SHB 701 en 1000164190 2 0

Service Manual
Compact loaders
Machine models 701s/sp

Edition 2.0
Language English
Item no. 1000164190
Documentation
Description Order no.
Operator's Manual 1000151639
Service manual 1000164190
Spare parts list Up to serial no. DB00708 1000150186
From serial no. DC00713 1000186575
Copyright 2009 Wacker Neuson Linz GmbH, Linz-Leonding

Printed in Austria
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.
Wacker Neuson Linz GmbH

Haidfeldstr. 37
A-4060 Linz-Leonding
Document: SERV-HB 701s sp EN
Order no.: 1000164190
Edition: 2.0
Table of contents
Table of contents
Table of contents
Operation
Important information on this service manual .......................................................... 1-1
Identification of warnings and dangers .................................................................... 1-2
Designated use and exemption from liability ........................................................... 1-3
Type labels and component numbers ...................................................................... 1-4
Machine overview .................................................................................................... 1-6
Cab overview ........................................................................................................... 1-7
Cab (legend) ............................................................................................................ 1-7
Round indicating instrument overview .................................................................... 1-8
Round indicating instrument (legend) ...................................................................... 1-8
Engine compartment overview ................................................................................ 1-9
701s ................................................................................................................... 1-9
701sp ............................................................................................................... 1-10
Engine cover (open): overview .............................................................................. 1-11
701s ................................................................................................................. 1-11
701sp ............................................................................................................... 1-12
Chassis overview ................................................................................................... 1-13
Tilting the cab ........................................................................................................ 1-14
Specifications
Chassis .................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Fuel injection pump ........................................................................................... 2-3
Capacity ............................................................................................................. 2-3
Tightening torque ............................................................................................... 2-3
Travelling drive ........................................................................................................ 2-4
Brakes ...................................................................................................................... 2-4
Work hydraulics ....................................................................................................... 2-4
Pilot control .............................................................................................................. 2-5
Additional control circuit + 3rd control circuit ........................................................... 2-5
Electric units ............................................................................................................ 2-6
Fuse box in instrument panel ............................................................................ 2-6
Main fuse box with relays .................................................................................. 2-6
Relays ................................................................................................................ 2-6
Tyres ........................................................................................................................ 2-7
Noise levels ............................................................................................................. 2-7
Vibration ................................................................................................................... 2-7
Coolant compound table .......................................................................................... 2-7
Dimensions .............................................................................................................. 2-8
Model-specific tightening torques ............................................................................ 2-9
General tightening torques ...................................................................................... 2-9
Tightening torques for hydraulic screw connections (dry assembly) ................. 2-9
Tightening torques for high-resistance screw connections .............................. 2-11
Fluids and lubricants ................................................................................................ 3-1
Additional oil change and filter replacement (hydraulics) .................................. 3-2
Maintenance label .................................................................................................... 3-3
Explanation of symbols on the maintenance label ............................................ 3-3
Maintenance plan (overview) ................................................................................... 3-5
Introduction .............................................................................................................. 3-8
Fuel system ............................................................................................................. 3-9
Specific safety instructions ................................................................................ 3-9
Refuelling ........................................................................................................... 3-9
Stationary fuel pumps ...................................................................................... 3-10
Diesel fuel specification ................................................................................... 3-10
Bleeding the fuel system ................................................................................. 3-10
SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm I-1

Table of contents
Emptying the fuel tank ..................................................................................... 3-11

Fuel prefilter with water separator ................................................................... 3-11
Replacing the fuel filter .................................................................................... 3-12
Engine lubrication system ...................................................................................... 3-13
Checking the oil level ....................................................................................... 3-13
Filling up engine oil .......................................................................................... 3-14
Changing engine oil ......................................................................................... 3-14
Replacing the engine oil filter cartridge ............................................................ 3-16
Cooling system ...................................................................................................... 3-17
Specific safety instructions .............................................................................. 3-17
Checking/filling up coolant ............................................................................... 3-18
Draining coolant ............................................................................................... 3-19
Air filter ................................................................................................................... 3-20
Replacing the filter ........................................................................................... 3-21
Functional check once a week of the dust valve ............................................. 3-22
V-belt ...................................................................................................................... 3-23
Checking V-belt tension ................................................................................... 3-23
Retightening V-belt .......................................................................................... 3-24
Pressure check ...................................................................................................... 3-25
General ............................................................................................................ 3-25
Standard micro ports ....................................................................................... 3-25
Variable displacement pump measuring points ............................................... 3-26
Preparatory work ............................................................................................. 3-28
Main pressure check (P1 & P2) ....................................................................... 3-28
Boost pressure check of pump and pilot control pressure check of work
hydraulics ......................................................................................................... 3-29
Work hydraulics pressure check ...................................................................... 3-30
Checking the pilot control pressure of the drive hydraulics ............................. 3-31
Checking the parking brake release pressure ................................................. 3-31
Checking the speed-sensitive control pressure ............................................... 3-32
Checking the pressure of the 3rd control circuit (Power Flow option 701sp) ... 3-32
Test report 701s ..................................................................................................... 3-33
Test report 701sp ................................................................................................... 3-35
Hydraulic system .................................................................................................... 3-38
Checking the hydraulic oil level ....................................................................... 3-39
Bleeding the hydraulic pump ........................................................................... 3-40
Filling up hydraulic oil ...................................................................................... 3-40
After changing the hydraulic oil ........................................................................ 3-41
Changing hydraulic oil ..................................................................................... 3-41
Monitoring the hydraulic oil reflux filter ............................................................ 3-42
Replacing the reflux filter ................................................................................. 3-42
Checking hydraulic pressure lines ................................................................... 3-43
Travelling drive ....................................................................................................... 3-44
Checking the oil level and filling up oil ............................................................. 3-44
Draining oil ....................................................................................................... 3-44
Tyre maintenance .................................................................................................. 3-45
Tyre check ....................................................................................................... 3-45
Wheel change .................................................................................................. 3-45
Raising and jacking up the machine ................................................................ 3-46
Removing the wheels ...................................................................................... 3-46
Mounting the wheels ........................................................................................ 3-46
Lubrication work ..................................................................................................... 3-47
Loader unit ....................................................................................................... 3-47
Lubrication points on the bucket ...................................................................... 3-47
Maintenance of attachments ............................................................................ 3-47
I-2 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm

Table of contents
Electrical system .................................................................................................... 3-48

Service and maintenance work at regular intervals ......................................... 3-48
Instructions concerning specific components .................................................. 3-49
Alternator ......................................................................................................... 3-49
Battery ............................................................................................................. 3-50
Jump-starting the engine ................................................................................. 3-50
General maintenance work .................................................................................... 3-51
Cleaning .......................................................................................................... 3-51
General instructions for all areas of the machine ............................................ 3-51
Inside the cab .................................................................................................. 3-52
Exterior of the machine .................................................................................... 3-52
Engine compartment ....................................................................................... 3-52
Screw connections and attachments ............................................................... 3-52
Pivots and hinges ............................................................................................ 3-52
Engine ...................................................................................................................... 4-1
Turbocharged engine 4TNV84T-XNSS Power Flow (up to serial no.
DB00708) .......................................................................................................... 4-1
Engine 4TNV88-XNSS (up to serial no. DB00708) ........................................... 4-3
Fuel system ............................................................................................................. 4-5
Checking and adjusting valve clearance ................................................................. 4-6
Valve clearance 4TNV88-XNSS (8 valves) ....................................................... 4-6
Valve clearance 4TNV84T-XNSS (16 valves) ................................................... 4-7
Tightening order for cylinder head bolts .................................................................. 4-8
Checking the injection nozzles ................................................................................ 4-9
Pressure check .................................................................................................. 4-9
Injection nozzle 4TNV88-XNSS (8 valves) ........................................................ 4-9
Injection nozzle 4TNV84T-XNSS (16 valves) .................................................... 4-9
Checking the nozzle jet .......................................................................................... 4-10
Injection time .......................................................................................................... 4-10
Checking injection time .................................................................................... 4-10
Setting injection time ....................................................................................... 4-11
Replacement of fuel injection pump ................................................................ 4-12
......................................................................................................................... 4-12
Manual/pedal throttle ............................................................................................. 4-13
Adjusting engine speed ......................................................................................... 4-13
Compression .......................................................................................................... 4-14
Checking the coolant thermostat ........................................................................... 4-14
Checking the thermal switch .................................................................................. 4-15
Oil pressure switch ................................................................................................ 4-15
Checking the coolant circuit ................................................................................... 4-15
Turbocharger RHB 31 ............................................................................................ 4-16
Tolerance values ............................................................................................. 4-17
Engine (tier 3) ........................................................................................................ 4-18
4TNV88-BKNSS (from serial no. DC00713) .................................................... 4-18
Turbocharged engine 4TNV84T-ZKNSS (from serial no. DC00713) .............. 4-20
Fuel system ........................................................................................................... 4-22
Removing the valve cover ..................................................................................... 4-23
Checking and adjusting valve clearance ............................................................... 4-23
Valve clearance 4TNV88-BKNSS (8 valves) ................................................... 4-23
Valve clearance 4TNV84T-ZKNSS (16 valves) ............................................... 4-24
Tightening order for cylinder head bolts ................................................................ 4-25
Checking the injection nozzles .............................................................................. 4-26
Pressure check ................................................................................................ 4-26
Injection nozzle 4TNV88-BKNSS (8 valves) .................................................... 4-26
Injection nozzle 4TNV84T-ZKNSS (16 valves) ................................................ 4-26

Table of contents
Checking the nozzle jet .......................................................................................... 4-27

Injection time .......................................................................................................... 4-27
Checking injection time .................................................................................... 4-27
Setting injection time ........................................................................................ 4-29
Replacement of fuel injection pump ................................................................. 4-30
Manual/pedal throttle ............................................................................................. 4-31
Adjusting engine speed .......................................................................................... 4-31
Compression .......................................................................................................... 4-32
Checking the coolant thermostat ........................................................................... 4-32
Checking the thermal switch .................................................................................. 4-33
Oil pressure switch ................................................................................................. 4-33
Checking the coolant circuit ................................................................................... 4-33
Turbocharger RHB 31 ............................................................................................ 4-34
Tolerance values ............................................................................................. 4-35
Engine trouble ........................................................................................................ 4-36
Electronic engine control unit (E-ECU) 4TNV84T-ZKNSS ..................................... 4-38
Turbocharged engine 4TNV84T-ZKNSS (from serial no. DC00713) ............... 4-38
Features ........................................................................................................... 4-38
Engine error codes ................................................................................................. 4-39
Error diagnosis ....................................................................................................... 4-43
E-ECU connector assignment ......................................................................... 4-43
Important information on the ECU maintenance wiring harness ..................... 4-44
Flash code 7 proportional injection pump solenoid (control rack) ................. 4-45
Related DTC (Diagnostic Trouble Codes) ....................................................... 4-45
Diagnosis description ....................................................................................... 4-47
Flash code 5 manual throttle ........................................................................ 4-49
Related DTC .................................................................................................... 4-49
Work description .............................................................................................. 4-51
Flash code 4-1 ECU internal ............................................................................ 4-52
Related DTC .................................................................................................... 4-52
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise
alarm ................................................................................................................ 4-54
Related DTC .................................................................................................... 4-54
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise
alarm ................................................................................................................ 4-56
Related DTC .................................................................................................... 4-56
Flash code 2-4 sensor 5 V ............................................................................ 4-60
Related DTC .................................................................................................... 4-60
Flash code 2-3 power supply voltage ........................................................... 4-63
(1) P0562/1: power supply voltage error (voltage too low) .............................. 4-63
DTC detection conditions ................................................................................. 4-63
Troubleshooting ............................................................................................... 4-63
(2) P0563/0: power supply voltage error (voltage too high) ............................. 4-64
DTC detection conditions ................................................................................. 4-64
Flash code 6 engine speed sensor ............................................................... 4-65
Flash code 1-1 backup engine speed sensor ............................................... 4-68
Related DTC .................................................................................................... 4-68
Flash code 9 overspeed error ....................................................................... 4-71

Table of contents
(1) P0219/0: overspeed error .......................................................................... 4-71

DTC detection conditions ................................................................................ 4-71
Diagnosis description ...................................................................................... 4-71
Flash code 1-7 proportional solenoid relay of the injection pump
(control rack) .................................................................................................... 4-72
Related DTC .................................................................................................... 4-72
Flash code 1-5 preheating relay ................................................................... 4-76
Related DTC .................................................................................................... 4-76
Flash code 1-4 CSD (cold start device) solenoid coil ................................... 4-80
Related DTC .................................................................................................... 4-80
Flash code 1-3 EGR (exhaust gas recirculation) valve ................................ 4-83
Related DTC .................................................................................................... 4-83
Flash code 2-1 oil pressure switch and 3-1 oil pressure drop error ........... 4-87
Related DTC .................................................................................................... 4-87
Flash code 8 proportional injection pump solenoid (control rack) ................ 4-91
Related DTC .................................................................................................... 4-91
Flash code 1-6 main relay ............................................................................ 4-95
Related DTC .................................................................................................... 4-95
Flash code 1-2 CAN (Controller Area Network) communication .................. 4-99
Related DTC .................................................................................................... 4-99
Work description ............................................................................................ 4-100
Hydraulic system
Rexroth A20 VG45 hydraulic pump ...................................................................... 5-2
Pump unit: exploded view .................................................................................. 5-4
Pump distribution ............................................................................................... 5-5
Main valve block ...................................................................................................... 5-7
Ports .................................................................................................................. 5-7
Legend ............................................................................................................... 5-7
Main valve block diagram .................................................................................. 5-9
Hydraulic control .................................................................................................... 5-10
Control lever .................................................................................................... 5-10
Joystick (left) .................................................................................................... 5-11
Joystick (right) ................................................................................................. 5-14
Auxiliary hydraulics control .............................................................................. 5-17
Function ........................................................................................................... 5-17
Adjustment ....................................................................................................... 5-17
Travelling drive ...................................................................................................... 5-18
Function ........................................................................................................... 5-18
Drive (exploded view) ...................................................................................... 5-18
Front drive gear ............................................................................................... 5-20
Rear drive gear (braked) ................................................................................. 5-21
Travelling drive layout ...................................................................................... 5-22
Valves .................................................................................................................... 5-23
3/3 directional valve (flush valve) .................................................................... 5-23
Parallel bucket lift ................................................................................................... 5-24
Function ........................................................................................................... 5-24
Layout .............................................................................................................. 5-25

Table of contents
Breather filter ......................................................................................................... 5-26

Troubleshooting in the hydraulic system ................................................................ 5-27
Hydraulics diagram A4 (701s) ................................................................................ 5-28
Hydraulics diagram (legend) (701s) ....................................................................... 5-29
Hydraulics diagram A4 (701sp) .............................................................................. 5-30
Hydraulics diagram (legend) (701sp) ..................................................................... 5-31
Hydraulics diagram H-controls A4 (701sp) ............................................................ 5-33
Hydraulics diagram H controls (701sp) (legend) .................................................... 5-34
Hydraulics diagram H-controls with lock A4 (701sp) ............................................. 5-35
Hydraulics diagram H controls with lock (701sp) (legend) ..................................... 5-35
Hydraulics diagram 701s A3 up to serial no. DB00708 ......................................... 5-37
Hydraulics diagram 701sp A3 up to serial no. DB00708 ....................................... 5-38
Hydraulics diagram 701s A3 from serial no. DC00713 .......................................... 5-39
Hydraulics diagram 701sp A3 from serial no. DC00713 ........................................ 5-40
Hydraulics diagram H-controls 701 sp A3 .............................................................. 5-41
Hydraulics diagram H-controls with lock 701 sp A3 ............................................... 5-42
Electrical system
Ohm's Law (current, voltage, resistance); power ..................................................... 6-1
Measuring equipment, measuring methods ............................................................. 6-1
Cable colour coding ................................................................................................. 6-3
Relays ...................................................................................................................... 6-3
Use, mode of function ........................................................................................ 6-3
Electric units ............................................................................................................. 6-4
Fuse box in instrument panel ............................................................................. 6-4
Main fuse box with relays .................................................................................. 6-4
Relays ................................................................................................................ 6-4
Socket ...................................................................................................................... 6-5
Turn indicators (option) ............................................................................................ 6-5
Round indicating instrument overview ..................................................................... 6-6
Switches: overview .................................................................................................. 6-7
Alternator ................................................................................................................. 6-7
Starter ...................................................................................................................... 6-8
Wiring diagram up to serial no. DB00708 (legend) ................................................ 6-10
Wiring diagram up to serial no. DB00708 .............................................................. 6-11
Wiring diagram from serial no. DC00713 (legend) ................................................. 6-12
Wiring diagram from serial no. DC00713 ............................................................... 6-13
701s engine chassis wiring harness 1000147293 up to serial no. DB00708
(legend) .................................................................................................................. 6-15
701s engine chassis wiring harness 1000147293 up to serial no. DB00708 ...... 6-16
701s engine chassis wiring harness 1000183063 from serial no. DC00713
(legend) .................................................................................................................. 6-17
701s engine chassis wiring harness 1000183063 from serial no. DC00713 ...... 6-18
701sp engine chassis wiring harness 1000185442 from serial no. DC00713
(legend) .................................................................................................................. 6-19

Table of contents
701sp engine chassis wiring harness 1000185442 from serial no. DC00713 .... 6-20
Switches wiring harness 1000139289 up to serial no. DB00708 (legend) ............ 6-21
Switches wiring harness 1000139289 up to serial no. DB00708 ........................... 6-22
701s switches wiring harness 1000183064 from serial no. DC00713 (legend) ..... 6-23
701s switches wiring harness 1000183064 from serial no. DC00713 ................... 6-25
701sp switches wiring harness 1000185268 from serial no. DC00713 (legend) ... 6-26
701sp switches wiring harness 1000185268 from serial no. DC00713 ................. 6-28
Wiring harness 1000147262: rear lights (option) ................................................... 6-29
Wiring diagram up to serial no. DB00708 (legend) ................................................ 6-31
Wiring diagram up to serial no. DB00708 .............................................................. 6-32
Wiring diagram from serial no. DC00713 (legend) ................................................ 6-33
Wiring diagram from serial no. DC00713 ............................................................... 6-34
701s engine chassis wiring harness 1000147293 up to serial no. DB00708
(legend) .................................................................................................................. 6-36
701s engine chassis wiring harness 1000147293 up to serial no. DB00708 ..... 6-37
701s engine chassis wiring harness 1000183063 from serial no. DC00713
(legend) .................................................................................................................. 6-38
701s engine chassis wiring harness 1000183063 from serial no. DC00713 ...... 6-39
701sp engine chassis wiring harness 1000185442 from serial no. DC00713
(legend) .................................................................................................................. 6-40
701sp engine chassis wiring harness 1000185442 from serial no. DC00713 .... 6-41
Switches wiring harness 1000139289 up to serial no. DB00708 (legend) ............ 6-42
Switches wiring harness 1000139289 up to serial no. DB00708 ........................... 6-43
701s switches wiring harness 1000183064 from serial no. DC00713 (legend) ..... 6-44
701s switches wiring harness 1000183064 from serial no. DC00713 ................... 6-45
701sp switches wiring harness 1000185268 from serial no. DC00713 (legend) ... 6-46
701sp switches wiring harness 1000185268 from serial no. DC00713 ................. 6-47
Wiring harness 1000147262: rear lights (option) A3 ............................................. 6-48
Options
Rear working light .................................................................................................... 7-1
Wiring harness ................................................................................................... 7-1
Connections ....................................................................................................... 7-1
BP Biohyd SE 46 .................................................................................................. 7-2
Properties .......................................................................................................... 7-2
Biodegradable oil Panolin ........................................................................................ 7-2
Properties .......................................................................................................... 7-2
Rearview mirror package ......................................................................................... 7-2
Drive interlock (antitheft protection) ......................................................................... 7-3
Machine ............................................................................................................. 7-3
Disabling the drive interlock ............................................................................... 7-3
Enabling the drive interlock ............................................................................... 7-3
Programming ..................................................................................................... 7-3
Rotating beacon ....................................................................................................... 7-4
Wiring harness ................................................................................................... 7-5
Connections ....................................................................................................... 7-5
Crane-handling bracket ........................................................................................... 7-6
FOPS roof level 2 .................................................................................................... 7-7
Backup warning system ........................................................................................... 7-8
Function ............................................................................................................. 7-8
Position .............................................................................................................. 7-8
Side window ............................................................................................................. 7-9
Attachment ........................................................................................................ 7-9

Table of contents
Full cab glazing (option) ......................................................................................... 7-10

Stabilisers .............................................................................................................. 7-11
Road travel certification ......................................................................................... 7-12
Airboss tyres .......................................................................................................... 7-13
Attachment ....................................................................................................... 7-13
Power Flow ports ................................................................................................... 7-13
Couplings ......................................................................................................... 7-14

Index
I
Index
A
Abbreviations .........................................................................................1-1
Air filter .................................................................................................3-20
F
Fluids and lubricants ..............................................................................3-1
Functional check
Dust valve .....................................................................................3-22
I
Important information
On this service manual ...................................................................1-1
M
Machine
Overview .........................................................................................1-6
Maintenance
Bleeding the fuel system ...............................................................3-10
Changing engine oil ......................................................................3-14
Checking the engine oil level ........................................................3-13
Checking the hydraulic oil level .....................................................3-39
Cleaning ........................................................................................3-51
Electrical system ...........................................................................3-48
Engine and hydraulics cooling system ..........................................3-17
Engine lubrication system .............................................................3-13
Filling in engine oil ........................................................................3-14
Filling up coolant ...........................................................................3-18
Fluids and lubricants .......................................................................3-1
Fuel system .....................................................................................3-9
General maintenance work ...........................................................3-51
Hydraulic pressure lines ................................................................3-43
Hydraulic system ...........................................................................3-38
Instructions concerning specific components ...............................3-49
Pivots and hinges ..........................................................................3-52
Replacing the engine oil filter cartridge .........................................3-16
Replacing the fuel filter .................................................................3-12
Screw connections ........................................................................3-52
Service and maintenance work at regular intervals ......................3-48
V-belt .............................................................................................3-23
O
Operation
Cab overview ..................................................................................1-7
Round indicating instrument overview ............................................1-8
R
Refuelling ...............................................................................................3-9
Round indicating instrument overview ...................................................1-8
S
Safety instructions
Identification ....................................................................................1-2
Specifications .......................................................................... 2-1, 4-1, 6-1
Additional control circuit ..................................................................2-5
Brakes .............................................................................................2-4
Chassis ...........................................................................................2-1
Coolant compound table .................................................................2-8
Dimensions .....................................................................................2-8
Engine ..................................................................................... 2-1, 2-4
Noise levels .....................................................................................2-7
Pilot control .....................................................................................2-1
Travelling drive ................................................................................2-4
Work hydraulics ..............................................................................2-4
SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0SIX.fm S-1

Index
S-2 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0SIX.fm

Operation
Operation
Operation
1 Operation
1.1 Important information on this service manual
This service manual contains important information on how to service your machine safely,
correctly and economically. Therefore, it aims not only at new operators, but it also serves
as a reference for experienced ones. Your knowledge and skills will help to avoid
dangerous situations and reduce repair costs and downtimes, Furthermore, the reliability
and the service life of the machine will be increased by following the instructions in the
service manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine.
Insist on using original spare parts when carrying out maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
Your Wacker Neuson After-Sales Service will be pleased to answer any further questions
regarding the machine or the service manual.
Abbreviations/symbols
This symbol stands for a list
Subdivision within lists or an activity. Follow the steps in the recommended sequence
This symbol requires you to carry out the activity described
Description of the effects or results of an activity
n. s. = not shown
Option = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A used for
identifying the control elements, means:
Figure no. 40/control element no. 18 or position A in figure no. 40
Figures carry no numbers if they are placed to the left of the text.
1-1 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

Operation
1.2 Identification of warnings and dangers

Important indications regarding the safety of the staff and the machine are identified in this
service manual with the following terms and symbols:
Danger!
Failure to observe the instructions identified by this symbol can result in
personal injury or death for the operator or other persons.
Measures for avoiding danger
Caution!
Failure to observe the instructions identified by this symbol can result in
damage to the machine.
Measures for avoiding danger for the machine
Notice!
This symbol identifies instructions for a more efficient and economical use of the
machine.
Environment!
Failure to observe the instructions identified by this symbol can result in damage to the
environment. The environment is in danger if environmentally hazardous material (e.g.
waste oil) is not subject to proper use or disposal.
SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-2

Operation
1.3 Designated use and exemption from liability

The machine is intended for:
moving earth, gravel, coarse gravel or ballast and rubble as well as for
working with the attachments mentioned in chapter Fields of application
Every other application is regarded as not designated for the use of the machine.
Wacker Neuson will not be liable for damage resulting from use other than mentioned
above. The user alone will bear the risk. Designated use also includes observing the
instructions set forth in the Operator's Manual and observing the maintenance and
service conditions.
The safety of the machine can be negatively affected by carrying out machine
modifications without proper authority and by using spare parts, equipment,
attachments and optional equipment which have not been checked and released by
Wacker Neuson Linz GmbH. Wacker Neuson Linz GmbH will not be liable for damage
resulting from this.
Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to
property caused by failure to observe the safety instructions and the Operator's
Manual, and by the negligence of the duty to exercise due care when:
handling
operating
servicing and carrying out maintenance work and
repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care, in the safety
instructions, the Operator's Manuals and maintenance manuals (machine/engine).
Read and understand the Operator's Manual before starting up, servicing or repairing
the machine. Observe the safety instructions!
The machine may not be used for transport jobs on public roads

Operation
1.4 Type labels and component numbers

Serial number
The serial number is stamped on the machine chassis under the hydraulic pump. It is also
located on the type label.
The type label is located on the left on the chassis in the leg room area.
Fig. 1: Type label: location

Type label information
Model: 701sp
Year: 2005
PIN: DA 00000
Power: 38.6 kW (51.8 hp)
Mass: 2300 kg
Load: 680 kg
Max. gross load: ---------------
Max. front axle load: ---------------
Fig. 2: Type label
Max. rear axle load: ---------------
Other information see Specifications on page 2-1
Cab number
The cab number is stamped on the side in the sheet metal.
Fig. 3: Cab number
Engine number
The type label (arrow) is located on the valve cover (engine).
Example: Yanmar 46557
Fig. 4: Diesel engine number

Operation
Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing.
Fig. 5: Hydraulic pump type label
Hydraulic motor numbers

The type label (arrow) is located on the hydraulic motor.
Fig. 6: Travelling drive type label

Operation
1.5 Machine overview
3
1
2
Rotating beacon (option)
1
Rear working light (option)
Left and right outside rearview mirrors
2
(option)
3 Front working lights 4
4 Handles 5
5 Standard bucket
6 Loader unit
7 Engine cover
8 Standard tyres
9 Exhaust pipe 7
Fig. 7: Machine outside views

Operation
1.6 Cab overview

10
1
1
11
11
2
8
4 7
12 12
1.7 Cab (legend)

Pos. Description For more information see page
1 Auxiliary hydraulics pedal
2 Control lever (left) 5-10
3 Safety bar
4 Throttle (below left-hand side armrest)
5 Document storage bin
6 Seat 5-10
7 Parking brake (up to serial no. DB00518); from serial no. DB00519: electric with switch
8 Control lever (right) 5-10
9 Accelerator pedal 4-13
10 Auxiliary hydraulics lock lever
11 Dirt opening
12 Armrest

Operation
1.8 Round indicating instrument overview

17 18 19
16 20
15 21
34
14
22
23
13
33
24
32
31
35 36 25 26 27 28 29 30
1.9 Round indicating instrument (legend)
13 Air filter telltale (red)
14 Telltale (yellow) fuel
15 Cold starter telltale (yellow)
16 Telltale (red) low hydraulic pump pressure (boost pressure) 3-29
17 Telltale (red) fouled hydraulic oil filter
18 Telltale (red) alternator charge function
19 Parking brake telltale (red)
20 Engine oil pressure telltale (red)
21 Coolant temperature telltale (red)
22 Turn indicator telltale (green)
23 Safety electrics telltale
24 Hour meter
25 Front working lights
26 Hazard warning system (option)
27 Rear working light (option) 7-1
28 Rotating beacon (option) 7-4
29 Parallel bucket lift (option)
30 3rd control circuit (Power Flow option) 7-4
31 Engine error LED (Power Flow option tier 3) 4-39
32 Turn indicator switch (option) 6-5
33 Wiper switch (option)
34 Fan switch (option)
35 Parking brake
36 Locking the work hydraulics

Operation
1.10 Engine compartment overview

701s
37 38 39 41 40

37 Dipstick 4-1
38 Air filter
39 Engine 4-1
40 Alternator 6-7
41 Silencer 4-2

Operation
701sp
31 32 33 34 35

31 Dipstick 4-1
32 Air filter
33 Engine 4-1
34 Turbocharger 4-16
35 Silencer 4-2

Operation
1.11 Engine cover (open): overview

701s
36 37 38 39

36 Water separator
37 Fuel pump
38 Combined radiator 3-17
39 Engine cover

Operation
701sp
38 36 37 39 40 41 42

36 Expansion tank
37 Water separator
38 Fuel pump
39 Silencer 4-2
40 Combined radiator 3-17
41 Reflux filter 3-41
42 Engine cover

Operation
1.12 Chassis overview
44
48
49
45
46
50
47

44 Silencer 4-2
45 Control lever (right) 5-10
46 Diesel engine
47 Main valve block
48 Air filter
49 Control lever (left) 5-10
50 Hydraulic pump 5-2

Operation
1.13 Tilting the cab
Danger!
Careful when tilting the cab
Danger of accidents!
Always tighten screws A when driving and working with the machine.
Place the machine on level ground.
Lower the loader unit and the attachments.
Stay clear from underneath the cab as you tilt it.
Stop the engine.
Remove the ignition key.
Fold up the safety bars.
Close the door (option).
Slackening the screws

Unscrew the screws as follows:
Stop the engine.
Remove the ignition key.
Remove screws A on either side with a suitable tool.
Screws A are located at the front left and right of the cab.
A
Fig. 8: Cab screw

Operation
Tilting the cab:
Danger!
Tilting the cab and incorrect locking of the gas strut
Always make sure gas strut C is safely locked when the cab is tilted.
When tilting the cab make sure no-one is underneath the cab.
Carefully tilt the cab back fully with handles B.

Make sure safety tube C is locked (visual check).
The safety tube must engage underneath the cylinder (see Fig. 9).
Lowering and locking the cab:
Danger!
Incorrect lowering of the cab
Danger of accidents and of crushing!
B
If the end E of the cylinder can no longer be seen, all persons must stay
clear of the danger area underneath the cab.
Lower the cab with both hands on the handles.
Make sure no-one is underneath the cab.
Before lowering the cab all the way down, make sure no equipment or
persons are squeezed.
Firmly retighten screws A once the cab is fully lowered.
Push the cab upwards with handles B.

