Wacker Neuson Group TH 522 Telehandler Technical Data Manual - PDF DOWNLOAD

TH 522 Ralf Zelder rze Technischer Servicetrainer TTR PGK

State: December 30th 2015

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Topically

General Operation

flashes 1/Sec Indicator lights test after engine start Fault in the electronics (during operation) Communication Error Error at the analog input Input open / short circuit on the input Overloaded output Output open / short circuit on the output Input signal from the VLS is not in the expected range Output overload / short circuit in the VLS

2/Sec

flashes during

1/Sec

2/Sec

during

flashes 1/Sec Indicator lights test after engine start Fault in the electronics (during operation) Communication Error Error at the analog input Input open / short circuit on the input Overloaded output Output open / short circuit on the output Input signal from the VLS is not in the expected range Output overload / short circuit in the VLS

2/Sec

flashes during

1/Sec

2/Sec

during

SPN - Codes

Special Operation

Regeneration suppress a maximum of 2x.

The motor coasts light up the display

with reduced power. If regeneration

of the 3rd is sometimes suppressed , regeneration must be triggered manually with the engine running.

If this is not done , and the engine is stopped , the engine will not start after that.

This problem can then only by Perkins - be eliminated distributor or dealer.

Upper Range with VLS

2200 kg

2200 kg = 4850.16 lb

Lower Range

without VLS

with VLS

Operating VLS

Operator movement Response of loading system

without VLS

with VLS

Operating Standard

Operator movement Response of loading system

Lowering by itself causes the machine to reach its tipping point

without VLS

Operating VLS

Operator movement Response of loading system

Almost vertical movement Almost no shifting of load torque lengthways along The machine

with VLS

< 32 ° = lower Range = Bucket mode > 32 ° = upper Range = Stack mode 32 ° ~ Lower edge tele - outer tube top = overload - display

Operating VLS

Operator movement Response of loading system

Almost vertical movement Almost no shifting of load torque lengthways along The machine

with VLS

< 32 ° = lower Range = Bucket mode > 32 ° = upper Range = Stack mode 32 ° ~ Lower edge tele - outer tube top = overload - display

Operating VLS

Operator movement Response of loading system

Almost vertical movement Almost no shifting of load torque lengthways along The machine

with VLS

< 32 ° = lower Range = Bucket mode > 32 ° = upper Range = Stack mode 32 ° ~ Lower edge tele - outer tube top = overload - display

Operating VLS

Operator movement Response of loading system

Almost vertical movement Almost no shifting of load torque lengthways along The machine

with VLS

< 32 ° = lower Range = Bucket mode > 32 ° = upper Range = Stack mode 32 ° ~ Lower edge tele - outer tube top = overload - display

Operating VLS

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Wacker Neuson

Weidemann

TH 522

T 5522

Sales Name

TL 48

Type

Type labels

Complete TMA – Nr. Nr. / HOM overview of WM - not all are available !!!

Engine: Tier IIIA = * Tier IIIB = ** HOM Nr.

Type

Sales Name

Name Sale Type

Engine

Power in KW at RPM

Overhead guardprotection / Cabin

Axlecombination mech. Transmisson Iges

Hydrostatic Drive Pump Motor

Pressure Type bar & PSI

Machine Speed in km/h / miles/h

F01

TL48

TH 522

Wacker-Telehandler TH 522

404D-22*

36,3 / 2800

Over head guard

Carraro / DB135 Iges = 40,14

A4VG 28 DA A6VM 60 HA

High pressure 450 Bar / 6525 PSI

20 km/h / 12 miles

F02

TL48

TH 522

Wacker-Telehandler TH 522

404D-22*

36,3 / 2800

Over head guard

Carraro / DB172 Iges = 26,966

A4VG 40 DA A6VM 85 HA

High pressure 450 Bar / 6525 PSI

28 km/h / 17 miles

F03

TL48

TH 522

Wacker-Telehandler TH 522

404D-22*

36,3 / 2800

Cabin

Carraro / DB135 Iges = 40,14

A4VG 28 DA A6VM 60 HA

High pressure 450 Bar / 6525 PSI

20 km/h / 12 miles

F04

TL48

TH 522

Wacker-Telehandler TH 522

404D-22*

36,3 / 2800

Cabin

Carraro / DB172 Iges = 26,966

A4VG 40 DA A6VM 85 HA

High pressure 450 Bar / 6525 PSI

28 km/h / 17 miles

F05

TL48

TH 522

Wacker-Telehandler TH 522

404F-22T**

44,7 / 2800

Over head guard

Carraro / DB135 Iges = 40,14

A4VG 28 DA A6VM 60 HA

High pressure 450 Bar / 6525 PSI

20 km/h / 12 miles

F06

TL48

TH 522

Wacker-Telehandler TH 522

404F-22T**

44,7 / 2800

Over head guard

Carraro / DB172 Iges = 26,966

A4VG 40 DA A6VM 85 HA

High pressure 450 Bar / 6525 PSI

28 km/h / 17 miles

F07

TL48

TH 522

Wacker-Telehandler TH 522

404F-22T**

44,7 / 2800

Cabin

Carraro / DB135 Iges = 40,14

A4VG 28 DA A6VM 60 HA

High pressure 450 Bar / 6525 PSI

20 km/h / 12 miles

F08

TL48

TH 522

Wacker-Telehandler TH 522

404F-22T**

44,7 / 2800

Cabin

Carraro / DB172 Iges = 26,966

A4VG 40 DA A6VM 85 HA

High pressure 450 Bar / 6525 PSI

28 km/h / 17 miles

Engine Data

TH 522 Tier IIIA

TH 522 Tier IIIB

Manufacturer

Perkins

Perkins

Engine type

404 D – 22*

404 F – 22 T **

4

4

36,3 / 49,4

44,7 / 60,8

Cylinder Max. power

kW/HP

at

RPM

2800

2800

Capacity

cm3

2216

2216

Water

Water

Cooling Electrical System Operating voltage

V

12

12

Battery

Ah

77

77

Generator

A

85

85

Weights Operating weight (standard)

kg / lb

4200 / 9259.40

4200 / 9259.40

Permissible total weight

kg / lb

5000 / 11023.10

5000 / 11023.10

Permissible load on each axle

kg / lb

3900 / 8598.02

3900 / 8598.02

Permissible payload with shovel

kg / lb

2200 / 4850.16

2200 / 4850.16

Permissible payload with pallet forks

kg / lb

1000 / 2204.62

1000 / 2204.62

Permissible trailer load with braked trailer (pitch max. 10%)

kg / lb

8000 / 17636.96

8000 / 17636.96

Permissible trailer load unbraked trailer (pitch max. 10%)

kg / lb

750 / 1653.47

750 / 1653.47

Permissible vertical load at the trailer coupling

kg / lb

100 / 220.46

100 / 220.46

Vehicle Data Driving speed

Km/h / miles/h

0 – 28 0 – 17.40

0 – 28 0 – 17.40

Capacity of Fuel tank

l / ga

70 / 18.49

70 / 18.49

l / ga

55 / 14.53

55 / 14.53

460 / 6671.74 450 / 6526.70

460 / 6671.74 450 / 6526.70

70 / 18.49

70 / 18.49

225 / 3263.35

225 / 3263.35

Hydraulic Data Hydraulic oil Hydraulic driving Working pressure 20 km/h/12.43 mil./h / 30 km/h/17.40 mil./h

bar / PSI

Hydraulic operation Output

l/min / ga/min

Working pressure

bar / PSI

Engine: Tier IIIA = * Tier IIIB = **

Assembly Groups 20 km/h / 12.43 miles/h miles/h Drive motor (Std.)

4 – Cyl. Perkins 404 D – 22 36,3 / 49,4 HP

Drive motor (Opt.)

4 – Cyl. Perkins 404 F – 22 T 44,7 kW / 61,0 HP

Hydraulic pump, drive (Std.)

A4VG28DA

Hydraulic pump, drive (Opt.)

///

Control valve, drive

4 / 3 Way valve

Hydraulic motor, drive (Std.)

A6VM60HA

Hydraulic motor, drive (Opt.)

///

Hydrauli pump, work (Std.)

GP 25 ccm / 0.0066 ga

Hydraulic pump, work ( Opt.)

///

Hydraulic pump, work in PTO (Opt.)

///

Hydraulic pump, Highflow (Opt.)

GP 19 ccm / 0.0050 ga (in PTO)

Control valve, work (Std.)

HDS 21 / 4

Control valve, work (Opt.)

HDS 21 / 5 / HDS 21 / 6 / HDS 21 / 7 / HDS 21 / 8

Hydraulic pump, steer (Std.)

GP 25 ccm / 0.0066 ga

Hydraulic pump, steer (Opt.)

///

Control valve, steer

OSPQ 125 LS

Priority valve

OLS 120

Axles

Carraro 26.16M DB Tranfergearbox TB 135

Axles (Opt.)

///

Hydraulic pump, Fan

///

Hydraulic motor, Fan

///

Assembly Groups 28 km/h / 17.40 miles/h miles/h Drive motor (Std.)

4 – Cyl. Perkins 404 D – 22 36,3 / 49,4 HP

Drive motor (Opt.)

4 – Cyl. Perkins 404 F – 22 T 44,7 kW / 61,0 HP

Hydraulic pump, drive (Std.)

A4VG40DA

Hydraulic pump, drive (Opt.)

///

Control valve, drive

4 / 3 Way valve

Hydraulic motor, drive (Std.)

A6VM85HA

Hydraulic motor, drive (Opt.)

///

Hydrauli pump, work (Std.)

GP 25 ccm / 0.0066 ga

Hydraulic pump, work ( Opt.)

///

Hydraulic pump, work in PTO (Opt.)

///

Hydraulic pump, Highflow (Opt.)

GP 19 ccm / 0.0050 ga (in PTO)

Control valve, work (Std.)

HDS 21 / 4

Control valve, work (Opt.)

HDS 21 / 5 / HDS 21 / 6 / HDS 21 / 7 / HDS 21 / 8

Hydraulic pump, steer (Std.)

GP 25 ccm / 0.0066 ga

Hydraulic pump, steer (Opt.)

///

Control valve, steer

OSPQ 125 LS

Priority valve

OLS 120

Axles

Carraro 26.16M DB Tranfergearbox TB 172

Axles (Opt.)

