fuses • Cable and grounding connections • Battery charge condition – see Battery on page 3-31 • Condition of battery terminals.

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SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance Instructions concerning specific components Cables, bulbs and fuses Always observe the following instructions: • Malfunctioning components of the electrical system must always be replaced by a Wacker Neuson service center. Bulbs and fuses may be changed by unqualified persons • When performing maintenance on the electrical system, pay particular attention to ensuring good contact in leads Alternator Always observe the following instructions: • Only test run the engine with the battery connected.

• When connecting the battery, ensure that the poles (+/–) are not inverted.

• Always disconnect the battery before performing welding work or connecting a quick battery charger.

SHB DT25 en - Edition 1.4* dt25b324.fm

3-30

Maintenance Battery

Danger!

Battery acid is highly caustic!

Caustic injury hazard!

Therefore when recharging and/or working near the battery:

☞ Always wear safety glasses and protective clothing with long sleeves If acid is spilled:

☞ immediately flush all contaminated surfaces with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once!

Especially when charging batteries, as well as during normal operation of batteries, an oxyhydrogen mixture is formed in the battery cells –

Explosion hazard! ☞ Avoid open lights and sparks near 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 burst or explode!

• Replace the battery immediately

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

Battery A is located under the engine cover. The battery is “maintenance-free”. However have the battery checked at regular intervals to ensure that the electrolyte level is between the MIN and MAX marks.

Checking the battery requires it to be removed and must be performed by a Wacker Neuson service center.

A

Always follow the specific battery safety instructions!

Notice!

Do not disconnect the battery while the engine is running!

+

-

Disconnecting the battery • – see chapter Battery master switch on page 3-32

Fig. 39: Battery

3-31

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance Battery master switch

A

B C

Notice!

Do not disconnect the battery while the engine is running!

Notice!

Interrupt the power supply with the key: • Before working on the electrical system

Fig. 40: Battery master switch

• As an antitheft precaution Interrupting power supply:

☞ Turn key A of the battery master switch to position B and remove it Establishing power supply:

☞ Insert key A in the battery master switch. ☞ Turn the key downwards to the notched position C Flashing headlight A hazard warning flash light and beacon can be mounted on the roll bar, as shown adjacently Fig. 41.

The switch-on button is located on the control panel.

Fig. 41: Mounting the flashing headlight (optional)

SHB DT25 en - Edition 1.4* dt25b324.fm

3-32

Maintenance 3.12 General maintenance Cleaning Cleaning the vehicle is divided into two separate areas: • Exterior of the vehicle • 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 put the health of the persons in charge of cleaning the machine at risk. Therefore always observe the following instructions.

General instructions for all areas of the vehicle Cleaning with washing solvents • Ensure sufficient room ventilation • Wear suitable protective clothing • Do not use flammable liquids, such as petrol or diesel Cleaning with compressed air • Work carefully • Wear safety glasses 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 • Electrical components and damping material must be covered and not directly exposed to the jet • Cover the vent filter on the hydraulic oil reservoir and the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture: • Hydraulic motor • Electrical components such as the alternator, etc.

• Control devices and seals • Air intake filters, etc.

Cleaning with volatile and easily flammable anti-corrosion agents and sprays: • Ensure sufficient room ventilation • Do not use unprotected lights or open flames • Do not smoke!

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SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance Exterior of the vehicle

Caution!

Cleaning the vehicle can cause engine damage.

☞ Protect the engine against humidity The following articles are generally suitable: • High-pressure cleaner • Steam jet Engine compartment

Danger!

Clean the engine only when it is at a standstill –

Injury hazard ☞ Stop the engine before cleaning it.

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!

Threaded fittings and attachments All threaded fittings must be checked regularly for tightness, even if they are not listed in the maintenance plans.

☞ Engine fastening screws ☞ Fastening screws of the hydraulic system ☞ Line and pin fastenings on the attachment Immediately tighten loosened connections; Contact an authorized workshop if necessary.

Pivots and hinges Lubricate all mechanical pivots on the vehicle (such as joints) and fittings at regular intervals even if they are not listed in the lubrication plan.

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3-34

Maintenance 3.13 Overview of grease nipples DT25 with swivel skip Always install the red maintenance work before performing maintenance with a raised or tilted-out skip – see Maintenance prop on page 1-8

Apply multipurpose lithium grease with an MoS² additive to all grease zerks indicated.

3-35

SHB DT25 en - Edition 1.4 * * dt25b324.fm

Maintenance 3.14 Overview of grease nipples DT25 with front skip (option) Always install the red maintenance work before performing maintenance with a raised or tilted-out skip – see Maintenance prop on page 1-8

Apply multipurpose lithium grease with an MoS² additive to all grease zerks indicated.

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3-36

Maintenance

3-37

SHB DT25 en - Edition 1.4 * * dt25b324.fm

SHB DT25 en - Edition 1.4 * dt25b325.fm

3.15

Test report DT25

Operating hydraulics with swivel skip– see chapter 6.7 Hydraulics diagram DT25 with swivel skip and front skip (option) on page 6-8 Function

Movement

Pressure limiting valve

Measurement connection

Lower

Main pressure limiting valve

Measurement connection 19

Swivel to the right

Oil pressure at 50 °C

Specified value Engine speed

Pressure (bar)

2350

175± 5 bar

1st measurement

2nd measurement

Skip

(spool)

Maintenance

Raise

Swivel to the left

Operating hydraulics with front tip skip (option) – see chapter 6.7 Hydraulics diagram DT25 with swivel skip and front skip (option) on page 6-8 Function

Skip

Movement

Pressure limiting valve

Measurement connection

Raise

Main pressure limiting valve

Measurement connection 19

Lower

Oil pressure at 50 °C

(spool)

Specified value Engine speed

Pressure (bar)

2350

175± 5 bar

1st measurement

2nd measurement

Operating hydraulics with additional PTO shaft (option) – see chapter 6.9 Hydraulics diagram DT25 with swivel skip, front skip and hydraulic PTO shaft (option) on page 6-10 Function

Hydraulic PTO shaft

Movement

Pressure limiting valve

Measurement connection

Additional Connection P

Main pressure limiting valve

Measurement connection 20

Additional Connection P1 Oil pressure at 50 °C

(spool)

Specified value Engine speed

Pressure (bar)

2350

175± 5 bar

1st measurement

2nd measurement

Charge-air pressure– see chapter 6.7 Hydraulics diagram DT25 with swivel skip and front skip (option) on page 6-8 Charge-air pressure

Oil pressure at 50 °C

Measurement connection 20

2350

24± 1 bar

Traveling drive– see chapter 6.7 Hydraulics diagram DT25 with swivel skip and front skip (option) on page 6-8

Left track

Forward travel

Measurement connection 15

Reverse driving

Main pressure limiting valve

Measurement connection 16

Forward travel

Oil pressure at 50 °C

Measurement connection 17

Reverse driving

Measurement connection 18

2350

350± 10 bar

3-38

Maintenance

Right track

Maintenance

3-39

SHB DT25 en - Issue 1.4 * dt25b325.fm

Engine

Engine

4

Engine

4.1

Engine overview

1

Intake pipe

2

Speed regulation lever

3

Engine stop lever

4

Fuel injection nozzle

5

Fuel pump

6

Fan

7

Fan drive belt

8

Oil filter insert

9

Coolant drain cock

10

Filler opening cover

11

Exhaust pipe

12

Alternator

13

Starter

14

Oil level gage

15

Oil filter

16

Flywheel

17

Oil drain plug

18

Oil sump

19

Engine hook

1

6

10

4

2 5 3

14

9

12

8

7

19

15

11 13

18

17

SHB DT25 en - Edition 1.4* dt25b410.fm

16

4-1

Engine 4.2

Checking and adjusting valve clearance ☞ Standard setting of valve clearance is possible: ➥ On a cold engine Procedure A

☞ Remove cylinder head cover A

Fig. 42: Cylinder head cover

C

B

☞ Turn the engine until mark B (1TC) of the flywheel coincides with projection C. ☞ Check whether piston no. 1 reaches the top dead centre of the compression cycle. ➥ Turn the flywheel 15° to check whether the piston is in the top dead centre during the compression or intake/exhaust cycle.

