Repair Manual for Wheel Loader WL 30 - Wacker Neuson

© 2008 Wacker Neuson SE - 80809 München, Germany 

1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 

Repair Manual for Wheel Loader WL 30 

WL 30

1000239425 - WDF-6001-00EN 

WL 30 - 10/2008-1 (WDF-7018-00EN)

Service address and 

spare parts 

WL 30 - 10/2008-1 (WDF-7018-00EN) 1000239425 - WDF-6001-00EN 

Repair Manual 


If you have any queries, contact your nearest Wacker Neuson SE dealership. 

You can find the address at www.wackerneuson.com. 

You can also order spare parts from there. 

The operator's manual for the loader is also available from here. 

Before you continue reading ... 

Operator's manual In addition to this repair manual, the operator's manual for the loader is also 

required for doing all work in full. 

The repair manual is comprised of six parts: 

1. Safety 

2. Technical data, testing equipment and special tools 

3. Inspections, maintenance work and troubleshooting 

4. Replacement and repair procedures 

5. Circuit diagrams and technical descriptions 

6. Supplier service manuals (must be added to locally) 

Structure Each part is subdivided into the following, based on the loader's structure: 

1. Complete vehicle 

2. Engine 

3. Hydraulic system 

4. Drive and axles 

5. Brake system (mechanical section) 

6. Vehicle frame and load arm 

7. Operator's platform/cab 

8. Electrical system 

9. Attachments 

Navigation In each part of the manual, there is a table of contents to assist you in 

searching for individual sections. 

The overall table of contents follows on the next pages, after the list of abbreviations 

and units. 

The overall list of key words can be found immediately before the "Safety" part. 

The list of key words for the respective part of the manual can be found at the 

end of that part. 

Applicability The repair manual applies to loaders of the type WL 30, with the following 

article numbers: 

0610135 

0610164 

0610174 

0610228 

Special features The repair manual also describes work on special features that are not present 

on every loader. 

0-3


Abbreviations and units 

% Percent 

A High-pressure connection on the variable displacement 

pump 

as req. As required 

B High-pressure connection on the variable displacement 

pump 

bar Unit of pressure 

BK Black 

BL Blue 

BN Brown 

cm Centimeter 

cm 3 Cubic centimeter 

F3 Fuse No. 3 

G Supply pressure at the variable displacement pump 

or 

Test pressure at the variable displacement motor 

GN Green 

GR Gray 

h Hour 

KL30 Terminal designation 

l Liter 

LB Light blue 

M 1 

M A 

max. Maximum, highest 

M B 

min Minute 

min. Minimum, at least 

Nm Newton meter 

Ø [mm 2 ] 

OR Orange 

P Pin, pin contact 

PK Pink 

RD Red 

Test pressure at the variable displacement motor 

Test pressure at the variable displacement pump 

Test pressure at the variable displacement pump 

Wire cross section [in square millimeters] 

rpm Unit of speed (revolutions per minute) 

s Second 

S Socket, socket contact 

SKA Standard configuration, SKA machines 

SP1 Welding point No. 1 in the machine's wiring harness 

SP1M Welding point No. 1 in the motor wiring harness 

SV Solenoid valve 

TR Transparent 

0-4 1000239425 - WDF-6001-00EN 


VI Violet 

WH White 

X Plug connector 

X 1 

X 2 

YE Yellow 



Control pressure at the variable displacement pump 

Control pressure at the variable displacement pump 

0-5


0-6 1000239425 - WDF-6001-00EN 


Part 1 Safety 

1 Repair work 

(complete vehicle) . . . . . . . . . . . 1-7 

2 Engine . . . . . . . . . . . . . . . . . . . . . . . 1-9 

3 Hydraulic system . . . . . . . . . . . 1-11 

4 Drive and axles . . . . . . . . . . . . . 1-13 

5 Brake system . . . . . . . . . . . . . . . 1-15 

6 Vehicle frame and 

load arm . . . . . . . . . . . . . . . . . . . . 1-17 

7 Electrical system. . . . . . . . . . . . 1-19 

Part 2 Technical data, testing 

equipment and special tools 

1 Technical data . . . . . . . . . . . . . . . 2-7 

2 Filling quantities . . . . . . . . . . . . . 2-9 

3 Tightening torques . . . . . . . . . . 2-11 

4 Pressure values . . . . . . . . . . . . . 2-13 

5 Flow rates. . . . . . . . . . . . . . . . . . . 2-15 

6 Safety stickers . . . . . . . . . . . . . . 2-17 

7 Testing equipment . . . . . . . . . . 2-23 

7.1 Test pressure gauge . . . . . . . . . . . . . 2-23 

7.2 Flow meter . . . . . . . . . . . . . . . . . . . . 2-23 

7.3 Test pump . . . . . . . . . . . . . . . . . . . . . 2-24 

8 Special tools . . . . . . . . . . . . . . . . 2-25 

8.1 Insertion tool . . . . . . . . . . . . . . . . . . . 2-25 

8.2 Sealing plate (2 x) . . . . . . . . . . . . . . . 2-25 

8.3 Expulsion and driving sleeves. . . . . . 2-25 

8.4 Driving bolts . . . . . . . . . . . . . . . . . . . 2-26 

8.5 Electrical contact key . . . . . . . . . . . . 2-27 

8.6 Generator tester . . . . . . . . . . . . . . . . 2-27 

8.7 Half-shells and pull-off fixture . . . . . . 2-28 

9 Hose book . . . . . . . . . . . . . . . . . . 2-29 

WL 30 - 10/2008-1 (WDF-7018-00DE) 1000239425 - WDF-6001-00EN 

Contents 

Part 3 Inspections, maintenance work 

and troubleshooting 

1 Complete vehicle . . . . . . . . . . . . 3-7 

1.1 Inspection log. . . . . . . . . . . . . . . . . . . 3-7 

2 Engine . . . . . . . . . . . . . . . . . . . . . . 3-9 

2.1 Checking and adjusting the 

valve play. . . . . . . . . . . . . . . . . . . . . . 3-9 

2.2 Inspecting the exhaust system 

for leaks . . . . . . . . . . . . . . . . . . . . . . 3-11 

2.3 Checking the radiator 

installation . . . . . . . . . . . . . . . . . . . . 3-12 

2.4 Inspect the radiator for leaks . . . . . . 3-13 

2.5 Troubleshooting on the engine . . . . 3-14 



starting speed . . . . . . . . . . . . . . . . . 3-17 


inching pedal . . . . . . . . . . . . . . . . . . 3-17 


pressure cut-off . . . . . . . . . . . . . . . . 3-18 

3.4 Adjusting the driving speed . . . . . . . 3-19 

3.5 Checking the variable displacement 

pump supply pressure . . . . . . . . . . . 3-20 


pump high pressure . . . . . . . . . . . . . 3-21 


pump positioning pressure. . . . . . . . 3-23 

3.8 Checking and adjusting the control 

commencement of the variable 

displacement motor . . . . . . . . . . . . . 3-24 

3.9 Testing the steering hydraulics . . . . 3-25 

3.10 Checking the gear pump . . . . . . . . . 3-27 

3.11 Checking the control valve 

function . . . . . . . . . . . . . . . . . . . . . . 3-29 

3.12 Troubleshooting on the hydraulic 

system . . . . . . . . . . . . . . . . . . . . . . . 3-30 


4.1 Inspecting the differential lock . . . . . 3-33 

4.2 Checking the water filling of the 

wheels . . . . . . . . . . . . . . . . . . . . . . . 3-34 

4.3 Troubleshooting on the drive . . . . . . 3-35 


load arm. . . . . . . . . . . . . . . . . . . . 3-37 


curling to load and dumping 

stops . . . . . . . . . . . . . . . . . . . . . . . . 3-37 

6 Cab. . . . . . . . . . . . . . . . . . . . . . . . . 3-39 

6.1 Checking the heater. . . . . . . . . . . . . 3-39 

6.2 Troubleshooting in the cab . . . . . . . 3-40 

0-7

Contents 

7 Electrical system . . . . . . . . . . . 3-41 

7.1 Checking the generator . . . . . . . . . . 3-41 

7.2 Checking the temperature 

sensors . . . . . . . . . . . . . . . . . . . . . . 3-41 

7.3 Testing the belt buckle circuit. . . . . . 3-42 

7.4 Testing the fuel level sensor . . . . . . 3-43 

7.5 Troubleshooting on the electrical 

system . . . . . . . . . . . . . . . . . . . . . . . 3-44 

Part 4 Replacement and repair 

procedures 

1 Complete vehicle . . . . . . . . . . . . 4-9 

1.1 Helpful tips . . . . . . . . . . . . . . . . . . . . . 4-9 

1.2 Replacing protective stickers . . . . . . . 4-9 

2 Engine. . . . . . . . . . . . . . . . . . . . . . 4-11 

2.1 Engine (as supplied) . . . . . . . . . . . . 4-11 

2.1.1 Engine removal . . . . . . . . . . . . . . . . 4-11 

2.1.2 Engine installation . . . . . . . . . . . . . . 4-13 

2.1.3 Replacing the front rubber 

buffers . . . . . . . . . . . . . . . . . . . . . . . 4-16 

2.1.4 Replacing the rear rubber buffer . . . 4-17 

2.1.5 Replacing the clutch PA flange . . . . 4-18 

2.1.6 Cleaning the engine (after toppling 

the loader) . . . . . . . . . . . . . . . . . . . . 4-19 

2.2 Radiator . . . . . . . . . . . . . . . . . . . . . . 4-21 

2.2.1 Removing the radiator . . . . . . . . . . . 4-21 

2.2.2 Installing the radiator . . . . . . . . . . . . 4-22 

2.3 Air filter system . . . . . . . . . . . . . . . . 4-25 

2.3.1 Replacing the complete air filter. . . . 4-25 

2.3.2 Replacing the air filter housing. . . . . 4-26 

2.4 Fuel system . . . . . . . . . . . . . . . . . . . 4-27 

2.4.1 Replacing the complete fuel 

filter . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 

2.4.2 Replacing the complete main 

fuel filter . . . . . . . . . . . . . . . . . . . . . . 4-28 

2.4.3 Replacing the water separator . . . . . 4-29 

2.4.4 Replacing the fuel feed pump . . . . . 4-30 

2.4.5 Replacing the fuel line . . . . . . . . . . . 4-31 

2.4.6 Tank lock emergency opening . . . . . 4-32 

2.5 Exhaust system . . . . . . . . . . . . . . . . 4-33 

2.5.1 Replacing the flue . . . . . . . . . . . . . . 4-33 

2.5.2 Replacing the muffler and 

flexi-pipe. . . . . . . . . . . . . . . . . . . . . . 4-33 


3.1 Complete vehicle . . . . . . . . . . . . . . . 4-37 

3.1.1 Depressurizing the hydraulic 

system . . . . . . . . . . . . . . . . . . . . . . . 4-37 

3.1.2 Replacing the pivot bearing on the 

hydraulic cylinder . . . . . . . . . . . . . . . 4-37 

3.1.3 Sealing the hydraulic cylinder . . . . . 4-38 

3.2 Driving hydraulics. . . . . . . . . . . . . . . 4-42 

3.2.1 Replacing the variable 

displacement pump . . . . . . . . . . . . . 4-42 

3.2.2 Replacing the clutch hub . . . . . . . . . 4-44 

3.2.3 Replacing the annular shaft seal 

of the variable displacement 

pump. . . . . . . . . . . . . . . . . . . . . . . . . 4-45 

3.2.4 Replacing the variable displacement 

motor . . . . . . . . . . . . . . . . . . . . . . . . 4-45 

3.3 Steering hydraulics . . . . . . . . . . . . . . 4-48 

3.3.1 Cleaning the priority valve . . . . . . . . 4-48 

3.3.2 Replacing the priority valve . . . . . . . 4-50 

3.3.3 Replacing the orbital steering 

valve . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 

3.3.4 Removing the steering cylinder . . . . 4-52 

3.3.5 Installing the steering cylinder . . . . . 4-54 

3.4 Brake hydraulics . . . . . . . . . . . . . . . . 4-55 

3.4.1 Replacing the main brake 

cylinder . . . . . . . . . . . . . . . . . . . . . . . 4-55 

3.4.2 Replacing the brake hydraulics 

tank. . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 

3.4.3 Replacing the brake fluid . . . . . . . . . 4-57 

3.4.4 Venting the brake hydraulics . . . . . . 4-58 

3.5 Working hydraulics . . . . . . . . . . . . . . 4-59 

3.5.1 Replacing the gear pump . . . . . . . . . 4-59 

3.5.2 Sealing the gear pump . . . . . . . . . . . 4-61 

3.5.3 Removing the control valve . . . . . . . 4-63 

3.5.4 Installing the control valve . . . . . . . . 4-64 

3.5.5 Sealing the control valve . . . . . . . . . 4-66 

3.5.6 Installing the catch on the control 

valve . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 

3.5.7 Replacing the cross controller . . . . . 4-70 

3.5.8 Replacing the lifting cylinder. . . . . . . 4-71 

3.5.9 Removing the tipping cylinder . . . . . 4-73 

3.5.10 Installing the tipping cylinder . . . . . . 4-75 

3.5.11 Replacing the rod-end bearing 

of the tipping cylinder . . . . . . . . . . . . 4-76 

3.6 Auxiliary hydraulics and hydraulic 

lock . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 

3.6.1 Replacing the cover of the auxiliary 

hydraulics . . . . . . . . . . . . . . . . . . . . . 4-77 

3.6.2 Replacing the control lever and 

cover of the auxiliary hydraulics . . . . 4-78 

3.6.3 Replacing the locking cylinder . . . . . 4-79 

3.7 Tank, filter and hydraulic lines . . . . . 4-80 

3.7.1 Replacing the hydraulic fluid tank. . . 4-80 

3.7.2 Replacing the complete return 

filter. . . . . . . . . . . . . . . . . . . . . . . . . . 4-82 

3.7.3 Replacing the pressure filter. . . . . . . 4-83 

3.7.4 Replacing the hydraulic line . . . . . . . 4-84 


4.1 Replacing the drive shaft . . . . . . . . . 4-85 

4.2 Front axle . . . . . . . . . . . . . . . . . . . . . 4-86 

4.2.1 Removing the front axle . . . . . . . . . . 4-86 

4.2.2 Installing the front axle . . . . . . . . . . . 4-88 

0-8 1000239425 - WDF-6001-00EN 

WL 30 - 10/2008-1 (WDF-7018-00DE)

4.3 Rear axle. . . . . . . . . . . . . . . . . . . . . . 4-91 

4.3.1 Removing the rear axle. . . . . . . . . . . 4-91 

4.3.2 Installing the rear axle. . . . . . . . . . . . 4-93 

4.4 Changing the wheel of the twin 

tires . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 

5 Brake system 

(mechanical section) . . . . . . . . 4-97 

5.1 Service brake . . . . . . . . . . . . . . . . . . 4-97 

5.1.1 Replacing the brake shoes . . . . . . . . 4-97 

5.1.2 Replacing the brake drum. . . . . . . . . 4-98 

5.2 Parking brake . . . . . . . . . . . . . . . . . . 4-99 

5.2.1 Replacing the Bowden cable 

of the parking brake . . . . . . . . . . . . . 4-99 


load arm . . . . . . . . . . . . . . . . . . . 4-103 

6.1 Front carriage . . . . . . . . . . . . . . . . . 4-103 

6.1.1 Replacing the front fender. . . . . . . . 4-103 

6.2 Rear carriage and engine hood. . . . 4-103 

6.2.1 Replacing the rear fender . . . . . . . . 4-103 

6.2.2 Replacing the additional 

weight/base plate . . . . . . . . . . . . . . 4-104 

6.2.3 Replacing the rear weight . . . . . . . . 4-105 

6.2.4 Replacing the engine hood . . . . . . . 4-107 

6.2.5 Replacing the lock of the engine 

hood . . . . . . . . . . . . . . . . . . . . . . . . 4-108 

6.2.6 Emergency release of the engine 

hood . . . . . . . . . . . . . . . . . . . . . . . . 4-109 

6.3 Center joint . . . . . . . . . . . . . . . . . . . 4-109 

6.3.1 Detaching the center joint . . . . . . . . 4-109 

6.3.2 Connecting the center joint . . . . . . . 4-111 

6.3.3 Replacing the bearing in the 

self-aligning bearing . . . . . . . . . . . . 4-115 

6.3.4 Replacing the lower bearing . . . . . . 4-116 

6.4 Step plate and insulation mats . . . . 4-117 

6.4.1 Removing the operator's 

platform . . . . . . . . . . . . . . . . . . . . . . 4-117 

6.4.2 Installing the operator's 

platform . . . . . . . . . . . . . . . . . . . . . . 4-120 

6.4.3 Replacing the rubber buffer 

of the step plate. . . . . . . . . . . . . . . . 4-123 

6.4.4 Replacing the insulation mat . . . . . . 4-124 

6.5 Load arm. . . . . . . . . . . . . . . . . . . . . 4-125 

6.5.1 Replacing the complete 

load arm . . . . . . . . . . . . . . . . . . . . . 4-125 

6.5.2 Replacing the bearings of the 

short drawbar . . . . . . . . . . . . . . . . . 4-127 


short reversing lever . . . . . . . . . . . . 4-128 


long reversing lever. . . . . . . . . . . . . 4-129 

6.5.5 Replacing the upper bearing 

of the long drawbar . . . . . . . . . . . . . 4-131 

6.5.6 Replacing the lower bearing 

of the long drawbar . . . . . . . . . . . . . 4-132 

6.6 Tool attachment . . . . . . . . . . . . . . . 4-133 


Contents 

6.6.1 Replacing the tool attachment . . . . 4-133 

6.6.2 Replacing the locking pin. . . . . . . . 4-134 

6.6.3 Replacing the lock of the tool 

attachment (US). . . . . . . . . . . . . . . 4-135 

7 Operator's platform 

and cab . . . . . . . . . . . . . . . . . . . 4-137 

7.1 Seat . . . . . . . . . . . . . . . . . . . . . . . . 4-137 

7.1.1 Replacing the driver's seat. . . . . . . 4-137 

7.1.2 Replacing the complete seat 

belt . . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

7.1.3 Replacing the belt buckle. . . . . . . . 4-138 

7.2 ROPS bar and driver's canopy . . . 4-139 

7.2.1 Replacing the ROPS bar . . . . . . . . 4-139 

7.2.2 Replacing the driver's canopy . . . . 4-139 

7.2.3 Replacing the lower section of 

the ROPS bar/driver's canopy . . . . 4-141 

7.2.4 Replacing the document 

compartment . . . . . . . . . . . . . . . . . 4-142 

7.2.5 Replacing the storage 

compartment . . . . . . . . . . . . . . . . . 4-143 

7.3 Cab . . . . . . . . . . . . . . . . . . . . . . . . 4-144 

7.3.1 Removing the complete cab . . . . . 4-144 

7.3.2 Installing the complete cab . . . . . . 4-146 

7.3.3 Replacing the windshield wiper 

arms. . . . . . . . . . . . . . . . . . . . . . . . 4-149 

7.3.4 Replacing the windshield washer 

container . . . . . . . . . . . . . . . . . . . . 4-150 

7.3.5 Replacing the door lock . . . . . . . . . 4-151 

7.3.6 Replacing the door stay . . . . . . . . . 4-152 

7.3.7 Replacing the complete door . . . . . 4-153 

7.3.8 Replacing the roof grille 

of the cab . . . . . . . . . . . . . . . . . . . . 4-154 

7.3.9 Replacing the window and the 

rubber clamping profile . . . . . . . . . 4-154 

7.3.10 Replacing a bonded-in window . . . 4-156 

7.3.11 Replacing the complete heater . . . 4-158 

7.4 Steering column. . . . . . . . . . . . . . . 4-159 

7.4.1 Replacing the instrument 

steering column . . . . . . . . . . . . . . . 4-159 

7.4.2 Replacing the steering wheel. . . . . 4-161 

8 Electrical system . . . . . . . . . . 4-163 

8.1 Generator, battery and motors. . . . 4-163 

8.1.1 Replacing the generator . . . . . . . . 4-163 

8.1.2 Replacing the starter . . . . . . . . . . . 4-164 

8.1.3 Replacing the rear windshield 

wiper motor . . . . . . . . . . . . . . . . . . 4-165 

8.1.4 Replacing the front windshield 

wiper motor . . . . . . . . . . . . . . . . . . 4-166 

8.2 Switches and sensors . . . . . . . . . . 4-167 

8.2.1 Replacing the switches in the 

instrument panel . . . . . . . . . . . . . . 4-167 

8.2.2 Replacing the combination 

switch. . . . . . . . . . . . . . . . . . . . . . . 4-168 

8.2.3 Replacing the glow-plug 

indicator . . . . . . . . . . . . . . . . . . . . . 4-168 

0-9

Contents 


cab . . . . . . . . . . . . . . . . . . . . . . . . . 4-169 

8.2.5 Replacing the ignition lock . . . . . . . 4-170 

8.2.6 Replacing the battery disconnect 

switch . . . . . . . . . . . . . . . . . . . . . . . 4-171 

8.2.7 Replacing the parking brake 

switch . . . . . . . . . . . . . . . . . . . . . . . 4-172 

8.2.8 Replacing the return filter 

overpressure switch . . . . . . . . . . . . 4-173 

8.2.9 Replacing the engine temperature 

sensor . . . . . . . . . . . . . . . . . . . . . . 4-174 

8.2.10 Replacing the temperature sensor 

of the hydraulic fluid tank . . . . . . . . 4-175 

8.2.11 Replacing the fuel level sensor . . . 4-176 

8.3 Relays, coils and fuses . . . . . . . . . 4-177 

8.3.1 Replacing the relays . . . . . . . . . . . 4-177 

8.3.2 Replacing the solenoid valve 

drives on the variable 

displacement motor . . . . . . . . . . . . 4-177 



pump . . . . . . . . . . . . . . . . . . . . . . . 4-178 

8.3.4 Replacing the coil on the variable 

displacement pump . . . . . . . . . . . . 4-179 

8.4 Indicator lamps, audible warning 

generators and instruments . . . . . . 4-180 

8.4.1 Replacing the indicator lamp 

in the instrument panel. . . . . . . . . . 4-180 

8.4.2 Replacing the instrument lights . . . 4-181 

8.4.3 Replacing the horn. . . . . . . . . . . . . 4-182 

8.4.4 Replacing the audible warning 

generator . . . . . . . . . . . . . . . . . . . . 4-183 

8.4.5 Replacing the engine-hour 

indicator . . . . . . . . . . . . . . . . . . . . . 4-183 

8.5 Lighting system . . . . . . . . . . . . . . . 4-185 

8.5.1 Replacing a complete headlamp 

with indicator . . . . . . . . . . . . . . . . . 4-185 

8.5.2 Replacing a complete tail lamp . . . 4-185 

8.5.3 Replacing the headlight . . . . . . . . . 4-186 

9 Attachments. . . . . . . . . . . . . . . 4-189 

9.1 Replacing the earth bucket 

digging tooth . . . . . . . . . . . . . . . . . 4-189 

Part 5 Circuit diagrams and technical 

descriptions 

1 Hydraulic circuit diagram . . . . 5-7 

2 Electrical circuit diagram . . . . 5-9 

3 Plug assignments / 

contact assignments. . . . . . . . 5-19 

4 Technical description . . . . . . . 5-21 

Part 6 Supplier service manuals 

1 Engine workshop manual 

(example) . . . . . . . . . . . . . . . . . . . . 6-7 

2 Variable displ. pump repair 

instructions (example) . . . . . . . 6-9 

3 Variable displ. motor repair 

instructions (example) . . . . . . 6-11 

4 Planetary axle workshop 

manual (example) . . . . . . . . . . . 6-13 

0-10 1000239425 - WDF-6001-00EN 


A 

Additional weight 

Replacement . . . . . . . . . . . . . . . . . . . . . . 4-104 

Air filter 

Replacing complete . . . . . . . . . . . . . . . . . . 4-25 

Replacing the housing . . . . . . . . . . . . . . . . 4-26 

Alternator 

See generator . . . . . . . . . . . . . . . . . . . . . 4-163 

Annular shaft seal, replacement 

Variable displacement pump . . . . . . . . . . . 4-45 

Assignment 

Combination switch . . . . . . . . . . . . . . . . . . 5-19 

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . 5-19 

Multi-function lever . . . . . . . . . . . . . . . . . . 5-19 

Windshield wiper switch . . . . . . . . . . . . . . 5-19 

Audible warning generator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-183 

Auxiliary hydraulics 

Replacing the cover . . . . . . . . . . . . . . . . . 4-77 

Axles 

Safety instructions . . . . . . . . . . . . . . . . . . . 1-13 

B 

Base plate 

Replacement . . . . . . . . . . . . . . . . . . . . . . 4-104 

Battery disconnect switch 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-171 

Bearings, replacing 

Drawbar, long . . . . . . . . . . . . . . . 4-131, 4-132 

Drawbar, short . . . . . . . . . . . . . . . . . . . . . 4-127 

Lower bearing . . . . . . . . . . . . . . . . . . . . . 4-116 

Reversing lever, long . . . . . . . . . . . . . . . 4-129 

Reversing lever, short . . . . . . . . . . . . . . . 4-128 

Self-aligning bearing . . . . . . . . . . . . . . . . 4-115 

Belt buckle 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

Belt buckle circuit 

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 

Brake cylinder 

see Main brake cylinder . . . . . . . . . . . . . . 4-55 

Brake drum 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 

Brake fluid 

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57 

Brake hydraulics 

Replacing the tank . . . . . . . . . . . . . . . . . . 4-56 

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 

Brake shoes 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 

Brake system 



C 

Index 

Cab 

Removing complete . . . . . . . . . . . 4-144, 4-146 

Switches, replacing . . . . . . . . . . . . . . . . 4-169 

Cardan shaft 

see Drive shaft . . . . . . . . . . . . . . . . . . . . . 4-85 

Center joint 

Connecting . . . . . . . . . . . . . . . . . . . . . . . 4-111 

Detaching . . . . . . . . . . . . . . . . . . . . . . . . 4-109 

Circuit diagram 

Electrical circuit diagram . . . . . . . . . . . . . . 5-9 

Hydraulic circuit diagram . . . . . . . . . . . . . . 5-7 

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

Clutch hub 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 

Clutch PA flange 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 

Combination switch 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-168 

Contact assignment . . . . . . . . . . . . . . . . . . . . 5-19 

Control valve 

Checking the function . . . . . . . . . . . . . . . 3-29 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 

Installing the catch . . . . . . . . . . . . . . . . . . 4-70 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-63 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 

Cover, replacing 

Auxiliary hydraulics control lever . . . . . . . 4-78 

Cross controller 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 

Curling to load stop 

Checking and adjusting . . . . . . . . . . . . . . 3-37 

D 

Depressurize the hydraulic system . . . . . . . . 4-37 

Description 

see Technical description . . . . . . . . . . . . 5-21 

Differential lock 

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 

Digging tooth, replacing 

Earth bucket . . . . . . . . . . . . . . . . . . . . . . 4-189 

Document compartment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-142 

Door 

Replacing complete . . . . . . . . . . . . . . . . 4-153 

Door lock 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-151 

Door stay 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-152 

0-11

Index 

Drawbar, long 

Lower bearing, replacing . . . . . . . . . . . . 4-132 

Upper bearing, replacing . . . . . . . . . . . . 4-131 

Drawbar, short 

Replacing the bearings . . . . . . . . . . . . . 4-127 

Drive 

Safety instructions . . . . . . . . . . . . . . . . . . 1-13 

Drive shaft 

Disassembling . . . . . . . . . . . . . . . . . . . . . 4-85 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 

Temporary securing . . . . . . . . . . . . . . . . . 4-86 

Driver's canopy 

Lower section, replacing . . . . . . . . . . . . 4-141 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-139 

Driver's seat 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-137 

Driving bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 

Driving motor 

see Variable displacement motor . . . . . . . 4-45 

Driving sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

Driving speed 

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 

Dumping stop 


E 

Electrical circuit diagram . . . . . . . . . . . . . . . . . 5-9 

Electrical contact key . . . . . . . . . . . . . . . . . . . 2-27 

Electrical system 

Safety instructions . . . . . . . . . . . . . . . . . . 1-19 

Engine 

Cleaning after toppling . . . . . . . . . . . . . . . 4-19 

Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-13 

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 


Temperature sensor, replacement . . . . . 4-174 

Troubleshooting . . . . . . . . . . . . . . . . . . . . 3-14 

Workshop manual (example) . . . . . . . . . . . 6-7 

Engine hood 

Emergency release . . . . . . . . . . . . . . . . 4-109 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-107 

Replacing the lock . . . . . . . . . . . . . . . . . 4-108 

Engine temperature gauge, replacing 

see Engine-hour indicator, replacing . . . 4-183 

Engine-hour indicator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-183 

Exhaust system 

Inspecting for leaks . . . . . . . . . . . . . . . . . 3-11 

Expulsion sleeve . . . . . . . . . . . . . . . . . . . . . . 2-25 

F 

Fender 

Replacing front . . . . . . . . . . . . . . . . . . . . 4-103 

Replacing rear . . . . . . . . . . . . . . . . . . . . 4-103 

Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 

Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 

Flue 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

Front axle 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 

Relieving the load . . . . . . . . . . . . . . . . . . . 4-87 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 

Fuel feed pump 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 

Fuel filter 

Replacing complete . . . . . . . . . . . . . . . . . 4-27 

Fuel level sensor 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-176 

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 

Fuel tank gauge, replacing 


G 

Gear pump 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 

Generator 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-163 

Generator tester . . . . . . . . . . . . . . . . . . . . . . . 2-27 

Glow-plug indicator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-168 

0-12 1000239425 - WDF-6001-00EN 

WL 30 - 10/2008-1 (WDF-7018-00DE) 

H 

Half-shells and pull-off fixture . . . . . . . . . . . . . 2-28 

Handbrake 

see Parking brake . . . . . . . . . . . . . . . . . . . 4-99 

Headlamp 


Headlight 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-186 

Heater 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 


High pressure, checking 

Variable displacement pump . . . . . . . . . . 3-21 

Horn 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-182 

see Audible warning generator . . . . . . . . 4-183

Hose book . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 

Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . 5-7 

Hydraulic cylinder 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 

Hydraulic fluid tank 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 


Hydraulic line 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 

Hydraulic motor 


Hydraulic pump 

see Gear pump . . . . . . . . . . . . . . . . . . . . . 4-59 

see Variable displacement pump . . . . . . . 4-42 

Hydraulic system 


I 

Ignition lock 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-170 

Inching pedal 

Checking and adjusting . . . . . . . . . . . . . . . 3-17 

Indicator lamp 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-180 

Insertion tool . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

Instrument lights 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-181 

Instrument panel 

Switches, replacing . . . . . . . . . . . . . . . . . 4-167 

Instrument steering column 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-159 

Insulation mat 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-124 

L 

Lifting cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-71 

Load arm 



Locking agent . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

Locking cylinder 

Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-79 

Locking pin 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-134 

Lower bearing 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-116 


Index 

M 

Main brake cylinder 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 

Main fuel filter 


Muffler 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

O 

Operator's platform 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . 4-120 

Removing . . . . . . . . . . . . . . . . . . . . . . . . 4-117 

Orbital steering valve 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 

Overpressure switch, replacing 

Return filter . . . . . . . . . . . . . . . . . . . . . . 4-173 

P 

Parking brake 

Fitting the Bowden cable . . . . . . . . 4-89, 4-100 

Removing the Bowden cable . . . . .4-87, 4-100 

Replacing the Bowden cable . . . . . . . . . . 4-99 

Switch, replacing . . . . . . . . . . . . . . . . . . 4-172 

Pivot bearing 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 

Planetary axle 

Workshop manual (example) . . . . . . . . . . 6-13 

Plug assignment . . . . . . . . . . . . . . . . . . . . . . 5-19 

Positioning pressure, checking 


Pressure cut-off 


Pressure filter 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 

Pressure value 

Variable displacement pump and 

variable displacement motor . . . . . . . . . . 2-13 

Priority valve 

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 

Protective stickers 

Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-9 

R 

Radiator 

Checking installation . . . . . . . . . . . . . . . . 3-12 


Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-22 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 

0-13

Index 

Rear axle 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 

Rear muffler 

see Muffler . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

Rear weight 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-105 

Relay 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-177 

Repair work 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 

Replacing the rubber buffers 

Engine, front . . . . . . . . . . . . . . . . . . . . . . . 4-16 

Engine, rear . . . . . . . . . . . . . . . . . . . . . . . 4-17 

Return filter 

Overpressure switch, replacing . . . . . . . 4-173 

Replacing the complete . . . . . . . . . . . . . . 4-82 

Reversing lever, long 


Reversing lever, short 


Roof grille 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-154 

ROPS bar 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-139 

Rubber buffer, replacing 

Step plate . . . . . . . . . . . . . . . . . . . . . . . . 4-123 

S 

Safety stickers 

Meaning and position . . . . . . . . . . . . . . . . 2-17 

Sealing plate . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

Seat belt 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

Self-aligning bearing 

Replacing bearings . . . . . . . . . . . . . . . . 4-115 

Small parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

Solenoid valve, replacing . . . . . . . . . . . . . . . 4-177 

Variable displacement pump . . . . . . . . . 4-178 

Solenoid valve, replacing the coil . . . . . . . . . 4-179 

Solenoid valve, replacing the drive 

Variable displacement motor . . . . . . . . . 4-177 

Starter 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-164 

Starting speed 


Steering cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 

Steering hydraulics 

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 

Steering wheel 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-161 

Step plate 

Rubber buffer, replacing . . . . . . . . . . . . . 4-123 

Stickers 

see Protective stickers . . . . . . . . . . . . . . . . 4-9 

Storage compartment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-143 

Supply pressure, checking 


Switch, replacing 

Parking brake . . . . . . . . . . . . . . . . . . . . . 4-172 

Switches, replacing 

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169 

Instrument panel . . . . . . . . . . . . . . . . . . . 4-167 

T 

Tail lamp 

Replacing the complete . . . . . . . . . . . . . 4-185 

Tank lock 

Drilling open . . . . . . . . . . . . . . . . . . . . . . . 4-32 

Emergency opening . . . . . . . . . . . . . . . . . 4-32 

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 

Technical description . . . . . . . . . . . . . . . . . . . 5-21 

Temperature sensor, replacement 

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-174 

Hydraulic fluid tank . . . . . . . . . . . . . . . . . 4-175 

Temperature sensors 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 

Test pressure gauge . . . . . . . . . . . . . . . . . . . . 2-23 

Test pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 

Tightening torques 

General . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 

Special . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 

Tipping cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 

Replacing the rod-end bearing . . . . . . . . . 4-76 

Tool attachment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-133 

Tool attachment (US) 

Lock, replacing . . . . . . . . . . . . . . . . . . . . 4-135 

Transmission pump 


Troubleshooting 

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 

Electrical system . . . . . . . . . . . . . . . . . . . . 3-44 

Hydraulic system . . . . . . . . . . . . . . . . . . . 3-30 

0-14 1000239425 - WDF-6001-00EN 


Turning the bearing 

see Engine, cleaning after toppling . . . . . . 4-19 

Twin tires 

Changing the wheel . . . . . . . . . . . . . . . . . 4-95 

V 

Valve play 

Checking and adjusting . . . . . . . . . . . . . . . . 3-9 

Variable displacement motor 

Repair instructions (example) . . . . . . . . . . 6-11 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 

Solenoid valve, replacement . . . . . . . . . . 4-177 

Variable displacement motor control 

commencement 


Variable displacement pump 

Annular shaft seal, replacement . . . . . . . . 4-45 

Coil, replacement . . . . . . . . . . . . . . . . . . 4-179 

High pressure, checking . . . . . . . . . . . . . . 3-21 

Repair instructions (example) . . . . . . . . . . . 6-9 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 

Solenoid valve, replacing . . . . . . . . . . . . 4-178 

Supply pressure, checking . . . . . . . . . . . . 3-20 

Vehicle frame 


W 

Water separator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 

Wheels 

Checking the water filling . . . . . . . . . . . . . 3-34 

Window, replacing 

Bonded-in window . . . . . . . . . . . . . . . . . . 4-156 

Window with rubber clamping profile . . . 4-154 

Windshield washer container 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-150 

Windshield wiper arms 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-149 

Windshield wiper motor, front 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-166 

Windshield wiper motor, rear 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-165 


Index 

0-15

Index 

0-16 1000239425 - WDF-6001-00EN 



1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 1 

Safety 


1000239425 - WDF-6001-00EN 



Safety 

Safety 

This part of the repair manual contains special safety instructions relating to 

the loader's individual assemblies. 