///

Hydraulic pump, Fan

///

Hydraulic motor, Fan

///

Assembly Groups Upper part

Type

1. ROPS - Rollover bar

///

2. FOPS - Overhead guard, Standard

///

3. FOPS – Overhead guard, Option

///

4. FOPS – Overhead guard, foldable EPS

///

5. Cabin

LK 167 (1950 mm / 76.77 in)

1

2+3

4

5

404 D – 22

Tightening torque Cylinderhead

Valve clearance

Nozzle pressure

Delivery start

1.Phase 101 Nm

Inlet valve 0,20 mm 0.0079 in

210 bar 3045.79 PSI

Marker CS Pulley

2. Phase ---

Exhaust valve 0,20 mm 0.0079 in

3. Phase --4. Phase ---

404 F – 22 T

Tightening torque Cylinderhead

Valve clearance

Nozzle pressure

Delivery start

1.Phase 101 Nm

Inlet valve 0,20 mm 0.0079 in

210 bar 3045.79 PSI

Marker CS Pulley

2. Phase ---

Exhaust valve 0,20 mm 0.0079 in

3. Phase --4. Phase ---

Drive motor Engine 404D – 22 Idle speed: 1000 RPM Starting speed: 1200 – 1300 RPM Maximum speed: 2800 RPM unloaded 2650 RPM loaded

Valve clearance

IV 0,20 mm / 0.0079 in EV 0,20 mm / 0.0079 in cold

Injection pressure

210 bar 3045.79 PSI

Drive motor Engine 404F – 22 T Idle speed: 1000 RPM Starting speed: 1200 – 1300 RPM Maximum speed: 2800 RPM unloaded 2650 RPM loaded

Valve clearance

IV 0,20 mm / 0.0079 in EV 0,20 mm / 0.0079 in cold

Injection pressure

210 bar 3045.79 PSI

Electrical Battery voltage Engine shut off

12 V

Charging voltage at 2000 RPM, loaded

14,4 V

Charging current at 2000 RPM, loaded

85 A

Variable displacement hydraulic pump

A4VG28DA

Number

Drive pump 20 km/h 12.43 miles/h miles/h

Machine type

TH 522 VLS

Setting pressure, bar / PSI

18 / 261.07

Orifice, mm / in

4,0/16 / 0.1575/0.6299

Drainnozzle, mm / in

0,7 / 0.0275

Nominal, ccm / ga

28 / 0.0074

Direction of rotation Drivepower, kW Highspeed (Laod), RPM

right 36,3 or 44,7 2800

Flowspeed at load, l./min / ga/min

78,4 / 20.71

Chargepressure at load, bar / PSI

28 / 406.11

Pressure relieve valve A, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Pressure relieve valve B, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Voltage, Volt Block curve: normally start at, RPM Highpressure 1, bar / PSI Take off valve Pressure Cut – off, bar / PSI

12 1000 50 / 725.19 hydr.

450 / 6526.70

Variable displacement hydraulic pump

A4VG40DA

Number

Drive pump 28 km/h 17.40 miles/h miles/h

Machine type

TH 522 VLS

Setting pressure, bar / PSI

22 / 319.08

Orifice, mm / in

4,7/16 / 0.1850/0.6299

Drainnozzle, mm / in

0,8 / 0.0315

Nominal, ccm / ga

28 / 0.0074

Direction of rotation Drivepower, kW Highspeed (Laod), RPM

right 36,3 or 44,7 2800

Flowspeed at load, l./min / ga/min

112 / 29.59

Chargepressure at load, bar / PSI

28 / 406.11

Pressure relieve valve A, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Pressure relieve valve B, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Voltage, Volt Block curve: normally start at, RPM Highpressure 1, bar / PSI Take off valve Pressure Cut – off, bar / PSI

12 1000 50 / 725.19 hydr.

450 / 6526.70

Drive hydraulic 20 km/h / 12.43 miles/h miles/h 404D – 22 + 404F 404F – 22 T A4VG28DA – A6VM60HA Ratio Hydrostatic = 2,14

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

460 bar / 6671.74 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

18 bar / 261.07 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

250 bar / 3625.94 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Drive hydraulic 28 km/h / 17.40 miles/h miles/h 404D – 22 A4VG40DA – A6VM85HA Ratio Hydrostatic = 2,125

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

450 bar / 6526.70 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

22 bar / 319.08 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

160 bar / 2320.60 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Drive hydraulic 28 km/h / 17.40 miles/h miles/h 404F – 22 T A4VG40DA – A6VM85HA Ratio Hydrostatic = 2,125

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

450 bar / 6526.70 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

22 bar / 319.08 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

200 bar / 2900.76 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Drive motor 20 km/h / 12.43 miles/h miles/h 404D – 22 + 404F 404F – 22 T A4VG28DA – A6VM60HA Variable displacement hydraulic motor

A6VM60HA

Number Maschine type

TH 522

Nominal, ccm / ga

12,8 – 60 / 0.0034 – 0.0159

Direction of rotation

right/left

Highspeed (Laod), RPM

1306 - 6203

Switch over pressure, bar / PSI

250 / 3625.94

Drive motor 28 km/h / 17.40 miles/h miles/h 404D – 22 A4VG40DA – A6VM85HA Variable displacement hydraulic motor

A6VM85HA

Number Maschine type

TH 522

Nominal, ccm / ga

18,7 – 85 / 0.0049 – 0.0225

Direction of rotation

right/left

Highspeed (Laod), RPM

1317 - 5989

Switch over pressure, bar / PSI

160 / 2320.60

Drive motor 28 km/h / 17.40 miles/h miles/h 404F – 22 T A4VG40DA – A6VM85HA Variable displacement hydraulic motor

A6VM85HA

Number Maschine type

TH 522

Nominal, ccm / ga

18,7 – 85 / 0.0049 – 0.0225

Direction of rotation

right/left

Highspeed (Laod), RPM

1317 - 5989

Switch over pressure, bar / PSI

200 / 2900.76

Hydrauliksystem Working- and Steering pump Working Gear pump

Measured value

Speed RPM

Temperature

Nominal ccm / ga

Delivery volume l/min / ga/min ga/min

unloaded

0 bar / 0 PSI

2800

> 55 ° C > 131 ° F

25,0 0.0066

70,0 18.49

loaded

180 bar / 2610.68 PSI

2650

> 55 ° C > 131 ° F

25,0 0.0066

46,2 12.20

unloaded

0 bar / 0 PSI

2800

> 55 ° C > 131 ° F

19,0 0.0050

47,5 12.55

loaded

180 bar / 2610.68 PSI

2650

> 55 ° C > 131 ° F

19,0 0.0050

31,4 8.30

Work hydraulic Value

Test point

Adjusting

Pressure Work hydraulic

225 bar / 3263.35 PSI Primarily

Control valve

PRV Primarily Control valve

Pressure Tilt out

200 bar / 2900.76 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure Tilt in

270 bar / 3916.02 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure Lifting

250 bar / 3625.94 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure, Pressure, secondary Telescop extend

270 bar / 3916.02 PSI Secondary

Control valve / Telescop cylinder

Secondary Valve Section Telescop retract

Pressure Rear PTO High Flow

225 bar / 3263.35 PSI Primarily

Control valve

PRV Primarily (2) Control valve

Steering hydraulic

Pressure Steering hydraulic

Value

175 bar / 2538.16 PSI Primarily 210 bar / 3045.79 PSI Secondary

Test point

Steering valve / Steering cylinder

Adjusting

Steering valve

Service kit Type

Feature

Engine

Model year

Chassisnumber

TH 522 VLS

///

404 D – 22 Tier IIIA

All

All

Servicekit

Engineoil

Fuel, Pre

Fuel, Main

Fuel, Separator

Air, outside

1000309661

1000231366

///

1000255796

///

1000000365

Air, inside

Hydraulic, Main

Hydraulic, Pressure

Ventilation

Cabin

Valve cover gasket

1000087796

1000231380

///

///

///

1000203390

Filling Quantities 404 D – 22 Tier IIIA in Liter

Fuel Tank

70,00

Diesel fuel

DIN EN 590

Engine oil with Filter

10,60

Engine oil SAE 15 W 40

API CG-4/API CH-4

Fill amount com. Axle

2,50 f. 2,50 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0,30

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0,50

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

68,00

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

55,00

Hydraulic oil HLP

ISO VG 46

Cooling System*

10,00*

HD Coolant & Antifreeze*

ASTM D 4985*

Brake System

1,00

ATF - Oil

10,50*

incl. Heating system*

1300 gr.

R 134a

Air-conditioning

Filling Quantities 404 D – 22 Tier IIIA in Gallon

Fuel Tank

18.49

Diesel fuel

DIN EN 590

Engine oil with Filter

2.80

Engine oil SAE 15 W 40

API CG-4/API CH-4

Fill amount com. Axle

0.92 f. / 1.00 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0.08

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0.13

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

17.96

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

14.52

Hydraulic oil HLP

ISO VG 46

Cooling System*

2.64*

HD Coolant & Antifreeze*

ASTM D 4985*

Brake System

0.26

ATF - Oil

2.77*

incl. Heating system*

2.86 lb.

R 134a

Air-conditioning

Service kit Type

Feature

Engine

Model year

Chassisnumber

TH 522 VLS

///

404 F – 22 T Tier IIIB

All

All

Servicekit

Engineoil

Fuel, Pre

Fuel, Main

Fuel, Separator

Air, outside

1000317997

1000231366

///

1000255796

///

1000000365

Air, inside

Hydraulic, Main

Hydraulic, Pressure

Ventilation

Cabin

Valve cover gasket

1000087796

1000231380

///

///

///

1000314618

Filling Quantities 404 F – 22 T Tier IIIB in Liter

Fuel Tank

70,00

Diesel fuel

DIN EN 590

Engine oil with Filter

10,60

Engine oil SAE 10 W 40

API CJ-4/ACEAE 9

Fill amount com. Axle

2,50 v. 2,50 h.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0,30

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0,50

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

68,00

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

55,00

Hydraulic oil HLP

ISO VG 46

Cooling System*

10,00*

HD Coolant & Antifreeze*

ASTM D 6210*

Brake System

1,00

ATF - Oil

10,50*

incl. Heating system*

1300 gr.

R 134a

Air-conditioning

Filling Quantities 404 F – 22 T Tier IIIB in Gallon

Fuel Tank

18.49

Diesel fuel

DIN EN 590

Engine oil with Filter

2.80

Engine oil SAE 10 W 40

API CJ-4/ACEAE 9

Fill amount com. Axle

0.92 f. / 1.00 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0.08

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0.13

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

17.96

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

14.52

Hydraulic oil HLP

ISO VG 46

Cooling System*

2.64*

HD Coolant & Antifreeze*

ASTM D 6210*

Brake System

0.26

ATF - Oil

2.77*

incl. Heating system*

2.86 lb.

R 134a

Air-conditioning

Engine: 404F – 22 T

Engine: 404F – 22 T

Engine: 404F – 22 T

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Engine: 404D – 22

Engine: 404D – 22

Engine: 404F – 22 T

Engine: 404F – 22 T

Type

Idle speed

Starting speed

Maximum speed

TH 522

1000

1200 - 1300

2800 unloaded 2650 loaded

Type

Idle speed

Starting speed

Maximum speed

TH 522

1000

1200 - 1300

2800 unloaded 2650 loaded

404 D – 22

Tightening torque Cylinderhead

Valve clearance

Nozzle pressure

Delivery start

1.Phase 101 Nm

Inlet valve 0,20 mm 0.0079 in

210 bar 3045.79 PSI

Marker CS Pulley

2. Phase ---

Exhaust valve 0,20 mm 0.0079 in

3. Phase --4. Phase ---

404 F – 22 T

Tightening torque Cylinderhead

Valve clearance

Nozzle pressure

Delivery start

1.Phase 101 Nm

Inlet valve 0,20 mm 0.0079 in

210 bar 3045.79 PSI

Marker CS Pulley

2. Phase ---

Exhaust valve 0,20 mm 0.0079 in

3. Phase --4. Phase ---

Engine: 404F – 22 T

Engine: 404F – 22 T

Engine: 404F – 22 T

Engine: 404F – 22 T

Engine: 404F – 22 T

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Hydraulic Parallelguide for Telescopliftingarm Tilt in = Piston site