➥ The piston is in the top dead centre during the compression cycle when the intake/ exhaust valves do not move.

➥ The piston is in the top dead centre during the intake/exhaust cycle when both Fig. 43: Valve clearance

valves move. In this case, turn the flywheel 360° until mark B (1TC) of the flywheel coincides with projection C.

☞ Check valve clearance D at the mark “●” with a feeler gauge ☞ Numbering order of cylinders: no. 1, no. 2, no. 3, no. 4, starting from the gearbox ➥ Valve clearance: 0.20 ± 0.02 mm Adjustable piston position of cylinder

Fig. 44: Numbering order of cylinders

If piston no. 1 is at the top dead centre during the compression cycle

Valve position Aspiration

Exhaust

• no. 1

●

●

• no. 2

●

• no. 3

●

• no. 4

4-2

SHB DT25 en - Edition 1.4 * * dt25b410.fm

Engine D

☞ Turn the flywheel 360° until mark B (1TC) of the flywheel coincides with projection C so that piston no. 1 is brought to the intake/exhaust position.

☞ Check whether piston no. 1 reaches the top dead centre of the intake/exhaust cycle. ➥ Turn the flywheel 15° to check whether the piston is in the top dead centre during the compression or intake/exhaust cycle.

➥ The piston is in the top dead centre during the compression cycle when the intake/ exhaust valves do not move. In this case, turn the flywheel 360° until mark B (1TC) of the flywheel coincides with projection C. Fig. 45: Valve clearance

➥ The piston is in the top dead centre during the intake/exhaust cycle when both valves move.

☞ Check valve clearance D at the mark “●” with a feeler gauge ☞ Numbering order of cylinders: no. 1, no. 2, no. 3, no. 4, starting from the gearbox ➥ Valve clearance: 0.20 ± 0.02 mm Adjustable piston position of cylinder

Valve position Aspiration

Exhaust

• no. 1 If piston no. 1 is at the top dead centre during the intake/exhaust cycle

E F

• no. 2

●

• no. 3

●

• no. 4

●

●

☞ Set the valve clearance on the cylinder by turning setting screw E ➥ Valve clearance: 0.20 ± 0.02 mm ☞ Tighten locknut F ➥ Check the setting again with the feeler gage ☞ Repeat the procedure for each cylinder ☞ Install the cylinder-head cover ➥ Specific torque 6.87 ÷ 11.2 Nm

Fig. 46: Set the valve clearance

SHB DT25 en - Edition 1.4* dt25b410.fm

4-3

Engine 4.3

Checking and adjusting maximum engine speed ☞ Check and adjust the maximum engine speed at normal engine operating temperature: ➥ On a warm engine Procedure

A

☞ Open engine cover A

Fig. 47: Engine cover

☞ Accelerate engine to maximum; to do this, move throttle B forward. ☞ Check the maximum engine speed ➥ Maximum engine speed: 2350 ± 50 rpm

B

Fig. 48: Throttle

C

☞ Adjust engine speed by turning adjusting screw C ☞ Tighten locknut D ➥ Check the maximum engine speed setting again ☞ Close engine cover A again

D

Fig. 49: Setting maximum engine speed

4-4

SHB DT25 en - Edition 1.4 * * dt25b410.fm

Engine 4.4

Fan belts: checking tension and replacement ☞ The checking and adjusting of the tension of the fan belt and the replacement of the belt can be performed:

➥ On a cold engine Checking the tension of the fan belt Procedure

A

☞ Remove cover A

Fig. 50: Inspection lid

☞ Check the slack B. Apply a load of 98 N (10 kgf) to the belt between the disks of the drive shaft and the alternator C

➥ Slack of the fan belt:8 ± 1 mm C B

Fig. 51: Fan belt tensioning

☞ If the slack is above the specified values, loosen the fastening screws D of the alternaD

tor and push these so that the belt is tensioned.

B

Fig. 52: Fan belt tensioning

SHB DT25 en - Edition 1.4* dt25b410.fm

4-5

Engine Fan belt damage and wear and tear Procedure

☞ Check the fan belt for damage ☞ If the belt has been damaged, it must be replaced ☞ Check whether the belt has worn out and sunk into the groove of the disk ☞ Swap out the belt if it is worn out and has penetrated down to the groove floor

Correct

Wrong

Fig. 53: Damage to the fan belt

Correct

Wrong

Fig. 54: Damage to the fan belt

4-6

SHB DT25 en - Edition 1.4 * * dt25b410.fm

Engine Fan belt replacement Procedure

A

☞ Remove cover A

Fig. 55: Inspection lid

☞ Loosen screws B and move the alternator B

Fig. 56: Fan belt tensioning

C

☞ Remove fan belt C ☞ Replace the belt with a new one ☞ Retension the belt correctly by moving the alternator ☞ Install cover A again.

Fig. 57: Fan belt

SHB DT25 en - Edition 1.4* dt25b410.fm

4-7

Engine 4.5

Engine malfunctions Problem

Possible causes Wrong SAE class / grade of engine lubrication oil Fuel grade does not comply with specifications Malfunctioning or empty battery Loose or oxidized cable connections in starter circuit Malfunctioning starter, or pinion does not engage Wrong valve clearance Malfunctioning fuel injector Malfunctioning starting relay

Engine does not start or is not easy to start

Malfunctioning glow plug/malfunctioning intake-air preheating Malfunctioning solenoid switch Cutoff solenoid does not attract Cutoff solenoid without current Clogged filter Malfunctioning fuel pump Air in fuel system Malfunctioning cutoff solenoid, timer or relay High pressure created immediately in the hydraulic system Fuel grade does not comply with specifications Wrong valve clearance

Engine starts, but does not run smoothly or faultless

Air in fuel system Injection line leaks Malfunctioning fuel injector Oil level too low Oil level too high Dirty air filter Dirty oil radiator fins

Engine overheats. Temperature warning system responds

Malfunctioning fan, torn or loose V-belt Resistance in cooling system too high, flow capacity too low Damaged seal on radiator Coolant level too low Malfunctioning fuel injector

4-8

SHB DT25 en - Edition 1.4 * * dt25b410.fm

Engine Problem

Possible causes Oil level too high Fuel grade does not comply with specifications Dirty air filter Malfunctioning air filter maintenance switch or gage

Insufficient engine power

Wrong valve clearance Injection line leaks Malfunctioning fuel injector Injection line leaks

Engine does not run on all cylinders

Malfunctioning fuel injector Oil level too low Excessive machine inclination (max. 15°)

Insufficient or no engine oil pressure

Dirty oil intake filter Wrong SAE class / grade of engine lubrication oil Oil level too high

Engine oil consumption too high

Excessive machine inclination (max. 15°) Oil level too high Blue

Too much machine inclination (max. 20°) Engine burns oil (malfunctioning cylinder head gasket) Engine starting temperature too low Fuel grade does not comply with specifications

White

Wrong valve clearance Malfunctioning fuel injector

Engine smoke

Coolant combustion (malfunctioning cylinder-head gasket) Dirty air filter Malfunctioning air filter maintenance switch or gage Black

Wrong valve clearance Malfunctioning fuel injector (drips) Wrong fuel injection pump setting

SHB DT25 en - Edition 1.4* dt25b410.fm

4-9

Engine

4-10

SHB DT25 en - Edition 1.4 * * dt25b410.fm

Traveling drive

Traveling drive

5

Traveling drive

5.1 Travelling drive pump DT25 14

13

1

16

15

4

3

2

18

17 34

5

7

21

20

33

9

23

26

11

19

4

24

25

SHB DT25 en - Edition 1.4* dt25b510.fm

28

29

31

3

30

12

10

32

2

22

27

8

6

1

5-1

Traveling drive 5.2

Legend: traveling drive pump DT25 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