Press safety tube C in the direction of D and at the same time:
Carefully lower the cab as soon as the end E of the cylinder can no longer be seen.
Carefully lower the cab all the way down with the handles.
Screw in and firmly tighten screws A with a suitable tool.
D Tightening torque: 110 Nm (81 ft. lbs.)
E Caution!
Check safety tube C, the cylinder and the tilt lock at regular intervals for
C cracks, cuts and other defects.
Replace defective parts immediately.
Fig. 9: Tilting the cab

Specifications
Technische Daten
Specifications
2 Specifications
2.1 Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2 Engine
Model 701s Model 701sp Model 701s Model 701sp
Engine
American Tier 2 (up to DB00708) Tier 3 (from DC00738)
Product Yanmar diesel engine
4TNV84T-XNSS 4TNV84T-ZKNSS
Type 4TNV88-XNSS 4TNV88-BKNSS
(turbocharged engine) (turbocharged engine)
Engine management Mechanical Electronic
Design Water-cooled 4 stroke diesel engine
No. of cylinders 4
Fuel injection system Direct injection
Aspiration Natural aspiration Turbocharger Natural aspiration Turbocharger
Cooling system Water-cooled/aspirating fan
Lubrication system Force-feed lubrication with trochoidal pump
Displacement 2190 cm (133.6 cu. in.) 1995 cm (121.7 cu. in.) 2190 cm (133.6 cu. in.) 1995 cm (121.7 cu. in.)
88 x 90 mm 84 x 90 mm 88 x 90 mm 84 x 90 mm
Nominal bore and stroke (3.46 x 3.54) (3.31 x 3.54) (3.46 x 3.54) (3.31 x 3.54)
32.6 kW (43.7 hp) 38.5 kW (51.6 hp) 34.4 kW (46.1 hp) 38.5 kW (51.6 hp)
Output at 2800 rpm at 2800 rpm at 2800 rpm at 2800 rpm
131.8 143.7 Nm 154.1 167.7 Nm 133.4 146.1 Nm 149.1 162.8 Nm
Max. torque (97.2 106 ft. lbs.) (113.7 123.7 ft. lbs.) (98.4 107.8 ft. lbs.) (110 120.1 ft. lbs.)
at 1680 rpm at 1680 rpm at 1680 rpm at 1680 rpm
Max. engine speed without 3000 25 rpm 2800 25 rpm
3000 25 rpm 2800 25 rpm
load
Idling speed 1200 25 rpm 1200 25 rpm 1200 25 rpm 1200 25 rpm
Valve clearance (intake = 0.15 0.25 mm/(0.007 0.01) cold
outlet)
1st cylinder Flywheel side
Compression 19.1 : 1 18.9:1 19.1 : 1 18.9:1
33 bar (479 psi) 30 bar (435 psi) 33 bar (479 psi) 30 bar (435 psi)
Compression: specified value at 250 rpm at 250 rpm at 250 rpm at 250 rpm
26 bar (377 psi) 25 bar (363 psi) 26 bar (377 psi) 25 bar (363 psi)
Compression: threshold value at 250 rpm at 250 rpm at 250 rpm at 250 rpm
Charge-air pressure - 0.9 bar (13 psi) 10 % - 0.9 bar (13 psi) 10 %
Engine oil pressure 4.4 bar 0.5 bar (64 psi 7 psi)

Technische Daten
Pressure switch for engine oil 0.5 0.1 bar

pump
Thermostat opening 69.5 72.5 C (157.1 162.5 F)
temperature
Thermal switch 107 113 C (224.6 235.4 F)
Firing order 1342
Counterclockwise
Direction of rotation (as seen from the flywheel)
Starting aid Glow plug (preheating time 10 15 s) Preheater (preheating time 10 15 s)
Max. inclined position (engine 30 in all directions
no longer supplied with oil): Observe the machine's tilting limit (20 laterally)!
Max. engine droop 1920 50 rpm 2000 50 rpm 1920 50 rpm 2000 50 rpm
260 g/kWh 249 g/kWh 260 g/kWh 249 g/kWh
Specific fuel consumption (0.427 lbs./hph) (0.409 lbs./hph) (0.427 lbs./hph) (0.409 lbs./hph)
97/68/EC Tier II 97/68/EC Tier 3A
Exhaust values according to EPA Tier II EPA Tier 4 interim

Technische Daten
Fuel injection pump

YPD-4MP2
Pump type
Model 701s Model 701sp
Design Single piston distributor injection pump
Up to DB00708 216 226 bar (3133 3278 psi)
Injection pressure
From DC00713 196 206 bar (2843 2988 psi)
Engine speed Up to DB00708 Mechanical
control From DC00713 Electronic
Lubrication
Engine oil lubrication
system
Capacity
Capacities Model 701s Model 701sp
Fuel tank 52 l (13.70 gal)
Engine oil (total/min max) 7.4 l/3.4 l (2 gal/0.9 gal)
Coolant (without radiator) 2.7 l (0.70 gal)
Radiator 3.0 l (0.80 gal)
Expansion tank 0.3 l (0.08 gal)
Tightening torque
Tightening torques Model 701s/sp (Nm/ft. lbs.)
Cylinder-head bolt 1st pass 41.1 46.9 (lubricated)/30.3 34.6
2nd pass 85.3 91.1 (lubricated)/62.9 67.2
Connecting rod bearing screw 44.1 49.0 (lubricated)/32.5 36.1
Main bearing screw 93.2 98.1 (lubricated)/68.7 72.4
Flywheel screw 83.3 88.2 (lubricated)/61.4 65.1

Technische Daten
2.3 Travelling drive
Variable Model 701s Model 701sp Model 701s Model 701sp

displacement pump American Tier 2 (up to DB00708) Tier 3 (from DC00738)
Design Infinitely variable axial-piston variable displacement pump
Displacement 2 x 38.5 cm/rev = 2 x 107.8 l/min at 2800 rpm 0 45 cm/rev
Max. system operating 300 bar 350 bar
pressure
Starting RPMs 1200 rpm
Boost pump Model 701s Model 701sp Model 701s Model 701sp
Design Gear (external)
Displacement 19.0 cm/rev
Charging/boost 25 bar
pressure
Driving direction Hydraulic
Hydraulic motor Model 701s Model 701sp Model 701s Model 701sp
Design Gerotor
Max. capacity 201.4 cm/rev
Drive speed 12 kph
Traction force 24 kN
2.4 Brakes
Service brake Model 701s Model 701sp

Design Hydrostatic
Location Travelling drive
Service brake via hydrostatic closed circuit by means of
Effect
neutral position of pump
Parking brake Model 701s Model 701sp
Up to Manual, negative-action mechanical disc brake
DB00708
Design
From Manual, negative-action electrohydraulic disc brake
DC00713
Location Rear gearbox (left and right)
Effect Hydraulic release; braked if no pressure
2.5 Work hydraulics

Hydraulic pump Model 701s Model 701sp
22.5 cm/rev = 63 l/min at
Displacement
2800 rpm
Control valve 3 sections
Max. operating pressure 210 bar
Secondary protection for loader unit ram Base side 300 bar
Filter Reflux filter
Hydraulic oil tank 55 l

Technische Daten
2.6 Pilot control
Pilot control Model 701s Model 701sp

Displacement 19 cm/rev
Charging/boost pressure 25 bar
Pilot control unit Model 701s Model 701sp
Hydraulic pressure sensor for driving and working
Control levers (loader unit, bucket)
Electric
Safety bar
Lock for unintentional operation
2.7 Additional control circuit + 3rd control circuit
Additional control circuit Model 701s Model 701sp

Hydraulic pump displacement 22.5 cm/rev = 63 l/min at 2800 rpm
Operation Mechanical pedal
3rd control circuit Model 701s Model 701sp
19 cm/rev = 53.2 l/min
at 2800 rpm
Hydraulic pump displacement
22.5 cm/rev = 63 l/min
at 2800 rpm
Operation Electric

Technische Daten
2.8 Electric units
Units
Alternator 12 V 55 Ah
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 88 Ah
Socket E.g. for cigarette lighter; 15 A max.
Fuse box in instrument panel
Rated current
Fuse Protected circuit
(A)
Tank sensor, starting relay, alternator, gauge
F2 10 A
element
F3 10 A Cutoff solenoid, fuel feed pump
F4 15A Valves
F5 10 A Rear working light, interior light
F6 10 A Front lights
F3 F5 F7 F9
F7 15A Turn indicators, horn
F8 10 A Hazard warning system, drive interlock (option)
F2 F4 F6 F8 F9 15A Socket, rotating beacon
Main fuse box with relays

The main fuse box is located under the cab.
K7
Fuse no. Rated current (A) Protected circuit
F1 50A Main fuse
Relay no.
K7 Starting relay
F1
Relays
The relays are located underneath the fuse box in the cab.
Switching relay
K8 Protected circuit
K6 no.
K6 10 s preheating timer
K9 K10 K8 Cutoff timer
K9 Cutoff solenoid timer, pick-up contact
K 10 Turn indicator relay

Technische Daten
2.9 Tyres
Tightening moments:
Wheel nuts: 175 Nm
Nuts for Airboss tyre segments: 13 Nm
Tyre pressure bar (psi)

Tyre size
Remarks Front Rear
10-16.5 Standard tyres 4.5 (65.3) 4.5 (65.3)
7.0-15 Option 4.1 (59.5) 4.1 (59.5)
Notice!
Same tyre sizes apply to Airboss tyres (option) as to standard tyres.
2.10 Noise levels

Sound power level Model 701s Model 701sp
Sound power level (LWA) 101.2 dB (A) 99.6 dB (A)
Sound pressure level (LPA) 86 dB (A) 88 dB (A)
Notice!
Measurement of sound power level according to EC Directive 2000/14 EC. Noise
level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/
EEC and 95/27/EEC. Measurements carried out on asphalted surface.
2.11 Vibration
Vibration
Effective acceleration value for the < 2.5 m
------ (<8.2 ft/s2)
upper extremities of the body * s2
Effective acceleration value for the < 0.5 m

------ (<1.6 ft/s2)
body * s2
* Measured according to 2002/44/EC. Machine and attachment operation and maintenance as per Operator's Manual.
2.12 Coolant compound table

Coolant: Halvoline XLC (based on ethylene glycol)
Outside Eurolub SF D12 coolant (based on ethylene glycol) from
temperature DC01045
Water Anticorrosion agent Antifreeze agent
% by cm/l
Up to C (F) % by volume % by volume
volume (in3/gal)
37 (34.6) 50 10 (2.6) 1 50
Use the 1:1 concentration for warm outside temperatures, too:
Protection against corrosion, cavitation and deposits
Do not mix the coolant with other coolants.
Coolant with specified features is filled in the machine at the factory.

Technische Daten
2.13 Dimensions
Fig. 1: Machine dimensions
Model 701s/sp
Main data (ft/in)
a Maximum height 3620 (11'11)
b Height below bucket joint 2860 (9'5)
c Cab height 1947 (6'5)
d Ground clearance 252 (0'10)
e Rear projection (rear axle onwards) 1056 (3'6)
f Wheelbase 890 (2'11)
g Overall length without attachment 2440 (8)
H Overall length with standard bucket 3060 (10)
I Maximum length of machine 3517 (11'6)
K Topmost bucket position 2660 (8'9)
L Maximum dump height 2325 (7'8)
m Reach 516 (1'8)
n Maximum reach (horizontal loader unit position) 1173 (3'10)
o Dump-in angle 29
P Dump-out angle 35
q Dump-in angle 105
R Departure angle 27
s Machine width (with standard tyres) 1475 (4'10)
t Bucket width 1520 (5')
u Rear turning radius 1520 (5')
v Front turning radius 1771 (5'10)

Technische Daten
2.14 Model-specific tightening torques
701s/sp
Component Thread Tightening torque
Travelling drive M14 12.9 180
Angled engine bracket M10 8.8 50
Engine bearing M12 8.8 85
Pump base M10 8.8 50
Pump M12 10.9 150
*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.
2.15 General tightening torques

Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)

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

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

Technische Daten
Screw connections with various seals for hydraulic applications (light execution)
Straight pipe fitting with thread and Non-return
screwed plug valve with Identification aid
Thread Sealing Elastic elastic outside
O-ring
washer seal seal
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) mm ()
M10X1.0 9 (7) 18 (13) 15 (11) 18 (13) 10 (0.4)
M12X1.5 20 (15) 25 (18) 25 (18) 25 (18) 12 (0.5)
M14X1.5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.55)
M16X1.5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6)
M18X1.5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7)
M22X1.5 65 (48) 125 (92) 60 (44) 125 (92) 22 (0.9)
M27X2.0 90 (66) 180 (133) 100 (74) 145 (107) 27 (1.0)
M33X2.0 150 (111) 310 (229) 160 (118) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7)
M48X2.0 290 (214) 540 (398) 260 (192) 540 (398) 48 (1.9)
G1/8A 9 (7) 18 (13) 15 (11) 18 (13) 9.73 (0.38)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 (0.52)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 (0.66)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 (0.83)
G3/4A 90 (66) 180 (133) 100 (74) 140 (103) 26.44 (1.04)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 (1.31)
G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41.91 (1.65)
G1 1/2A 290 (214) 540 (398) 260 (192) 540 (398) 47.80 (1.88)
Torque tolerance: 10 %; countermaterial: steel/aluminium
Screw connections with various seals for hydraulic applications (heavy execution)
Straight pipe fitting with thread and Non-return
screwed plug valve with Identification aid
Thread Sealing Elastic elastic outside
O-ring
washer seal seal
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) mm ()
M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5)
M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.55)
M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6)
M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7)
M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.9)
M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0)
M27X2.0 90 (66) 180 (133) 170 (126) 135 (100) 12 (0.5)
M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7)
M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9)
G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 (0.52)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.66)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.83)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.04)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.31)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.65)
G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 (1.88)
Torque tolerance: 10 %; countermaterial: steel/aluminium

Technische Daten
Tightening torques for high-resistance screw connections
With coarse-pitch thread

Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)
M5 5.5 (4) 8 (6) 10 (7) 5 (4) 7 (5)
M6 10 (7) 14 (10) 17 (13) 8.5 (6) 12 (9)
M8 25 (18) 35 (26) 42 (31) 20 (15) 30 (22)
M10 45 (33) 65 (48) 80 (59) 40 (30) 59 (44)
M12 87 (64) 110 (81) 147 (108) 69 (51) 100 (74)
M14 135 (100) 180 (133) 230 (170) 110 (81) 160 (118)
M16 210 (155) 275 (203) 350 (258) 170 (125) 250 (184)
M18 280 (207) 410 (302) 480 (354) 245 (181) 345 (254)
M20 410 (302) 570 (420) 690 (509) 340 (251) 490 (361)
M22 550 (406) 780 (575) 930 (686) 460 (339) 660 (487)
M24 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620)
M27 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922)
M30 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254)
DIN 912 hexagon socket head cap screw; DIN 931/DIN 933 hexagon head screw with/without shaft;
DIN 7984 hexagon socket head cap screw with short head
All values subject to a friction coefficient of = 0.12 and are to be used as approximate figures.
With fine-pitch thread

Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)
M8X1.0 25 (18) 37 (28) 43 (32) 22 (16) 32 (24)
M10X1.0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48)
M10X1.25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46)
M12X1.25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81)
M12X1.5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77)
M14X1.5 135 (100) 200 (148) 235 (173) 120 (89) 175 (129)
M16X1.5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195)
M18X1.5 315 (232) 450 (332) 530 (391) 270 (199) 385 (284)
M20X1.5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391)
M22X1.5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524)
M24X2.0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664)
M27X2.0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959)
M30X2.0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364)
DIN 912 hexagon socket head cap screw; DIN 931/DIN 933 hexagon head screw with/without shaft;
DIN 7984 hexagon socket head cap screw with short head
All values subject to a friction coefficient of = 0.12 and are to be used as approximate figures.

Maintenance
Maintenance
Maintenance
3.1 Fluids and lubricants

Maintenance
Component/ Engine/machine Season/

Specification Capacities1
application fluid temperature
-20 C (-4 F)
Diesel engine Engine oil Q8 T 660, SAE10W-402 7.8 l (2.1 gal)
+40 C (104 F)
Q8 T 55, SAE85W-90
About 1.3 l
Travelling drive Gearbox oil 3
FINA PONTONIC GLS, Year-round
(0.34 gal) each
SAE85W-90
Hydraulic oil HVLP464
PANOLIN HLP Synth 46
Hydraulic oil tank Year-round 55 l (14.5 gal)
Biodegradable oil5 BP BIOHYDRAN SE 46
BP BIOHYD SE-46
Grease nipples Multipurpose grease6 BP Energrease L21 M Year-round As required
Battery terminals Acid-proof grease7 FINA Marson L2 Year-round As required
No. 2-D, DIN 51601 grade Over 4 C
Fuel tank Diesel fuel 52 l (13.7 gal)
No. 1-D, DIN 51601 grade Below 4 C
Water + antifreeze; ASTM 4985,
Diesel engine radiator Coolant based on ethylene glycol, Year-round 6.0 l (1.6 gal)
silicone-free
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
Capacities indicated are no system fills
2. As per DIN 51502; API CH4, CE/SJ; ACEA A3, B3, E3
3. Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)
4. According to DIN 51524 section 3
5. Hydraulic ester oils (HEES)
6. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
7. Standard acid-proof grease

Oil grades for the diesel engine, depending on temperature
Engine oil grade Ambient temperature (C)
C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40
SAE 10W
SAE 20W
SAE 10W-30
SAE 10W-40
API CH4, CE/SJ SAE 15W-40

ACEA A3,B3,E3
SAE 20
SAE 30
SAE 40
F -4 5 14 23 32 41 50 59 68 77 86 95 104
Additional oil change and filter replacement (hydraulics)
Caution!
An additional oil change and filter replacement can be required depending on
how the machine is used. Failure to observe these replacement intervals can
cause damage to hydraulic components.
Observe the following intervals.
Application Hydraulic oil Hydraulic oil filter insert

Normal work (loading work) Every 1000 s/h Replace the first time after 50 s/h, then every 500 s/h
20 % Every 800 s/h
300 s/h
40 % Every 400 s/h
Percentage of hammer work
60 % Every 300 s/h
100 s/h
Over 80 % Every 200 s/h
Notice!
See Chapter 3.3 Maintenance plan (overview) for other maintenance work.

3.2 Maintenance label
Explanation of symbols on the maintenance label
Symbol Assembly Explanation
General Visual check
General Grease instructions
Fuel system Drain condensation water
Fuel system Replace the fuel filter, clean the fuel prefilter
Radiator Check the coolant level
Radiator Drain and fill in new coolant
Engine Check valve clearance. Adjust if necessary
Engine Check the engine oil level
Engine Change engine oil
Engine Replace the oil filter
Engine Check V-belt tension
Travelling drive Change oil
Travelling drive Check oil
Hydraulic system Check oil level
Hydraulic system Change hydraulic oil
Hydraulic system Replace the hydraulic oil filter, replace the breather filter

Symbol Assembly Explanation
Radiator fins Clean
Battery Check battery fluid and fill up if necessary
1000h
500h
250h
50h
10h
1
DIN 51 502
6 DIN 51 502
4
API GL5
API GL5 SAE 80W90
SAE 80W90
2x 2x 2x 2x
ASTM D4985
-34C / -29F
ASTM D6210
10h
50h
250h
1 1 1
500h
1000h
API CF
SAE 10W-40
1000149170-B

Maintenance
3-5
Maintenance
Maintenance plan/service hours (s/h)
3.3 Maintenance plan (overview)
Maintenance work
Every 1000 s/h
Every 1500 s/h

Every 250 s/h
Every 500 s/h

(once a day)
Every 50 s/h
Work description
once a year
Authorised
workshop
Customer
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
of the attachment manufacturer as well.
Fluid and filter changes ( ):

Carry out the following oil and filter changes (check oil levels after test run):
Engine oil1
Engine oil filter2
3
Fuel filter
Air filter element as indicated by telltale
Coolant
Hydraulic oil filter insert 4
Hydraulic oil
Hydraulic oil tank breather
Gearbox oil5
Hydraulic oil reflux filter (model 701)
Inspection work ( ):
Check the following material. Refill if necessary:
Engine oil
Engine coolant
Hydraulic oil
SERV-HB 701s sp EN Edition 2.0 *701s311.fm
Gearbox oil6
Clean water ducts 7
Check engine/hydraulic oil radiator and air conditioning for dirt. Clean if necessary
Check cooling systems, heating and hoses for leaks and damage (visual check)
Air filter (damage)
Prefilter with water separator: drain water
Clean

Maintenance work
Every 1000 s/h
Every 1500 s/h

Every 250 s/h
Every 500 s/h

Every 50 s/h
(once a day)
Work description
once a year
Authorised
workshop
Customer
Check V-belt condition and tension

Check exhaust system for damage and condition
Check valve clearance, adjust if necessary
Check the fuel injection pump
Check the injection pressure
Check the injection nozzles 8
Empty the diesel fuel tank (to avoid condensation water)

Check battery fluid, fill up with distilled water if necessary, check for leaks, visual check
Check alternator, starter and electric connections, bearing play and function9
Preheating system, electric connections10
Check wheels for cracks, cuts, check profile and air pressure
Check wheel nuts
Check piston rods for damage
Check screws for tightness
Pin lock
Line fixtures
Check telltales for correct function
Tilt lock and gas strut of cab
Couplings, dirt pile-up on hydraulic system dust caps
Maintenance
Check insulating mats in the engine compartment for damage/attachment
Adhesive labels and Operator's Manual
Pressure check of work and drive hydraulics
3-6
3-7
Maintenance
Maintenance work
Every 1000 s/h
Every 1500 s/h

Every 250 s/h
Every 500 s/h

(once a day)
Every 50 s/h
Work description
once a year
Authorised
workshop
Customer
Lubrication service ( ):
Lubricate the following assemblies/components:
Quickhitch
Mobile parts of lock mechanism
Attachments
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
Lights, signalling system, acoustic warning system
Check function of safety bar, check for damage
Check emergency lowering
Safety device: maintenance strut of loader unit
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
Visual check
Engine and hydraulic system
Cooling and heating circuit
Travelling drive
1. Drain engine oil the first time after 50 s/h, then every 250 s/h
2. Replace the engine oil filter the first time after 50 s/h, then every 250 s/h
3. Replace the fuel filter the first time after 50 s/h, then every 500 s/h
4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h
5. Drain the gearbox oil the first time after 250 s/h, then every 1000 s/h
6. Check the gearbox oil every other 50 s/h servicing
7. Clean the water ducts every other 1000 s/h servicing
8. Check the injection nozzles and the valves every other 1500 s/h servicing
9. First check of alternator and starter at 50 s/h, then every 500 s/h
10. First check of preheating system at 50 s/h, then every 500 s/h
Maintenance
Maintenance
3.4 Introduction
Operational readiness and the service life of machines are heavily dependent on
maintenance.
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in
Chapter 2 SAFETY INSTRUCTIONS in the Operator's Manual
The Operator's Manuals of the attachments.
Secure open (engine) covers appropriately.
Do not open (engine) covers on slopes or in strong wind.
Dirt can be blown away and cause severe injuries when using compressed air. Always
wear protective goggles, masks and clothing.
Daily service and maintenance work, and maintenance according to maintenance plan
A must be carried out by a specifically trained driver. All other maintenance work must
be carried out by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be
carried out ( see Maintenance plan (overview) on page 3-5).

Maintenance
3.5 Fuel system

Specific safety instructions Extreme caution is essential when handling fuel high risk of fire.
Never carry out work on the fuel system in the vicinity of naked flames or sparks.
Do not smoke when working on the fuel system or when refuelling.
Before refuelling, stop the engine and remove the ignition key.
Do not refuel in closed rooms.
Wipe away fuel spills immediately.
Keep the machine clean to reduce the risk of fire.
Refuelling
Filler inlet A for the fuel tank is located behind the cab, on the right in driving direction.
Lock B on the filler inlet can be opened with the key of the machine.
B
Danger!
All work involving fuel carries an increased
A
Danger of fire and poisoning!
Do not refuel in closed rooms.
Never carry out work on the fuel system in the vicinity of naked flames or
sparks.
No smoking, no fire.
Fig. 1: Fuel filler inlet

Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner.
Notice!
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel
system. This requires bleeding the fuel system see Bleeding the fuel system on
page 3-10.
A
Notice!
Fill up the tank with the correct fuel type at the end of each working day to prevent
the formation of condensation water in the fuel tank (condensation water damages
the injection pump). Do not fill the tank completely but leave some space for the
fuel to expand.
3-9 SERV-HB 701s sp EN Edition 2.0 *701s312.fm

Maintenance
Stationary fuel pumps General

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty.
Even the smallest particles of dirt can cause
Increased engine wear
Malfunctions in the fuel system and
Reduced effectiveness of the fuel filters
Refuelling from barrels
wrong If refuelling from barrels cannot be avoided, note the following points (see fig. 2):
Barrels must neither be rolled nor tilted before refuelling.
Protect the suction pipe opening of the barrel pump with a fine-mesh screen.
Immerse it down to a max. 15 cm (6) above the floor of the barrel.
right Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter.
Keep all refuelling containers clean at all times.
Fig. 2: Refuelling from a barrel
Diesel fuel specification Use only high-grade fuels.
Grade Use
2-D ASTM D975 94
USA
1-D ASTM D975 94
EN 590: 96 EU
ISO 8217 DMX International
BS 2869 A1
England
BS 2869 A2
Bleeding the fuel system
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
Never bleed the fuel system if the engine is hot.
Bleed the fuel system in the following cases:

After removing and fitting the fuel filter, prefilter or the fuel lines back on again
After running the fuel tank empty
After running the engine again, after it has been out of service for a longer period of
time.
Bleed the fuel system as follows:
Fill up the fuel tank.
Turn the ignition key to the first position.
Wait about 5 minutes while the fuel system bleeds itself automatically.
Start the engine.
If the engine runs smoothly for a while and then stops, or if it does not run smoothly:
Stop the engine.
Bleed the fuel system again as described above.
Have this checked by authorised staff if necessary.

Maintenance
Emptying the fuel tank
A Danger!
Danger of burns!
Never bleed the fuel system if the engine is hot.
Fig. 3: Fuel drain plug Due to the formation of condensation water in the fuel tank, empty the fuel tank every 500
service hours as follows:
Place a container with sufficient capacity under the fuel tank to collect the fuel as
it drains.
Open the drain plug to drain the fuel A.
Check the fuel tank for contamination and clean if necessary.
Replace the filter according to the maintenance specifications.
Screw the drain plug back in correctly.
Fill up the fuel tank.
Bleed the fuel system see chapter Bleeding the fuel system on page 3-10.
Fuel prefilter with water separator

On Check the fuel prefilter as follows:
If the red indicator ring rises to position C,
Off unscrew thread A.
The water drains.
Wait until the indicator ring returns to the bottom of the water separator.
Screw thread A back on again.
B Interrupt fuel supply as follows:

Turn ball-type cock B to the OFF mark.
Fuel supply is interrupted.
Turn ball-type cock B to the ON mark.
C Fuel supply is open again.
Environment!
A
Thread A is fitted with a hose. Collect the water as it drains with a suitable container and
Fig. 4: Fuel prefilter
dispose of it in an environmentally friendly manner.

Maintenance
Replacing the fuel filter

Up to serial no. DB00708, fuel filter A is mounted direct on the engine.
Danger!
Danger of burns!
A Never change the fuel filter if the engine is hot.
Environment!
Fig. 5: Fuel filter position Use a suitable container to collect the fuel as it drains and dispose of it in an
From serial no. DC00713, fuel filter A is fastened separately on the chassis (see fig. 5).
Change fuel filter 5/A as follows:

Close the fuel feed line with the stop cock on the fuel prefilter.
Thoroughly clean the outside surfaces of fuel filter 5/A.
A
Place a suitable container under the filter.
Slacken and unscrew fuel filter cartridge using a commercially available tool.
Collect the fuel as it drains.
Fig. 6: Unscrewing the fuel filter
Clean the sealing surface of the filter carrier if it is dirty.

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

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

A Open the stop cock on the water separator again.
Bleed the fuel system see Bleeding the fuel system on page 3-10.
Make a test run and check for tightness.
Dispose of the old fuel filter cartridge by an ecologically safe method.
Fig. 8: Tightening the fuel filter
3.6 Engine lubrication system
Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
Engine damage or loss of output!
Have the oil changed by an authorised workshop see Maintenance plan
(overview) on page 3-5.
Checking the oil level

Notice!
Check the oil level once a day. We recommend checking it before starting the
engine. After stopping a warm engine, wait at least 5 minutes before checking.
Checking the oil level

Proceed as follows:
Park the machine on level ground.
A Stop the engine.
max

min
Let the engine cool down.

Open the engine cover.
Clean the area around the oil dipstick with a lint-free cloth.
Oil dipstick A:
Pull it out,
Fig. 9: Checking the oil level Wipe it with a lint-free cloth.
Push it back in as far as possible.
Withdraw it and read off the oil level.
However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A.

Maintenance
Filling up engine oil

Caution!
Too much or incorrect engine oil can result in engine damage! For this reason:
Do not add engine oil above the MAX mark of oil dipstick 10/A.
Use only the specified engine oil.
Use engine oils of the same brand and grade => never mix different oils.
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
Proceed as follows:
Clean the area around oil filler cap B with a lint-free cloth.
B Open filler cap B.
OIL Raise oil dipstick A slightly to allow any trapped air to escape.
A Fill in engine oil.
Wait about 3 minutes until all the oil has run into the oil sump.
Check the oil level see Checking the oil level on page 3-13.
Fill up if necessary and check the oil level again.
Close filler cap B.
Push oil dipstick A back in as far as possible.
Completely remove all oil spills from the engine.
Fig. 10: Oil dipstick and oil filler cap
Changing engine oil
Danger!
Caution when draining hot engine oil
Danger of burns!
+ 80 C
+176 F Wear protective gloves.
Use suitable tools.
OIL
Fig. 11: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an

Maintenance
Change the engine oil as follows:

Let the engine run until it reaches its operating temperature (oil temperature about 80
C/176 F).
Stop the engine.
Remove the chassis cover (fig.12):
A Slacken the 4 fastening screws A.
Remove the plate.
Fig. 12: Chassis cover
Caution!
Danger of injuries due to the weight of the chassis cover. Secure the plate to
prevent it from falling down.
Place a container under the opening to collect the oil as it drains.

Unscrew oil drain plug B.
Completely drain the oil.
Screw the oil drain plug back on again.
Fill in engine oil see chapter Filling up engine oil on page 3-14.
Start the engine and let it run briefly at low engine speed.
Stop the engine.
B Wait a moment until all the oil has run into the oil sump.
Check the oil level again.
Fill up if necessary and check again.
Fig. 13: Oil drain plug
Mount the chassis cover.

Maintenance
Replacing the engine oil filter

cartridge
Danger!
Caution when draining hot engine oil
A
Danger of burns!
Wear protective gloves.
Fig. 14: Engine oil filter position
Environment!
Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an
Change the filter as follows:

Stop the engine.
Place a suitable container underneath the oil filter to collect the oil as it drains.
A
Slowly slacken oil filter cartridge A using a commercially available tool.
Let the oil drain into the container.
Remove the filter cartridge once the oil is completely drained.
Make sure the thread adapter is correctly placed in the filter head.
Fig. 15: Unscrewing the fuel filter
Clean the inside of the filter head.

Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge.
Tighten the new filter cartridge by hand until the gasket makes contact.
B
Fig. 16: Cleaning the sealing surface and oiling the gasket
Tighten oil filter cartridge A by hand by about a further half revolution.

A Make sure the oil level is correct.
Let the engine run briefly.
Stop the engine.
Check the seal of oil filter cartridge A and retighten by hand.
Check the oil level and fill in engine oil if necessary.
Fig. 17: Tightening the fuel filter
Dispose of the used oil filter in an environmentally friendly manner.

Maintenance
3.7 Cooling system

The water radiator is located in the engine compartment, behind the engine.
The hydraulic oil cooler is located on the radiator.
The expansion tank for the coolant is also located in the engine compartment, to the left of
the combined radiator.
Specific safety instructions Dirt on the radiator fins reduces the cooler's heat dissipation capacity! To avoid this:
Clean the outside of the radiator at regular intervals. Use oil-free compressed air (2
bar/29 psi max.) to clean. Maintain a certain distance from the radiator to avoid
damage to the radiator fins. Refer to the maintenance plans in the appendix for the
cleaning intervals.
In dusty or dirty work conditions, clean more frequently than indicated in the
maintenance plans.
An insufficient coolant level reduces the heat dissipation capacity as well and can lead
to engine damage. Therefore:
Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals.
If coolant must be added frequently, check the cooling system for leaks and/or
contact your dealer.
Never fill in cold water/coolant if the engine is warm.
After filling the expansion tank, make a test run with the engine and check the coolant
level again after stopping the engine.
The use of the wrong coolant can destroy the engine and the cooler. Therefore:
Add enough antifreeze compound to the coolant but never more than 50 %. If
possible use brand-name antifreeze compounds with anticorrosion additives.
Observe the coolant compound table see Dimensions on page 2-8.
Do not use cooler cleaning compounds if an antifreeze compound has been added to
the coolant otherwise this causes sludge to form, which can damage the engine.
Once you have filled the expansion tank:
Test run the engine.
Stop the engine.
Check the coolant level again.
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in an

Maintenance
Checking/filling up coolant
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
Wait at least 15 minutes after stopping the engine.
Wear protective gloves and clothing.
Open filler cap 19/B to the first notch and release the pressure.
Make sure the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands.
Danger!
Antifreeze is flammable and poisonous
Keep away from flames.
Avoid eye contact with antifreeze.
If antifreeze comes into contact with the eyes:
immediately rinse with clean water and seek medical assistance.
Checking the coolant level
Proceed as follows:
FULL Park the machine on level ground.
Stop the engine.
LOW
Remove the key and carry it with you.
A Let the engine and the coolant cool down.
Check the coolant level on the transparent coolant tank 18/A and on radiator 19/B.
Fig. 18: Expansion tank for coolant
If the coolant level is below the LOW seam or if there is no coolant at the radiator's
filler inlet:
Fill up coolant.
Notice!
Check the coolant level once a day. We recommend checking it before starting the
engine.

Maintenance
Filling up coolant
After the engine has cooled down:
Release overpressure in the radiator.
B Carefully open filler cap 19/B to the first notch and allow the pressure to fully escape.
Open filler cap 19/B.
Fill in coolant up to the lower edge of the filler inlet (radiator).
Close filler cap 19/B.
Start the engine and let it warm up for about 5 10 minutes
Stop the engine.
Fig. 19: Radiator filler cap Let the engine cool down.
Check the coolant level again.
The coolant level must be between the LOW and FULL tank seams.
If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant.
Notice!
Check the antifreeze every year before the cold season sets in.
Draining coolant
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
Wait at least 10 minutes after stopping the engine.
Wear protective gloves and clothing.
Open filler cap 19/B to the first notch and release the pressure.
After the engine has cooled down:

Release overpressure in the radiator.
Open filler cap 19/B to the first notch.
Allow the pressure to fully escape.
Open filler cap 19/B.
Open the drain plug of the radiator and drain the coolant.
Close the drain plug again.
Fill up the radiator with suitable coolant see Fluids and lubricants on page 3-1.
Fig. 20: Radiator drain plug
Check the coolant level see chapter Checking the coolant level on page 3-18.

Maintenance
3.8 Air filter
Caution!
The filter cartridge is damaged if it is washed or brushed out.
Bear in mind the following to avoid premature engine wear:
Do not clean the filter cartridge.
Replace the filter cartridge when the telltale comes on.
Never reuse a damaged filter cartridge.
Ensure cleanliness when replacing the filter cartridge.
Maintenance switch A on the air filter activates telltale 13 in the round indicating
instrument which monitors the filter cartridge.
Replace outside filter B and inside filter C:
If telltale 13 in the round indicating instrument comes on.
13
According to the maintenance plan.
Notice!
For applications in especially dusty environment, the air filter is fitted with an
extra inside filter C. Do not clean inside filter C.
A
Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
Replace outside filter B and inside filter C at the latest after 50 service
hours.
General instructions for air filter maintenance:

Store filters in their original packaging and in a dry place.
Do not knock the filter against other objects as you install it.
Check air filter attachments, air intake hoses and air filters for damage, and
immediately repair or replace if necessary.
B Check the screws at the induction manifold and the clamps for tightness.
Check the function of the dust valve, replace if necessary.
Fig. 21: Air filter

Maintenance
Replacing the filter

Replace outside filter A as follows:
D Stop the engine.
E Open the engine cover.
Remove dirt and dust from the air filter and the area around the air filter.
Fold both bow clips D on lower housing section E to the outside.
Remove lower housing section E.
Fig. 22: Removing the lower housing section Carefully remove outside filter B with slightly turning movements.
Make sure all dirt (dust) inside the upper and lower housing sections, including the dust
valve, has been removed.
B Clean the parts with a clean lint-free cloth, do not use compressed air.
Check the air filter cartridges for damage, only install intact filters.
Carefully insert new outside filter B in the upper housing section.
Position lower housing section E (make sure it is properly seated).
Close both bow clips D.
Fig. 23: Removing the filter element
Replace inside filter C as follows:

Stop the engine.
Remove dirt and dust from the air filter and the area around the air filter.
C Fold both bow clips D on lower housing section E to the outside.
Remove lower housing section E.
Carefully remove outside filter B with slightly turning movements.
Fig. 22: Replacing the inside filter Carefully remove inside filter C.
Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
from entering the engine.
Clean the parts with a clean lint-free cloth, do not use compressed air.
Remove the cloth from the air supply.
Check the air filter cartridges for damage, only install intact filters.
Carefully insert the new inside filter C.
Carefully insert outside filter B.
Position lower housing section E (make sure it is properly seated).
Close both bow clips D.
Notice!
Make sure dust valve 23/F shows downwards once it is installed!