Warning notices Warning notices are identified by a symbol, and differ in terms of the type and 

severity of the hazard described. The various types are shown below. 

DANGER 

Identifies a hazard that will result in death or serious, irreversible 

injury if it is not prevented. 

Follow the instructions in order to prevent the hazard. 

WARNING 

Identifies a hazard that can result in death or serious, irreversible 

injury if it is not prevented. 


CAUTION 

Identifies a hazard that can result in minor reversible injury. 


Identifies possible damage to the loader or to other property. 

Notices The following notices point out important items of information: 

Identifies a special item of information that is required for effective and efficient 

working. 

Identifies an environmental notice. 

Do not start working until you have read and understood all safety instructions. 

Sequence The sequence of the described work is binding. Keep to the defined sequence 

in order to avoid hazards. 

1-3

Safety 

1-4 1000239425 - WDF-6001-00EN 


1 Repair work 

(complete vehicle) . . . . . . . . . . . 1-7 

2 Engine . . . . . . . . . . . . . . . . . . . . . . . 1-9 



5 Brake system . . . . . . . . . . . . . . . 1-15 


load arm . . . . . . . . . . . . . . . . . . . . 1-17 

7 Electrical system. . . . . . . . . . . . 1-19 


Contents 

1-5

Contents 

1-6 1000239425 - WDF-6001-00EN 



Repair work (complete vehicle) 1 

1Repair work (complete vehicle) 

Safety instructions for repair work (complete vehicle) 

Repair personnel The repair personnel must have specialized knowledge of and experience 

in repairing this or comparable loaders. 

Should such knowledge be lacking, thorough training must be provided by 

experienced repair personnel from e.g. the manufacturer's in-house Service 

Department. 

Personnel requiring training, familiarization or instruction, or personnel who 

are currently undergoing general training, may work on or with the machine 

only under the constant supervision of an experienced, authorized supervisor. 

Equipment and work 

safety 

Besides the safety regulations outlined here, also pay attention to all safety 

instructions in the operator's manual. 

Workshop equipment appropriate for the work being done is absolutely 

essential for carrying out maintenance and repair measures. 

When working above head height, use suitable, safe climbing aids and 

work platforms. Never use parts of the machine as climbing aids. Keep all 

handles, steps, railings, pedestals, platforms and ladders free of dirt, snow 

and ice. 

If there are particular hazards involved, e.g. toxic gases, corrosive vapors, 

a toxic machine environment etc., wear personal safety equipment (filter for 

the inhaled air, protective overalls). 

Environmental protection Ensure that fuels, consumables and replacement parts are disposed of 

safely and in an environmentally responsible way. 

General safety No modifications, attachments or conversions that could impair safety may 

be applied to the loader unless expressly authorized by the manufacturer. 

The same also applies to the installation and settings of safety devices and 

safety valves, and also to welding on supporting parts. 

Replace the ROPS or FOPS protective structures if they are deformed or 

corroded (even only partially), or if they have been modified. 

Consult the manufacturer if the attachment points, the frame or the fasteners 

are damaged. Do not attempt to repair, align or reuse damaged 

ROPS or FOPS protective structures. 

Spare parts, fuels and consumables must conform to the technical requirements 

specified by the manufacturer. This is always the case with original 

spare parts. 

Before dispatch, empty components completely in order to prevent 

damage, e.g. from frost. 

It is prohibited to change rated pressures of pressure control valves without 

the manufacturer's express approval. 

Before repairs The entire loader, particularly the connections and screw attachments, 

must be cleaned with care agents at the start of the maintenance and repair 

work. Use fiber-free cleaning cloths and do not use any aggressive 

cleaning agents. 

Before cleaning the loader with water, a steam jet (high-pressure cleaner) 

or other cleaning agents, cover or seal all openings into which no water, 

steam or cleaning agents must not enter for safety or function-related reasons. 

The electrical components, the inlet and outlet openings for the engine's 

combustion air and refueling openings are at particular risk. 

Remove the covers and seals completely after cleaning. 

1-7

1 Repair work (complete vehicle) 

Removing components Burn hazard from hot parts or liquids! Do not remove components when the 

loader is still at operating temperature! 

Clean components carefully before disassembly. 

So that no dirt can enter, carefully close off connections and any open 

holes uncovered when the component was removed. 

Lifting loads When carrying out repairs on and replacing heavy individual parts and 

assemblies, use lifting gear to lift and secure them. Use only suitable lifting 

gear and load support equipment that is in perfect condition and that has a 

sufficient load-carrying capacity. Never stand or work under suspended 

loads! 

Only experienced personnel may be tasked with securing loads and 

instructing crane drivers. The instructor must be within sight of the operator, 

or must be in voice contact with him. 

Installing components When it is necessary to dismantle safety devices for mounting, maintenance 

or repair work: Immediately after completing the work, refit all safety 

devices and check that they function correctly. 

Secure Bowden cables and safety cables at the ends so that the eyes 

remain rotatable in order to prevent the cables from bending and then 

breaking. 

Screw connections that have been undone during maintenance and repair 

work, particularly on lines carrying oil or fuel, must be tightened again prior 

to restarting. When carrying out maintenance and repair work, check all 

lines and screw connections for leaks and to make sure that they are 

secure. 

After repairs If an area has been repainted and a safety sticker has been damaged or 

rendered illegible: Replace the safety sticker before restarting the machine. 

If there was a safety sticker on a replaced component or assembly: Also 

apply a safety sticker to the replacement part. Replacement stickers are 

available from the manufacturer. 

Apply protective varnish to all bare metal parts in order to prevent corrosion 

damage. 

Reattach the cable fastening screws after completing the repair work. 

After completing repair work, reinstall all safety fixtures, covers and insulation 

to protect against noise and vibrations. 

Check the function of the loader, particularly the function of the repaired 

components, in a test operation. When doing this, ensure that nobody is 

within the loader's danger area. 

Do not approve the loader for use again until it functions correctly in all 

areas. 

1-8 1000239425 - WDF-6001-00EN 


Safety instructions for working on the engine 


Engine 2 

Only perform repair work when the loader is secured (see operator's 

manual "Securing the loader"). 

Caution: Risk of poisoning! Engine exhausts are toxic! Do not inhale any 

engine exhaust fumes! 

Perform the following measures for all work involving running the engine in 

an enclosed room: Ventilate the room well and extract the exhaust fumes 

with an extractor system. 

Risk of injury from rotating and hot parts! Allow the engine to cool down 

after switching it off. 

Inspect the V-belt only when the engine is stationary. 

Do not smoke when handling flammable liquids, and avoid naked flame or 

fire. 

Do not use water to extinguish fires on the loader and burning liquids. Use 

suitable extinguishing agents such as powder, carbon dioxide or foam. 

Always call the Fire Department in the event of a fire! 

Fix oil and fuel leaks immediately. 

Avoid damaging the environment. Do not allow oil and waste containing oil 

to enter the soil or bodies of water. 

Absorb escaped oil or fuel immediately using a binding agent. Dispose of 

the binding agent and the absorbed liquid separately from other waste and 

in an environmentally responsible manner. 

Biodegradable "environmentally friendly" oil must also be disposed of separately, 

just like any other oil. 

2Engine 

1-9

2 Engine 

1-10 1000239425 - WDF-6001-00EN 



Hydraulic system 3 

Safety instructions for working on the hydraulic 

system 

3Hydraulic system 

Only trained experts with special knowledge and experience may work on 

hydraulic equipment. 

Residual pressure decreases only gradually! Even when the loader is 

parked on a horizontal surface with its lift frame lowered and its engine 

switched off, there can still be significant residual pressure in parts of the 

hydraulic system. 

Depressurize the system before carrying out repair work on the hydraulic 

system (see the section "Depressurizing the hydraulic system" in Part 4). 

Leaks from which oil escapes must be repaired in order to prevent the following 

hazards: 

Environmental hazard 

Fire hazard 

Slip hazard 

Explosion hazard 

Injury hazard 

Caution: Injury hazard! A fine, pressurized jet of hydraulic fluid can penetrate 

the skin! Seek immediate medical attention if oil gets in your eyes or 

penetrates your skin. 

Do not search for leaks using your hands! To trace a leak, use a piece of 

card or paper that shows up sprayed-out oil. 

Do not repair damaged pipelines and hydraulic hoses. Instead, replace 

them immediately with new ones even if only the penetration of dampness 

is visible. 

Hydraulic hoses must be replaced after a service life of six years. 

Open hydraulic connections with care, so that you can react if large quantities 

of oil escape. 

Do not open damaged pre-tensioned units (e.g. hydraulic accumulators)! 

Always replace them completely instead. 

Use only suitable vessels to collect hydraulic oil. 

Dispose of escaped oil and waste containing oil in an environmentally 

responsible manner. 

Handle O-rings, Q-rings and gaskets with particular care. 

Replace damaged or lost O-rings, Q-rings and gaskets immediately. 

Hydraulic lines must be laid and installed correctly! This work may only be 

done by authorized experts. Ensure that no connections are mixed up. The 

fittings, length and quality - particularly the pressure and temperature resistance 

of hydraulic lines - must meet requirements. 

1-11

3 Hydraulic system 

1-12 1000239425 - WDF-6001-00EN 



Drive and axles 4 

4Drive and axles 

Safety instructions for working on the drive and axles 

When jacking up the loader, keep the load arm as low as possible in order 

to keep the center of gravity as close to the ground as possible. 

Use only suitable equipment, e.g. a garage jack, to jack up and support the 

loader. 

1-13

4 Drive and axles 

1-14 1000239425 - WDF-6001-00EN 



Brake system 5 

Safety instructions for working on the brake system 

Repair work on brakes may only be carried out if the personnel is trained 

for working on brake systems. If in doubt, the manufacturer's Service 

Department must do the work. 

It is forbidden to use any brake fluid not approved by the manufacturer. 

When working with brake fluid, pay attention to the health hazard information 

and environmental protection. 

Only perform repair work on brakes when the loader is secured (see operator's 

manual "Securing the loader"). 

5Brake system 

1-15


1-16 1000239425 - WDF-6001-00EN 



Vehicle frame and load arm 6 

6Vehicle frame and load arm 

Safety instructions for working on the vehicle frame 

and load arm 

Fit the support provided for the lift frame before commencing work on the 

raised lift frame, so that the lift frame does not descend suddenly and unintentionally. 

This fixture must conform to ISO 10533. 

When carrying out repair work in the articulation crush zone, always block 

the articulated link with the articulation frame lock. 

Remove the block after completing the repair work. 

Welding work Welding work may only be done by persons with the necessary training. 

Containers that contain or have contained materials that are combustible, 

promote combustion, are explosive or can produce harmful vapor, gas, 

mist or dust during welding work: Only authorized persons under the supervision 

of a competent expert may carry out welding work on these containers. 

Always consult the manufacturer's Service Department if you have 

any problems or queries. 

Disconnect the battery before commencing welding work (see "Disconnecting 

and connecting the battery/changing the battery" in the operator's 

manual). 

Protect bare terminals and connections against short circuits! 

Attach the welding grounding terminal in the immediate vicinity of the 

welding location. The welding current must not pass through gears, bolts, 

articulated joints or hydraulic cylinders. 

Connect the battery after welding (see "Disconnecting and connecting the 

battery/changing the battery" in the operator's manual). 

1-17

6 Vehicle frame and load arm 

1-18 1000239425 - WDF-6001-00EN 



Electrical system 7 

7Electrical system 

Safety instructions for working on the electrical system 

Work on the machine's electrical equipment may only be carried out by a 

qualified electrician or by trained persons working under the supervision of 

a qualified electrician. 

Caution: Explosion hazard! Batteries give off explosive gases! No not 

smoke or bring naked flames near to a battery. 

Do not place any objects on the battery. If a metal object touches both the 

positive pole and the negative pole of a battery, a short occurs - and possibly 

an explosion. This can result in serious burns. 

Caution: Injury hazard! Battery acid is corrosive. Make sure that battery 

acid does not come into contact with your skin, eyes, mouth and clothes. 

Wear protective gloves and safety goggles. If you come into direct contact 

with battery acid, rinse off the contaminated part of your body immediately 

with a lot of clean water. Seek immediate medical attention. 

Always remove metal jewelry and watches before working on the battery or 

the electrical system. 

Dispose of old batteries in an environmentally responsible manner and 

separate from other waste. 

Replacement fuses must be of the same type and current rating as specified 

by the manufacturer. 

1-19

7 Electrical system 

1-20 1000239425 - WDF-6001-00EN 


A 

Axles 


B 

Brake system 


D 

Drive 


E 

Electrical system 


Engine 

Safety instructions . . . . . . . . . . . . . . . . . . . . 1-9 

H 



L 

Load arm 


R 

Repair work 

Safety instructions . . . . . . . . . . . . . . . . . . . . 1-7 

V 

Vehicle frame 



Index 

1-21

Index 

1-22 1000239425 - WDF-6001-00EN 



1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 2 

Technical data, testing equipment and special tools 


1000239425 - WDF-6001-00EN 



Technical data 


This part of the repair manual contains general technical data that gives an 

overview of the loader's properties. 

Filling quantities The list of filling quantities contains the fuels and consumables that are 

required for smooth operation of the loader. 

Tightening torques The list of tightening torques contains the values that must be maintained in 

order to reliably secure components and at the same time prevent damage to 

the connecting elements. 

Pressure values The list of pressure values refers to the variable displacement pump and variable 

displacement motor. The list simplifies troubleshooting on the hydraulic 

system. 

Meaning and position of 

the safety stickers 

On the loader there are safety stickers that warn about hazards or give instructions. 

The meanings and location points for the safety stickers are summarized in a 

list. 

Testing equipment Special testing equipment is required for troubleshooting and adjustment 

work. 

The standard tools for the work described are required in addition to the testing 

equipment summarized in this list. 

Special tools The described special tools are absolutely essential for the work described. 

However, the special tools make work easier and in most cases you can make 

them yourself with little effort. 

2-3


2-4 1000239425 - WDF-6001-00EN 


1 Technical data . . . . . . . . . . . . . . . 2-7 

2 Filling quantities . . . . . . . . . . . . . 2-9 

3 Tightening torques . . . . . . . . . . 2-11 

4 Pressure values . . . . . . . . . . . . . 2-13 

5 Flow rates. . . . . . . . . . . . . . . . . . . 2-15 

6 Safety stickers . . . . . . . . . . . . . . 2-17 

7 Testing equipment . . . . . . . . . . 2-23 

7.1 Test pressure gauge . . . . . . . . . . . . . 2-23 

7.2 Flow meter . . . . . . . . . . . . . . . . . . . . 2-23 

7.3 Test pump . . . . . . . . . . . . . . . . . . . . . 2-24 

8 Special tools . . . . . . . . . . . . . . . . 2-25 

8.1 Insertion tool . . . . . . . . . . . . . . . . . . . 2-25 

8.2 Sealing plate (2 x) . . . . . . . . . . . . . . . 2-25 

8.3 Expulsion and driving sleeves. . . . . . 2-25 

8.4 Driving bolts . . . . . . . . . . . . . . . . . . . 2-26 

8.5 Electrical contact key . . . . . . . . . . . . 2-27 

8.6 Generator tester . . . . . . . . . . . . . . . . 2-27 

8.7 Half-shells and pull-off fixture . . . . . . 2-28 

9 Hose book . . . . . . . . . . . . . . . . . . 2-29 


Contents 

2-5

Contents 

2-6 1000239425 - WDF-6001-00EN 


Engine Perkins 4-cylinder Diesel engine 

Output 35.7 kW / 49 HP at 2600 rpm 

Type 404 D – 22 water-cooled 

Capacity 2216 cm 3 

Hydraulic system Driving hydraulics 

Flow rate 72.8 l/min 

Working pressure 450 bar 

Working hydraulics 

Flow rate 49 l/min 

Primary pressure, working pressure 210 bar 

Secondary pressure, curling to load 250 bar 

Secondary pressure, dumping 140 bar 


Flow rate 49 l/min 

Working pressure 210 bar 

Drive (driving speed) 1. gear 0 - 7 km/h 

2. gear 0 - 20 km/h 

Electrical system Operating voltage 12 V 

Battery 77 Ah 

Generator 

Charging voltage 14 V (at 2000 rpm) 

Maximum capacity 65 A 


Technical data 1 

1Technical data 

2-7

1 Technical data 

2-8 1000239425 - WDF-6001-00EN 



Filling quantities 2 

All values are approximate values. 

The inspection holes, inspection glasses or dipsticks must be used to 

obtain a correct filling. 

Location Quantity in 

liters 

Liquid Specification 

Engine Fuel tank 53 Diesel fuel DIN 51601 (see engine 

manual) 

Engine oil with filter 

Cooling system 

contents 

with heater 

Hydraulic system Complete hydraulic 

system 

Hydraulic fluid 

tank 

Drive and axles Front axle APR 

715-PA940 

8.3 Engine oil SAE 

10 W 40 

Ambient temperature 

-20 °C to 

+40 °C 

11.5 Water with 

standard HP 

12 coolant / antifreeze 

40 Hydraulic fluid 

HLP 

30 Hydraulic fluid 

HLP 

API CG-4 / API CH-4 

(see engine manual) 

HP coolant / antifreeze: 

ASTM D3306 

ISO VG 46 

ISO VG 46 

Brake hydraulics 1 Hydraulic oil ATF oil 

Rear axle APR 

715-PA940 

3.2 Transmission oil 

SAE 90 GL 5 

3.9 Transmission oil 

SAE 90 GL 5 

Hypoid 

Hypoid 

2Filling quantities 

2-9

2 Filling quantities 

2-10 1000239425 - WDF-6001-00EN 


Special tightening 

torques 

General tightening 

torques 

Screws with coarse-pitch 

thread 


Tightening torques 3 

This section summarizes the tightening torques in two groups: 

Special tightening torques 

General tightening torques 

If no special tightening torque is stipulated, the general tightening torques 

apply (see "General tightening torques"). 

Assembly Connection Tightening torque (Nm) 

Engine Cylinder head cover: 

Bolt 

Nut 

Drive and axles Front axle securing 360 

Tightening torques for screws with coarse-pitch thread as a function of the 

quality 

14 

14 

Rear axle securing 360 

Wheel Wheel nut 285 

Wheel (twin tires) Hooked bolt nut 285 

Thread size in mm Tightening torque 1) in Nm 

Quality 8.8 Quality 10.9 Quality 12.9 

M4 3 4 5 

M5 5.5 8 10 

M6 10 14 16 

M8 23 34 40 

M10 46 67 79 

M12 79 115 135 

M14 125 185 220 

M16 195 290 340 

M18 280 400 470 

M20 395 560 660 

M22 540 760 890 

M24 680 970 1150 

M27 1000 1450 1700 

M30 1350 1950 2300 

1) These values apply to screws with an untreated, unlubricated surface. 

3Tightening torques 

2-11

3 Tightening torques 

Screws with fine-pitch 

thread 

Tightening torques for screws with fine-pitch thread as a function of the quality 

Thread size in mm Tightening torque 1) in Nm 

Quality 8.8 Quality 10.9 Quality 12.9 

M8x1 28 39 46 

M10x1.25 53 74 89 

M12x1.5 91 126 151 

M14x1.5 150 210 250 

M16x1.5 225 315 380 

M18x1.5 325 460 550 

M20x1.5 460 640 770 

M22x1.5 610 860 1050 

M24x2 780 1100 1300 

M27x2 1160 1640 1970 

M30x2 1600 2330 2730 

1) These values apply to screws with an untreated, unlubricated surface. 

Hydraulic lines Tightening torques for conical sealing screw connections 

Pipe outside diameter Tightening torque 1) in Nm ± 5 % 

L 6 20 

L 8 30 

L 10 40 

L 12 50 

L 15 70 

L 18 90 

L 22 120 

L 28 160 

L 35 250 

L 42 380 

S 6 25 

S 8 40 

S 10 50 

S 12 60 

S 14 75 

S 16 85 

S 20 140 

S 25 190 

S 30 270 

S 38 400 

1) Union nut waxed, thread oiled (source: www.voss.de, 07.09.08) 

2-12 1000239425 - WDF-6001-00EN 


Variable displacement 

pump, driving forward 


pump, reversing 


motor 


Pressure values 4 

The stated values are guideline values and can vary between loaders. 

The values are intended as orientation aids for troubleshooting. 

The following table contains the pressure values (in bar) at the variable displacement 

pump for driving forward and with the drive blocked. 

Speed [rpm] Pressure (in bar) at measuring point 

G X2MA X1 MB 980 25 6 35 < 2 25 

1050 25 7 110 < 2 25 

1370 27 9 220 < 2 25 

1600 25 11 300 < 2 25 

2350 27 16 450 < 2 25 

2800 27 18 450 < 2 25 


pump for reversing and with the drive blocked. 


G X2MA X1 MB 980 25 < 2 25 6 35 

1050 25 < 2 25 7 110 

1370 27 < 2 25 9 220 

1600 25 < 2 25 11 300 

2350 27 < 2 25 16 450 

2800 27 < 2 25 18 450 


motor with the drive blocked. 


G M1 980 25 0 

1050 110 0 

1370 220 110 

1600 300 300 

2350 450 450 

2800 450 450 

4Pressure values 

2-13

4 Pressure values 

2-14 1000239425 - WDF-6001-00EN 


The gear pump delivers 19 cm3 per revolution. 

This provides the following flow rates in liters per minute: 


Flow rates 5 

The stated values are guideline values and can vary between loaders. 

The values are intended as orientation aids for troubleshooting. 

Speed [rpm] Flow rate [l/min] 

Gear pump 980 19 

1050 20 

1370 26 

1600 30 

2350 45 

2600 49 

2800 53 

5Flow rates 

2-15

5 Flow rates 

2-16 1000239425 - WDF-6001-00EN 


Meaning and position of the safety stickers 

Meaning The stickers have the following meanings: 

Sticker Meaning 


Safety stickers 6 

Hazard 

Stay out of the loader's danger area during operation. 

Do not walk under the raised lift frame. 

Hazard 

Risk of injury by moving parts. 

Never open the safety devices while the engine is running. 

Hazard 

Always stay outside the unsecured danger area. 

Use the safety supports. 

Hazard 

Always lock the roll bar in the protection position as 

soon as working conditions allow. 

Hazard 

Remove the ignition key before starting maintenance 

and repair work. 

Always follow the operator's manual when carrying out 

maintenance and repair work. 

6Safety stickers 

2-17

6 Safety stickers 


Risk of equipment damage 

Lubricate the center joint daily before start-up. 

Refer to the lubrication plan in the operator's manual. 

Hazard 

Hot surfaces can cause burns. 

Never touch hot surfaces. 

Allow the surface to cool down and wear protective 

gloves. 

Hazard 

Risk of injury from falling. 

Do not climb into the raised earth bucket. 

Never lift persons with the earth bucket. 

Hazard 

Hot coolant can cause scalding injuries! 

Never open the cooling system when it is under pressure 

or when the engine is hot. 

Allow the engine to cool down and wear protective 

gloves. 

Hazard 

Falling out of the loader can cause injury. 

Always wear a seat belt when working. 

2-18 1000239425 - WDF-6001-00EN 




Hazard 

Risk of injury from being run over. 

Never carry passengers in the loader. 

Never sit on the fenders. 



The ROPS bar and the driver's canopy are safety components 

that must never be modified. 

Do not drill holes in the material. 

Do not weld the material. 

Only do work that is described in this documentation. 

Hazard 

Risk of crush injury. 

All persons must remain outside the working loader's 

danger area. 

Always maintain a safety clearance from the working 

loader. 

Always use the climbing aids to climb in and out of the 

loader. 

Hazard 

Risk of crush injury. 

Always lock the center joint when carrying out maintenance 

work. 

Hazard 

When hydraulically operated attachments are used, the 

lever must always be set to "Hydraulic connection". 


Close both doors before tilting the cab. 

Identifies an attachment point 

2-19



Identifies a tie-down point 

Identifies the maximum acoustic power level 

Indicates the use of hydraulic oil 

Indicates the use of oil in the brake system 

Indicates that hardening time of the varnish 

Location The locations of the safety stickers are shown in the following drawings: 

Fig. 1 Stickers located on the left in the driving direction 

2-20 1000239425 - WDF-6001-00EN 


Fig. 2 Stickers located on the right in the driving direction 

Fig. 3 Stickers located in the engine 

compartment (left) 



Fig. 4 Stickers located in the engine 

compartment (right) 

2-21


2-22 1000239425 - WDF-6001-00EN 


7.1 Test pressure gauge 


Testing equipment 7 

Purpose The test pressure gauge shows the pressure of the hydraulic circuit, the test 

connection of which it is connected to. 

Configuration For the pressure ranges, see the table "Pressure range and number" 

Measuring line (Fig. 5,2) 

Adapter (Fig. 5,1) 

Pressure range and 

number 

Fig. 5 Test pressure gauge (up to 

400 bar) 

Pressure range Number required 

0 ... 60 bar 3 

0 ... 250 bar 1 

0 ... 600 bar 2 

7.2 Flow meter 

Purpose The flow meter shows the flow and the pressure of the hydraulic circuit in 

which the flow meter is installed. 

Configuration Pressure range up to 400 bar 

Flow up to 200 l/min 

Oil temperature up to 114 °C 

Fig. 6 Flow meter 

7Testing equipment 

2-23

7 Testing equipment 

7.3 Test pump 

Purpose The test pump checks the pressure resistance of the cooling system and that 

it is free of leaks. 

Configuration Pressure range up to 1.6 bar 

Hand pump 

Connection for cooler opening 

Fig. 7 Test pump 

2-24 1000239425 - WDF-6001-00EN 


8.1 Insertion tool 


Special tools 8 

Purpose The insertion tool is used to insert the annular seals into the guide bushes of 

the hydraulic cylinders, without bending or otherwise damaging the annular 

seals. 

Configuration Metal 

2 hand levers 

Fig. 8 Insertion tool 

8.2 Sealing plate (2 x) 

Purpose The sealing plates seal the hydraulic lines to the gear pump for as long as the 

gear pump is removed. 

Configuration Metal plate 

Square 

4 holes 

Fig. 9 Sealing plate 

8.3 Expulsion and driving sleeves 

Purpose The expulsion and driving sleeves are used to expel and drive in pivot bearings 

(e.g. of the steering cylinder) straight and without damaging the pivot 

bearing. 

For expulsion, the expulsion and driving sleeves of the next largest pivot 

bearing can be placed as a support under the component from which the pivot 

bearing is being expelled. 

Configuration Metal, solid material 

For details, see the table "Dimensions and bearing types" 

8Special tools 

2-25

8 Special tools 

Dimensions and 

bearing types 

Fig. 10 Expulsion and driving sleeves 

(section) 

Bearing type Dimensions in mm 

D d H h 

GE25 37 31 30 20 

GE30 42 37 30 20 

GE40 60 50 50 25 

GE45 70 60 50 25 

GE50 (removal) 66 60 50 25 

GE50 (installation) 75 51 50 25 

GE50FO 81 72 50 25 

GE63 (removal) 82 75 50 25 

GE63 (installation) 94 64 50 25 

GE70 110 100 50 25 

8.4 Driving bolts 

Purpose The driving bolts are used to drive in bearing bushes (e.g. sliding bearings on 

the short drawbar) straight and without damaging the bearing. 


Cylindrical 

Handle (Fig. 11,1) 

d < inside diameter of the bearing bush 

D > outside diameter of the bearing bush 

Fig. 11 Driving bolt 

2-26 1000239425 - WDF-6001-00EN 


8.5 Electrical contact key 


Special tools 8 

Purpose The electrical contact key is used to remove and install the contacts on the tab 

connectors of the cables leading to the control unit. 

Configuration Metal/plastic 

Fig. 12 Electrical contact key 

Availability The electrical contact key, Article No. 124423, is available via: 

Berner GmbH 

Befestigungs- und Verbindungstechnik 

Bernerstr. 4 

74653 Künzelsau, Germany 

8.6 Generator tester 

Purpose The generator tester allows the charging voltage and current intensity to be 

measured as a function of the engine speed. 

At an engine speed of 2000 rpm, the charging voltage must be 14 V and the 

current intensity must be 65 A. 

Configuration 1 current indicator 

1 voltage indicator 

3 adjustable voltage ranges 

3 adjustable current ranges 

1 zero position 

1 variable load 

2 heavy current cable 

1 clip-on ammeter 

Fig. 13 Generator tester 

1 Heavy current cable 

2 Variable load 

3 Generator tester 

4 Clip-on ammeter 

2-27

8 Special tools 

Fig. 14 Measurement set-up 

1 Generator tester 

2 Clip-on ammeter 

3 Generator 

4 Battery 

Fig. 14 shows a possible measuring set-up with a generator tester (Fig. 14,1). 

The two heavy current cables connect the battery (Fig. 14,4) to the generator 

tester (Fig. 14,1). The clip-on ammeter (Fig. 14,2) covers the cable between 

the generator (Fig. 14,3) and the battery (Fig. 14,4). 

8.7 Half-shells and pull-off fixture 

Purpose The two half-shells and a three-arm pull-off fixture are used to pull the steering 

wheel off the steering column without damaging the steering wheel. 


For details, see the table "Dimensions" 

Fig. 15 Half-shells (section view) Fig. 16 Half-shells (top view) 

Dimensions in mm 

D d H 

Dimensions 52 46 7 

2-28 1000239425 - WDF-6001-00EN 


Enter every replaced hydraulic line in the hose book. 