5-2

Designation Reciprocating pump with adjustable piston displacement for right track Reciprocating pump with adjustable piston displacement for left track Pressure increase pump Gear pump for work operation Supply for forward travel (right track) Pressure measuring point for forward travel (right track) Supply for reverse travel (right track) Pressure measuring point for reverse travel (right track) Supply for forward travel (left track) Pressure measuring point for forward travel (left track) Supply for reverse travel (left track) Pressure measuring point for reverse travel (left track) Drive control connection for forward travel (right track) Drive control connection for reverse travel (right track) Drive control connection for forward travel (left track) Drive control connection for reverse travel (left track) Mechanical zero point of pump (right track) Adjustment of max. pump displacement (right track, reverse travel) Adjustment of max. pump displacement (right track, forward travel) Mechanical zero point of pump (left track) Adjustment of max. pump displacement (left track, reverse travel) Adjustment of max. pump displacement (left track, forward travel) Suction side of the gear pump for work hydraulics Gear pump outlet for work operation Pressure measuring point for work operation Pressure-increase pump intake Boost-pressure line Pressure reducing valve for primary boost pressure Measuring point for boost pressure Pressure reducing valve for secondary boost pressure Registration of initial position of automotive control Pilot control supply Reservoir line Engine cleaning line

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Traveling drive 5.3 Automotive valve DT25 3 1

2

3

1

2 Item 1 2 3

SHB DT25 en - Edition 1.4* dt25b510.fm

Designation Automotive control valve Pressure reducing valve for secondary boost pressure Registration of initial position of automotive control

5-3

Traveling drive Description: The automotive valve regulates the boost pressure of the left-hand control lever (pilot controls) depending on the speed range of the diesel engine; If the speed drops, the boost pressure of the pilot controls drops, too, and therefore the max. control pressure for pump displacement, too.

If the diesel engine is overloaded, and if the number of revolutions is reduced, the control pressure is reduced, and therefore the pump displacement and the power input, too.

Pump diagram with variable displacement with automotive valve 1

4 3

M

2

Item 1 2 3 4

5-4

Designation Automotive control valve Pressure reducing valve for primary boost pressure Pressure reducing valve for secondary boost pressure Registration of initial position of automotive control

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Traveling drive 5.4 Hydraulic motor 2

1 6

8

8

7 3 9 5

4 7 10 4

Item 1 2 3 4 5 6 7 8 9 10

SHB DT25 en - Edition 1.4* dt25b510.fm

Designation Supply for forward travel (right track)/reverse travel (left track) Supply for reverse travel (right track)/forward travel (left track) Engine cleaning line Reservoir line Brake valve Capacity modification control Negative brake unlock control Hydraulic motor Epicycloidal gearbox Gearbox oil fill and drain cover

5-5

Traveling drive 5.5 Left control lever 3

4 2

5

Item 1 2 3 4 5 6

5-6

1

6

Designation Reverse travel control Left-turn control Forward travel control Right-turn control Pilot control supplied with oil by pressure-increase pump Reservoir line

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Traveling drive 5.6 Solenoid valve for changeover of Drive control 2

4 8 1

5

6

3

7

1

Item 1 2 3 4 5 6 7 8

SHB DT25 en - Edition 1.4* dt25b510.fm

Designation Reverse travel control Left-turn control Forward travel control Right-turn control Supply for forward travel control of pump (right track) Supply for forward travel control of pump (left track) Supply for reverse travel control of pump (right track) Supply for reverse travel control of pump (left track)

5-7

Traveling drive 5.7

Test instructions

Checking travel pressure DT25 Ensure utmost cleanliness of all measuring points and connections, micro measuring lines and pressure gauges that are connected for checking pressure => even the slightest traces of dirt, for example a grain of sand, can impair tightness and cause leaks Tools required: • 4 x Pressure gauge 600 bar Travel pressure measuring point for forward travel (left track)

Travel pressure measuring point for forward travel (right track)

Travel pressure measuring point for reverse travel (left track)

Travel pressure measuring point for reverse travel (right track)

Check the travel pressure as follows:

☞ Switch off the vehicle ☞ Connect the 600 bar pressure gauge to the test connections ☞ Starts the engine ☞ Increase engine speed to 2350 rpm ☞ Make the vehicle travel against hydraulic resistance ➥ The track must not turn ☞ Actuate the corresponding joysticks ➥ Rated pressure: 350 ± 10 bar ☞ Repeat the work steps for the other measuring points

5-8

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Traveling drive Checking straight-ahead vehicle travel If after a certain time the vehicle noticeably steers to the right or left during forward or backward vehicle travel, adjustments have to be performed on the mechanical end stops of the relevant track.

Minor deviations from straight-ahead machine travel are allowed However, if the machine moves more than 45 cm from the centerline over a distance of approx. 10 meters, then the end stops have to be correctly adjusted again.

Tools required: • 1 x Optical tachometer

Ma

10

x.

40

–4

5c

m

m

Adjusting screw for slow reverse travel (right track)

Adjusting screw for slow forward travel (right track)

Adjusting screw for slow reverse travel (left track)

Adjusting screw for slow forward travel (left track)

Adjusting screw for fast travel

SHB DT25 en - Edition 1.4* dt25b510.fm

5-9

Traveling drive Check and adjust the travel speed as follows:

☞ Raising the vehicle ☞ Starts the engine ☞ Increase engine speed to 2350 rpm ☞ Actuate the corresponding joysticks ☞ Speed of the drive pinion at low travel ➥ Nominal speed at slow speed 70 (at ±1 rpm) ☞ Correct any deviation of the speed of rotation by means of the adjusting screw ☞ After determining the speed at slow travel, determine the speed of the drive pinion at fast speed

➥ Nominal speed at fast speed 123 (at ±1 rpm) ☞ Correct any deviation of the speed of rotation by means of the adjusting screw ☞ Repeat the work steps for both tracks in both travel directions

5-10

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Traveling drive Checking: automotive valve DT25 Check the power consumption of the engine by driving the vehicle against a block.

Tools required: • 4 x Pressure gauge 600 bar • 1x tachometer for the diesel engine Adjustment screw for switch-on point - automotive valve

Travel pressure measuring point for forward travel (right track)

Travel pressure measuring point for forward travel (left track)

Travel pressure measuring point for reverse travel (left track)

Travel pressure measuring point for reverse travel (right track)

To control the power consumption of the engine and the switch-on point of the automotive valve, proceed as follows:

☞ Switch off the vehicle ☞ Connect the 600 bar pressure gauge to the test connections ☞ Starts the engine ☞ Increase engine speed to 2350 rpm ☞ Make the vehicle travel against hydraulic resistance ➥ The track must not turn ☞ Actuate the corresponding joysticks ➥ Rated pressure: 350 ± 10 bar ☞ Check that the speed of the diesel engine does not drop below 1800 rpm after the vehicle has been driven at a nominal driving pressure of 350 ± 10 bar "against block"

➥ Minimum engine speed: 1850 ± 50 rpm ☞ Correct any deviation by means of the adjusting screw

SHB DT25 en - Edition 1.4* dt25b510.fm

5-11

Traveling drive

5-12

SHB DT25 en - Edition 1.4 * * dt25b510.fm

Hydraulic system

Hydraulic system

6

Hydraulic system

6.1 Gear pump for functions DT25 1

1

Item 1 2 3

SHB DT25 en - Edition 1.4* dt25b610.fm

2

3

Designation 17 cm³ gear pump for work operation Pressure side gear pump for work hydraulics Suction side of the gear pump for work hydraulics

6-1

Hydraulic system 6.2 Right-hand control lever

3

4

2

5

Item 1 2 3 4 5 6

6-2

1

6

Designation Skip rotation control to the left Operation skip tilt out Skip rotation control to the right Operation skip tilt out Pilot controls supplied with oil by gear pump Reservoir line

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system 6.3 Hydraulic control valve DT25 with swivel skip, front skip (option) 4

1

12

5 7

10

11 9 6 8

3

2 Item 1 2 3 4 5 6 7 8 9 10 11 12 13

SHB DT25 en - Edition 1.4* dt25b610.fm

Designation Skip rotation control to the left Operation skip tilt out Skip rotation control to the right Operation skip tilt out Cylinder connection for Swivel skip rotation - rod side Cylinder connection for Swivel skip rotation - base side Tilt cylinder rod-side connection Tilt cylinder base-side connection Work hydraulics supplied by gear pump Reservoir line Oil supply hydraulic control valve hydraulic PTO shaft (option) Tank line and hydraulic PTO shaft (option) Pressure limiting valve work hydraulics

6-3

Hydraulic system 6.4 Check valve DT25 with swivel skip 1

2

3

4

Item 1 2 3 4

6-4

Designation Skip swivel ram rod-side connection Skip swivel ram base-side connection Oil supply of valve for hydraulic work-operation ram Oil supply of valve for hydraulic work-operation ram