Tilt cylinder / Lowering brake valve

Compensation cylinder

Accumulator

Lifting arm damping valve

Lifting cylinder / Lowering brake valve

Telescopic cylinder

Control valve A Lifting Control valve A Tilt in

Control valve B Tilt out

Control valve B Lowering Control valve A Telescop extend

Steuerventil B Telescop retract

Tank

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

PA – Axle Carraro 26.16 M DB TB 135 20 km/h / 12.43 miles/h

20 km/h 12.43 miles/h miles/h

P Pumpe / Pump T Tank / Tank

Brake ∅ 224

Front axle

Rear axle

I Differential = 2,909 I Transfer = 2,300 x I Differential = 2,909 x I Planet = 6,000 x I Total = 40,140

with Differential lock

I Transfer = 2,300

I Planet = 6,000

PA – Achse Carraro 26.16 M DB TB 172 28 km/h / 17.40 miles/h

28 km/h 17.40 miles/h miles/h

P Pumpe / Pump T Tank / Tank

Brake ∅ 224

Front axle

Rear axle

I Differential = 2,909 I Transfer = 1,545 x I Differential = 2,909 x I Planet = 6,000 x I Total = 26,966

with Differential lock

I Transfer = 1,545

I Planet = 6,000

CheckCheck- and Filling screw Differential Drain screw Differential

Bottom edge parallel to the ground

CheckCheck- and Filling screw Transfer gear Drain screw Transfer gear

CheckCheck-, DrainDrainFilling screw Planentary gear

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Work and control before testing of the hydraulic system Engine oil diesel engine - if necessary, correct oil level Cooling water level water cooler diesel engine - if necessary, correct State diesel engine parts – may be repair or replace Oil level hydraulic system - if necessary, correct State hydraulic oil cooler and radiator - if necessary, clean, repair or replace State parts hydraulic system parts hydraulic system – may be repair or replace State fan cooling system may also separate hydraulic oil cooler – may be repair or replace State drive belt water pump and fan blades - if necessary, replace Check machine for leaks (coolant, oil, fuel and hydraulic oil) - if necessary, sea Attach the dial gauges Bring the machine to operating temperature = 55 ° Celsius Low Speed diesel engine (the core values are based) - if necessary, correct High Speed diesel engine (the core values are based) - if necessary, correct Hydraulic pressures check only with high speed !!!

Hydraulic pressures check - if necessary, correct (the pressure charts are based) Test run with corrected values - if necessary, correct again

Filter, outlet Hydraulic pump

Oil cooler

Filter, inlet Maintfilter

Safetyfilter

Hydr.

Hydr. Return line filter

Return line

Complete Hydrostatic Closed Oil Circuit Variable displacement pump and axial variable displacement motor

Hydraulic pump

Hydraulic motor

Universal joint shaft Drive motor

Axle Planentary gear

Complete Hydrostatic Closed Oil Circuit Variable displacement pump and axial variable displacement motor

Complete Hydrostatic Closed Oil Circuit One hydraulic motor Universal joint shaft Planetary axles

Planentary axles Drive pump Universal joint shaft

Drive motor

Working- and Steering pump

Drum brake

Hydraulioc motor, variable displacement

Hydraulical Take – off, Highpressure valve 1. Version, Chargepressure valve 1. Version Connection Take – off valve Adjusting Take - off Take – off valve Setting pressure X1

Pressure Cut – off Solenoid

Bleeding Take – off valve Workingline B Pressure relieve valve B

Casing pressure R High pressure B Setting pressure X2

Control valve Start of control

Charge pressure Charge pressure valve Tank T2 Zero setting

Adjustment Control pressure Workingline A PS

High pressure A Pressure relieve valve A

Hydraulikkomponenten

Charge pressure valve

Pressure relieve valve

Pressure Cut off

Hydraulikkomponenten

4 / 3 Way valve with Take – off valve

Control valve

Hydraulicsystem

The DA - Regulation protects the diesel engine against him "strangle". strangle".

Rising pressure in the working administrations of the driving pump leads to a reduction of the slewing angle.

By the reduced slewing angle the pump supplies less conveyor current and fits thereby the performance admission to the power output to the performance being available in the diesel engine in.

This protects the diesel engine against him "strangle".

The DA – Regulation lets the Pump slewing angle l of the engine speed follow. follow.

With the printings of the accelerator there rises the diesel engine speed.

An increase of the engine speed also causes a higher pumping speed.

Because the feed pump is integrated into the impulse pump, the conveyor current also rises.

The more volume current flows by the DA- valve, the stronger the pump swivels and supplies so appropriately higher conveyor current.

The driving speed increases therefore on account of the higher diesel speed and the bigger slewing angle of the driving pump.

The direction of the traffic is preselected about an integrated road valve (forward - neutrally -backwards).

As a hydraulic engine can be chosen a constant motor (e.g., A2FM) or a variable dis. motor (e.g., A6VM).

Hydraulicsystem

Accelerate 1. In the stagnation(standstill) runs the diesel on low idling speed.

The DA - pump there promotes no volume current in this condition.

2. As long as the accelerator is pressed, the engine high turns.

The pump there recognizes the rise of the engine speed and begins with the pressure construction.

Besides, the frictional resistance of the vehicle is not overcome immediately - the engine does not move yet.

3. The vehicle overcomes own imprisonment frictional forces and drives off.

4. Much stronger printinging of the accelerator leads to the speed rise in the diesel engine.

The DA - pump there farther swivels and supplies with it more and more conveyor current. The vehicle accelerates.

5. With reaching of the maximum speed the pressure decreases something, because no other acceleration performance is required.

The vehicle must master only own frictional resistance.

Hydraulicsystem

Upward gradient 1. The vehicle goes with maximum speed on the straight lines: The pump is fully swilled out and supplies the maximum conveyor current. Besides, the pumping pressure corresponds directly to the driving resistance (rolling plus air resistance).

2. In the upward gradient the tensile force must become bigger.

An increase of the hydraulic system pressure arises from it.

The diesel engine is pressed by the higher required performance.

The engine speed sinks.

To recognize the ability of the pumping engine, printings, cares for the fact that the Pump slewing angle and with it the conveyor current decreases and covers therefore the power demand of the pump with the performance offer of the diesel engine also with the pressure level higher now.

Hydraulicsystem

Overload protection 1. While the loader with average speed on even ground goes, a certain pressure level appropriate to the driving resistance adjusts itself .

2. As long as the shovel dives into the material, the tensile force need increases. The system pressure rises appropriately. At the same moment the pressure-feeling pump there decreases the conveyor current and prevents an overloading of the diesel engine.

3. If the shovel of the wheel loader farther digs in the material, the system pressure still farther rises.

This load leads to another reduction of the diesel engine speed.

4. If the system pressure exceeds preopposed values (in general defines by the permissible limit values of the hydraulic components), reduces the Pressure cut off of the DA -pump there the conveyor current.

The pump puts the slewing angle independently such that the full system pressure and with it the maximum tensile force will maintain, without the hydraulic system heats up needlessly.

Positive Take - off

Take - off hydr.

Take – off valve

4/3 Way valve

Measuring point MB High pressure backward

Measuring point PS DA - Pressure

Workingline High presssure backward

PS

Control valve

Power unit

MB

B

Charge pump

backward Pressure relieve valve Setting cylinder

forward Pressure cut - off

X2

X1

Measuring point X2 Measuring point X1 Setting pressure Setting pressure backward forward

G

Charge pressure valve

Measuring point G Charge pressure

MA

A

Workingline High presssure forward Measuring point MA High pressure forward

Positive Take - off Gas pedal

Gas cable

Brake-/Take – off pedal

Take – off line

Cable Forward Backward

Take - off hydr.

Brake line Cable Direction detection

Cable Slow / Fast

Forward energized = Direction detection activated (automaticly) Backward de - energized = Direction detection deactivated (automaticly) Slow = energized Fast = de - energized

Hydraulic Take - off (positive), Pressure relieve valve 1st Version, Charge pressure valve 1st Version Hydraulikkomponenten

Take – off valve

Solenoid

Setting pressure X1

Setting pressure X2

Start of control

Control pressure PS

Take - off hydr. < 1200 RPM

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Neutral

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Forward

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Forward activated

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Neutral

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Backward

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Backward activated

PS

X1

X2

G

MB

B

MA

A

Take - off hydr. > 1200 RPM Neutral

PS

X1

X2

G

MB

B

MA

A

Option:

Hand Take - off

Option:

Hand Take - off

Solenoid A = Forward Setting pressure on X2

Solenoid B = Backward Setting pressure on X1

Setting pressure X1 = Backward Pressure on MB MB Setting pressure X2 = Forward Pressure on MA

MA Zero setting : Rolls Forward -- Clockwise to Neutral Rolls Backward – Anti clockwise to Neutral

Adjustment : < 90° 90° Clockwise : + MA / - MB Anti clockwise : - MA / + MB

Variable displacement hydraulic pump

A4VG28DA

Number

Drive pump 20 km/h 12.43 miles/h miles/h

Machine type

TH 522 VLS

Setting pressure, bar / PSI

18 / 261.07

Orifice, mm / in

4,0/16 / 0.1575/0.6299

Drainnozzle, mm / in

0,7 / 0.0275

Nominal, ccm / ga

28 / 0.0074

Direction of rotation Drivepower, kW Highspeed (Laod), RPM

right 36,3 or 44,7 2800

Flowspeed at load, l./min / ga/min

78,4 / 20.71

Chargepressure at load, bar / PSI

28 / 406.11

Pressure relieve valve A, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Pressure relieve valve B, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Voltage, Volt Block curve: normally start at, RPM Highpressure 1, bar / PSI Take off valve Pressure Cut – off, bar / PSI

12 1000 50 / 725.19 hydr.

450 / 6526.70

Variable displacement hydraulic pump

A4VG40DA

Number

Drive pump 28 km/h 17.40 miles/h miles/h

Machine type

TH 522 VLS

Setting pressure, bar / PSI

22 / 319.08

Orifice, mm / in

4,7/16 / 0.1850/0.6299

Drainnozzle, mm / in

0,8 / 0.0315

Nominal, ccm / ga

28 / 0.0074

Direction of rotation Drivepower, kW Highspeed (Laod), RPM

right 36,3 or 44,7 2800

Flowspeed at load, l./min / ga/min

112 / 29.59

Chargepressure at load, bar / PSI

28 / 406.11

Pressure relieve valve A, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Pressure relieve valve B, Start opening, bar / PSI

488 / 7077.84

Differential pressure setting, bar / PSI

460 / 6671.73

Voltage, Volt Block curve: normally start at, RPM Highpressure 1, bar / PSI Take off valve Pressure Cut – off, bar / PSI

12 1000 50 / 725.19 hydr.

450 / 6526.70

Drive hydraulic 20 km/h / 12.43 miles/h miles/h 404D – 22 + 404F 404F – 22 T A4VG28DA – A6VM60HA Ratio Hydrostatic = 2,14

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

460 bar / 6671.74 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

18 bar / 261.07 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

250 bar / 3625.94 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Drive hydraulic 28 km/h / 17.40 miles/h miles/h 404D – 22 A4VG40DA – A6VM85HA Ratio Hydrostatic = 2,125

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

450 bar / 6526.70 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

22 bar / 319.08 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

160 bar / 2320.60 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Drive hydraulic 28 km/h / 17.40 miles/h miles/h 404F – 22 T A4VG40DA – A6VM85HA Ratio Hydrostatic = 2,125

Value

Test point

Adjusting

Chargepressure

28 bar / 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Speed Starting

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive hydraulic

450 bar / 6526.70 PSI

MA forward MB backward Hydraulic pump

PRV Pressuer Cut off

Pressure Setting cylinder

22 bar / 319.08 PSI

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 1050 RPM 715.19 PSI / 1050 RPM

MA forward MB backward Hydraulic pump

Adjustment

Switch over pressure Hydraulic motor

200 bar / 2900.76 PSI

M Hydraulic motor

Switch over pressure Hydraulic motor

Hydraulical Take – off, Highpressure valve 1. Version, Chargepressure valve 1. Version Connection Take – off valve Adjusting Take - off Take – off valve Setting pressure X1

Pressure Cut – off Solenoid

Bleeding Take – off valve Workingline B Pressure relieve valve B

Casing pressure R High pressure B Setting pressure X2

Control valve Start of control

Charge pressure Charge pressure valve Tank T2 Zero setting

Adjustment Control pressure Workingline A PS

High pressure A Pressure relieve valve A

Dry running Hydraulic pump !!!