Maintenance
Functional check once a week of the dust valve

The air filter is located in the engine compartment, on the left side of the machine.
Proceed as follows:
Stop the engine.
Apply the parking brake.
Squeeze the discharge slot of dust valve F.
Remove hardened dust by squeezing the upper area of the valve.
Clean the discharge slot if necessary.
F
Fig. 23: Replacing the inside filter

Maintenance
3.9 V-belt
Danger!
Only check or retighten/replace the V-belt when the engine is stopped
Danger of personal injury!
Stop the engine before carrying out inspection work in the engine
compartment.
Disconnect the battery.
Caution!
Cracked and stretched V-belts cause engine damage.
Have the V-belt replaced by an authorised workshop.
Check the V-belt once a day or every 10 service hours, and retighten if necessary!
Retighten new V-belts after about 15 minutes of running time.
Checking V-belt tension

Check as follows:
1 Stop the engine.
Carefully check V-belt 24/1 for damage, cracks or cuts.
Replace the V-belt if it touches the base of the V-belt groove or the discs of the
pulley.
Fig. 24: Checking V-belt tension
If the V-belt is damaged:
Have the V-belt replaced by authorised staff.
Press with your thumb to check the deflection of the V-belt between the crankshaft
disc and the fan wheel position C. A new V-belt should have a deflection of 6 to
8 mm (0.2 0.3), a used V-belt (after about 5 minutes running time) should have a
deflection of 7 to 9 mm (0.3 0.35).
Retighten the V-belt if necessary.

Maintenance
Retightening V-belt
Caution!
Overtightening the V-belt can damage the V-belt, the V-belt guide and the
water pump bearing. Avoid contact of oil, grease or similar substances with the
V-belt.
Check V-belt tension see Checking V-belt tension on page 3-23.
Retighten as follows:
Stop the engine.
2 Fold up the safety bars.
A Open the engine cover.
Slacken fastening screws 25/2 of alternator 25/3.
Use a suitable tool to push the alternator in the direction of arrow 25/A until reaching
the correct V-belt tension.
3
Keep the alternator in this position, and at the same time retighten fastening
Fig. 25: Retightening the V-belt
screws 25/2.
Check V-belt tension again and adjust it if necessary.
Connect the battery.
Close the engine cover.

Maintenance
3.10 Pressure check

General Run the machine warm before checking the pressure. Hydraulic oil temperature: 50 C/
122 F min. (operating temperature).
Set the primary pressure limiting valves (PPLV) at maximum engine speed.
Bleed the hydraulic pump whenever you reconnect or reroute hydraulic hoses see
chapter Bleeding the hydraulic pump on page 3-39.
Pressure measurements may be carried out by trained staff only.
Ensure utmost cleanliness of all measuring points and ports, micro measuring
lines and pressure gauges that are connected for checking pressure => even the
slightest traces of dirt, e.g. a grain of sand, can impair tightness and cause leaks!
Pressure settings:
see Work hydraulics on page 2-4 and
see Test report 701sp on page 3-35
see Test report 701s on page 3-33
Standard micro ports
3
3
Pos. Description
2 Measuring port MP 2 Work hydraulics
pressure 2
3 Measuring port MP 3 Brake release pressure

Maintenance
Variable displacement pump

measuring points
Pos. Description
4 Measuring port Y Speed-sensitive pilot control pressure for
driving
5 Measuring port G1 Boost pressure/work hydraulics pilot control
pressure

Maintenance
8 9
Pos. Description
6 Measuring port Mb2 To front right hydraulic motor
7 Measuring port Mb1 To front left hydraulic motor
8 Measuring port Ma2 (on lower side of pump) To rear right hydraulic motor
9 Measuring port Ma1 (on lower side of pump) To rear left hydraulic motor

Maintenance
Preparatory work
Carefully open the cap of the hydraulic tank to the first notch and fully release the
pressure
Open the cap of the hydraulic tank.
Install the micro ports at the specific test points.
Connect the measuring instrument.
Bleed the hydraulic pump see chapter Bleeding the hydraulic pump on page 3-39.
Close the cap of the hydraulic tank.
Run the machine warm.
Hydraulic oil temperature: 50 C/122 F min. (operating temperature).
You can then carry out the measurements.
Main pressure check (P1 & P2)

Checking main pressure
7 Tilt the cab see Tilting the cab on page 1-14.
Unscrew the plugs of the variable displacement pump.
Screw in the micro measuring device (1000015578) with screw connection
(1000085130) into measuring ports Ma1 27/9, Ma2 27/8, Mb1 27/7 and Mb2 27/6 and
6 connect it with the measuring instrument.
The inside threads of the pump micro ports are 9/16 UNF threads.
Make sure no wires or cables can be damaged.
Lower the cab.
Start the engine.
Check and make a note of the pressure value.
Rated pressure:
Measure the pressure at maximum engine speed.
Measurements
Keep the machine in a firm position so that the wheels cannot turn with the joystick in
8 final position (e.g. drive against an earth mound).
Drive forwards
9 final position (e.g. drive against an earth mound).
Drive backwards
Fig. 26: Measuring ports Ma1, Ma2, Mb1, Mb2

Maintenance
Boost pressure check of pump and pilot control pressure check of work hydraulics
Checking boost pressure (up to DB00518)
Tilt the cab upwards see Tilting the cab on page 1-14
Remove the hoses on port G1 (fig. 27/5), of the variable displacement pump.
5 Install a T-fitting with a micro measuring device and connect it with the measuring
instrument.
Install the hoses again.
Start the engine leave the cab in the tilted position.
Fig. 27: Measuring port G1
Measure the pressure at idling speed.
Measurement
Machine at a standstill (joystick not actuated).
Up to DB00518
The boost pressure is monitored by pressure switch A on the distributing block.
If the boost pressure drops below 8.0 bar (116 psi), the pump can be damaged by
A cavitation.
The pressure switch activates telltale 28/16 pump pressure.
16
From DB00519
Remove the hoses on port G1 (fig. 27/5), of the variable displacement pump.
Fig. 28: Boost pressure switch Install a T-fitting with a micro measuring device and connect it with the measuring
instrument.
1 Make sure no wires or cables can be damaged.
PS1
Measurement
PS2
The boost pressure is monitored by pressure switch PS1 on the distributing block.
If the boost pressure drops below 8.0 bar (116 psi), the pump can be damaged by
cavitation.
The pressure switch activates telltale 28/16 pump pressure.

Maintenance
Work hydraulics pressure check

Checking the work hydraulics pressure
2
Tilt the cab see Tilting the cab on page 1-14.
Connect the measuring instrument with micro measuring device MA 2 29/2.
Lower the cab.
Start the engine.
Rated pressure:
Fig. 29: Measuring port M2
Measurements
Extend/retract (base/rode side) the bucket ram as far as it will go.
Extend/retract (base/rode side) the loader unit ram as far as it will go.
Actuate the auxiliary hydraulics fully in both directions.
When checking by extending/retracting (base/rode side) the loader unit ram:
Danger!
Checking the pressure or adjusting with the loader unit function
Adjusting the work hydraulics pressure

Adjust the pressure at the pressure limiting valve (PLV 1) 30/B on the control valve.
Slacken the locknut of the pressure limiting valve.
Unscrew the pressure limiting valve until you can read off a pressure drop on the
measuring instrument.
B The valve seat may be stuck and must be slackened first.
Adjust the pressure limiting valve and tighten the locknut.
Adjustment value see
see Work hydraulics on page 2-4
see Test report 701s on page 3-33
see Test report 701sp on page 3-35
Check the pressure limiting valve PLV1 and the pressure drop again once adjustment
Fig. 30: Work hydraulics pressure limiting valve
is over.

Maintenance
Checking the pilot control pressure of the drive hydraulics

Checking the drive hydraulics pressure (left-hand side joystick)
Remove the hoses on port Y (fig. 31/4), of the variable displacement pump.
Install a T-fitting with a micro measuring device and connect it with the measuring
instrument.
Fig. 31: Measuring port Y Lower the cab.
Start the engine.
Measurement
Checking the parking brake release pressure

Checking the brake release pressure (up to DB00518)
Measurement
Checking the brake release pressure (from DB00519)

Connect the measuring instrument with micro measuring device MA 3 32/3 (screw in
the measuring port if necessary).
3 Measurement

Maintenance
Checking the speed-sensitive control pressure

Checking the speed-sensitive control pressure
Remove the hoses on port Y (fig. 33/4), of the variable displacement pump.
Install a T-fitting with a micro measuring device and connect it with the measuring
instrument.
Fig. 33: Measuring port Y Lower the cab.
Start the engine.
Measurement
Straight-ahead driving with the joystick fully actuated.
Engine droop
Install a tachometer in addition.
Check and make a note of the pressure value and of the engine speed.
Measure the pressure and the engine speed at maximum engine speed.
Measurement
final position (e.g. drive against an earth mound).
Checking the pressure of the 3rd control circuit (Power Flow option 701sp)
Checking the Power Flow pressure
3 Tilt the cab see Tilting the cab on page 1-14.
Lower the cab.
Start the engine.
30 Enable Power Flow 34/30.
Measurement
Enable the 3rd control circuit (Power Flow) with switch 34/30.

Maintenance
3-33
Maintenance
3.11 Test report 701s
Boost pressure
Specified values Measured Measured
Supplied by P4 (19 cm/1.16 cu. in.)
Engine speed Pressure in bar (psi) value 1 value 2
Min. engine speed Rated value 25 1 (363 14.5)
G1 measuring port
Max. engine speed Rated value 25 1 (363 14.5)
Work hydraulics
Measured Measured
Function Movement Pressure limiting valve Measuring port Specified values
value 1 value 2
max. 215 3 (3118 43.5)
DUMP OUT
Min. 202 1 (2930 14.5)
Bucket
max. 215 3 (3118 43.5)
DUMP IN
Min. 202 1 (2930 14.5)
max. 215 3 (3118 43.5)
UP
Pressure limiting valve Min. 202 1 (2930 14.5)
Loader unit Measuring port MP 2
(control valve) max. 215 3 (3118 43.5)
DOWN
Min. 202 1 (2930 14.5)
max. 215 3 (3118 43.5)
A
Auxiliary Min. 202 1 (2930 14.5)
hydraulics max. 215 3 (3118 43.5)
B
Min. 202 1 (2930 14.5)
Brake release pressure

Measured Measured
Supplied by P4 (19 cm/1.16 cu. in.) Specified values
value 1 value 2
Measuring port MP 3
3.11 Test report 701s
Pilot control pressure, drive (on the spot)
Y measuring port
DA control + drive pilot control pressure (driving forwards without load)
Measured Measured
Supplied by P4 (19 cm/1.16 cu. in.) Specified values
value 1 value 2
Min. engine speed Rated value 91(13114.5) at 120050 rpm
Y measuring port Max. engine speed Rated value 271(39114.5) at 299550 rpm
Max. engine droop Rated value 161(23214.5) at 192050 rpm
Main pressure (P1 and P2)
Supplied by variable displacement pumps P1 and P2 (38.5 cm/2.35 cu. in.)
Measured Measured
Function Engine speed Measuring port Specified values
value 1 value 2
Ma1 Rated value 23 2 (334 29)
Forwards Max. engine speed
Mb1 Rated value 300 10 (4351 145)
Mb2 Rated value 300 10 (4351 145)
Ma1 Rated value 300 10 (4351 145)
Ma2 Rated value 300 10 (4351 145)
Reverse Max. engine speed
Mb1 Rated value 23 2 (334 29)
Maintenance
3-34
3-35
Maintenance
3.12 Test report 701sp
Boost pressure
Supplied by P5 (19 cm)
G1 measuring port
Work hydraulics
Pressure limiting Measured Measured
Function Movement Measuring port Specified values
valve value 1 value 2
max. 212 3 (3075 43.5)
DUMP OUT
Min. 196 1 (2843 43.5)
Bucket
max. 212 3 (3075 43.5)
DUMP IN
Min. 196 1 (2843 43.5)
max. 212 3 (3075 43.5)
UP
Pressure limiting Min. 196 1 (2843 43.5)
Loader unit Measuring port MP 2
valve (control valve) max. 212 3 (3075 43.5)
DOWN
Min. 196 1 (2843 43.5)
max. 212 3 (3075 43.5)
A
Min. 196 1 (2843 43.5)
Auxiliary hydraulics
max. 212 3 (3075 43.5)
B
Min. 196 1 (2843 43.5)
Brake release pressure

Measured Measured
Supplied by P5 (19 cm) Specified values
value 1 value 2
Measuring port MP 3
3.12 Test report 701sp
Drive pilot control pressure
Y measuring port
DA control
Measured Measured
value 1 value 2
Min. engine speed Rated value 9 1 bar at 1200 50 rpm
Y measuring port Max. engine speed Rated value 24 1 bar at 2800 50 rpm
Max. engine droop Rated value 15 1 bar at 2000 50 rpm
Power Flow (3rd control circuit)
Measured Measured
value 1 value 2
Measuring port MA2 Max. engine speed Rated value 200 3 (2901 43.5)
Main pressure (P1 and P2)
Supplied by variable displacement pumps P1 and P2 (38.5 cm)
Measured Measured
Function Engine speed Measuring port Specified values
value 1 value 2
Forwards Max. engine speed
Mb1 Rated value 300 10 (4351 145)
Mb2 Rated value 300 10 (4351 145)
Ma1 Rated value 300 10 (4351 145)
Ma2 Rated value 300 10 (4351 145)
Maintenance
Reverse Max. engine speed
3-36
Maintenance
Maintenance
3.13 Hydraulic system

Specific safety instructions
Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
Lower all hydraulically controlled attachments to the ground
Move all control levers of the hydraulic control valves several times with the safety
bar closed and ignition switched on.
Fold the control lever base up.
Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Therefore always consult a doctor immediately, even in the case of minor
wounds otherwise serious infections could set in.
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This can cause damage to the hydraulic pump.
Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slackened nuts and
damaged hoses and lines are detected.
Contact your Wacker Neuson dealer immediately.
Caution!
Dirty hydraulic oil, lack of oil or wrong hydraulic oil
Danger of severe damage to the hydraulic system!
Take care to avoid dirt when working.
Always use the filling screen when refilling hydraulic oil.
Only use authorised oils of the same type see Fluids and lubricants on
page 3-1.
Always fill up hydraulic oil before the level gets too low see Filling up
hydraulic oil on page 3-40.
If the hydraulic system is filled with biodegradable oil, then only use
biodegradable oil of the same type observe the sticker on the hydraulic oil
tank.
Contact customer service if the hydraulic system filter is dirty and contains
metal chippings. Otherwise, follow-on damage can result.
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of
drained oil and used filters by an ecologically safe method. Always contact the relevant
authorities or commercial establishments in charge of oil disposal before disposing of
biodegradable oil.

Maintenance
Checking the hydraulic oil level

Caution!
Do not fill up oil if the oil level is above the FULL mark, otherwise the hydraulic
system can be damaged and escaping oil can cause serious injuries.
Check the hydraulic oil level each time the machine is put into operation or
once a day.
If the attachment is not positioned as shown:

Start the engine and let it run at idling speed
Retract the loader unit ram, lower the bucket to the ground.
Stop the engine again.
Fig. 35: Parking the loader
B Proceed as follows:
FULL
B Stop the engine.
LOW
Sight glass 36/B is located on hydraulic oil tank 36/A.
Check the oil level on sight glass B.
The oil level must be at the FULL level.
A
A gauge element in sight glass B indicates the oil level.
If the oil level is lower,
FULL
Fill up hydraulic oil.
The oil level varies according to the machine's operating temperature:
Machine condition Hydraulic oil temperature Oil level

LOW Before putting into Between 10 and 30 C LOW mark
operation (50 and 86 F)
Normal operation Between 50 and 90 C FULL mark
Fig. 36: Oil level indicator on the hydraulic oil tank
(122 and 194 F)
Notice!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.
1

Maintenance
Bleeding the hydraulic pump
Caution!
Bleed the hydraulic pump whenever you reconnect or reroute hydraulic hoses,
otherwise the pump can be damaged.
S Proceed as follows:
Retract the rams of the loader unit, lower the bucket to the ground.
Fig. 37: Bleeding the hydraulic pump Stop the engine.
Unscrew both plugs 37/S on the upper side of the variable displacement pump until a
little oil escapes.
Screw plug 37/S back on again.
Lower the cab and secure it with the screws.
Filling up hydraulic oil
Danger!
Removing the filler plug can cause oil to escape
Carefully unscrew the plug to slowly reduce the pressure inside the tank.
C
Do not fill up the hydraulic oil unless the engine is stopped. Otherwise, hydraulic oil will
overflow at the filler opening on the hydraulic tank.
Fill up as follows:
Fig. 38: Hydraulic oil filler inlet Retract the rams of the loader unit, lower the bucket to the ground.
Stop the engine.
Slowly open plug C.
With the filter insert in place:
Fill up hydraulic oil.
C
Check the hydraulic oil level on sight glass B.
Fill up if necessary and check again.
Firmly retighten plug C.

Maintenance
After changing the hydraulic oil

Caution!
Never start the engine if the oil tank is empty otherwise the pump is damaged.
Make sure all control levers are in neutral position
Let the engine run at idling speed for 2 to 3 minutes.
Actuate the attachment.
Move all pistons several times to remove air in the system.
Check the oil level and fill up oil if necessary.
Changing hydraulic oil

Notice!
Only change the hydraulic oil if it is warm (about 50 C/122 F). Retract all
hydraulic rams before changing the oil.
Open the breather filter to release pressure.

B Open drain plug 39/B and let the oil drain into a container.
Check the hydraulic oil tank for dirt and clean if necessary.
Replace the filter according to the maintenance specifications.
Screw the drain plug back in correctly.
Fill in clean hydraulic oil through the screen see Filling up hydraulic oil on page 3-40.
Close the hydraulic oil tank correctly.
Let the machine run at idling speed without load for some minutes.
Fig. 39: Hydraulic oil drain plug

Maintenance
Monitoring the hydraulic oil reflux filter

Pressure switch 41/A activates the red telltale 40/14 in the instrument panel which
14
monitors the reflux filter.
The control pressure is set at 5 bar (72.5 psi).
Replace the filter element:
If telltale 14 comes on when the hydraulic oil is at operating temperature.
at the latest after 1000 service hours (once every year).
In cold weather telltale 14 can come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
Set engine speed so that telltale 14 goes out.
Fig. 40: Telltale for reflux filter
Fig. 41: Reflux filter pressure switch
Replacing the reflux filter
B
R Environment!
Use a suitable container to collect the hydraulic oil as it drains and dispose of it in an
A Replace the reflux filter as follows:

Remove sheet metal A by means of screw and locknut B.
Thoroughly clean the outside of reflux filter 42/R.
C Place a suitable container under the filter.
Slacken and unscrew screws C.
Remove cover D.
Collect the hydraulic oil as it drains.
Remove the old reflux filter E and replace it by a new one.
E Clean the sealing surface of cover D if it is dirty.
Put cover D in place.
Screw in screws C by hand until cover D is seated correctly.
D
Tighten screws C.
Install sheet metal A by means of screw and locknut B.
Make a test run and check for tightness.
Dispose of the replaced reflux filter in an environmentally friendly manner.
Fig. 42: Replacing the reflux filter

Maintenance
Checking hydraulic pressure lines

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

authorised workshop or after-sales staff. This not only increases the operating safety of
your machine but also helps to protect the environment.
Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged.
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and
occupational health and safety in your country. Also observe DIN 20 066.
1 Q/05 The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication 1 Q/05 means manufactured in the 1st quarter of 2005.

Maintenance
Danger!
Immediately after stopping the engine, the engine's components and the oil
are very hot. This can cause burns. If the inside of the drive gear is under
pressure, the oil or the plug can be squeezed out.
Danger of injury and scalding!
Wait until the engine has cooled down before taking up work.
Slowly open the plug to reduce the pressure inside.
Checking the oil level and filling up oil

Park the machine on firm and horizontal ground.
Place the machine so that filler plug A is in the topmost position and screw B is at an
angle of 90 with respect to the filler plug
Stop the engine.
Unscrew screws A and B with a suitable tool.
A small quantity of oil must flow out of opening B.
If the oil does not flow out of opening B, fill up oil:
A
Fill in oil through opening A,
until a small quantity of oil flows out of opening B.
Screw screws A and B back in again.
B
Move the machine a few metres.
Check the oil level again.
If the oil level is not correct:
Fig. 43: Checking the oil level
Repeat the procedure.
Draining oil
A Park the machine on firm and horizontal ground.

Place the machine so that filler plug B is at the bottom.
Stop the engine.
B Let the engine cool down.
Unscrew screws A and B with a suitable tool.
Fig. 44: Draining oil The oil now flows out of opening B.
Use a suitable container to collect the oil as it drains.
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly
manner.

Maintenance
3.15 Tyre maintenance
Danger!
Improper tyre repairs
All repair work on tyres and rims may only be carried out by authorised
workshops.
Notice!
Regular inspections of the tyres
Improve operating safety
Increase the service life of the tyres
Reduce machine downtimes. Please refer to Chapter 2.9 Tyres for the
authorised tyre types and the correct tyre pressures.
Tyre check Carry out the following maintenance work once a day:
Check tyre pressure.
Check tyres and rims for damage (cracks, ageing etc.) also on the inside.
Remove foreign bodies from the tyre tread.
Remove traces of oil and grease from the tyres.
Check tyres for wear and measure tread depth.
Wheel change
Danger!
Use of wrong tyres or wheels
Use only wheels and tyres authorised for your machine.
Check the wheel nuts for tightness after every wheel or tyre change.
Caution!
The wheels are heavy and can damage the threads on the wheel studs if they
are handled incorrectly.
Use suitable assembly tools, such as covering sleeves for the studs, a jack
etc.

Maintenance
Raising and jacking up the machine

Danger!
Jacking up the machine incorrectly or insufficiently
Jack up the machine with adequately sized jacks.
Jack up the machine as follows:

Raise the machine at the points provided for to this effect.
Place jacks underneath the machine's main chassis. Make sure the jacks can support
the machine's gross weight rating.
Carefully lower the machine onto the jacks.
A The front edge of the bucket must be lowered to the ground.
Fig. 45: Jacking up the machine
Removing the wheels Proceed as follows:

Park the machine on level and firm ground and prevent it from rolling away.
Slacken the wheel nuts of the wheel you want to remove by one turn.
Jack up the machine.
Check the machine is standing firmly.
Completely remove the wheel nuts.
Remove the wheel
Mounting the wheels Proceed as follows:

Place the wheel onto the wheel studs.
Tighten all wheel nuts part-way.
Raise the machine from the jacks and lower it again on firm and level ground
Fully tighten the wheel nuts to 175 Nm (129 ft. lbs.) torque.

Maintenance
3.16 Lubrication work

Apply multipurpose lithium grease with an MoS additive to all lubrication points indicated.
Loader unit
Apply grease to lubrication points A on the loader unit ram.
Apply grease to lubrication points B on the loader unit.
The grease nipples are located on the pins on the inside of the chassis.
Lubricate a total of 6 pins.
A
Notice!
Lubricate every 500 service hours or according to the maintenance plan.
B
Fig. 46: Loader unit lubrication points
Lubrication points on the bucket

Apply grease to lubrication point C for the bucket ram.
Apply grease to lubrication points D on the loader unit.
C
Fig. 47: Loader unit lubrication points
Maintenance of attachments
Notice!
Correct maintenance and service is absolutely necessary for smooth and
continuous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments.

Maintenance
3.17 Electrical system

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

Check every time before driving the machine:
Is the light system OK?
Is the signalling and warning system OK?
Every week
Check once a week:
Electric fuses see chapter Fuse box in instrument panel on page 2-6.
Cable and earth connections.
Battery charge condition see Battery on page 3-50.
Condition of battery terminals.

Maintenance
Instructions concerning specific Cables, bulbs and fuses

components Always observe the following instructions:
Defective components of the electrical system must always be replaced by an
authorised expert. Bulbs and fuses may be changed by unqualified persons.
When carrying out maintenance work on the electrical system, pay particular attention
to ensuring good contact in leads and fuses.
Blown fuses indicate overloading or short circuits. The electrical system must therefore
be checked before installing the new fuse.
Only use fuses with the specified load capacity (amperage) see chapter Fuse box in
instrument panel on page 2-6.
Alternator Always observe the following instructions:

Only test run the engine with the battery connected.
When connecting the battery, make sure the poles (+/) are not inverted.
Always disconnect the battery before carrying out welding work or connecting a quick
battery charger.
Replace defective charge telltales immediately see Telltale (red) alternator charge
function on page 1-8.

Maintenance
Battery
Danger!
Battery acid is highly caustic.
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
Always wear goggles and protective clothing with long sleeves.
If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water.
Thoroughly wash any part of the body touched by the sulphuric acid
immediately with plenty of water and seek medical attention at once.
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells
Danger of explosion!
Avoid naked lights and sparks in the vicinity of the battery and do not
smoke.
Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode.
Replace the battery immediately.
Always disconnect the negative terminal () from the battery before starting
repair work on the electrical system.
--
+
The battery is located in the legroom area underneath the footrest plate. The battery is
maintenance-free. However have the battery checked at regular intervals to make sure
the electrolyte level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be carried out by an authorised
workshop.
Always follow the specific battery safety instructions.
Fig. 48: Battery

Notice!
Do not disconnect the battery while the engine is running.
Jump-starting the engine Connect the plus lead of the starting aid with the plus lead on the battery of the machine
requiring jump-start.
Connect the earthing lead of the starting aid to a bare part of the chassis of the machine
requiring jump-start.
Charge the flat battery for a few minutes (let the engine run).
Start the engine.
Remove the earthing lead of the starting aid from the chassis.
Remove the plus lead of the starting aid from the battery of the machine requiring
jump-start.

Maintenance
3.18 General maintenance work

Cleaning Cleaning the machine is divided into 3 separate areas:
Inside the cab
Exterior of the machine
Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. It is therefore essential to observe the following instructions.
General instructions for all areas of the machine
Cleaning with washing solvents

Ensure adequate room ventilation.
Wear suitable protective clothing.
Do not use flammable liquids, such as petrol or diesel.
Cleaning with compressed air
Work carefully.
Wear goggles and protective clothing.
Do not aim the compressed air at the skin or at other people.
Do not use compressed air for cleaning your clothing.
Cleaning with a high-pressure cleaner or steam jet

Electric components and damping material must be covered and not directly exposed
to the jet.
Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
Protect the following components from moisture:
Engine
Electric components such as the alternator etc.
Control devices and seals
Air intake filters etc.
Cleaning with volatile and easily flammable anticorrosion agents and sprays:
Ensure adequate room ventilation.
Do not use unprotected lights or naked flames.
Do not smoke.

Maintenance
Inside the cab

Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure can
Penetrate into the electrical system and cause short circuits and
Damage seals and disable the controls.
We recommend using the following aids to clean the cab:
Broom
Vacuum cleaner
Moist cloth
Bristle brush
Water with mild soap solution
Cleaning the seat belt:
Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they can destroy the fabric.
Exterior of the machine The following articles are generally suitable:
High-pressure cleaner
Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only
Stop the engine before cleaning.
Caution!
When cleaning the engine with a water or steam jet
The engine must be cold
and do not point the jet directly at electric sensors such as the oil pressure
switch.
The humidity penetrating any such sensors causes them to fail and leads to
engine damage.
Screw connections and attachments

All screw connections must be checked regularly for tightness, even if they are not listed in
the maintenance schedules.
Retighten loose connections immediately. Contact an authorised workshop if necessary.
Pivots and hinges

All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

Maintenance

Engine
4-1
4.1
Coolant temperature switch
Engine
Engine
Engine
Air intake
Oil filler neck
Oil dipstick
Fuel injection pump

Turbocharged engine 4TNV84T-XNSS Power Flow (up to serial no. DB00708)
Fuel filter
Engine oil filter
Oil pressure switch
Oil drain plug

Valve cover

Exhaust manifold
Water pump
Tightening bracket
Starter
Fan blade Alternator
V-belt
Engine
4-2
4-3
Air intake
Coolant temperature switch Engine

Exhaust manifold
Fuel filter
Engine 4TNV88-XNSS (up to serial no. DB00708)
Oil filler neck
Oil dipstick
Fuel injection pump
Oil filter
Oil pressure switch
Oil drain plug

Air intake
Valve cover

Water pump
Exhaust manifold
Fan blade
Starter
Alternator
V-belt
Engine
4-4
4-5
4.2
Engine
Reflux
Fuel system
Fuel injection pump
Tank
Fuel filter
Fuel level switch
Feed line
Fuel pump
Water separator with stop

cock

Engine
4.3 Checking and adjusting valve clearance

Standard setting of valve clearance is possible:
On a cold engine
Remove the valve cover.
Turn the engine until the 1st cylinder reaches the top dead centre of the compression
cycle.
Valve overlapping
Check the valve cap for abnormal wear.

normal abnormal
Fig. 1: Valve cap wear
Valve clearance 4TNV88-XNSS (8 valves)

Check valve clearance 2/A with a feeler gauge.
Valve clearance: 0.15 0.25 mm (0.006 0.01)
Adjust valve clearance by turning set screw 2/B.
B C
A Tighten locknut 2/C see General tightening torques on page 2-9.
Check the setting again with the feeler gauge.
Repeat the procedure for each cylinder.
Fig. 2: Valve clearance

Engine
Valve clearance 4TNV84T-XNSS (16 valves)
A
Notice!
Use pliers to prevent the valve bridge from turning as you slacken the lock nut.

Slacken locknut 3/E.
Slacken locknut 3/C on the valve bridge.
B C Press down the valve bridge and reduce the distance from valve stem heads 3/D to 0
with set screw 3/B.
Tighten locknut 3/C on the valve bridge.
D Adjust valve clearance by turning set screw 3/F.
D Valve clearance: 0.15 0.25 mm (0.006 0.01)
Tighten locknut 3/E see General tightening torques on page 2-9.
F E

Engine
4.4 Tightening order for cylinder head bolts
Mount the cylinder-head bolts

Tightening torque:
1st pass 41.1 46.9 Nm (30.31 34.59 ft. lbs.)
2nd pass 85.3 91.1 Nm (62.91 67.19 ft. lbs.)
Caution!
Bear in the mind the order for tightening the cylinder-head bolts.
See figure
Flywheel Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them.
Order for removing the cylinder-head bolts
Flywheel Fan
Notice!
Always carry out work on the cylinder head on a cold engine.

Engine
4.5 Checking the injection nozzles

Pressure check
Remove the injection line and the injection nozzle.
Connect the injection nozzle with the high pressure line of the nozzle tester.
Slowly increase pressure until the nozzle ejects fuel and read the pressure off the
pressure gauge.
If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If
the pressure is too high, replace the spacer by a thinner one.
Injection pressure: 220 230 bar (3191 3336 psi)
Spacer thickness of 0.1 mm (0.004) corresponds to modification by 19 bar (276 psi).
Fig. 4: Nozzle tester
Check the injection nozzle for drips after it has ejected fuel.
Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel drips from the nozzle.
Injection nozzle 4TNV88-XNSS (8 valves)
Upper nozzle screw Lower nozzle screw

Leak oil line fitting Spacers Pressure spring centring Nozzle needle fitting
Compression Compression
spring spring seat Nozzle body
Tightening moment for lower nozzle screw fitting:

39.2 44.1 Nm (28.9 32.5 ft. lbs.)
Injection nozzle 4TNV84T-XNSS (16 valves)
Lower nozzle screw

Spacers Compression spring seat fitting
Upper nozzle screw Pressure spring centring
fitting Compression spring
Nozzle body
Nozzle needle

39.2 44.1 Nm (28.9 32.5 ft. lbs.)

Engine
4.6 Checking the nozzle jet

Remove the injection lines and the injection nozzles.
Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times).
Hold a white sheet of paper about 30 cm (12) away from the nozzle and let the nozzle
eject fuel.
The nozzle jet must create a shape on the paper as shown in fig. 6.
Normal atomisation
Fig. 5: Nozzle jet
optimal --------------variation--------------
Fig. 6: Shape of nozzle jet
Bad atomisation
4.7 Injection time

Checking injection time
Preparatory work:
Remove the injection lines from the fuel injection pump.
Remove plug 7/1 from the piston.
Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
1
Screw the dial gauge into the bore of the piston as shown in fig. 7.
Measurement
Remove the rubber cover from the flywheel housing.
Turn the crankshaft (ring gear on flywheel) until the piston in the fuel injection pump
reaches the lowest point (pay no attention to the position of the cylinders).
Set the measuring equipment to 0.
Use suitable equipment (at the ring gear) to turn the flywheel to the top until the piston
Fig. 7: Measuring equipment
of the fuel injection pump reaches a stroke of 2.5 mm (0.1).
Read the degrees before top dead centre by means of the indentations on the flywheel.
Indentations 1, 2 and 3 stand for the top dead centre of the respective cylinders.
Scaling: 12/15/20/25 before top dead centre
Rated value: 25 + 1 before top dead centre (fourth indentation)
Fig. 8: Top dead centre indentation and 10 before top

dead centre

Engine
Setting injection time

Variations outside the tolerance range can be corrected by turning the fuel injection
pump.
Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump see fig. 9.
Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
about a revolution (do not unscrew completely).
Rotate the pump in the required direction, and tighten one of the screws before you
check the setting.
Label for setting
Rotated towards the engine: earlier injection time
Rotated away from the engine: later injection time
Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted.
Fig. 9: Mark on housing
Check injection time again.
Adhesive label number 1000158808

Engine
Replacement of fuel injection pump

Mark on pump housing Mark the initial position on the pump and wheel case housing before removing the fuel
Labels injection pump see fig. 9.
Remove gear casing cover 11/1 of the fuel injection pump.
Mark the position of the gear of the fuel injection pump 12/A with respect to gear 12/B
see fig. 12.
Completely slacken lock nut 12/2 of the drive pinion.
Example: +1 Example: +0.25
Fig. 10: Correction of injection angle
Remove the fuel injection pump.