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system 6.5 Solenoid valve for hydraulic PTO shaft (option) 2

1

5

3

Item 1 2 3 4 5 6

SHB DT25 en - Edition 1.4* dt25b610.fm

6

4 Designation Additional connection P Additional connection P1 Supply of additional connection P Additional connection P1 Solenoid valve supplied with oil by means of hydraulic HPCO main control valve Reservoir line

6-5

Hydraulic system 6.6

Test instructions

Checking the operating pressure of the operating hydraulics DT25 with swivel skip, front skip (option) Ensure utmost cleanliness of all measuring points and connections, micro measuring lines and pressure gauges that are connected for checking pressure => even the slightest traces of dirt, for example a grain of sand, can impair tightness and cause leaks Tools required: • 1 x pressure gauge 200 bar Adjusting screw of operating hydraulics pres-

Measuring point of operating hydraulics pressure Check the operating hydraulics pressure as follows:

☞ Switch off the vehicle ☞ Connect the 200 bar pressure gage to the test connection ☞ Starts the engine ☞ Increase engine speed to 2350 rpm ☞ Actuate the skip joystick until the skip control cylinder is fully extended ➥ Skip is tilted out ☞ Continue actuating the skip joystick ➥ Rated pressure: 175 ± 5 bar ☞ Correct any pressure deviation by means of the adjusting screw

6-6

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system Checking boost pressure DT25 Tools required: • 1 x Pressure gauge 50 bar Primary boost-pressure adjusting screw

Measuring point for boost pressure

Secondary boost-pressure adjusting screw Check the boost pressure as follows:

☞ Switch off the vehicle ☞ Connect the 50 bar pressure gauge to the test connection ☞ Starts the engine ☞ Increase engine speed to 2350 rpm ➥ Rated pressure: 23 – 25 bar ☞ Correct the pressure differences with the adjusting screw for the secondary boost pressure There are two pressure reducing valves for the boost pressure. As a rule, the pressure reducing valve for the secondary boost pressure does not have to be adjusted.

If the rated pressure of 23 – 25 bar cannot be reached by tightening the adjusting screw for the secondary boost pressure to the limit, proceed as follows:

☞ Increase engine speed to 2350 rpm ☞ Fully tighten the adjusting screw for the secondary boost pressure ☞ Set the boost pressure to the following value by means of the adjusting screw for the primary boost pressure:

➥ Rated pressure: 25 – 27 bar ☞ Then turn the adjusting screw for the secondary boost pressure to adjust the pressure to the following value:

➥ Rated pressure: 23 – 25 bar

SHB DT25 en - Edition 1.4* dt25b610.fm

6-7

Hydraulic system 6.7 Hydraulics diagram DT25 with swivel skip and front skip (option) 14 Swivel

34 35

Skip

36 29

3

1 4 L1

2

23

8

17

B

A

Brake

X

L

Br

32

19

27 18

38

2° Vel.

13

20

12

30

31

L

Br

L1

28

22

B

A

X

24 37

10 33

16 15 25

9

26

C

M

T

6

P

21

11

6-8

5

7

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system 6.8

Legend: hydraulics diagram DT25 with swivel skip and front skip (option) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

SHB DT25 en - Edition 1.4* dt25b610.fm

Designation Pressure accumulator Radiator Tilt cylinder Swivel cylinder Hydraulic motor Solenoid valve for enabling Machine travel operation Intake filter Return filter Left-hand control lever (travel controls) Right-hand control lever (work operation controls) Connection for Drain Right track hydraulic motor Left track hydraulic motor Hydraulic distributor Travel pressure measuring point for forward travel (right track) Travel pressure measuring point for reverse travel (right track) Travel pressure measuring point for forward travel (left track) Travel pressure measuring point for reverse travel (left track) Measuring point of operating hydraulics pressure Pressure measuring point of pressure increase pump Reciprocating pump with adjustable piston displacement for right track Reciprocating pump with adjustable piston displacement for left track Operating hydraulics gear pump Pressure increase pump Maximum pressure valve for forward travel (right track) Maximum pressure valve for reverse travel (right track) Maximum pressure valve for forward travel (left track) Maximum pressure valve for reverse travel (left track) Work hydraulics pressure relief valve Maximum pressure valve of primary pressure increase pump Maximum pressure valve of secondary pressure increase pump Solenoid valve lock for brake, 2nd travel speed, travel operation activation Solenoid valve for changeover of travel controls One-way throttle valve ø 1.5 mm One-way throttle valve ø 2.0 mm Check valve One-way valve Valve group “Automotive”

6-9

Hydraulic system

P

A B

15

T

6.9 Hydraulics diagram DT25 with swivel skip, front skip and hydraulic PTO shaft (option)

7

Swivel

35 36

Skip

37 30

3

1 2

4 24

L1

20

18

B

A

Brake

X

L

Br

33

9

14

39

19

21

L1

29

L

Br

2° Vel.

13

28

31

32

23

B

A

X

25

38 11 17

34 16 10

C

M

T

22 P

6

27

26

12 6-10

5

8

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system 6.10 Legend: hydraulics diagram DT25 with swivel skip, front skip and hydraulic PTO shaft (option) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

SHB DT25 en - Edition 1.4* dt25b610.fm

Designation Pressure accumulator Radiator Tilt cylinder Swivel cylinder Hydraulic motor Solenoid valve for enabling Machine travel operation Solenoid valve for control of hydraulic PTO shaft Intake filter Return filter Left-hand control lever (travel controls) Right-hand control lever (work operation controls) Connection for Drain Right track hydraulic motor Left track hydraulic motor Hydraulic distributor Travel pressure measuring point for forward travel (right track) Travel pressure measuring point for reverse travel (right track) Travel pressure measuring point for forward travel (left track) Travel pressure measuring point for reverse travel (left track) Measuring point of operating hydraulics pressure Pressure measuring point of pressure increase pump Reciprocating pump with adjustable piston displacement for right track Reciprocating pump with adjustable piston displacement for left track Operating hydraulics gear pump Pressure increase pump Maximum pressure valve for forward travel (right track) Maximum pressure valve for reverse travel (right track) Maximum pressure valve for forward travel (left track) Maximum pressure valve for reverse travel (left track) Work hydraulics pressure relief valve Maximum pressure valve of primary pressure increase pump Maximum pressure valve of secondary pressure increase pump Solenoid valve lock for brake, 2nd travel speed, travel operation activation Solenoid valve for changeover of travel controls One-way throttle valve ø 1.5 mm One-way throttle valve ø 2.0 mm Check valve One-way valve Valve group “Automotive”

6-11

Hydraulic system 6.11 Hydraulics diagram DT25 with swivel skip and dozer blade (option)

%

7

+3&2

14

39

Stabiliz-

%

$

BLADE

Swivel

35

Skip

DUMPING

% &

$

&

%

3

%

3

SWIVEL

$

34

36 A1 B1 A2 B2

&

&

3

9

3

9

29

40

A B

T

4 1

19

17

2

23

8

3

/

%U

/

7

/HIW -

27

*

5LJKW -

%

%

$

;

20

30

*

%U

0

0

31

24 *

6

3

/

7

*

28

$

%5

38

12

QG VSHHG

2° Vel.