Hose book 9 

9Hose book 

2-29

9 Hose book 

Model: WL 30 Publisher: Wacker Neuson SE Date/Edition: Inspections: 

Chassis number: Place: D-80809 München 

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

Hose line Next hose Date of hose Hose line Next hose Date of hose Hose line Next hose 

installation / replacement line installation / replacement line installation / replacement 

company date manufacture company date manufacture company date 

[Quarters] [Month / year] [Date] [Quarter / year] [Month / year] [Date] [Quarter / year] [Month / year] [Date] [Quarter / year] 

Date of hose 

line 

manufacture 

Max. 

period of use 

In acc. with 

DIN / EN / ISO 

Ser. 

No. Article number Installation location 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 

2-30 1000239425 - WDF-6001-00EN 


D 

Driving bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 

Driving sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

E 

Electrical contact key . . . . . . . . . . . . . . . . . . . . 2-27 

Expulsion sleeve . . . . . . . . . . . . . . . . . . . . . . . 2-25 

F 

Flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 

Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 

G 

Generator tester . . . . . . . . . . . . . . . . . . . . . . . 2-27 

H 

Half-shells and pull-off fixture . . . . . . . . . . . . . 2-28 

Hose book . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 

I 

Insertion tool . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

P 

Pressure value 

Variable displacement pump and 

variable displacement motor . . . . . . . . . . . 2-13 

S 

Safety stickers 

Meaning and position . . . . . . . . . . . . . . . . 2-17 

Sealing plate . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 

T 

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 

Test pressure gauge . . . . . . . . . . . . . . . . . . . . 2-23 

Test pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 

Tightening torques 

General . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 

Special . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 


Index 

2-31

Index 

2-32 1000239425 - WDF-6001-00EN 



1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 3 

Inspections, maintenance work and troubleshooting 


1000239425 - WDF-6001-00EN 




Inspections 

Inspections 

This part of the repair manual contains inspection and adjustment procedures, 

details of special maintenance work (if applicable) and individual troubleshooting 

lists, subdivided on the basis of the loader's assemblies. 

Only Wacker Neuson Customer Service may remove the lead seals. Unauthorized 

removal of the lead seals renders the warranty void. If in doubt, 

consult Wacker Neuson Customer Service. 

Some adjustment screws on the variable displacement pump and variable 

displacement motor have been lead-sealed by the manufacturer. 

For all inspections on the variable displacement motor, it must be operated 

across its entire control range, i.e. the variable displacement motor must be 

switched to "overdrive" (if present). 

Maintenance The operator's manual contains a complete overview of the maintenance work 

and intervals. 

3-3

Inspections 

3-4 1000239425 - WDF-6001-00EN 


1 Complete vehicle. . . . . . . . . . . . . 3-7 

1.1 Inspection log . . . . . . . . . . . . . . . . . . . 3-7 

2 Engine . . . . . . . . . . . . . . . . . . . . . . . 3-9 

2.1 Checking and adjusting the valve 

play . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 

2.2 Inspecting the exhaust system for 

leaks . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 

2.3 Checking the radiator installation . . . 3-12 

2.4 Inspect the radiator for leaks. . . . . . . 3-13 

2.5 Troubleshooting on the engine . . . . . 3-14 



starting speed . . . . . . . . . . . . . . . . . . 3-17 


inching pedal. . . . . . . . . . . . . . . . . . . 3-17 


pressure cut-off . . . . . . . . . . . . . . . . . 3-18 

3.4 Adjusting the driving speed. . . . . . . . 3-19 

3.5 Checking the variable 

displacement pump supply 

pressure . . . . . . . . . . . . . . . . . . . . . . 3-20 


displacement pump high 

pressure . . . . . . . . . . . . . . . . . . . . . . 3-21 


displacement pump positioning 

pressure . . . . . . . . . . . . . . . . . . . . . . 3-23 


control commencement of the 

variable displacement motor . . . . . . . 3-24 

3.9 Testing the steering hydraulics . . . . . 3-25 

3.10 Checking the gear pump . . . . . . . . . . 3-27 

3.11 Checking the control valve 

function . . . . . . . . . . . . . . . . . . . . . . . 3-29 

3.12 Troubleshooting on the hydraulic 

system. . . . . . . . . . . . . . . . . . . . . . . . 3-30 


4.1 Inspecting the differential lock. . . . . . 3-33 

4.2 Checking the water filling of the 

wheels. . . . . . . . . . . . . . . . . . . . . . . . 3-34 

4.3 Troubleshooting on the drive. . . . . . . 3-35 


load arm . . . . . . . . . . . . . . . . . . . . 3-37 


curling to load and dumping 

stops . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 

6 Cab . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 

6.1 Checking the heater . . . . . . . . . . . . . 3-39 

6.2 Troubleshooting in the cab . . . . . . . . 3-40 


Contents 

7 Electrical system . . . . . . . . . . . 3-41 

7.1 Checking the generator . . . . . . . . . . 3-41 

7.2 Checking the temperature 

sensors . . . . . . . . . . . . . . . . . . . . . . 3-41 

7.3 Testing the belt buckle circuit . . . . . 3-42 

7.4 Testing the fuel level sensor . . . . . . 3-43 

7.5 Troubleshooting on the electrical 

system . . . . . . . . . . . . . . . . . . . . . . . 3-44 

3-5

Contents 

3-6 1000239425 - WDF-6001-00EN 


1.1 Inspection log 

Vehicle data Vehicle type 


Complete vehicle 1 

1Complete vehicle 

Before the measurements, the vehicle must be brought to an operating 

temperature of between 50 and 60 °C (oil temperature). 

If you wish to use the inspection log more than once, copy it before entering 

the inspection results. 

Chassis number 

Factory number of the variable displacement 

pump 

Factory number of the variable displacement 

motor 

Inspection characteristic 

Note Setpoint Actual 

Engine Idling speed 980 rpm 

Maximum speed No load 2800 rpm 

Valve play 0.2 mm 


Hydraulic system Starting speed On a level surface 

Driving speed, max. Downhill and 

loaded 

Pressure cut-off At maximum 

speed 


pump supply 

pressure 

High pressure M A 

High pressure M B 

Positioning pressure 

X 2 


X 1 


At maximum 

speed 

At maximum 

speed, forwards 

At maximum 

speed, reverse 

At maximum 

speed, forwards 

At maximum 

speed, reverse 

Steering pressure Steering wheel 

fully turned 

Primary pressure, 

gear pump 

At maximum 

speed 

Flow rate, gear pump At maximum 

speed, no load 

"Dumping" secondary 

pressure 

"Curling to load" secondary 

pressure 

1080 rpm 

27 km/h 

450 bar 

27 bar 

450 bar 

450 bar 

18 bar 

18 bar 

190 bar 

210 bar 

53 l/min 

140 bar 

250 bar 

3-7

1 Complete vehicle 


Electrical system Battery voltage Engine switched 

off 

Charging voltage At 2000 rpm, 

loaded 

Charging current At 2000 rpm, 

loaded 


3-8 1000239425 - WDF-6001-00EN 

WL 30 - 10/2008-1 (WDF-7021-00EN) 

12 V 

14 V 

65 A

2.1 Checking and adjusting the valve play 


Engine 2 

WARNING 


Do not open the engine hood when the engine is running, unless this 

manual expressly instructs you to do so. 

The valve play may only be adjusted when the engine is cold. 

The adjustment sequence refers to the view of the engine from the fan side 

(see Fig. 4). 

Rotate the crankshaft clockwise. 

Valve play (inlet and outlet): 0.2 mm, cold 

Fig. 1 Cylinder arrangement 

1 

2 

V1 

V2 

V3 

V4 

V5 

V6 

V7 

V8 

Z1 

Z2 

Z3 

Z4 

Fan wheel 

Flywheel, ring gear 

Inlet valve 1 

Outlet valve 2 

Inlet valve 3 


Inlet valve 5 


Inlet valve 7 


Cylinder 1 

Cylinder 2 

Cylinder 3 

Cylinder 4 

2Engine 

3-9

2 Engine 

Requirements Ensure the following: 

Removing the cylinder head 

cover 

Checking and adjusting the 

valve play 

Overlap Adjust valve play 

Cylinder 4 1 and 2 




The operator's platform is tilted (see operator's manual "Tilting the operator's 

platform"). 

Fig. 2 Connection to the air filter Fig. 3 Cylinder head cover attachment 

Release the 2 clamps (Fig. 2,1). 

Remove the hose (Fig. 2,2). 

Unscrew the 4 nuts (Fig. 3,1). 

Unscrew the 5 screws (Fig. 3,2). 

Remove the cylinder head cover (Fig. 3,3). 

Fig. 4 Valve 7 

Push the feeler gauge (Fig. 4,1) under the tipping lever (Fig. 4,2). 

If necessary, hold the nut with a suitable wring wrench and adjust the valve 

play with a screwdriver. 

3-10 1000239425 - WDF-6001-00EN 


Installing the cylinder head 

cover 

Inspecting the engine 

compartment interior 

Fig. 5 Cylinder head cover seal 


Engine 2 

Inspect the cylinder head cover seal (Fig. 5) and replace it if necessary. 

Put the cylinder head cover (Fig. 3,3) into position. 

Screw in the 5 screws (Fig. 3,2). 

Screw the 4 nuts (Fig. 3,1) onto the threaded bolts. 

Tighten the screws and nuts with a tightening torque of 14 Nm. 

Attach the hose (Fig. 2,2) with clamps (Fig. 2,1) to the air filter and suction 

pipe. 

Tighten the 2 clamps (Fig. 2,1). 

Final work Tilt the operator's platform back (see operator's manual "Tilting the operator's 


2.2 Inspecting the exhaust system for leaks 

WARNING 

Hot parts can cause burns. 

Never work on the engine when it is at operating temperature. 

Allow the engine to cool down or wear protective gloves. 

WARNING 


Never work on the exhaust when it is at operating temperature. 

Allow the exhaust to cool down or wear protective gloves. 

Open the engine hood (see operator's manual "Opening the engine hood"). 

Inspect the engine compartment interior for soot deposits. 

If there are no soot deposits, the exhaust system is free of leaks and this 

concludes the inspection. 

Localizing the leak If there are soot deposits, inspect the exhaust system for visible damage. 

3-11

2 Engine 

DANGER 

Exhaust fumes are toxic and potentially lethal! 

Do not inhale exhaust fumes. 

Ensure that the area where you are carrying out the inspection is sufficiently 

well ventilated. 

WARNING 


Never reach into the engine compartment while the engine is running. 

If there is no visible damage, start the engine, close the exhaust and check 

the exhaust system for escaping smoke. 

Switch off the engine. 

If damage is found: 

Remedying the problem Replace the damaged component. 

Repeat the inspection. 

Final work Close the engine hood. 

2.3 Checking the radiator installation 

WARNING 


Never open the cooling system when the engine is hot or the cooling 

system is pressurized. 



The loader is secured (see operator's manual "Securing the loader"). 

The engine hood is open (see operator's manual "Opening the engine 

hood"). 

Fig. 6 Radiator 

Check that the fan wheel has sufficient clearance from other parts. 

Manually check that the fan wheel (Fig. 6,2) turns smoothly. 

Check whether the fan wheel projects approx. 1/3 into the opening of the 

air deflector (Fig. 6,1). 

Inspect the foam insulation (Fig. 6,3) fan for damage. Short circuit risk! 

3-12 1000239425 - WDF-6001-00EN 


If a fault is found: 


Engine 2 

Remedying the problem Correct the position of the radiator (see Part 4, "Installing the radiator" section). 

Add to the foam insulation if necessary. 


2.4 Inspect the radiator for leaks 


Spare parts and 

auxiliary equipment 

WARNING 







hood"). 

Designation Quantity 

Test pump 1 

Fig. 7 Leakage inspection 

Remove the cover (Fig. 7,3) from the radiator (Fig. 7,2). 

Place the test pump (Fig. 7,1) onto the radiator and lock it. 

Generate a pressure of approx. 1 bar in the radiator with the hand pump. 

Wait overnight. 

Read off the pressure on the pressure gauge. 

When the pressure has dropped, check the radiator and the engine for 

leaks. 

Remedy any leaks and repeat the inspection. 

Final work Remove the inspection tools. 

Close the engine hood. 

3-13

2 Engine 

2.5 Troubleshooting on the engine 

Symptom Possible cause Remedy 

Engine will not start Parking brake not applied Apply parking brake 

Driving direction switch 

switched 

Bring the driving direction 

switch into the Neutral 

position 

Fuel tank empty Fill the fuel tank and, if 

necessary, vent the fuel 

system (see operator's 

manual "Venting the fuel 

system") 

Fuel filters dirty (paraffin 

precipitation in winter) 

Enabling solenoid on the 

engine does not pick up 

Change all fuel filters 

(see operator's manual 

"Servicing the fuel system"), 

refill with winter 

fuel 

Check fuse element for 

continuity and replace if 

necessary 

Fuel line leaking Check the condition of 

the fuel lines and replace 

if necessary 

Starter speed too low Check the battery and 

charge if necessary, 

clean the battery pole terminals 

and check that all 

is secure 

Starter defective Replace the starter 

Engine speed too low Insufficient fuel supply Inspect the fuel filter and 

fuel pump and replace if 

necessary 

Accelerator actuator dirty Clean the accelerator actuator 

Bowden cable of the accelerator 

actuator stiff 

Inspect the accelerator 

actuator and replace the 

Bowden cable if necessary 

Air filter system dirty Check the air filter system 

for cleanliness 

Engine faulty Replace the engine or repair 

it as described in the 

engine manufacturer's 

workshop manual 

3-14 1000239425 - WDF-6001-00EN 



Engine pressed hard High-pressure valves of 

the variable displacement 

pump incorrectly set 


pump defective (wear) 

Transposition of the variable 

displacement pump 

incorrectly set 

Control commencement 


motor incorrectly 

set 


motor defective (wear) 


Engine 2 

Adjust high-pressure 

valves or replace variable 


Replace variable displacement 

pump 

Have transposition set, 

check diameter of the diaphragm 

in the control 

cartridge or replace the 

variable displacement 

pump 

Check and adjust the 

control commencement 


motor 


motor 

Insufficient fuel supply Inspect the fuel filter and 

fuel pump and replace if 

necessary 

Injection pump defective Replace engine and have 

injection pump inspected 

Engine overheats Radiator dirty Clean the radiator 

Liquid level too low Top up liquid level (see 

operator's manual 

"Checking the coolant 

level/refilling the coolant") 

Radiator incorrectly installed 

Check the radiator installation 

Radiator defective Inspect radiator and replace 

it if necessary 

Thermostat sticks Replace thermostat (see 

the engine manufacturer's 

repair manual) 

V-belt on fan blade loose Check and adjust V-belt 

tension (see the engine 

manufacturer's repair 

manual) 

Oil level too low or too 

high 

Check oil level (see operator's 

manual "Checking 

the engine oil level") 

Engine power too low Air filter system dirty Check the air filter system 

for cleanliness 

Wrong fuel type Change fuel 

Engine speed too low See above 

3-15

2 Engine 

3-16 1000239425 - WDF-6001-00EN 


3.1 Checking and adjusting the starting speed 

Checking the starting speed Park the loader on level ground. 

Start the engine. 

Adjusting the starting speed Undo the nut (Fig. 8,1). 



Carry out all checks, inspections and adjustment work on the hydraulic 

system when it is at operating temperature. 

In all cases, also refer to the variable displacement pump manufacturer's 

workshop manual. 

Increase speed until the loader starts to move (setpoint value: idling 

speed + 100 rpm). 

Adjust the starting speed if it is too low or too high. 

Fig. 8 Adjustment screw 

Turn the screw (Fig. 8,2) 1/8 of a turn clockwise. 

Tighten the nut (Fig. 8,1). 

Recheck the starting speed. 

3.2 Checking and adjusting the inching pedal 

In all cases, also refer to the variable displacement pump manufacturer's 

workshop manual. 

There should be a pedal travel "X" at which the loader rolls, but it should be 

the minimum. 

Checking the inching pedal Stop the loader on an ascent with the service brake. 

Maintain the driving direction and apply full throttle. 

Release the service brake slowly until the loader starts to roll backwards. 

Release the service brake further until the loader starts to move forwards. 

Adjust the inching pedal as necessary. 


3-17


Adjusting the inching pedal Remove the cap (Fig. 9,1). 

Undo the nut (Fig. 10,1). 

Adjust the inching pedal at the screw (Fig. 10,2): 

Rotate the screw clockwise: The pedal travel "X" is reduced. 

Turn the screw counterclockwise: The pedal travel "X" is increased. 


Check the inching pedal again. 

3.3 Checking and adjusting the pressure cut-off 




Checking the pressure 

cut-off 

Fig. 9 Cover Fig. 10 Adjustment screw 

Pay attention to the "Safety instructions for working on the hydraulic 

system" (see Part 1 "Safety"). 




Test pressure gauge 0 ... 600 bar 1 

Fig. 11 Test connections Fig. 12 Obstacle 

Connect the test pressure gauge, 0 ... 600 bar to the test connection M A 

(Fig. 11,1) of the variable displacement pump. 

Tilt the operator's platform back (see operator's manual "Tilting the operator's 


3-18 1000239425 - WDF-6001-00EN 


Adjusting the pressure 

cut-off 



Carefully drive the loader with the tool attachment in front of an obstacle 

(Fig. 12). 

Driving forwards, press the loader against the obstacle and slowly increase 

the speed to the maximum. 

Read off the pressure on the test pressure gauge (setpoint value: 450 bar). 

Adjust the pressure cut-off if necessary. 


Remove the cap (Fig. 13,1). 


Adjust the pressure cut-off at the screw (Fig. 14,1): 

Rotate the screw clockwise: The pressure increases. 

Turn the screw counterclockwise: The pressure decreases. 


Check the pressure cut-off pedal again. 




3.4 Adjusting the driving speed 

DANGER 

Excessive speed can be fatal! 

The set driving speed must not be significantly exceeded even if the 

operating temperature has been reached and the loader is driving downhill 

fully loaded. 

Do not set the driving speed higher than the permissible maximum 

speed of 27 km/h. 

The cap (Fig. 15,1) serves as a lead seal. 

Only Wacker Neuson Customer Service may remove the lead seals. Unauthorized 

removal of the lead seals renders the warranty void. If in doubt, 

consult Wacker Neuson Customer Service. 

Use suitable, calibrated measuring devices to determine the driving speed. 

3-19




Adjust the driving speed at the screw (Fig. 16,1): 

Rotate the screw clockwise: The driving speed decreases. 

Turn the screw counterclockwise: The driving speed increases. 


Put a new cap (Fig. 15,1) on the screw (Fig. 16,1). 

Check the driving speed again. 

3.5 Checking the variable displacement pump supply 

pressure 







The hydraulic system is depressurized (see Part 4, "Depressurizing the 

hydraulic system"). 





3-20 1000239425 - WDF-6001-00EN 




Connect the test pressure gauge to the test connection (Fig. 17,1) of the 

solenoid valve. 




Read off the supply pressure "G" on the test pressure gauge (setpoint 

value: 25 bar). 


If the supply pressure does not reach the setpoint value, the supply pump 

is probably faulty. 


Remedying the problem Inspect the supply pressure valve. 

Inspect the supply pump and replace it if necessary (see the variable displacement 

pump manufacturer's repair instructions). 




3.6 Checking the variable displacement pump high 

pressure 




Fig. 17 Test connection 

If the supply pump shows no visible signs of wear, the variable displacement 

pump may be seriously damaged. 

Replace the variable displacement pump or have it repaired. 







3-21


Checking the high pressure 

- driving forward 

Checking the high pressure 

- reversing 

Fig. 18 Test connections 

Connect a test pressure gauge to each of the two test connections 

(Fig. 18,1 and 2). 



Carefully drive the loader with the tool attachment in front of an obstacle 

(Fig. 12). 

Select the fast forward driving stage. 

Press the loader against the obstacle and slowly increase the speed to the 

maximum. 

Read off the high pressure "M A " at the test pressure gauge (for the setpoint 

values, see Part 2, "Pressure values" section). 

If the high pressure "M A" does not reach the setpoint values, the variable 

displacement pump is defective. 

Secure the tool attachment very securely at a suitable point (e.g. tractor) in 

order to block the drive. 

Release the parking brake. 

Select the fast reversing stage. 

Slowly increase the speed to the maximum. 

Read off the high pressure "MB " on the test pressure gauge (setpoint 

values: see Part 2, "Pressure values" section). 


If the high pressure "MB " does not reach the setpoint values, the variable 

displacement pump is defective. 


Remedying the problem Replace the variable displacement pump or have it repaired. 




3-22 1000239425 - WDF-6001-00EN 




3.7 Checking the variable displacement pump positioning 

pressure 










Test adapter 2 

Fig. 19 Screw attachments Fig. 20 Test adapter 

Unscrew 2 screw attachments (Fig. 19,1 and 2). 

Screw in and tighten 2 test adapters (Fig. 20,1). 

Connect 1 test pressure gauge, 0 ... 60 bar to each test adapter. 



Carefully drive the loader with the tool attachment in front of an obstacle. 



Read off the positioning pressure "X 2 " on the test pressure gauge (setpoint 

values: see Part 2, "Pressure values" section). 


Remedying the problem Initiate a fault search (see the section 3.12 "Troubleshooting on the 


Final work Remove all test adapters. 



Perform a function test. 

3-23


3.8 Checking and adjusting the control commencement of 

the variable displacement motor 


Checking the control 

commencement 



Pressure (in bar) at measuring point 

G M1 Setpoint values < 220 bar 0 bar 

= 220 bar 110 bar 



> 220 bar same as G 

Set the control commencement so that the variable displacement motor 

switches to the high displacement volume as from 220 bar high pressure. 

The control process begins when half the high pressure of Connection G is 

reached at M 1. 





Test adapter 2 

Fig. 21 Screw attachments Fig. 22 Test adapter 

Unscrew 2 screw attachments (Fig. 21,1 and 2). 

Screw in and tighten 2 test adapters (Fig. 22,1). 

Connect 1 test pressure gauge, 0 ... 600 bar to each test adapter. 



Carefully drive the loader with the tool attachment in front of an obstacle. 



Read off the pressure "G" and pressure "M1" of the variable displacement 

motor on the test pressure gauges (setpoint values: see Setpoint Values 

table). 

3-24 1000239425 - WDF-6001-00EN 


Adjusting the control 

commencement 



Adjust the control commencement at the screw (Fig. 24,2): 



Rotate the screw clockwise: Earlier control commencement (at lower 

pressure "G"). 

Turn the screw counterclockwise: Later control commencement (at 

higher pressure "G"). 


Put a new cap (Fig. 23,1) on the screw (Fig. 24,2). 

Check the control commencement. 





3.9 Testing the steering hydraulics 




Fig. 23 Protective cap Fig. 24 Adjustment screw 









T-screw connection 1 

3-25


Testing the steering 

pressure 

Adjusting the steering 

pressure 

Checking the steering 

cylinder for internal leaks 


Install the T-screw connection with the test adapter (Fig. 25,1) in the base 

hydraulic line of the steering cylinder. 

Connect a test pressure gauge, 0 ... 600 bar. 

Turn the steering wheel clockwise with the engine running until the articulated 

link is at the limit position. 

Read off the steering pressure on the test pressure gauge (setpoint value: 

190 bar). 

Adjust the steering pressure if it deviates from the setpoint value. 

Fig. 26 Orbital steering valve 

Undo the screw connection (Fig. 26,1). 

Set the steering pressure at the screw underneath: 

Rotate the screw clockwise: Pressure increases. 

Turn the screw counter-clockwise: Pressure drops. 

Screw in and tighten the screw connection (Fig. 26,1). 

Fig. 27 Hydraulic connection, rod end 

Extend the steering cylinder fully. 

Unscrew and close off the hydraulic line (Fig. 27,1). 

3-26 1000239425 - WDF-6001-00EN 


Checking the emergency 

steering capability 



Leave the hydraulic connection on the steering cylinder open. 

Turn the steering wheel further clockwise with the engine running. 

When oil escapes at the hydraulic connection, the steering cylinder must 

be sealed on the inside (see Part 4, "Sealing the hydraulic cylinder" section). 

Turn the steering wheel counter-clockwise with the engine not running until 

the articulated link is at the limit position. 

If the steering wheel can still be turned despite reaching the limit position, 

replace the orbital steering valve (see Part 4, "Replacing the orbital 

steering valve" section). 





3.10 Checking the gear pump 




Checking the primary 

pressure 









T-screw connection 1 

Flow meter 1 

Fig. 28 Test connection P H 

Install the T-screw connection with the test adapter (Fig. 28,1) in the 

hydraulic line between the gear pump and the pressure filter. 

Connect a test pressure gauge, 0 ... 600 bar at the test adapter. 

Move the lift frame to its stop with the "Lift" function. 

3-27


Setting the primary 

pressure 

Checking the secondary 

pressures 

Read off the supply pressure "P H " on the test pressure gauge (setpoint 

value: 210 bar). 

Check the secondary pressures when the setpoint value is reached. Otherwise, 

set the primary pressure and repeat the test. 

Fig. 29 Cover Fig. 30 Pressure control valve 

Unscrew the cap (Fig. 29,1) from the primary pressure control valve on the 

control valve. 

Turn the primary pressure control valve (Fig. 30,1) clockwise with a 

hexagon socket wrench: Pressure increases. 

Check the primary pressure. 

If the primary pressure has changed, adjust the primary pressure control 

valve until the setpoint value is reached. 

If the primary pressure has not changed, turn the primary pressure control 

valve another turn clockwise. 

Check the primary pressure. 

If the primary pressure has changed, adjust the primary pressure control 

valve until the setpoint value is reached. Then check the secondary pressures. 

If the primary pressure has not changed, turn the primary pressure control 

valve another 2 turns counter-clockwise. Then check the gear pump flow. 

Screw the cap (Fig. 29,1) onto the primary pressure control valve and 

tighten it. 


Install the T-screw connection with the test adapter (Fig. 31,1) in the rodend 

hydraulic line of the tipping cylinder. 

Connect a test pressure gauge, 0 ... 600 bar at the test adapter. 

Raise the lift frame until it is approximately horizontal. 

Tip out the tool attachment completely. 

3-28 1000239425 - WDF-6001-00EN 




Raise the lift frame and read off the "Dumping" secondary pressure on the 

test pressure gauge (setpoint value: 140 bar). 

To check the "Curling to load" secondary pressure, swap round the 

hydraulic lines on the tipping cylinder and repeat the test (setpoint value: 

250 bar). 

If the secondary pressures do not correspond to the setpoint values, 

replace the secondary pressure control valves on the control valve. 

Fig. 32 Flow meter 

Checking the flow rate Install a flow meter in the hydraulic line between the gear pump and the 

pressure filter (Fig. 32). 

Read off the gear pump's flow rate on the flow meter (setpoint value: 

49 l/min at 2600 rpm). 

If the flow rate is too low, seal or replace the gear pump. 





3.11 Checking the control valve function 

Check all functions of the working hydraulics (see operator's manual "Control 

lever for lift frame"). 

Lifting 

Lowering 

Curling to load 

Dumping 

Float control 

Check whether the multi-function lever springs into the zero position when 

it is released. 

Check all functions of the auxiliary hydraulics (see operator's manual "Auxiliary 

hydraulics control lever"). 

Unlock 

Lock 

Check whether the control lever of the auxiliary hydraulics springs into the 

zero position when it is released. 

Check the function of the lift frame locking system (see operator's manual 

"Lift frame locking system"). 

3-29



Remedying the problem Inspect the gear pump (see the section 3.10 "Checking the gear pump"). 

Seal the control valve (see Part 4, "Sealing the control valve" section) or 

replace it (see Part 4, "Removing the control valve" section and "Installing 

the control valve" section). 

Inspect the hydraulic cylinder if necessary. 

3.12 Troubleshooting on the hydraulic system 


No hydraulic function 

while the engine is running 

High pressure of the driving 

hydraulics insufficient 

Hydraulic component of 

the driving direction recognition 

defective 

Driving speed 

changeover does not 

work 

Insufficient thrust or driving 

speed 

Clutch hub of the variable 

displacement pump defective 

Clutch PA flange of the 

engine defective 

Pressure cut-off maladjusted 

Incorrect starting speed 

set 

Pressure "G" at the variable 

displacement motor 

too low 

Driving direction recognition 

defective 


defective 

Replacing the clutch hub 

Replace the clutch PA 

flange 

Check that the pressure 

cut-off is at the correct 

value 


starting speed 

Check pressure "G" of 


motor, replace the coil 

and drive of the solenoid 

valve if necessary 

Inspect the electrical controller 

Inspect the electrical controller 




Supply pressure "G" of 


pump too low 1) 

Hydraulic fluid level too 

low 



Check the hydraulic fluid 

level (see operator's 

manual "Checking the 

hydraulic fluid level") 

Wrong oil used Change the hydraulic fluid 


"Changing the hydraulic 

fluid") 

Hydraulic fluid filter dirty 

(warning lamp lights up) 

Hydraulic fluid filter dirty 


Suction hose between 

hydraulic fluid filter and 


pump bent or defective 

Supply pressure valve 

sticks open 

Supply pump of the variable 


defective 


motor defective 

Check the hydraulic fluid 

filter for cleanliness and 

replace it if necessary 


"Changing the return filter 

element"). If the hydraulic 

fluid is dirty, also change 

the hydraulic fluid (see 



fluid") 

Check the overpressure 

switch of the return filter 

for cleanliness and replace 

it if necessary (see 


"Changing the return filter 

element"). If the hydraulic 

fluid is dirty, also change 

the hydraulic fluid (see 



fluid") 

Check that the hose has 

been laid correctly and is 

in good condition, and if 

necessary relay or replace 

the hose 

Inspect the supply pressure 

valve and clean or 

replace it if necessary 

(see the variable displacement 

pump manufacturer's 

repair 

instructions). 

Check the supply pressure 


pump, replace 

supply pump 

Replace the variable displacement 

motor and 

have it repaired if necessary. 

Engine speed too low See the section 2.5 

"Troubleshooting on the 

engine" 

3-31




("X 1" or "X 2") of the variable 


too low 

High pressure "M A " or 

"M B " insufficient 

Oil temperature too high 



set 

Inching pedal incorrectly 

set 

Brake linkage incorrectly 

set 

Main brake cylinder defective 

(pressure on the 

brake line without pedal 

actuation) 

Clean the cooling system 

and check for leaks, 

replace parts if necessary 




inching pedal 

Check the brake linkage 

and pedal play, adjust 

the pedal play if necessary 

(setpoint value: 

2mm) 

Replace the main brake 

cylinder 

Inching actuator sticks Inspect inching actuator 

and replace it if necessary 

Inching valve defective Replace the solenoid 

valve 

Pressure cut-off incorrectly 

set 

Positioning cylinder in the 


pump leaks 

High pressure valve is 

still in the towing position 


pressure cut-off 


pump or have 

it repaired 

Check the high pressure 

valve and set to Driving 

operation if necessary 


"Disconnecting the 

drive") 

High pressure valve dirty Remove the high pressure 

valve, perform a visual 

inspection and clean 

if necessary (see the 


pump manufacturer's repair 

instructions) 


pump defective 


motor defective 


pump or have 

it repaired 


motor or have 

it repaired 

1) When measuring the supply pressure "G", it is necessary to eliminate the possibility 

of leaks at the connected secondary loads. 

3-32 1000239425 - WDF-6001-00EN 


4.1 Inspecting the differential lock 




2 persons are required to carry out this work. 

When the differential lock is engaged and is active, the wheels cannot be 

rotated against the resistance of the transmission pump. 

The loader is secured against rolling away at the axle that is not being 

raised (e.g. with chocks). 

The articulated link is blocked (see operator's manual "Blocking the articulated 

link"). 

The parking brake is released. 

Fig. 33 Rotation of the wheels 

Performing the inspection Lift the loader on the axle to be inspected (e.g. with a jack) until the wheels 

can rotate freely. 

If the differential lock is not engaged, the wheels rotate in opposite directions. 

At the same time, rotate one wheel and observe the other wheel. 


Switch on the differential lock (see operator's manual "Differential lock"). 

If the differential lock is engaged, the wheel can no longer be rotated. 

Rotate the wheel until the differential lock tangibly engages. 

Switch off the differential lock (see operator's manual "Differential lock"). 

If the differential lock is not engaged, the wheels rotate in opposite directions. 

At the same time, rotate one wheel and observe the other wheel. 


Remedying the problem Check electrical actuation of the differential lock. 

Check the differential lock in the axle (see the axle manufacturer's workshop 

manual). 


3-33


4.2 Checking the water filling of the wheels 

WARNING 

Risk of injury from aggressive tire-filler fluid. 

Avoid contact with the hands. 

Wear protective gloves. 

Rinse any fluid splashes off the skin immediately using plenty of clean 

water and seek medical advice as a precaution. 

Fig. 34 Position of the wheel Fig. 35 Water filling valve 

The valve on tires with a water filling (Fig. 35) differs in terms of the air 

valve design. 

Park the loader so that the tire valve is at the top (Fig. 34). 