Read off the injection angle on the pump.
Read off the injection angle on the new pump.
Read off the imprint on the engine side of the fuel injection pump.
Fig. 11: Gear casing cover
Difference of Angle of new pump Angle of old pump gives you the mounting angle
2 of the new fuel injection pump.
Positive value: later injection time (away from the engine)
A Negative value: earlier injection time (towards the engine)
Install the fuel injection pump

Check the marked position of the drive pinion of the fuel injection pump (fig. 11).
B Unscrew nut 12/2 and tighten to 78 88 Nm (57.5 64.9 ft. lbs.).
Fig. 12: Gear casing
Check injection time.
Mount gear casing cover 11/1 of the fuel injection pump.
Notice!
A Do not slacken screws 13/3 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
manufacturer.
-
3 B

Engine
4.8 Manual/pedal throttle

Engine speed control with pedal throttle
Used for frequent changes of the engine speed setting.
Pressing the pedal throttle F briefly increases the engine speed set with the manual
F throttle H.
Notice!
Engine speed cannot be increased with pedal throttle F if maximum engine speed
has been set with manual throttle H.
Fig. 14: Accelerator pedal
Fig. 14: Manual throttle
4.9 Adjusting engine speed
Notice!
The maximum engine speed is set and sealed by the manufacturer without the
pump and may not be modified.
Adjust engine speed without load

Run the diesel engine until it reaches operating temperature.
A
Check idling speed A and maximum engine speed B with all attachment functions in
neutral.
Idling speed 1000 25 rpm
Max. engine speed: 2995 25 rpm
Adjust as shown if values differ.
B
Fig. 15: Adjusting engine speed

Engine
4.10 Compression
Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid).
Turn the engine.
Mount the compression gauge on the cylinder you want to measure.
Turn the engine with the starter and read the pressure off the pressure gauge.
Machine 701s 701sp

Fig. 16: Compression Specified value 35 1 bar (508 14.5 psi) at 250 30 1 bar (435 14.5 psi) at
rpm 250 rpm
Threshold value 28 1 bar (406 14.5 psi) at 250 25 1 bar (363 14.5 psi) at
rpm 250 rpm
4.11 Checking the coolant thermostat

Remove the thermostat.
The thermostat is located on the water pump see Turbocharged engine 4TNV84T-
XNSS Power Flow (up to serial no. DB00708) on page 4-1.
see Engine 4TNV88-XNSS (up to serial no. DB00708) on page 4-3.
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 17: Coolant thermostat
Warm up the thermostat in a container with water.

Thermometer
Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge).
Thermostat opening temperature: 69.5 72.5 C (157.1 162.5 F)

Engine
4.12 Checking the thermal switch

Remove the thermal switch.
Thermometer
Warm up the thermal switch in a container with antifreeze or oil.
Measure the resistance of the thermal switch as shown by means of an ohmmeter.
The switch must allow the coolant to pass at a temperature of 107 113 C (224.6
235.4 F).
Test prods
Fig. 18: Checking the thermal switch
4.13 Oil pressure switch

Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid).
Measurement
prods Start the engine, check for correct idling speed.
Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
Oil pressure switch OK: infinite resistance
The oil pressure switch is defective if the oil can pass.
Fig. 19: Oil pressure switch
4.14 Checking the coolant circuit

Leakage check
Fill up the radiator completely.
Mount an adapter on the radiator as shown.
Increase the pressure in the cooling system by means of a hand pump to about 1 bar
(15 psi).
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge.
Fig. 20: Checking the radiator for leaks
Check the radiator cap.

Remove the radiator cap and mount it onto the adapter as shown.
Increase the pressure to about 1 bar/15 psi (stamped onto the radiator cap) with the
hand pump.
The radiator cap must open.
Radiator cap
Fig. 21: Checking the radiator cap

Engine
4.15 Turbocharger RHB 31

Charge-air pressure: 0.9 bar (13 psi) 10 %
Pos. Description Pos. Description

1 Turbine shaft 2 Pressure disc
3 Oil scraper 4 Seal
5 Seal 6 Seal (turbine side)
7 Nut 8 Impeller
9 Sealing plate 10 Friction bearing
11 Bearing 12 Turbocharger housing
13 Pin 14 Washer
15 Bow 16 Turbine housing
17 Pin 18 Bow
19 Bearing housing 20 Circlip
21 Screw 22 Screw
23 Shake proof washer 24 Heat shield
25 Liquid seal 26 Diaphragm case for waste gate
27 Hose 28 Adapter
29 Clamp 30 Circlip
31 Charge pressure valve 32 Linkage

Engine
Tolerance values
Description Standard dimensions (mm) Limit (mm)

A 6.257 6.263 6.25
E 1.0.38 1.062 1.0.7
Turbine shaft G1 1.02 1.03 1.04
G2 0.82 0.83 0.84
Shaft eccentricity 0.002 0.005
C (inside) 6.275 6.285 6.29
Bearing D (outside) 9.940 9.946 9.93
B (housing) 9.995 10.005 10.01
J 3.59 3.61 3.58
Axial bearing
K 3.632 3.642 3.65
F 11.00 11.018 11.03
Sealing surfaces H1 9.987 10.025 10.04

H2 7.968 8.00 8.01
Axial play 0.022 0.053 0.07
Radial play 0.061 0.093 0.12
Tightening torques
M5 3.9 4.9 Nm
M5 11.8 12.8 Nm
M8 11.8 12.8 Nm
Axial bearing screws M3 1.2 1.4 Nm
Bearing and sealing screws M3 1.2 1.4 Nm
Turbine screw (left-hand thread) M5 0.9 1.1 Nm

Engine (tier 3)
Engine (tier 3)
4.1 Engine (tier 3)

4TNV88-BKNSS (from serial no. DC00713)
Air intake incl. Oil filler neck

preheater
Exhaust silencer
Valve cover
Fuel injection
pump
Oil dipstick
Cutoff solenoid
Engine oil filter
Oil pressure switch
Oil drain plug

Engine (tier 3)
Tightening bracket
Water pump
Starter
Fan blade
Alternator bracket Alternator
V-belt

Engine (tier 3)
Turbocharged engine 4TNV84T-ZKNSS (from serial no. DC00713)
Oil filler neck
Air intake
Exhaust silencer
Valve cover
Fuel injection pump
Oil dipstick
Control unit
Engine
oil filter
Oil pressure switch
Flywheel

Engine (tier 3)
Water pump
Fan blade
Starter
Alternator
Tightening bracket
V-belt

4.2
Reflux
Fuel system
Tank

Tank
Fuel injection pump Fuel filter

Fuel level switch
Feed line
Fuel pump
Water separator with stop

cock
Engine (tier 3)
4-22
Engine (tier 3)
4.3 Removing the valve cover
Notice!
In order to avoid damage to the glow elements, remove them before removing the
cylinder head.
Allow the engine to cool down for at least 30 minutes before removing (engine oil
temperature < 80 C/< 176 F), then drain the coolant in an environmentally friendly way.
Remove as follows:
Remove all dirt on the engine with a lint-free cloth.

Unscrew all hoses and fuel injection lines from the valve cover.
Remove the air intake and the exhaust manifold.
Unscrew and remove the valve cover.
Fig. 1: Removing the valve cover
4.4 Checking and adjusting valve clearance

Standard setting of valve clearance is possible:
On a cold engine
Remove the valve cover.
Turn the engine (as described in 4.21) until the cylinder reaches the top dead centre of
the compression cycle.
Valve overlapping
Check the valve cap for abnormal wear.

normal abnormal
Fig. 2: Valve cap wear
Valve clearance 4TNV88-BKNSS (8 Check valve clearance 2/A with a feeler gauge.
valves) Valve clearance: 0.15 0.25 mm (0.006 0.01)
A
Place the valve cover gasket
Mount the valve cover
Fig. 3: Checking valve clearance

Engine (tier 3)
Valve clearance 4TNV84T-ZKNSS (16 valves)
A
Notice!
Use pliers to prevent the valve bridge from turning as you slacken the lock nut.

Slacken locknut 4/E.
Slacken locknut 4/C on the valve bridge.
B C Press down the valve bridge and reduce the distance from valve stem heads 3/D to 0
with set screw 4/B.
Tighten locknut 4/C on the valve bridge.
D Adjust valve clearance by turning set screw 4/F.
D Valve clearance: 0.15 0.25 mm (0.006 0.01)
Tighten locknut 4/E see General tightening torques on page 2-9.
F E

Engine (tier 3)
4.5 Tightening order for cylinder head bolts

Order for removing the cylinder-head bolts
Flywheel Fan
Notice!
Always carry out work on the cylinder head on a cold engine.
Mount the cylinder-head bolts

Tightening torques:
1st pass 42.6 45.5 Nm (31.4 33.6 ft. lbs.)
2nd pass 85.3 91.1 Nm (62.9 67.2 ft. lbs.)
Caution!
Bear in the mind the order for tightening the cylinder-head bolts.
See figure
Flywheel Fan
Notice!
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting
them.

Engine (tier 3)
4.6 Checking the injection nozzles

Pressure check
Remove the injection line and the injection nozzle.
Slowly increase pressure until the nozzle ejects fuel and read the pressure off the
pressure gauge.
If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If
the pressure is too high, replace the spacer by a thinner one.
Injection pressure: 196 206 bar (2843 2988 psi)
Spacer thickness of 0.1 mm (0.004) corresponds to modification by 19 bar (276 psi).
Fig. 5: Nozzle tester
Check the injection nozzle for drips after it has ejected fuel.
Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel drips from the nozzle.
Injection nozzle 4TNV88-BKNSS (8 valves)
Upper nozzle screw Lower nozzle screw

Leak oil line fitting Spacers Pressure spring centring Nozzle needle fitting
Compression
Compression
spring seat Nozzle body
spring

39.2 44.1 Nm (28.9 32.5 ft. lbs.)
Injection nozzle 4TNV84T-ZKNSS (16 valves)
Lower nozzle screw

Spacers Compression spring seat fitting
Upper nozzle screw Pressure spring centring
Compression
fitting
spring Nozzle body
Nozzle needle

39.2 44.1 Nm (28.9 32.5 ft. lbs.)

Engine (tier 3)
4.7 Checking the nozzle jet

Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times).
Hold a white sheet of paper about 30 cm (12) away from the nozzle and let the nozzle
eject fuel.
The nozzle jet must create a shape on the paper as shown in fig. 7/left.
Normal atomisation
optimal --------------variation--------------
Fig. 7: Shape of nozzle jet
Bad atomisation
Fig. 6: Nozzle jet
4.8 Injection time

Checking injection time
Preparatory work:
Remove all dirt on the engine with a lint-free cloth.
Remove the high pressure fuel injection lines.
Remove plug 8/1 from the piston.
Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
1 gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
Screw the dial gauge into the bore of the piston as shown in Fig. 8.
Measurement:
Remove the rubber plug from the flywheel housing.
Turn the ring gear on the flywheel with a screwdriver until the piston reaches the lowest
point in the fuel injection pump (proceed by comparing with the first cylinder), or turn at
the front on the crankshaft disc with a key (wrench size 19).
Fig. 8: Measuring equipment
Set the measuring equipment to 0.
Continue turning the ring gear upwards on the flywheel with the screwdriver until the
piston in the fuel injection pump reaches a stroke of 2.5 mm (0.1).

Engine (tier 3)
Read the degrees before top dead centre by means of the indentations on the flywheel.
Indentations 1/4 and 3/2 stand for the top dead centre of the respective cylinders.
Scaling: 12/15/20/25 before top dead centre
Fig. 9: Top dead centre indentation and 10 before top

dead centre
Rated value: calculation according to Yanmar manual:

value on injection pump (example: 6.8 see page 20, Fig. 12) x 2 + FIR

Engine (tier 3)
Setting injection time

Variations outside the tolerance range can be corrected by turning the fuel injection
pump.
Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump see Fig. 10.
Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
Label for setting about a revolution (do not unscrew completely).
Rotate the pump in the required direction, and tighten one of the screws before you
check the setting.
Rotated towards the engine: later injection time
Rotated away from the engine: earlier injection time
Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted.
Fig. 10: Mark on housing
Check injection time again.

Engine (tier 3)
Replacement of fuel injection pump

Mark on pump housing Mark the initial position on the pump and wheel case housing before removing the fuel
Labels injection pump see Fig. 11.
Remove gear casing cover 12/1 of the fuel injection pump.
Turn the engine until the indents on the gears coincide.
Completely slacken lock nut 13/2 of the drive pinion.
Example: +1 Example: +0.25
Fig. 11: Correction of injection angle
Remove the fuel injection pump.

Read off the injection angle on the pump.
Read off the injection angle on the new pump.
Read off the imprint on the engine side of the fuel injection pump.
1
Fig. 12: Gear casing imprint
Tightening torque: 23 28 Nm (17 21 ft. lbs.)
Difference of Angle of new pump Angle of old pump gives you the mounting angle
2 of the new fuel injection pump
Positive value: earlier injection time (towards the engine)
A Negative value: later injection time (away from the engine)
Install the new fuel injection pump
Check the marked position of the drive pinion of the fuel injection pump (fig. 13).
B Screw on and tighten nut 13/2 (tightening torque: 23 28 Nm/17 21 ft. lbs.).
Check injection time.
Mount gear casing cover 12/1 of the fuel injection pump.
Tightening torque: 78 88 Nm (57.5 65 ft. lbs.)
If a front housing cover is installed, the drive wheel of the injection pump is adapted to
the running wheel by means of marks A,B,C (see Fig. 13):
1...Injection pump drive wheel 2...Camshaft drive wheel
3...Auxiliary drive wheel (option) 4...Crankshaft drive wheel
5...Direction of rotation 6...Fuel pump drive wheel (4TNV)
7...Running wheel
Notice!
A Do not slacken screws 14/3 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
manufacturer.
3 B

Engine (tier 3)
4.9 Manual/pedal throttle

Engine speed control with pedal throttle
Used for frequent changes of the engine speed setting.
Pressing the pedal throttle F briefly increases the engine speed set with the manual
F throttle H.
Notice!
Engine speed cannot be increased with pedal throttle F if maximum engine speed
has been set with manual throttle H.
Fig. 15: Accelerator pedal
Fig. 15: Manual throttle
4.10 Adjusting engine speed
Notice!
The maximum engine speed is set and sealed by the manufacturer without the
pump and may not be modified.
Adjust engine speed without load

Run the diesel engine until it reaches operating temperature.
A
Check idling speed A and maximum engine speed B with all attachment functions in
neutral.
Idling speed 1100 25 rpm
Max. engine speed: 2590 25 rpm
Adjust as shown if values differ.
B
Fig. 16: Adjusting engine speed

Engine (tier 3)
4.11 Compression
Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid).
Turn the engine.
Mount the compression gauge on the cylinder you want to measure.
Turn the engine with the starter and read the pressure off the pressure gauge.
Machine 701s 701sp

Fig. 17: Compression Specified value 35 1 bar (508 14.5 psi) at 250 30 1 bar (435 14.5 psi) at
rpm 250 rpm
Threshold value 28 1 bar (406 14.5 psi) at 250 25 1 bar (363 14.5 psi) at
rpm 250 rpm
4.12 Checking the coolant thermostat

Remove the thermostat.
The thermostat is located on the water pump
see 4TNV88-BKNSS (from serial no. DC00713) on page 4-18
see Turbocharged engine 4TNV84T-ZKNSS (from serial no. DC00713) on page 4-
Housing cover 20.
Thermostat
Seal
Housing
Thermal switch
Fig. 18: Coolant thermostat
Warm up the thermostat in a container with water.

Thermometer
Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge).
Thermostat opening temperature: 69.5 72.5 C (157.1 162.5 F)

Engine (tier 3)
4.13 Checking the thermal switch

Remove the thermal switch.
Thermometer
Warm up the thermal switch in a container with antifreeze or oil.
Measure the resistance of the thermal switch as shown by means of an ohmmeter.
The switch must allow the coolant to pass at a temperature of 107 113 C (224.6
235.4 F).
Test prods
Fig. 19: Checking the thermal switch
4.14 Oil pressure switch

Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid).
Measurement prod Start the engine, check for correct idling speed.
Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
Oil pressure switch OK: infinite resistance
The oil pressure switch is defective if the oil can pass.
Fig. 20: Oil pressure switch
4.15 Checking the coolant circuit

Leakage check
Fill up the radiator completely.
Mount an adapter on the radiator as shown.
Increase the pressure in the cooling system by means of a hand pump to about 1 bar
(15 psi).
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge.
Fig. 21: Checking the radiator for leaks
Check the radiator cap.

Remove the radiator cap and mount it onto the adapter as shown.
Increase the pressure to about 1 bar/15 psi (stamped onto the radiator cap) with the
hand pump.
The radiator cap must open.
Radiator cap
Fig. 22: Checking the radiator cap

Engine (tier 3)
4.16 Turbocharger RHB 31

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

1 Turbine shaft 2 Pressure disc
3 Oil scraper 4 Seal
5 Seal 6 Seal (turbine side)
7 Nut 8 Impeller
9 Sealing plate 10 Friction bearing
11 Bearing 12 Turbocharger housing
13 Pin 14 Washer
15 Bow 16 Turbine housing
17 Pin 18 Bow
19 Bearing housing 20 Circlip
21 Screw 22 Screw
23 Shake proof washer 24 Heat shield
25 Liquid seal 26 Diaphragm case for waste gate
27 Hose 28 Adapter
29 Clamp 30 Circlip
31 Charge pressure valve 32 Linkage

Engine (tier 3)
Tolerance values
Description Standard dimensions (mm) Limit (mm)

A 6.257 6.263 6.25
E 1.0,38 1.062 1.0,7
Turbine shaft G1 1.02 1.03 1.04
G2 0.82 0.83 0.84
Shaft eccentricity 0.002 0.005
C (inside) 6.275 6.285 6.29
Bearing D (outside) 9.940 9.946 9.93
B (housing) 9.995 10.005 10.01
J 3.59 3.61 3.58
Axial bearing
K 3.632 3.642 3.65
F 11.00 11.018 11.03
Sealing surfaces H1 9.987 10.025 10.04

H2 7.968 8.00 8.01
Axial play 0.022 0.053 0.07
Radial play 0.061 0.093 0.12
Tightening torques
M5 3.9 4.9 Nm
M5 11.8 12.8 Nm
M8 11.8 12.8 Nm
Axial bearing screws M3 1.2 1.4 Nm
Bearing and sealing screws M3 1.2 1.4 Nm
Turbine screw (left-hand thread) M5 0.9 1.1 Nm

Engine (tier 3)
4.17 Engine trouble
Problem Possible causes

No fuel
Air in fuel system
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Defective or flat battery
Loose or oxidised cable connections in starter circuit
Defective starter, or pinion does not engage
Engine does not start or is not easy to start Wrong valve clearance
Defective fuel injector
Defective starting relay
Defective glow plug
Defective solenoid switch
Cutoff solenoid does not attract
Cutoff solenoid without current
High pressure created immediately in the hydraulic system
Wrong valve clearance
Engine starts, but does not run smoothly or faultless Injection line leaks
Air in fuel system
Oil level too low
Damaged water pump
Oil level too high
Dirty air filter
Engine overheats. Temperature warning system responds Dirty cooler fins
Defective fan, torn or loose V-belt
Defective thermostat
Resistance in cooling system too high, flow capacity too low
Oil level too high
Dirty air filter
Insufficient engine output Wrong valve clearance
Air in fuel system
Injection line leaks

Engine (tier 3)

Injection line leaks
Engine does not run on all cylinders
Oil level too low
Defective engine oil pump
Insufficient or no engine oil pressure Machine inclination too high
Clogged engine oil intake filter
Wrong SAE grade of engine lubrication oil
Oil level too high
Engine oil consumption too high
Machine inclination too high
Oil level too high
Blue Machine inclination too high
Engine oil combustion (defective cylinder-head gasket)
Engine starting temperature too low
White
Engine smoke Wrong valve clearance
Coolant combustion (defective cylinder-head gasket)
Exteme misalignment of injection time
Dirty air filter
Wrong valve clearance
Black
Defective fuel injector (drips)
Wrong fuel injection pump setting

Electronic engine control unit (E-ECU) 4TNV84T-ZKNSS
4.18 Electronic engine control unit (E-ECU) 4TNV84T-ZKNSS

Turbocharged engine 4TNV84T-ZKNSS (from serial no. DC00713)
The Electronic Engine Control Unit (E-ECU) replaces the mechanical engine control used
so far.
Features The electronic engine control unit controls the engine speed, injection pump (flow rate),
intake-air preheating, starting relay, cold start device (CSD) and exhaust gas recirculation
(EGR) electronically as a function of engine load and temperature.
The following figure shows how the electronic engine control unit works:
CSD Cold Start Device Fuel injection pump CSD

Proportional solenoid
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation OFF

Engine speed ON
sensor
E-ECU Start
Ignition lock
EGR
Preheating system
Indicator
Coolant temperature
sensor
Manual throttle
Starter Engine

4.19 Engine error codes

The ECU saves all important engine data. Error messages can be read out by means of a
cable and software (diagnosis kit: 1000184395).
In the case of specific errors:

Engine speed and output are reduced.
The engine is switched off.
The engine no longer starts.
31
Example for flash codes:
Example A 5 5x short
5x short
Ignition ON
1x long 3x short
1x long 3x short
Example B 1 3
Ignition ON
Example C 5 and 1 3 5x short 1x long 3x short 5x short
Ignition ON

Engine diagnosis codes Page

Flash Error
code Component Troubleshooting diagnosis
Loose connector Tighten the connector
Proportional injection pump
Check and replace the defective 4-45
7 solenoid (control rack) (Rack Wiring error
component
position sensor failure)
Defective sensor Contact an authorised workshop
Wiring error
Check and replace the defective
Sensor voltage: component
Manual throttle lever 4-49
5 4.6 V or more, or 0.2 V or less
(Accelerator sensor failure)
Replace the manual throttle lever
Defective manual throttle lever sensor
sensor
ECU internal 4-52
( ECU internal)
4-1 Internal ECU error Contact your dealer
ECU failure 4-55
(ECU failure)
ECU overheated 4-55
2-5 ECU temperature too high Allow to cool down
(ECU overheat alarm)
Wiring harness error
Coolant temperature sensor Check and replace the defective
Sensor voltage: component 4-56
4 (Coolant temperature sensor
4.8 V or more, or 0.2 V or less
failure)
Defective coolant temperature sensor Replace the sensor
Overheated engine Let the engine cool down
Not enough coolant Fill up coolant
Coolant temperature too high
3-6 (Coolant temperature high Check the engine cooling system 4-58
alarm) Defective engine cooling system and replace the defective
component if necessary
Defective coolant temperature sensor Replace the sensor
5 V sensor Sensor voltage: less than 4.5 V or more than component 4-60
2-4
(Sensor 5 V failure) 5.5 V
Internal ECU error Contact an authorised workshop
Old battery Replace the battery
Oxidised battery terminals Clean the battery terminals
Power supply Defective alternator Replace the alternator 4-63
2-3
(Power supply voltage abnormal)
Battery voltage: more than 10 V or more component
than 16 V


Defective starter Replace the starter
Engine speed sensor Defective fuel injection Contact an authorised workshop 4-65
6
(Speed sensor failure)
Battery voltage too low Charge the battery
component
Backup engine speed sensor
Check and replace the defective 4-70
1-1 (alternator) Defective wiring harness
component
(Backup speed sensor failure)
component
Overspeed 4-71
9 Reduce engine speed and brake
(Overspeed) Engine runs at overspeed
the machine
Proportional solenoid relay of Defective relay Contact an authorised workshop

1-7 injection pump (control rack) Internal ECU error Contact an authorised workshop 4-72
(Rack actuator relay failure)
component
Preheating relay Wiring harness error
1-5 component 4-76
(Air heater relay failure)
Defective relay Replace the start relay
Cold start device Wiring harness error
1-4 component 4-80
(CSD solenoid valve failure)
Defective solenoid valve of cold start device Contact an authorised workshop
Exhaust gas recirculation valve Wiring harness error
1-3 component 4-83
( EGR valve failure)
Defective EGR valve stepping motor Contact an authorised workshop
Oil pressure switch Wiring harness error
2-1 component 4-87
(Oil pressure switch failure)
Defective oil pressure switch Replace oil pressure switch


Oil pressure loss Wiring harness error
3-1 component 4-87
(Oil pressure descend error)
Defective oil pressure switch Replace oil pressure switch
component
Proportional injection pump sole- Defective regulator Contact an authorised workshop
8 noid (control rack) 4-91
(Rack actuator failure) Internal ECU error Contact an authorised workshop
Stuck regulator Contact an authorised workshop
Reduce engine speed and brake
Engine runs at overspeed
the machine
Main relay Wiring harness error
1-6 component 4-95
(Main relay failure)
Defective main relay Replace main relay
Battery voltage too low Charge the battery
CAN (Controller Area Network) Loose connector Tighten the connector

1-2 connection Check and replace the defective 4-99
(CAN communication failure) Wiring harness error
component
( ) Text in brackets appears in the diagnosis tool display.

4.20 Error diagnosis

E-ECU connector assignment
Connector on wiring harness side Connectors on ECU side
Number Description Code Number Description Code

E01 4-A D-phase stepping motor STPM-D E06 4-F Automatic idling speed setting APP-IP6
E07 4-G Ignition lock IGNSW E08 4-H Engine start recognition STARTSW
E10 4-K Backup engine speed sensor RENRPM E11 3-A C-phase stepping motor STPM-C
E12 3-B Telltale failure FAIL-LMP E14 3-D Oil pressure APP-IP2
E16 3-F RET E17 3-G Automatic idling speed pressure APP-IP4
Coolant temperature
switch
E18 3-H Speed input (-) NRPM-GND E19 3-J Speed input (+) NRPM
E20 3-K Start relay APP-OP1 E21 2-A B-phase stepping motor STPM-B
E23 2-C Preheating telltale PREHT-LMP E24 2-D Drop mode APP-IP1
E28 2-H GND sensor GND-A E30 2-K CAN terminal resistor RECAN
E31 1-A STPM-A E33 1-C Proportional solenoid relay of RACK-RLY

A-phase stepping motor
injection pump (control rack)
E34 1-D Main relay MAIN-RLY E35 1-E Manual throttle sensor APS
E36 1-F Proportional injection pump RPS E38 1-H AVCC

5 V sensor
solenoid (control rack)
E39 1-J CANL CANL E40 1-K CANH CANH
E41 4-L CSD-CL E42 4-M Proportional injection pump RACKSOL

CSD solenoid coil
solenoid (control rack)
E43 3-L 12 V sensor AVB E44 3-M Preheating relay AIRHT-RLY
E45 2-L Power GND GND E47 1-L GND CSD GND-P
E48 1-M 12 V power VB

Important information on the ECU maintenance wiring harness

Error diagnosis within the scope stated in this document includes measuring voltages with
the maintenance wiring harness. Therefore, disconnect the E-ECU and the machine wiring
harness before carrying out error diagnosis, and connect the maintenance wiring harness
between the E-ECU and the machine wiring harness.
The ECU maintenance wiring harness can be ordered stating no. 1000188305.
See below for details on the error diagnosis for the specific areas.
Use a multimeter to measure the voltage in accordance with the following list.
Maintenance wiring harness: Pin assignment list

1000188305
Machine
Connection between E-ECU wiring
wiring
harness and machine wiring harness.
harness
Measure the voltage between the

specified terminals by means of a
multimeter.

Flash code 7 proportional injection pump solenoid (control rack)
Related DTC (Diagnostic Trouble Codes)
P1202/4 Proportional solenoid position sensor error (voltage too low)

DTC
P1203/3 Proportional solenoid position sensor error (voltage too high)
Initial diagnosis with the diagnosis tool
DTC in the error history display Check the error

A. Check the error display. conditions.
Error is
displayed.
[Check items]:
B. Check the detected Proportional solenoid position sensor voltage (D/A value) Signal data (SD)
value to assess the cause SD=0 (OV) or equivalent => signal line disconnected?
of the error.
SD=5000 (5.0 V) or equivalent => sensor GND line disconnected?
Error diagnosis
1. Check input voltage of NG 2. Check the wiring

NG Replace the wiring
proportional solenoid harness.
harness for
position sensor (wiring
harness + E-ECU).
continuity.
OK
OK
3. Carry out proportional NG

solenoid position Replace the injection pump.
control (with
diagnosis tool).
OK Replace the E-ECU.

Wiring diagram
Check points
Battery
Main relay K1
Fuse F11
Proportional injection pump solenoid
Proportional solenoid position sensor
Connector on proportional solenoid side Connector on wiring harness side
*E-ECU connector assignment see E-ECU connector assignment on page 4-43.

Diagnosis description 1. Check the input voltage of the proportional injection pump solenoid (wiring
harness + E-ECU).
Switch off ignition and disconnect connector of proportional solenoid from injection
pump. Do not disconnect the E-ECU connector from the E-ECU.
Switch on ignition to switch on E-ECU voltage.
Measure the voltage between sensor terminals E43 and E28 by means of a multimeter.
Terminal Normal value
Sensor connectors E43 E28 Equivalent to the battery voltage
NG Check the wiring harness for continuity. -> Next: [2. Check the wiring harness for continuity:]
With the diagnosis tool Diagnosis test: active control, check whether Position control for proportional injection
OK pump solenoid can be carried out. -> Next: [3. Check the execution of the position control of the proportional
injection pump solenoid:]
2. Check the wiring harness for continuity:

Disconnect the connector from the proportional injection pump solenoid, and the
E-ECU from the wiring harness.
Check the wiring harness for continuity by means of a multimeter.
Terminal Continuity Status
Sensor signal line E36 Yes OK: normal
[between E-ECU and sensor connector] No NG: open wiring harness
Sensor GND line E28 Yes OK: normal
12 V sensor line E43 Yes OK: normal
No OK: normal
Between E36 and other terminal/GND and
between E43 and other terminal/GND Yes NG: wiring harness short-circuited to GND
Yes OK: normal

Between E28 and GND/E45/E47
No NG: open wiring harness
No OK: normal
Between E28 and other terminals
Yes NG: wiring harness short-circuited with other cable
Check whether the wiring harness is damaged, or whether the wiring is correct.
NG
Replace the wiring harness.
With the diagnosis tool Diagnosis test: active control, check whether Position control for proportional injection
OK pump solenoid can be carried out. -> Next: [3. Check the execution of the position control of the proportional
injection pump solenoid:]

3. Check the execution of the position control of the proportional injection pump
solenoid:
Connect all connectors (sensors, E-ECU).
Connect the diagnosis tool, switch on ignition and log in to the diagnosis tool.
With the diagnosis tool Diagnosis test: active control, carry out the position control for
the proportional injection pump solenoid. Place the control rack in any position within
the admissible setting range.
Then check whether the proportional injection pump solenoid has moved to the control
rack position that has been set.
NG Replace the injection pump.

Flash code 5 manual throttle
Related DTC
P1125/1 Manual throttle sensor error (manual throttle in closed position)
P1126/0 Manual throttle sensor error (manual throttle in open position)

DTC
P1225/1 Manual throttle backup sensor error (manual throttle in closed position)
P1226/0 Manual throttle backup sensor error (manual throttle in open position)

A. Check the error
conditions.
display.
Error is
displayed.
B. Check the
detected value to
assess the cause of the
error.
Error diagnosis
1. Continuity check NG Replace the manual throttle.

(manual throttle only):
OK
NG
2. Continuity check NG 3. Continuity check Replace the wiring
(manual throttle + (wiring harness) harness.
wiring harness)
OK
OK
4. Movement check NG Replace the E-ECU or

(with diagnosis tool) manual throttle.
OK
Replace the E-ECU.

Wiring diagram
Check points
Manual throttle sensor (standard)

Work description 1. Check the wiring harness for continuity:

Disconnect the manual throttle sensor and the E-ECU from the wiring harness.
5 V sensor line E38 Yes OK: normal

No OK: normal
Between E35 and other terminal/GND and
between E38 and other terminal/GND Yes NG: wiring harness short-circuited to GND
Yes OK: normal
No OK: normal
Between E28 and other terminals NG: wiring harness short-circuited with other
Yes
cable
NG
OK Check output voltage of manual throttle sensor. -> Next: [4. Check manual throttle sensor output voltage:]
2. Check manual throttle sensor output voltage:

Connect the maintenance wiring harness between the E-ECU and the machine wiring
harness (see [Important information on the maintenance wiring harness] 4-44 for
details). Connect all connectors (sensors, E-ECU).
Voltage Status Action

E35 0.2 [V] NG
Replace the manual throttle sensor.
0.2 [V] < E35 < 3.8 [V] OK (normal range) Replace the E-ECU.

3.8 V E35 NG
NG

Flash code 4-1 ECU internal
Related DTC
P0601/12 EEPROM error (read/write error)
P1601/2 EEPROM error (check sum)
P0605/12 ROM error flashes (check sum A)
P1605/2 ROM error flashes (check sum B)

DTC P1606/2 ROM error flashes (check sum C)
P1610/12 Error A with sub-CPU
P1611/12 Error B with sub-CPU
P1612/12 Error C with sub-CPU
P1620/12 Map format error

Error is
displayed.
[Check items]: error code
Error diagnosis
Repeat
Switch ignition ON/
OFF.
1. Carry out the same DTC in the error history display Check the error
steps as in the initial conditions.
diagnosis above.
OK
Overwrite the E-ECU

software or replace the
E-ECU.

Work description 1. Work with the diagnosis tool:

Switch off ignition.
Connect the diagnosis tool and check whether errors have been detected on the error
display.
No Check the error history display, confirm errors if an error history is displayed.
Switch ignition ON/OFF. -> Next: [1. Work with the diagnosis tool:]
Yes Overwrite the E-ECU software.
Replace the E-ECU.

Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
Related DTC
P0668/4 ECU temperature sensor error (voltage too low)
DTC P0669/3 ECU temperature sensor error (voltage too high)
P1644/2 Intermittent error with ECU temperature sensor

Error is
displayed.
[Check items]: ECU temperature

B. Check the detected ECU temperature remains constant at 30 C => ECU possibly defective.
value to assess the cause ECU temperature equivalent to ambient temperature => normal
of the error.
Error diagnosis
Repeat Switch ignition ON/OFF.
1. Carry out the DTC in the error history display Check the error
same steps as in the
conditions.
initial diagnosis
above.
OK
Replace the
E-ECU.

Work description 1. Work with the diagnosis tool:

Check the error display.
Switch ignition off and on again.
Connect the diagnosis tool and check whether errors have been detected on the error
display.
No Check the error history display, confirm errors if an error history is displayed.
Yes Check the detected value by means of the diagnosis tool. -> Next: [ Check the detected value]
Check the detected value.

Check the value indicated in the E-ECU temperature with the Diagnosis test
diagnosis tool function.
Displayed value Status Action
Constant at 30 C/86 F NG Replace the E-ECU.
Ambient temperature OK Replace the E-ECU.
NG Replace the E-ECU.

Switch ignition ON/OFF again and carry out [ Check the error display] [Check the detected value].
OK
Replace the E-ECU.

Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
Related DTC
P0117/4 Coolant temperature sensor error (voltage too low)
DTC P0118/3 Coolant temperature sensor error (voltage too high)
P0119/2 Intermittent coolant temperature sensor error

Error is
displayed.
[Check items]: engine coolant temperature Signal Data (SD)
SD 200 (0.2 V) => short-circuited to GND?
B. Check the detected
200 (0.2 V) < SD < 4800 (4.8 V) => normal
value to assess the cause
of the error. 4800 (4.8 V) SD => disconnected?
Error diagnosis
1. Check the sensor NG Replace the sensor.

resistance value
(sensor only).
2. Check the NG
sensor resistance
NG 3. Check the wiring Replace the wiring
harness for harness.
value (sensor + wiring
continuity.
harness):

OK
4. Check the output NG Replace the E-ECU or

voltage of the coolant sensor.
temperature
sensor.
OK
Replace the E-ECU.

Sensor drawing
Wiring diagram
Check points
Coolant temperature sensor (high accuracy)
Connector on wiring
harness side

Work description 1. Check the sensor resistance value (sensor only)

Disconnect the wiring harness from the coolant temperature sensor.
Measure the resistance between the terminals A and B of the coolant temperature
sensor by means of a multimeter.
Check whether the measured resistance value is within the normal range. See the
following table <Parameters of coolant temperature sensor>.
Parameters of coolant temperature sensor
Ratio between coolant temperature and sensor resistance:
Resistance (k)
Temperature (C/F)
High accuracy
-30/-22 25.4
-20/- 4 15.04
-10 / 14 9.16
0 / 32 5.74
10 / 50 3.7
20 / 68 2.45
30/86 1.66
40/104 1.15
50 / 122 0.811
60 / 140 0.584
70 / 158 0.428
80 / 176 0.318
90 / 194 0.24
100 / 212 0.1836
110 / 230 0.1417
120 / 248 0.1108
NG Replace the coolant temperature sensor.
OK Check the sensor resistance with the sensor and the wiring harness connected. -> Next: [2. Check the sensor
resistance value (sensor + wiring harness):]
2. Check the sensor resistance value (sensor + wiring harness):

Connect the coolant temperature sensor and the wiring harness, and disconnect
E-ECU from the wiring harness.
Measure the resistance between the E-ECU connector terminals E16 and E28 on the
wiring harness side by means of a multimeter.
Check whether the measured resistance value is within the normal range. See the
previous table <Parameters of coolant temperature sensor>.
OK Check the output voltage of the coolant temperature sensor. -> Next: [4. Check the output voltage of the coolant
temperature sensor:]


Disconnect the coolant temperature sensor and E-ECU from the wiring harness.
[E-ECU between sensor connector] No NG: open wiring harness
No OK: normal
Between E16 and other terminal/GND
Yes NG: wiring harness short-circuited to GND
Yes OK: normal

E28 GND/E45/E47
No OK: normal
Between E28 and other terminals
NG
OK Check the output voltage of the coolant temperature sensor. -> Next: [4. Check the output voltage of the coolant
temperature sensor:]
4. Check the output voltage of the coolant temperature sensor.

Measure the voltage between sensor terminals E16 and E28 (E35 and E28) by means
of a multimeter.

E16 0.2 [V] NG
Replace the coolant temperature sensor.

4.8 V E16 NG
Replace the coolant temperature sensor.
NG

Flash code 2-4 sensor 5 V
Related DTC
P0642/4 SENSOR 5 V error (voltage too low)
DTC P0643/3 SENSOR 5 V error (voltage too high)
P1644/2 Intermittent SENSOR 5 V error

Error is
displayed.
[Check items]: SENSOR 5 V voltage
B. Check the SENSOR 5V voltage 4.5 V => short-circuited to GND?
detected value to assess the 4.5 V < SENSOR 5 V voltage < 5.5 V => normal
cause of the error.
5.5 V SENSOR 5 V voltage => short-circuited with power supply?
Error diagnosis
NG Replace the sensor.

1. Check the manual
throttle sensor.
*See [Manual throttle sensor] for the check procedure.
OK
2. Check output NG 3. Check the wiring NG Replace the wiring

voltage (sensor not harness for harness.
connected) continuity.
OK
OK
4. Check the
output voltage (with the
NG Replace the E-ECU.
sensor connected):
OK
Replace the E-ECU.

Work description 1. Check the manual throttle sensor.

For details, see [Manual throttle sensor] (see page 4-49).
2. Check output voltage (sensor not connected)
Disconnect the manual throttle sensor from the wiring harness. Do not disconnect the
E-ECU connector from the E-ECU.
Switch on ignition to switch on E-ECU voltage.
Measure the voltage between the wiring-harness side connector terminals E38 and
GND of the manual throttle sensor by means of a multimeter.
Terminal Normal value
Sensor connectors E38 GND 5V
OK With the manual throttle sensor connected, check the output voltage. -> Next: [4. Check the output voltage (with the
sensor connected):]

Disconnect the manual throttle sensor and the E-ECU from the wiring harness.
No OK: normal
Between E38 and E28/E45/E47/GND
No OK: normal
Between E38 and E43/E48
Yes NG: wiring harness short-circuited with power supply
Between E-ECU and sensor connector No NG: open wiring harness
Yes OK: normal

No OK: normal
Between E38/E28 and other terminals
NG
OK With the manual throttle sensor connected, check the output voltage. -> Next: [4. Check the output voltage (with the
sensor connected):]

4. Check the output voltage (with the sensor connected):


E38 4.5 [V] NG

5.5 V E38 NG
NG

Flash code 2-3 power supply voltage
(1) P0562/1: power supply voltage error (voltage too low)
DTC P0562/1 Power supply voltage error (voltage too low)
DTC detection conditions
1 Prerequisite; 2 Detection condition(s); 3 Flash code in error display Check points
1. Engine runs. Battery
2. E-ECU supply voltage below 10 [V] Alternator
3. 2 flash pulses followed by 3 flash pulses. Wiring harness
Troubleshooting
[Operation is resumed]: The system lets the engine run without any restrictions after the error has been
Error mode
detected.
Operation
No.
restrictions?
Recovery conditions Yes: This error is automatically reset if a normal supply voltage (10 to 16 [V]) is applied.
Remarks
Possible error cause/condition

Bad battery condition.
Wrong battery connection.
Alternator defect.
Wiring harness disconnected or short-circuited.
Defect in internal E-ECU circuit.
Diagnosis description
1) Initial diagnosis with the diagnosis tool
Check the battery voltage.
Switch off ignition to stop the engine.

Check battery voltage with a multimeter.
Inspect the charging system of the engine.
2) Engine
inspection Switch on ignition after a short time to check whether a DTC has
been detected.
*Refer to the Service Manual (Engine) for a description of the engine
inspection and how to carry it out.
Check whether the battery connections are OK

3) Error diagnosis
and whether the cable insulation is undamaged.

(2) P0563/0: power supply voltage error (voltage too high)
DTC P0563/0 Power Supply Voltage Error (High Voltage)
1. Engine runs. Battery
2. E-ECU supply voltage over 16 [V] Alternator
3. 2 flash pulses followed by 3 flash pulses. Wiring harness
Troubleshooting
[Operation is resumed]: The system lets the engine run without any restrictions after the error has been
Error mode
detected.
Operation
No.
restrictions?
Recovery conditions Yes: This error is automatically reset if a normal supply voltage (10 to 16 [V]) is applied.
Remarks

An incompatible battery (such as a 24 V battery) has possibly been used.
Wrong battery connection.
Alternator defect.
Wiring harness disconnected or short-circuited.
1) Initial diagnosis with the diagnosis tool
Check the battery voltage.

Inspect the charging system of the engine.
2) Engine
inspection Switch on ignition after a short time to check whether a DTC has
been detected.
Check whether the battery connections are OK

3) Error diagnosis
and whether the cable insulation is undamaged.

Flash code 6 engine speed sensor

Related DTC
DTC P0340/4 Engine speed sensor error

Error is
displayed.
B. Check the [Check items]: actual engine speed [value]

detected value to
assess the cause Value = 0 => disconnected? Sensor error?
of the error.
Error diagnosis
1. Check the sensor NG Replace the sensor.

resistance value
(sensor only).
OK
2. Check the
sensor resistance NG 3. Check the wiring NG Replace the wiring
value (sensor + wiring harness for harness.
harness): continuity.
OK
4. Check the wiring NG Replace the wiring harness.

harness for wrong
connections.

Wiring diagram
Check points
Connector on sensor
side
Connector on wiring
harness side

Work description 1. Check the sensor resistance value (sensor only)

Disconnect the engine speed sensor from the wiring harness.
Measure the resistance between the engine speed sensor terminals A and B by means
of a multimeter.
(REF) coil resistance value of standard Yanmar engine speed sensor.
Terminal Specification
Sensor A B 0.5 0.1 k
NG Replace the engine speed sensor.
OK With the engine speed sensor and the wiring harness connected, check the resistance between sensor terminals A
and B. -> Next: [2. Check the sensor resistance value (sensor + wiring harness):]
2. Check the sensor resistance value (sensor + wiring harness):

Connect the engine speed sensor and the wiring harness, and disconnect the E-ECU
from the wiring harness.
Measure the resistance between the E-ECU connector terminals E19 and E18 on the
wiring harness side by means of a multimeter.
*See above, (REF) coil resistance value of standard Yanmar engine speed sensors.
NG Replace the wiring harness.
OK Check the wiring harness for continuity. -> Next: [3. Check the wiring harness for continuity:]

Disconnect the engine speed sensor and the E-ECU from the wiring harness.
Sensor signal line (+) E 19 Yes OK: normal
Sensor signal line (-) E 18 Yes OK: normal

Between E 19 and GND/E45/E47 No OK: normal
(between E 18 and GND/E45/E47) Yes NG: wiring harness short-circuited to GND
NG

Flash code 1-1 backup engine speed sensor
Related DTC
DTC P1340/4 Backup engine speed sensor error

Error is
displayed.
B. Check the
[Check items]: backup engine speed sensor Value
detected value to
assess the cause Value = 0 => disconnected? Sensor error?
of the error.
Error diagnosis
NG Replace the battery or

1. Check battery voltage check the alternator.
OK
NG
2. Check the wiring Replace the wiring harness.
harness for
continuity.
OK Check the alternator or replace the

E-ECU.

Wiring diagram
Check points
Battery
Starter
Fuse
Ignition lock in ON
or START position
Fuse
Engine speed sensor
Backup engine speed sensor (option) Connector on wiring

(alternator) harness side

Work description 1. Battery voltage check:

Set the manual throttle lever to the Iowest position and start the engine.
Battery voltage (in normal condition) 10 to 16 [V]
Check the alternator.

NG
Replace the battery.

Disconnect the connector from the backup engine speed sensor, and the E-ECU from
the wiring harness.
Alternator terminal P (E10) Yes OK: normal
[between E-ECU and alternator] No NG: open wiring harness
Alternator terminal IG Yes OK: normal
[between ignition lock and alternator] No NG: open wiring harness

Alternator terminal B Yes OK: normal
[between battery and alternator] No NG: open wiring harness
No OK: normal
NG
Check the alternator.

OK
Replace the E-ECU.

Flash code 9 overspeed error

(1) P0219/0: overspeed error
DTC P0219/0 Overspeed error

1. Engine runs. Wiring harness
2. Sensor signal at or above the upper limit (high idling speed +600[min-1]) Engine speed sensor
Proportional injection pump
3. 2 flash pulses followed by 3 flash pulses. solenoid
E-ECU
Troubleshooting
Error mode [Immediate stop]: The engine stops running.
Operation Yes: The proportional solenoid relay of the injection pump is switched off and the control rack position is
restrictions? forced to the engine stop position.
Recovery conditions No.
Remarks

Wiring defect in wiring harness
The wiring of the proportional injection pump solenoid is possibly short-circuited to
GND.
Engine speed sensor signal pulse created incorrectly
Incorrect wiring of engine speed sensor
Engine overspeed due to consumer
Control error of injection pump
The wiring of the proportional injection pump solenoid is possibly short-circuited to
GND.
1) Initial diagnosis with the diagnosis tool Check the error display.

Inspect the engine and the machine.
2) Engine Switch on ignition after a short time to check whether a DTC has
inspection been detected.
3) Error Check the proportional injection pump solenoid.

diagnosis *See 4-68 for more details on the diagnosis method and procedure

Flash code 1-7 proportional solenoid relay of the injection pump (control rack)
Related DTC
P1222/4 Error A on proportional solenoid relay of the injection pump
DTC P1223/3 Error B on proportional solenoid relay of the injection pump
P1224/2 Intermittent error A on proportional solenoid relay of the injection pump

Error is
displayed.
B. Check the [Check item]: Proportional solenoid relay of injection pump

detected value to Contact status -> ON => normal?
assess the cause
of the error. Contact status -> OFF => abnormal?
Error diagnosis
1. Check the relay coil NG Replace the relay.

resistance (relay only).
2. Check the relay coil NG 3. Check the wiring NG Replace the wiring
resistance (relay + harness for harness.
wiring harness). continuity.
OK
OK
NG Replace the E-ECU or

4. Check the relay for
the wiring harness.
movement (with the
diagnosis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Relay-side connector
Proportional solenoid Battery

relay K42 of injection
pump Main relay K1
Fuse F11
Fuse F2 50 A
Ignition
ON
Fuse F3 10 A
Connector on wiring
harness side
Proportional injection
pump solenoid to coil
input

Work description 1. Check the relay coil resistance value (relay only):
Disconnect the proportional solenoid relay of the injection pump from the wiring
harness.
Measure the resistance between terminals C and D on the relay side by means of a
multimeter.
Measurement conditions
Measured value Status
Tester (+) side Tester (-) side
Terminal C Terminal D Existing (*)
OK if both are normal
Terminal D Terminal C Infinite (*)
Terminal C Terminal D
Infinite (*) NG: internal relay circuit error
Terminal D Terminal C
*A series-connected diode integrated in reverse direction requires using the checking method mentioned above and causes the measured
value to vary depending on the multimeter used.
NG Replace the proportional solenoid relay of the injection pump.
OK With the proportional solenoid relay of the injection pump and the wiring harness connected, check the relay coil
resistance. -> Next: [2. Check the relay coil resistance value (relay + wiring harness side):]
2. Check the relay coil resistance value (relay + wiring harness side):
Connect the proportional solenoid relay of the injection pump onto the wiring harness.
Disconnect the E-ECU from the wiring harness.
Measure the resistance between E-ECU connectors E07 and E33 by means of a
multimeter.
E07 E33 Existing (*)
OK: normal
E33 E07 Infinite (*)
E07 E33
Infinite (*) NG: wiring harness error
E33 E07
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next:
[4. Check the relay for movement:]


Disconnect the proportional solenoid relay of the injection pump and the E-ECU from
the wiring harness.
Relay coil (output side) E33 Yes OK: normal
Relay coil (input side) E07 Yes OK: normal
No OK: normal
Between E33 and GND/E28/E45/E47
No OK: normal
NG
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next:
[4. Check the relay for movement:]
4. Check the relay for movement:

details). Connect all connectors (proportional solenoid relay of injection pump, E-ECU).
Activate the proportional solenoid relay of the injection pump by means of the diagnosis
tool Diagnosis test: active control, and measure the voltage between terminals E33
and E45.
ON/OFF setting status Voltage Status
1.75 [V] and below OK: normal

ON
Over 1.75 [V] NG: wiring harness short-circuited with power supply or E-ECU error
2.5 [V] and above OK: normal

OFF
Under 2.5 [V] NG: wiring harness short-circuited to GND or E-ECU error
NG

Flash code 1-5 preheating relay
Related DTC
P1232/4 Error A of preheating relay
DTC P1233/3 Error B of preheating relay
P1234/2 Intermittent error B of preheating relay

Error is displayed.
B. Check the [Check items]: air heater relay 1

assess the cause
Error diagnosis
1. Check the relay NG Replace the relay.

coil resistance
(relay only).
NG NG Replace the wiring

2. Check the relay coil 3. Check the wiring
resistance (relay + harness for harness.
wiring harness). continuity.
OK
OK

4. Check the relay for
the wiring harness.
movement (with the
diagnosis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Air heating relay
Fuse F1 50 A
C
Air heater
Disconnect the preheating relay from the wiring harness.
multimeter.
(REF) total resistance value of Yanmar preheating relay.
Relay coil side C D (40 A relay) 103 10 % (at 20 C/68 F)
Relay coil side C D (70 A relay) 103 10 % (at 20 C/68 F)
Relay coil side C D (90 A relay) 80 (at 20 C/68 F)

NG Replace the preheating relay.
OK With the preheating relay and the wiring harness connected, check the relay coil resistance. -> Next: [2. Check the
relay coil resistance value (relay + wiring harness side):]
2. Check the relay coil resistance value (relay + wiring harness side):
Connect the preheating relay onto the wiring harness.
Measure the resistance between E-ECU connectors E44 and B00 with a multimeter.
*See above, (REF) coil resistance value of standard Yanmar preheating relay.
OK Check the movement of the preheating relay with the diagnosis tool. -> Next: [4. Check the relay for movement:]

Disconnect the preheating relay and the E-ECU from the wiring harness.
Relay coil (input side) E44 Yes OK: normal
Relay coil (output side) B00 Yes OK: normal

No OK: normal
No OK: normal
NG
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next: [4.
Check the relay for movement:]

4. Check the relay for movement:

details). Connect all connectors (preheating relay, E-ECU).
Activate the preheating relay by means of the diagnosis tool Diagnosis test: active
control, and measure the voltage between terminals E44 and E45.

ON

OFF
NG

Flash code 1-4 CSD (cold start device) solenoid coil
Related DTC
P1242/4 Error A at CSD solenoid valve
DTC P1243/3 Error B at CSD solenoid valve
P1244/2 Intermittent CSD solenoid valve error

Error is
displayed.
[Check items]: CSD solenoid valve

B. Check the
assess the cause Contact status -> OFF => abnormal?
of the error.
Error diagnosis
1. Check the
resistance value of the NG Replace the relay.
CSD solenoid valve
coil (solenoid valve
only):
2. Check the
resistance value of the NG 3. Check the wiring NG Replace the wiring
CSD solenoid valve coil harness for harness.
(solenoid valve + wiring continuity.
harness).
OK
OK
4. Check the CSD

solenoid valve for
the wiring harness.
movement (with the
diagnosis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Injection pump
CSD solenoid valve
C
D
Connector on wiring
harness side
Work description 1. Check the resistance value of the CSD solenoid valve coil (solenoid valve only):
Disconnect the CSD solenoid valve connector from the wiring harness.
Measure the resistance between terminals C and D on the side of the CSD solenoid
valve by means of a multimeter.
(REF) coil resistance of the CSD solenoid valve
CSD solenoid valve side C D (400W) 8 (at 23 C/73.4 F)
NG Replace the solenoid valve.
With the CSD solenoid valve connector and the wiring harness connected, check the coil resistance of the CSD
OK solenoid valve. -> Next: [2. Check the resistance value of the CSD solenoid valve (solenoid valve + wiring
harness):]

2. Check the resistance value of the CSD solenoid valve coil (solenoid valve +
wiring harness)
Connect the CSD solenoid valve and the wiring harness.
Measure the resistance between E-ECU connectors E41 and B00 by means of a
multimeter.
*See (REF) coil resistance of standard Yanmar CSD solenoid valve above
OK Check the movement of the CSD solenoid valve by means of the diagnosis tool. -> Next: [4. Check the CSD
solenoid valve for movement:]

Disconnect the CSD solenoid valve connector and the E-ECU from the wiring harness.
CSD solenoid valve (input side) E41 Yes OK: normal
No OK: normal
No OK: normal
NG
OK Check the movement of the CSD solenoid valve by means of the diagnosis tool. -> Next: [4. Check the CSD
solenoid valve for movement:]
4. Check the CSD solenoid valve for movement:

details). Connect all connectors (CSD solenoid valve connector, E-ECU).
Activate the preheating relay by means of the diagnosis tool Diagnosis test: active
control, and measure the voltage between terminals E41 and E45.
ON
OFF
NG

Flash code 1-3 EGR (exhaust gas recirculation) valve
Related DTC
P1402/4 Error A at EGR valve (stepping motor A-phase)

P1403/3 Error B at EGR valve (stepping motor A-phase)
P1412/4 Error A at EGR valve (stepping motor B-phase)
P1413/3 Error B at EGR valve (stepping motor B-phase)
DTC
P1422/4 Error A at EGR valve (stepping motor C-phase)
P1423/3 Error B at EGR valve (stepping motor C-phase)
P1432/4 Error A at EGR valve (stepping motor D-phase)
P1433/3 Error B at EGR valve (stepping motor D-phase)

B. Check the
[Check items]: stepping motor A-phase (B-phase, C-phase, D-phase)
detected value to
assess the cause Contact status -> ON => normal?
Error diagnosis
1. Check the resistance NG Replace the sensor.

of the EGR stepping motor
coil (EGR valve only)
2. Check the resistance of NG 3. Check the wiring

the EGR stepping motor harness for harness.
coil (EGR valve + wiring continuity.
harness)
OK
4. Check the EGR for NG Replace the E-ECU or

movement (with the the wiring harness.
diagnosis tool).
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Connector on EGR side Main relay K1

Fuse
Valve
Connector on wiring
harness side

Work description 1. Check the resistance of the EGR stepping motor coil (EGR only):
Disconnect the EGR valve from the wiring harness.
Measure the resistance between the coil terminals 4-5, (1-2, 5-6, 2-3) on the EGR side
by means of a multimeter.
(REF) resistance value of standard Yanmar EGR stepping motor coil
Coil terminal 4 5 (A-phase)
Coil terminal 1 2 (B-phase)

15 2
Coil terminal 5 6 (C-phase)
Coil terminal 2 3 (D-phase)
NG Replace the EGR valve.
OK With the EGR valve and the wiring harness connected, check the EGR stepping motor coil resistance. -> Next: [2.
Check the resistance of the EGR stepping motor coil (relay + wiring harness side):]
2. Check the resistance of the EGR stepping motor coil (relay + wiring harness
side):
Connect the EGR valve with the wiring harness.
Measure the coil resistance at the E-ECU connector by means of a multimeter.
*See (REF) resistance of standard Yanmar EGR stepping motor coil above.
Stepping motor ECU connector terminal number
A-phase E31-E48
B-phase E21-E48
C-phase E11-E48
D-phase E01-E48
OK Check the EGR for movement by means of the diagnosis tool. -> Next: [4. Check the EGR for movement:]


Disconnect the EGR valve and the E-ECU from the wiring harness.
Motor coil (output side) E31 (E21/E11/E01) Yes OK: normal
[between E-ECU and EGR connector] No NG: open wiring harness
Motor coil (input side) E48 Yes OK: normal
[between E-ECU and EGR connector] No NG: open wiring harness
Between E31 (E21/E11/E01) and No OK: normal
GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
Between E31 (E21/E11/E01) and No OK: normal
E43/E48 Yes NG: wiring harness short-circuited with power supply
NG
OK Check the EGR for movement by means of the diagnosis tool. -> Next: [4. Check the EGR for movement:]
4. Check the EGR for movement:

details). Connect all connectors (EGR valve, E-ECU).
Activate each stepping motor of the EGR valve by means of the diagnosis tool
Diagnosis test: active control, and measure the voltage between stepping motor coil
terminals E31 E45, (E21 E45, E11 E45, E01 E45).

ON

OFF
NG

Flash code 2-1 oil pressure switch and 3-1 oil pressure drop error
Related DTC
P1192/4 Oil pressure switch error

DTC
P1198/1 Abnormal oil pressure drop

Error is
displayed.
[Check items]: oil pressure switch terminal ON/OFF status

B. Check the Oil pressure switch
detected value to
assess the cause Before engine start: ON => normal
of the error. : OFF => disconnected?
Error diagnosis
1. Continuity check (oil NG Replace the separate oil

pressure switch only) pressure switches.
OK
NG 3. Continuity check
2. Continuity check (oil harness.
pressure switch + (wiring harness)
wiring harness)
OK
OK
Replace the wiring harness or

4. Check oil pressure
NG the separate oil pressure
switch for movement switches.
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Ignition lock
Fuse F3 10 A
Telltale
(see round indicating instrument 37)
Automatic idling speed setting pressure
Automatic idling speed setting S87
switch S86
Oil pressure switch

Work description 1. Continuity check (oil pressure switch only)

Disconnect the wiring harness from the separate oil pressure switches.
Check the continuity between the oil pressure switch terminal and the chassis by
means of a multimeter and the following table.
Terminal name Continuity

Pos. Status
(terminal no.) [between terminal and chassis]
Yes OK: normal
Oil pressure switch APP-IP2 (E14)
No NG: internal circuit error
NG Replace the oil pressure switch.
OK Check the continuity with the oil pressure switch and the wiring harness connected. -> Next: [2. Continuity check
(oil pressure switch + wiring harness):]
2. Continuity check (oil pressure switch + wiring harness)

Connect the oil pressure switch and the wiring harness, and disconnect the E-ECU
from the wiring harness.
Check the continuity between the ECU connector terminal on the wiring harness and
the chassis by means of a multimeter. Refer to the text above for the terminal
description to be checked [1. Continuity check (oil pressure switch only):].
OK Use the diagnosis tool Diagnosis test to check whether the movement of the oil pressure switch is correctly
detected. -> Next: [4. Check the oil pressure switch for movement:]

Disconnect the oil pressure switch and the E-ECU from the wiring harness.
Switch signal line E14 (*) Yes OK: normal
[between E-ECU and switch connector] No NG: open wiring harness
Between E14 (*) and E38/E43/E48 No OK: normal
Yes NG: wiring harness short-circuited with power

(power supply line)
supply
Between E14 (*) and E28/E45/E47 No OK: normal
(GND line)/GND Yes NG: wiring harness short-circuited to GND
*An oil pressure switch is used as an example in this table. Use the same procedure to check the coolant temperature switch (E17) for
continuity.
NG
OK Use the diagnosis tool Diagnosis test to check whether the movement of the oil pressure switch is correctly
detected. -> Next: [4. Check the oil pressure switch for movement:]

4. Check the oil pressure switch for movement:

Connect all connectors (oil pressure switch, E-ECU).
Monitor the separate components displayed with the diagnosis tool Diagnosis test:
digital input etc.. Check ON/OFF display of the oil pressure switch under the
circumstances indicated.
Pos. Check conditions ON/OFF display Status

ON OK: normal
Before engine start
OFF NG: wiring harness error or internal circuit error
Oil pressure switch
OFF OK: normal
With the engine running
ON NG: wiring harness error or internal circuit error
Replace the oil pressure switch.

Flash code 8 proportional injection pump solenoid (control rack)
Related DTC
P1212/4 Proportional injection pump solenoid error (voltage too low)
DTC P1213/3 Proportional injection pump solenoid error (voltage too high)
P1211/7 Proportional injection pump solenoid, mechanical error

Error is
displayed.
[Check items]: error code
Error diagnosis
1. Check the resistance NG

Replace the sensor.
of the proportional solenoid
coil (solenoid only).
2. Check the
NG 3. Check the wiring NG Replace the wiring
resistance of the harness for harness.
proportional solenoid continuity.
coil (solenoid + wiring
harness).
OK
OK
Replace the E-ECU or the
4. Check the NG injection pump.
proportional solenoid
for movement.
OK
Replace the E-ECU.

Wiring diagram
Check points
Proportional
Battery
solenoid relay of
injection pump Main relay K1
Fuse F11
Fuse F2 50 A
Ignition ON
Fuse F3 10 A
Connectors on solenoid side
Connector on wiring harness side
Proportional injection
pump solenoid
Proportional solenoid
position sensor

Work description 1. Check the coil resistance of the proportional injection pump solenoid (solenoid
only):
Disconnect the wiring harness from the proportional injection pump solenoid.
Measure the resistance between terminals A and B of the proportional injection pump
solenoid by means of a multimeter.
(REF) coil resistance value of standard Yanmar proportional injection pump
solenoid.
Coils A B 1 10 %
NG Replace the injection pump.

With the proportional injection pump solenoid and the wiring harness connected, check the resistance between
OK solenoid terminals A and B. -> Next: [2. Check the coil resistance of the proportional injection pump solenoid (relay
+ solenoid):]
2. Check the coil resistance of the proportional injection pump solenoid (solenoid +
wiring harness):
Connect the proportional injection pump solenoid and the wiring harness, and
disconnect the E-ECU and the proportional injection pump solenoid from the wiring
harness.
Measure the resistance between the E-ECU connector terminal E42 on the wiring
harness side and the relay contact of the proportional injection pump solenoid E18 on
the output side by means of a multimeter.
*See above, (REF) coil resistance value of standard Yanmar engine speed sensors.
OK Check the solenoid for movement by means of the diagnosis tool. -> Next: [4. Check the proportional injection
pump solenoid for movement:]

Disconnect the proportional injection pump solenoid and the E-ECU from the wiring
harness.
Solenoid coil line (output side) E42 Yes OK: normal
Between solenoid coil (input) and Yes OK: normal
relay contact of proportional injection pump solenoid (output) No NG: open wiring harness
Between relay contact of proportional injection pump Yes OK: normal
solenoid (output)
and main relay contact (output) No NG: open wiring harness
NG

4. Check the proportional injection pump solenoid for movement:

Connect all connectors (proportional injection pump solenoid, E-ECU).
With the diagnosis tool Diagnosis test: active control, carry out the position control for
the proportional solenoid. Place the control rack in any position within the settings.
Then check whether the proportional injection pump solenoid has moved to the control
rack position that has been set.
OK Check the solenoid for movement by means of the diagnosis tool. -> Next: [4. Check the proportional injection
pump solenoid for movement:]

Flash code 1-6 main relay
Related DTC
DTC P0686/4 Main relay error

Error is
displayed.
Ignition OFF
[Check items]: log onto the diagnosis tool

Cannot log in -> normal
B. Log onto diagnosis
Can log in -> main relay contact stuck?
tool.
Main relay coil output short-circuited to GND?
Error diagnosis

contact for
continuity.
OK

coil resistance
(relay only).
OK
3. Check the relay OK 4. Check the wiring NG Replace the wiring harness.
coil resistance (relay harness for
+ wiring harness). continuity.
NG OK Replace the E-ECU.

Wiring diagram
Check points
Relay-side connector
Battery
Lock-up relay K1
Fuse F11
Fuse F2 5 A
Ignition ON
Connector on wiring harness

side
Fuse F3 10 A

Disconnect the E-ECU main relay from the wiring harness.
Check the continuity between terminals A and B on the relay side by means of a
multimeter.
NG Replace the E-ECU main relay.
OK Check the resistance of the E-ECU main relay coil. -> Next: [2. Check the resistance value of the relay coil (relay
only):]
2. Check the relay coil resistance value (relay only):

Disconnect the E-ECU main relay from the wiring harness.
multimeter.
Terminal C Terminal D Existing (*)
OK if both are normal
Terminal D Terminal C Infinite (*)
Terminal C Terminal D
Infinite (*) NG: internal relay circuit error
Terminal D Terminal C
NG Replace the E-ECU main relay.
OK With the E-ECU main relay and the wiring harness connected, check the relay coil resistance. -> Next: [3. Check
the resistance value of the relay coil (relay + wiring harness side):
3. Check the resistance value of the relay coil (relay + wiring harness side):
Connect the E-ECU main relay onto the wiring harness.
Measure the resistance between the battery cable (+) and the E-ECU connector E34
on the wiring harness side.
Battery (+) line E34 Existing (*)
OK: normal
E34 Battery (+) line Infinite (*)
Battery (+) line E34
Infinite (*) NG: wiring harness error
E34 Battery (+) line



Disconnect the E-ECU main relay and the E-ECU from the wiring harness.
Between relay coil (output side) E34 No OK: normal
and GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
Between relay contact (output side) No OK: normal
E48 and E43/battery (+) Yes NG: wiring harness short-circuited with power supply
NG
Connect all connectors (E-ECU main relay, E-ECU) and check again whether all errors have been detected with
OK the diagnosis tool Error code: error display.
Replace the E-ECU.

Flash code 1-2 CAN (Controller Area Network) communication
Related DTC
DTC U0001/12 CAN communication error

Error is
[Check Items]: battery voltage
displayed.
12 [V] or equivalent battery voltage < 16 [V]
-> open CAN wiring?
B. Check the
detected value to 10.5 [V] battery voltage <12 [V] or equivalent
assess the cause -> Battery voltage drop?
of the error. Another ECU deactivated?
Error diagnosis
NG
1. Check battery voltage Charge or replace battery.
(diagnosis tool).
OK
2. Check the wiring NG

harness for continuity.
OK Check other ECUs for movement or

replace the E-ECU.

Work description 1. Battery voltage check:

With the engine running, connect the diagnosis tool and log in to the diagnosis tool.
Check the battery voltage with the diagnosis tool Diagnosis test: pulse/analog etc..
OK
Approx.12 [V] battery voltage < 16 [V] Check the wiring harness for continuity.
(normal range)
Charge or replace battery.
10.5 [V] battery voltage < approx.12 [V] NG
Check the movement of other E-ECUs.
Charge or replace battery.

NG

CAN wiring (high side) E40 Yes OK: normal
(between E-ECU and sensor connector) No NG: open wiring harness
CAN wiring (low side) E39 Yes OK: normal
(between E-ECU and sensor connector) No NG: open wiring harness
Between E39/E40 and No OK: normal
GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
NG
OK
Replace the E-ECU.