Brake

18

/

32

*

13

%

37

$

3

10

7

7

;

%

$

;

;

7

22

25

7

7

21

;

%

0

C

%

T

6

P

)

26

7

)

3

15 ;

33

7

9

0

0

*

16

11

6-12

5

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Hydraulic system 6.12 Legend: hydraulics diagram DT25 with swivel skip and dozer blade (option) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

SHB DT25 en - Edition 1.4* dt25b610.fm

Designation Pressure accumulator Radiator Tilt cylinder Swivel cylinder Hydraulic motor Solenoid valve for enabling Machine travel operation Intake filter Return filter Left-hand control lever (travel controls) Right-hand control lever (work operation controls) Connection for Drain Right track hydraulic motor Left track hydraulic motor Hydraulic distributor Travel pressure measuring point for forward travel (right track) Travel pressure measuring point for reverse travel (right track) Travel pressure measuring point for forward travel (left track) Travel pressure measuring point for reverse travel (left track) Measuring point of operating hydraulics pressure Pressure measuring point of pressure increase pump Reciprocating pump with adjustable piston displacement for right track Reciprocating pump with adjustable piston displacement for left track Operating hydraulics gear pump Pressure increase pump Maximum pressure valve for forward travel (right track) Maximum pressure valve for reverse travel (right track) Maximum pressure valve for forward travel (left track) Maximum pressure valve for reverse travel (left track) Work hydraulics pressure relief valve Maximum pressure valve of primary pressure increase pump Maximum pressure valve of secondary pressure increase pump Solenoid valve lock for brake, 2nd travel speed, travel operation activation Solenoid valve for changeover of travel controls One-way throttle valve ø 1.5 mm One-way throttle valve ø 2.0 mm Check valve One-way valve Valve group “Automotive” Dozer blade cylinder Solenoid valve for activating the dozer blade

6-13

Hydraulic system

6-14

SHB DT25 en - Edition 1.4 * * dt25b610.fm

Electrical system

Electrical system

7 7.1

Electrical system Ohmic 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 (W)

! Mnemonic:

U R

I

Power Power “P” – Watt (W) P = U x I = R x I² = U²/R

7.2

Measuring equipment, measuring methods Multifunction measuring device • Measurement 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-energized vehicle electrical system and of wiring harnesses.

SHB DT25 en - Edition 1.4* dt25b710.fm

7-1

Electrical system Measuring methods – multifunction measuring device • Measuring current (starter switched on): • Black cable in COM socket (ground), • red cable in A socket or mA socket; connect in series to consumer.

• Measuring voltage (starter switched on): • Black cable in COM socket (ground), • red cable in V socket; • connect in parallel to consumer.

• Measurement of starter (starter switched off): • Black cable in COM socket (ground), • red cable in W socket; • connect in parallel to consumer (see measuring voltage).

Test lamp The test lamp is used for testing lines and functions with the starter switched on.

• Line test (testing voltage): Connect test lamp between test point (live cable) and vehicle ground or between test point (grounding 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.

7.3

7-2

Electric units Electrical system

Model DT25

Dynamo

12 V 480 W

Starter

12 V 2.0 kW

Battery

12 V 105 Ah

SHB DT25 en - Edition 1.4 * * dt25b710.fm

Electrical system 7.4

Fuses Fuse box A is located under the operator seat. The 3 power fuses B are located under the engine cover

Description

Fuse

A

8

10

11

3

4

5

6

7

9

2

1

12 13

14

Rated current (A)

1

1-pole socket 12 V

10 A

2

Lights switch

15 A1

3

Armrest microswitch

4

Switch supply depending on speed and seat rotation

5

Not used

6

Electro-stop

7

Not used

8

Rotating beacon switch

10 A

9

Switch lights

3A

10

Alternator excitation

5A

11

Horn relay

7.5 A

12

Diesel engine glow plug preheating

40 A

13

Main supply

60 A

14

Alternator

50 A

5A 7.5 A 5A -

B

Fig. 58: Fuses

SHB DT25 en - Edition 1.4* dt25b710.fm

7-3

Electrical system 7.5 Instrument panel overview

9

4

5

3

6 7

2

8

11

1 10

Item 1 2 3 4 5 6 7 8 9 10 11

7-4

Designation Indicator light (red) – clogged air filter Indicator light (red) – coolant temperature Indicator light (red) – engine oil pressure Indicator light (red) – alternator charge function Indicator light (yellow) – diesel engine glow plug preheating Indicator light (yellow) – fuel gage Indicator light (green) – second travel speed switched on Indicator light (red) - Armrest safety display switched on Fuel level indicator Hour meter Preheating start switch