DANGER

Check Charge pressure and adjust

Pressure gauge 60 bar / 870.23 PSI attaching Start engine Pressure reading Nominal value: 28 bar / 406.11 PSI Charge pressure under nominal value: Charge pressure valve leaking - cleaning! cleaning! 1 Charge pressure too low / high - adjusting! adjusting!

Control valve leaking - seal! seal!

Line PS open - close! close!

Hand Take – off activated - deactivate! deactivate!

4/3 Way valve leaking - change! change!

Setting cylinder leaking – seal poss. poss. change Pump!

2

or Charge pump leaking - change! change! 2 Stop engine

1

Not Weidemann

F 0 B Start

Neutral

G

Bleeding Take – off

Attaching Bottle at Bleeding valve Open Bleeding valve System bleeding Mechanically with Break-/Take – off pedal Check Break-/Take – off Close Bleeding valve Remove Bottle from Bleeding valve Control Liquid level in Reservoir Poss. refill

F 0 B Stop

Neutral

Machine rolls too far !!!

DANGER

Check Take – off and adjust

Start engine Insert direction Loader stop at gradient Maintain direction and apply full throttle Service break slowly release, up loader rolls slowly.

Service break further release, until the Loader drives in selected direction

Pedalway too big: big Pedalway over nominal value: Taxiway too long! long!

DANGER 2 Charge pressure valve too low – leaking poss. poss. adjust! djust!

Control valve leaking - seal! seal!

Nut 1 solve Adjusting screw 2 screw in. in Nut 1 tighten

1

Pedalway too small: small Pedalweg unter nominal value: Driven against Break!

Charge pressure valve too high – adjust! adjust!

Nut 1 solve Einstellschraube 2 screw out. out Nut 1 tighten

F 0 B Start

Forward / Backward

Machine moves without Driver himself !!!

DANGER Start engine Insert direction Increase Idle speed: ap. 200 - 300 RPM higher then Idle speed Loader should set in motion The loader too early in motion: Starting speeed under nominal value: Control valve adjusted - adjust, adjust, Wider tires – check!

Charge pressure valve too high - adjust! adjust!

Nut 1 solve Adjusting screw 2 srew in Nut 1 tighten Check again Starting speed

Check Starting speed and adjust Type TH 522

Idle speed

Starting speed

Maximum speed

404D – 22

1000

1200 - 1300

2800

404F – 22 T

1000

1200 - 1300

2800

DANGER 1

The loader too late in motion : Starting speed over nominal value: Control valve adjusted - adjust, adjust, Narrower tires – check!

Increased machine weight - check!

Charge pressure valve leaking – cleaning poss. poss. adjust! adjust!

Control valve leaking – seal! seal!

Nut 1 solve Adjusting screw 2 screw out Nut 1 tighten Check again Starting speed

2

F 0 B Start

Forward / Backward

Hydraulic pump controls over Pressure relieve valve - risk of overheating !!!

DANGER Pressure gauge 600 bar / 8702.26 PSI attaching Start engine Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: 460 bar / 6671.74 PSI = 20 km/h / 12.43 miles/h miles/h 450 bar / 6526.70 PSI = 30 km/h / 17.40 miles/h miles/h

Check Pressure Cut - off and adjust

2 1

Pressure Cut - off too low Pressure Cut - off under nominal value: Pressure relief valves let off – cleaning poss. poss. adjust! adjust!

Hydraulic motor demaged! demaged!

Nut 1 solve Adjusting screw 2 screw in Nut 1 tighten Pressure Cut - off too high Pressure Cut - off over nominal value: Pressure Cut – off wrong adusted - adjust! adjust!

Nut 1 solve Adjusting screw 2 screw out Nut 1 tighten

MB

MA

DANGER

F 0 B Start

Forward / Backward

Check High pressure

High pressure lines X retrench and close Pump Pressure gauge 600 bar / 8702.26 PSI attaching Start engine Insert direction Pressure reading Nominal value: 460 bar / 6671.74 PSI = 20 km/h / 12.43 miles/h miles/h 450 bar / 6526.70 PSI = 30 km/h / 17.40 miles/h miles/h Nut 1 solve Adjusting screw 2 screw in High pressure under nominal value: Charge pressure valve leaking – cleaning! cleaning!

Charge pressure too low – leaking! leaking!

Control valve leaking - seal! seal!

Line PS open - close! close!

Hand Take – off activated - deactivate! deactivate!

4/3 Way valve leaking - change! change!

Setting cylinder leaking – seal poss. poss. change Pump!

Pressure relief valves leaking – cleaning poss. poss. adjust! adjust!

Hydraulic pump demaged - change! change!

High pressure reaches nominal value: Hydraulic motor demaged - change! change!

Stop engine

2 1

X

MB

MA

X

F 0 B Start

Forward / Backward

Pressure gauge 600 bar / 8702.26 PSI attaching Nut 1 solve Adjusting screw 2 screw in until bolt and nut flush Start engine Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: 500 bar / 7251.89 PSI High pressure under nominal value: Charge pressure valve leaking – cleaning! cleaning!

Charge pressure too low – adjust! adjust!

Control valve leaking - seal! seal!

Line PS open - close! close!

Hand Take – off activated - deactivate! deactivate!

4/3 Way valve leaking - change! change!

Setting cylinder leaking – seal poss. poss. change Pump!

Pressure relief valves leaking – cleaning poss. poss. adjust Hydraulic pump demaged - change! change!

Adjusting screw 2 screw out until screw is on nominal value Nut 1 tighten Stop engine

Check Pressure relieve valves

2 1

Attention Pressure Cut – off without Function !!!

Risk of overheating !!!

MB

MA

F 0 B Start

Forward / Backward

Check Setting pressure

Pressure gauge 60 bar / 870.27 PSI attaching Start engine Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: A4VG28 DA 18 bar / 261.07 PSI A4VG40 DA 22 bar / 319.08 PSI Max. Difference X1 /X2 = 2 bar / 29.01 PSI Max. Back pressure = 2 bar / 29.01 PSI Setting pressure under nominal value: Charge pressure valve leaking – cleaning! cleaning!

Charge pressure too low – adjust! adjust!

Control valve leaking - seal! seal!

Line PS open - close! close!

Hand Take – off activated - deactivate! deactivate!

4/3 Way valve leaking - change! change!

Setting cylinder leaking – seal poss. poss. change Pump!

Stop engine

X1 X2

F 0 B Start

Forward / Backward

Machine driven without Driver himself !!!

DANGER Loader sets forward in Neutral moving Jack up the machine, Start engine Nut 1 solve Fix tool Adjusting screw 2 screw in Adjust loader to standstill Beginning / End Forward Mark the position of the tool Adjusting screw 2 screw in Adjust loader to backward driving Adjusting screw 2 screw out Adjust loader to standstill Beginning / End Backward Mark the position of the tool Adjusting screw 2 screw out Mediate position of tool between tag Beginning / End Forward and Beginning / End Backward Nut 1 tighten

Loader sets backward in Neutral moving Jack up the machine, Start engine Nut 1 solve Fix tool Adjusting screw 2 screw out Adjust loader to standstill Beginning / End Backward Mark the position of the tool Adjusting screw 2 screw out Adjust loader to forward driving Adjusting screw 2 screw in Adjust loader to standstill Beginning / End Forward Mark the position of the tool Adjusting screw 2 screw in Mediate position of tool between tag Beginning / End Backward and Beginning / End Forward Nut 1 tighten

Adjust Zero setting

1

2

Beginning / End Backward

Beginning / End Forward

Zero position

F 0 B Start

Neutral

Check Adjustment

Pressure gauge 600 bar / 8702.26 PSI attaching Start engine Insert direction Forward Drive loader against obstacle Press loader against obstacle Speed to app. 1000 bis 1050 RPM Pressure reading Nominal value: 50 bar / 725.19 PSI Pressure under nominal value: Charge pressure valve leaking – cleaning! cleaning!

Charge pressure too low – adjust! adjust!

Control valve leaking - seal! seal!

Line PS open - close! close!

Hand Take – off activated - deactivate! deactivate!

4/3 Way valve leaking - change! change!

Setting cylinder leaking – seal poss. poss. change Pump!

Bearing Pump demaged – change Pump!

MA

F 0 B Start

Forward

Adjustment too late Pressure gauge 600 bar / 8702.26 PSI attaching Start engine Insert direction Forward Drive loader against obstacle Press loader against obstacle Speed to app. 1000 bis 1050 RPM Nut 1 solve Adjusting screw 2 screw in Pressure reading Nominal value: 50 bar / 725.19 PSI Nut 1 tighten

Adjust Adjustment

Adjustment too early Pressure gauge 600 bar / 8702.26 PSI attaching Start engine Insert direction Forward Drive loader against obstacle Press loader against obstacle Speed to app. 1000 bis 1050 RPM Nut 1 solve Adjusting screw 2 screw out Pressure reading Nominal value: 50 bar / 725.19 PSI Nut 1 tighten

Adjustment : < 90° 90° Clockwise : + MA / - MB Counter Clockwise : - MA / + MB

MA 1

2

F 0 B Start

Forward

Check Pump stationary

Pressure gauges attaching High pressure lines X retrench and close Pump res. res.

High pressure lines X close at Hydraulic motor Start engine Pressure reading Stop engine

X1 Value

Test point

Adjusting

Charge pressure

28 bar 406.11 PSI

G Charge pressure Hydraulic pump

PRV Charge pressure

Starting Speed

1200 RPM

Speedmeter

Adjusting screw Start of control

Pressure Drive Hydraulic

460 bar / 6671.74 PSI = 20 km/h / 12.43 miles/h 450 bar / 6526.70 PSI = 28 km/h / 17.40 miles/h

MA forward MB backward Hydraulic pump

PRV Pressuer Cut -off

Pressure Setting cylinder

18 bar / 261.07 PSI A4VG28DA 22 bar / 319.08 PSI A4VG40DA

X2 forward X1 backward

Screen Control valve

Pressure Adjustment

50 bar / 725.19 PSI / 1050 U/min

MA forward MB backward Hydraulic pump

Adjustment

X2

X MB

G MA

X

F 0 B Start

Neutral

Adjust Towingfunction 1

Nut 1 solve Adjust screw 2 screw in until bolt and nut flush Loader towing With max. 6 km/h / 3.73 miles/h miles/h and max. 500 Meter / 1640.42 ft Adjusting screw 2 screw out until the screw is stopped Nut 1 tightend

1

1

2

2

F 0 B Stop

Neutral

Adjust Towingfunction 2

Pressure relieve valve complete screw out 2 – 3 Turns Loader towing With max. 6 km/h / 3.73 miles/h miles/h and max. 500 Meter / 1640.42 ft Pressure relieve valve complete screw in Until is stopped

1

1

F 0 B Stop

Neutral

Adjust Towingfunction 3

Test point MA – MB connect the measuring hose Loader towing With max. 6 km/h / 3.73 miles/h miles/h and max. 500 Meter / 1640.42 ft Retrench measuring hose

F 0 B Stop

Neutral

Hydraulikkomponenten Testing instructions for too low of a thrust

MB

X1 X2

Hydromatic Pump AxVGxxDA Speed and thrust diminish when the oil is warm.