Hydraulic system
Hydraulic system
Hydraulic system
5 Hydraulic system
The hydraulic system is a closed system.
5.1 Rexroth A20 VG45 hydraulic pump

Double variable displacement pump + 2 gear pumps
Gear pump unit Variable displacement pump unit
Pos. Description
1 Tank suction side
2 Pilot control port right, forwards driving
3 Control spool
4 Front right hydraulic motor
5 Rear right hydraulic motor
6 Front left hydraulic motor
7 Rear left hydraulic motor
8 Boost pump supply
9 P supply, drive (left-hand side joystick)
10 Pilot control port left, forwards driving
11 Leak oil

Hydraulic system
I I
Variable displacement pump unit Gear pump unit
Pos. Description
A Pilot control port
B Control spool
C Control valve (speed-sensitive)
D P supply (right-hand side joystick)
E High pressure limiting valve
F Pilot control port
G Gear pump output control valve supply
Gear pump output work hydraulics/boost pressure supply (701s)
H
Gear pump output work hydraulics supply/3rd control circuit supply (701sp)
I Mechanical zero-position setting
J Boost pressure valve (low-pressure valve)

Hydraulic system
Pump unit: exploded view
7
6
2
3
E
J
4
Pos. Description
1 Pump housing
2 Bearing flange
3 Power train (rotation to the left)
4 Power train (rotation to the right)
5 Hydraulic adjustment
6 Axial piston
7 Roller bearing
C Control valve (speed-sensitive)
E High pressure limiting valve
J Boost pressure valve (low-pressure valve)

Hydraulic system
Pump distribution
Model 701s Model 701sp

Variable displacement pump Drive section Drive section
Pump 1 Supply of left-hand side hydraulic motors Supply of left-hand side hydraulic motors
Pump 2 Supply of right-hand side hydraulic motors Supply of right-hand side hydraulic motors
Pump 3 Main valve block supply Main valve block supply
Pump 4 Boost pump Section 3rd control circuit Power Flow
Pump 5 ----- Boost pump supply
Pump 4 Pump 3 Variable displacement pump

Pump 2 Pump 1
Pump 4 (19 cm3/ Pump 3 (22 cm3/ Variable displacement pump

1.16 cu. in.) 1.34 cu. in.)
Pump 2 (38.5 cm3/2.35 cu. in.) Pump 1 (38.5 cm3/2.35 cu. in.)
Boost pump/supply Control valve supply Supply of left-hand side hydraulic
of Supply of right-hand side hydraulic motors motors
3rd control circuit
Power Flow (701sp)
Pump 5 (701sp option)
Pump 5 (19 cm3/1.16 cu. in.) (701sp option)

Boost pump supply
A...position of SP pump

Hydraulic system
5.2 Main valve block

Ports
1
P
Pressure limiting valve
A1 B1 Bucket
A2 B2 Loader unit
4 3
B3 Auxiliary hydraulics
A3
Legend Control lines

Port Legend Controlled via
Right-hand side joystick (to
A1 Bucket ram control (extend)
the right)
Right-hand side joystick (to
B1 Bucket ram control (retract)
the left)
Right-hand side joystick
A2 Controls loader unit raising
(backwards)
Right-hand side joystick
B2 Controls loader unit lowering
(forwards)
A3 Auxiliary hydraulics control (left) Auxiliary hydraulics pedal
B3 Auxiliary hydraulics control (right) Auxiliary hydraulics pedal
Pump/tank lines
Port Legend
P Gear pump port
T Tank line via pressure filter to boost pressure port of pump
Valve Legend
1 Pressure limiting valve
2 Non-return valve
3 Secondary pressure limiting valve
4 Anticavitation valve

Hydraulic system
Main valve block diagram
Pressure limiting valve

1
Bucket
2
3
Loader unit
4 2
Auxiliary hydraulics
Pos. Description
A Gear pump input
B Output via reflux filter to tank/boost pump port
1 Pressure limiting valve
2 Non-return valve
3 Secondary pressure limiting valve
4 Anticavitation valve

Hydraulic system
5.3 Hydraulic control

Control lever F1 drive control
F2 work hydraulics control
F2
F1
F1
Left-hand side control lever F1, right-hand side control lever F2
ISO controls H controls option

Actuation of left-hand side lever
Reaction Reaction
(F1)
Control lever (left) Machine turns to the left Lowers the loader unit
Control lever (right) Machine turns to the right Raises the loader unit
Control lever forwards Machine moves forwards Travelling drive to the front left
Control lever backwards Machine reverses Travelling drive to the rear left
Control lever fully to the front left into - Lowers the loader unit to the float
the engaged position position
Actuation of right-hand side lever
Reaction Reaction
(F2)
Control lever (left) Dumps out the attachment Tilts in the attachment
Control lever (right) Tilts in the attachment Dumps out the attachment
Control lever forwards Lowers the loader unit Travelling drive to the front right
Control lever backwards Raises the loader unit Travelling drive to the rear right
Control lever fully to the front right Lowers the loader unit to the float -
into the engaged position position

Hydraulic system
Joystick (left)
1
1-a
76 MA = 50 Nm
87
6
10
24
3
610
MA = 1,5 Nm
Loctite 262 4
3-a
MA = 40 Nm 5
3-d
2 3
1 4
9
19
MA = 50 Nm
6
11
21
10
20
MA = 18 Nm o

1 Handle 2 Rubber collar
3 Stud 4 Curved lever
5 Hexagon nut M12 6 Tappet
7 Universal joint 8 Retaining plate
9 Sealing kit 10 Shuttle valve plate (ISO only)
11 Shuttle valve plate sealing kit (ISO only)

Hydraulic system
ISO characteristic curves (left-hand side joystick): Ports:

Pressure (bar)
Ports 1 3
Joystick angle ()
Pressure (bar)
Ports 2 4
Joystick angle ()
Port Description Port Controlled via port

1 Reverse driving (ports E and F) 1 E and F
2 Turn to the left (ports C und F) 2 C and F
3 Forwards driving (ports C and D) 3 C and D
4 Turn to the right (ports D and E) 4 D and E
G Backup warning system pressure switch
P Pilot control pressure
T Tank line

Hydraulic system
Characteristic curve of H controls option (left-hand side joystick): Ports:

Pressure (bar)
Joystick
angle ()
Joystick
angle ()
Joystick
angle ()
x...angle from which the float position is active

1 Raise loader unit 1 1
2 Travelling drive to the rear left 2 2
3 Lower loader unit or float position 3 3
4 Travelling drive to the front left 4 4
T Tank line

Hydraulic system
Joystick (right)
MA = 40 Nm
67
MA = 50 Nm
2
8
7
3
6
10
6 MA = 1,5 Nm
10
Loctite 262 4
3-a
MA = 40 Nm 3-d
5
9
17-r
2 3 10
1 4
11
MA = 18 Nm
12
19
MA = 50 Nm

1 Handle 2 Rubber collar
3 Stud 4 Curved lever
5 Hexagon nut M12 6 Tappet
7 Universal joint with notch 8 Retaining plate
9 Solenoid 10 2-pin connector
11 Screw M4 x 8 12 Sealing kit

Hydraulic system
ISO characteristic curves (right-hand side joystick): Ports:

Pressure (bar)
Ports 1 2 4
Joystick angle ()
Pressure (bar)
Port 3
Joystick angle ()
x...angle from which the float position is active

1 Raises the loader unit 1 1
2 Tilts in the attachment 2 2
3 Lowers the loader unit/lowers it to float position 3 3
4 Dumps out the attachment 4 4
T Tank line

Hydraulic system
Characteristic curve of H controls option (right-hand side joystick):

Pressure (bar)
Ports:
Joystick
angle ()
Joystick
angle ()

1 Travelling drive to the rear right 1 1
2 Tilts in the attachment 2 2
3 Travelling drive to the front right 3 3
4 Dumps out the attachment 4 4
T Tank line

Hydraulic system
Auxiliary hydraulics control

Control valve (rocker pedal version)
1 2
3
Additional controls (exploded view)
Pos. Description
1 Rocker pedal
2 Control linkage
3 Cover
4 Lock unit
Function
Main valve block segment (A) is actuated by means of a control linkage (2) mounted on
control pedal (4). Pressing the pedal forwards or backwards actuates the auxiliary
hydraulics segment on the main valve block.
Danger!
Unintentional actuation of the auxiliary hydraulics pedal
A Always lock the pedal if it is not needed.
Additional hydraulic segment
Adjustment The control pedal is set by means of the control linkage threads. At maximum actuation in
either direction, the pedal must have its maximum control effect on the main valve block
segment.

Hydraulic system

Function General
The diesel engine permanently drives two axial-piston variable displacement pumps
whose oil flow is sent to the right and left-hand side drive motors.
Driving:
Actuating the control lever causes the swash plate of the pump to swivel.
Swash plate swivel creates high pressure at outputs A or B (depends on the direction in
which the control lever is actuated).
This pressure drop has its effect on the motors connected in series and drives the motors
via the oil flow (forwards or reverse, depending on the direction in which the control lever is
actuated).
Brakes:
Moving the control levers to neutral interrupts the oil flow. There is no pressure drop at the
motors. This creates a generator effect, i.e. the motor tries to keep on turning and brakes
itself in doing so (hydrostatic brake).
Parking brake:
The gear pump 19 cm (1.16 cu. in.) doubles up as the boost pump for the double variable
displacement pump (tandem pump). Boost pressure is 25 bar (363 psi). This pressure also
opens the brake discs in the gearbox. Switching off the diesel engine causes this pressure
to drop and to enable the brake. If the engine is running, the brake lever must be actuated
for fully intentional braking as usual.
Drive (exploded view)
A
Pos. Description
A Hydraulic motor
Front drive gear
B
Rear drive gear (braked)
1 Cheese-head screw M14x60
2 Nord-Lock washer NL14
3 Hexagon nut M14
Tightening torques:
Hydraulic motor drive gear: 110 Nm (81 ft. lbs.)
Drive gear chassis: 180 Nm (133 ft. lbs.)

Hydraulic system
Example: front right hydraulic motor
C B
D A
For hydraulic motors on left side of machine For hydraulic motors on right side of machine
A Brake pressure line to rear hydraulic motor A Brake pressure line to rear hydraulic motor
B Brake pressure line to right-hand side hydraulic motor B Brake pressure line to left-hand side hydraulic motor
C Connection with rear hydraulic motor C Connection with rear hydraulic motor
D Pressure line from pump 1 D Pressure line from pump 2
E Pressure line from flush valve E Pressure line from flush valve

5-18
Front drive gear
Hydraulic system
25 Nm (18 ft. lbs.)

5
1
35 Nm (26 ft. lbs.)
2
8 12 Nm (6 9 ft.
2
25 Nm (18 ft. Pos. Description
1 Bearing
3
2 Bearing
3 Studs
4 4 Wheel nuts M14x1.5
175 Nm (129 ft. 5 Drive gear sealing kit
150 Nm (111 ft. lbs.)

7
Rear drive gear (braked)

7
25 Nm (18 ft. lbs.)

5
1 25 Nm (18 ft. lbs.)
6
8 12 Nm (6 9 ft.
150 Nm (111 ft. lbs.)
2
3
4 Pos. Description
1 Bearing
35 Nm (26 ft. lbs.) 2 Steel washer
3 Washer
4 Bearing
5 Studs
6 Wheel nut M14x1.5
7 Drive gear sealing kit
5-19
Hydraulic system
5-20
6
Travelling drive layout

Hydraulic system
3 2 1
Pos. Description
1 Axial piston variable displacement pump
2 Flush valve
3 Front right travelling drive
4 Front left travelling drive 2
5 Rear left drive
6 Rear right drive
Danger!
These components and the oil are very hot after stopping the engine.
Danger of burns!
Always allow the oil to cool down before carrying out (repair) work.
4

Hydraulic system
5.5 Valves
3/3 directional valve (flush valve) Function
Mixes the oil. The valve mixes the cold and warm oil in the closed system as soon as the
pressure goes beyond the 13 bar (188.5 psi) of the pressure limiting valve.
The system has 2 flush valves installed in the travelling drive circuit.
Oil flow: 8 l/min (2.11 gpm)
2 1 1 2
Pos. Description
1 Input A
2 Input B
3 Output to radiator
4 Pressure limiting valve 13 bar (188.5 psi)

Hydraulic system
5.6 Parallel bucket lift

Function
Actuating parallel bucket lift keeps the bucket at the preset angle with respect to the
ground. The bucket does not need to be corrected manually when raising the loader unit
Bucket ram action is always automatically corrected in order to maintain the correct angle.
Lowering the bucket deactivates the parallel lift.
Hydraulic diagram
Port Legend
A Outgoing line to bucket
B Incoming line from bucket
C Outgoing line to loader unit
D Line to main valve block

Hydraulic system
Layout
3
2
Port Legend
1 Main valve block
2 Parallel lift valve
3 Work hydraulics pressure limiting valve

Hydraulic system
5.7 Breather filter

The breather filter is in charge of:
Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil
level) prevents the oil tank from inflating.
Pre-tension of the oil tank to the specified overpressure -> supports the variable
displacement pump's suction
Filtering the intake air
Opens at 0.4 bar (5.8 psi).
The breather filter is located under the tank cover, between the hydraulic filler inlet and the
fuel filler inlet.
Fig. 1: Breather filter position

Replace the breather filter according to the instructions in the maintenance plan see
Maintenance plan (overview) on page 3-5.
Notice!
The breather filter must be replaced at 1000 s/h under all circumstances.
Pos. Description
1 Filter fabric
2 Bleeder valve
Fig. 2: Breather filter

Hydraulic system
5.8 Troubleshooting in the hydraulic system

Hydraulic oil level too low
Defective pressure limiting valve on main valve block
Hydraulic system without function Spool is stuck.
Hose rupture (work hoses)
Defective connection on solenoid valve
Driving without actuating the control levers, more
Misalignment of neutral position slackened fastening nut
propulsion on one side
Brake is released. Defective brake valve
Quickhitch couplings not connected correctly
Hydraulic hammer does not work correctly. Hydraulic oil quantity too high/too low
Hydraulic oil pressure too high/too low

Hydraulic system
5.9 Hydraulics diagram A4 (701s)
5
6
2
8
4
3
23
10
9
11
1
23
12
13
23
16
15
14
18
17
22
19
20
21

Hydraulic system
5.10 Hydraulics diagram (legend) (701s)
Pos. Description
1 Diesel engine
2 Variable displacement pump
3 Hydraulic motors (right)
4 Hydraulic motors (left)
5 Left-hand side control lever with shuttle
valve block
6 Control lever (right)
7 Pressure accumulator
8 Flush valve
9 Tank
10 Flush valve
11 Parking brake (up to DB00518)
12 Distributing block
13 Gear pumps
14 Main valve block
15 Oil cooler
16 Reflux filter
17 Stabiliser valve (option)
18 Stabilisers (option)
19 Auxiliary hydraulics
20 Loader unit ram
21 Bucket ram
22 Parallel lift
23 Measuring port
Pressure Spring-loaded Pressure Fixed displacement Variable displacement Fixed displacement Double variable
accumulator solenoid valve limiting valve motor motor pump displacement pump
Tank line Measuring Stop cock Non-return valve Throttle Oil cooler Filter Double-acting ram
port orifice

Hydraulic system
5.11 Hydraulics diagram A4 (701sp)
5
6
2
8
25
4
3
13
9
11
1
12
25
10
25
14
18
15
17
16
19
20
24
22
23
21

Hydraulic system
5.12 Hydraulics diagram (legend) (701sp)
Pos. Description
1 Diesel engine
5 Control lever (left)
8 Flush valve
9 Tank
10 Gear pumps
13 Flush valve
14 Power Flow valve
15 SP pump
16 Reflux filter
17 Oil cooler
18 Main valve block
22 Loader unit ram
23 Bucket ram
24 Parallel lift
25 Measuring port
Pressure Spring-loaded Pressure limiting Fixed displacement Variable displacement Fixed displacement Double variable
accumulator solenoid valve valve motor motor pump displacement pump
port orifice

Hydraulic system
5.13 Hydraulics diagram H-controls A4 (701sp)
5
6
2
8
12
4
3
13
9
10
11
12
12
14
18
12
15
17
16
19
20
24
21
23
22

Hydraulic system
5.14 Hydraulics diagram H controls (701sp) (legend)
Pos. Description
1 Diesel engine
8 Flush valve
9 Tank
10 Gear pumps
11 Brake valve
12 Measuring port
13 Flush valve
14 Power Flow valve
15 SP pump
16 Reflux filter
17 Oil cooler
18 Main valve block
22 Loader unit ram
23 Bucket ram
24 Parallel lift
port orifice

Hydraulic system
5.15 Hydraulics diagram H-controls with lock A4 (701sp)
7
25
5
6
2
8
12
4
3
13
9
1
10
11
12
12
12
14
15
18
17
16
19
20
24
21
23
22

Hydraulic system
5.16 Hydraulics diagram H controls with lock (701sp) (legend)
Pos. Description
1 Diesel engine
8 Flush valve
9 Tank
10 Gear pumps
11 Brake valve
12 Measuring port
13 Flush valve
14 Power Flow valve
15 SP pump
16 Reflux filter
17 Oil cooler
18 Main valve block
22 Loader unit ram
23 Bucket ram
24 Parallel lift
25 Work hydraulics lock
port orifice

Hydraulic system
Hydraulic system
5.13 Hydraulics diagram 701s A3 up to serial no. DB00708

1 Diesel engine 15 Oil cooler
2 Variable displacement pump 16 Reflux filter
3 Hydraulic motors (right) 17 Stabiliser valve (option) 8 6
4 Hydraulic motors (left) 18 Stabilisers (option)
5 Left-hand side control lever with shuttle valve block 19 Auxiliary hydraulics
6 Control lever (right) 20 Loader unit ram
7 Pressure accumulator 21 Bucket ram
8 Flush valve 22 Parallel lift
9 Tank 23 Measuring port
10 Flush valve
12 Measuring port
13 Gear pumps
14 Main valve block
23
22
14
21 3
9
13
20
10
17 5
19
15
23 4
18
12
16
11 23

Hydraulic system
5.14 Hydraulics diagram 701sp A3 up to serial no. DB00708

1 Diesel engine 15 SP pump
2 Variable displacement pump 16 Reflux filter
3 Hydraulic motors (right) 17 Oil cooler 8 6
4 Hydraulic motors (left) 18 Main valve block
5 Left-hand side control lever with 19 Stabilisers (option)
shuttle valve block 20 Stabiliser valve (option)
6 Control lever (right) 21 Auxiliary hydraulics
7 Pressure accumulator 22 Loader unit ram
8 Flush valve 23 Bucket ram
9 Tank 24 Parallel lift
10 Gear pumps 25 Measuring port
13 Flush valve
14 Power Flow valve 25
24
23 18
10 9 3
22
13
20 5
21
17
25
4
14
11
15 12
19
16 25

Hydraulic system
5.15 Hydraulics diagram 701s A3 from serial no. DC00713

1 Diesel engine 14 Main valve block
2 Variable displacement pump 15 Oil cooler
3 Hydraulic motors (right) 16 Reflux filter
4 Hydraulic motors (left) 17 Stabiliser valve (option) 6
5 Left-hand side control lever with shuttle valve block 18 Stabilisers (option) 8
6 Control lever (right) 19 Auxiliary hydraulics
7 Pressure accumulator 20 Loader unit ram
8 Flush valve 21 Bucket ram
9 Tank 22 Parallel lift
10 Flush valve
11 Brake valve
12 Measuring port
13 Gear pumps
12
22
14
3
21
9
13
20
10
17
19 5
15
4
18
12
16
11
12

Hydraulic system
5.16 Hydraulics diagram 701sp A3 from serial no. DC00713

1 Diesel engine 14 Power Flow valve
2 Variable displacement pump 15 SP pump
3 Hydraulic motors (right) 16 Reflux filter
4 Hydraulic motors (left) 17 Oil cooler
5 Left-hand side control lever with shuttle valve block 18 Main valve block 6
6 Control lever (right) 19 Stabilisers (option)
8
7 Pressure accumulator 20 Stabiliser valve (option)
8 Flush valve 21 Auxiliary hydraulics
9 Tank 22 Loader unit ram
10 Gear pumps 23 Bucket ram
11 Brake valve 24 Parallel lift
12 Measuring port
13 Flush valve
12
24
18
23 10 9 3
22
13
20
21 5
17
4
14
15 12
19 16
11
12

Hydraulic system
5.17 Hydraulics diagram H-controls 701 sp A3

Pos. Description
1 Diesel engine 8 6
8 Flush valve
9 Tank
10 Gear pumps 23 25 10
24
18
11 Brake valve
9
3
13 Flush valve
14 Power Flow valve
15 SP pump 2
16 Reflux filter
17 Oil cooler 1
18 Main valve block
19 Stabilisers (option) 22
20 Stabiliser valve (option) 7
22 Loader unit ram
23 Bucket ram
13
24 Parallel lift
20
25 Measuring port 21
17 5
4
14
15
16
19 25 25
12 25
11

Hydraulic system
5.18 Hydraulics diagram H-controls with lock 701 sp A3
Pos. Description
8 6
1 Diesel engine
8 Flush valve
9 Tank 26 10
10 Gear pumps 24 18
23
11 Brake valve 9 3 25
13 Flush valve
14 Power Flow valve
15 SP pump 2
16 Reflux filter
1
17 Oil cooler
18 Main valve block
22
20 Stabiliser valve (option) 7
22 Loader unit ram
23 Bucket ram 13
24 Parallel lift 20
21
25 Work hydraulics lock
17 5
26 Measuring port
4
14
15
16
26 26
19
12 26 11

Electrical system
Electrical system
Electrical system
6 Electrical system
6.1 Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current I Ampere (A)

Voltage U Volt (V)
Resistance R Ohm (W)
Mnemonic: U
R I
Output
Power P Watt (W)
P = U x I = R x I = U/R
6.2 Measuring equipment, measuring methods

Multifunction measuring device
Measurements of values (U, R, I, f)
Continuity test
Diode test
Calculate the measuring range using known data (P, U, R, I) and set before measuring.
Observe AC/DC basic setting.
AC = alternating current/voltage;
DC = direct current/voltage
Test device with acoustic and optical signal output
Continuity test in de-energised machine electrical system and of wiring harnesses

Electrical system
Measuring method multifunction measuring device

Measuring current (ignition switched on):
Black cable in COM socket (earth),
red cable in A socket or mA socket; connect in series to consumer.
Measuring voltage (ignition switched on):
red cable in V socket;
connect in parallel to consumer.
Measuring resistance (ignition switched off):
red cable in socket;
connect in parallel to consumer (see measuring voltage).
Test lamp
The test lamp is used to test lines and functions with the ignition switched on.
Line test (testing voltage):
Connect test lamp between test point (live cable) and machine earth or between test point
(earth line) and a live cable.
Functional check (testing current):
Connect test lamp between a connection on the consumer to be tested and the connection
line.

Electrical system
6.3 Cable colour coding
Colour Code
Black blk
Brown brn
Red red
Orange org
Yellow yel
Green grn
Blue blu
Violet vio
Grey gry
White wht
Pink pnk
6.4 Relays
Use, mode of function Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by microelectronics or
microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be
make-contact, break-contact or changeover switches. These undertake the actual
switching function.
Zero-centre relay
86 30 86 = Start of coil (control line)
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
85 87 87a 87 a= Break-contact switch output (load line)
Terminal description on relay

Electrical system
6.5 Electric units
Units
Alternator 12 V 55 Ah
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 88 Ah
Socket E.g. for cigarette lighter; 15 A max.
Fuse box in instrument panel
Rated current
Fuse Protected circuit
(A)
Tank sensor, starting relay, alternator, gauge
F2 10 A
element
F3 10 A Cutoff solenoid, fuel feed pump
F4 15A Valves
F5 10 A Rear working light, interior light
F6 10 A Front lights
F3 F5 F7 F9
F7 15A Turn indicators, horn
F8 10 A Hazard warning system, drive interlock
F2 F4 F6 F8 F9 15A Socket, rotating beacon
Main fuse box with relays

The main fuse box is located under the cab.
K7
Fuse no. Rated current (A) Protected circuit
F1 50A Main fuse
Relay no.
K7 Starting relay
F1
Relays
The relays are located underneath the fuse box in the cab.
Switching relay
K8 Protected circuit
K6 no.
K6 10 s preheating timer
K9 K10 K8 Cutoff timer
K9 Cutoff solenoid timer, pick-up contact
K 10 Turn indicator relay

Electrical system
6.6 Socket
The socket is located at the top right in the cab.
Voltage: 12 V
Fig. 1: Socket
6.7 Turn indicators (option)

see Road travel certification on page 7-12
Switch Function
To the left Left-hand side turn indicators
To the right Right-hand side turn indicators

Electrical system
6.8 Round indicating instrument overview
1
7
2 5
Pos. Description
1 Instrument panel console
2 Socket
3 Round indicating instrument
4 Preheating start switch (S1)
5 Switch ( see Switches: overview on page 6-7)
6 Interior light
7 Fuse box ( see Fuse box in instrument panel on page 6-4)

Electrical system
6.9 Switches: overview
7 8 1 2 3 4 5 6
Pos. Description
1 Front working light switch
2 Hazard warning system switch (option)
3 Rear working light switch (option)
4 Rotating beacon switch (option)
5 Parallel bucket lift switch (option)
6 Power Flow switch (option)
7 Parking brake
8 Locking the work hydraulics
6.10 Alternator
The alternator charges the battery and supplies direct current to electric consumers.
Pos. Description
1 Connection B (battery)
Connection P starting relay
2 Ignition (IG) telltale (12V) connection
Port L telltale (during service 12 V, otherwise 0 V)
1 2
Fig. 2: Alternator

Electrical system
6.11 Starter
2 Pos. Description
1 Connection S starting relay
2 Connection B battery
1
Fig. 3: Starter

Elektrische Anlage
Elektrische Anlage
Wiring diagrams and wiring harnesses
include all options.
6.12 Wiring diagram up to serial no. DB00708 (legend)

No. Description Section No. Description Section No. Description Section
B1 Fuel level indicator E7 H27 Rear left turn indicator F15 Option X4 9 pole connection drive interlock C/D1
B2 Horn C14 H28 Rotating beacon B14/15 Option X5 7 pole connection armrest/chassis D11/12
B3 Backup warning system D11 K6 Preheating time lag relay A2 X6 5 pole connection armrest switch C11/12
B14 Diodes (warning buzzer unit) E6 K7 Start high current relay E2 X7 6 pole connection joystick (right) C/D 11
E1 Front right parking light C14 Option K8 Cutoff solenoid time lag relay A5 X8 6 pole connection joystick (left) D11
E2 Rear right light F13 Option K9 Cutoff solenoid switching relay A4 X10 15 pole connection round indicating B/C3
E3 Front left parking light C14 Option K10 Turn indicator relay C12 Option instrument
E4 Rear left light F15 Option M1 Starter F2 X11 2 pole connection Vario indicator B6
E5 High, low beam (right) C14 Option M9 Fuel pump F3 X12 9 pole connection cab C13/14
E6 High, low beam (left) C14 Option P1 Hour meter B1 X13 5 pole connection engine temperature A3
E7 Rear working light B14/15 Option R1 Glow plug F4 X14 2 pole connection automatic engine C/D 3
speed setting
E14 Interior light C10 Option S1 Preheating start switch A1
X15 1 pole connection drive alarm D/E 1
E16 Main fuse: starter, preheating F14 Option S2 Engine oil pressure switch F5
X16 3 pole connection drive alarm E2
F1 Main fuse E1 S3 Engine temperature switch F5
X19 1 pole connection socket F7
F2 Indicating instrument, alternator, tank A3 S4 Air filter pressure switch F10
sensor XE11 2 pole connection loader unit working E9
S5 Hydraulic oil pressure switch F6 light
F3 Cutoff solenoid, fuel feed pump A3/A4 S6 Hydraulic oil temperature switch F7 XS41 2 pole connection safe load indicator E8
F4 Valves A8 S7 Hydraulic oil level switch (701) F7 Y1 Cutoff solenoid F4
F5 Interior light A10 S10 Parking brake switch (spare) B8/9 Y3 High-speed solenoid valve F9
F6 Front lights A11 S11 Parking brake pressure switch F9 Y13 Solenoid valve for safety valve F11
F7 Turn indicators A12 S12 Turn indicator switch (501) C11 Option Y14 Solenoid valve automatic idling speed F9 Option
F8 Hazard warning system A13 S14 Light switch B11 Option setting
F9 Socket, rotating beacon A13 S16 Rear working light switch B10 Option Y15 Solenoid valve auxiliary hydraulics/ F10
G1 Alternator F2/F3 S18 Rotating beacon switch B13 Option swivel
G2 Battery F1 S19 Hazard warning switch C12 Y16 Solenoid valve additional control F10 Option
H1 High beam telltale C1 circuit
S26 Pump pressure switch E12
H2 Preheating telltale C1 Y17 Solenoid valve additional control F11 Option
S27 Backup warning system switch D12 Option circuit
H3 Engine temperature telltale C1 S29 Safety switch (701) C7 Y31 Solenoid valve air conditioning F12 Option
H4 Engine oil pressure telltale B1 S30 Horn tip switch D10
H5 Alternator charge function telltale B1 S32 Parallel lift switch B8 Option
H6 Air filter telltale B1 S33 Power Flow switch B9
Elektrische Anlage
H7 Hydraulic oil filter telltale B1 Y1 Cutoff solenoid F3
H8 Hydraulic oil temperature telltale B1 Y13 Safety valve (701) F11
H9 Overload telltale C1 Y29 Parallel lift solenoid F8 Option
H18 Parking brake telltale B1 Y32 Power Flow solenoid F9/10
H22 Turn indicator telltale C1 Y36 Parking brake solenoid D4-6
H24 Front right turn indicator H25 Option X19 Socket B14
H25 Rear right turn indicator F13 Option X3 2 pole main connection D0
6-10
6.13 Wiring diagram up to serial no. DB00708
6-11
Elektrische Anlage
+ nur bei 701

* nur bei 501
6.14 Wiring diagram from serial no. DC00713 (legend)

B1 Fuel level indicator E7 H24 Front right turn indicator H25 Option Y29 Parallel lift solenoid F8 Option
B2 Horn C14 H25 Rear right turn indicator F13 Option Y32 Power Flow solenoid F9/10
B3 Backup warning system D11 H27 Rear left turn indicator F15 Option Y36 Parking brake solenoid D4-6
B14 Diodes (warning buzzer unit) E6 H28 Rotating beacon B14/15 Option X19 Socket B14
E1 Front right parking light C14 Option K6 Preheating time lag relay A2 X3 2 pole main connection D0
E2 Rear right light F13 Option K7 Start high current relay E2 X4 9 pole connection drive interlock C/D1
E3 Front left parking light C14 Option K8 Cutoff solenoid time lag relay A5 X5 7 pole connection armrest/chassis D11/12
E4 Rear left light F15 Option K9 Cutoff solenoid switching relay A4 X6 5 pole connection armrest switch C11/12
E5 High, low beam (right) C14 Option K10 Turn indicator relay C12 Option X7 6 pole connection joystick (right) C/D 11
E6 High, low beam (left) C14 Option M1 Starter F2 X8 6 pole connection joystick (left) D11
E7 Rear working light B14/15 Option M9 Fuel pump F3 X10 15 pole connection round indicating B/C3
E14 Interior light C10 Option P1 Hour meter B1 instrument
E16 Main fuse: starter, preheating F14 Option R1 Glow plug F4 X11 2 pole connection Vario indicator B6
F1 Main fuse E1 S1 Preheating start switch A1 X12 9 pole connection cab C13/14
F2 Indicating instrument, alternator, tank A3 S2 Engine oil pressure switch F5 X13 5 pole connection engine A3
sensor temperature
S3 Engine temperature switch F5
F3 Cutoff solenoid, fuel feed pump A3/A4 X14 2 pole connection automatic engine C/D 3
S4 Air filter pressure switch F10
speed setting
F4 Valves A8 S5 Hydraulic oil pressure switch F6
X15 1 pole connection drive alarm D/E 1
F5 Interior light A10 S6 Hydraulic oil temperature switch F7
X16 3 pole connection drive alarm E2
F6 Front lights A11 S7 Hydraulic oil level switch (701) F7
X19 1 pole connection socket F7
F7 Turn indicators A12 S10 Parking brake switch (spare) B8/9
XE11 2 pole connection loader unit working E9
F8 Hazard warning system A13 S11 Parking brake pressure switch F9 light
F9 Socket, rotating beacon A13 S12 Turn indicator switch (501) C11 Option XS41 2 pole connection safe load indicator E8
G1 Alternator F2/F3 S14 Light switch B11 Option Y1 Cutoff solenoid F4
G2 Battery F1 S16 Rear working light switch B10 Option Y3 High-speed solenoid valve F9
H1 High beam telltale C1 S18 Rotating beacon switch B13 Option Y13 Solenoid valve for safety valve F11
H2 Preheating telltale C1 S19 Hazard warning switch C12 Y14 Solenoid valve automatic idling speed F9 Option
H3 Engine temperature telltale C1 S26 Pump pressure switch E12 setting
H4 Engine oil pressure telltale B1 S27 Backup warning system switch D12 Option Y15 Solenoid valve auxiliary hydraulics/ F10
H5 Alternator charge function telltale B1 S28 Work hydraulics lock D5/6 Option swivel
H6 Air filter telltale B1 S29 Safety switch (701) C7 Y16 Solenoid valve additional control F10 Option
Elektrische Anlage
H7 Hydraulic oil filter telltale B1 circuit
S30 Horn tip switch D10
H8 Hydraulic oil temperature telltale B1 Y17 Solenoid valve additional control F11 Option
S32 Parallel lift switch B8 Option
circuit
H9 Overload telltale C1 S33 Power Flow switch B9
Y31 Solenoid valve air conditioning F12 Option
H18 Parking brake telltale B1 Y1 Cutoff solenoid F3
H22 Turn indicator telltale C1 Y13 Safety valve (701) F11
6-12
Elektrische Anlage
6.15 Wiring diagram from serial no. DC00713