SHB DT25 en - Edition 1.4 * * dt25b710.fm

50A

R10

R10

F1b

X20

F1a

X20

R10

60A

12Vcc

R50

B4

F1b

X19

F1a

X19

R10

B4

X16.2

R10 R10

1

X16.1

X15

85

X15

30

X15

X15

87

B4

R4

X18.2

X18.1

1 2

X18.1

40A

M6

M6

B-N1

N1

N1

S1 B-R1.5

86

X21

F1b

X17

F1a

X17

2

X6

1

X6

3

X6

1

2

X24

X24

L-N1

R4 R10

N50

N50

B-N1.5 L-N1

18 H-L1 1

X23.2

1

X23.1

44 L-N1

38 N1

Z-B1 H/N1

1

0

H-R1 X22

1

1

-

X14

5

X10

X10

5 V-B1 V/B1 B1

10

X10

9

X10 1 0

X99.p

G2.5

1

X5

5

X5

2

X5

6

X5

10

X5

9

X5

A B

X12.p

1

1 2 3 4 5 6 7 8 9 10 11 12 X99.p

M6 M-N1 R1.5 R10

V-N1

H1.5

X13.p

N2.5

A/R1 N1 N1

G/R1 G/R1 N1

R10 R1.5

0

1

X9

5

X9

X33.2

1

X33.1

1

10A

F1b

X32

X32

F1a

10

X9

9

X9

1

X39.2

15A

1

85

X34

X39.1

GND

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

N2.5 B-N1 B-N1.5 H/N1 L-N1 H-L1 V-B1 V/B1 S1 B1 B-R1.5 Z-B1 N2.5 N1.5 N1.5 N2.5 N1.5 N1.5

G1.5

H-N1.5 G1.5

N1.5 N1

G/R1 N1 R-N1.5

Z1.5 R-G1.5 R-N1.5 N1.5

A2.5

G2.5 H1.5 H-N1.5 G/R1 N1 R-G1.5 Z1.5 H-R1 V-N1 A/R1 M6 R10

V/B1

R-N1.5

A4 G/R1

R-N1.5

N1 B-N1.5 H/N1 L-N1 H-L1 V-B1 V/B1 S1 B1 B-R1.5 Z-B1 N1

G2.5

5A

F3b

X32

X32

F3a

N1.5

7.5A

F4b

X32

X32

F4a

87a

I

86

-

X34

X34

X11.2

87

30

X11.1

1

X34

X34

X34

Z1.5 M-N1

N1

F2b

X32

X32

F2a

V-N1

A2.5 A/R1

A2.5 N1

X32

F5a

5A

A2.5 L-N1

F6b

X32

X32

F6a

C-R1

A2.5 A-N1 H-R1 C1.5 N1.5

1

-

X31.2

X31.1

-

X30.2

1

X30.1

1 2 3 4

X2.s X2.s X2.s X2.s

10A

X35

2

X7

1

X7

30 X35

85

X35

87a 87

X35

86

X35

X32

F7a

C-N1.5

L-R1 L-R1 L-R1 L/N1 H1.5 N1.5

A2.5

N1 N1 B-G1 L-R1 C-R1 C-N1 H-N1.5 N1.5

X5

X5

X5

X5

X5

X5

X5

X5

X5

X5

85 X25

F8b

X32

X32

F8a

3A F9b

X32

X32

F9a

30

X25

86 X25

5A

2

X8

1

X8

A2.5

F10b

X32

X32

F10a

7.5A

87a X25

87 X25

F11b

X32

X32

F11a

X5

1 2 3 4 5 6 7 8 9 10 11 12

X5

R1.5 R-G1.5

A2.5 L-R1

A2.5 B-G1

X40

X29

2

1

1

2

X37

X37

X40

3 4

5 6 X40

X40

Z-B1

AUX CONNECTOR

X29

X100.p

A-N1 M6

A4

R10

B-N1 M1

A2.5 A2.5 M-B1

C1.5 C-R1 H-R1

L-R1 N1 N1 M-B1

0 1 2 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

H-R1

M-B1 Z-B1 B/R1

G/R1 N1 H/N1 H-L1 V-B1 H-N1 B/R1 M-B1 Z-B1 M1 S1 B1 N1

21

N1

X4

X4

1 2 3 X4

H

C-N1.5 C-N1 C/B1

B/R1 A-N1 B-N1 B/R1 M

N1 M-N1 L/N1

2

X26

1

X26

H-N1.5

V-B1 M1 S1 H-L1 B1 L N

1 2 3

X88 X88 X88

H

G2.5 H1.5 H-N1.5 G/R1 N1 R-G1.5 Z1.5 H-R1 V-N1 A/R1

4

N1

2

X27

1

X27

C/B1

N1 H-N1 B-N1 B/N1 B/R1 M

Z1.5 N1.5 L-R1.5 N1.5 L-R1 C/B1

20

C/B1

33

X36.1

2

X28

1

X28

6

N1

24

L/N1

19

L N

25

48

N1

26

45

N1

27 C/B1

B-N1.5 A4 M-B1 Z-B1 B/R1 H/N1 V-B1 M1 S1 H-L1 B1 B-N1.5 G/R1 N1 H-N1

28

N1

C/B1

X36.1

5 6

X3

X3

GND

GND

1

X36.2

X36.2

M6 3 4 X36.2

R6 1 2 3 X3

H-R1 B/N1

A4 B/R1 M

R6

2

X36.2

8

X36.1

X98.p

1 2 3 4

M6 R10 A4 A4 L-R1

M6 R10 A4 A4

SHB DT25 en - Edition 1.4* dt25b710.fm

23

H

41 L N

R6 R6 R10 A4 M6

7

X36.1

X1.p

L/N1

A4 M6 L-R1

36 M6

37 SA1

1 2 3 4 5 6 7 8

C1.5 H1.5 H-N1.5

30 17 9 L/N1

40 35

C1.5 H1.5 H-N1.5 H-R1 M-B1 L-R1 L/N1 L/N1

A4

Electrical system

Loader unit

7.6 DT25 diagram 34

39 47 46

43 42 7

8 2

3

1

31

22

29

32

7-5

Electrical system 7.7

DT25 diagram (legend) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

7-6

Designation Fuel level sensor Horn Engine oil pressure switch Coolant temperature switch Air filter clogging switch Switch position front/rear side of operator seat Front right light Front left light Auxiliary fuse Front light fuse Armrest lock switch fuse Main fuse 2nd travel speed and operator seat position Electro-stop fuse Rotating beacon fuse Instrument panel light fuse Alternator fuse Horn fuse Glow plug preheating fuse Master fuse Starter fuse Battery Alternator Horn Starter relay Parking brake relay Horn relay 2nd travel speed relay Timer for glow plug preheating Starter Instrument panel Preheating glow plugs Battery master switch Control lever on the left Armrest (right) switch Armrest (left) switch Front light switch Rotating beacon switch Parking brake push button

SHB DT25 en - Edition 1.4 * * dt25b710.fm

Electrical system 39 40 41 42 43 44 45 46 47 48

SHB DT25 en - Edition 1.4* dt25b710.fm

Switch (operator seat not in correct position) Starter 1-pole socket 12 V Solenoid valve for enabling controls Solenoid valve for second travel speed Solenoid valve for electro-stop Parking brake solenoid valve Travel controls changeover solenoid valve Travel controls changeover solenoid valve Electro-stop

7-7

Electrical system

7-8

SHB DT25 en - Edition 1.4 * * dt25b710.fm

SHB DT25 en - Edition 1.4 * dt25b711.fm

Electrical system

7-9

Electrical system

Wiring harnesses (overview)

Engine wiring harness DT25

Symbols legend PVC strap Shrink terminal Clamp Closed corrugated hose PA6 Heavy PVC tube No coating Cable colors legend

BK

Black

RD

Red

PK

Pink

GN

Green

VT

Violet

CY

Light blue

WH

White

OG

Orange

YE

Yellow

GY

Gray

BU

Blue

BN

Brown WH-RD: white/red lengthwise WH/RD: white/red crosswise

SHB DT25 en - Edition 1.4 * dt25b711.fm

Working light wiring

Electrical system

7-10

7.8

SHB DT25 en - Edition 1.4 * dt25b711.fm

7.9

Instrument panel wiring harness DT25 (right)

Symbols legend PVC strap Shrink terminal Clamp Closed corrugated hose PA6 Heavy PVC tube No coating Cable colors legend

BK

Black

RD

Red

PK

Pink

GN

Green

VT

Violet

CY

Light blue

WH

White

OG

Orange

YE

Yellow

GY

Gray

BU

Blue

BN

Brown WH-RD: white/red lengthwise WH/RD: white/red crosswise

Electrical system

7-11

Symbols legend PVC strap Shrink terminal Clamp Closed corrugated hose PA6 Heavy PVC tube No coating Cable colors legend

BK

Black

RD

Red

PK

Pink

GN

Green

VT

Violet

CY

Light blue

WH

White

OG

Orange

YE

Yellow

GY

Gray

BU

Blue

BN

Brown WH-RD: white/red lengthwise WH/RD: white/red crosswise

Electrical system

7-12

7.10 Instrument panel wiring harness DT 25 (left)

SHB DT25 en - Edition 1.4 * dt25b711.fm

SHB DT25 en - Edition 1.4 * dt25b711.fm

7.11 Control unit wiring harness DT25 Symbols legend PVC strap Shrink terminal Clamp Closed corrugated hose PA6 Heavy PVC tube No coating Cable colors legend

BK

Black

RD

Red

PK

Pink

GN

Green

VT

Violet

CY

Light blue

WH

White

OG

Orange

YE

Yellow

GY

Gray

BU

Blue

BN

Brown WH-RD: white/red lengthwise WH/RD: white/red crosswise

Electrical system

7-13

Symbols legend PVC strap Shrink terminal Clamp Closed corrugated hose PA6 Heavy PVC tube No coating Cable colors legend

BK

Black

RD

Red

PK

Pink

GN

Green

VT

Violet

CY

Light blue

WH

White

OG

Orange

YE

Yellow

GY

Gray

BU

Blue

BN

Brown WH-RD: white/red lengthwise WH/RD: white/red crosswise

Electrical system

7-14

7.12 Chassis wiring harness DT25

SHB DT25 en - Edition 1.4 * dt25b711.fm

SHB DT25 en - Edition 1.4 * dt25b711.fm

7.13 Table of conductors DT25 Line

Connector X6 X12.s

Position 1 2 3 A B 1 2 3

X16.1

4 5 6 7 8 9 10 11 12 13 14 15 1 85 86 30 87 1

X16.2

1

X13.p

Engine wiring X14 X15

X17

X18.2 X19 X20

F1b

7-15

F1a F1b

Cross section (mm²) 1 1 1 6 10 2.5

Function Diesel fuel level indicator Diesel fuel level indicator light Ground Glow plug output +30 fuse 50 A (fuse) Ground

Destination X13.p/4 X13.p/12 Gnd2 X17/F1a X19/F1b Gnd2

BK-WH BK-WH GY/BK BU-BK GY-BU GN-WH GN/WH PK WH WH-RD VT-WH BK BK BK WH BK WH-BK RD WH WH RD RD BN BN PK WH-RD

1.5 1 1 1 1 1 1 1 1 1.5 1 2.5 2.5 2.5 1 1 1 4 4 4 10 10 6 6 1 1.5

50 A start 50 A start Diesel fuel level indicator +15 electro-stop Air filter indicator light Indicator light for high coolant temperature Buzzer (high water temperature) Alternator indicator light Engine oil pressure indicator light +15 alternator excitation Diesel fuel level indicator light Ground Ground Ground Engine oil pressure indicator light Ground 50 A start +30 starter relay 50 A starter relay 50 A starter relay +30 (positive) +30 (positive) Glow plug output Glow plug output Alternator indicator light +15 alternator excitation

X24/1 X15/86 X6/1 X24/2 X23.1 X22 X22 X18.1/1 X14 X18.1/2 X6/2 Gnd2 Gnd2 Gnd2 X13.p/10 Gnd2 X13.p/3 X19/F1b X16.1 X15/87 X20/F1b X19/F1a X12.s/A X21 X13.p/9 X13.p/11

RD RD RD RD RD RD

10 10 10 4 10 10

+30 alternator charging +30 (positive) +30 fuse 50 A (fuse) +30 starter relay +30 alternator charging +30 (positive)