Release some air in order to eliminate the residual water from the valve. 

Check the air pressure (see operator's manual "Pumping up the tires"). 

Check the wheel for leaks, i.e. escaping water or air. 

If the wheel is leaking, have it emptied and repaired or replaced by experts. 

Observe the specified composition of the tire-filler fluid. 

3-34 1000239425 - WDF-6001-00EN 


4.3 Troubleshooting on the drive 


Loader does not move 

when the engine is running 

Loader does not stop 

when the engine is running 

Loader starts moving too 

late 



Parking brake applied Release the parking 

brake 

Parking brake switch defective 



pump incorrectly 

set 

Mechanical zero position 



set 


set 


set 




set 

Supply pressure "G" of 


pump too low 


("X 1 " or "X 2 ") of the variable 


too low 

Check the switching behavior 

of the parking 

brake switch (see circuit 

diagram) and replace if 

necessary 




pump (see the variable 


manufacturer's repair instructions) 

Check the Mechanical 

zero position of the variable 


(see the variable displacement 

pump manufacturer's 

repair 

instructions) 




inching pedal 




pump 

See the section 3.12 


hydraulic system" 




3-35



Insufficient thrust Incorrect tire size Check that tires are the 

correct size 

Driving speed not 

reached 

Parking brake applied Release the parking 

brake. 

Bowden cable of the 

parking brake stiff 

Inspect the parking brake 

and replace the Bowden 

cable if necessary 

Engine speed too low See the section 2.5 


engine" 

High pressure of the driving 

hydraulics insufficient 

Electrical component of 


defective 

Hydraulic component of 


defective 




set 






electrical system" 







pump 

Engine speed too low Check and adjust the engine 

speed (see the repair 

manual of the engine 

manufacturer) 


set 


("X 1" or "X 2") of the variable 


too low 


inching pedal 




Incorrect tire size Check that tires are the 

correct size 



motor incorrectly 

set 




motor 

Overdrive deactivated Activate overdrive (see 


"Changing speeds"). 

Electrical component of 

the overdrive circuit defective 



electrical system" 

3-36 1000239425 - WDF-6001-00EN 



curling to load stop 


dumping stop 



5.1 Checking and adjusting the curling to load and 

dumping stops 

The stops protect the kinematics and the hydraulic cylinder. 

Correctly set stops help to prevent damage. 

Fig. 36 Curling to load stop 


Raise the load arm approximately 1 m. 

Curl the tool attachment until the tipping cylinder is at the stop on the rod 

end. 

Lower the load arm as far as possible. 


Unscrew the stop screw (Fig. 36,1) until the screw head just touches the 

attachment. 

Tighten the nut. 

Fig. 37 Front stop Fig. 38 Dumping stop 

Tilt out the tool attachment until the tipping cylinder is at the bottom-end 

stop. 

Raise the load arm until the front stops (Fig. 37) just touch the tool attachment. 

Unscrew the 2 screws (Fig. 38,1) on the dumping stop. 

Place a sufficient number of stop irons (Fig. 38,2) underneath so that the 

reversing lever is supported without play. 

Tighten the 2 screws. 

3-37


3-38 1000239425 - WDF-6001-00EN 


6.1 Checking the heater 


Set the temperature regulator (Fig. 39,1) to the lowest temperature. 

Set the fan switch (Fig. 39,2) to "I": The fan blows air into the cab. 


Cab 6 

DANGER 





Carry out this test only when at operating temperature. 

Fig. 39 Heater 

Set the air regulators in turn to "II" and "III": The fan blows more air into the 

cab. 

Set the temperature regulator to the highest temperature: The air blown 

into the cab becomes warmer. 



Remedying the problem Check the coolant (see operator's manual "Checking the coolant level/ 

refilling the coolant") 

If necessary, check the electrical connections (see the section 7.5 "Troubleshooting 

on the electrical system"). 

Replace the heater if necessary (see Part 4, "Replacing the complete 

heater" section). 

6Cab 

3-39

6 Cab 

6.2 Troubleshooting in the cab 


Ventilation system not 

working 

Fuse element faulty Check fuse element for 


necessary 

Fan switch defective Check the switch and replace 

it if necessary 

Fan motor defective Replace the fan motor 

Heater not working Coolant cold Keep the engine running 

until the coolant is warm 

Heater regulator faulty Replace the heater regulator 

3-40 1000239425 - WDF-6001-00EN 


7.1 Checking the generator 


Measuring the battery 

voltage 



DANGER 





If possible, test the generator with a generator tester (see Part 2, "Generator 

tester" section) (setpoint values: see "Technical data"). 

If no generator tester is available, the a basic test of the generator can be 

performed using the method described here. 



The engine hood is folded over the engine. 


Measure the battery voltage at idling speed (setpoint value: 14 V). 

Switch on all headlamps. 

Measure the battery voltage at idling speed (setpoint value: 13.8 V). 

Measure the battery voltage at maximum speed (setpoint value: 14 V). 



Remedying the problem Replace the generator (see Part 4, "Replacing the generator" section). 


7.2 Checking the temperature sensors 

WARNING 




Perform the test if the engine temperature/hydraulic fluid temperature 

warning lamp also lights up in the cooled-down state. 

The temperature sensors in the hydraulic fluid tank (Fig. 40) and in the 

engine (Fig. 41) switch on the indicator lamp at 110 °C. 




hood"). 


3-41


Fig. 40 Temperature sensor on the 

hydraulic fluid tank 

Switch on the ignition. 

Remove the plug (Fig. 40,2). 

When the warning lamp goes out, replace the temperature sensor 

(Fig. 40,1) (see Part 4, "Replacing the temperature sensor of the hydraulic 

fluid tank" section). 

Plug the plug onto the temperature sensor. 


When the warning lamp goes out, replace the temperature sensor 

(Fig. 41,1) (see Part 4, "Replacing the engine temperature sensor" section). 

If the warning lamp does not go out, check the cable for shearing and short 

circuit, and replace it if necessary. 


Switch off the ignition. 


7.3 Testing the belt buckle circuit 

Fasten the seat belt. 

Switch on the ignition. Both indicator lamps for the driving directions light 

up. 

Select the driving direction at the multi-function lever: The indicator lamp of 

the unselected driving direction goes out. 

Unfasten the belt buckle: Both indicator lamps for the driving directions light 

up. 

Fasten the seat belt: Both indicator lamps for the driving directions remain 

on. 

Set the driving direction switch to any desired driving direction via the Neutral 

position: The indicator lamp of the unselected driving direction goes 

out. 

Switch off the ignition. 


Fig. 41 Temperature sensor on the 

engine 

Remedying the problem Replace the belt buckle (see Part 4, "Replacing the complete seat belt" 

section). 

3-42 1000239425 - WDF-6001-00EN 


7.4 Testing the fuel level sensor 




WARNING 

Explosion and fire hazard! 

Do not smoke when handling fuel, and avoid naked flame or fire. 

Do not mix gasoline with the Diesel fuel. 

Avoid damaging the environment. Collect any escaping fuel and dispose of 

it in an environmentally responsible way. 

If the fuel tank is too full, fuel can escape from the fuel level sensor opening. 

Empty the fuel tank until the fuel level is below the tank sensor opening. 

The stated resistance values are guideline values and can vary between 

loaders. 

The fuel level sensor has been removed (see Part 4, "Replacing the fuel 

level sensor" section). 

Fig. 42 Electrical cable 

Testing the fuel level sensor Connect the ohmmeter to the black and orange wires. 

Hold the fuel level sensor so that the tubes point upwards. 

Read off the resistance on the ohmmeter. 

The displayed measured value must be approx. 5 Ω (tolerance ± 5 Ω). 

Hold the fuel level sensor in the normal position. 

Read off the resistance on the ohmmeter. 

The displayed measured value must be approx. 320 Ω (tolerance ± 20 Ω). 


Remedying the problem Replace the fuel level sensor (see Part 4, "Replacing the fuel level sensor" 

section). 

3-43


7.5 Troubleshooting on the electrical system 


Electrical part of the gear 

changer is not working 

Low gear selection cannot 

be engaged 



necessary 

Multi-function lever defective 


solenoid valve defective 


of the multi-function 

lever (see circuit 

diagram) and replace if 

necessary 

Check the function of the 

solenoid valve, replace 

the coil and drive if necessary 

Cable defective Check cable for continuity 

and replace if necessary 



necessary 

Button for overdrive circuit 

defective 

Solenoid valve of the 

overdrive circuit defective 


of the button (see 

circuit diagram) and replace 

if necessary 

Check the function of the 

solenoid valve, replace 

the coil and drive if necessary 

Cable defective Check cable for continuity 

and replace if necessary 

3-44 1000239425 - WDF-6001-00EN 


B 

Belt buckle circuit 

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 

C 

Control valve 

Checking the function . . . . . . . . . . . . . . . . 3-29 

Curling to load stop 


D 

Differential lock 

Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 

Driving speed 

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 

Dumping stop 


E 

Engine 

Troubleshooting . . . . . . . . . . . . . . . . . . . . 3-14 

Exhaust system 

Inspecting for leaks . . . . . . . . . . . . . . . . . . 3-11 

F 


Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 

G 

Gear pump 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 

Generator 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 

H 

Heater 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 

High pressure, checking 


I 

Inching pedal 


P 

Positioning pressure, checking 


Pressure cut-off 



Index 

R 

Radiator 

Checking installation . . . . . . . . . . . . . . . . 3-12 


S 

Starting speed 



Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 

Supply pressure, checking 


T 

Temperature sensors 

Checking . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 

Troubleshooting 

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 

Electrical system . . . . . . . . . . . . . . . . . . . 3-44 

Hydraulic system . . . . . . . . . . . . . . . . . . . 3-30 

V 

Valve play 


Variable displacement motor control 

commencement 



High pressure, checking . . . . . . . . . . . . . 3-21 

Supply pressure, checking . . . . . . . . . . . . 3-20 

W 

Wheels 

Checking the water filling . . . . . . . . . . . . . 3-34 

3-45

Index 

3-46 1000239425 - WDF-6001-00EN 



1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 4 

Replacement and repair procedures 


1000239425 - WDF-6001-00EN 



Replacement 

Replacement 

This part of the repair manual contains the necessary replacement and repair 

procedures. 

Sequence The sequence of the described work is binding. Keep to the defined sequence 

in order to avoid hazards. 

Safety Pay attention to ensuring your own safety and that of others. Obey the safety 

and warning notices in order to avoid the risk of injury and property damage. 

Connection Work not described in this repair manual may not be carried out. 

Spare parts Use only original spare parts or spare parts that the manufacturer has 

expressly approved. 

4-3

Replacement 

4-4 1000239425 - WDF-6001-00EN 


1 Complete vehicle. . . . . . . . . . . . . 4-9 

1.1 Helpful tips . . . . . . . . . . . . . . . . . . . . . 4-9 

1.2 Replacing protective stickers . . . . . . . 4-9 

2 Engine . . . . . . . . . . . . . . . . . . . . . . 4-11 

2.1 Engine (as supplied) . . . . . . . . . . . . . 4-11 

2.1.1 Engine removal . . . . . . . . . . . . . . . . . 4-11 

2.1.2 Engine installation. . . . . . . . . . . . . . . 4-13 

2.1.3 Replacing the front rubber buffers. . . 4-16 

2.1.4 Replacing the rear rubber buffer . . . . 4-17 

2.1.5 Replacing the clutch PA flange . . . . . 4-18 

2.1.6 Cleaning the engine (after toppling 

the loader). . . . . . . . . . . . . . . . . . . . . 4-19 

2.2 Radiator. . . . . . . . . . . . . . . . . . . . . . . 4-21 

2.2.1 Removing the radiator. . . . . . . . . . . . 4-21 

2.2.2 Installing the radiator. . . . . . . . . . . . . 4-22 

2.3 Air filter system . . . . . . . . . . . . . . . . . 4-25 

2.3.1 Replacing the complete air filter . . . . 4-25 

2.3.2 Replacing the air filter housing . . . . . 4-26 

2.4 Fuel system. . . . . . . . . . . . . . . . . . . . 4-27 

2.4.1 Replacing the complete fuel filter . . . 4-27 

2.4.2 Replacing the complete main 

fuel filter. . . . . . . . . . . . . . . . . . . . . . . 4-28 

2.4.3 Replacing the water separator . . . . . 4-29 

2.4.4 Replacing the fuel feed pump . . . . . . 4-30 

2.4.5 Replacing the fuel line. . . . . . . . . . . . 4-31 

2.4.6 Tank lock emergency opening . . . . . 4-32 

2.5 Exhaust system. . . . . . . . . . . . . . . . . 4-33 

2.5.1 Replacing the flue . . . . . . . . . . . . . . . 4-33 

2.5.2 Replacing the muffler and 

flexi-pipe . . . . . . . . . . . . . . . . . . . . . . 4-33 


3.1 Complete vehicle. . . . . . . . . . . . . . . . 4-37 

3.1.1 Depressurizing the hydraulic 

system. . . . . . . . . . . . . . . . . . . . . . . . 4-37 

3.1.2 Replacing the pivot bearing on the 

hydraulic cylinder . . . . . . . . . . . . . . . 4-37 

3.1.3 Sealing the hydraulic cylinder . . . . . . 4-38 

3.2 Driving hydraulics . . . . . . . . . . . . . . . 4-42 


pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 

3.2.2 Replacing the clutch hub. . . . . . . . . . 4-44 

3.2.3 Replacing the annular shaft seal 


pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 


motor. . . . . . . . . . . . . . . . . . . . . . . . . 4-45 

3.3 Steering hydraulics . . . . . . . . . . . . . . 4-48 

3.3.1 Cleaning the priority valve. . . . . . . . . 4-48 

3.3.2 Replacing the priority valve. . . . . . . . 4-50 

3.3.3 Replacing the orbital steering 

valve . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 

3.3.4 Removing the steering cylinder. . . . . 4-52 

3.3.5 Installing the steering cylinder. . . . . . 4-54 


Contents 

3.4 Brake hydraulics . . . . . . . . . . . . . . . 4-55 

3.4.1 Replacing the main brake 

cylinder . . . . . . . . . . . . . . . . . . . . . . 4-55 

3.4.2 Replacing the brake hydraulics 

tank . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 

3.4.3 Replacing the brake fluid . . . . . . . . . 4-57 

3.4.4 Venting the brake hydraulics . . . . . . 4-58 

3.5 Working hydraulics . . . . . . . . . . . . . 4-59 

3.5.1 Replacing the gear pump. . . . . . . . . 4-59 

3.5.2 Sealing the gear pump. . . . . . . . . . . 4-61 

3.5.3 Removing the control valve . . . . . . . 4-63 

3.5.4 Installing the control valve . . . . . . . . 4-64 

3.5.5 Sealing the control valve . . . . . . . . . 4-66 

3.5.6 Installing the catch on the control 

valve . . . . . . . . . . . . . . . . . . . . . . . . 4-70 

3.5.7 Replacing the cross controller . . . . . 4-70 

3.5.8 Replacing the lifting cylinder . . . . . . 4-71 

3.5.9 Removing the tipping cylinder . . . . . 4-73 

3.5.10 Installing the tipping cylinder . . . . . . 4-75 

3.5.11 Replacing the rod-end bearing 

of the tipping cylinder. . . . . . . . . . . . 4-76 

3.6 Auxiliary hydraulics and hydraulic 

lock . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 

3.6.1 Replacing the cover of the auxiliary 

hydraulics. . . . . . . . . . . . . . . . . . . . . 4-77 

3.6.2 Replacing the control lever and 

cover of the auxiliary hydraulics. . . . 4-78 

3.6.3 Replacing the locking cylinder . . . . . 4-79 

3.7 Tank, filter and hydraulic lines . . . . . 4-80 

3.7.1 Replacing the hydraulic fluid 

tank . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 

3.7.2 Replacing the complete return 

filter . . . . . . . . . . . . . . . . . . . . . . . . . 4-82 

3.7.3 Replacing the pressure filter . . . . . . 4-83 

3.7.4 Replacing the hydraulic line. . . . . . . 4-84 


4.1 Replacing the drive shaft . . . . . . . . . 4-85 

4.2 Front axle. . . . . . . . . . . . . . . . . . . . . 4-86 

4.2.1 Removing the front axle. . . . . . . . . . 4-86 

4.2.2 Installing the front axle. . . . . . . . . . . 4-88 

4.3 Rear axle . . . . . . . . . . . . . . . . . . . . . 4-91 

4.3.1 Removing the rear axle . . . . . . . . . . 4-91 

4.3.2 Installing the rear axle . . . . . . . . . . . 4-93 

4.4 Changing the wheel of the twin 

tires . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 


(mechanical section) . . . . . . . 4-97 

5.1 Service brake. . . . . . . . . . . . . . . . . . 4-97 

5.1.1 Replacing the brake shoes . . . . . . . 4-97 

5.1.2 Replacing the brake drum . . . . . . . . 4-98 

5.2 Parking brake. . . . . . . . . . . . . . . . . . 4-99 

5.2.1 Replacing the Bowden cable of the 

parking brake . . . . . . . . . . . . . . . . . . 4-99 

4-5

Contents 


load arm . . . . . . . . . . . . . . . . . . . 4-103 

6.1 Front carriage. . . . . . . . . . . . . . . . . 4-103 

6.1.1 Replacing the front fender . . . . . . . 4-103 

6.2 Rear carriage and engine hood . . . 4-103 

6.2.1 Replacing the rear fender . . . . . . . 4-103 

6.2.2 Replacing the additional 

weight/base plate . . . . . . . . . . . . . . 4-104 

6.2.3 Replacing the rear weight . . . . . . . 4-105 

6.2.4 Replacing the engine hood . . . . . . 4-107 

6.2.5 Replacing the lock of the engine 

hood . . . . . . . . . . . . . . . . . . . . . . . . 4-108 

6.2.6 Emergency release of the engine 

hood . . . . . . . . . . . . . . . . . . . . . . . . 4-109 

6.3 Center joint. . . . . . . . . . . . . . . . . . . 4-109 

6.3.1 Detaching the center joint . . . . . . . 4-109 

6.3.2 Connecting the center joint . . . . . . 4-111 

6.3.3 Replacing the bearing in the 

self-aligning bearing. . . . . . . . . . . . 4-115 

6.3.4 Replacing the lower bearing . . . . . 4-116 

6.4 Step plate and insulation mats. . . . 4-117 

6.4.1 Removing the operator's 

platform . . . . . . . . . . . . . . . . . . . . . 4-117 

6.4.2 Installing the operator's 

platform . . . . . . . . . . . . . . . . . . . . . 4-120 

6.4.3 Replacing the rubber buffer 

of the step plate . . . . . . . . . . . . . . . 4-123 

6.4.4 Replacing the insulation mat . . . . . 4-124 

6.5 Load arm . . . . . . . . . . . . . . . . . . . . 4-125 

6.5.1 Replacing the complete 

load arm . . . . . . . . . . . . . . . . . . . . . 4-125 


short drawbar . . . . . . . . . . . . . . . . . 4-127 


short reversing lever . . . . . . . . . . . 4-128 


long reversing lever . . . . . . . . . . . . 4-129 

6.5.5 Replacing the upper bearing 

of the long drawbar . . . . . . . . . . . . 4-131 


of the long drawbar . . . . . . . . . . . . 4-132 

6.6 Tool attachment . . . . . . . . . . . . . . . 4-133 

6.6.1 Replacing the tool attachment . . . . 4-133 

6.6.2 Replacing the locking pin . . . . . . . . 4-134 

6.6.3 Replacing the lock of the tool 

attachment (US). . . . . . . . . . . . . . . 4-135 

7 Operator's platform 

and cab. . . . . . . . . . . . . . . . . . . . 4-137 

7.1 Seat . . . . . . . . . . . . . . . . . . . . . . . . 4-137 

7.1.1 Replacing the driver's seat. . . . . . . 4-137 

7.1.2 Replacing the complete seat 

belt . . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

7.1.3 Replacing the belt buckle. . . . . . . . 4-138 

7.2 ROPS bar and driver's canopy . . . 4-139 

7.2.1 Replacing the ROPS bar . . . . . . . . 4-139 

7.2.2 Replacing the driver's canopy. . . . . 4-139 

7.2.3 Replacing the lower section 

of the ROPS bar/driver's 

canopy . . . . . . . . . . . . . . . . . . . . . . 4-141 

7.2.4 Replacing the document 

compartment. . . . . . . . . . . . . . . . . . 4-142 

7.2.5 Replacing the storage 

compartment. . . . . . . . . . . . . . . . . . 4-143 

7.3 Cab . . . . . . . . . . . . . . . . . . . . . . . . . 4-144 

7.3.1 Removing the complete cab . . . . . . 4-144 

7.3.2 Installing the complete cab . . . . . . . 4-146 

7.3.3 Replacing the windshield 

wiper arms . . . . . . . . . . . . . . . . . . . 4-149 

7.3.4 Replacing the windshield 

washer container . . . . . . . . . . . . . . 4-150 

7.3.5 Replacing the door lock . . . . . . . . . 4-151 

7.3.6 Replacing the door stay . . . . . . . . . 4-152 

7.3.7 Replacing the complete door . . . . . 4-153 

7.3.8 Replacing the roof grille 

of the cab . . . . . . . . . . . . . . . . . . . . 4-154 

7.3.9 Replacing the window and the 

rubber clamping profile . . . . . . . . . . 4-154 

7.3.10 Replacing a bonded-in window. . . . 4-156 

7.3.11 Replacing the complete heater. . . . 4-158 

7.4 Steering column . . . . . . . . . . . . . . . 4-159 


steering column . . . . . . . . . . . . . . . 4-159 

7.4.2 Replacing the steering wheel . . . . . 4-161 

8 Electrical system . . . . . . . . . . 4-163 

8.1 Generator, battery and motors . . . . 4-163 

8.1.1 Replacing the generator . . . . . . . . . 4-163 

8.1.2 Replacing the starter . . . . . . . . . . . 4-164 

8.1.3 Replacing the rear windshield 

wiper motor. . . . . . . . . . . . . . . . . . . 4-165 

8.1.4 Replacing the front windshield 

wiper motor. . . . . . . . . . . . . . . . . . . 4-166 

8.2 Switches and sensors. . . . . . . . . . . 4-167 


instrument panel . . . . . . . . . . . . . . . 4-167 

8.2.2 Replacing the combination 

switch . . . . . . . . . . . . . . . . . . . . . . . 4-168 

8.2.3 Replacing the glow-plug 

indicator . . . . . . . . . . . . . . . . . . . . . 4-168 

8.2.4 Replacing the switches 

in the cab . . . . . . . . . . . . . . . . . . . . 4-169 

8.2.5 Replacing the ignition lock . . . . . . . 4-170 

8.2.6 Replacing the battery disconnect 

switch . . . . . . . . . . . . . . . . . . . . . . . 4-171 

8.2.7 Replacing the parking brake 

switch . . . . . . . . . . . . . . . . . . . . . . . 4-172 

8.2.8 Replacing the return filter 

overpressure switch . . . . . . . . . . . . 4-173 

8.2.9 Replacing the engine temperature 

sensor. . . . . . . . . . . . . . . . . . . . . . . 4-174 

8.2.10 Replacing the temperature sensor 

of the hydraulic fluid tank . . . . . . . . 4-175 

4-6 1000239425 - WDF-6001-00EN 


8.2.11 Replacing the fuel level sensor . . . . 4-176 

8.3 Relays, coils and fuses . . . . . . . . . . 4-177 

8.3.1 Replacing the relays . . . . . . . . . . . . 4-177 


drives on the variable 

displacement motor. . . . . . . . . . . . . 4-177 



pump . . . . . . . . . . . . . . . . . . . . . . . . 4-178 

8.3.4 Replacing the coil on the variable 

displacement pump. . . . . . . . . . . . . 4-179 

8.4 Indicator lamps, audible warning 

generators and instruments . . . . . . 4-180 

8.4.1 Replacing the indicator lamp 

in the instrument panel . . . . . . . . . . 4-180 


lights . . . . . . . . . . . . . . . . . . . . . . . . 4-181 

8.4.3 Replacing the horn . . . . . . . . . . . . . 4-182 

8.4.4 Replacing the audible warning 

generator. . . . . . . . . . . . . . . . . . . . . 4-183 

8.4.5 Replacing the engine-hour 

indicator. . . . . . . . . . . . . . . . . . . . . . 4-183 

8.5 Lighting system . . . . . . . . . . . . . . . . 4-185 

8.5.1 Replacing a complete headlamp 

with indicator . . . . . . . . . . . . . . . . . . 4-185 

8.5.2 Replacing a complete tail 

lamp . . . . . . . . . . . . . . . . . . . . . . . . 4-185 

8.5.3 Replacing the headlight. . . . . . . . . . 4-186 

9 Attachments . . . . . . . . . . . . . . . 4-189 

9.1 Replacing the earth bucket 

digging tooth . . . . . . . . . . . . . . . . . . 4-189 


Contents 

4-7

Contents 

4-8 1000239425 - WDF-6001-00EN 


1.1 Helpful tips 


Complete vehicle 1 

Locking agent Locking agent hardens quickly. 

Work quickly when using locking agent, so as to prevent it from hardening 

during assembly. 

Small parts Small parts are especially sensitive to dirt. 

Use suitable vessels (e.g. plastic bowls) for the temporary storage of small 

parts while working. 

Cleanliness Foreign bodies can damage the loader's systems (e.g. the hydraulic system). 

Clean the loader before starting repair work. 

Close off the openings and connections in order to prevent the ingress of foreign 

bodies. 

Drive shaft Parts of the drive shaft are not easy to access. 

The drive shaft can be rotated into a better position for working. 

Secure the loader to prevent it from rolling away (e.g. with chocks). 

Release the parking brake. 

Rotate the drive shaft into the desired position. 

Apply the parking brake 

Changing a wheel Wheels can be very heavy and unwieldy. 

If necessary, lift a wheel with a wheel spider on the hub. 

Hydraulic connections Some hydraulic lines are secured very tightly to the connections. 

When loosening the hydraulic connection, hold the screw attachment securely 

in place in order to prevent damage to the screw attachment or the hydraulic 

cylinder. 

Coolant Coolant is expensive. 

Collect the coolant during disassembly, filter it and reuse during for reassembly. 

1.2 Replacing protective stickers 

Stickers Stickers are applied to the loader in order to warn the operator about hazards 

or to give him operating instructions. 

The stickers used and their locations are shown in a drawing (see Part 2, 

"Safety stickers" section). 


The remainder of the damaged or missing sticker has been completely 

removed. 

The surface is completely clean and free of grease. 

1Complete vehicle 

4-9

1 Complete vehicle 

Fig. 1 Example 

Replacement Peel off approximately 1/3 of the protective film on the back of the sticker. 

Apply the sticker in the desired location. 

At the same time, remove the remainder of the protective film and smooth 

out the sticker with your hand. 

4-10 1000239425 - WDF-6001-00EN 


2.1 Engine (as supplied) 

2.1.1 Engine removal 



Engine 2 

WARNING 




WARNING 






Use suitable lifting gear to lift the engine (e.g. workshop crane). 

The engine must be replaced by two persons. 

Mark the electric cables in order to avoid mix-ups. 

The radiator has been removed (see the section 2.2.1 "Removing the radiator"). 

The starter has been removed (see the section 8.1.2 "Replacing the 

starter"). 

The complete air filter has been removed (see the section 2.3.1 "Replacing 

the complete air filter"). 

The brake hydraulics tank has been removed (see the section 3.4.2 

"Replacing the brake hydraulics tank"). 

Fig. 2 Electrical connections (right) Fig. 3 Securing the grounding strip 

(right) 

Removing the cables (right) Unplug the plugs from the temperature sensors (Fig. 2,1 and Fig. 2,2). 

Remove the 3 cables from the generator (Fig. 2,3). 

Unscrew the screw (Fig. 3,1) on the grounding strip. 

2Engine 

4-11

2 Engine 

Removing the holder and 

plug 

Fig. 4 Holder attachment Fig. 5 Temperature sensor plug 

Mark the position of the holder on the rear carriage. 

Undo 2 nuts (Fig. 4) and remove the holder. 

Remove the plug from the temperature sensor (Fig. 5,1). 

Fig. 6 Connections (left) 

Removing the cables (left) Unplug the plug from the oil pressure switch (Fig. 6,2), from the hydraulic 

fluid switch (Fig. 6,5) and from the cutoff solenoid (Fig. 6,8). 

Detach the connection (Fig. 6,1) for the glow plugs. 

Fix the grounding strip (Fig. 6,10) on the engine. 

Loosen the hydraulic line (Fig. 6,7), rotate it outwards and tighten it. 

Unhook the accelerator cable (Fig. 6,4). 

Close off and separate the fuel line (Fig. 6,6) and fuel return line (Fig. 6,9) 

(e.g. with a hose clamp). 

Remove the 2 heater cables (Fig. 6,3) (if present). 

4-12 1000239425 - WDF-6001-00EN 


Releasing the engine 

mounts 

Fig. 7 Engine attachment Fig. 8 Engine mount 


Engine 2 

Attach suitable lifting gear to the engine (e.g. workshop crane) (Fig. 7). 

Undo 1 screw (Fig. 8,1) on each engine mount (Fig. 8,2). 

Fig. 9 Clutch bell attachment 

Lifting out the engine Undo 8 nuts (Fig. 9) for securing the clutch bell. 

Carefully lift out the engine upwards and towards the rear. 

If necessary, remove the clutch PA flange (see the section 2.1.5 "Replacing 

the clutch PA flange"). 

2.1.2 Engine installation 

WARNING 






Use suitable lifting gear to lift the engine (e.g. workshop crane). 

The engine must be replaced by two persons. 

4-13

2 Engine 

Fig. 10 Engine attachment Fig. 11 Clutch bell support 

Installing the engine Using suitable lifting gear, carefully install the engine from above and the 

rear (Fig. 10). 

Raise the clutch bell slightly (e.g. with a jack) (Fig. 11). 

Fig. 12 Connecting elements Fig. 13 Clutch bell attachment 

Connecting the engine Swivel the engine into the clutch bell so that the bolts (Fig. 12,2) engage in 

the corresponding holes on the engine. 

Screw some of the 8 nuts (Fig. 13) loosely onto the bolts in order to fix the 

position of the clutch bell and the engine. 

Rotate the engine on the fan wheel until the clutch hub (Fig. 12,1) engages 

in the clutch PA flange. 

Push the engine forwards until the clutch bell abuts. 

Tighten 8 nuts (Fig. 13) for securing the clutch bell. 

Remove the clutch bell support 

Fig. 14 Engine mount 

Securing the engine Undo 2 screws (Fig. 14,4) on each of the rubber buffers, but do not 

unscrew them completely. 

Screw in 1 screw (Fig. 14,1) on each of the engine mounts but do not 

tighten. 

4-14 1000239425 - WDF-6001-00EN 


Fig. 15 Connections (left) 


Engine 2 

Installing the lines (left) Connect the fuel line (Fig. 15,6) and fuel return line (Fig. 15,9) with a clamp 

and open them (e.g. remove hose clamp). 

Hook in the accelerator cable (Fig. 15,4), pull it taut and secure it with the 

screw. 

Loosen the hydraulic line (Fig. 15,7), rotate it inwards and tighten it. 

Lay the grounding strip (Fig. 15,10) in the direction of the battery. 

Fit the connection (Fig. 15,1) for the glow plugs. 

Plug in the plug on the oil pressure switch (Fig. 15,2), on the hydraulic fluid 

pressure switch (Fig. 15,5) and on the cutoff solenoid (Fig. 15,8). 

Install the 2 heater cables (Fig. 15,3) (if present). 

Fig. 16 Temperature sensor plug Fig. 17 Holder attachment 

Fitting the holder and plug Plug the plug onto the temperature sensor (Fig. 16,1). 

Place the holder into position, align it and tighten the 2 nuts (Fig. 17). 

4-15

2 Engine 

Fig. 18 Securing the grounding strip 

(right) 

Installing the cables (right) Secure the grounding strip with the screw (Fig. 18,1), spring lock washer 

and disk. 

Connect the 3 cables to the generator (Fig. 19,3). 

Plug in the plug on the temperature sensors (Fig. 19,1 and Fig. 19,2). 

Final work Install the brake hydraulics tank (see the section 3.4.2 "Replacing the brake 

hydraulics tank"). 

Install the complete air filter (see the section 2.3.1 "Replacing the complete 

air filter"). 

Install the starter (see the section 8.1.2 "Replacing the starter"). 

Install the radiator (see Part 3, "Installing the radiator" section). 

Make sure that the engine is in the correct position with respect to the radiator 

and lower it (see Part 3, "Checking the radiator installation" section). 

Tighten 2 screws in each case (Fig. 14,4). 

Tighten 1 screw in each case (Fig. 14,1). 

Vent the fuel lines (see operator's manual "Venting the fuel system"). 

2.1.3 Replacing the front rubber buffers 


Fig. 19 Electrical connections (right) 

WARNING 




Between the engine mount and the rubber buffer, there can be shim 

washers in order to reduce the play and prevent damage. 