Elektrische Anlage
6.16 701s engine chassis wiring harness 1000147293 up to serial no. DB00708 (legend)
6-15
Elektrische Anlage
No. From Up to Colour mm No. From Up to Colour mm
1 M1/ starter G1/alternator red 10 33 XF1 X1/l engine/chassis connection blu 1
2 M1/ starter F1 main fuse red 10 34 XF1 B1/I fuel tank sensor blu 1
3 F1/main fuse X1/A engine/chassis connection red 4 35 XF1 G1/2 alternator blu 1
4 F1 main fuse X1/B engine/chassis connection red 4 36 Y1 cutoff solenoid X1/J engine/chassis connection blu/red 1
5 F1/main fuse K7/A start high current relay red 2.5 37 XF1 K7/1 start high current relay blu 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 38 Y1 M9 feed pump blu/red 1
7 R1/ glow plug X1/C engine/chassis connection brn 4 39 X3/3 joystick (right) X6 gry/blk 1
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
9 Y1/ cutoff solenoid GND earth blk 2.5 41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1 43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1 46 K7/5 start high current relay GND earth blk 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1 47 S4 air filter pressure switch GND earth blk 1
15 A S5/3 hydraulic oil pressure switch X5/4 lights blk 1 48 X3/2 backup warning system connection GND earth blk 1
16 S6 temperature switch X1/6 engine/chassis connection org/blu 1 50 GND earth X1/E engine/chassis connection blk 1.5
16B S6 temperature switch S7/1 hydraulic oil level switch org/wht 1 51 GND earth X1/F engine/chassis connection blk 1.5
17 X4/3 turn indicator connection GND earth blk 1 52A Y13/1 safety valve (701) X1/17 brn/wht 1
17A X4/3 turn indicator connection M9 fuel feed pump blk 1 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
17B X6 backup warning system connection M9 fuel feed pump blk 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
17C X6 backup warning system connection S7/2 hydraulic oil level switch blk 1 92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
18 B1/2 fuel tank sensor X1/7 engine/chassis connection vio/blk 1 93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
19 X2/1 joystick (right) X1/8 engine/chassis connection org 1 94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
20 Y29/1 parallel lift solenoid X1/9 engine/chassis connection gry/yel 1 95 S14/10 light switch S19/10 hazard warning system switch blk 1
21 S 26 pump pressure switch GND earth blk 1 96 S14/10 light switch S10/10 parking brake switch blk 1
21A S 26 pump pressure switch Y13.1/2 safety valve blk 1 97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
21B Y13/2 safety valve Y13.1/2 safety valve blk 1 98 DNG1 earth X19 socket blk 1
21C Y13/2 safety valve Y29 parallel lift solenoid blk 1 99 GND1 earth X8/7 lights connection blk 1
22 Y36/1 parking brake solenoid X1/10 engine/chassis connection blk/red 1 100 GND1 earth E14 interior light blk 1
23 S11 parking brake pressure switch Y36/2 parking brake solenoid blk 1 101 GND1 earth K8 cutoff solenoid time lag relay blk 1
24 S11 parking brake pressure switch X1/11 engine/chassis connection blk/red 1 102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
25 S11 parking brake pressure switch GND blk 1 103 K6 preheating time lag relay V1 diode blk 1
26 Y32/1 Power Flow solenoid X1/12 engine/chassis connection gry/brn 1 104 X7/3 terminal strip connection V1 diode blk 1
27 Y32/2 Power Flow solenoid GND blk 1 105 GND1 earth X9/3 rear lights connection blk 1
28 G1/3 alternator K7/6 high current relay blk/blu 1 106 X9/4 rear lights connection X9/3 rear lights connection blk 1
29 S4 air filter pressure switch X1/12 engine/chassis connection gry/blu 1 107 GND1 earth K10/87 turn indicator relay blk 1
31 X2/2 horn connection X1/H engine/chassis connection gry 1
32 X2/2 horn connection X3/1 backup warning system connection gry 1
6.17 701s engine chassis wiring harness 1000147293 up to serial no. DB00708

Power Flow
Starter Parking brake Parallel
Fuel tank lift Safety valve Safety valve
Safety Pressure switch
switch Parking brake
Pump
Joystick (right)
Oil filter
Oil tank
Alternator
Lights
Rear
Temperature
Hydraulic oil
Starter motor
Engine temperature
Elektrische Anlage
Engine Preheat
oil pressure Air filter
Fuel pump
Cutoff solenoid
Turn indicators
6-16
6.18 701s engine chassis wiring harness 1000183063 from serial no. DC00713 (legend)
6-17
Elektrische Anlage
1 M1/ starter G1/ alternator red 10 27 Y32/2 Power Flow solenoid GND blk 1
2 M1/ starter F1 main fuse red 10 28 G1/3 alternator K7/6 high current relay blk/blu 1
3 F1/ main fuse X1/A engine/chassis connection red 4 29 S4 air filter pressure switch X1/12 engine/chassis connection gry/blu 1
4 F1 main fuse X1/B engine/chassis connection red 4 31 X2/2 horn connection X1/H engine/chassis connection gry 1
5 F1/ main fuse K7/A start high current relay red 2.5 32 X2/2 horn connection X3/1 backup warning system connection gry 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 33 XF1 X1/l engine/chassis connection blu 1
7 R1/ glow plug X1/C engine/chassis connection brn 4 34 XF1 B1/I fuel tank sensor blu 1
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 35 XF1 G1/2 alternator blu 1
9 Y1/cutoff solenoid GND earth blk 2.5 36 Y1 cutoff solenoid X1/J engine/chassis connection blu/red 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 37 XF1 K7/1 start high current relay blu 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1 38 Y1 M9 feed pump blu/red 1
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1 39 X3/3 joystick (right) X6 gry/blk 1
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1 40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1 41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1 42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
15 A S5/3 hydraulic oil pressure switch X5/4 lights blk 1 43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1
16 S6 temperature switch X1/6 engine/chassis connection org/blu 1 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
16B S6 temperature switch S7/1 hydraulic oil level switch org/wht 1 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
17 X4/3 turn indicator connection GND earth blk 1 46 K7/5 start high current relay GND earth blk 1
17A X4/3 turn indicator connection M9 fuel feed pump blk 1 47 S4 air filter pressure switch GND earth blk 1
17B X6 backup warning system connection M9 fuel feed pump blk 1 48 X3/2 backup warning system connection GND earth blk 1
17C X6 backup warning system connection S7/2 hydraulic oil level switch blk 1 50 GND earth X1/E engine/chassis connection blk 1.5
18 B1/2 fuel tank sensor X1/7 engine/chassis connection vio/blk 1 51 GND earth X1/F engine/chassis connection blk 1.5
19 X2/1 joystick (right) X1/8 engine/chassis connection org 1 52A Y13/1 safety valve (701) X1/17 brn/wht 1
20 Y29/1 parallel lift solenoid X1/9 engine/chassis connection gry/yel 1 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
21 S 26 pump pressure switch GND earth blk 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
21A S 26 pump pressure switch Y13.1/2 safety valve blk 1
21B Y13/2 safety valve Y13.1/2 safety valve blk 1
21C Y13/2 safety valve Y29 parallel lift solenoid blk 1
22 Y36/1 parking brake solenoid X1/10 engine/chassis connection blk/red 1
23 S11 parking brake pressure switch Y36/2 parking brake solenoid blk 1
24 S11 parking brake pressure switch X1/11 engine/chassis connection blk/red 1
25 S11 parking brake pressure switch GND blk 1
26 Y32/1 Power Flow solenoid X1/12 engine/chassis connection gry/brn 1
6.19 701s engine chassis wiring harness 1000183063 from serial no. DC00713
Power Flow Parallel Safety Safety

Parking lift valve valve
Fuel tank Starter brake Parking
pressure brake
switch
50 A
Pump
Joystick (right) Emergency lowering
pressure switch
Oil filter
Oil tank
Alternator
Rear lights
Hydraulic oil
temperature switch
Starter
Engine temperature
Elektrische Anlage
Backup warning
system switch
Fuel pump
Cutoff Oil pressure Preheat Air filter
solenoid
Turn indicators
6-18
6.20 701sp engine chassis wiring harness 1000185442 from serial no. DC00713 (legend)
6-19
Elektrische Anlage
1 M1/ starter G1/ alternator red 10 34 XF1 B1/I fuel tank sensor blu 1
2 M1/ starter F1 main fuse red 10 35 XF1 G1/2 alternator blu 1
3 F1/ main fuse X1/A engine/chassis connection red 4 36 Y1 cutoff solenoid X1/J engine/chassis connection blu/red 1
4 F1 main fuse X1/B engine/chassis connection red 4 37 XF1 K7/1 start high current relay blu 1
5 F1/ main fuse K7/A start high current relay red 2.5 38 Y1 M9 feed pump blu/red 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 39 X3/3 joystick (right) X6 gry/blk 1
7 R1/ glow plug X1/C engine/chassis connection brn 4 40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1
9 Y1/cutoff solenoid GND earth blk 2.5 42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1 46 K7/5 start high current relay GND earth blk 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1 47 S4 air filter pressure switch GND earth blk 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1 48 X3/2 backup warning system connection GND earth blk 1
15 A S5/3 hydraulic oil pressure switch X5/4 lights blk 1 50 GND earth X1/E engine/chassis connection blk 1.5
16 S6 temperature switch X1/6 engine/chassis connection org/blu 1 51 GND earth X1/F engine/chassis connection blk 1.5
16B S6 temperature switch S7/1 hydraulic oil level switch org/wht 1 52A Y13/1 safety valve (701) X1/17 brn/wht 1
17 X4/3 turn indicator connection GND earth blk 1 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
17A X4/3 turn indicator connection M9 fuel feed pump blk 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
17B X6 backup warning system connection M9 fuel feed pump blk 1
17C X6 backup warning system connection S7/2 hydraulic oil level switch blk 1
18 B1/2 fuel tank sensor X1/7 engine/chassis connection vio/blk 1
19 X2/1 joystick (right) X1/8 engine/chassis connection org 1
20 Y29/1 parallel lift solenoid X1/9 engine/chassis connection gry/yel 1
21 S 26 pump pressure switch GND earth blk 1
27 Y32/2 Power Flow solenoid GND blk 1
28 G1/3 alternator K7/6 high current relay blk/blu 1
29 S4 air filter pressure switch X1/12 engine/chassis connection gry/blu 1
33 XF1 X1/l engine/chassis connection blu 1
6.21 701sp engine chassis wiring harness 1000185442 from serial no. DC00713
SERV-HB 701s sp EN Edition 2.0 *701s611.fm Parking

brake
Parking
pressure
brake ECU
Pump switch
Power
Flow Engine Fuel Parallel Safety Safety
electronics injection Starter Preheat lift valve valve
Fuel pump
tank
Hydraulic oil pressure Joystick (right) Emergency lowering

switch pressure switch
Alternator
Rear lights Oil tank

Engine temperature
Starter
sensor
Oil filter
Cold start valve

Hydraulic oil temperature
switch
Engine speed
potentiometer Engine speed
Fuel injection pump
Elektrische Anlage
Backup warning Backup warning
system switch system
Fuel pump
Preheat Air filter Exhaust gas recirculation

Turn indicators (EGR)
6-20
6.22 Switches wiring harness 1000139289 up to serial no. DB00708 (legend)
6-21
Elektrische Anlage
No. From To Colour No. From To Colour
3 X1/A engine/chassis connection S1/1 preheating start switch red 4 45A X10/2 round indicating instrument connection S14/6 light switch yel/blk 1
4 X1/A engine/chassis connection F8 hazard warning system red 4 50 X1/E engine/chassis connection GND1 blk 1.5
7 X1/C engine/chassis connection S1/1 preheating start switch brn 4 51 X1/F engine/chassis connection GND1 blk 1
7A S1/4 preheating start switch S1/9 preheating start switch brn 2.5 52 X10/2 round indicating instrument connection S29 safety switch brn/wht 1
7B S1/8 preheating start switch K6 preheating time lag relay brn 1 52A X1/17 engine/chassis connection S29 safety switch brn/wht 1
8 X1/D engine/chassis connection K9/87 cutoff solenoid switching relay wh/red 2.5 53 X1/18 engine/chassis connection B14/8 warning buzzer unit diodes brn/blk 1
10 X1/1 engine/chassis connection K6 preheating time lag relay wht 1 53A X10/6 round indicating instrument connection B14/2 warning buzzer unit diodes brn/blk 1
10A X7/4 terminal strip connection K6 preheating time lag relay wht 1 54 S14/8 light switch X8/3 lights connection yel/blk 1
10B X7/8 terminal strip connection S1/7 preheating start switch wht 1 55 S14/3 light switch X8/4 lights connection yel/grn 1
10C X7.1/4 terminal strip connection X7.1/8 terminal strip connection wht 1 56 S16/5 working light switch X9/1 rear lights connection yel/red 1
11 X1/2 engine/chassis connection B14/5 warning buzzer unit diodes pnk 1 57 S18/5 X9/2 rear lights connection vio 1
11A X10/8 round indicating instrument connection B14/5 warning buzzer unit diodes pnk 1 58 X10/12 round indicating instrument connection K6 preheating time lag relay gry/red 1
12 X1/3 engine/chassis connection B14/9 warning buzzer unit diodes blk/grn 1 60 F8 hazard warning system fuse K9/30 cutoff solenoid switching relay red 2.5
12A X10/14 round indicating instrument connection B14/4 warning buzzer unit diodes blk/grn 1 61 K9/85 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
13 X1/4 engine/chassis connection B14/6 warning buzzer unit diodes wht/gn 1 62 K9/86 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
13A X10/10 round indicating instrument connection B14/1 warning buzzer unit diodes wht/grn 1 63 S1/5 preheating start switch F3 cutoff solenoid fuse blu/red 1
14 X1/5 engine/chassis connection XS 5 org/wht 1 64 F2 indicator fuse X10/1 round indicating instrument connection blu 1
16 X1/6 engine/chassis connection XS 5 org/blu 1 65 F3 indicators and engine relay fuse X7/5 terminal strip connection blu/red 1
16 A X10/7 round indicating instrument connection XS 5 org/blk 1 65A X7/7 terminal strip connection X7/5 terminal strip connection blu/red 1
18 X1/7 engine/chassis connection X10/11 round indicating instrument connection vio/blk 1 65B X7.1/9 terminal strip connection X7.1/5 terminal strip connection blu/red 1
19 X1/8 engine/chassis connection X8/5 lights connection org 1 66 F4 valve fuse S33/1 Power Flow switch gry 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 67 S33/9 Power Flow switch S33/1 Power Flow switch gry 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 68 S33/9 Power Flow switch S32/1 parallel lift switch gry 1
24 X1/11 engine/chassis connection X10/9 round indicating instrument connection blk/red 1 69 S32/9 parallel lift switch S32/1 parallel lift switch gry 1
26 X1/12 engine/chassis connection S33/5 Power Flow switch gry/brn 1 70 S32/9 parallel lift switch S10/5 parking brake switch gry 1
29 X1/13 engine/chassis connection X10/3 round indicating instrument connection gry/blu 1 71 S10/9 parking brake switch S10/5 parking brake switch gry 1
30 S29 safety switch X7/1 terminal strip connection gry 1 73 F5 interior light fuse S16/1 working light switch blu/yel 1
30A F4 valves X7/6 terminal strip connection gry 1 74 S16/9 working light switch S16/1 working light switch blu/yel 1
30B X7.1/1 terminal strip connection X7.1/6 terminal strip connection gry 1 75 S16/9 working light switch S18/9 rotating beacon switch blu/yel 1
31 X1/H engine/chassis connection S29 safety switch gry 1 76 F5 interior light fuse E14 interior light blu/yel 1
33 X1/I engine/chassis connection F2 alternator, fuel level sensor, indicators, start blu 1 77 F6 front lights fuse S14/1 light switch yel 1
relay fuse 78 S14/2 light switch S14/1 light switch yel 1
36 X1/J engine/chassis connection X7/9 terminal strip connection blu/red 1 79 S14/2 light switch S14/9 light switch yel 1
36A V1 diode X7/9 terminal strip connection blu/red 1 80 F7 turn indicator fuse S19/7 hazard warning system switch grn 1
36B V1 diode K8 cutoff solenoid timer blu/red 1 81 S19/8 hazard warning system switch S19/7 hazard warning system switch grn 1
40 X1/G engine/chassis connection K10/C turn indicator relay brn/yel 1 82 F8 hazard warning system fuse S19/2 hazard warning system switch red/blu 1
40A S19/1 hazard warning system switch K10/C turn indicator relay brn/yel 1 83 S19/4 hazard warning system switch S19/6 hazard warning system switch grn/blu 1
40B S19/1 hazard warning system switch S12 turn indicator switch brn/yel 1 84 S19/4 hazard warning system switch K10/+ turn indicator relay grn/blu 1
41 X1/15 engine/chassis connection S19/3 hazard warning system grn/blk 1 85 K10/P turn indicator relay X10/15 round indicating instrument connection grn/yel 1
41A X8/1 lights switch S19/3 hazard warning system grn/blk 1 86 F9 socket fuse X19 socket red 1
41B X8/1 lights switch S12 turn indicator switch grn/blk 1 87 F9 socket fuse S18/1 rotating beacon switch red 1
43 X1/16 engine/chassis connection S19/5 hazard warning system grn/red 1 88 F8 hazard warning system fuse X7/2 terminal strip connection red 1
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 90 GND1 earth S33/10 Power Flow switch blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 91 S32/10 parallel lift switch S33/10 Power Flow switch blk 1
45 X1/14 engine/chassis connection S14/6 light switch yel/blk 1
6.23 Switches wiring harness 1000139289 up to serial no. DB00708

Cutoff
solenoid Turn indicators
Round indicating instrument
Hazard warning system
Rotating beacon
Working lights
Parking brake
Power Flow
Parallel lift
Lights
Rear lights
Interior
Lights
Ignition lock
Safety
switch
Lights Timer
Diode
Preheat Cutoff solenoid
Elektrische Anlage
Turn indicators
6-22
6.24 701s switches wiring harness 1000183064 from serial no. DC00713 (legend)
6-23
Elektrische Anlage
19 X1/8 engine/chassis connection X8/5 lights connection org 1 66 F4 valve fuse S33/1 High Flow switch gry 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 67 S33/9 High Flow switch S33/1 High Flow switch gry 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 68 S33/9 High Flow switch S32/1 parallel lift switch gry 1
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 90 GND1 earth S33/10 High Flow switch blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 91 S32/10 parallel lift switch S33/10 High Flow switch blk 1
No. From Up to Colour mm
92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
95 S14/10 light switch S19/10 hazard warning system switch blk 1
96 S14/10 light switch S10/10 parking brake switch blk 1
97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
98 DNG1 earth X19 socket blk 1
99 GND1 earth X8/7 lights connection blk 1
100 GND1 earth E14 interior light blk 1
101 GND1 earth K8 cutoff solenoid time lag relay blk 1
102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
103 K6 preheating time lag relay V1 diode blk 1
104 X7/3 terminal strip connection V1 diode blk 1
105 GND1 earth X9/3 rear lights connection blk 1
106 X9/4 rear lights connection X9/3 rear lights connection blk 1
107 GND1 earth K10/87 turn indicator relay blk 1
Elektrische Anlage
6-24
6.25 701s switches wiring harness 1000183064 from serial no. DC00713
6-25
Elektrische Anlage
Cutoff Turn
solenoid indicators
Work hydraulics lock
Rotating beacon
Round indicating
Hazard warning
Working lights
Parking brake
instrument
Power Flow
Parallel lift
system
Lights
Rear lights
Interior light
Ignition lock
Socket Safety switch
Timer
Diode Cutoff solenoid

Preheat
Lights
Turn indicators
6.26 701sp switches wiring harness 1000185268 from serial no. DC00713 (legend)

19 X1/8 engine/chassis connection X8/5 lights connection org 1 66 F4 valve fuse S33/1 High Flow switch gry 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 67 S33/9 High Flow switch S33/1 High Flow switch gry 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 68 S33/9 High Flow switch S32/1 parallel lift switch gry 1
Elektrische Anlage
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 90 GND1 earth S33/10 High Flow switch blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 91 S32/10 parallel lift switch S33/10 High Flow switch blk 1
6-26
6-27
Elektrische Anlage
No. From Up to Colour mm
92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
95 S14/10 light switch S19/10 hazard warning system switch blk 1
96 S14/10 light switch S10/10 parking brake switch blk 1
97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
98 DNG1 earth X19 socket blk 1
99 GND1 earth X8/7 lights connection blk 1
100 GND1 earth E14 interior light blk 1
101 GND1 earth K8 cutoff solenoid time lag relay blk 1
102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
103 K6 preheating time lag relay V1 diode blk 1
104 X7/3 terminal strip connection V1 diode blk 1
105 GND1 earth X9/3 rear lights connection blk 1
106 X9/4 rear lights connection X9/3 rear lights connection blk 1
107 GND1 earth K10/87 turn indicator relay blk 1
6.27 701sp switches wiring harness 1000185268 from serial no. DC00713

Work hydraulics lock
Round indicating Cutoff Turn indicators
Rotating beacon
instrument solenoid
Working lights
Parking brake
Power Flow
Parallel lift
ECU telltale Rear lights
Lights
Interior light
Ignition lock
Lights
Elektrische Anlage
Turn indicators
6-28
6.28 Wiring harness 1000147262: rear lights (option)
6-29
Elektrische Anlage
Rear right light
Numberplate light
Rear left light
No. Up to To Colour mm
15 X5/4 rear lights connection X15 earth blk 1
15 A E2/3 rear right light switch X15 earth blk 1
15B E4/3 rear left light switch X15 earth blk 1
15C E16 numberplate light X15 earth blk 1
42 X5/1 rear lights connection E4/1 rear left turn indicator switch grn/blk 1
44 X5/2 rear lights connection E2/1 rear right turn indicator switch grn/red 1
45 X5/4 rear lights connection X45 position light yel/blk 1
45A E2/2 rear right light switch X45 position light yel/blk 1
45b E4/2 rear left light switch X45 position light yel/blk 1
45C E16 numberplate light switch X45 position light yel/blk 1
Electrical system
Electrical system
Wiring diagrams and wiring harnesses include all

options.

Electrical system
6.29 Wiring diagram up to serial no. DB00708 (legend)

No. Description Section No. Description Section
B1 Fuel level indicator E7 K10 Turn indicator relay C12 Option
B2 Horn C14 M1 Starter F2
B3 Backup warning system D11 M9 Fuel pump F3
B14 Diodes (warning buzzer unit) E6 P1 Hour meter B1
E1 Front right parking light C14 Option R1 Glow plug F4
E2 Rear right light F13 Option S1 Preheating start switch A1
E3 Front left parking light C14 Option S2 Engine oil pressure switch F5
E4 Rear left light F15 Option S3 Engine temperature switch F5
E5 High, low beam (right) C14 Option S4 Air filter pressure switch F10
E6 High, low beam (left) C14 Option S5 Hydraulic oil pressure switch F6
E7 Rear working light B14/15 Option S6 Hydraulic oil temperature switch F7
E14 Interior light C10 Option S7 Hydraulic oil level switch (701) F7
E16 Main fuse: starter, preheating F14 Option S10 Parking brake switch (spare) B8/9
F1 Main fuse E1 S11 Parking brake pressure switch F9
F2 Indicating instrument, alternator, tank sensor A3 S12 Turn indicator switch (501) C11 Option
F3 Cutoff solenoid, fuel feed pump A3/A4 S14 Light switch B11 Option
F4 Valves A8 S16 Rear working light switch B10 Option
F5 Interior light A10 S18 Rotating beacon switch B13 Option
F6 Front lights A11 S19 Hazard warning switch C12
F7 Turn indicators A12 S26 Pump pressure switch E12
F8 Hazard warning system A13 S27 Backup warning system switch D12 Option
F9 Socket, rotating beacon A13 S29 Safety switch (701) C7
G1 Alternator F2/F3 S30 Horn tip switch D10
G2 Battery F1 S32 Parallel lift switch B8 Option
H1 High beam telltale C1 S33 Power Flow switch B9
H2 Preheating telltale C1 Y1 Cutoff solenoid F3
H3 Engine temperature telltale C1 Y13 Safety valve (701) F11
H4 Engine oil pressure telltale B1 Y29 Parallel lift solenoid F8 Option
H5 Alternator charge function telltale B1 Y32 Power Flow solenoid F9/10
H6 Air filter telltale B1 Y36 Parking brake solenoid D4-6
H7 Hydraulic oil filter telltale B1 X19 Socket B14
H8 Hydraulic oil temperature telltale B1
H9 Overload telltale C1
H18 Parking brake telltale B1
H22 Turn indicator telltale C1
H24 Front right turn indicator H25 Option
H25 Rear right turn indicator F13 Option
H27 Rear left turn indicator F15 Option
H28 Rotating beacon B14/15 Option
K6 Preheating time lag relay A2
K7 Start high current relay E2
K8 Cutoff solenoid time lag relay A5 Wiring diagram (legend)
K9 Cutoff solenoid switching relay A4

Electrical system
6.30 Wiring diagram up to serial no. DB00708
+ nur bei 701

* nur bei 501

Electrical system
6.31 Wiring diagram from serial no. DC00713 (legend)

B1 Fuel level indicator E7 K8 Cutoff solenoid time lag relay A5 X10 15 pole connection round indicating B/C3
B2 Horn C14 K9 Cutoff solenoid switching relay A4 instrument
B3 Backup warning system D11 K10 Turn indicator relay C12 Option X11 2 pole connection Vario indicator B6
B14 Diodes (warning buzzer unit) E6 M1 Starter F2 X12 9 pole connection cab C13/14
E1 Front right parking light C14 Option M9 Fuel pump F3 X13 5 pole connection engine temperature A3
E2 Rear right light F13 Option P1 Hour meter B1 X14 2 pole connection automatic engine speed C/D 3
E3 Front left parking light C14 Option R1 Glow plug F4 setting
E4 Rear left light F15 Option S1 Preheating start switch A1 X15 1 pole connection drive alarm D/E 1
E5 High, low beam (right) C14 Option S2 Engine oil pressure switch F5 X16 3 pole connection drive alarm E2
E6 High, low beam (left) C14 Option S3 Engine temperature switch F5 X19 1 pole connection socket F7
E7 Rear working light B14/15 Option S4 Air filter pressure switch F10 XE11 2 pole connection loader unit working light E9
E14 Interior light C10 Option S5 Hydraulic oil pressure switch F6 XS41 2 pole connection safe load indicator E8
E16 Main fuse: starter, preheating F14 Option S6 Hydraulic oil temperature switch F7 Y1 Cutoff solenoid F4
F1 Main fuse E1 S7 Hydraulic oil level switch (701) F7 Y3 High-speed solenoid valve F9
F2 Indicating instrument, alternator, tank sensor A3 S10 Parking brake switch (spare) B8/9 Y13 Solenoid valve for safety valve F11
F3 Cutoff solenoid, fuel feed pump A3/A4 S11 Parking brake pressure switch F9 Y14 Solenoid valve automatic idling speed F9 Option
F4 Valves A8 S12 Turn indicator switch (501) C11 Option setting
F5 Interior light A10 S14 Light switch B11 Option Y15 Solenoid valve auxiliary hydraulics/swivel F10
F6 Front lights A11 S16 Rear working light switch B10 Option Y16 Solenoid valve additional control circuit F10 Option
F7 Turn indicators A12 S18 Rotating beacon switch B13 Option Y17 Solenoid valve additional control circuit F11 Option
F8 Hazard warning system A13 S19 Hazard warning switch C12 Y31 Solenoid valve air conditioning F12 Option
F9 Socket, rotating beacon A13 S26 Pump pressure switch E12
G1 Alternator F2/F3 S27 Backup warning system switch D12 Option
G2 Battery F1 S28 Work hydraulics lock D5/6 Option
H1 High beam telltale C1 S29 Safety switch (701) C7
H2 Preheating telltale C1 S30 Horn tip switch D10
H3 Engine temperature telltale C1 S32 Parallel lift switch B8 Option
H4 Engine oil pressure telltale B1 S33 Power Flow switch B9
H5 Alternator charge function telltale B1 Y1 Cutoff solenoid F3
H6 Air filter telltale B1 Y13 Safety valve (701) F11
H7 Hydraulic oil filter telltale B1 Y29 Parallel lift solenoid F8 Option
H8 Hydraulic oil temperature telltale B1 Y32 Power Flow solenoid F9/10
H9 Overload telltale C1 Y36 Parking brake solenoid D4-6
H18 Parking brake telltale B1 X19 Socket B14
H22 Turn indicator telltale C1 X3 2 pole main connection D0
H24 Front right turn indicator H25 Option X4 9 pole connection drive interlock C/D1
H25 Rear right turn indicator F13 Option X5 7 pole connection armrest/chassis D11/12
H27 Rear left turn indicator F15 Option X6 5 pole connection armrest switch C11/12
H28 Rotating beacon B14/15 Option X7 6 pole connection joystick (right) C/D 11 Wiring diagram (legend)
K6 Preheating time lag relay A2 X8 6 pole connection joystick (left) D11
K7 Start high current relay E2

Electrical system
6.32 Wiring diagram from serial no. DC00713

Electrical system

Electrical system
6.33 701s engine chassis wiring harness 1000147293 up to serial no. DB00708 (legend)
1 M1/ starter G1/ alternator red 10 39 X3/3 joystick (right) X6 gry/blk 1
2 M1/ starter F1 main fuse red 10 40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
3 F1 main fuse X1/A engine/chassis connection red 4 41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1
4 F1 main fuse X1/B engine/chassis connection red 4 42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
5 F1 main fuse K7/A start high current relay red 2.5 43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
7 R1/ glow plug X1/C engine/chassis connection brn 4 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 46 K7/5 start high current relay GND earth blk 1
9 Y1/cutoff solenoid GND earth blk 2.5 47 S4 air filter pressure switch GND earth blk 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 48 X3/2 backup warning system connection GND earth blk 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1 50 GND earth X1/E engine/chassis connection blk 1.5
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1 51 GND earth X1/F engine/chassis connection blk 1.5
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1 52A Y13/1 safety valve (701) X1/17 brn/wht 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
15 A S5/3 hydraulic oil pressure switch X5/4 lights blk 1
16 S6 temperature switch X1/6 engine/chassis connection org/blu 1
16B S6 temperature switch S7/1 hydraulic oil level switch org/wht 1
17 X4/3 turn indicator connection GND earth blk 1
17A X4/3 turn indicator connection M9 fuel feed pump blk 1
34 XF1 B1/I fuel tank sensor blu 1
35 XF1 G1/2 alternator blu 1
36 Y1 cutoff solenoid X1/J engine/chassis connection blu/red 1
37 XF1 K7/1 start high current relay blu 1
38 Y1 M9 feed pump blu/red 1 Engine chassis wiring harness 1000147293 (legend)

Electrical system
6.34 701s engine chassis wiring harness 1000147293 up to serial no. DB00708
Power Flow
Starter Parallel
Parking brake Safety valve Safety valve
Fuel tank lift
Safety Pressure switch
switch Parking brake
Pump
Joystick (right)
Oil filter
Oil tank
Alternator
Rear lights
Temperature
Hydraulic oil
Starter
Engine temperature
Fuel pump
Engine
Preheat
oil pressure
Air filter
Cutoff solenoid
Turn indicators

Electrical system
6.35 701s engine chassis wiring harness 1000183063 from serial no. DC00713 (legend)
1 M1/ starter G1/ alternator red 10 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
2 M1/ starter F1 main fuse red 10 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
3 F1/ main fuse X1/A engine/chassis connection red 4 46 K7/5 start high current relay GND earth blk 1
4 F1 main fuse X1/B engine/chassis connection red 4 47 S4 air filter pressure switch GND earth blk 1
5 F1/ main fuse K7/A start high current relay red 2.5 48 X3/2 backup warning system connection GND earth blk 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 50 GND earth X1/E engine/chassis connection blk 1.5
7 R1/ glow plug X1/C engine/chassis connection brn 4 51 GND earth X1/F engine/chassis connection blk 1.5
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 52A Y13/1 safety valve (701) X1/17 brn/wht 1
9 Y1/cutoff solenoid GND earth blk 2.5 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1
38 Y1 M9 feed pump blu/red 1
39 X3/3 joystick (right) X6 gry/blk 1
40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1 Engine chassis wiring harness 1000183063 (legend)
42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1

Electrical system
6.36 701s engine chassis wiring harness 1000183063 from serial no. DC00713
Power Flow Parking Parallel Safety valve Safety valve

Starter brake Parking lift
Fuel tank pressure brake
switch
50 A
Pump
Joystick (right)
Emergency lowering pressure
Oil filter switch
Oil tank
Alternator
Rear lights
Hydraulic oil temperature

switch
Starter
Engine temperature
Backup warning
system switch
Fuel pump
Cutoff Oil pressure Preheat Air filter

solenoid
Turn indicators

Electrical system
6.37 701sp engine chassis wiring harness 1000185442 from serial no. DC00713 (legend)
1 M1/ starter G1/ alternator red 10 44 X4/4 turn indicator connection X5/2 rear lights grn/red 1
2 M1/ starter F1 main fuse red 10 45 X5/3 rear lights X1/14 engine/chassis connection yel/blk 1
3 F1/ main fuse X1/A engine/chassis connection red 4 46 K7/5 start high current relay GND earth blk 1
4 F1 main fuse X1/B engine/chassis connection red 4 47 S4 air filter pressure switch GND earth blk 1
5 F1/ main fuse K7/A start high current relay red 2.5 48 X3/2 backup warning system connection GND earth blk 1
6 K7/B start high current relay M1/ starter wht/brn 2.5 50 GND earth X1/E engine/chassis connection blk 1.5
7 R1/ glow plug X1/C engine/chassis connection brn 4 51 GND earth X1/F engine/chassis connection blk 1.5
8 Y1/ cutoff solenoid X1/D engine/chassis connection wht/red 2.5 52A Y13/1 safety valve (701) X1/17 brn/wht 1
9 Y1/cutoff solenoid GND earth blk 2.5 52B Y13/1 safety valve (701) Y13.1/1 safety valve (701) brn/wht 1
10 K7/3 start high current relay X1/1 engine/chassis connection wht 1 53 S26 pump pressure switch X1/18 engine/chassis connection brn/blk 1
11 G1/1 alternator X1/2 engine/chassis connection pnk 1
12 S3 engine temperature switch X1/3 engine/chassis connection blk/grn 1
13 S2 engine oil pressure switch X1/4 engine/chassis connection wht/grn 1
14 S5/1 hydraulic oil pressure switch X1/5 engine/chassis connection org/wht 1
15 S5/3 hydraulic oil pressure switch GND earth blk 1
38 Y1 M9 feed pump blu/red 1
39 X3/3 joystick (right) X6 gry/blk 1
40 X4/1 turn indicator connection X1/G engine/chassis connection brn/yel 1
41 X4/2 turn indicator connection X1/15 engine/chassis connection grn/blk 1 Engine chassis wiring harness 1000185442 (legend)
42 X4/2 turn indicator connection X5/1 rear lights grn/blk 1
43 X4/4 turn indicator connection X1/16 engine/chassis connection grn/red 1

Electrical system
6.38 701sp engine chassis wiring harness 1000185442 from serial no. DC00713
Parking
brake
pressure Parking
switch brake ECU
Pump
Power
Flow Parallel lift Safety valve Safety valve
Engine Fuel injection
electronics Starter Preheat
pump
Fuel
tank
Hydraulic oil pressure Joystick (right) Emergency lowering

switch pressure switch
Alternator
Rear lights Oil tank

Engine temperature
Starter sensor
Cold start valve

Engine speed Hydraulic oil temperature
potentiometer switch
Engine speed
Fuel injection pump

Backup warning Backup warning
system switch system
Fuel pump
Preheat Air filter Exhaust gas recirculation

Turn indicators (EGR)