Check the High pressure and Setting pressure: Forward: The High Pressure MA should be s. right and the Set Pressure X2 should be about s. right Backward: Backward: The High Pressure MB should be s. right and the Set Pressure X1 should be about s. right If the Set Pressure and the High Pressure are lower: Check that the Take – off valve is at the 0 position Check that the starting speed is 200 – 300 R.P.M. higher than the idle speed Install a smaller Orifice in the Take – off valve Check the adjusting of the Pressure Cut – off

MA

High pressure:

20 km/h / 12.43 miles/h 460 bar / 6671.74 PSI 30 km/h / 17.40 miles/h 450 bar / 6526.70 PSI

Setting pressure:

A4VG28 DA 16 - 18 bar / 232.06 - 261.07 PSI A4VG40 DA 20 - 22 bar / 290.08 - 319.08 PSI

Attention!!

When measuring Setting Pressure at X1, then X2 must not have a higher back pressure of more than 2 bar (29.01 PSI) and is also applied when X2 is measured. If the backpressure is too high then the T - Nozzle under the solenoid should be checked poss. could be an reason for an defective solenoid.

Hydrauliksystem

Drive motor 20 km/h / 12.43 miles/h miles/h 404D – 22 + 404F 404F – 22 T A4VG28DA – A6VM60HA Variable displacement hydraulic motor

A6VM60HA

Number Maschine type

TH 522

Nominal, ccm / ga

12,8 – 60 / 0.0034 – 0.0159

Direction of rotation

right/left

Highspeed (Laod), RPM

1306 - 6203

Switch over pressure, bar / PSI

250 / 3625.94

Drive motor 28 km/h / 17.40 miles/h miles/h 404D – 22 A4VG40DA – A6VM85HA Variable displacement hydraulic motor

A6VM85HA

Number Maschine type

TH 522

Nominal, ccm / ga

18,7 – 85 / 0.0049 – 0.0225

Direction of rotation

right/left

Highspeed (Laod), RPM

1317 - 5989

Switch over pressure, bar / PSI

160 / 2320.60

Drive motor 28 km/h / 17.40 miles/h miles/h 404F – 22 T A4VG40DA – A6VM85HA Variable displacement hydraulic motor

A6VM85HA

Number Maschine type

TH 522

Nominal, ccm / ga

18,7 – 85 / 0.0049 – 0.0225

Direction of rotation

right/left

Highspeed (Laod), RPM

1317 - 5989

Switch over pressure, bar / PSI

200 / 2900.76

High pressure Low pressure Leaking oil pres.

Setting pressure

Hydrauliksystem

Magnet B – Direction detection Magnet A – Fast gear

Magnet B – Direction detection Direction forward - Magnet B - energized Direction in 0-Position - Magnet B - de - energized Direction backward - Magnet B - de - energized

Magnet A – Fast gear Driving speed 0-Max. km/h / 0-Max.miles/h - Magnet A - de - energized Driving speed 0-8 km/h / 0-4.97 miles/h - Magnet A - energized

Hydrauliksystem

M = Displacement Motor

G = High pressure Pump

Driving speed too low Remove Cap Nut 1 solve Adjusting screw 2 screw out Testdrive 20 km/h / 12.43 miles/h = 100 m / 328.08 ft in 18 sec.

28 km/h / 17.40 miles/h = 100 m / 328.08 ft in 12 sec.

Nut 2 tightend Fasten Cap 1

Adjust Driving speed

Driving speed too high Remove Cap Nut 1 solve Adjusting screw 2 screw in Testdrive 20 km/h / 12.43 miles/h = 100 m / 328.08 ft in 18 sec.

28 km/h / 17.40 miles/h = 100 m / 328.08 ft in 12 sec.

Nut 2 tightend Fasten Cap 1

2 1

F 0 B Start

Forward / Backward

Pressure gauge 600 bar / 8702.26 PSI attaching G = High pressure Pump M = Displacement Motor Start engine, Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: 20 km/h / 12.43 miles/h 404D – 22 + 404F – 22 T A4VG28DA – A6VM60HA 250 bar / 3625.94 PSI

Check Switch over pressure

30 km/h / 17.40 miles/h 404D – 22 A4VG40DA – A6VM85HA 160 bar / 2320.60 PSI

M

30 km/h / 17.40 miles/h 404F – 22 T A4VG40DA – A6VM85HA 200 bar / 2900.76 PSI G < 250/160/200 bar < 3625.94/2320.60/2900.76 PSI 250/160/200 bar 3625.94/2320.60/2900.76 PSI > 250/160/200 bar > 3625.94/2320.60/2900.76 PSI

M 0 bar 0 PSI 125/80/100 bar 1812.97/1160.30/1450.38 PSI same like G in bar same like on G in PSI

G

F 0 B Start

Forward / Backward

Adjust Switch over pressure

Switch over pressure too early Later Switch over pressure Too lower pressure on G Pressure gauge 600 bar / 8702.26 PSI attaching G = High pressure Pump M = Displacement Motor Remove Cap Nut 1 solve Start engine, Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: 20 km/h / 12.43 miles/h 404D – 22 + 404F – 22 T A4VG28DA – A6VM60HA 250 bar / 3625.94 PSI

Switch over pressure too late Earlier Switch over pressure Too higher pressure on G Pressure gauge 600 bar / 8702.26 PSI attaching G = High pressure Pump M = Displacement Motor Remove Cap Nut 1 solve Start engine, Insert direction Drive loader against obstacle Press loader against obstacle Pressure reading Nominal value: 20 km/h / 12.43 miles/h 404D – 22 + 404F – 22 T A4VG28DA – A6VM60HA 250 bar / 3625.94 PSI

30 km/h / 17.40 miles/h 404D – 22 A4VG40DA – A6VM85HA 160 bar / 2320.60 PSI

30 km/h / 17.40 miles/h 404D – 22 A4VG40DA – A6VM85HA 160 bar / 2320.60 PSI

30 km/h / 17.40 miles/h 404F – 22 T A4VG40DA – A6VM85HA 200 bar / 2900.76 PSI Adjusting screw 2 screw out G M < 250/160/200 bar 0 bar < 3625.94/2320.60/2900.76 PSI 0 PSI 250/160/200 bar 125/80/100 bar 3625.94/2320.60/2900.76 PSI 1812.97/1160.30/1450.38 PSI > 250/160/200 bar same like G in bar > 3625.94/2320.60/2900.76 PSI same like on G in PSI Nut 2 tighten Fasten Cap

30 km/h / 17.40 miles/h 404F – 22 T A4VG40DA – A6VM85HA 200 bar / 2900.76 PSI Adjusting screw 2 screw in G M < 250/160/200 bar 0 bar 1 < 3625.94/2320.60/2900.76 PSI 0 PSI 250/160/200 bar 125/80/100 bar 3625.94/2320.60/2900.76 PSI 1812.97/1160.30/1450.38 PSI > 250/160/200 bar same like G in bar > 3625.94/2320.60/2900.76 PSI same like on G in PSI Nut 2 tighten Fasten Cap

2

F 0 B

Start

Forward / Backward

Pressure gauge 600 bar / 8702.26 PSI attaching MB = High pressure Pump, backward M = Displacement Motor Driving machine full load forward Foot off the accelerator Coasting Nominal value: 0 bar / 0 PSI on M

Check Direction detection

M

MB

F 0 B Start

Forward / Backward

Check Direction detection

Pressure gauge 600 bar / 8702.26 PSI attaching MB = High pressure Pump, backward M = Displacement Motor With the HA.R1 or HA.R2 control, the high-pressure related closed loop control can be overridden by an Driving machine full load forward electric signal to switching solenoid b.

Foot off the accelerator When the over-ride solenoid is energized, the variable motor swivels to the maximum swivel angle without Coasting stopping at an intermediate position.

Nominal value: 0 bar / 0 PSI on M The travel direction valve ensures that the preselected pressure side of the hydraulic motor always controls the swivel angle, even if the high-pressure side changes (e.g. travel drive during a descent). This therefore prevents an undesirable swiveling of the variable motor to a larger displacement.

Depending on the direction of rotation (direction of travel), the travel direction valve (see page 25) can be actuated through the pressure spring or switching solenoid a.

Application in travel drives in closed circuits. The travel direction valve of the motor is switched using the 4/3-directional valve on the control device of the driving pump.

When the pump (AA4VG, AA10VG) is switched to the neutral position or into reverse, the vehicle may experience impulsive braking depending on the vehicle's mass and current speed.

This impulsive braking is prevented through the use of the following electric circuit.

With this control, when the pump (AA4VG, AA10VG) is switched 1. to the neutral position: the previous travel direction is retained.

2. to reverse: the motor switches to the other travel direction following a time delay (approx. 0.8 s) with respect to the pump.

F 0 B Start

Forward / Backward

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Work and control before testing of the hydraulic system Engine oil diesel engine - if necessary, correct oil level Cooling water level water cooler diesel engine - if necessary, correct State diesel engine parts – may be repair or replace Oil level hydraulic system - if necessary, correct State hydraulic oil cooler and radiator - if necessary, clean, repair or replace State parts hydraulic system parts hydraulic system – may be repair or replace State fan cooling system may also separate hydraulic oil cooler – may be repair or replace State drive belt water pump and fan blades - if necessary, replace Check machine for leaks (coolant, oil, fuel and hydraulic oil) - if necessary, sea Attach the dial gauges Bring the machine to operating temperature = 55 ° Celsius Low Speed diesel engine (the core values are based) - if necessary, correct High Speed diesel engine (the core values are based) - if necessary, correct Hydraulic pressures check only with high speed !!!

Hydraulic pressures check - if necessary, correct (the pressure charts are based) Test run with corrected values - if necessary, correct again

High pessure filter

Filter, outlet Priority valve

Filter, inlet Gear pump

ThreeThree-point rear attachment

High Flow

Rear PTO

Control valve B Rear PTO Control valve A High Flow

Control valve B Three-point rear attachment lowering

Control valve A Three-point rear attachment lifting

Hydrauliksystem

GP 25 ccm / 0.0066 ga GP 19 ccm / 0.0050 ga at Option Rear hydro connection in PTO

Hydrauliksystem Working- and Steering pump Working Gear pump

Measured value

Speed RPM

Temperature

Nominal ccm / ga

Delivery volume l/min / ga/min ga/min

unloaded

0 bar / 0 PSI

2800

> 55 ° C > 131 ° F

25,0 0.0066

70,0 18.49

loaded

180 bar / 2610.68 PSI

2650

> 55 ° C > 131 ° F

25,0 0.0066

46,2 12.20

unloaded

0 bar / 0 PSI

2800

> 55 ° C > 131 ° F

19,0 0.0050

47,5 12.55

loaded

180 bar / 2610.68 PSI

2650

> 55 ° C > 131 ° F

19,0 0.0050

31,4 8.30

P Pumpe / Pump

T Tank / Tank

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B Teleskop ein / Telescop in A Teleskop aus / Telescop out A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

A

P

U3

U2

1

2

H

E

HDS 21/4

E/L

A

Drosselsteuerventile Throttle valves

E

T T5 Druckentlastung / Pressure Relief

4

A

V/R

B

3

4

Druckbegrenzungsventil, einkippen sekundär Pressure relieve valve, tilt in secondary 270 Bar / 3916,02 PSI