The battery has been removed (see operator's manual "Disconnecting and 

connecting the battery/changing the battery"). 

4-16 1000239425 - WDF-6001-00EN 




Removing the rubber 

buffers 


Engine 2 

Unscrew the screw (Fig. 20,1) on the bearing to be replaced. 

Unscrew 1 screw (Fig. 20,1) on each of the other bearings. 

Attach the engine on one side (Fig. 21) using suitable lifting gear (e.g. 

workshop crane). 


Remove the rubber buffers (Fig. 20,3). 

Installing the rubber buffers Insert the rubber buffer (Fig. 20,3). 

Insert the 2 screws (Fig. 20,4) but do not tighten them yet. 

Screw in the screw (Fig. 20,1) but do not tighten it yet. 


and lower it (see Part 3, "Checking the radiator installation" section). 

Tighten the 2 screws (Fig. 20,4). 

Tighten 1 screw (Fig. 20,1) on each engine mount. 

Final work Install the battery (see operator's manual "Disconnecting and connecting 

the battery/changing the battery"). 

2.1.4 Replacing the rear rubber buffer 



Rubber buffer 2 

Fig. 20 Engine mount Fig. 21 Engine attachment 

WARNING 







The flue has been removed (see the section 2.5.1 "Replacing the flue"). 

The complete air filter has been removed (see the section 2.3.1 "Replacing 

the complete air filter"). 

4-17

2 Engine 




buffers 

Unscrew the screw (Fig. 22,1) on the bearing to be replaced. 

Unscrew 1 screw (Fig. 22,1) on each of the other bearings. 

Attach the engine on one side (Fig. 23) using suitable lifting gear (e.g. 

workshop crane). 


Remove the rubber buffers (Fig. 22,3). 

Installing the rubber buffers Insert the rubber buffer (Fig. 22,3). 

Insert the 2 screws (Fig. 22,4) but do not tighten them yet. 

Screw in the screw (Fig. 22,1) but do not tighten it yet. 


(see Part 3, "Checking the radiator installation" section) and lower it. 


Tighten 1 screw (Fig. 22,1) on each engine mount. 

Final work Install the complete air filter (see the section 2.3.1 "Replacing the complete 

air filter"). 

Install the flue (see the section 2.5.1 "Replacing the flue"). 

2.1.5 Replacing the clutch PA flange 






Fig. 22 Engine mount Fig. 23 Engine attachment 

The engine has been removed (see the section 2.1.1 "Engine removal"). 


Clutch PA flange 1 

4-18 1000239425 - WDF-6001-00EN 


Fig. 24 Clutch PA flange attachment Fig. 25 Installation direction 

Removing the flange Unscrew the 8 screws (Fig. 24,1). 

Remove the clutch PA flange. 

Place the clutch PA flange into position. 


Install the engine (see the section 2.1.2 "Engine installation"). 

2.1.6 Cleaning the engine (after toppling the loader) 



Engine 2 

Pay attention to the installation direction (Fig. 25) of the clutch PA flange. 

WARNING 




WARNING 






hood"). 

4-19

2 Engine 

Turning the engine 

manually 

Turning the engine with the 

starter (3 seconds) 

Turning the engine with the 

starter (5 seconds) 

Fig. 26 Engine (left side) 

Detach and insulate the connection (Fig. 26,1) for the glow plugs. 

Remove the distributor busbar and glow plugs (see the engine manufacturer's 

workshop manual). 

Cover the glow plug holes with an absorptive cloth. 

Slowly turn the engine manually (e.g. at the fan wheel) through 5 full revolutions. 

Remove any escaped oil. 

Cover the glow plug holes with absorptive cloths so that the cloths cannot 

be pulled in by moving parts. 


Actuate the starter for 3 seconds. 

Open the engine hood. 


Cover the glow plug holes with absorptive cloths so that the cloths cannot 

be pulled in by moving parts. 


Actuate the starter for 5 seconds. 

Open the engine hood. 


A slight deviation from the compression setpoint value occurs due to 

residual oil in the cylinders. 

If the deviation is greater than 3 bar, repair the engine in accordance with 

the manufacturer's workshop manual. 

Perform a compression measurement (see the engine manufacturer's 

workshop manual) 

Remove the glow plugs and distributor busbar (see the engine manufacturer's 

workshop manual). 

Fit the connection (Fig. 26,1) for the glow plugs. 

4-20 1000239425 - WDF-6001-00EN 


Checking the air supply and 

oil level 

Starting the engine Start the engine. 


Engine 2 

Check the air filter system for cleanliness. 

Remove the cylinder head cover (see Part 3, "Checking and adjusting the 

valve play" section). 

Check the intake manifold for cleanliness. 

Check the valve drive for completeness and that the parts are in the correct 

position (see the engine manufacturer's workshop manual). 

Install the cylinder head cover (see Part 3, "Checking and adjusting the 

valve play" section). 

Check the engine oil level (see operator's manual "Checking the engine oil 

level") 

Give the engine a cursory external clean. 


Heavy smoke when the engine is started is caused by residual oil in the cylinders. 

If the exhaust does not become noticeably clearer after a maximum of 

30 minutes, repair the engine in accordance with the manufacturer's workshop 

manual. 

If unusual noises occur for any length of time, repair the engine as 

described in the manufacturer's workshop manual. 

2.2 Radiator 

2.2.1 Removing the radiator 

WARNING 




WARNING 








The hydraulic system is depressurized (see the section 3.1.1 "Depressurizing 

the hydraulic system"). 

The engine hood has been removed (see the section 6.2.4 "Replacing the 

engine hood"). 

The additional weight/base plate has been removed (see the section 6.2.2 

"Replacing the additional weight/base plate"). 

4-21

2 Engine 

Detaching the lines on the 

underside 

Fig. 27 Underside of the radiator Fig. 28 Cooling hose 



Place a collecting vessel under the radiator. 

Open the radiator cap. 

Detach the hose clamp on the cooling hose (Fig. 28). 

Pull off the cooling hose slowly to allow coolant to run off in a controlled 

manner. 

Fig. 29 Topside of the radiator Fig. 30 Side radiator attachment 

Removing the radiator Detach the hose clamp on the cooling hose (Fig. 29,1). 

Pull off the cooling hose. 


Undo 1 screw (Fig. 30,1) on both sides of the radiator, but do not unscrew 

them completely. 

Carefully tilt the radiator back and lift it out. 

2.2.2 Installing the radiator 

The coolant must consist of equal amounts of water and antifreeze. This 

mixture guarantees an optimum ratio between cooling performance and 

corrosion protection. 

Do not fill with coolant too quickly. Fill at a maximum of 5 l/min. If the 

cooling system is filled too quickly, air can be trapped in the cooling system 

and cause the engine to overheat. 



4-22 1000239425 - WDF-6001-00EN 





Water/oil cooler 1 

Coolant approx. 11.5 l 

Fig. 31 Attachment points 


Engine 2 

Putting in the radiator Put in the radiator carefully so that the screws on the underside of the radiator 

engage in the attachment point slots (Fig. 31). 

Fig. 32 Side radiator attachment Fig. 33 Topside of the radiator 

Attaching the radiator Carefully tilt the radiator forwards until the screws (Fig. 32,1) slide into the 

guides on both sides of the radiator with 1 washer each. 

Tighten 1 screw on both sides. 

Push the cooling hose (Fig. 33,1) onto the connection on the radiator and 

tighten the hose clamp. 

Screw the hydraulic line (Fig. 332) onto the connection on the radiator and 

tighten it. 

4-23

2 Engine 

Connecting the lines on the 

underside 

Fig. 34 Cooling hose Fig. 35 Underside of the radiator 

Push the cooling hose (Fig. 34) onto the connection on the radiator and 

tighten the hose clamp. 

Align the radiator so that the fan wheel of the engine projects approx. 2/3 

of the way into the air deflector (see Part 3, "Checking the radiator installation"). 

Tighten the 2 nuts (Fig. 35,1) with disks and spring lock washers. 

Screw the hydraulic line (Fig. 35,2) onto the connection on the radiator and 

tighten it. 

Slowly fill with coolant until the radiator slats are covered with coolant. 

Close the radiator cap. 

Fill with coolant. 

WARNING 


Never reach into the engine compartment while the engine is running. 


Set the heater temperature regulator (if present) to the maximum setting. 

Slowly increase the speed and maintain it for 2 minutes. 


Check the coolant level (see operator's manual "Checking the coolant 

level/refilling the coolant"). 

Final work Install the additional weight/base plate (see the section 6.2.2 "Replacing 

the additional weight/base plate"). 

Install the engine hood (see the section 6.2.4 "Replacing the engine 

hood"). 

Check the coolant level after half an hour's operation (see operator's 

manual "Checking the coolant level/refilling the coolant") 

4-24 1000239425 - WDF-6001-00EN 


2.3 Air filter system 

2.3.1 Replacing the complete air filter 




Removing the complete 

air filter 

Installing the complete 

air filter 


Engine 2 

WARNING 




WARNING 






hood"). 


Bellows 1 

Air filter 1 

Retaining clamp 1 

Vacuum indicator 1 

Rubber dust valve 1 

Fig. 36 Air filter 

Mark the position of the air filter (Fig. 36,3) on the mount (Fig. 36,4). 

Undo the hose clamp (Fig. 36,2) and pull off the hose. 


Remove the complete air filter. 

Close off the air inlet on the engine (e.g. with a cloth). 

If necessary, uncover the air inlet on the engine (e.g. remove cloth). 

Put in the complete air filter and align it on the marking on the mount 

(Fig. 36,4). 

Tighten the 2 screws (Fig. 36,1) with washers. 

4-25

2 Engine 

Push the hose onto the engine's air inlet and tighten the hose clamp 

(Fig. 36,2). 

Check the position of the air filter if necessary (see the section 2.3.2 

"Replacing the air filter housing"). 


2.3.2 Replacing the air filter housing 




Removing the air filter 

housing 

Installing the air filter 

housing 

WARNING 






hood"). 


Air filter 1 

Fig. 37 Air filter Fig. 38 Air filter holder 

Mark the position of the air filter housing on the retaining clamp (Fig. 37,3). 

Remove the cover and the filter insert (see operator's manual "Servicing 

the air filter system"). 

Undo the hose clamp (Fig. 37,4) and pull off the hose. 


Carefully bend open the retaining clamp (Fig. 38) and remove the air filter 

housing. 

If necessary, apply the marking to the air filter housing. 

Carefully bend open the retaining clamp and insert the air filter housing so 

that the markings correspond. 


Push the hose onto the connection on the air filter housing and tighten hose 

clamp (Fig. 37,4). 

Install the filter inserts and cover (see operator's manual "Servicing the air 

filter system"). 

4-26 1000239425 - WDF-6001-00EN 


Checking the position of the 

air filter 

Fig. 39 Position of the air filter 


Engine 2 

Tilt the operator's platform (see operator's manual "Tilting the operator's 


Carefully close the engine hood and check the position of the air filter 

(Fig. 39). 

The intake opening of the air filter must cover the intake opening of the 

engine hood. 

If the intake opening of the air filter does not cover the intake opening of the 

engine hood, rotate the air filter housing in the air filter holder. 

Lower the operator's platform (see operator's manual "Tilting the operator's 



2.4 Fuel system 

2.4.1 Replacing the complete fuel filter 

WARNING 










Filter 1 

Clamp 2 

4-27

2 Engine 

Fig. 40 Fuel filter attachment Fig. 41 Fuel filter connections 

Removing the fuel filter Undo the screw (Fig. 40,1). 

Swivel the fuel filter (Fig. 40,2) to the side. 

Mark the fuel lines (input and output side) in order to prevent mix-ups. 

Close off the fuel lines (Fig. 41,2). 

Remove the 2 clamps (Fig. 41,1). 

Pull off the fuel lines and remove the fuel filter (Fig. 41,3). 

Installing the fuel filter Attach the fuel lines (Fig. 41,2) with clamps (Fig. 41,1) to the fuel filter 

(Fig. 41,3). 

Secure the 2 clamps (Fig. 41,1). 

Open the fuel lines. 

Position the fuel filter (Fig. 40,2), screw in the screw (Fig. 40,1) with the 

washer and tighten it. 

Final work Vent the fuel system (see operator's manual "Venting the fuel system"). 

2.4.2 Replacing the complete main fuel filter 

WARNING 







This section describes the replacement of the complete filter (including the 

housing). 

Replacement of the filter insert is described in the operator's manual. 




Filter 1 

Clamp 2 

4-28 1000239425 - WDF-6001-00EN 


Removing the main 

fuel filter 

Fig. 42 Main fuel filter 


Engine 2 




Pull off the fuel lines. 

Unscrew the 2 screws (Fig. 42,4) and remove the main fuel filter 

(Fig. 42,1). 

Installing the main fuel filter Position the main fuel filter (Fig. 42,1). 

Screw in and tighten the 2 screws (Fig. 42,4) with 1 washer for each. 

Plug the fuel lines (Fig. 42,3) with clamps (Fig. 42,2) onto the main fuel 

filter. 




2.4.3 Replacing the water separator 

WARNING 







This section describes replacement of the water separator. 

Servicing the water separator is described in the operator's manual. 




Water separator 1 

Clamp 2 

4-29

2 Engine 

Removing the water 

separator 

Installing the water 

separator 

Fig. 43 Water separator 

Undo the screw (Fig. 43,3). 




Pull off the fuel lines and remove the water separator (Fig. 43,4). 

Plug the fuel lines (Fig. 43,1) with clamps (Fig. 43,2) onto the water separator 

(Fig. 43,4). 



Position the water separator, screw in the screw (Fig. 43,3) with the spring 

lock washer and disk, and tighten it. 


2.4.4 Replacing the fuel feed pump 

WARNING 










Pump 1 

Clamp 2 



Removing the fuel feed 

pump 

Fig. 44 Fuel feed pump 


Engine 2 


Disconnect the electrical plug (Fig. 44,3). 




Pull off the fuel lines and remove the fuel feed pump (Fig. 44,5). 

Installing the fuel feed pump Plug the fuel lines (Fig. 44,2) with clamps (Fig. 44,4) onto the fuel feed 

pump. 



Connect the plug (Fig. 44,3). 

Position the fuel feed pump, screw in the 2 screws (Fig. 44,1) with 1 spring 

lock washer and 1 disk for each, and tighten. 


2.4.5 Replacing the fuel line 

WARNING 









This section describes the replacement of a fuel line. 

The other fuel lines are replaced in the same way. 

Reuse fuel in the fuel line or dispose of it in an environmentally responsible 

manner. 


Hose (meter goods) as req. 

Clamp 2 

4-31

2 Engine 

Removing the fuel line Close off the fuel line (Fig. 45,1) at both ends. 

Remove the clamp (Fig. 45,2) and clamp (Fig. 46,4). 

Pull off the fuel line. 

Remove the fuel line. 

Installing the fuel line Cut the new fuel line to the required length. 

Attach the fuel line to the water separator (Fig. 45,4) and fuel feed pump 

(Fig. 46,5) using 1 clamp (Fig. 45,2) in each case. 

Secure the clamp (Fig. 45,2) and clamp (Fig. 46,4). 



Fig. 45 Water separator Fig. 46 Fuel feed pump 


2.4.6 Tank lock emergency opening 

Do not allow any foreign bodies to enter the fuel tank. 


Tank cap 1 

Fig. 47 Tank cap 

Drill a hole (Fig. 47) on the edge of the tank cap. 

Screw a sheet metal screw into the hole. 

Open and remove the tank cap. 

Close off the tank nozzle with a new tank cap. 

4-32 1000239425 - WDF-6001-00EN 


2.5 Exhaust system 

2.5.1 Replacing the flue 





Engine 2 

WARNING 






hood"). 


Flue 1 

Fig. 48 Flue 

Removing the flue Undo the bolt clamp (Fig. 48,1). 


Remove the flue and seal (Fig. 48,2). 

If necessary, secure the seal loosely to the engine with 4 screws in order 

to prevent loss of the seal. 

Close off the uncovered openings (e.g. with cloths). 

Installing the flue Uncover the openings if necessary (e.g. remove the cloths). 

Place the flue with the seal (Fig. 48,2) onto the engine. 

Tighten the 4 screws (Fig. 48,3) with spring lock washers and disks. 

Tighten the bolt clamp (Fig. 48,1). 


2.5.2 Replacing the muffler and flexi-pipe 

WARNING 


Never work on the exhaust when it is at operating temperature. 

Allow the exhaust to cool down or wear protective gloves. 

4-33

2 Engine 




The rear weight has been removed (see the section 6.2.3 "Replacing the 

rear weight"). 


Muffler 1 

Flexi-pipe 1 

Fig. 49 Rear attachment Fig. 50 Side attachment 

Removing the cover Mark the position of the cover (Fig. 49,4) on the rear carriage. 

Undo the 2 screws (Fig. 49,3). 


Remove the cover to the side. 

Fig. 51 Muffler attachment 

Replacing the muffler Mark the position of the muffler (Fig. 51,3) on the rear carriage. 

Undo the clamp (Fig. 51,1). 


Remove the muffler. 

Position the new muffler and screw in the 2 screws. 

Tighten the clamp (Fig. 51,1). 

Align the muffler and tighten the 2 screws (Fig. 51,2). 

Replacing the flexi-pipe Release the 2 clamps (Fig. 51,1) on the flexi-pipe. 

Remove the flexi-pipe. 

Insert a new flexi-pipe. 

Tighten the 2 clamps (Fig. 51,1) on the flexi-pipe. 

4-34 1000239425 - WDF-6001-00EN 



Engine 2 

Fitting the cover Put the cover (Fig. 49,4) into position at the side and push under the screws 

(Fig. 49,3) with washers. 

Screw in the screw (Fig. 50,1) with the washer. 

Align the cover and tighten the screws. 

Final work Check the exhaust for leaks (see Part 3, "Inspecting the exhaust system for 

leaks" section). 

Install the rear weight (see the section 6.2.3 "Replacing the rear weight"). 

4-35

2 Engine 

4-36 1000239425 - WDF-6001-00EN 


Depressurizing the 

hydraulic system 

3.1 Complete vehicle 

3.1.1 Depressurizing the hydraulic system 





Fig. 52 Depressurizing the hydraulic 

system 


Fully lower the lift frame. 


Immediately after switching off the engine, move all control levers and 

pedals of the hydraulic system several times in all directions. 

Open the cap (Fig. 52,2) in order to depressurize the hydraulic fluid tank. 

Briefly open the cap (Fig. 52,1) so that the hydraulic fluid can flow out of the 

return filter and into the hydraulic fluid tank. 

Close the 2 caps (Fig. 52,1 and 2). 

3.1.2 Replacing the pivot bearing on the hydraulic cylinder 

WARNING 

Risk of injury from flying metal chips! 

Wear safety goggles and protective gloves. 




Use home-made sleeves to expel and drive in the bearings (see Part 2, 

"Expulsion and driving sleeves" section). 

The hydraulic cylinder has been removed (see the section 3.3.4 "Removing 

the steering cylinder", 3.5.8 "Replacing the lifting cylinder" or 3.5.9 

"Removing the tipping cylinder"). 

The hydraulic cylinder is lying horizontally on a workbench and is secured 

against accidental movement. 


Pivot bearing as req. 

Locking ring 1 per bearing 

Lubricating grease as req. 

4-37


Fig. 53 Securing the bearing Fig. 54 Expulsion tool 

Removing the pivot bearing Remove the locking ring (Fig. 53). 

Rotate the hydraulic cylinder. 

Drive out the pivot bearing downwards using a suitable expulsion tool 

(Fig. 54). 

Fig. 55 Driving tool Fig. 56 Securing the bearing 

Installing the pivot bearing Rotate the hydraulic cylinder if necessary. 

Position the pivot bearing from above and use a suitable driving tool to 

drive it in (Fig. 55). 

Insert the locking ring (Fig. 56). 

Check that all locking rings are fitted correctly. 

Final work Install the hydraulic cylinder (see the section 3.3.5 "Installing the steering 

cylinder", 3.5.8 "Replacing the lifting cylinder" or 3.5.10 "Installing the tipping 

cylinder"). 

Lubricate the new bearing. 

3.1.3 Sealing the hydraulic cylinder 



4-38 1000239425 - WDF-6001-00EN 







The hydraulic cylinder has been removed (see the section 3.3.4 "Removing 

the steering cylinder", 3.5.8 "Replacing the lifting cylinder" or 3.5.9 

"Removing the tipping cylinder"). 

The hydraulic cylinder is lying horizontally on a workbench and is secured 

against accidental movement. 


Set of seals 1 


Crepe tape as req. 

Locking agent (e.g. Loctite ® ) 

Removing the piston Undo the screw (Fig. 57,1). 

Unscrew the guide bush (Fig. 57,2) with a sickle spanner (Fig. 58). 

Remove the plug in the base of necessary. 

Carefully pull the piston out of the cylinder. 

Inspect the inside of the cylinder for damage. 

as req. 

Fig. 57 Securing the guide bush Fig. 58 Sickle spanner 

Collect any escaping hydraulic fluid. 

If there are any scratches, furrows or similar on the inside of the cylinder, 

the complete hydraulic cylinder must be replaced. 

4-39


Fig. 59 Guide rings Fig. 60 Securing the piston 

Removing the piston Remove the 2 guide rings (Fig. 59,1). 

Remove the annular seal (Fig. 60,3) and the O-ring underneath. 

Unscrew the stud screw (Fig. 60,2). 

Unscrew the piston (Fig. 60,4) with a face spanner. 

Remove the spacer (Fig. 60,1) with the O-ring. 

Carefully pull the guide bush off the piston rod. 

If there are any scratches, furrows or similar on the piston rod or piston, the 

complete hydraulic cylinder must be replaced. 

Inspect the piston rod and the piston for damage. 

Fig. 61 Compression of the annular 

seal 

Sealing the piston Clean the piston thoroughly. 

Place the O-ring in the middle groove. 

The annular seal is always widened slightly when it is removed. 

Place the annular seal (Fig. 60,3) over the O-ring. 

Wrap the annular seal securely in several layers of crepe tape (Fig. 61). 

Press the annular seal into its original shape with a clip. 

4-40 1000239425 - WDF-6001-00EN 


Cleaning the guide bush Remove the O-ring (Fig. 62,1). 

Remove the support ring (Fig. 62,2). 

Remove the annular seal (Fig. 63,2). 

Remove the dust arrester (Fig. 63,1). 



Fig. 62 Inside of the guide bush Fig. 63 Outside of the guide bush 

Clean the guide bush thoroughly. 

If there are any scratches, furrows or similar on the guide bush, the complete 

hydraulic cylinder must be replaced. 

Inspect the guide bush for damage. 

Fig. 64 Annular seal with insertion tool 

Sealing the guide bush Insert the dust arrester (Fig. 63,1) into the guide bush so that the seal lip 

faces outwards. 

Slightly grease the annular seal (Fig. 63,2) and, with the insertion tool 

(Fig. 64), insert it into the guide bush so that the groove faces inwards. 

Insert the support ring (Fig. 62,2). 

Insert the O-ring (Fig. 62,1). 

Installing the piston Clean the piston rod thoroughly. 

Carefully push the guide bush onto the piston rod. 

Carefully push the spacer (Fig. 60,1) with the O-ring onto the piston rod. 

Screw and tighten the piston (Fig. 60,4) onto the piston rod. 

Coat the stud screw (Fig. 60,2) with locking agent and screw it in. 

Insert the 2 guide rings (Fig. 59,1). 

Installing the piston Remove the clamp and the crepe tape (Fig. 61). 

Slightly grease the cylinder on the thread and the piston. 

4-41


Carefully push the piston into the cylinder. 

Screw in the guide bush until the recesses for the screw (Fig. 57,1) correspond. 

Screw in and tighten the screw (Fig. 57,1). 

Final work Install the hydraulic cylinder (see the section 3.3.5 "Installing the steering 

cylinder", 3.5.8 "Replacing the lifting cylinder" or 3.5.10 "Installing the tipping 

cylinder"). 

Lubricate the new bearing. 

3.2 Driving hydraulics 

3.2.1 Replacing the variable displacement pump 

CAUTION 

Risk of injury by a heavy component. 

The variable displacement pump weighs approx. 30 kg. 

When removing and installing the variable displacement pump, use suitable 

lifting gear or work with another person. 










The battery has been removed (see "Disconnecting and connecting the 

battery/changing the battery" in the operator's manual). 

The gear pump has been removed (see the section 3.5.1 "Replacing the 

gear pump"). 


Variable displacement pump 1 

4-42 1000239425 - WDF-6001-00EN 




Detaching the lines Unscrew and close off the hydraulic line from the inching pedal (Fig. 65,2). 

Removing the variable 


Installing the variable 


Fig. 65 Topside of the variable displacement 

pump 

Fig. 66 Output end of the variable displacement 

pump 

Mark the connectors of the solenoid valves in order to avoid mix-ups. 

Undo 1 screw on each of the connectors (Fig. 65,1), pull the connectors off 

the solenoid valves and protect the contacts (e.g. with a protective cap). 

Unscrew and close off the hydraulic line to the cross flushing connection 

(Fig. 65,4). 

Unscrew and close off the hydraulic line to the differential lock (Fig. 66,2). 

Unscrew and close off the hydraulic line from the combination filter 

(Fig. 66,3). 

Undo 4 screws on each of the flange halves of the two high pressure lines 

(Fig. 66,1) and remove the flange halves. 

Remove and close off the high pressure lines. 


Two persons must then carefully lift out the variable displacement pump. 

If the clutch hub is to be reused, remove it (see the section 3.2.2 "Replacing 

the clutch hub"). 

If necessary, fit the clutch hub (see the section 3.2.2 "Replacing the clutch 

hub"). 

Two persons must then carefully insert the variable displacement pump. 


Connecting the lines Put each flange half for securing the high pressure lines (Fig. 66,1) into 

position and loosely screw in 2 screws with spring lock washers. 

Press 1 high pressure line under each flange half and align so that the 

second flange half can be put into position. 

Put each second flange half into position and loosely screw in 2 screws with 

spring lock washers. 

Tighten the 4 screws on each of the high pressure lines. 

Screw the hydraulic line from the combination filter (Fig. 66,3) onto the connection 

on the variable displacement pump and tighten. 

Screw the hydraulic line to the differential lock (Fig. 66,2) onto the connection 


Screw the hydraulic line to the cross flushing connection (Fig. 65,4) onto 

the connection on the variable displacement pump and tighten. 

4-43


Plug the connectors (Fig. 65,1) onto the solenoid valves and secure with 

1 screw for each. 

Screw the hydraulic line of the inching pedal (Fig. 65,2) onto the connection 


Final work Install the gear pump (see the section 3.5.1 "Replacing the gear pump"). 

Install the battery (see operator’s manual "Disconnecting and connecting 

the battery/changing the battery"). 

Vent the service brake (see the section 3.4.3 "Replacing the brake fluid"). 

3.2.2 Replacing the clutch hub 




The variable displacement pump has been removed (see the section 3.2.1 

"Replacing the variable displacement pump"). 

Removing the clutch hub Undo the screw (Fig. 67,2). 


Clutch hub 1 


as req. 

Fig. 67 Clutch hub attachment Fig. 68 Variable displacement pump 

drive 

Widen the gap in the clutch hub (Fig. 67,1) slightly using a suitable tool 

(e.g. wedge). 

Pull off the clutch hub. 

Clean the internal teeth of the clutch hub and variable displacement pump 

drive (Fig. 68) to remove locking agent residues. 

Fitting the clutch hub Coat the internal teeth of the clutch hub with locking agent. 

Place the clutch hub onto the variable displacement pump drive. 

Coat the screw thread with locking agent. 

Tighten the screw. 

Final work Install the variable displacement pump (see the section 3.2.1 "Replacing 

the variable displacement pump"). 

4-44 1000239425 - WDF-6001-00EN 


3.2.3 Replacing the annular shaft seal of the variable 





Removing the annular shaft 

seal 





The clutch hub has been removed (see the section 3.2.2 "Replacing the 

clutch hub"). 


Annular shaft seal 1 

Locking ring 1 

Fig. 69 Securing the annular shaft seal Fig. 70 Annular shaft seal 

Remove the locking ring (Fig. 69,1). 

Screw 2 sheet metal screws into the holes (Fig. 70,1). 

Pull out the annular shaft seal (Fig. 70,2) on the sheet metal screws. 

Fitting the annular shaft seal Slightly oil the new annular shaft seal (Fig. 70,2). 

Place the annular shaft seal into position so that the metal ring faces away 

from the variable displacement pump (Fig. 70,3). 

Using a suitable driving tool, carefully drive in the annular shaft seal sufficiently 

far for the locking ring (Fig. 69,1) to be inserted. 

Insert the locking ring (Fig. 69,1). 

Final work Install the clutch hub (see the section 3.2.2 "Replacing the clutch hub"). 

3.2.4 Replacing the variable displacement motor 

WARNING 


The variable displacement motor weighs approx. 26 kg. 

When removing and installing the variable displacement motor, use suitable 

lifting gear or work with another person. 

4-45






topside 



The parking brake has been applied and the loader secured against rolling 

away (e.g. with chocks). 

The drive shaft has been removed on the rear axle (see the section 4.1 

"Replacing the drive shaft"). 




Variable displacement motor 1 

Sealant as req. 



motor 

as req. 




Undo 1 screw on each of the connectors (Fig. 71,2), pull the connectors off 

the solenoid valves and protect the contacts (e.g. with a protective cap). 

Unscrew and close off the hydraulic line of the cross flushing connection 

(Fig. 71,3). 






4-46 1000239425 - WDF-6001-00EN 


Removing the variable 





(Fig. 72,2). 

Loosen the 4 screws (Fig. 72,1) but do not unscrew them. 

Get a second person to help you hold the variable displacement motor 

securely in place. 

Unscrew the 4 screws and carefully lift off the variable displacement motor 

(two persons). 

Close off the opening in the rear axle (e.g. with a cloth). 

Gear wheel replacement Unscrew the screw (Fig. 73,1) and remove the washer (Fig. 73,2). 

Installing the variable 


Fig. 72 Underside of the variable displacement 

motor 

Fig. 73 Variable displacement motor 

output 

Pull off the gear wheel (Fig. 73,3). 

Fig. 74 Sealing the variable displacement 

motor 

Place the gear wheel in the correct position on the new variable displacement 

motor (Fig. 74). 

Coat the thread of the screw with the washer with locking agent. 

Screw in and tighten the screw with the washer. 

Clean the contact surfaces on the variable displacement motor and the rear 

axle. 

Uncover the opening on the rear axle if necessary (e.g. remove the cloths). 

Apply sealant along the O-ring (Fig. 74,1). 

Coat the thread of the 4 screws (Fig. 72,1) with locking agent. 

Carefully (two people!) insert the variable displacement motor into the rear 

axle and screw in the 4 screws. 

Tighten the 4 screws. Sealant escapes at the side. 

Screw the hydraulic line of the cross flushing connection (Fig. 72,2) onto 

the connection on the variable displacement motor and tighten. 

4-47



topside 


motor 



Put each flange half for securing the high pressure lines into position 

(Fig. 75,1) and loosely screw in 2 screws with spring lock washers. 












Final work Install the drive shaft on the rear axle (see the section 4.1 "Replacing the 

drive shaft"). 

3.3 Steering hydraulics 

3.3.1 Cleaning the priority valve 



Under the screw attachment there is a spring that is under slight pressure. 




4-48 1000239425 - WDF-6001-00EN 


Fig. 76 Steering cover Fig. 77 Priority valve 

Opening the priority valve Unscrew the 4 screws (Fig. 76,1). 

Remove the cover (Fig. 76,2). 

Undo the screw attachment (Fig. 77,1). 



Fig. 78 Control piston Fig. 79 Individual parts 

Cleaning the control piston Carefully screw the M6 screw into the control piston from above. 

Carefully pull out the control piston and unscrew the M6 screw. 

Do not damage the outer surfaces of the control piston (Fig. 78,1). 

If necessary, hold the control piston firmly in the recesses (Fig. 78). 

Unscrew the nozzle (Fig. 78,2). 

Clean the control piston and nozzle thoroughly and blow them off with compressed 

air. 

Screw the nozzle into the control piston and tighten hand-tight. 

Carefully place the control piston into the priority valve. 

Closing off the priority valve Screw the screw attachment (Fig. 77,1) into the priority valve and tighten 

hand-tight. 

Place on the cover (Fig. 76,2). 

Screw in the 4 screws (Fig. 76,1) with washers and tighten. 

4-49


3.3.2 Replacing the priority valve 









Priority valve 1 

Fig. 80 Steering cover Fig. 81 Priority valve 

Removing the priority valve Unscrew the 4 screws (Fig. 80,1). 


Mark the hydraulic lines in order to prevent mix-ups. 

Unscrew and close off the hydraulic lines (Fig. 81,3). 


Remove the priority valve (Fig. 81,1). 

Installing the priority valve Place the priority valve (Fig. 81,1) into position. 

Screw in and tighten the 2 screws (Fig. 81,2). 

Screw the hydraulic lines (Fig. 81,3) onto the connection on the priority 

valve and tighten. 