X20/F1a X16.2 X12.s/B X15/30 X18.2 X16.2

Electrical system

X18.1

F1a F1b 1 2 3 1 F1a

Color GY/BK VT-WH BK BN RD BK

1

X22

1

X23.1 X23.2

1 1 1 2

X24 Engine wiring

Gnd2

X5

Right-hand instrument panel wiring

X36.1

SHB DT25 en - Edition 1.4 * dt25b711.fm

X36.2

X98.p

X100.s

1

1 2 3 4 5 6 7 8 9 10 11 12 5 6 7 8 9 10 1 2 3 4 1 2 3 4 1 2 3

BN GN/WH GN-WH GY-BU BK WH-BK BU-BK BK BK BK BK BK BK BK YE/RD BK GY/BK GY-BU GN-WH GY-BK WH/RD BN-WH VT-WH BN PK WH CY CY WH-BK BN

6 1 1 1 1 1.5 1 1 2.5 2.5 2.5 2.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1.5 6

Glow plug output Buzzer (high water temperature) Indicator light for high coolant temperature Air filter clogging indicator light Ground 50 A start +15 electro-stop Ground Ground Ground Ground Ground Ground Ground +15 machine Ground Diesel fuel level indicator Air filter clogging indicator light Indicator light for high coolant temperature Machine lights Armrest microswitch 2nd speed range indicator light Diesel fuel level indicator light Indicator light for glow plug preheating Alternator indicator light Engine oil pressure indicator light/hour meter +15/54 from ignition +15/54 from ignition 50 A start Glow plug output

X17/F1b X13.p/8 X13.p/7 X13.p/6 Gnd2 X13.p/3 X13.p/5 X23.2 X13.p/13 X13.p/14 X13.p/1 X13.p/15 X6/3 X15/85 X100.s/11 X100.s/12 X100.s/4 X100.s/8 X100.s/5 X100.s/13 X100.s/3 X100.s/1 X100.s/2 X100.s/6 X100.s/7 X100.s/9 X98.p/3 X98.p/4 X100.s/10 X36.2/4

RD RD BN BN BN RD CY CY BN-WH VT-WH WH/RD

6 6 6 6 6 10 4 4 1 1 1

+30 from fuse 50 A +30 from fuse 50 A Glow plug output Glow plug output Glow plug output +30 from fuse 50 A +15/54 from ignition +15/54 from ignition 2nd speed range indicator light Diesel fuel level indicator light Armrest microswitch

SA1 SA1 X98.p/1 X36.1/8 X36.2/3 SA1 X36.1/5 X36.1/6 X5/8 X5/9 X5/7

Electrical system

7-16

X21

SHB DT25 en - Edition 1.4 * dt25b711.fm

X100.s

4 5 6 7 8 9 10 11 12 13 14 15

SA1

1

Right-hand instrument panel wiring

1 2 3 4 5 X5

6 7 8 9 10

Left-hand instrument panel wiring

X9

7-17

1 1 1 1 1 1 1.5 1 1 1

Diesel fuel level indicator Indicator light for high coolant temperature Indicator light for glow plug preheating Alternator indicator light Air filter clogging indicator light Engine oil pressure indicator light 50 A start +15 machine Ground Machine lights

X5/3 X5/5 X5/10 X5/11 X5/4 X5/12 X36.1/7 X5/1 X5/2 X5/6

RD RD RD GY GY-BK

10 6 6 1.5 1.5

+30 from fuse 50 A +30 from fuse 50 A +30 from fuse 50 A Low beam (front left) Low beam (front right)

X98.p/2 X36.2/2 X36.2/1 X99.p/2 X99.p/3

YE YE YE

2.5 1.5 1.5

+15 lights switch +15 lights switch +15 lights switch

X99.p/1 X5/6 X5/5

YE/RD YE/RD BK BK VT

1 1 1 1 1.5

Switch lights Switch lights Ground Ground Flashing headlight

X99.p/4 X9/9 X9/10 X10/10 X99.p/7

RD-YE

1.5

+30 rotating beacon switch

X99.p/6

YE/RD BK GY-RD

1 1 1

Switch lights Ground Supply parking brake switch

X5/9 X5/10 X99.p/8

GN-BK

1

Brake switch

X99.p/9

Electrical system

X10

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5

GY/BK GN-WH BN PK GY-BU WH WH-BK YE/RD BK GY-BK

10

Left-hand instrument panel wiring

X99.p

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4

X1.s

Control unit wiring X2.s

SHB DT25 en - Edition 1.4 * dt25b711.fm

X3

X4 X12.p

5 6 7 8 9 1 2 3 4 1 2 3 1 2 3 A

CY/RD BK BK YE GY GY-BK YE/RD BK RD-YE VT GY-RD GN-BK CY/RD

1 1 1 2.5 1.5 1.5 1 1 1.5 1.5 1 1 1

Brake indicator light Ground Ground +15 lights switch Low beam (front left) Low beam (front right) Switch lights Ground +30 rotating beacon switch Flashing headlight Supply parking brake switch Brake switch Brake indicator light

X99.p/10 X99.p/5 X5/10 X5/5 X5/1 X5/2 X5/9 X10/10 X9/5 X9/1 X10/1 X10/5 X10/9

OG GY GY-BK GY-BK GY-RD GY-RD BN-BK BN-BK BU-RD BU/BK WH/RD GY-RD WH-YE BU-RD OG-RD OG-BK WH/BK GY-RD WH/RD CY-BK WH/BK WH/RD BN-BK BN

1.5 1.5 1 1.5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6

Horn Low beam (front left) Machine lights Low beam (front right) Supply parking brake switch Permision Microswitch right-hand armrest Solenoid valve 2nd travel speed 2nd speed range indicator light +15 seat rotation microswitch Brake solenoid valve Armrest microswitch +15 brake relay 2nd speed range indicator light +15 microswitch relay (2nd travel speed) Horn signal +15 push button for Horn Armrest microswitch (left) Permision Microswitch right-hand armrest Armrest microswitch +15 armrest microswitch Armrest microswitch (left) Armrest microswitch Glow plug signal Glow plug output

X35/87 X99.s/2 X100.p/13 X99.s/3 X99.s/8 X3/2 X25/87a X100.p/1 X32/F4b X34/87a X100.p/3 X34/86 X25/85 X32/F4b X35/86 X32/F11b X4/2 X1.s/4 X100.p/3 X32/F3b X3/1 X100.p/3 X40/4 X98.s/1

Electrical system

7-18 X10

6 7 8 9

SHB DT25 en - Edition 1.4 * dt25b711.fm

X12.p

B 1

X13.s

2 3 4 5 6 7 8 9 10 11 12 13 14 15 85

Control unit wiring

86 30 X25

87 87a I 1 2 3 F1a F1b F2a F2b F3a F3b F4a

1.5 10 1.5 1

+30 from fuse 50 A +30 from fuse 50 A Ground Ground

X32/F8a X98.s/2 X33.2 X100.p/12

WH-BK GY/BK BU-BK GY-BU GN-WH GN/WH PK WH WH-RD VT-WH BK BK BK BK WH-YE BU-RD BU-RD BK BK BU-RD BN-WH

1.5 1 1 1 1 1 1 1 1.5 1 1 1 1.5 1.5 1 1 1 1 1 1 1

50 A start Diesel fuel level indicator +15 electro-stop Air filter clogging indicator light Indicator light for high coolant temperature Buzzer (high water temperature) Alternator indicator light Engine oil pressure indicator light Alternator excitation Diesel fuel level indicator light Ground Ground Ground Ground 2nd speed range indicator light +15 microswitch relay (2nd travel speed) +15 microswitch relay (2nd travel speed) Ground Ground +15 microswitch relay (2nd travel speed) Solenoid valve 2nd travel speed

X100.p/10 X100.p/4 X32/F6b X100.p/8 X100.p/5 X39.1 X100.p/7 X100.p/9 X32/F10b X100.p/2 X34/30 X99.s/5 X60.s/2 X60.s/4 X2.s/1 X25/87 X32/F4b X35/85 X34/30 X25/86 X1.s/5

CY CY RD-BK CY CY YE CY CY CY-BK CY CY

4 2.5 1.5 2.5 2.5 2.5 2.5 2.5 1 2.5 2.5

+15/54 from ignition +15/54 from ignition +15 1-pole socket 12 V +15/54 from ignition +15/54 from ignition +15 lights switch +15/54 from ignition +15/54 from ignition +15 armrest microswitch +15/54 from ignition +15/54 from ignition

X98.s/3 X32/F2a X33.1 X32/F1a X32/F3a X99.s/1 X32/F2a X32/F4a X4/1 X32/F3a X32/F11a