U1

Druckbegrenzungsventil, primär Pressure relieve valve, primary 225 Bar / 3263,35 PSI Druckbegrenzungsventil, ein sekundär Pressure relieve valve, in secondary 270 Bar / 3916,02 PSI

S

U4

2

1

Druckbegrenzungsventil, heben sekundär Pressure relieve valve, lift secondary 250 Bar / 3625,94 PSI

Druckbegrenzungsventil, auskippen sekundär Pressure relieve valve, tilt out secondary 200 Bar / 2900,76 PSI

3

P Pumpe / Pump

T Tank / Tank

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection B Teleskop ein / Telescop in A Teleskop aus / Telescop out A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site

P

E/L

A

U3

U2

1

2

H

E

HDS 21/5

L

A

B rechte Kupplung / right Connection A linke Kupplung / left Connection

Drosselsteuerventile Throttle valves

4. Steuerkreis vorne 4th Control circuit, circuit, front

T

V/R

T5 Druckentlastung / Pressure Relief

4

S

A

B

R

3

4

Druckbegrenzungsventil, einkippen sekundär Pressure relieve valve, tilt in secondary 270 Bar / 3916,02 PSI

U1

Druckbegrenzungsventil, primär Pressure relieve valve, primary 225 Bar / 3263,35 PSI Druckbegrenzungsventil, ein sekundär Pressure relieve valve, in secondary 270 Bar / 3916,02 PSI

E

U4

2

1

Druckbegrenzungsventil, heben sekundär Pressure relieve valve, lift secondary 250 Bar / 3625,94 PSI

Druckbegrenzungsventil, auskippen sekundär Pressure relieve valve, tilt out secondary 200 Bar / 2900,76 PSI

3

P Pumpe / Pump

T Tank / Tank

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis hinten 4th Control circuit, circuit, back

Right side on the next page

B Teleskop ein / Telescop in A Teleskop aus / Telescop out

HDS 21/6 left Side

U3

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

1 L

P

A

H

Drosselsteuerventile Throttle valves

R

T T5 Druckentlastung / Pressure Relief

4

S

4

U1

Druckbegrenzungsventil, primär Pressure relieve valve, primary 225 Bar / 3263,35 PSI Druckbegrenzungsventil, ein sekundär Pressure relieve valve, in secondary 270 Bar / 3916,02 PSI

E

Druckbegrenzungsventil, heben sekundär Pressure relieve valve, lift secondary 250 Bar / 3625,94 PSI

1

A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

Left side on the previous page

HDS 21/6 right Side

U2

B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis vorne

2

4th Control circuit, circuit, front

E

E/L

L

A P

Drosselsteuerventile Throttle valves

A

V/R

3

U4 Druckbegrenzungsventil, einkippen sekundär Pressure relieve valve, tilt in secondary 270 Bar / 3916,02 PSI

2

Druckbegrenzungsventil, auskippen sekundär Pressure relieve valve, tilt out secondary 200 Bar / 2900,76 PSI

3

R

B

P Pumpe / Pump

T Tank / Tank

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis hinten 4th Control circuit, circuit, back

Right side on the next page

B Teleskop ein / Telescop in A Teleskop aus / Telescop out A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site

L

P

A

U3

U2

1

2

H

E

HDS 21/7 left Side

Drosselsteuerventile Throttle valves

R

T T5 Druckentlastung / Pressure Relief

4

S

A 3

4

Druckbegrenzungsventil, einkippen sekundär Pressure relieve valve, tilt in secondary 270 Bar / 3916,02 PSI

U1

Druckbegrenzungsventil, primär Pressure relieve valve, primary 225 Bar / 3263,35 PSI Druckbegrenzungsventil, ein sekundär Pressure relieve valve, in secondary 270 Bar / 3916,02 PSI

E

U4

2

Druckbegrenzungsventil, heben sekundär Pressure relieve valve, lift secondary 250 Bar / 3625,94 PSI

1

Druckbegrenzungsventil, auskippen sekundär Pressure relieve valve, tilt out secondary 200 Bar / 2900,76 PSI

3

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

A Heckkraftheber heben / Rear Power lift lift B Heckkraftheber senken / Rear Power lift lower

Left side on the previous page

HDS 21/7 right Side

Heckkraftheber Rear Power lift B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis vorne 4th Control circuit, circuit, front

E/L

H

L

A P

Drosselsteuerventile Throttle valves

V/R

S

R

B

P Pumpe / Pump

T Tank / Tank

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis hinten 4th Control circuit, circuit, back

Right side on the next page

B Teleskop ein / Telescop in A Teleskop aus / Telescop out A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site

L

P

A

U3

U2

1

2

H

E

HDS 21/8 left Side

Drosselsteuerventile Throttle valves

R

T T5 Druckentlastung / Pressure Relief

4

S

A 3

4

Druckbegrenzungsventil, einkippen sekundär Pressure relieve valve, tilt in secondary 270 Bar / 3916,02 PSI

U1

Druckbegrenzungsventil, primär Pressure relieve valve, primary 225 Bar / 3263,35 PSI Druckbegrenzungsventil, ein sekundär Pressure relieve valve, in secondary 270 Bar / 3916,02 PSI

E

U4

2

Druckbegrenzungsventil, heben sekundär Pressure relieve valve, lift secondary 250 Bar / 3625,94 PSI

1

Druckbegrenzungsventil, auskippen sekundär Pressure relieve valve, tilt out secondary 200 Bar / 2900,76 PSI

3

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

Vorsteuerung / Pilot control B Senken / Lowering U 1 A Heben / Lift U 3 A Einkippen / Tilt in U 2 B Auskippen / Tilt out U 4

A Heckkraftheber heben / Rear Power lift lift B Heckkraftheber senken / Rear Power lift lower

Left side on the previous page

HDS 21/8 right Side

Heckkraftheber Rear Power lift B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis vorne 4th Control circuit, circuit, front A High Flow B Heckzapfwelle / Rear PTO

E/L

H

L

HF

A P

AnschlussPlatte Connection plate

V/R

S

R

Drosselsteuerventile Throttle valves

ZW

Anschluß HF Pumpe Connecting HF pump

B

Work hydraulic Value

Test point

Adjusting

Pressure Work hydraulic

225 bar / 3263.35 PSI Primarily

Control valve

PRV Primarily Control valve

Pressure Tilt out

200 bar / 2900.76 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure Tilt in

270 bar / 3916.02 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure Lifting

250 bar / 3625.94 PSI Secondary

Control valve / Tilt cylinder

PRV secondary Control valve

Pressure, Pressure, secondary Telescop extend

270 bar / 3916.02 PSI Secondary

Control valve / Telescop cylinder

Secondary Valve Section Telescop retract

Pressure Rear PTO High Flow

225 bar / 3263.35 PSI Primarily

Control valve

PRV Primarily (2) Control valve

A Einkippen / Tilt in Bodenseitig / Piston site B Auskippen / Tilt out Stangenseitig / Rod site

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

HDS 21/4 B Teleskop ein / Telescop in Stangenseitig / Rod site A Teleskop aus / Telescop out Bodenseitig / Piston site

270 Bar

200 Bar

3916,02 PSI 2900,76 PSI

250 Bar

270 Bar

3625,94 PSI

3916,02 PSI

225 Bar 3263,35 PSI

T5 Druckentlastung / Pressure Relief

T Tank / Tank Pp Druckweiterleitung / Pressure Forwarding

Druckbegrenzungsventil „primär“ Pressure relieve valve, primary

P Pumpe / Pump

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

4. Steuerkreis vorne 4th Control circuit, circuit, front B rechte Kupplung / right Connection A linke Kupplung / left Connection

B Teleskop ein / Telescop in Stangenseitig / Rod site A Teleskop aus / Telescop out Bodenseitig / Piston site

A Einkippen / Tilt in Bodenseitig / Piston site B Auskippen / Tilt out Stangenseitig / Rod site

HDS 21/5 B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

270 Bar

200 Bar

3916,02 PSI 2900,76 PSI

250 Bar

270 Bar

3625,94 PSI

3916,02 PSI

225 Bar 3263,35 PSI

T5 Druckentlastung / Pressure Relief

T Tank / Tank Pp Druckweiterleitung / Pressure Forwarding

Druckbegrenzungsventil „primär“ Pressure relieve valve, primary

P Pumpe / Pump

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection 4. Steuerkreis hinten 4th Control circuit, circuit, back B rechte Kupplung / right Connection A linke Kupplung / left Connection

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

A Einkippen / Tilt in Bodenseitig / Piston site B Auskippen / Tilt out Stangenseitig / Rod site

B Teleskop ein / Telescop in Stangenseitig / Rod site A Teleskop aus / Telescop out Bodenseitig / Piston site

HDS 21/6 4. Steuerkreis vorne 4th Control circuit, circuit, front

B rechte Kupplung / right Connection A linke Kupplung / left Connection

270 Bar

200 Bar

250 Bar

3916,02 PSI 2900,76 PSI 3625,94 PSI

270 Bar 3916,02 PSI

225 Bar 3263,35 PSI

T5 Druckentlastung / Pressure Relief

Pp Druckweiterleitung / Pressure Forwarding

T Tank / Tank Druckbegrenzungsventil „primär“ Pressure relieve valve, primary

P Pumpe / Pump

Heckkraftheber Rear Power lift A Heckkraftheber heben / Rear Power lift lift B Keckkraftheber senken / Rear Power lift lower

4. Steuerkreis vorne 4th Control circuit, circuit, front B rechte Kupplung / right Connection A linke Kupplung / left Connection

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

A Einkippen / Tilt in Bodenseitig / Piston site B Auskippen / Tilt out Stangenseitig / Rod site

B Teleskop ein / Telescop in Stangenseitig / Rod site A Teleskop aus / Telescop out Bodenseitig / Piston site

HDS 21/7 4. Steuerkreis hinten 4th Control circuit, circuit, back B rechte Kupplung / right Connection A linke Kupplung / left Connection

270 Bar

200 Bar

250 Bar

3916,02 PSI 2900,76 PSI 3625,94 PSI

270 Bar 3916,02 PSI

225 Bar 3263,35 PSI

Pp Druckweiterleitung / Pressure Forwarding

T5 Druckentlastung / Pressure Relief

T Tank / Tank Druckbegrenzungsventil „primär“ Pressure relieve valve, primary

P Pumpe / Pump

Heckkraftheber Rear Power lift A Heckkraftheber heben / Rear Power lift lift B Keckkraftheber senken / Rear Power lift lower

B Heckzapfwelle / Rear PTO

B Verriegeln / Locking Bodenseitig / Piston site A Entriegeln / Unlocking Stangenseitig / Rod site B rechte Kupplung / right Connection A linke Kupplung / left Connection

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site B Teleskop ein / Telescop in Stangenseitig / Rod site A Teleskop aus / Telescop out Bodenseitig / Piston site

A Einkippen / Tilt in Bodenseitig / Piston site B Auskippen / Tilt out Stangenseitig / Rod site

HDS 21/8

4. Steuerkreis hinten 4th Control circuit, circuit, back

B rechte Kupplung / right Connection A linke Kupplung / left Connection

A High Flow

270 Bar

200 Bar

250 Bar

3916,02 PSI 2900,76 PSI 3625,94 PSI

270 Bar 3916,02 PSI

225 Bar 3263,35 PSI

Pp Druckweiterleitung / Pressure Forwarding

T5 Druckentlastung / Pressure Relief

T Tank / Tank Druckbegrenzungsventil „primär“ Pressure relieve valve, primary

P Pumpe / Pump

P Pumpe / Pump

T Tank / Tank

A Einkippen / Tilt in Stangenseitig / Rod site B Auskippen / Tilt out Bodenseitig / Piston site