4-50 1000239425 - WDF-6001-00EN 




Removing the steering 

column cladding 

3.3.3 Replacing the orbital steering valve 






Steering 1 

Valve as req. 

Fig. 82 Upper cladding Fig. 83 Lower cladding 



Carefully pull the upper steering column cladding (Fig. 82,4) apart so that 

the screws (Fig. 83,1) are freed. 



Remove the lower steering column cladding (Fig. 83,2). 

Carefully connect the upper steering column cladding and screw in 1 screw 

(Fig. 82,3) loosely. 

Fig. 84 Steering cover Fig. 85 Hydraulic lines 

Detaching the lines Unscrew the 4 screws (Fig. 84,1). 


Mark the hydraulic lines in order to avoid mix-ups. 


4-51


Replacing the orbital 

steering valve 


Remove the orbital steering valve (Fig. 86,3) to the rear and lift it out 

upwards and to the rear. 

If necessary, remove the priority valve (Fig. 87,2) and reuse it. 

Insert the new orbital steering valve from the top and rear, and attach it onto 

the steering column from below. 

Screw in the 4 screws (Fig. 86,1) with spring lock washers and tighten. 

Connecting the lines Screw the hydraulic lines (Fig. 85,2) onto the connections on the priority 

valve (Fig. 85,1) and tighten. 



Installing the steering 


Fig. 86 Steering attachment Fig. 87 Steering 

Unscrew 1 screw (Fig. 82,3). 

Carefully pull the steering column cladding (Fig. 82,4) apart slightly. 

Place the lower steering column cladding (Fig. 83,2) into position. 



Carefully connect the upper steering column cladding, screw in the 

4 screws (Fig. 82,3) and tighten. 

Align the instrument panel (Fig. 82,1), screw in the 4 screws (Fig. 82,2) and 

tighten. 

3.3.4 Removing the steering cylinder 



On both sides of the bearing, there can be shim washers in order to reduce 

the play and prevent damage. 

Take out the shim washers during the removal procedure and reuse them 

during installation if necessary. 

Avoid damaging the piston rod. 

4-52 1000239425 - WDF-6001-00EN 




cylinder at the rod end 


cylinder at the bottom end 


cylinder 






link"). 

Fig. 88 Steering cylinder, rod end Fig. 89 Steering cylinder support surface 

Remove the locking ring (Fig. 88,2) and take off the washer. 

Drive out the pin (Fig. 88,1) downwards. 

Hold and guide the piston rod (Fig. 88,3) in the painted area. 

Slowly rotate the steering wheel counter-clockwise until the steering cylinder 

is fully in. 

Place the steering cylinder on the rear carriage (Fig. 89). 

Fig. 90 Hydraulic line, rod end Fig. 91 Steering cylinder, bottom end 

Depressurize the hydraulic system (see the section 3.1.1 "Depressurizing 






Unscrew the remote lubrication line (Fig. 91,2). 

Remove the locking ring (Fig. 91,3) and take off the washer. 

Drive out the pin (Fig. 91,4) downwards. 

Pull the steering cylinder forwards out of the pin holder. 

Lift out the steering cylinder up and to the rear. 

If necessary, unscrew the bottom-end screw attachments. 

4-53




Inserting the steering 

cylinder 


cylinder at the bottom end 

3.3.5 Installing the steering cylinder 



On both side of the bearing, there can be shim washers in order to reduce 


If the pin holder on the front carriage is worn out, replace it with a new one. 

If the pin holder on the rear carriage is worn out, use an expander pin in the 

installation procedure (see "Expander pin documentation"). 

Avoid damaging the piston rod. 


Expander pin 1 


Fig. 92 Hydraulic line, rod end Fig. 93 Steering cylinder, bottom end 

If necessary, screw in the bottom-end screw attachments. 

Guide the steering cylinder from the rear and above through the opening 

next to the center joint. 

Push the bottom end of the steering cylinder into the pin holder from the 

front, if necessary with shim washers. 

Grease the pin and bearing slightly. 

Carefully align the pin holder, bearing and shim washers over each other 

so that there are no noticeable steps on the inside between the components. 

Drive in the pin (Fig. 93,4) with the washer from above. 

Place the washer into position at the bottom and secure it with the locking 

ring (Fig. 93,3). 

Screw the remote lubrication line (Fig. 93,2) onto the connection on the 

steering cylinder and tighten. 

Screw the hydraulic line (Fig. 93,1) onto the connection on the steering cylinder 

and tighten. 

Screw the hydraulic line (Fig. 92,1) onto the connection on the steering cylinder 

and tighten. 



4-54 1000239425 - WDF-6001-00EN 






Lift and guide the piston rod in the painted area (Fig. 95). 

Rotate the steering wheel clockwise slowly until the bearing of the steering 

cylinder projects into the pin holder of the front carriage. 


Insert shim washers if necessary. 

Carefully align the pin holder, bearing and shim washers over each other 

so that there are no noticeable steps on the inside between the components. 

Drive in the pin (Fig. 94,1) with the washer from above. 

Place the washer into position at the bottom and secure it with the locking 

ring (Fig. 94,2). 

3.4 Brake hydraulics 

3.4.1 Replacing the main brake cylinder 




Fig. 94 Steering cylinder, rod end Fig. 95 Steering cylinder support surface 




For the brake hydraulics, use only mineral oil of the specified quality (see 

Part 2 "Filling quantities"). 






Main brake cylinder 1 

4-55


Removing the main brake 

cylinder 

Installing the main brake 

cylinder 

Fig. 96 Connection to the brake 

linkage 

Unlock the pin (Fig. 96,1) and pull it out of the fork end. 

Unscrew and close off the 2 hydraulic lines (Fig. 97,4). 

Close off the hydraulic line (Fig. 97,3) with a clip, open the clamp and pull 

off the hydraulic line. 


Remove the main brake cylinder (Fig. 97,2). 

Insert the main brake cylinder (Fig. 97,2). 


Attach the hydraulic line (Fig. 97,3) to the connection on the main brake 

cylinder, secure it with a clamp and open the clip. 

Screw the 2 hydraulic lines (Fig. 97,4) onto the connections on the main 

brake cylinder and tighten. 

Push the pin (Fig. 96,1) through the fork end and brake linkage and secure. 

Final work Vent the brake hydraulics (see the section 3.4.4 "Venting the brake hydraulics"). 



3.4.2 Replacing the brake hydraulics tank 


Fig. 97 Hydraulic connections 

WARNING 










hood"). 

4-56 1000239425 - WDF-6001-00EN 




Removing the tank Unscrew the 2 screws (Fig. 98,1). 

Remove the tank. 

Replacing the tank Unscrew the cap (Fig. 98,2). 

Pour the mineral oil into a suitable vessel. 

Remove the tab clamp (Fig. 98,4). 

Pull the tank off the hose. 

Push a new tab clamp over the hose. 

Insert the new tank into the hose. 

Secure the tab clamp. 

Installing the tank Place the tank into position on the holder (Fig. 98,3). 

Tighten the 2 screws (Fig. 98,1) with washers. 



Final work Top up the mineral oil (see operator's manual "Checking the brake fluid 

level/refilling the brake fluid") 

Vent the brake hydraulics (see the section 3.4.4 "Venting the brake hydraulics"). 


3.4.3 Replacing the brake fluid 



Brake fluid container 1 

Tab clamp 1 

Mineral oil Transfluid JD as req. 

Fig. 98 Brake hydraulics tank 







4-57





Hose, transparent as req. 

Fig. 99 Front axle venting nipple Fig. 100 Variable displacement pump 

venting nipple 

Draining off the brake fluid Pull off the protective cap (Fig. 99,1). 

Attach the transparent hose to the venting nipple (Fig. 99,2). 

Pull off the protective cap (Fig. 100,1). 

Attach the transparent hose to the venting nipple (Fig. 100,2). 

Collect the brake fluid in suitable vessels. 

Unscrew both venting nipples by 1/2 a turn. 

Open the lid of the brake hydraulics tank. 

Press down the brake pedal as many times as necessary until no more oil 

comes out of either of the two venting nipples. 

Filling the brake fluid Tighten both venting nipples. 

Fill the brake hydraulics tank 

Final work Vent the brake hydraulics (see the section 3.4.4 "Venting the brake hydraulics"). 



3.4.4 Venting the brake hydraulics 





Never mix mineral oil and ordinary brake fluid. 

If possible, vent the brake hydraulics with a brake venting unit for mineral 

oil. 

If no brake venting unit is available, the brake hydraulics can be vented 

using the method described here. 

4-58 1000239425 - WDF-6001-00EN 





Venting the brake line to the 

front axle 

Venting the brake line to the 

variable displacement pump 






Hose, transparent as req. 

Fig. 101 Front axle venting nipple Fig. 102 Variable displacement pump 

venting nipple 

Press down the brake pedal as many times as necessary until a tangible 

pressure has built up. 

Hold down the brake pedal in the uppermost position against the pressure. 

Unscrew the venting nipple (Fig. 101,2) by 1/2 a turn. Air and brake fluid 

escape. 

Tighten the venting nipple when the brake pedal is in the lowest position. 

Build up the pressure and release it via the front axle venting nipple as 

often as necessary until the brake fluid emerges without any bubbles at the 

venting nipple. 

Pull the transparent hose off the venting nipple. 

Place the protective cap (Fig. 101,1) onto the venting nipple. 

Build up the pressure and release it via the variable displacement pump 

venting nipple (Fig. 102,2) as often as necessary until the brake fluid 

emerges without any bubbles at the venting nipple. 

Pull the transparent hose off the venting nipple. 

Place the protective cap (Fig. 102,1) onto the venting nipple. 

Fill up the brake hydraulics tank. 



3.5 Working hydraulics 

3.5.1 Replacing the gear pump 



4-59





Use home-made sealing plates to temporarily seal the hydraulic lines at the 

screw connections (see Part 2, "Sealing plate" section). 






Gear pump 1 

Seal 1 

O-ring 1 

O-ring 2 

Fig. 103 Gear pump Fig. 104 Gear pump seals 

Removing the gear pump Unscrew 4 screws on each of the screw connections of the hydraulic lines 

(Fig. 103,1). 

Remove and close off the hydraulic lines. 


Carefully remove the gear pump. 

Before installing the gear pump, replace the used seals with new ones. 

Installing the gear pump Place a seal (Fig. 104,3) onto the flange (Fig. 104,1) of the gear pump. 

Place an O-ring (Fig. 104,2) onto the seal. 

Carefully position gear pump on the variable displacement pump. 

Tighten the 2 screws (Fig. 103,2) with spring lock washers. 

Put on the hydraulic lines (Fig. 103,1) with new O-rings. 

Tighten 4 screws with spring lock washers on each of the screw connections 

of the hydraulic lines. 



4-60 1000239425 - WDF-6001-00EN 


3.5.2 Sealing the gear pump 




Disassembling the gear 

pump 





The gear pump has been removed (see the section 3.5.1 "Replacing the 

gear pump"). 



Fig. 105 Gear pump housing Fig. 106 Internal configuration 

Mark the pump housing and cover. 


Remove the cover (Fig. 105,2) and place it aside. 

The position and sequence of the internal components is important. 

Do not mix up any components and do not alter the installation position. 

Carefully remove the housing (Fig. 105,3) and place it aside. 

Remove the outer bearing (Fig. 106,2) and place it aside. 

Remove the gears (Fig. 106,1 and 3) and place them aside. 

Remove the inner bearing (Fig. 106,4) and place it aside. 

4-61


Replacing the seals Remove 1 support ring (Fig. 107,2) on each of the two bearings. 

Replacing the annular shaft 

seal 

Fig. 107 Bearing seal Fig. 108 Housing seal 

Remove 1 spectacle seal (Fig. 107,1) on each of the two bearings. 

Clean the bearing. 

Insert 1 new support ring into each of the two bearings. 

Insert 1 new spectacle seal into each of the two bearings. 

Remove 1 seal (Fig. 108,1) on each side of the housing. 

Clean the housing. 

Insert 1 new seal on each side of the housing. 

Fig. 109 Annular shaft seal 

Remove the locking ring (Fig. 109,1). 

Drive out the shaft seal (Fig. 109,2) outwards. 

Clean the flange (Fig. 109,3) thoroughly. 

Drive in the new annular shaft seal from the outside sufficiently far so that 

the locking ring can engage. 

Insert the locking ring. 

Assembling the gear pump Place the inner bearing (Fig. 106,4) onto the flange. 

Insert the gear wheel (Fig. 106,1) through the bearing and the flange. 

Insert the gear wheel (Fig. 106,3) into the inner bearing. 

Connect the outer bearing (Fig. 106,2) onto the gear wheels. 

Pull the housing (Fig. 105,3) over the internal components. 

Place the cover (Fig. 105,2) onto the housing. 


Final work Install the gear pump (see the section 3.5.1 "Replacing the gear pump"). 

4-62 1000239425 - WDF-6001-00EN 


3.5.3 Removing the control valve 


Removing the control valve 

console 

Removing the multi-function 

lever 









Fig. 110 Control valve console 

Release the 2 clamps (Fig. 110,4). 

Pull the bellows (Fig. 110,3 and 5) upwards over the handles. 

Unscrew the ball (Fig. 110,6) off the lever of the lift frame lock. 

Unscrew the 4 bolts (Fig. 110,1). 

Remove the control valve console (Fig. 110,2) carefully upwards. 

Fig. 111 Control unit Fig. 112 Multi-function lever attachment 

Unplug the plug (Fig. 111) on the control unit. 

Carefully guide the cable of the multi-function lever outwards through the 

opening under the control valve console. 

Loosen the stud screw (Fig. 112,2) but do not unscrew it. 


Unscrew the multi-function lever (Fig. 112,1). 

4-63


Detaching the lines Undo 1 screw on each of the connectors (Fig. 113,1). 

Pull off 1 connector on both the topside and underside of the solenoid valve 

and protect the contacts. 

Mark the hydraulic lines in order to prevent mix-ups. 


Removing the control valve Remove 3 caps (Fig. 114,1). 



Fig. 113 Underside of the control valve 

Fig. 114 Covers Fig. 115 Control valve attachment 


Lift out the control valve upwards. 

Remove the cross controller if necessary. 

3.5.4 Installing the control valve 




Control valve 1 

Securing material (e.g. cable ties) as req. 

4-64 1000239425 - WDF-6001-00EN 


Inserting the control valve Install the cross controller if necessary. 

Insert the control valve from above. 




Connecting the lines Screw the hydraulic lines (Fig. 117,2) onto the connection on the control 


Plug in 1 plug (Fig. 117,1) on both the topside and underside of the solenoid 

valve, and secure with 1 screw in each case. 

Installing the multi-function 

lever 

Fig. 116 Control valve attachment 

Fig. 117 Underside of the control valve 

Fig. 118 Securing the multi-function 

lever 

Fig. 119 Control unit 

Screw the multi-function lever (Fig. 118,1) onto the piston rod and align it. 

Secure the multi-function lever with the nut (Fig. 118,3). 

Tighten the stud screw (Fig. 118,2) hand-tight. 

Carefully guide the cable of the multi-function lever inwards through the 

opening under the control valve console and secure it. 

Plug in the plug (Fig. 119) on the control unit. 

Perform a control valve function test. If the function test is successful, continue 

with installation. 

4-65


Installing the control valve 

console 

Press 3 caps (Fig. 120,1) into the holes. 

Carefully place the valve control console (Fig. 121,2) on from above so that 

the lever of the lift frame lock moves easily. 


Screw the ball (Fig. 121,6) onto the lift frame lock. 

Pull down the bellows (Fig. 121,3 and 5). 

Tighten the 2 clamps (Fig. 121,4). 



3.5.5 Sealing the control valve 




Fig. 120 Covers Fig. 121 Control valve console 



The control valve has been removed (see the section 3.5.3 "Removing the 

control valve"). 

The cross controller has been removed (see the section 3.5.7 "Replacing 

the cross controller"). 

The auxiliary hydraulics cover has been removed (see the section 3.6.1 

"Replacing the cover of the auxiliary hydraulics"). 




as req. 


4-66 1000239425 - WDF-6001-00EN 


Removing the coils Unscrew 1 nut (Fig. 122,2) on both sides. 

Pull off the 2 coils (Fig. 122,1). 

Removing the valve body Unscrew the 2 drives (Fig. 123,1). 

Disassembling the control 

valve 

Fig. 122 Control valve 

Carefully pull out the control piston (Fig. 124,3). 



Fig. 123 Drives and valves Fig. 124 Valve control piston 

Unscrew the secondary pressure control valve (Fig. 123,3). 

Unscrew the dummy plug (Fig. 123,2). 

Unscrew the non-return valve (Fig. 123,4) on the rear side. 



Remove the valve body (Fig. 124,4). 

Fig. 125 Valves of the control valve Fig. 126 Seals of the slide valve 

Mark the valves (Fig. 125,2) and slide valves (Fig. 125,1) in order to prevent 

mix-ups. 

Unscrew the 3 valves (Fig. 125,2). 

Unscrew the 3 non-return valves (Fig. 125,3). 

4-67



Remove the 3 caps (Fig. 125,6). 

Removing the slide valve Unscrew 1 screw (Fig. 127,3) for each. 

Removing the pressure 

control valve 

Cleaning and sealing the 

control valve 

Installing the pressure 

control valve 

Fig. 127 Spring assembly attachment 

Remove 1 spring assembly (Fig. 127,2) in each case. 

Remove 1 sleeve (Fig. 127,1) in each case. 

Pull out the 3 slide valves (Fig. 125,1). 

Remove the 3 washers (Fig. 126,2) with O-rings (Fig. 126,1). 

Unscrew the 3 dummy plugs (Fig. 126,3). 

Fig. 128 Pressure control valve 

Unscrew the cap (Fig. 128,1). 

Unscrew the pressure control valve (Fig. 128,2). 

Clean all components thoroughly. 

Inspect the contact, sealing and sliding surfaces for damage. 

Replace all seals in the set of seals. 

When assembling, make sure that the parts move easily. 

Replace damaged or stiff parts. 

Slightly grease all parts apart from the slide valves. 

Screw in and tighten the pressure control valve (Fig. 128,2) with the O-ring. 

Screw the cap (Fig. 128,1) with the copper seal onto the pressure control 

valve and tighten it. 

4-68 1000239425 - WDF-6001-00EN 




Installing the slide valve Push 1 sleeve (Fig. 129,2) onto each slide valve (Fig. 129,3) as far as necessary 

so that both abut evenly. 

Coat the thread of the screws (Fig. 129,1) with locking agent. 

Screw 1 screw (Fig. 129,1) with a spring assembly into each slide valve 

and tighten. 

Slightly oil the slide valves. 

Insert 3 slide valves (Fig. 125,1) into the control valve. 

Press 3 caps (Fig. 125,6) onto the spring assemblies. 

Screw in and tighten 4 screws (Fig. 125,5) in each case. 

Fit 3 washers (Fig. 126,2) with O-rings (Fig. 126,1) onto the slide valves. 

Screw in the 3 dummy plugs (Fig. 126,3) with copper seals and tighten. 

Assembling the control 

valve 

Fig. 129 Securing the spring assembly 

Screw in and tighten the 3 non-return valves (Fig. 125,3) with O-rings. 

Screw in and tighten the 3 valves (Fig. 125,2) with O-rings. 

Installing the valve bodies Fit the valve bodies (Fig. 124,4) with O-rings to the threaded rods. 

Fit the covers (Fig. 124,2) with O-rings to the valve bodies. 

Screw the 3 nuts (Fig. 124,1) with spring lock washers onto the threaded 

rods and tighten. 

Screw in and tighten the non-return valve (Fig. 123,4) with an O-ring on the 

rear side. 

Screw in and tighten the dummy plugs (Fig. 123,2) with the copper seal. 

Screw in and tighten the secondary pressure control valve (Fig. 123,3) with 

the copper seal. 

Carefully insert the control piston (Fig. 124,3) into the valve body. 

Screw in and tighten the 2 drives (Fig. 123,1) with O-rings. 

Installing the coils Fit the 2 coils (Fig. 122,1) with O-rings onto the drives. 

Screw and tighten 1 nut (Fig. 122,2) with an O-ring onto the drives on each 

side. 

Final work Install the auxiliary hydraulics cover (see the section 3.6.1 "Replacing the 

cover of the auxiliary hydraulics"). 

Install the cross controller (see the section 3.5.7 "Replacing the cross controller"). 

Install the control valve (see the section 3.5.4 "Replacing the control 

valve"). 

4-69


3.5.6 Installing the catch on the control valve 






Replacing the cover Unscrew the 4 screws (Fig. 130,1). 

Remove the cover (Fig. 130,2). 

Unscrew the screw (Fig. 131,1). 

Remove the spring assembly (Fig. 131,2). 

Put a new spring assembly (Fig. 131,2) on the slide valve (Fig. 131,3). 

Coat the thread of the screw (Fig. 131,1) with locking agent. 


Place the cover with the catch onto the control valve. 

Screw in and tighten the 4 screws. 



3.5.7 Replacing the cross controller 







Cover with catch 1 


as req. 

Fig. 130 Underside of the control valve Fig. 131 Securing the spring assembly 

The multi-function lever been removed (see the section 3.5.3 "Removing 

the control valve"). 


Cross controller 1 

Stop nut 3 

4-70 1000239425 - WDF-6001-00EN 


Removing the cross 

controller 

Installing the cross 

controller 

Fig. 132 Securing the cross controller 



Unscrew the nut (Fig. 132,4). 

Remove the lifting unit lock (Fig. 132,5). 

Unscrew the nut (Fig. 132,2) and pull out the stay pin. 

Unscrew the nut (Fig. 132,3) and pull out the stay pin. 

Pull out the third stay pin and remove the cross controller (Fig. 132,1). 

Place the cross controller into position, insert the stay pin through the 

attachment and screw the nut (Fig. 132,4) loosely onto the thread. 

Insert the stay pin through the hole and screw the nut (Fig. 132,3) onto the 

thread. 

Insert the stay pin through the hole and screw the nut (Fig. 132,2) onto the 

thread. 


Position the lifting unit lock (Fig. 132,5) so that the pin engages in the 

holder of the cross controller. 

Screw the nut (Fig. 132,4) onto the stay pin and tighten it. 

Tighten the 2 nuts (Fig. 132,3 and 2). 

Final work Fit the multi-function lever (see the section 3.5.4 "Installing the control 

valve"). 

3.5.8 Replacing the lifting cylinder 

CAUTION 


The lifting cylinder weighs approx. 22 kg. 

When removing and installing the lifting cylinder, use suitable lifting gear 

or work with another person. 





This section describes replacement of a lifting cylinder. 

The second lifting cylinder is replaced in the same way. 

4-71




Removing the lifting 

cylinder, rod end 

Removing the lifting 

cylinder, bottom end 

Installing the lifting cylinder, 

bottom end 


Hydraulic cylinder 1 


Fig. 133 Lift frame safety lock Fig. 134 Hydraulic lines 

Raise the lifting cylinder, and to prevent accidental lowering (Fig. 133,2), 

secure it at the side on which the lifting cylinder is not being replaced. 




Drive out the pin (Fig. 133,1). 

Carefully place the lifting cylinder on the front carriage. 

Insert the lifting cylinder fully. 

Detach and close off the hydraulic lines (Fig. 134,1). 

Fig. 135 Locking the pin 

Unscrew the 2 screws (Fig. 135,3) and remove the locking plate 

(Fig. 135,2). 

At the same time, hold the lifting cylinder in place and drive out the pin 

(Fig. 135,1), removing the shim washers if necessary. 

Remove the lifting cylinder (two persons). 

Unscrew the screw attachments if necessary. 

Screw in and tighten the screw attachments if necessary. 

Insert the lifting cylinder so that the pin holders at the bottom end line up 

exactly. 

Insert shim washers if necessary. 

Grease the pin slightly. 

4-72 1000239425 - WDF-6001-00EN 


Installing the lifting cylinder, 

rod end 

Unlocking the pin, bottom 

end 



Drive in the pin (Fig. 135,1) so that the groove for the locking plate points 

towards the screws (Fig. 135,3). 

Insert the locking plate (Fig. 135,2). 


Screw the hydraulic lines (Fig. 134,1) onto the connection on the bottom 

end and the rod end and tighten. 

At the same time, raise the lifting cylinder and extend it sufficiently far that 

the pin holders at the rod end line up exactly. 

Grease pin and bearing slightly. 

Drive in the pin (Fig. 133,1). 

Screw in and tighten the screw (Fig. 133,2) with the washer. 

Final work Lubricate the lifting cylinder bearings. 

3.5.9 Removing the tipping cylinder 

CAUTION 


The tipping cylinder weighs approx. 27 kg. 

When removing and installing the tipping cylinder, use suitable lifting 

gear or work with another person. 





Fig. 136 Securing the lift frame Fig. 137 Locking the pin 

Raise the lift frame and secure it to prevent accidental lowering (Fig. 136). 

The pin at the bottom end is secured with a hollow dowel pin. 

Before removing, mark the position of the pin on the front carriage so that 

the holes for the hollow dowel pin line up again precisely during installation. 

4-73


Removing the tipping 




Drive out the hollow dowel pin (Fig. 137,1). 

Remove the lift frame safety lock 

Fig. 138 Resting the tool attachment Fig. 139 Rod end attachment 

Set down the tool attachment slightly raised on a suitable aid (e.g. block of 

wood) (Fig. 138). 



Detach and close off the hydraulic lines at the rod end and bottom end. 



Fig. 140 Raising the tipping cylinder Fig. 141 Bottom end attachment 

Do not bend or damage the tilting indicator (Fig. 140,1). 

Raise the tipping cylinder at the rod end as far as possible using suitable 

lifting gear (e.g. a crane). 

Drive out the pin (Fig. 141,1) and remove the shim washers (Fig. 141,3) if 

necessary. 

Remove the tipping cylinder. 

Unscrew the screw attachments if necessary. 

4-74 1000239425 - WDF-6001-00EN 




Installing the tipping 


3.5.10 Installing the tipping cylinder 



CAUTION 


The tipping cylinder weighs approx. 27 kg. 

When removing and installing the tipping cylinder, use suitable lifting 

gear or work with another person. 



Do not bend or damage the tilting indicator (Fig. 142,1). 




Hydraulic cylinder 1 


Fig. 142 Raising the tipping cylinder Fig. 143 Bottom end attachment 

Screw in and tighten the screw attachments if necessary. 

Using suitable lifting gear (e.g. a crane), guide the tipping cylinder into the 

front carriage from above so that the pin holders line up precisely. 

Insert shim washers (Fig. 143,3) if necessary. 


Drive in the pin (Fig. 143,1) so that the holes for the hollow dowel pin line 

up precisely. 

Drive the hollow dowel pin into the hole (Fig. 143,2). 

4-75








Fig. 144 Rod end attachment 

Lower the tipping cylinder until the rod-end pin holders line up precisely. 




Screw the hydraulic lines onto the rod-end and bottom-end connections 

and tighten. 

Final work Lubricate the tipping cylinder bearings. 

3.5.11 Replacing the rod-end bearing of the tipping cylinder 




Bearing 1 


Fig. 145 Rod end attachment Fig. 146 Piston rod support 



Raise the tipping cylinder and carefully extend it until the painted part of the 

piston rod is lying on the pin holder of the reversing lever (Fig. 146). 

Unscrew the grease nipple (Fig. 146,2). 

Replacing the bearing Drive out the bearing (Fig. 146,1). 

Drive in the new bearing. 

4-76 1000239425 - WDF-6001-00EN 




Drill a hole through the bearing (Fig. 146,1). 

Screw in the grease nipple (Fig. 146,2). 



Raise the tipping cylinder and carefully retract it until the pin holders line up 

precisely. 





3.6 Auxiliary hydraulics and hydraulic lock 

3.6.1 Replacing the cover of the auxiliary hydraulics 




Drill the next hole as large as possible without damaging the thread. 

Centering pieces are pushed onto the retaining screws between the cover 

and valve body. 

Do not damage or lose the centering pieces. 

The control valve console been removed (see the section 3.5.3 "Removing 



Cover 1 

Fig. 147 Auxiliary hydraulics valve 

Removing the cover Unscrew the 2 screws (Fig. 147,1). 

Remove the cover (Fig. 147,2) with centering pieces. 

Installing the cover Carefully put the cover with the centering pieces into position. 

Hold the cover in place and check that the valve actuates smoothly. 


Final work Install the control valve console (see the section 3.5.4 "Installing the control 

valve"). 

4-77


3.6.2 Replacing the control lever and cover of the auxiliary 

hydraulics 




Removing the control lever 

and cover 

Installing the cover and 

control lever 

Centering pieces are pushed onto the retaining screws between the cover 

and valve body. 

Do not damage or lose the centering pieces. 




Lever 1 

Nut 1 

Cover 1 

Fig. 148 Securing the control lever Fig. 149 Valve drive 


Unscrew the control lever (Fig. 148,3). 


Remove the cover (Fig. 148,2) with centering pieces. 

If necessary, pull the bellows off the control lever and fit them to the new 

control lever. 

Place the cover (Fig. 148,2) with centering pieces onto the control valve so 

that the lever engages inside the valve's drive (Fig. 149). 


Screw the control lever (Fig. 148,3) into the lever. 



valve"). 

4-78 1000239425 - WDF-6001-00EN 




3.6.3 Replacing the locking cylinder 

Removing the pins Unscrew 1 screw (Fig. 150,1) for each. 

Removing the locking 

cylinder 

Installing the locking 

cylinder 

Remove the covers (Fig. 150,2). 

Unscrew 1 screw (Fig. 151,1) for each. 

Remove 1 sleeve (Fig. 151,2) in each case. 

Push the pin fully out. 






Locking cylinder 1 

Stop nut 2 

Fig. 150 Covers Fig. 151 Pin attachment 

Fig. 152 Locking cylinder 

Retract the locking cylinder fully. 

Lift the locking cylinder upwards and to the rear out of the tool attachment. 

Extend the locking cylinder fully. 

With the engine switched off, move the auxiliary hydraulics lever back and 

forth several times in order to depressurize the auxiliary hydraulics. 


Screw the hydraulic lines (Fig. 152,1) onto the connections on the locking 

cylinder and tighten. 

Retract the locking cylinder fully. 

Insert the locking cylinder into the tool attachment from the rear and above. 

4-79


Fitting the pins Attach the rod-end pin onto the locking cylinder. 

Screw in and tighten the screw (Fig. 151,1) with a sleeve (Fig. 151,2). 

Attach the rod-end pin onto the locking cylinder. 

Screw in and tighten the screw with the washer. 

Place on the covers (Fig. 150,2). 

Screw in and tighten 1 screw (Fig. 150,1) in each case. 

3.7 Tank, filter and hydraulic lines 

3.7.1 Replacing the hydraulic fluid tank 




Fig. 153 Euro holder 

In the case of the Euro holder, the retaining screws (Fig. 153,1) of the 

locking pins are not behind a cover. 



The hydraulic fluid tank is empty (see operator's manual "Replacing the 

hydraulic fluid"). 

The rear weight has been removed (see the section 6.2.3 "Replacing the 

rear weight"). 


Hydraulic fluid tank 1 

4-80 1000239425 - WDF-6001-00EN 


Detaching the lines Remove the plug (Fig. 154,1) from the temperature sensor. 

Replacing the hydraulic fluid 

tank 




Fig. 154 Connections on the underside Fig. 155 Connections on the topside 

Pull off the connector (Fig. 155,3) from the pressure switch. 


Fig. 156 Rear attachment 

Mark the position of the hydraulic fluid tank (Fig. 156,1) on the rear carriage. 

Undo the 2 screws (Fig. 156,2). 


Remove the hydraulic fluid tank to the side. 

Replace the return filter if necessary. 

Put the new hydraulic fluid tank into position at the side and push under the 

screws (Fig. 156,2) with washers. 


Align the hydraulic fluid tank and tighten the screws. 

Connecting the lines Screw the hydraulic lines (Fig. 155,2) onto the return filter and tighten. 

Attach the connector (Fig. 155,3) onto the pressure switch. 

Screw the hydraulic lines (Fig. 154,2) onto the connections on the hydraulic 

fluid tank and tighten. 


Final work Install the rear weight (see the section 6.2.3 "Replacing the rear weight"). 

Fill the hydraulic fluid tank (see operator's manual "Replacing the hydraulic 

fluid") 

4-81


3.7.2 Replacing the complete return filter 






Foreign bodies and sealant can damage the hydraulic system. 

Do not allow any foreign bodies to enter the hydraulic fluid tank. 

Do not allow any sealant to enter the hydraulic fluid tank. 



hood"). 

Removing the return filter Open the cap (Fig. 157,4). 


Return filter 1 


Fig. 157 Return filter 

Briefly open the cap (Fig. 157,3) so that the fluid can flow out of the return 

filter and into the hydraulic fluid tank. 


Pull off the connector (Fig. 157,2) from the pressure switch. 



Pull the return filter (Fig. 157,5) upwards and to the rear out of the hydraulic 

fluid tank. 

Cover the openings immediately (e.g. with cloths). 