7-19

Electrical system

X32

RD RD BK BK

F5a

BU-RD BU-RD BU-RD CY CY

1 1 1 2.5 2.5

+15 microswitch relay (2nd travel speed) +15 seat rotation microswitch +15 microswitch relay (2nd travel speed) +15/54 from ignition +15/54 from ignition

X2.s/2 X1.s/6 X25/86 X32/F6a X32/F9a

CY CY BU-BK CY CY

2.5 2.5 1 2.5 4

+15/54 from ignition +15/54 from ignition +15 electro-stop +15/54 from ignition +15/54 from ignition

X32/F5a X32/F7a X13.s/5 X32/F6a X98.s/4

RD RD-YE BU-RD CY CY YE/RD YE/RD YE/RD CY CY WH-RD CY CY OG-BK OG-BK RD-BK BK GN-BK GY-RD GY-RD BK BK GY-RD BU/BK CY/RD

1.5 1.5 1.5 2.5 2.5 1 1 1 2.5 2.5 1.5 2.5 2.5 1.5 1 1.5 1.5 1 1 1 1 1 1 1 1

+30 from fuse 50 A +30 rotating beacon switch +30 (positive) +15/54 from ignition +15/54 from ignition Switch lights Switch lights Switch lights +15/54 from ignition +15/54 from ignition Alternator excitation +15/54 from ignition +15/54 from ignition +15 horn relay +15 push button for Horn +15 1-pole socket 12 V Ground Brake switch +15 brake relay +15 brake relay Ground Ground +15 brake relay Brake solenoid valve Brake indicator light

X12.p/B X99.s/6 X60.s/3 X32/F5a X32/F10a X99.s/4 X39.2 X100.p/11 X32/F11a X32/F9a X13.s/11 X32/F4a X32/F10a X35/30 X2.s/4 X32/F1b X13.s/1 X99.s/9 X34/87 X1.s/9 X25/30 X13.s/13 X34/86 X1.s/7 X99.s/10

BK BK OG-RD

1 1 1

Ground Ground Horn signal

X25/30 X40/3 X2.s/3

F5b F6a F6b F7a F7b F8a X32

F8b F9a F9b F10a

Control unit wiring

F10b F11a F11b X33.1 X33.2

1 1 85 86 30

SHB DT25 en - Edition 1.4 * dt25b711.fm

X34

X35

87 87a I 1 2 3 85 86

Electrical system

7-20

F4b

SHB DT25 en - Edition 1.4 * dt25b711.fm

X35

X39.1 X39.2

X40

X60.s

Control unit wiring X98.s

X99.s

3

7-21

4

OG-BK OG

1.5 1.5

+15 horn relay Horn

X32/F11b X1.s/1

GN/WH YE/RD

1 1

Buzzer (high water temperature) Switch lights

X13.s/8 X32/F9b

BK BN-BK WH-BK BN VT BK BU-RD BK

1 1 1 1 1.5 1.5 1.5 1.5

Ground Glow plug signal 50 A start Indicator light for glow plug preheating Flashing headlight Ground +30 (positive) Ground

X35/85 X12.p/A X100.p/10 X100.p/6 X99.s/7 X13.s/14 X32/F8b X13.s/15

BN RD CY CY YE GY GY-BK YE/RD BK RD-YE VT GY-RD GN-BK CY/RD

6 10 4 4 2.5 1.5 1.5 1 1 1.5 1.5 1 1 1

Glow plug output +30 from fuse 50 A +15/54 from ignition +15/54 from ignition +15 lights switch Low beam (front left) Low beam (front right) Switch lights Ground +30 rotating beacon switch Flashing headlight Supply parking brake switch Brake switch Brake indicator light

X12.p/A X12.p/B X32/F1a X32/F7a X32/F2b X1.s/2 X1.s/3 X32/F9b X13.s/13 X32/F8b X60.s/1 X1.s/4 X32/85 X34/I

BN-WH VT-WH WH/RD WH/RD WH/RD GY/BK

1 1 1 1 1 1

2nd speed range indicator light Diesel fuel level indicator light Armrest microswitch Armrest microswitch Armrest microswitch Diesel fuel level indicator

X1.s/5 X13.s/12 X4/3 X3/3 X1.s/8 X13.s/4

Electrical system

X100.p

30 87 87A I 1 2 3 1 1 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2

Control unit wiring

X100.p

X1.p

10 11 12 13 14 15 1 2 3 4 5 6 7

X7

X8 Chassis wiring X11.1 X11.2 X26

SHB DT25 en - Edition 1.4 * dt25b711.fm

X27

X28

X29 X30.1

8 9 1 2 T 1 2 T 1 1 1 2 T 1 2 T 1 2 T 1 2 1

GN-WH BN PK GY-BU WH WH-BK WH-BK YE/RD BK GY-BK

1 1 1 1 1 1 1.5 1 1 1

Indicator light for high coolant temperature Indicator light for glow plug preheating Alternator indicator light Air filter clogging indicator light Engine oil pressure indicator light 50 A start 50 A start Switch lights Ground Machine lights

X13.s/7 X40/6 X13.s/9 X13.s/6 X13.s/10 X40/5 X13.s/3 X32/F9b X13.s/1 X1.s/3

OG GY GY-BK GY-RD BN-WH BU-RD BU/BK BU/BK WH-RD GY-RD GY-RD BK

1.5 1.5 1.5 1 1 1 1 1 1 1 1 1

Horn Low beam (front left) Low beam (front right) Permision Microswitch right-hand armrest Solenoid valve 2nd travel speed Supply for seat rotation microswitch Brake solenoid valve Brake solenoid valve Armrest microswitch +15 brake relay Pilot control solenoid valve Ground

X11.1 X31.1 X30.1 X38/1 X8/1 X29/1 X37/1 X26/1 X38/3 X38/2 X38/2 Gnd1.2

BN-WH BK

1 1

Solenoid valve 2nd travel speed Ground

X1.p/5 Gnd1.1

OG BK BU/BK BK

1.5 1.5 1 1

Horn Ground Negative-brake solenoid valve Ground

X1.p/1 Gnd1.2 X1.p/7 Gnd1.1

OG/WH BK

1 1

Direction changeover solenoid valve Ground

X29/2 Gnd1.1

OG/WH BK

1 1

Direction changeover solenoid valve Ground

X29/2 Gnd1.2

BU-RD OG/WH OG/WH GY-BK

1 1 1 1.5

Supply for seat rotation microswitch Direction changeover solenoid valve Direction changeover solenoid valve Low beam (front right)

X1.p/6 X27/1 X28/1 X1.p/3

Electrical system

7-22

5 6 7 8 9

SHB DT25 en - Edition 1.4 * dt25b711.fm

X30.2 X31.1 X31.2 X37

X38

1 1 1 1 2 T 1 2 3

Chassis wiring

Gnd1.1

1

Gnd1.2

1

BK GY BK BU/BK BK

1.5 1.5 1.5 1 1

Ground Low beam (front left) Ground Negative-brake solenoid valve Ground

Gnd1.1 X1.p/2 Gnd1.2 X1.p/7 Gnd1.1

GY-RD GY-RD GY-RD WH-RD BK BK BK BK BK BK BK BK BK

1 1 1 1 1 1.5 1 1 1 1 1 1.5 1.5

Permision Microswitch right-hand armrest Pilot control solenoid valve +15 brake relay Armrest microswitch Ground Ground Ground Ground Ground Ground Ground Ground Ground

X1.p/4 X7 X1.p/9 X1.p/8 X8/2 X30.2 X37/2 X27/2 X26/2 X7/2 X28/2 X11.2 X31.2

Electrical system

7-23

Electrical system

7-24

SHB DT25 en - Edition 1.4 * dt25b711.fm

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 figures and descriptions in this documentation that do not reflect products that have already been delivered and that will not be implemented on these vehicles.

Technical data, dimensions and weights are only given as an indication. 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 Flughafenstr. 7 A-4063 Hörsching Austria

Wacker Neuson Linz GmbH Flughafenstr. 7 A-4063 Hörsching Austria

Tel. +43 (0) 7221 63000-0 Fax: +43 (0) 7221 63000-4000 E-mail office.linz@wackerneuson.com www.wackerneuson.com Order No. 1000279465 Language en