A Heben / Lift Bodenseitig / Piston site B Senken / Lowering Stangenseitig / Rod site

A

T

4 T P

H

S

P 1

3 E

2

Lift / Lowering Detection

P Pumpe / Pump

T Tank / Tank

Lowering Tilt in Lift Tilt out

VLS S084 Switch hydraulic function shutdown S141 Switch VLS-Mode S163 Pressure switch lowering detection S162 Pressure switch lifting detection N001 Driveelectronics

S163 Pressure switch lowering detection Control valve B S162 Pressure switch lifting detection Control valve A

VLS F008 Diagnosis, VLS, Handbrake, Roadblock, Seat ECU N001 F005 Instruments, Switch illumination S084 Switch hydraulic function shutdown S141 Switch VLS-Mode P006 Overload warning device B040 Thumbwheel Telescoping R014 Potentiometer lifting / lowering S163 Pressure switch lowering detection S162 Pressure switch lifting detection B008 Load sensor Strain gauges N001 Driveelectronics S142 Limitswitch Telescope S116 Limitswitch Telescope Y024 Solenoid Tele exrend Y023 Solenoid Tele retract Y102 Solenoid vertical lowering

Pressure gauge 300 bar / 4351.13 PSI attaching Quick Coupling or Lifting- or Locking cylinder Start engine Additional hydraulics or Load arm go against stop Pressure reading Nominal value: 225 bar / 3263.35 PSI When working pressure „primarily" o. K. : Check working pressure „secondary“ When working pressure „primarily" not no o. K. K : Pressure relieve valve Primarily pressure 1 complete Turn screw in Pressure reading When working pressure "primarily" not no o. K. K : Pressure relieve valve Primarily pressure 1 complete Turn screw in When working pressure "primarily" not no o. K. K : Pressure relieve valve Primarily pressure 2 complete Turn screw out Check Flow rate

Check Working pressure „primarily“ and adjust

1

F 0 B Start

Neutral

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Tilt cylinder Piston side Tilt in = Rod site Tilt out = Piston site Start engine Load arm in horizontal Position Tilt out Frame complete Load arm lift and pressure value „Tilt out“ reading Pressure reading Nominal value: 200 bar / 2900.76 PSI Working pressure „secondary“ too low Nut 1 solve Adjusting screw 2 screw in Pressure reading Nominal value: 200 bar / 2900.76 PSI Nut 1 tighten

Check Working pressure „secondary“ „Tilt out“ and adjust

Working pressure „secondary“ too high Nut 1 solve Adjusting screw 2 screw out Pressure reading Nominal value: 200 bar / 2900.76 PSI Nut 1 tighten

1

F 0 B Start

Neutral

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Tilt cylinder Piston side Tilt in = Rod site Tilt out = Piston site Start engine Load arm in highest Position Tilt in Frame complete Load arm lower and pressure value „Tilt in“ reading Pressure reading Nominal value: 270 bar / 3916.02 PSI Working pressure „secondary“ too low Nut 1 solve Adjusting screw 2 screw in Pressure reading Nominal value: 270 bar / 3916.01 PSI Nut 1 tighten

Check Working pressure „secondary“ „Tilt in“ and adjust

Working pressure „secondary“ too high Nut 1 solve Adjusting screw 2 screw out Pressure reading Nominal value: 270 bar / 3916.02 PSI Nut 1 tighten

1

F 0 B Start

Neutral

Steering cylinder

Steering valve

V2

V3

V1

Steering hydraulic

Pressure Steering hydraulic

Value

175 bar / 2538.16 PSI Primarily 210 bar / 3045.79 PSI Secondary

Test point

Steering valve / Steering cylinder

Adjusting

Steering valve

Steering cylinder

Steering valve 210 Bar 3045,79 PSI

V2

V3 Druckbegrenzungsventil, rechts sekundär Pressure relieve valve, right secondary

Druckbegrenzungsventil, links sekundär Pressure relieve valve, left secondary 175 Bar 2538,16 PSI

V1

Druckbegrenzungsventil, primär Pressure relieve valve, primary

Solenoid B energized

Solenoid A + B de - energized

Solenoid A energized

Front axle steering

L

R

4 wheel steering

Crab steering

L

L

R

R

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Steering cylinder Piston side right or left Start engine Steering wheel right- or left turning – until is stopped (depending where gauge is mounted) Pressure reading Nominal value: 175 bar / 2538.16 PSI

Steering pressure „ primarily“ too low Stop engine Plug V1 remove Start engine Steering wheel right- or left turning – until is stopped (depending where gauge is mounted) Pressure reading Nominal value: 175 bar / 2538.16 PSI Adjusting screw screw in Plug V1 insert

Check Steering pressure „primarily“ and adjust

Steering pressure „ primarily“ too high Stop engine Plug V1 remove Start engine Steering wheel right- or left turning – until is stopped (depending where gauge is mounted) Pressure reading Nominal value: 175 bar / 2538.16 PSI Adjusting screw screw out Plug V1 insert

F 0 B Start

Neutral

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Steering cylinder Piston left or right Start engine Steering wheel right- or left turning – until is stopped (depending where gauge is mounted) Press machine on the bucket on the opposite side Pressure reading Nominal value: 210 bar / 3045.79 PSI

Check Steering pressure „secondary“

F 0 B Start

Neutral

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Steering cylinder Piston side right (blue) Start engine Steering wheel right turning– until app. to the middle Press machine on the bucket on the opposite side Pressure reading Nominal value: 210 bar / 3045.79 PSI Steering pressure „secondary“ too low Stop engine Plug V3 remove Start engine Pressure reading Nominal value: 210 bar / 3045.79 PSI Adjusting screw screw in Plug V3 insert

Adjust Steering pressure „secondary“ right

Steering pressure „secondary“ too high Stop engine Plug V3 remove Start engine Pressure reading Nominal value: 210 bar / 3045.79 PSI Adjusting screw screw out Plug V3 insert

F 0 B Start

Neutral

Pressure gauge 300 bar / 4351.13 PSI attaching T-Piece Steering cylinder Piston side left (red) Start engine Steering wheel left turning– until app. to the middle Press machine on the bucket on the opposite side Pressure reading Nominal value: 210 bar / 3045.79 PSI Steering pressure „secondary“ too low Stop engine Plug V2 remove Start engine Pressure reading Nominal value: 210 bar / 3045.79 PSI Adjusting screw screw in Plug V2 insert

Adjust Steering pressure „secondary“ left

Steering pressure „secondary“ too high Stop engine Plug V2 remove Start engine Pressure reading Nominal value: 210 bar / 3045.79 PSI Adjusting screw screw out Plug V2 insert

F 0 B Start

Neutral

Hydrauliksystem

Hydraulic diagram

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Electric diagram

Fusebox

F

F

F

F

F

F

F

F

1

2

3

4

5

6

7

8

F

F

F

F

F

F

F

F

9

10

11

12

13

14

15

16

Electric diagram

Fusebox

F 17

F 20

F 18

F 21

F 19

F 22

Electric diagram

Fusebox

F

F

F

F

F

F

F

F

23

24

25

26

27

28

F

F

F

F

F

F

F

F

29

30

31

32

33

34

35

36

Electric diagram

Fusebox

F

F

306 305

F

F

F

F

304

303

302

301

Position Diagnostic connector Engine and Hydraulic

Drive direction F-N-R Red. F-N-R Telescop retract/extend Red. Telescop retract/extend 3 rd/4 th Control circuit Red. 3 rd/4 th Control circuit Differentail lock Electric function 1 Slow gear Electric function 2 Reserve control lever Hydro Comfort Connection

Pos. B (Grey) Tele „retract/extend“ (current) Proportional adjustment wheel back Pos. B (Grey) Additional hydraulic 3rd/4th Control circuit Supply voltage: 5V Redudantes Output signal: - Signal 1 0,5…4,5V - Siganl 2 0,5…2,5V Characteristic of the thumb wheel with 30 ° deflection

Tolerance

Sight glass

Reason

Remedy

In sight glass bubbles form.

– Refill refrigerant – Check system for leaks

Lack of refrigerant !!

Bubbles free

Amount of refrigerant in order

Fault

Reason

Troubleshooting (only by a refrigeration specialist)

System is not running

Electrical connections loose

Check Electrical connections

Defective fuse

Change Fuse

Control Panel broken

Change Control Panel

Over pressure

Clean condenser fins

Negative pressure clogged Dryer

Change Dryer – only by a refrigeration specialist

Negative pressure clogged Expansion valve

Cleaning Expasion vale, app. change – only by a refrigeration specialist

Leaks in the system Lack of refrigerant R 134a: 1100 gr. / 2.43 lb.

Check system for leaks – Refill refrigerant – Change Dryer – only by a refrigeration specialist

System runs, turns off

Overpressure due to high outdoor temperature

un system until pressure is stabilizes

System running, but not cooling

Defective Solenoid valve – Heating on -

Check Solenoid valve - Heating off

Loud noise compressor

Ball bearings at compressor expired

Change compressor – only by a refrigeration specialist

Magnetic clutch defective

Change Magnetic clutch

V-belt worn V-belt too loose

– Change V-Belt – Span V-Belt

Whistling on belts

404 D – 22

404 D – 22

404 D – 22

404 F – 22

404 F – 22

404 F – 22

VLS F008 Diagnosis, VLS, Handbrake, Roadblock, Seat ECU N001 F005 Instruments, Switch illumination S084 Switch hydraulic function shutdown S141 Switch VLS-Mode P006 Overload warning device B040 Thumbwheel Telescoping R014 Potentiometer lifting / lowering S163 Pressure switch lowering detection S162 Pressure switch lifting detection B008 Load sensor Strain gauges N001 Driveelectronics S142 Limitswitch Telescope S116 Limitswitch Telescope Y024 Solenoid Tele exrend Y023 Solenoid Tele retract Y102 Solenoid vertical lowering

Adjusting the Load Display with Scale TH 522 State machine Airpressure of the tires Straight solid ground Find out Test load - see load table operation manual State Test load State attachment Security areas noted Security rules observe

2,2 t

Adjusting the Load Display with Scale TH 522 Test weight 2.2 tons ( maximum load ) Vehicle min. 5 minutes drive (Temperature compensation sensor).

Vehicle on a suitable scale ( Plates – Axle scale, etc.) drive.

2,2 t

Servicing and Inspection

Systemlight

Ignition off = Systemlight off Ignition on = Systemlight on

Servicing and Inspection

Control key

Press = function test (all LEDs light up and warning) Long press = LED's brightness is reduced - starting brightness = bright

Servicing and Inspection

6. LED red 110% 5. LED orange 100% 4. LED green 85% 3. LED green 70% 2. LED green 55% 1. LED green 40%

Weight is required for the calibration For the 100% calibration weight on a pallet fork.

The telescopic arm is fully retracted.

About 50 cm / 19.69 in lift up.

The weight to the set must be 2.2 tons ( maximum load ).

This can be also a full bucket.

It must be ensured that after the calibration at 100% load on the load display, the rear axle still, with at least 400 kg ± 20 kg / 881.85 lb ± 44.09 lb is loaded!

TH 522

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs

Control key

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key After this display will change in two inward current light bar.

The preparation Servicing of the and calibration Inspection procedure can max. 10x be repeated.

Then, the calibration can not be started and the OMD proceeds to normal operation

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key After this display will change in two inward current light bar.

This condition will not leave.