4-82 1000239425 - WDF-6001-00EN 




Installing the return filter Clean the contact surfaces on the return filter and the hydraulic fluid tank. 

Apply sealant along both O-rings (Fig. 158). 

Carefully place the return filter into the hydraulic fluid tank from above. 


Screw the hydraulic lines (Fig. 157,1) onto the return filter and tighten. 



3.7.3 Replacing the pressure filter 




Fig. 158 Sealing 








Pressure filter 1 

Fig. 159 Connections Fig. 160 Securing the pressure filter 

Unscrew and close off the 2 hydraulic lines (Fig. 159,1). 


Remove the pressure filter (Fig. 159,2). 

4-83


Put a new pressure filter in place. 


Screw the 2 hydraulic lines (Fig. 159,1) onto the connections on the pressure 

filter and tighten. 



3.7.4 Replacing the hydraulic line 






This section describes replacement of a hydraulic line. 

The other hydraulic lines are replaced in the same way. 

Reuse hydraulic fluid in the hydraulic line or dispose of it in an environmentally 

responsible manner. 




Hydraulic hose (prefabricated) as req. 

Fig. 161 Hydraulic connections Fig. 162 Hydraulic connection 

Removing the hydraulic line Unscrew and close off the hydraulic line (Fig. 161,3). 


Remove the hydraulic line. 

Installing the hydraulic line Select the required hydraulic line. 

Screw the hydraulic line (Fig. 162,1) onto the coupling and tighten. 

Screw the hydraulic line (Fig. 161,3) onto the screw connection and 

tighten. 

4-84 1000239425 - WDF-6001-00EN 


4.1 Replacing the drive shaft 






Do not disassemble the drive shaft for removal or installation. 

If the drive shaft has been disassembled, pay attention to the markings 

during assembly (Fig. 163). If necessary, apply markings yourself. 

Do not damage the grease nipple on the drive shaft. 

Fig. 163 Markings on the drive shaft 




link"). 


Drive shaft 1 

Stop nut - hexagon M10 8 

Stop nut - hexagon M8x1 6 


Removing the drive shaft Unscrew the 8 nuts (Fig. 164,1). 


Detach the drive shaft from the front axle. 

Detach the drive shaft from the rear axle. 

as req. 

Fig. 164 Connection to the front axle Fig. 165 Connection to the rear axle 

Clean both contact surfaces if the same drive shaft is to be re-installed. 


4-85


Installing the drive shaft Clean the contact surface and the threaded bolts on the front axle. 

Coat the 8 threaded bolts with locking agent. 

Place the drive shaft onto the threaded bolts on the front axle. 

Screw the 8 nuts (Fig. 164,1) onto the threaded bolts and tighten. 

Clean the contact surface and the threaded bolts on the rear axle. 

Coat the 6 threaded bolts and the contact surface with locking agent. 

Place the drive shaft onto the threaded bolts on the rear axle. 

Screw the 6 nuts (Fig. 165,1) onto the threaded bolts and tighten. 

If you must only remove the drive shaft on one side, you can swing the drive 

shaft to the side and secure it temporarily to allow you to work more easily 

(Fig. 166). 

Fig. 166 Temporary securing 

4.2 Front axle 

4.2.1 Removing the front axle 



Rest the axle on a suitable support (e. g. a jack) to prevent it from tipping 

over and to prevent damage. 


The rear axle of the loader is secured to prevent it from rolling away (e.g. 

with chocks). 


link"). 



The drive shaft has been removed on the front axle (see the section 4.1 



4-86 1000239425 - WDF-6001-00EN 


Removing the hydraulic 

lines 

Relieving the load on the 

front axle 

Removing the Bowden 

cable 

Fig. 167 Hydraulic line of the differential 

lock 



Fig. 168 Hydraulic line of the service 

brake 

Unscrew and close off the hydraulic line of the differential lock (Fig. 167). 

Unscrew and close off the hydraulic line of the service brake (Fig. 168). 

Fig. 169 Front carriage support Fig. 170 Lift frame safety lock 

Raise the front carriage (e.g. with a jack). 

Support the front carriage with suitable blocks to prevent it from tipping 

over (Fig. 169), and so that the wheels can be turned freely. 

Remove the wheels (see operator's manual "Changing wheels"). 

Raise the lift frame and secure it to prevent accidental lowering (Fig. 170). 

Fig. 171 Bowden cable on the handbrake 

lever 

Fig. 172 Bowden cable on the front axle 



Unscrew the nut (Fig. 171,1) on the handbrake lever 

Unhook the Bowden cable holder with the spacer ring. 

Tilt the operator's platform back. 

Push back the sleeve (Fig. 172,3). 

4-87


Carefully bend the hook of the fastener (Fig. 172,2) out to the side. 

Pull out the Bowden cable (Fig. 172,1) to the side. 

Removing the front axle Support the front axle with the jack (Fig. 173). 



Fig. 173 Front axle support 


Carefully lower and extend the front axle. 

Place the spacer plates (Fig. 173,2) to the side. 

4.2.2 Installing the front axle 



Rest the axle on a suitable support (e. g. a jack) to prevent it from tipping 

over and to prevent damage. 



4-88 1000239425 - WDF-6001-00EN 


Fig. 174 Front axle support 



Securing the front axle Clean the contact surfaces on the front axle and front carriage. 

Carefully press the front axle with the spacer plates (Fig. 174,2) against the 

front carriage from below. 

Insert the 4 bolts (Fig. 174,1) with washers through the holes from above. 

Screw the 4 nuts with washers onto the bolts (Fig. 174,1). 

Tighten the 4 bolts (Fig. 174,1) with a tightening torque of 360 Nm. 

Fig. 175 Bowden cable on the front axle Fig. 176 Bowden cable on the handbrake 

lever 

Fitting the Bowden cable Push in the Bowden cable (Fig. 175,1) at the side. 

Push the fastener (Fig. 175,2) towards the brake drum and secure it with 

the hook. 

Push the sleeve (Fig. 175,3) over the fastener. 



Hook in the Bowden cable with the spacer ring on the handbrake lever. 

Tighten the nut (Fig. 176,1) so that the Bowden cable holder remains rotatable 

in the handbrake lever. 

Lower the operator's platform. 

Slowly apply the parking brake 6 x in order to adjust the automatic brake 

setting. 

4-89


Loading the front axle Remove the fastener (Fig. 177) and lower the lift frame. 

Connecting the hydraulic 

lines 

Fig. 177 Lift frame safety lock Fig. 178 Front axle support 

Fit the wheels (see operator's manual "Changing wheels"). 

Raise the front carriage and remove the chocks (Fig. 178). 

Lower the front carriage. 


lock 



Screw the hydraulic line of the differential lock (Fig. 179) onto the connection 

on the axle bracket and tighten. 

Do not allow any oil to enter the brake drum. 

Clean the brake drum if oil enters it. 

Fig. 180 Hydraulic line of the service 

brake 

Screw the hydraulic line of the service brake (Fig. 180) onto the connection 

on the brake drum and tighten. 

Final work Install the drive shaft (see the section 4.1 "Replacing the drive shaft"). 

Adjust the parking brake (see the section 5.2.1 "Replacing the Bowden 

cable of the parking brake"). 

Vent the service brake (see the section 3.4.4 "Venting the brake hydraulics"). 

4-90 1000239425 - WDF-6001-00EN 


4.3 Rear axle 

4.3.1 Removing the rear axle 


Relieving the load on the 

rear axle 





Rest the axle on a suitable support (e. g. a jack with a pallet) to prevent it 

from tipping over and to prevent damage. 




link"). 



The drive shaft has been removed on the rear axle (see the section 4.1 


The lift frame has not been fully lowered. 

Fig. 181 Rear axle with support Fig. 182 Rear carriage support 

Raise the rear carriage to the height of the rear axle with the support 

(Fig. 181, H). 

Support the rear carriage with suitable chocks to prevent it from tipping 

over. 

If necessary, secure the loader with suitable lifting gear. 

Remove the wheels (see operator's manual "Changing wheels"). 

4-91


Detaching the hydraulic 

lines on the underside 


topside 


lock 

Unscrew and close off the hydraulic line of the differential lock (Fig. 183,1). 


(Fig. 184,1). 


motor 

Fig. 184 Hydraulic line of the cross 

flushing connection 




Undo 1 screw on each of the connectors (Fig. 185,2), pull the connectors 

off the solenoid valves and protect the contacts (e.g. with a protective cap). 


(Fig. 185,3). 






4-92 1000239425 - WDF-6001-00EN 




Removing the rear axle Provide a suitable support for the rear axle (e.g. pallet and lifting carriage) 

(Fig. 186). 

Unscrew 2 bolts (Fig. 187,1) on each side of the rear axle. 

Carefully lower the rear axle. 



Fig. 186 Rear axle support Fig. 187 Securing the rear axle 

Make sure that the solenoid valves are not damaged. 

Carefully pull out the rear axle to the side. 

Place the spacer plates (Fig. 187,2) to the side. 

4.3.2 Installing the rear axle 



Rest the axle on a suitable support (e. g. a jack with a pallet) to prevent it 

from tipping over and to prevent damage. 

Make sure that the solenoid valves are not damaged. 



Fig. 188 Securing the rear axle 

Securing the rear axle Clean the contact surfaces on the rear axle and rear carriage. 

Carefully push the rear axle under the rear carriage from the side. 

4-93



topside 

Carefully press the rear axle with the spacer plates (Fig. 188,2) against the 

rear carriage from below. 

Insert 2 bolts (Fig. 188,1) with washers on both sides of the rear axle 

through the holes from above. 

Screw the 2 nuts with washers onto the bolts (Fig. 188,1). 

In each case, tighten the 2 bolts (Fig. 188,1) with a tightening torque of 

360 Nm. 


motor 





Put each flange half for securing the high pressure lines (Fig. 189,1) into 

position and loosely screw in 2 screws with spring lock washers. 












4-94 1000239425 - WDF-6001-00EN 



lines on the underside 


lock 



Screw the hydraulic line of the differential lock (Fig. 190,1) onto the connection 

on the axle bracket and tighten. 



Fig. 192 Rear carriage support 

Loading the rear axle Fit the wheels (see operator's manual "Changing wheels"). 

Raise the rear carriage and remove the chocks (Fig. 192). 

Lower the rear carriage. 


4.4 Changing the wheel of the twin tires 

Fig. 191 Hydraulic line of the cross 

flushing connection 

DANGER 

Risk of death/risk of injury! 

To change the wheel, park the loader on a flat, solid surface. 

Use only a safe, suitable jack with sufficient lifting strength. Pay attention 

to the loader's operational weight. 

Always tighten the wheel bolts with a torque wrench and the specified tightening 

torque. 

Always tighten the wheel bolts opposite each other alternately. 

After changing the wheel, check the tightening torque of the wheel bolts 

every two hours until it remains constant. 

Pay attention to the tire profile so that the greatest power of the loader is 

attained when driving forwards. 

4-95



The loader is secured against rolling away at the axle that is not being 

raised (e.g. with chocks). 


link"). 


Fig. 193 Securing the wheels Fig. 194 Twin tires 

Removing the wheel Use suitable lifting gear (e.g. a garage jack) to raise the axle on the side on 

which the wheel is to be changed. 


Release the 2 hooks (Fig. 193,3). 

Remove the wheel (Fig. 194,1). 

If no new wheel is fitted, unscrew 2 eye nuts (Fig. 193,4) and replace them 

with suitable wheel nuts. 

Fitting the wheel Put the wheel (Fig. 194,1) in place. 

Hook the 2 hooks (Fig. 193,3) into the eye nut and insert them through the 

holders (Fig. 193,2). 

Screw the 2 nuts (Fig. 193,1) onto the hooks and tighten. 

4-96 1000239425 - WDF-6001-00EN 


5.1 Service brake 

5.1.1 Replacing the brake shoes 





Brake system (mechanical section) 5 

5Brake system (mechanical section) 

Keep the contact surface of the brake drum and the brake shoes free of 

grease and oil. 

The brake drum has been removed (see the section 5.1.2 "Replacing the 

brake drum"). 


Brake shoe 1 

Brake shoe with brake lever 1 


Fig. 195 Brake shoe attachment Fig. 196 Upper bearing 

Releasing the brake shoes Undo the 2 screws (Fig. 195,1 and 4). 

Apply a suitable lever between the metal plate (Fig. 195,2) and the brake 

cylinder (Fig. 195,6). 

With the lever, move the metal plate (Fig. 195,2) slightly upwards and 

unscrew the screw (Fig. 195,1). 

Unhook and remove the 2 springs (Fig. 195,3) on the metal plate 

(Fig. 195,2). 

Press the 2 springs (Fig. 195,7) through the brake shoes (Fig. 195,5), 

rotate them clockwise through 90° and pull them out. 

Temporarily secure the metal plate (Fig. 196,2) with the screw (Fig. 196,1). 

Do not lose the washer (Fig. 196,4). 

Press the brake shoes together on the upper bearing against the spring 

(Fig. 196,3) and remove. 

4-97

5 Brake system (mechanical section) 

Removing the brake shoes Unhook the spring (Fig. 197,1) on both sides. 

Checking and setting the 

adjustment device 

Fig. 197 Lower bearing Fig. 198 Bowden cable attachment 

Unhook the hook (Fig. 198,1) from the Bowden cable (Fig. 198,2). 

Remove the brake shoes. 

Check that adjustment device is in perfect condition. 

If the adjustment device has visible damage, contact the manufacturer. 

Slightly grease the thread (Fig. 198,5). 

Raise the lock (Fig. 198,4) and rotate the adjustment wheel (Fig. 198,3) as 

far as possible clockwise. 

Installing the brake shoes Place the brake shoes into position. 

Hook the hook (Fig. 198,1) into the Bowden cable (Fig. 198,2). 

Hook the spring (Fig. 197,1) into the brake shoes on both sides. 

Plug the brake shoes onto pin (Fig. 197,2). 

Securing the brake shoes Push the brake shoes (Fig. 195,5) together on the upper bearing against 

the spring (Fig. 196,3) with the washer (Fig. 196,4) and insert. 

Press the 2 springs (Fig. 195,7) through the brake shoes, rotate them 

counter-clockwise through 90° and hook them in on the rear side of the 

brake housing. 

Hook the 2 springs (Fig. 195,3) into the brake shoes. 


Hook in the 2 springs (Fig. 195,3) in the center of the metal plate 

(Fig. 195,2). 

Apply a suitable lever between the metal plate (Fig. 195,2) and the brake 

cylinder (Fig. 195,6). 

Move the metal plate (Fig. 195,2) sufficiently far up and tension the springs 

(Fig. 195,3) sufficiently so that the screw (Fig. 195,1) can be screwed in. 

Screw in the screw (Fig. 195,1). 

Screw in and tighten the 2 screws (Fig. 195,1 and 4). 

Final work Install the brake drum (see the section 5.1.2 "Replacing the brake drum"), 

including the final work. 

5.1.2 Replacing the brake drum 

Keep the contact surface of the brake drum and the brake shoes free of 

grease and oil. 

Clean the contact surfaces thoroughly if they are contaminated with oil or 

grease. 

4-98 1000239425 - WDF-6001-00EN 








with chocks). 


link"). 



The drive shaft has been removed on the front axle (see the section 4.1 



Removing the brake drum Unscrew the 2 screws (Fig. 199,2). 

Remove the brake drum (Fig. 199,1). 

Fitting the brake drum Put the brake drum into position. 

Screw in and tighten the 2 screws hand-tight. 


Adjust the parking brake (see the section 5.2.1 "Replacing the Bowden 



5.2 Parking brake 

5.2.1 Replacing the Bowden cable of the parking brake 





Brake drum 1 

Fig. 199 Brake drum 


with chocks). 





Bowden cable 1 

4-99



cable 

Fig. 200 Bowden cable on the handbrake 

lever 

Unscrew the nut (Fig. 200,1) on the handbrake lever 

Unhook the Bowden cable holder with the spacer ring. 


Push back the sleeve (Fig. 201,3). 

Carefully bend the hook of the fastener (Fig. 201,2) out to the side. 

Pull out the Bowden cable (Fig. 201,1) to the side. 

Fig. 202 Bowden cable attachment 

Pulling in the Bowden cable Unscrew the nut (Fig. 202,1) from the Bowden cable. 

Remove the holder (Fig. 202,2) with the spacer ring and nut. 

Pull off the rubber bushing (Fig. 202,3). 

Fig. 201 Bowden cable on the front axle 

Unscrew the nut (Fig. 202,4) and remove it from the Bowden cable with 

2 washers. 

Undo or remove all fastenings (e.g. cable ties) along the Bowden cable. 

At the same time, pull out the Bowden cable towards the front axle and at 

the same time pull in the new Bowden cable. 

Secure the Bowden cable with 2 washers and nuts (Fig. 202,4). 

Attach the rubber bushing (Fig. 202,3) onto the Bowden cable. 

Attach the holder (Fig. 202,2) with the spacer ring and nut onto the Bowden 

cable and secure with the nut (Fig. 202,1). 

Fitting the Bowden cable Push in the Bowden cable (Fig. 201,1) at the side. 

Push the fastener (Fig. 201,2) towards the brake drum and secure it with 

the hook. 

Push the sleeve (Fig. 201,3) over the fastener. 



4-100 1000239425 - WDF-6001-00EN 




Hook in the Bowden cable with the spacer ring on the handbrake lever. 

Tighten the nut (Fig. 200,1) so that the Bowden cable holder remains rotatable 

in the handbrake lever. 


Adjusting the parking brake Screw the nut (Fig. 202,1) onto the Bowden cable sufficiently far so that the 

parking brake can be pulled in up to the fifth or sixth catch. 

Final work Tighten or replace undone or removed fastenings (e.g. cable ties) along the 

Bowden cable. 



4-101


4-102 1000239425 - WDF-6001-00EN 




6.1 Front carriage 

6.1.1 Replacing the front fender 



Replacing the fender Unscrew the 3 screws (Fig. 203,2) and remove the fender. 

Position a new fender in place so that the recess (Fig. 203,1) is exactly 

above the holder. 

Mark the position of the holes from below and drill them. 



Final work If necessary, undo the screw (Fig. 204,1) and move the fender to the side 

so that it is exactly in the center above the wheel. 

Tighten the screw (Fig. 204,1). 

6.2 Rear carriage and engine hood 

6.2.1 Replacing the rear fender 





Fender 270 mm 1 

Fig. 203 Fender Fig. 204 Attachment 

The holes must be 0.5 mm smaller than the outside diameter of the 

threaded sleeves. 

This section describes replacement of a fender. 

The second fender is replaced in the same way. 




Fender 1 

Threaded sleeve 11 

4-103


Fig. 205 Fender attachment 

Removing the fender Unscrew the 11 screws (Fig. 205,1). 

Remove the fender (Fig. 205,2). 

Fig. 206 Fender attachment 

Attaching the fender Place the fender into position so that the bead (Fig. 206,2) is exactly below 

the rear carriage and the wheel projects approximately 10 mm over the 

fender (Fig. 206,3). 

Mark the position of the first hole (Fig. 206,1) and drill it. 

Press the threaded sleeve into the hole from the inside. 

Screw in the 1 screw (Fig. 206,1). 

Align the fender parallel to the wheel. 

Mark the position of the other holes and drill them. 

Press the threaded sleeves into the hole from the inside. 

Screw in the 10 screws (Fig. 205,1) and tighten all screws. 



6.2.2 Replacing the additional weight/base plate 

DANGER 


The additional weight weighs approx. 97 kg. 

Use suitable lifting gear to remove and install the additional weight. 

The base plate is much lighter than the additional weight and can be 

removed in the same way without aids. 

4-104 1000239425 - WDF-6001-00EN 




Removing the additional 

weight 

Installing the additional 

weight 



Provide a suitable support for the additional weight (e.g. pallet and lifting 

carriage) so that it is secure against slipping or tipping over. 


Lower the additional weight. 

Carefully press the additional weight against the rear carriage from above. 


6.2.3 Replacing the rear weight 





Additional weight 1 

Base plate 1 

Fig. 207 Support for the additional 

weight 

DANGER 


The rear weight weighs approx. 140 kg. 

Use suitable lifting gear to remove and install the rear weight. 

Attach the rear weight to the side crane eyes. 

Do not damage the exhaust when removing and installing the rear weight. 

Do not damage the electrical cables when removing and installing the rear 

weight. 



The engine hood has been removed (see the section 6.2.4 "Replacing the 

engine hood"). 


Rear weight 1 

4-105


Fig. 208 Cable for the rear lighting 

Disconnecting the cable Disconnect the electrical plug (Fig. 208,1). 

Fig. 209 Securing the rear weight Fig. 210 Rear weight attachment 

Removing the rear weight Unscrew 1 screw (Fig. 209,2) in each case. 

Rotate the crane eyes (Fig. 209,1) upwards on both sides and tighten 

1 screw in each case. 

Secure the rear weight with suitable lifting gear (e.g. a crane). 

Unscrew the 4 nuts (Fig. 210). 

Carefully separate the rear weight from the rear carriage. 

Installing the rear weight Carefully swivel the rear weight against the rear carriage using suitable 

lifting gear (e.g. a crane). 

Screw the 4 nuts (Fig. 210) onto the bolts. 

Align the rear weight so that it abuts flush at the top and sides. 

Tighten the 4 nuts. 

Unscrew 1 screw (Fig. 209,2) in each case. 

Rotate the crane eyes (Fig. 209,1) downwards on both sides and tighten 

1 screw in each case. 

Final work Connect and secure the electrical plug (Fig. 208,1). 

Install the engine hood (see the section 6.2.4 "Replacing the engine 

hood"). 

Install the additional weight/base plate (see the section 6.2.2 "Replacing 


4-106 1000239425 - WDF-6001-00EN 


6.2.4 Replacing the engine hood 






WARNING 




Replace the engine hood with another person. 

If you are working alone, use a bench that is as high as the upper edge of 

the rear weight. 



hood"). 


Engine hood 1 

Fig. 211 Cable Fig. 212 Engine hood attachment 

Removing the engine hood Loosen the nut (Fig. 211,1) but do not unscrew it. 

Mark the position of the fastenings. 

Loosen 1 nut (Fig. 212,2) in each case, but do not unscrew it. 

Get a second person to help you firmly hold the engine hood. 

Unscrew 1 nut (Fig. 212,2) in each case and remove the bolt (Fig. 212,1). 

Unscrew the nut (Fig. 211,1) and pull out the eye (Fig. 211,2). 

Remove the engine hood. 

Installing the engine hood Get a second person to help you position the engine hood. 

Push the eye (Fig. 211,2) onto the thread with washers. 

Push the nut (Fig. 211,1) loosely onto the thread with a washer. 

In each case, insert 1 bolt (Fig. 212,1) through the fastening from below 

and secure it. 

In each case, screw 1 nut (Fig. 212,2) loosely onto the bolt with a washer. 

Align the engine hood and tighten 1 bolt (Fig. 212,2) in each case. 

Tighten the nut (Fig. 211,1) so that the eye remains rotatable. 


4-107


6.2.5 Replacing the lock of the engine hood 






hood"). 


Lock 1 

Handle 1 

Metal plate 1 

Fig. 213 Securing the lock 

Removing the lock Mark the position of the lock (Fig. 213,2) on the holder (Fig. 213,3). 

Unscrew the 2 bolts (Fig. 213,1) and remove the fender. 

Fig. 214 Securing the handle Fig. 215 Holes in the engine hood 

Replacing the handle Unscrew the 2 screws (Fig. 214,2). 

Thread the handle with the metal plate (Fig. 214,1) through the hole 

(Fig. 215) and remove. 

Insert the new handle with the metal plate (Fig. 214,1) through the hole 

(Fig. 215). 


Installing the lock Place the lock (Fig. 213,2) on the holder and align it. 


Final work If necessary, align the lock until the engine hood closes reliably. 


4-108 1000239425 - WDF-6001-00EN 


6.2.6 Emergency release of the engine hood 


Emergency release of the 

engine hood 



Two persons are required for the emergency release. 

Release the engine hood with a home-made hook at least 1 m long. 



Fig. 216 Underside of the rear carriage Fig. 217 Engine hood lock 

Push the hook between the engine and rear carriage (Fig. 216) from below 

so that the lever (Fig. 217) on the engine hood lock can be pulled down. 

At the same time, pull down the lever (Fig. 217) and open the engine hood. 



6.3 Center joint 

6.3.1 Detaching the center joint 

For the front and rear carriages, the center of gravity is behind the 

axle in each case. 

Support the front carriage between the axle and the center joint. 

Support the rear carriage at the rear weight. 



Mark the line assemblies in order to avoid mix-ups during installation. 


Both axles of the loader are secured to prevent it from rolling away (e.g. 

with chocks). 

The front and rear carriages are supported (e.g. with jacks). 

The drive shaft has been removed (see the section 4.1 "Replacing the drive 

shaft"). 

The steering cylinder has been removed at the rod end (see the section 

3.3.4 "Removing the steering cylinder"). 



The articulated link is not blocked. 

4-109


Fig. 218 Securing the solenoid valve Fig. 219 Securing the lines 

Exposing the center joint Undo 2 screws (Fig. 218,1) on each solenoid valve. 

Temporarily secure the solenoid valves on the front carriage at the side 

(e.g. with belts). 

Unscrew the 2 screws (Fig. 219,2) and remove the holder (Fig. 219,1). 




Lift up all the lines and temporarily secure them on the operator's platform 

(e. g. with belts). 


Fig. 220 Hydraulic line of the front differential 

lock 

Preparing the lower bearing Unscrew and close off the hydraulic line (Fig. 220,1). 

Unscrew the grease nipple (Fig. 221,1). 

Fig. 221 Securing the lower bearing 

Unscrew the 6 screws (Fig. 221,2) and remove the perforated disk 

(Fig. 221,3). 

Unscrew the bolt (Fig. 221,5) and remove the liner (Fig. 221,4) with the 

disk. 

Screw the screw (Fig. 221,5) loosely into the thread. 

4-110 1000239425 - WDF-6001-00EN 


Preparing the self-aligning 

bearing 

Removing the self-aligning 

bearing 

Separating the front and 

rear carriage 

Remove the protective caps (Fig. 222,1). 

Remove the 2 locking rings (Fig. 223,1). 

Unscrew the 2 grease nipples (Fig. 223,2). 



Fig. 222 Protective caps Fig. 223 Retaining mounts of the selfaligning 

bearing 

Fig. 224 Removing the self-aligning 

bearing 

Pull up the self-aligning bearing using a suitable tool (Fig. 224). 

Using a suitable removal tool, press the shaft of the front carriage up and 

out of the lower bearing (Fig. 225). 

Swivel the front carriage to the side. 

6.3.2 Connecting the center joint 

Fig. 225 Removing the shaft 

The pivot bearings can sit very securely on the shaft or the bolt. 

If necessary, use a hydraulic tool (Fig. 225) to pull off, drive out or drive in 

the pivot bearings (e.g. hydraulic hand pump). 





The pivot bearings can sit very securely on the shaft or the bolt. 

If necessary, use a hydraulic tool to pull off, drive out or drive in the pivot 

bearings (e.g. hydraulic hand pump). 

4-111




Securing the lower bearing Coat the thread of the bolts (Fig. 226,2) with locking agent. 

Connecting the front and 

rear carriages 


Locking ring 2 

Rubber washer 1 


Put the perforated disk in position (Fig. 226,1). 


as req. 


Fig. 226 Securing the lower bearing 

Fig. 227 Shaft and bearing Fig. 228 Pressing tool 

Position the shaft of the front carriage exactly over the lower bearing 

(Fig. 227). 

Grease the pin and the bearing slightly. 

If the rubber washer (Fig. 227,1) is faulty, replace it with a new one. 

If necessary, fit shim washers (Fig. 227,2) onto the shaft. 

Press the shaft into the bearing from above using a suitable pressing tool 

(Fig. 228). 

4-112 1000239425 - WDF-6001-00EN 


Installing the self-aligning 

bearing 

Securing the self-aligning 

bearing 

Fig. 229 Self-aligning bearing 




If necessary, fit shim washers onto the pins. 

Place the self-aligning bearing onto the pins from above (Fig. 229). 

If necessary, readjust the front and rear carriages. 

Using a suitable tool, press the self-aligning bearing from above onto the 

pins. 

Fig. 230 Protective caps Fig. 231 Retaining mounts of the selfaligning 

bearing 

If necessary, fit shim washers (Fig. 231,3) onto the pins. 

Insert 1 locking ring (Fig. 231,1) for each. 

Screw 2 grease nipples (Fig. 231,2) into the self-aligning bearing. 

Press 1 protective cap (Fig. 230,1) into each hole. 


4-113


Securing the front carriage 

at the bottom 

Fig. 232 Lower bearing attachment Fig. 233 Hydraulic line of the front differential 

lock 

Coat the thread of the bolt (Fig. 232,5) with locking agent. 

Screw in the liner (Fig. 232,4) with the disk. 


Screw in the grease nipple (Fig. 232,1). 

Screw the hydraulic line (Fig. 233,1) onto the connection on the valve and 

tighten. 

Fig. 234 Line attachment Fig. 235 Solenoid valve attachment 

Attaching the lines Put the holder (Fig. 234,7) into position and tighten the 2 screws 

(Fig. 234,8). 

Place the lower line assembly into the holder. 

Put the holder (Fig. 234,9) into position and tighten the 2 screws 

(Fig. 234,10). 


(Fig. 234,5). 

Place the upper line assembly onto the holders. 


(Fig. 234,4). 


(Fig. 234,2). 

Place the solenoid valves onto the front carriage and tighten 2 screws 

(Fig. 235,1) for each. 



Install the steering cylinder at the rod end (see the section 3.3.5 "Installing 

the steering cylinder"). 

4-114 1000239425 - WDF-6001-00EN 




Install the drive shaft (see the section 4.1 "Replacing the drive shaft"). 

Lubricate all bearings of the center joint. 

6.3.3 Replacing the bearing in the self-aligning bearing 




WARNING 





The self-aligning bearing has been removed (see the section 6.3.1 

"Detaching the center joint"). 





Fig. 236 Securing the bearing Fig. 237 Expulsion tool 

Driving out the pivot bearing Remove the locking ring (Fig. 236,2) and washer (Fig. 236,1) on the underside 

of the self-aligning bearing. 

Turn the self-aligning bearing over. 


(Fig. 237). 

4-115


Fig. 238 Underside of the self-aligning 

bearing 

Driving in the pivot bearing Slightly grease the pivot bearing and the bearing eye. 

Put the pivot bearing into position on the underside (Fig. 238) of the selfaligning 

bearing and drive it in using a suitable driving tool. 

Insert the washer (Fig. 239,1) and locking ring (Fig. 239,2). 

Final work Install the self-aligning bearing (see the section 6.3.2 "Connecting the 

center joint"). 






WARNING 



Fig. 239 Securing the bearing 



The front and rear carriages are separated (see the section 6.3.1 

"Detaching the center joint"). 





4-116 1000239425 - WDF-6001-00EN 




Fig. 240 Rear carriage support Fig. 241 Expulsion tool 

Driving out the pivot bearing Support the rear carriage with a suitable support (Fig. 240). 


(Fig. 241). 

Fig. 242 Driving tool 

Driving in the pivot bearing Slightly grease the bearing and the bearing eye. 

Put the bearing into position and press it in using a suitable pressing tool 

(Fig. 242). 

Final work Connect the front and rear carriages (see the section 6.3.2 "Connecting the 

center joint"). 

6.4 Step plate and insulation mats 

6.4.1 Removing the operator's platform 








The battery disconnect switch has been removed (see the section 8.2.6 

"Replacing the battery disconnect switch"). 

4-117


Detaching the lines Mark the hydraulic lines in order to avoid mix-ups. 


cylinder 


cables 

Fig. 243 Underside of the control valve Fig. 244 Control unit 

Undo 1 screw on each of the connectors (Fig. 243,1). 

Pull off 1 connector on both the topside and underside of the solenoid valve 

and protect the contacts. 


Unplug the plug (Fig. 244,3) on the control unit (Fig. 244,1). 

Unscrew the nut (Fig. 244,2) and remove the relay and grounding cable. 

Fig. 245 Main brake cylinder 




Pull out the main brake cylinder (Fig. 245,3) to the rear and set it down. 

Fig. 246 Bowden cable of the parking 

brake 

Fig. 247 Bowden cable of the accelerator 

Unscrew the nut (Fig. 246,1) and remove the spacer (Fig. 246,2). 


Remove the Bowden cable (Fig. 246,3) from the holder (Fig. 246,5). 

4-118 1000239425 - WDF-6001-00EN 


Disconnecting electrical 

cables 






Disconnect the plug (Fig. 248,1) of the belt switch. 

Pull the plug (Fig. 248,2) off the parking brake switch. 

Mark and disconnect all plugs (Fig. 249). 

Disconnecting connections Disconnect the Bowden cables, electrical and hydraulic lines from the step 

plate and place them on the rear carriage (Fig. 250). 


Remove the eye bolt (Fig. 251,1) and place the cable on the rear carriage. 