Electrical system
6.39 Switches wiring harness 1000139289 up to serial no. DB00708 (legend)

No. Up to To Colour No. Up to To Colour
3 X1/A engine/chassis connection S1/1 preheating start switch red 4 56 S16/5 working light switch X9/1 rear lights connection yel/red 1
4 X1/A engine/chassis connection F8 hazard warning system red 4 57 S18/5 X9/2 rear lights connection vio 1
7 X1/C engine/chassis connection S1/1 preheating start switch brn 4 58 X10/12 round indicating instrument connection K6 preheating time lag relay gry/red 1
7A S1/4 preheating start switch S1/9 preheating start switch brn 2.5 60 F8 hazard warning system fuse K9/30 cutoff solenoid switching relay red 2.5
7B S1/8 preheating start switch K6 preheating time lag relay brn 1 61 K9/85 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
8 X1/D engine/chassis connection K9/87 cutoff solenoid switching relay wh/red 2.5 62 K9/86 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
10 X1/1 engine/chassis connection K6 preheating time lag relay wht 1 63 S1/5 preheating start switch F3 cutoff solenoid fuse blu/red 1
10A X7/4 terminal strip connection K6 preheating time lag relay wht 1 64 F2 indicator fuse X10/1 round indicating instrument connection blu 1
10B X7/8 terminal strip connection S1/7 preheating start switch wht 1 65 F3 indicators and engine relay fuse X7/5 terminal strip connection blu/red 1
10C X7.1/4 terminal strip connection X7.1/8 terminal strip connection wht 1 65A X7/7 terminal strip connection X7/5 terminal strip connection blu/red 1
11 X1/2 engine/chassis connection B14/5 warning buzzer unit diodes pnk 1 65B X7.1/9 terminal strip connection X7.1/5 terminal strip connection blu/red 1
11A X10/8 round indicating instrument connection B14/5 warning buzzer unit diodes pnk 1 66 F4 valve fuse S33/1 Power Flow switch gry 1
12 X1/3 engine/chassis connection B14/9 warning buzzer unit diodes blk/grn 1 67 S33/9 Power Flow switch S33/1 Power Flow switch gry 1
12A X10/14 round indicating instrument connection B14/4 warning buzzer unit diodes blk/grn 1 68 S33/9 Power Flow switch S32/1 parallel lift switch gry 1
13 X1/4 engine/chassis connection B14/6 warning buzzer unit diodes wht/gn 1 69 S32/9 parallel lift switch S32/1 parallel lift switch gry 1
13A X10/10 round indicating instrument connection B14/1 warning buzzer unit diodes wht/grn 1 70 S32/9 parallel lift switch S10/5 parking brake switch gry 1
14 X1/5 engine/chassis connection XS 5 org/wht 1 71 S10/9 parking brake switch S10/5 parking brake switch gry 1
16 X1/6 engine/chassis connection XS 5 org/blu 1 73 F5 interior light fuse S16/1 working light switch blu/yel 1
16 A X10/7 round indicating instrument connection XS 5 org/blk 1 74 S16/9 working light switch S16/1 working light switch blu/yel 1
18 X1/7 engine/chassis connection X10/11 round indicating instrument connection vio/blk 1 75 S16/9 working light switch S18/9 rotating beacon switch blu/yel 1
19 X1/8 engine/chassis connection X8/5 lights connection org 1 76 F5 interior light fuse E14 interior light blu/yel 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 77 F6 front lights fuse S14/1 light switch yel 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 78 S14/2 light switch S14/1 light switch yel 1
24 X1/11 engine/chassis connection X10/9 round indicating instrument connection blk/red 1 79 S14/2 light switch S14/9 light switch yel 1
26 X1/12 engine/chassis connection S33/5 Power Flow switch gry/brn 1 80 F7 turn indicator fuse S19/7 hazard warning system switch grn 1
29 X1/13 engine/chassis connection X10/3 round indicating instrument connection gry/blu 1 81 S19/8 hazard warning system switch S19/7 hazard warning system switch grn 1
30 S29 safety switch X7/1 terminal strip connection gry 1 82 F8 hazard warning system fuse S19/2 hazard warning system switch red/blu 1
30A F4 valves X7/6 terminal strip connection gry 1 83 S19/4 hazard warning system switch S19/6 hazard warning system switch grn/blu 1
30B X7.1/1 terminal strip connection X7.1/6 terminal strip connection gry 1 84 S19/4 hazard warning system switch K10/+ turn indicator relay grn/blu 1
31 X1/H engine/chassis connection S29 safety switch gry 1 85 K10/P turn indicator relay X10/15 round indicating instrument connection grn/yel 1
33 X1/I engine/chassis connection F2 alternator, fuel level sensor, indicators, start relay fuse blu 1 86 F9 socket fuse X19 socket red 1
36 X1/J engine/chassis connection X7/9 terminal strip connection blu/red 1 87 F9 socket fuse S18/1 rotating beacon switch red 1
36A V1 diode X7/9 terminal strip connection blu/red 1 88 F8 hazard warning system fuse X7/2 terminal strip connection red 1
36B V1 diode K8 cutoff solenoid timer blu/red 1 90 GND1 earth S33/10 Power Flow switch blk 1
40 X1/G engine/chassis connection K10/C turn indicator relay brn/yel 1 91 S32/10 parallel lift switch S33/10 Power Flow switch blk 1
40A S19/1 hazard warning system switch K10/C turn indicator relay brn/yel 1 92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
40B S19/1 hazard warning system switch S12 turn indicator switch brn/yel 1 93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
41 X1/15 engine/chassis connection S19/3 hazard warning system grn/blk 1 94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
41A X8/1 lights switch S19/3 hazard warning system grn/blk 1 95 S14/10 light switch S19/10 hazard warning system switch blk 1
41B X8/1 lights switch S12 turn indicator switch grn/blk 1 96 S14/10 light switch S10/10 parking brake switch blk 1
43 X1/16 engine/chassis connection S19/5 hazard warning system grn/red 1 97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 98 DNG1 earth X19 socket blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 99 GND1 earth X8/7 lights connection blk 1
45 X1/14 engine/chassis connection S14/6 light switch yel/blk 1 100 GND1 earth E14 interior light blk 1
45A X10/2 round indicating instrument connection S14/6 light switch yel/blk 1 101 GND1 earth K8 cutoff solenoid time lag relay blk 1
50 X1/E engine/chassis connection GND1 blk 1.5 102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
51 X1/F engine/chassis connection GND1 blk 1 103 K6 preheating time lag relay V1 diode blk 1
52 X10/2 round indicating instrument connection S29 safety switch brn/wht 1 104 X7/3 terminal strip connection V1 diode blk 1
52A X1/17 engine/chassis connection S29 safety switch brn/wht 1 105 GND1 earth X9/3 rear lights connection blk 1
53 X1/18 engine/chassis connection B14/8 warning buzzer unit diodes brn/blk 1 106 X9/4 rear lights connection X9/3 rear lights connection blk 1
53A X10/6 round indicating instrument connection B14/2 warning buzzer unit diodes brn/blk 1 107 GND1 earth K10/87 turn indicator relay blk 1
54 S14/8 light switch X8/3 lights connection yel/blk 1
55 S14/3 light switch X8/4 lights connection yel/grn 1
Wiring harness 1000139289 switches (legend)

Electrical system
6.40 Switches wiring harness 1000139289 up to serial no. DB00708

Cutoff
solenoid Turn indicators
Round indicating instrument
Rotating beacon
Working lights
Parking brake
Power Flow
Parallel lift
Lights
Rear lights
Interior
Lights
Ignition lock
Safety
switch
Lights Timer
Diode Preheat Cutoff solenoid
Turn indicators

Electrical system
6.41 701s switches wiring harness 1000183064 from serial no. DC00713 (legend)
3 X1/A engine/chassis connection S1/1 preheating start switch red 4 56 S16/5 working light switch X9/1 rear lights connection yel/red 1
4 X1/A engine/chassis connection F8 hazard warning system red 4 57 S18/5 X9/2 rear lights connection vio 1
7 X1/C engine/chassis connection S1/1 preheating start switch brn 4 58 X10/12 round indicating instrument connection K6 preheating time lag relay gry/red 1
7A S1/4 preheating start switch S1/9 preheating start switch brn 2.5 60 F8 hazard warning system fuse K9/30 cutoff solenoid switching relay red 2.5
7B S1/8 preheating start switch K6 preheating time lag relay brn 1 61 K9/85 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
10 X1/1 engine/chassis connection K6 preheating time lag relay wht 1 63 S1/5 preheating start switch F3 cutoff solenoid fuse blu/red 1
10A X7/4 terminal strip connection K6 preheating time lag relay wht 1 64 F2 indicator fuse X10/1 round indicating instrument connection blu 1
10B X7/8 terminal strip connection S1/7 preheating start switch wht 1 65 F3 indicators and engine relay fuse X7/5 terminal strip connection blu/red 1
10C X7.1/4 terminal strip connection X7.1/8 terminal strip connection wht 1 65A X7/7 terminal strip connection X7/5 terminal strip connection blu/red 1
11 X1/2 engine/chassis connection B14/5 warning buzzer unit diodes pnk 1 65B X7.1/9 terminal strip connection X7.1/5 terminal strip connection blu/red 1
11A X10/8 round indicating instrument connection B14/5 warning buzzer unit diodes pnk 1 66 F4 valve fuse S33/1 High Flow switch gry 1
12 X1/3 engine/chassis connection B14/9 warning buzzer unit diodes blk/grn 1 67 S33/9 High Flow switch S33/1 High Flow switch gry 1
12A X10/14 round indicating instrument connection B14/4 warning buzzer unit diodes blk/grn 1 68 S33/9 High Flow switch S32/1 parallel lift switch gry 1
13 X1/4 engine/chassis connection B14/6 warning buzzer unit diodes wht/gn 1 69 S32/9 parallel lift switch S32/1 parallel lift switch gry 1
13A X10/10 round indicating instrument connection B14/1 warning buzzer unit diodes wht/grn 1 70 S32/9 parallel lift switch S10/5 parking brake switch gry 1
14 X1/5 engine/chassis connection XS 5 org/wht 1 71 S10/9 parking brake switch S10/5 parking brake switch gry 1
16 X1/6 engine/chassis connection XS 5 org/blu 1 73 F5 interior light fuse S16/1 working light switch blu/yel 1
16 A X10/7 round indicating instrument connection XS 5 org/blk 1 74 S16/9 working light switch S16/1 working light switch blu/yel 1
18 X1/7 engine/chassis connection X10/11 round indicating instrument connection vio/blk 1 75 S16/9 working light switch S18/9 rotating beacon switch blu/yel 1
19 X1/8 engine/chassis connection X8/5 lights connection org 1 76 F5 interior light fuse E14 interior light blu/yel 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 77 F6 front lights fuse S14/1 light switch yel 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 78 S14/2 light switch S14/1 light switch yel 1
26 X1/12 engine/chassis connection S33/5 Power Flow switch gry/brn 1 80 F7 turn indicator fuse S19/7 hazard warning system switch grn 1
29 X1/13 engine/chassis connection X10/3 round indicating instrument connection gry/blu 1 81 S19/8 hazard warning system switch S19/7 hazard warning system switch grn 1
30 S29 safety switch X7/1 terminal strip connection gry 1 82 F8 hazard warning system fuse S19/2 hazard warning system switch red/blu 1
30A F4 valves X7/6 terminal strip connection gry 1 83 S19/4 hazard warning system switch S19/6 hazard warning system switch grn/blu 1
30B X7.1/1 terminal strip connection X7.1/6 terminal strip connection gry 1 84 S19/4 hazard warning system switch K10/+ turn indicator relay grn/blu 1
31 X1/H engine/chassis connection S29 safety switch gry 1 85 K10/P turn indicator relay X10/15 round indicating instrument connection grn/yel 1
33 X1/I engine/chassis connection F2 alternator, fuel level sensor, indicators, start blu 1 86 F9 socket fuse X19 socket red 1
relay fuse 87 F9 socket fuse S18/1 rotating beacon switch red 1
36 X1/J engine/chassis connection X7/9 terminal strip connection blu/red 1 88 F8 hazard warning system fuse X7/2 terminal strip connection red 1
36A V1 diode X7/9 terminal strip connection blu/red 1 90 GND1 earth S33/10 High Flow switch blk 1
36B V1 diode K8 cutoff solenoid timer blu/red 1 91 S32/10 parallel lift switch S33/10 High Flow switch blk 1
40 X1/G engine/chassis connection K10/C turn indicator relay brn/yel 1 92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
40A S19/1 hazard warning system switch K10/C turn indicator relay brn/yel 1 93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
40B S19/1 hazard warning system switch S12 turn indicator switch brn/yel 1 94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
41 X1/15 engine/chassis connection S19/3 hazard warning system grn/blk 1 95 S14/10 light switch S19/10 hazard warning system switch blk 1
41A X8/1 lights switch S19/3 hazard warning system grn/blk 1 96 S14/10 light switch S10/10 parking brake switch blk 1
41B X8/1 lights switch S12 turn indicator switch grn/blk 1 97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
43 X1/16 engine/chassis connection S19/5 hazard warning system grn/red 1 98 DNG1 earth X19 socket blk 1
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 99 GND1 earth X8/7 lights connection blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 100 GND1 earth E14 interior light blk 1
45 X1/14 engine/chassis connection S14/6 light switch yel/blk 1 101 GND1 earth K8 cutoff solenoid time lag relay blk 1
45A X10/2 round indicating instrument connection S14/6 light switch yel/blk 1 102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
50 X1/E engine/chassis connection GND1 blk 1.5 103 K6 preheating time lag relay V1 diode blk 1
51 X1/F engine/chassis connection GND1 blk 1 104 X7/3 terminal strip connection V1 diode blk 1
52 X10/2 round indicating instrument connection S29 safety switch brn/wht 1 105 GND1 earth X9/3 rear lights connection blk 1
52A X1/17 engine/chassis connection S29 safety switch brn/wht 1 106 X9/4 rear lights connection X9/3 rear lights connection blk 1
53 X1/18 engine/chassis connection B14/8 warning buzzer unit diodes brn/blk 1 107 GND1 earth K10/87 turn indicator relay blk 1
53A X10/6 round indicating instrument connection B14/2 warning buzzer unit diodes brn/blk 1
55 S14/3 light switch X8/4 lights connection yel/grn 1

Electrical system
6.42 701s switches wiring harness 1000183064 from serial no. DC00713
Cutoff

Turn indicators
solenoid
Round indicating
Rotating beacon
Work hydraulics
instrument
Working lights
Parking brake
Power Flow
Parallel lift
Lights
Rear lights
lock
Interior light
Ignition lock
Socket
Safety switch
Timer
Diode Cutoff solenoid

Preheat
Lights
Turn indicators

Electrical system
6.43 701sp switches wiring harness 1000185268 from serial no. DC00713 (legend)
3 X1/A engine/chassis connection S1/1 preheating start switch red 4 55 S14/3 light switch X8/4 lights connection yel/grn 1
4 X1/A engine/chassis connection F8 hazard warning system red 4 56 S16/5 working light switch X9/1 rear lights connection yel/red 1
7 X1/C engine/chassis connection S1/1 preheating start switch brn 4 57 S18/5 X9/2 rear lights connection vio 1
7A S1/4 preheating start switch S1/9 preheating start switch brn 2.5 58 X10/12 round indicating instrument connection K6 preheating time lag relay gry/red 1
7B S1/8 preheating start switch K6 preheating time lag relay brn 1 60 F8 hazard warning system fuse K9/30 cutoff solenoid switching relay red 2.5
10 X1/1 engine/chassis connection K6 preheating time lag relay wht 1 62 K9/86 cutoff solenoid switching relay K8 cutoff solenoid time lag relay blu/red 1
10A X7/4 terminal strip connection K6 preheating time lag relay wht 1 63 S1/5 preheating start switch F3 cutoff solenoid fuse blu/red 1
10B X7/8 terminal strip connection S1/7 preheating start switch wht 1 64 F2 indicator fuse X10/1 round indicating instrument connection blu 1
10C X7.1/4 terminal strip connection X7.1/8 terminal strip connection wht 1 65 F3 indicators and engine relay fuse X7/5 terminal strip connection blu/red 1
11 X1/2 engine/chassis connection B14/5 warning buzzer unit diodes pnk 1 65A X7/7 terminal strip connection X7/5 terminal strip connection blu/red 1
11A X10/8 round indicating instrument connection B14/5 warning buzzer unit diodes pnk 1 65B X7.1/9 terminal strip connection X7.1/5 terminal strip connection blu/red 1
12 X1/3 engine/chassis connection B14/9 warning buzzer unit diodes blk/grn 1 66 F4 valve fuse S33/1 High Flow switch gry 1
12A X10/14 round indicating instrument connectionB14/4 warning buzzer unit diodes blk/grn 1 67 S33/9 High Flow switch S33/1 High Flow switch gry 1
13 X1/4 engine/chassis connection B14/6 warning buzzer unit diodes wht/gn 1 68 S33/9 High Flow switch S32/1 parallel lift switch gry 1
13A X10/10 round indicating instrument connectionB14/1 warning buzzer unit diodes wht/grn 1 69 S32/9 parallel lift switch S32/1 parallel lift switch gry 1
14 X1/5 engine/chassis connection XS 5 org/wht 1 70 S32/9 parallel lift switch S10/5 parking brake switch gry 1
16 X1/6 engine/chassis connection XS 5 org/blu 1 71 S10/9 parking brake switch S10/5 parking brake switch gry 1
16 A X10/7 round indicating instrument connection XS 5 org/blk 1 73 F5 interior light fuse S16/1 working light switch blu/yel 1
18 X1/7 engine/chassis connection X10/11 round indicating instrument connection vio/blk 1 74 S16/9 working light switch S16/1 working light switch blu/yel 1
19 X1/8 engine/chassis connection X8/5 lights connection org 1 75 S16/9 working light switch S18/9 rotating beacon switch blu/yel 1
20 X1/9 engine/chassis connection S32/5 parallel lift switch gry/yel 1 76 F5 interior light fuse E14 interior light blu/yel 1
22 X1/10 engine/chassis connection S10/7 parking brake switch blk/red 1 77 F6 front lights fuse S14/1 light switch yel 1
26 X1/12 engine/chassis connection S33/5 Power Flow switch gry/brn 1 79 S14/2 light switch S14/9 light switch yel 1
29 X1/13 engine/chassis connection X10/3 round indicating instrument connection gry/blu 1 80 F7 turn indicator fuse S19/7 hazard warning system switch grn 1
30 S29 safety switch X7/1 terminal strip connection gry 1 81 S19/8 hazard warning system switch S19/7 hazard warning system switch grn 1
30A F4 valves X7/6 terminal strip connection gry 1 82 F8 hazard warning system fuse S19/2 hazard warning system switch red/blu 1
30B X7.1/1 terminal strip connection X7.1/6 terminal strip connection gry 1 83 S19/4 hazard warning system switch S19/6 hazard warning system switch grn/blu 1
31 X1/H engine/chassis connection S29 safety switch gry 1 84 S19/4 hazard warning system switch K10/+ turn indicator relay grn/blu 1
33 X1/I engine/chassis connection F2 alternator, fuel level sensor, indicators, start blu 1 85 K10/P turn indicator relay X10/15 round indicating instrument connection grn/yel 1
relay fuse 86 F9 socket fuse X19 socket red 1
36 X1/J engine/chassis connection X7/9 terminal strip connection blu/red 1 87 F9 socket fuse S18/1 rotating beacon switch red 1
36A V1 diode X7/9 terminal strip connection blu/red 1 88 F8 hazard warning system fuse X7/2 terminal strip connection red 1
36B V1 diode K8 cutoff solenoid timer blu/red 1 90 GND1 earth S33/10 High Flow switch blk 1
40 X1/G engine/chassis connection K10/C turn indicator relay brn/yel 1 91 S32/10 parallel lift switch S33/10 High Flow switch blk 1
40A S19/1 hazard warning system switch K10/C turn indicator relay brn/yel 1 92 S32/10 parallel lift switch S18/1 rotating beacon switch blk 1
40B S19/1 hazard warning system switch S12 turn indicator switch brn/yel 1 93 S16/10 rear working light switch S18/10 rotating beacon switch blk 1
41 X1/15 engine/chassis connection S19/3 hazard warning system grn/blk 1 94 S16/10 rear working light switch S19/10 hazard warning system switch blk 1
41A X8/1 lights switch S19/3 hazard warning system grn/blk 1 95 S14/10 light switch S19/10 hazard warning system switch blk 1
41B X8/1 lights switch S12 turn indicator switch grn/blk 1 96 S14/10 light switch S10/10 parking brake switch blk 1
43 X1/16 engine/chassis connection S19/5 hazard warning system grn/red 1 97 X10/5 round indicating instrument connection S10/10 parking brake switch blk 1
43A X8/2 lights connection S19/5 hazard warning system grn/red 1 98 DNG1 earth X19 socket blk 1
43B X8/2 lights connection S12 turn indicator switch grn/red 1 99 GND1 earth X8/7 lights connection blk 1
45 X1/14 engine/chassis connection S14/6 light switch yel/blk 1 100 GND1 earth E14 interior light blk 1
45A X10/2 round indicating instrument connection S14/6 light switch yel/blk 1 101 GND1 earth K8 cutoff solenoid time lag relay blk 1
50 X1/E engine/chassis connection GND1 blk 1.5 102 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
51 X1/F engine/chassis connection GND1 blk 1 103 K6 preheating time lag relay V1 diode blk 1
52 X10/2 round indicating instrument connection S29 safety switch brn/wht 1 104 X7/3 terminal strip connection V1 diode blk 1
52A X1/17 engine/chassis connection S29 safety switch brn/wht 1 105 GND1 earth X9/3 rear lights connection blk 1
53 X1/18 engine/chassis connection B14/8 warning buzzer unit diodes brn/blk 1 106 X9/4 rear lights connection X9/3 rear lights connection blk 1
53A X10/6 round indicating instrument connection B14/2 warning buzzer unit diodes brn/blk 1 107 GND1 earth K10/87 turn indicator relay blk 1

Electrical system
6.44 701sp switches wiring harness 1000185268 from serial no. DC00713
Cutoff

Turn indicators
solenoid
Round indicating
Rotating beacon
Work hydraulics
instrument
Working lights
Parking brake
Power Flow
Parallel lift
ECU telltale
Lights
Rear lights
lock Interior light
Ignition lock
Lights
Turn indicators

Electrical system
6.45 Wiring harness 1000147262: rear lights (option) A3
Rear right light
Numberplate light
Lights connection Rear left light
Rear lights wiring harness (option)
No. Up to To Colour mm
15 X5/4 rear lights connection X15 earth blk 1
15 A E2/3 rear right light switch X15 earth blk 1
15B E4/3 rear left light switch X15 earth blk 1
15C E16 numberplate light X15 earth blk 1
42 X5/1 rear lights connection E4/1 rear left turn indicator switch grn/blk 1
44 X5/2 rear lights connection E2/1 rear right turn indicator switch grn/red 1
45 X5/4 rear lights connection X45 position light yel/blk 1
45A E2/2 rear right light switch X45 position light yel/blk 1
45b E4/2 rear left light switch X45 position light yel/blk 1
45C E16 numberplate light switch X45 position light yel/blk 1

Electrical system

Options
Options
7 Options
7.1 Rear working light
Working light Working light
Notice!
Depending on the legal regulations of your country, the rear working light may
possibly only be available if your machine is certified for road travel.
Wiring harness
Connections
No. From To
56 X9/1 rear lights connection E7/1 rear working light
105 X9/3 rear lights connection E7/2 rear working light

Options
7.2 BP Biohyd SE 46
Properties Hydraulic ester oil (HEES)
BP Biohyd SE-S is a pressure medium based on saturated synthetic esters and synthetic
hydrocarbons
It can be used in all hydraulic systems!
Viscosity at 40 C (104 F) Viscosity at 100 C (212 F)

46 cSt 9 cSt
7.3 Biodegradable oil Panolin

Properties This is a fully synthetic, environmentally compatible high-performance hydraulic oil based
on saturated esters. A combination of special additives and high-performance base oils
greatly reduces the formation of ageing products, deposits and gumming at high operating
temperatures
Viscosity at 40 C (104 F) Viscosity at 100 C (212 F)

48.7 cSt 8.7 cSt
7.4 Rearview mirror package
Notice!
Depending on the legal regulations of your country, the mirror package may be
available with the road travel option see Road travel certification on page 7-12.

Options
7.5 Drive interlock (antitheft protection)

Machine
1 Pos. Description
1 Transponder receiver surface
2 Red LED
2
Fig. 1: Drive interlock
Disabling the drive interlock Approach the transponder to 2 cm (0.8) from the transponder receiver surface.
The red LED goes out
Insert the ignition key into the ignition lock within 30 seconds and turn it at least to
position 1.
The drive interlock remains disabled.
Enabling the drive interlock Remove or turn the ignition key to position 0.
The drive interlock is enabled after 30 seconds.
The blinking red LED indicates the drive interlock is enabled.
Programming Coding transponder keys

The so-called main or master key is required for coding a new or uncoded key, or a key
with different coding, for the drive interlock.
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45 seconds see Disabling the drive interlock on
page 7-3.
The LED changes to a steady green light.
The system is in programming mode now (coding mode).
Remove the master key from the transponder receiver surface.
The LED changes to a rapidly blinking green light.
Hold the key to be programmed against the transponder receiver surface.
The key is coded once the diode comes on slowly three times.
Hold further keys next to the transmitter/receiver surface to code them as mentioned
above.
The drive interlock is enabled as soon as there is no key contact for 30 seconds.
Blinking red light

Options
Deleting programming/coding
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45 seconds see Disabling the drive interlock on
page 7-3.
The LED changes to a steady green light.
The system is in programming mode now (coding mode).
Hold the master key against the transponder receiver surface for a further 30 seconds.
The LED changes to a steady red light.
The system is in delete mode now (coding mode).
Remove the master key
The LED changes to a rapidly blinking red light.
You have 30 seconds to hold the master key again to the transponder receiver surface
to confirm deletion.
The system is deleted once the diode comes on slowly three times.
Caution!
Deletion deletes all normal transponders and the master!
Reason: once a key is lost, you can no longer delete it.
Therefore, the entire system is deleted for safety reasons and can be
completely recoded with the remaining (or newly ordered) keys.
Configuration of the deleted system

Once deletion is over, the system recognises any TREBE transponder key, i.e. the system
can be disabled with any key.
The first transponder key to be recoded for the system is automatically the new master and
can be used for coding the normal transponder keys see Programming on page 7-3.
Notice!
The following applies both to the coding and programming mode: the system
leaves the coding and programming modes and is disabled as soon as the ignition
key is inserted in the ignition lock and turned to the first position.
7.6 Rotating beacon

It is located at the rear right of the roof.

Options
Wiring harness
Connections
Pos. From To
57 X9/2 rear lights connection H28 rotating beacon
106 X9/4 rear lights connection H28 rotating beacon
Notice!
Observe the legal regulations of your country for operating the rotating beacons.

Options
7.7 Crane-handling bracket

Fixture for raising the complete skid steer loader.
The crane-handling bracket is screwed together as shown below and is then installed on
the cab (figure on the left).
Pos Pos
Description Description
. .
1 Shackle 8 Schnorr lock S12
2 Damping element 9 Washer 13
3 Attachment plate 10 Hex screw M12x60-10.9 A2C
4 Hex screw M20x130 11 Spacer bushing
Cheese-head screw M 12x30-10.9
5 Washer 21 12
DACRO500-5
6 Hex nut M20-8 A2C 13 Hex nut M12-8 A2C
7 Hex screw M12x30-10.9 A2C 14 Hex nut M12-8 A2C

Options
7.8 FOPS roof level 2

FOPS falling object protective structures
The FOPS protective structure must cover and go beyond the complete vertical projection
of the deformation limit range.
Level 2 means that a higher amount of energy can be absorbed (up to 10 000 J) in an
emergency.
The protective structure is installed on the cab as shown in both figures.
Pos
Description
.
1 FOPS Falling Object Protective Structure
2 Spacer bushing
3 Hexagon head screw M12x60
4 Washer 13
5 Hexagon head screw M12x30-10.9 A2C

Options
7.9 Backup warning system

Function Emits a signal when reversing
A pressure switch is actuated and a signal is emitted upon pulling back the steering lever.
Position It is installed in the engine compartment on the left A
Pos
Description Position Pos. Description
.
1 Signal transmitter 1 Accumulator wiring harness
2 Hexagon head screw M8 x 20-8.8 Engine 2 Float position wiring harness
3 Washer B8.4-140HV A2C compartment 3 Backup warning system wiring harness
4 Hexagon nut M8-8 A2C 4+5 Wedges
5 Screw connection Joystick (left) S43 + S43.1 Flat plug sleeve
6 Pressure switch see chapter S45 Insulating sleeve
7 Screw connection Joystick (left) X13 Pin housing
on page 5-11
8 Screw connection X3 Flat plug housing
X3.1 Socket housing
Y13.1 Plug

Options
7.10 Side window

Protection against weather.
Pos
Description
.
1 Side window with seal
2 Glass bracket
3 Hexagon nut M6-8 A2C
4 Schnorr lock S6
5 Washer 6.4
Attachment The side windows are screwed with 7 brackets each onto the fastening points A.

Options
7.11 Full cab glazing (option)

Full cab glazing option includes:
Left and right-hand side windows
Front door
Front door washer system
Door sensor
Notice!
Close the door as you put the machine into operation!
Washer system
Wiper and washer water switch A
Cab heating and ventilation, available only in connection with full cab glazing.
The cab is fitted with 2 air nozzles.
Each nozzle can be closed and directed separately.

Options
7.12 Stabilisers
This option is required when using excavator equipment.
Pos Pos
Description Description
. .
1 Stabiliser 8 Pin 30x154
2 Pin 30x225 9 Pin 30x137
3 Bushing 30/36x29 10 Cylinder
4 Stabiliser 11 Chassis cover
5 Ram bracket (left) 12 Hexagon head screw M8x70-8.8 A2C
6 Ram bracket (right) 13 Hexagon nut M8-8 A2C
7 Cylinder

Options
7.13 Road travel certification

Notice!
Depending on the legal regulations of your country, only specifically certified
machines may be allowed to travel on public roads.
1
Numberplate bracket
Rear light bracket
Rearview mirrors
Protective plate
Pos. Description
Rear lights
2
Shackle
Lights
1
2
3
4
5
6
7
3
4
5 6

Options
7.14 Airboss tyres
A
B
Pos. Description
A Tyre segment 10-16.5 Airboss
B Hexagon nut M8-8 A2C
Tyre and rim damage does not affect Airboss tyres as much as so-called conventional
tyres. In case of damage, the separate tyre segments can be replaced quickly and without
removing the entire tyre.
An Airboss wheel consists of:
1 steel rim and
20 tyre segments screwed onto the rim.
Attachment Tightening moment of nuts for tyre segments: 13 Nm (9.6 ft. lbs.)
Wheel nut tightening torque: 175 Nm (129 ft. lbs.)
7.15 Power Flow ports
Notice!
Follow the instructions in the Operator's Manual of the attachment manufacturer
for connecting the auxiliary hydraulics to attachments.
Quick couplers:
A B C Port Description
A Pressure line quick coupler 1/2
B Reflux line without pressure quick coupler 1/2
Fig. 2: Power Flow ports
C Reflux line without pressure quick coupler 1/2
Couplings according to ISO 16028

Options
Couplings
Connect and disconnect the couplings as follows:
Removing the coupling:
Park the machine on firm and level ground
Lower the loader unit completely and set the attachment to the ground
Stop the engine
Release the pressure in the pressure lines by moving the right-hand side control lever
A in all directions
B
Fold up the safety bar
Unfasten the seat belt
Turn lock sleeve B towards lock ball A
Pull lock sleeve B upwards
The coupling opens
Connecting the coupling:

Connect the coupling onto the loader unit connection making sure it is straight
Wait until you hear a hissing sound of the connection
Fully connect the coupling on the connection
Turn back the lock again (away from lock ball A)

1-1 SERV-HB 701s sp EN Edition 2.0 *701schlussbl.fm
Wacker Neuson Linz GmbH
Haidfeldstr. 37
A-4060 Linz/Leonding
Telephone +43 (0) 732/90590-0
Fax +43 (0) 732/90590-200
Email: office@wackerneuson.com
www.wackerneuson.com

SHB 701 en 1000164190 2 0

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Service Manual

Machine models 701s/sp

Description Order no.

Operator's Manual 1000151639

Service manual 1000164190

Spare parts list Up to serial no. DB00708 1000150186

From serial no. DC00713 1000186575

Copyright 2009 Wacker Neuson Linz GmbH, Linz-Leonding

Wacker Neuson Linz GmbH

SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm I-1

Emptying the fuel tank ..................................................................................... 3-11

I-2 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm

Electrical system .................................................................................................... 3-48

SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm I-3

Checking the nozzle jet .......................................................................................... 4-27

I-4 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm

(1) P0219/0: overspeed error .......................................................................... 4-71

SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm I-5

Breather filter ......................................................................................................... 5-26

I-6 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm

SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm I-7

Full cab glazing (option) ......................................................................................... 7-10

I-8 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0IVZ.fm

SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0SIX.fm S-1

S-2 SERV-HB 701s sp EN - Edition 2.0 *Sh701en2_0SIX.fm

1-1 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

1.2 Identification of warnings and dangers

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-2

1.3 Designated use and exemption from liability

1-3 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

1.4 Type labels and component numbers

Fig. 1: Type label: location

Fig. 3: Cab number

Example: Yanmar 46557

Fig. 4: Diesel engine number

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-4

Hydraulic pump number

Fig. 5: Hydraulic pump type label

Hydraulic motor numbers

Fig. 6: Travelling drive type label

1-5 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

1.5 Machine overview

Fig. 7: Machine outside views

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-6

1.6 Cab overview

1.7 Cab (legend)

1-7 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

1.8 Round indicating instrument overview

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-8

1.10 Engine compartment overview

Pos. Description For more information see page

1-9 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

Pos. Description For more information see page

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-10

1.11 Engine cover (open): overview

Pos. Description For more information see page

1-11 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

Pos. Description For more information see page

SERV-HB 701s sp EN Edition 2.0 *701s110.fm 1-12

1.12 Chassis overview

Pos. Description For more information see page

1-13 SERV-HB 701s sp EN Edition 2.0 * *701s110.fm

1.13 Tilting the cab