If the calibration aborted here will switch off the ignition.

The old calibration data are retained.

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Control key

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Vehicle on a suitable scale.

Bring vehicle in 0% -Loading condition – Loading arm at the head – Loading arm fully retract

2,2 t

This process may take a few seconds.

During this time, the vehicle must not be moved.

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Vehicle on a suitable scale.

Bring vehicle in 0% -Loading condition – Loading arm at the head – Loading arm fully retract Press the Control key 0% Calibration will be stored Upon completion, the red LED lights and Beep occurs.

Test load pick up

2,2 t

Control key

Servicing and Inspection

Telescopicarm bringing in horizontal position.

About 50 cm / 19.69 in over the ground

2,2 t

Servicing and Inspection

Telescopicarm bringing in horizontal position.

2,2 t

Servicing and Inspection

Telescopicarm bringing in 100% load.

Min. Load pressure

Max. Axle pressure 2,2 t

Servicing and Inspection

Telescopicarm bringing in 100% load.

Mid. Load pressure

Mid. Axle pressure 2,2 t

Servicing and Inspection

Telescopicarm bringing in 100% load.

Max. Load pressure

2,2 t

Min. Axle pressure 400 kg ± 20 kg 881.85 lb ± 44.09 lb

Determine the extension distance from the telescopic arm for the maximum load: For the 100% calibration weight on a pallet fork.

The telescopic arm is fully retracted.

About 50 cm / 19.69 in lift up.

The weight to the set must be 2.2 tons ( maximum load ).

This can be also a full bucket.

It must be ensured that after the calibration at 100% load on the load display, the rear axle still, with at least 400 kg ± 20 kg / 881.85 lb ± 44.09 lb is loaded!

This process may take a few seconds.

During this time, the vehicle must not be moved.

Press the Control key 100% Calibration will be stored

Control key Min. Axle pressure 400 kg ± 20 kg 881.85 lb ± 44.09 lb

Press the Control key 100% Calibration will be stored Two inward current light bar( 3x) show the completion of the calibration Ignition off Ignition on / Start engine Loading arm fully retract.

Servicing and Inspection

Press the Control key 100% Calibration will be stored Two inward current light bar( 3x) show the completion of the calibration Ignition off Ignition on / Start engine Loading arm fully retract.

Test load dependent Telescopicarm bringing in horizontal position.

About 50 cm / 19.69 in over the ground.

Machine with the WEDIAS connect and switch to OM display.

2

The calibration was performed correctly when the Loadstate Present load < 20 % (2) in the unloaded condition and the Difference A/B Current value < 2 % (1) in the unloaded condition (Telescopicarm about 50 cm / 19.69 over the ground, retract and unloaded) is.

1

Adjusting the Load Display without Scale TH 522 State machine Airpressure of the tires Straight solid ground Find out Test load - see load table operation manual State Test load State attachment Security areas noted Security rules observe

Adjusting the Load Display without Scale TH 522 Test weight Vehicle min. 5 minutes drive (Temperature compensation sensor).

Video is available !!!

Systemlight

Ignition off = Systemlight off Ignition on = Systemlight on

Control key

Press = function test (all LEDs light up and warning) Long press = LED's brightness is reduced - starting brightness = bright

6. LED red 110% 5. LED orange 100% 4. LED green 85% 3. LED green 70% 2. LED green 55% 1. LED green 40%

Weight is required for the calibration For the 100% calibration weight on a pallet fork.

The telescopic arm is fully retracted.

About 50 cm / 19.69 in lift up.

The weight to the set must be about 50 - 75% of maximum.

This can be also a full bucket.

The weight must be so hard, that rear rises the machine, when the telescopic arm is extended.

It must be ensured that after the calibration at 100% load on the load display, the rear axle still, with at least 400 kg ± 20 kg / 881.85 lb ± 44.09 lb is loaded!

TH 522

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs

Control key

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key After this display will change in two inward current light bar.

The preparation of the calibration procedure can max. 10x be repeated.

Then, the calibration can not be started and the OMD proceeds to normal operation

Ignition off Press the control key and continue to hold.

Start engine Orange LED lights Beep occurs Orange LED goes Release the Control key After this display will change in two inward current light bar.

This condition will not leave.

If the calibration aborted here will switch off the ignition.

The old calibration data are retained.

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Control key

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Bring vehicle in 0% -Loading condition – Loading arm at the head – Loading arm fully retract

This process may take a few seconds.

During this time, the vehicle must not be moved.

Press the Control key 1.Green LED lights Vehicle min. 5 minutes drive.

Bring vehicle in 0% -Loading condition – Loading arm at the head – Loading arm fully retract Press the Control key 0% Calibration will be stored Upon completion, the red LED lights and Beep occurs.

Test load pick up

Control key

Telescopicarm bringing in horizontal position.

About 50 cm / 19.69 in over the ground

Telescopicarm bringing in horizontal position.

About 50 cm / 19.69 in over the ground

Telescopicarm bringing in 100% load.

Telescopicarm bringing in 100% load.

Telescopicarm bringing in 100% load.

Telescopicarm bringing in 100% load.

Telescopicarm bringing in 100% load.

Determine the extension distance from the telescopic arm for the maximum load: For the 100% calibration weight on a pallet fork.

The telescopic arm is fully retracted.

About 50 cm / 19.69 in lift up.

The weight to the set must be about 50 - 75% of maximum.

This can be also a full bucket.

The weight must be so hard, that rear rises the machine, when the telescopic arm is extended.

It must be ensured that after the calibration at 100% load on the load display, the rear axle still, with at least 400 kg ± 20 kg / 881.85 lb ± 44.09 lb is loaded!

Telescopicarm mark in 100% load.

2/3

1/3

Telescopicarm 1/3 telescop retract

1/3

2/3

This process may take a few seconds.

During this time, the vehicle must not be moved.

Press the Control key 100% Calibration will be stored

Press the Control key 100% Calibration will be stored Two inward current light bar( 3x) show the completion of the calibration Ignition off Ignition on / Start engine Loading arm fully retract.

Press the Control key 100% Calibration will be stored Two inward current light bar( 3x) show the completion of the calibration Ignition off Ignition on / Start engine Loading arm fully retract.

Test load dependent Telescopicarm bringing in horizontal position.

About 50 cm / 19.69 in over the ground.

Machine with the WANDA connect and switch to OM display.

2

The calibration was performed correctly when the Loadstate Present load < 20 % (2) in the unloaded condition and the Difference A/B Current value < 2 % (1) in the unloaded condition (Telescopicarm about 50 cm / 19.69 over the ground, retract and unloaded) is.

1

Servicing and Inspection

Sensor power outside the work area Display before dark - probably Cable break Sensor Has been previously shown either full load Short circuit or external voltage at OMD Sensor input

Servicing and Inspection

Sensor current is too high - short circuit Sensor line External voltage sensor input

Servicing and Inspection

Signal difference between 0% and 100% is too low possibly loose sensor

Servicing and Inspection

Sensor Mounting: The mounting surface is (240 grit) slightly roughened with sandpaper and cleaned with cleaner ( SF Loctite® 7063 ) thoroughly several times.

Paper is unsuitable for this purpose , so use lint-free swab.

Clean the mounting surface of the sensor also with the cleaner Loctite® 7063 SF thoroughly.

Adhesive ( Loctite 638 ) lightly and evenly on the mounting surface of the sensor.

Medium strength thread lock applied to the screw thread.

After bonding, the machine must not be moved 12 hours ! ( approximately 20 degrees).

Now the sensor with acrylic caulk ( It is important not to use silicone !).

Torque sensor:

35 Nm 1. Step 70 Nm 2. Step

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Operating

Inspection

Tech. Datas

Maintenance

Drive motor

Agenda Elektric / Elektronic

Load arm

WorkWork- and Steering hydraulic

Axles

Drive hydraulic

Service kit Type

Feature

Engine

Model year

Chassisnumber

TH 522 VLS

///

404 D – 22 Tier IIIA

All

All

Servicekit

Engineoil

Fuel, Pre

Fuel, Main

Fuel, Separator

Air, outside

1000309661

1000231366

///

1000255796

///

1000000365

Air, inside

Hydraulic, Main

Hydraulic, Pressure

Ventilation

Cabin

Valve cover gasket

1000087796

1000231380

///

///

///

1000203390

Filling Quantities 404 D – 22 Tier IIIA in Liter

Fuel Tank

70,00

Diesel fuel

DIN EN 590

Engine oil with Filter

10,60

Engine oil SAE 15 W 40

API CG-4/API CH-4

Fill amount com. Axle

2,50 f. 2,50 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0,30

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0,50

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

68,00

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

55,00

Hydraulic oil HLP

ISO VG 46

Cooling System*

10,00*

HD Coolant & Antifreeze*

ASTM D 4985*

Brake System

1,00

ATF - Oil

10,50*

incl. Heating system*

1300 gr.

R 134a

Air-conditioning

Filling Quantities 404 D – 22 Tier IIIA in Gallon

Fuel Tank

18.49

Diesel fuel

DIN EN 590

Engine oil with Filter

2.80

Engine oil SAE 15 W 40

API CG-4/API CH-4

Fill amount com. Axle

0.92 f. / 1.00 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0.08

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0.13

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

17.96

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

14.52

Hydraulic oil HLP

ISO VG 46

Cooling System*

2.64*

HD Coolant & Antifreeze*

ASTM D 4985*

Brake System

0.26

ATF - Oil

2.77*

incl. Heating system*

2.86 lb.

R 134a

Air-conditioning

Service kit Type

Feature

Engine

Model year

Chassisnumber

TH 522 VLS

///

404 F – 22 T Tier IIIB

All

All

Servicekit

Engineoil

Fuel, Pre

Fuel, Main

Fuel, Separator

Air, outside

1000317997

1000231366

///

1000255796

///

1000000365

Air, inside

Hydraulic, Main

Hydraulic, Pressure

Ventilation

Cabin

Valve cover gasket

1000087796

1000231380

///

///

///

1000314618

Filling Quantities 404 F – 22 T Tier IIIB in Liter

Fuel Tank

70,00

Diesel fuel

DIN EN 590

Engine oil with Filter

10,60

Engine oil SAE 10 W 40

API CJ-4/ACEAE 9

Fill amount com. Axle

2,50 v. 2,50 h.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0,30

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0,50

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

68,00

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

55,00

Hydraulic oil HLP

ISO VG 46

Cooling System*

10,00*

HD Coolant & Antifreeze*

ASTM D 6210*

Brake System

1,00

ATF - Oil

10,50*

incl. Heating system*

1300 gr.

R 134a

Air-conditioning

Filling Quantities 404 F – 22 T Tier IIIB in Gallon

Fuel Tank

18.49

Diesel fuel

DIN EN 590

Engine oil with Filter

2.80

Engine oil SAE 10 W 40

API CJ-4/ACEAE 9

Fill amount com. Axle

0.92 f. / 1.00 r.

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Transfer gear box

0.08

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Fill amount Plenatray gear

0.13

Transm. oil SAE 90 GL 5

API GL 5-MIL 2105

Hydraulic System com.

17.96

Hydraulic oil HLP

ISO VG 46

Hydraulic Tank

14.52

Hydraulic oil HLP

ISO VG 46

Cooling System*

2.64*

HD Coolant & Antifreeze*

ASTM D 6210*

Brake System

0.26

ATF - Oil

2.77*

incl. Heating system*

2.86 lb.

R 134a

Air-conditioning

Engine: 404F – 22 T

Engine: 404F – 22 T

Engine: 404F – 22 T

Inspection