Removing the operator's 

platform 

Fig. 248 Electrical plug Fig. 249 Electrical cables 

Fig. 250 Lines Fig. 251 Securing the cable 

Fig. 252 Front attachment (right) Fig. 253 Rear attachment (left) 

Unscrew the bolt (Fig. 252,2) and remove the grounding strip. 

Secure the operator's platform with suitable lifting gear (e.g. a crane). 

Unscrew 1 nut (Fig. 252,1) on both front attachments. 

4-119




Placing the operator's 

platform into position 

Unscrew 1 nut (Fig. 253,1) on both rear attachments. 

Carefully lift off the operator's platform upwards with lifting gear. 

6.4.2 Installing the operator's platform 




Step plate 1 

Driver's canopy 1 

or ROPS bar 1 

Fig. 254 Rear attachment (left) Fig. 255 Front attachment (right) 

Secure the operator's platform with suitable lifting gear (e.g. a crane). 

Carefully place the operator's platform onto the rear carriage from above 

so that the attachments are lined up. 

On each of the two rear attachments, screw 1 nut (Fig. 254,1) onto the bolt 

with a spring lock washer and disk. 

On each of the two front attachments, screw 1 nut (Fig. 255,1) onto the bolt 



Screw in and tighten the screw (Fig. 255,2) on the grounding strip with a 

spring lock washer and disk. 

4-120 1000239425 - WDF-6001-00EN 


Securing the operator's 


Connecting the electrical 

cables 

Fig. 256 Cable attachment 





Place the eye bolt (Fig. 256,1) into position and secure it with the bolt, disk, 

spring lock washer and nut (Fig. 256,2). 

Fig. 257 Electrical cables Fig. 258 Electrical plug 

Connect and secure all plugs (Fig. 257). 

Plug the plug (Fig. 258,2) onto the parking brake switch. 

Connect and secure the plug (Fig. 258,1) of the belt switch. 


Fitting the Bowden cables Push the Bowden cable (Fig. 259,4) into the holder (Fig. 259,3) at the side. 


Secure the Bowden cable with the screw (Fig. 259,1). 


brake 

Insert the Bowden cable (Fig. 260,3) into the holder (Fig. 260,5) from 

above. 


Secure the Bowden cable with a spacer (Fig. 260,2) and nut (Fig. 260,1). 

4-121


Fitting the main brake 

cylinder 


Insert the main brake cylinder (Fig. 261,3) through the metal plate from the 

rear. 

Tighten the 2 bolts (Fig. 261,2). 

Screw the hydraulic line (Fig. 261,4) onto the connection on the main brake 


Push the pin (Fig. 261,1) through the fork end and secure. 

Fig. 262 Control unit Fig. 263 Underside of the control valve 

Connecting lines Insert the screw (Fig. 262,2) with the spring lock washer and disk through 

the relay and grounding cable, screw it in and tighten it. 

Plug in the plug (Fig. 262,3) on the control unit (Fig. 262,1). 

Screw the hydraulic lines (Fig. 263,2) onto the connection on the control 


Plug in 1 plug (Fig. 263,1) on both the topside and underside of the solenoid 

valve, and secure with 1 screw in each case. 

Final work Adjust the parking brake (see the section 5.2.1 "Replacing the Bowden 





4-122 1000239425 - WDF-6001-00EN 




6.4.3 Replacing the rubber buffer of the step plate 





buffers 

Do not damage electrical or hydraulic lines when lifting the step plate. 

Work very carefully. 

This section describes how to replace the front rubber buffer. 

The rear rubber buffers are replaced in the same way. 



hood"). 



Fig. 264 Front grounding strip Fig. 265 Securing the step plate 


Unscrew 1 nut (Fig. 265,1) on both sides. 


Carefully raise the operator's platform at the font using suitable lifting gear 

(e.g. a crane) so that the rubber buffers (Fig. 265,4) can be removed. 

Remove 1 spacer plate in each case (Fig. 265,2) and place it aside. 

Lift out 1 rubber buffer (Fig. 265,4) upwards in each case. 

Installing the rubber buffers Insert 1 rubber buffer (Fig. 265,4) from above in each case. 

In each case place 1 spacer plate (Fig. 265,2) centrally onto the rubber 

buffer. 

Carefully lower the operator's platform so that the attachments line up 

exactly. 

In each case, insert 1 bolt (Fig. 265,5) with a washer from below through 

the rubber buffer and hold it securely in place. 

In each case, screw 1 nut (Fig. 265,1) with a spring lock washer and disk 

onto the bolt and tighten. 




4-123




Removing the insulation 

mat 

6.4.4 Replacing the insulation mat 

CAUTION 

Risk of injury by pointed objects. 

The attachment pins can be sharp. 

Do not knock or press onto the attachment pins with your bare hand. 

Wear protective gloves. 

This section describes an example replacement of an insulation mat. 

The replacement procedure for the other insulation mats may differ slightly. 


Set of insulation mats 1 

Fig. 266 Insulation mat Fig. 267 Attachment pins 

Remove the attachment clips (Fig. 266,1). 

Remove the entire insulation mat (Fig. 266,2). 

Installing the insulation mat Clean the bonding surface and attachment pins (Fig. 267). 

Place the insulation mat into position and press it carefully onto the attachment 

pins. 

Remove the insulation mat and cut the protective film on the rear with a 

knife. 

Carefully press the insulation mat onto the attachment pins. 

Slightly raise the insulation mat on the upper edge, pull off the protective 

film and press on the insulation mat. 

Raise the lower edge of the insulation mat slightly, pull off the second half 

of the protective film and press on the insulation mat. 

Connect the attachment clips (Fig. 266,1) to the attachment pins and knock 

them carefully into place with the hammer. 



4-124 1000239425 - WDF-6001-00EN 


6.5 Load arm 

6.5.1 Replacing the complete load arm 





lines 



DANGER 


The complete load arm weighs approx. 170 kg. 

Use suitable lifting gear (e.g. a crane) to remove and install the load arm. 





The hydraulic lock (if present) is completely extended. 




Load arm, complete 1 


Fig. 268 Hydraulic lines 

Unscrew and close off the hydraulic lines of the auxiliary hydraulics 

(Fig. 268,1, 2 and 3). 

4-125




Fully lower the lift frame. 

Remove the tipping cylinder at the rod end (see the section 3.5.11 

"Replacing the rod-end bearing of the tipping cylinder"). 

Raise the tipping cylinder and use suitable means (e.g. a fabric belt) to prevent 

it from descending accidentally (Fig. 269). 



Place both lifting cylinders on the front carriage. 

Removing the load arm Secure the load arm with suitable lifting gear (Fig. 271). 


(Fig. 272,2). 

Drive out the pin (Fig. 272,1) (e.g. with a slide hammer puller). 

Raise the load arm with suitable lifting gear. 

Reverse the loader away carefully. 

Installing the load arm Carefully drive the loader under the load arm. 

Carefully lower the load arm so that the pin holders line up exactly. 

Drive in the pin (Fig. 272,1) from the outside so that the groove for the 

locking plate points towards the screws (Fig. 272,3). 

Insert 1 locking plate (Fig. 272,2). 


Fitting the hydraulic cylinder 

at the rod end 

Fig. 269 Securing the tipping cylinder Fig. 270 Attachment of the lifting cylinder 

at the rod end 

Fig. 271 Securing the load arm Fig. 272 Securing the pin 

Raise the lifting cylinder until the rod-end pin holders line up precisely. 


4-126 1000239425 - WDF-6001-00EN 



lines 






Install the tipping cylinder at the rod end (see the section 3.5.11 "Replacing 

the rod-end bearing of the tipping cylinder"). 



Screw the hydraulic lines of the auxiliary hydraulics (Fig. 268,1, 2 and 3) 

onto the screw attachments near the center joint and tighten them. 


Lubricate the lifting cylinder bearings. 

Lubricate the load arm bearings. 

6.5.2 Replacing the bearings of the short drawbar 

This section describes replacement of one bearing. 

The second bearing is replaced in the same way. 


Bearing 2 


Fig. 273 Securing the drawbar Fig. 274 Bearings 

Removing the bearings Set down the tool attachment so that it cannot tip over (e.g. on the work 

bench). 

Unscrew the 2 nuts (Fig. 273,1) and remove the three hydraulic lines 

(Fig. 273,2) of the auxiliary hydraulics. 



Fold the drawbar forwards and tilt in the lift frame at the same time. 

Drive out the bearing (Fig. 274) outwards. 

Use a suitable tool to drive in the bearing without tilting it (see Part 2, 

"Driving bolts"). 

Installing the bearing Drive in the bearing (Fig. 274) from the outside. 

At the same time, fold the drawbar towards the loader and tilt out the lift 

frame sufficiently far that the pin holders line up precisely. 


4-127




Removing the reversing 

lever 



Place 3 hydraulic lines (Fig. 273,2) of the auxiliary hydraulics into position 

and in each case screw 2 nuts (Fig. 273,1) onto the thread and tighten. 

Final work Lubricate the drawbar bearing. 

6.5.3 Replacing the bearings of the short reversing lever 




Bearing 2 


Fig. 275 Securing the reversing lever Fig. 276 Securing the pin 

Set down the tool attachment so that it cannot tip over (e.g. on the work 

bench). 

Secure the reversing lever with suitable lifting gear (e.g. a crane) 

(Fig. 275). 


(Fig. 276,2). 


Fig. 277 Bearing in the short reversing 

lever 

Replacing the bearing Lower the reversing lever sufficiently far that the bearing (Fig. 277,1) is 

free. 

Drive out the bearing outwards. 

4-128 1000239425 - WDF-6001-00EN 


Drive in a new bearing from the outside. 



Installing the reversing lever Using a suitable tool, raise the reversing lever sufficiently far that the pin 

holders line up precisely. 


Drive in the pin so that the groove for the locking plate points towards the 

screws (Fig. 276,3). 

Insert the locking plate (Fig. 276,2). 

Screw in the 2 bolts (Fig. 276,3) with spring lock washers and tighten. 







Final work Lubricate the reversing lever bearing. 

6.5.4 Replacing the bearings of the long reversing lever 




Bearing 2 


Fig. 278 Resting the tool attachment Fig. 279 Securing the tipping cylinder 

Set down the tool attachment slightly raised on a suitable aid (e.g. block of 

wood) (Fig. 278). 

Remove the tipping cylinder at the rod end (see the section 3.5.11 

"Replacing the rod-end bearing of the tipping cylinder"). 

Raise the tipping cylinder and use suitable means (e.g. a fabric belt) to prevent 

it from descending accidentally. 

4-129


Removing the reversing 

lever 

Fig. 280 Securing the reversing lever Fig. 281 Reversing lever attachment 

Secure the reversing lever with suitable lifting gear (e.g. a crane) 

(Fig. 280). 



Fig. 282 Center bearing 

Replacing the bearing Set down the reversing lever forwards. 

Drive out the bearing (Fig. 282,1) outwards. 




Installing the reversing lever Using suitable lifting gear (e.g. a crane), raise the reversing lever sufficiently 

far that the pin holders line up precisely. 

Drive in the pin (Fig. 281,1) from the left. 


Install the tipping cylinder at the rod end (see the section 3.5.11 "Replacing 

the rod-end bearing of the tipping cylinder"). 

Final work Lubricate the reversing lever bearing. 

4-130 1000239425 - WDF-6001-00EN 






6.5.5 Replacing the upper bearing of the long drawbar 




Bearing 2 


Fig. 283 Securing the drawbar Fig. 284 Drawbar support 

Removing the bearing Set down the tool attachment so that it cannot tip over (e.g. on the work 

bench). 



Raise the drawbar and support it by suitable means (e.g. wooden block). 




Installing the bearing Drive in a new bearing (Fig. 284,1) from the outside. 

Remove the aid and guide the drawbar down sufficiently far that the pin 

holders line up precisely. 





4-131




6.5.6 Replacing the lower bearing of the long drawbar 




Bearing 2 


Fig. 285 Securing the tool attachment Fig. 286 Securing the pin 

Removing the drawbar Set down the tool attachment approximately vertically (e.g. on the work 

bench) and secure it with suitable lifting gear (Fig. 285). 


Remove the disk with the spacer (Fig. 286,1). 


Fig. 287 Lower bearing 

Replacing the bearing Allow the drawbar to hang down. 





4-132 1000239425 - WDF-6001-00EN 




Installing the drawbar Raise the drawbar until the pin holders line up precisely. 





Insert the disk with the spacer (Fig. 286,1). 



Removing the tool 

attachment 

Installing the tool 

attachment 

6.6 Tool attachment 

6.6.1 Replacing the tool attachment 

If the tool attachment has a hydraulic lock, the locking cylinder must first be 

removed (see the section 3.6.3 "Replacing the locking cylinder"). 


Tool attachment 1 


Fig. 288 Securing the tool attachment 

Set down the tool attachment so that it cannot tip over (e.g. on the work 

bench). 


Drive out the pin (Fig. 288,4) on the drawbar. 

Tilt in the drawbar. 

Drive out the 2 pins (Fig. 288,1). 

Carefully raise the load arm until the tool attachment (Fig. 288,3) is free. 

Lower the load arm into the tool attachment (Fig. 288,3) so that the holes 

of the pin holders line up precisely. 


Drive in the 2 pins (Fig. 288,1). 

Tilt out the drawbar until the pin holders line up precisely. 



4-133


Final work Check and, if necessary, adjust the curling to load and dumping stops (see 

Part 3, section "Checking and adjusting the curling to load and dumping 

stops"). 

Lubricate the tool attachment bearings. 

If necessary, install the locking cylinder (see the section 3.6.3 "Replacing 

the locking cylinder"). 

6.6.2 Replacing the locking pin 




If the locking pin is rusty, check that guide is clean and grind it out if necessary. 

The locking cylinder has been removed (see the section 3.6.3 "Replacing 

the locking cylinder"). 


Pin 2 


Fig. 289 Locking pin 

Replacing the locking pin Remove the locking pin (Fig. 289,2) inwards out of the guide (Fig. 289,1). 

Grease the guide and pin slightly. 

Insert a new pin into the guide from the inside. 

Final work Install the locking cylinder (see the section 3.6.3 "Replacing the locking cylinder"). 

Lubricate the locking pin. 

4-134 1000239425 - WDF-6001-00EN 






6.6.3 Replacing the lock of the tool attachment (US) 


Lock 1 

Stop nut 1 

Fig. 290 Securing the lock Fig. 291 Inserting the lock 

Removing the lock Bring the tool attachment into an approximately vertical position. 

Drive in the hollow dowel pin (Fig. 290,3) from the front sufficiently far so 

that it no longer projects into the slot (Fig. 291,1). 


Remove the disk and spring. 

Turn the lock (Fig. 290,1) clockwise and lift it out. 

Installing the lock Insert the lock (Fig. 290,1) into the guide (Fig. 291,2) from above. 

Rotate the lock counter-clockwise until the hole and thread line up precisely. 

Put the spring and disk onto the bolt. 

Screw the nut (Fig. 290,2) onto the bolt and tighten it hand-tight. 

Drive in the hollow dowel pin (Fig. 290,3) forwards sufficiently far so that it 

projects into the slot (Fig. 291,1). 

Final work Lubricate the lock via the grease nipple on the guide (Fig. 291,2). 

4-135


4-136 1000239425 - WDF-6001-00EN 


7.1 Seat 

7.1.1 Replacing the driver's seat 





Operator's platform and cab 7 

7Operator's platform and cab 




Seat 1 

Stop nut, hexagon 4 

Fig. 292 Belt switch plug Fig. 293 Securing the driver's seat 

Removing the seat Disconnect the plug (Fig. 292,1) of the belt switch. 




Remove the driver's seat upwards. 

Fig. 294 Spacer 

Installing the seat Place the square tubes (Fig. 294,1) onto the step plate so that the holes 

line up with the slots (Fig. 294,2). 

Place the driver's seat with the bolts onto the square tubes from above. 



Screw the 4 nuts (Fig. 293,1) with washers onto the bolts. 

Align the driver's seat and tighten the nuts. 




4-137

7 Operator's platform and cab 



7.1.2 Replacing the complete seat belt 

Removing the seat belt Unplug the plug (Fig. 295,1). 

Unscrew 1 cap (Fig. 295,2) on both sides. 

Unscrew 1 screw (Fig. 296,2) on both sides. 

Remove the seat belt, including the belt buckle (Fig. 296,1). 

Fitting the seat belt Position the new seat belt so that the belt buckle (Fig. 296,1) is on the left 

side. 

Screw in 1 screw (Fig. 296,2) on both sides and tighten. 

Fit a cap (Fig. 295,2) to each screw on both sides. 

Connect and secure the plug (Fig. 295,1). 




Seat belt 1 

Fig. 295 Belt switch plug Fig. 296 Securing the seat belt 

7.1.3 Replacing the belt buckle 


Belt buckle 1 

Fig. 297 Belt switch plug Fig. 298 Securing the seat belt 

Removing the belt buckle Unplug the plug (Fig. 297,1). 



Remove the belt buckle (Fig. 298,1). 

4-138 1000239425 - WDF-6001-00EN 




Fitting the belt buckle Position the new belt buckle (Fig. 298,1) on the left side. 




Put a cap (Fig. 297,2) onto the screw. 


7.2 ROPS bar and driver's canopy 

7.2.1 Replacing the ROPS bar 

CAUTION 


The ROPS bar weighs approx. 22 kg. 

When removing and installing the ROPS bar, use suitable lifting gear or 

work with another person. 

Removing the ROPS bar Hook up the ROPS bar with suitable lifting gear (Fig. 299). 

Unscrew 2 screws (Fig. 300,1) on both sides. 

Carefully remove the ROPS bar upwards. 

Installing the ROPS bar Carefully place the ROPS bar into position from above. 

Screw in 2 screws (Fig. 300,1) with washers on both sides and tighten. 

Remove the lifting gear. 

7.2.2 Replacing the driver's canopy 



ROPS bar 1 

Fig. 299 Hooking up Fig. 300 Securing the ROPS bar 

WARNING 


The driver's canopy weighs approx. 68 kg. 

Use suitable lifting gear (e.g. a crane) to remove and install the driver's 

canopy. 



4-139




Disconnecting the cables Disconnect 1 plug (Fig. 301) for the headlights. 

Hooking up the driver's 

canopy 

Removing the driver's 

canopy 


Driver's canopy 1 

Fig. 301 Electrical cables Fig. 302 Rear headlight 



Unplug 1 plug (Fig. 302,1) from each of the two rear headlights. 

Fig. 303 Hooking up 

Hook up the driver's canopy with suitable lifting gear (Fig. 303). 

Fig. 304 Front attachment Fig. 305 Rear attachment 

Unscrew 2 screws (Fig. 304,1) at the front on both sides. 

Unscrew 2 screws (Fig. 305,1) at the rear on both sides. 

Carefully lift off the driver's canopy upwards. 

4-140 1000239425 - WDF-6001-00EN 


Installing the driver's 

canopy 



Carefully place the new driver's canopy onto the step plate from above. 

Screw and tighten in 2 screws (Fig. 305,1) with washers at the rear on both 

sides. 

Screw and tighten in 2 screws (Fig. 304,1) with washers at the front on both 

sides. 

Remove the lifting gear. 

Connecting lines Plug in 1 plug (Fig. 302,1) on each of the rear headlights. 



Connect and secure 1 plug (Fig. 301) for the headlights. 



7.2.3 Replacing the lower section of the ROPS bar/driver's canopy 

WARNING 


The lower section weighs approx. 32 kg. 

When removing and installing the lower section, use suitable lifting gear 

(e.g. a crane) or work with another person. 




The ROPS bar has been removed (see the section 7.2.1 "Replacing the 

ROPS bar"). 

The headlight has been removed (see the section 8.5.3 "Replacing the 

headlight"). 

or 

The driver's canopy has been removed (see the section 7.2.2 "Replacing 

the driver's canopy"). 

The document compartment has been removed (see the section 7.2.4 

"Replacing the document compartment"). 

The storage compartment has been removed (see the section 7.2.5 

"Replacing the storage compartment" - model-specific). 




Lower section 1 

Stop nut 8 

4-141


Removing the lower section Unscrew 1 bolt (Fig. 306,1) on both sides. 



If necessary, disconnect the cable of the headlight. 

Unscrew the 4 nuts (Fig. 307,1). 

Raise the lower section with suitable lifting gear. 

Installing the lower section Carefully the position the lower section with suitable lifting gear. 

Tighten the 4 nuts (Fig. 307,1). 

If necessary, connect the cable of the headlight. 



Screw in 1 bolt (Fig. 306,1) on both sides and tighten. 



Install the storage compartment (see the section 7.2.5 "Replacing the 

storage compartment" - model-specific). 

Install the document compartment (see the section 7.2.4 "Replacing the 

document compartment"). 

Install the driver's canopy (see the section 7.2.2 "Replacing the driver's 

canopy"). 

or 

Install the headlight (see the section 8.5.3 "Replacing the headlight"). 

Install the ROPS bar (see the section 7.2.1 "Replacing the ROPS bar"). 

7.2.4 Replacing the document compartment 




Fig. 306 Upper attachment Fig. 307 Lower attachment 



hood"). 


Document compartment 1 

4-142 1000239425 - WDF-6001-00EN 


Removing the document 

compartment 

Installing the document 

compartment 

Open the document compartment. 

Unscrew the 3 screws (Fig. 308,1). 

Remove the document compartment (Fig. 308,2). 

Place the document compartment into position. 

Screw in the 3 screws with washers and tighten. 

Close the document compartment. 


7.2.5 Replacing the storage compartment 




Removing the storage 

compartment 

Fig. 308 Document compartment 





hood"). 


Storage compartment 1 

Fig. 309 Securing the storage compartment 

Open the lid of the storage compartment (Fig. 309,1). 

Unscrew the 2 screws (Fig. 309,2). 

Remove the storage compartment. 

4-143


Installing the storage 

compartment 

Place the storage compartment into position. 


Close the lid of the storage compartment. 


7.3 Cab 

7.3.1 Removing the complete cab 






The battery disconnect switch has been removed (see the section 8.2.6 

"Replacing the battery disconnect switch"). 

Detaching the lines Mark the hydraulic lines in order to prevent mix-ups. 


cylinder 



Fig. 310 Underside of the control valve Fig. 311 Control unit 


Unplug the plug (Fig. 311,3) on the control unit (Fig. 311,1). 

Unscrew the nut (Fig. 311,2) and remove the relay and grounding cable. 




4-144 1000239425 - WDF-6001-00EN 



cables 




Pull out the main brake cylinder (Fig. 312,3) to the rear and set it down. 


brake 

Unscrew the nut (Fig. 313,1) and remove the spacer (Fig. 313,2). 






Fig. 315 Electrical plugs Fig. 316 Lines 

Disconnecting the lines Disconnect the plug (Fig. 315,1) of the belt switch. 

Pull the plug (Fig. 315,2) off the parking brake switch. 

Mark and disconnect all plugs (Fig. 316,1). 


Mark, disconnect and close off the lines (Fig. 316,2) of the heater. 

4-145


Disconnecting connections Disconnect the Bowden cables, electrical and hydraulic lines from the step 

plate and place them on the rear carriage (Fig. 317). 


Remove the eye bolt (Fig. 318,1) and place the cable on the rear carriage. 



Removing the cab Unscrew the screw (Fig. 319,2) and remove the grounding strip. 



Fig. 317 Lines Fig. 318 Cable attachment 

Fig. 319 Front attachment (right) Fig. 320 Rear attachment (left) 

Hook up the cab with suitable lifting gear (e.g. a crane). 

Unscrew 1 nut (Fig. 319,1) on both front attachments. 

Unscrew 1 nut (Fig. 320,1) on both rear attachments. 

Carefully lift off the cab upwards with lifting gear. 

7.3.2 Installing the complete cab 




Step plate 1 

Cab 1 

4-146 1000239425 - WDF-6001-00EN 




Placing the cab into position Hook up the cab with suitable lifting gear (e.g. a crane). 

Securing the operator's 


Fig. 321 Rear attachment (left) Fig. 322 Front attachment (right) 

Carefully place the cab onto the rear carriage from above so that the 

attachments are lined up. 

On each of the two rear attachments, screw 1 nut (Fig. 321,1) onto the bolt 


On each of the two front attachments, screw 1 nut (Fig. 322,1) onto the bolt 





Fig. 323 Cable attachment 



Place the eye bolt (Fig. 323,1) into position and secure it with the bolt, disk, 

spring lock washer and nut (Fig. 323,2). 

Fig. 324 Lines Fig. 325 Electrical plugs 

Connecting lines Connect the lines (Fig. 324,2) of the heater. 


4-147


Plug the plug (Fig. 325,2) onto the parking brake switch. 


Fitting the Bowden cables Push the Bowden cable (Fig. 326,4) into the holder (Fig. 326,3) at the side. 

Fitting the main brake 

cylinder 



Secure the Bowden cable with the screw (Fig. 326,1). 

Insert the Bowden cable (Fig. 327,3) into the holder (Fig. 327,5) from 

above. 


Secure the Bowden cable with a spacer (Fig. 327,2) and nut (Fig. 327,1). 



brake 

Insert the main brake cylinder (Fig. 328,3) through the metal plate from the 

rear. 


Screw the hydraulic line (Fig. 328,4) onto the connection on the main brake 


Push the pin (Fig. 328,1) through the fork end and secure. 

4-148 1000239425 - WDF-6001-00EN 




Connecting lines Insert the bolt (Fig. 329,2) with the spring lock washer and disk through the 

relay and grounding cable, screw it in and tighten it. 

Plug in the plug (Fig. 329,3) on the control unit (Fig. 329,1). 

Screw the hydraulic lines (Fig. 330,2) onto the connection on the control 




Final work Adjust the parking brake (see the section 5.2.1 "Replacing the Bowden 


Vent the service brake (see the section 3.4.4 "Replacing the brake fluid"). 

Vent the heater system (see operator's manual "Checking the coolant 

level/refilling the coolant") 



Removing the rear 

windshield wiper arm 

Fitting the rear windshield 

wiper arm 

Fig. 329 Control unit Fig. 330 Underside of the control valve 

7.3.3 Replacing the windshield wiper arms 


Windshield wiper arm 1 

or windshield wiper arm, parallel 1 

Fig. 331 Rear windshield wiper arm 

Mark the position of the windshield wiper arm. 

Fold the cap (Fig. 331,1) away from the fastening. 


Press the windshield wiper arm (Fig. 331,3) against the nut with a lever. 

Remove the nut and windshield wiper arm. 

Fit a new windshield wiper arm onto the bolt. 

Screw the nut (Fig. 331,2) onto the bolt and tighten it. 

4-149


Removing the front 

windshield wiper arms 

Fitting the front windshield 

wiper arms 

Check the function. 

Readjust the windshield wiper arm if the desired wiping area is not covered. 

Fold the cap (Fig. 331,1) over the nut. 

Fig. 332 Front windshield wiper arm 

Mark the position of the windshield wiper arms. 

Pull off the hose (Fig. 332,3) of the windshield washer system. 

Fold the 2 caps (Fig. 332,4) away from the fastening. 

Undo the 2 nuts (Fig. 332,2). 

Press both windshield wiper arms (Fig. 332,1) against the nuts with a lever. 

Remove the nuts and windshield wiper arms. 

Fit new windshield wiper arms onto the bolts. 

Screw the 2 nuts (Fig. 332,2) onto the bolts and tighten. 

Check the function. 

Readjust the windshield wiper arms if the desired wiping area (the center 

of the front windshield) is not covered. 

Fold the 2 caps (Fig. 332,4) over the nuts. 

Insert the hose (Fig. 332,3) onto the connection below the windshield. 

7.3.4 Replacing the windshield washer container 

WARNING 








hood"). 


Windshield washer container 1 

4-150 1000239425 - WDF-6001-00EN 


Removing the windshield 

washer container 

Installing the windshield 

washer container 





Fig. 333 Windshield washer container Fig. 334 Holder 

Unplug the cable (Fig. 333,3) from the cable eye. 

Unplug the plug (Fig. 333,1) from washer water pump. 

Unplug the transparent hose (Fig. 333,4) from the washer water pump and 

close it off. 

Pull up the windshield washer container (Fig. 333,2) and remove it from the 

holder (Fig. 334,1). 

Push the windshield washer container (Fig. 333,2) onto the holder 

(Fig. 334,1) from above 

Connect the transparent hose (Fig. 333,4) to the washer water pump. 

Plug the connector (Fig. 333,1) onto the washer water pump. 

Press the cable (Fig. 333,3) into the cable eye. 

Final work Top up the washing water (see operator's manual "Filling the container for 

the windshield washer system"). 

Check that the washer water pump is working. 

7.3.5 Replacing the door lock 


Lock 1 

Handle 1 

Fig. 335 Door lock 

Removing the door lock Carefully remove the plastic rivet (Fig. 335,4). 

The cover is partially under the clamping profile. 

4-151


Carefully remove the cover (Fig. 335,3). 


Remove the lock (Fig. 335,2). 

Removing the door handle Undo the screw (Fig. 336,2). 

Rotate the button (Fig. 336,1) upwards so that it fits through the opening in 

the door plate. 


Remove the door handle outwards. 

Installing the door handle Insert the door handle from the outside. 


Rotate the button (Fig. 336,1) horizontally. 


Fitting the door lock Place on the lock (Fig. 335,2) into position. 


Place the cover (Fig. 335,3) into position and carefully insert it under the 

clamping profile. 

Insert the plastic rivet (Fig. 335,4) into the hole. 



Fig. 336 Door handle attachment 

7.3.6 Replacing the door stay 


Holder 1 

Stop nut, hexagon M5 3 

4-152 1000239425 - WDF-6001-00EN 




Fig. 337 Securing the door stay 


Remove the door stay (Fig. 337,2) outwards. 



Insert the new door stay from the outside so that the handle points down. 

Screw the 3 nuts onto the bolts and tighten them. 

7.3.7 Replacing the complete door 

The hinges are lined with plastic washers. 

Take off the plastic washers after removal and put them back during installation. 


Door 1 

Stop nut, hexagon 1 

Fig. 338 Securing the door 

Removing the door Unscrew the nut (Fig. 338,1). 

Open the door. 

Carefully lift the door up and remove it. 

Installing the door Carefully insert the door from above first into the upper and then into the 

lower hinge. 

Close the door. 

Screw the nut (Fig. 338,1) onto the bolt and tighten it. 

Final work Lubricate both hinges. 

4-153




7.3.8 Replacing the roof grille of the cab 


Roof grille 1 

Stop nut, M10 4 

Fig. 339 Roof grille attachment 

Removing the roof grille Unplug 1 plug (Fig. 339,1) from the headlight on each side. 

Remove 4 caps (Fig. 339,3). 


Remove the roof grille (Fig. 339,2). 

Installing the roof grille Place the roof grille carefully into position. 

Screw the 4 nuts (Fig. 339,4), with washers, onto the bolts and tighten. 

Fit the 4 caps (Fig. 339,3) onto the nuts. 

Plug 1 plug (Fig. 339,1) onto the headlight on each side. 



7.3.9 Replacing the window and the rubber clamping profile 

WARNING 

Risk of injury by falling window. 

Windows can be very heavy and unwieldy. 

Use suitable lifting gear, or get a second person to assist you. 

Always follow the glass manufacturer's fitting instructions. 

Always follow the adhesive manufacturer's fitting instructions. 

Windows can break when under stress. 

Avoid pending or twisting (torsion) the window. 

This section describes how to replace a window with a rubber clamping 

profile. 

All other windows with a rubber clamping profile are replaced in the 

same way. 


Window 1 

Rubber clamping profile (meter goods) as req. 

Rubber clamping profile filler (meter goods) as req. 

4-154 1000239425 - WDF-6001-00EN 




Fig. 340 Rubber clamping profile Fig. 341 Starting point 

Removing the window Use a disassembly tool (Fig. 340,2) to lift the rubber clamping profile filler 

(Fig. 340,1) at the joint. 

Slowly remove the rubber clamping profile filler all round. 

At one corner (Fig. 341), insert the disassembly tool between the window 

and the rubber clamping profile. 

Carefully lever the window out of the rubber clamping profile all the way 

round. 

Remove the rubber clamping profile if necessary. 

Fig. 342 Inserting the window Fig. 343 Rubber clamping profile filler 

Installing the window If necessary, cut a new rubber clamping profile to the correct length and 

attach it to the metal so that the groove for the rubber clamping profile filler 

faces outwards. 

Coat the rubber clamping profile (Fig. 342,1) and the edge of the window 

(Fig. 342,2) with a suitable lubricant (e.g. silicone spray). 

Fix the window to one side of the rubber clamping profile. 

Using the disassembly tool (Fig. 342,3), carefully pull the rubber clamping 

profile over the edge of the window all the way round. 

Align the window with the metal in the rubber clamping profile. 

Thread the rubber clamping profile filler (Fig. 343,2) through the assembly 

tool (Fig. 343,1) and use this to press the rubber clamping profile filler into 

the groove of the rubber clamping profile (Fig. 343,3). 

Cut the rubber clamping profile filler to the correct length at the abutment. 

4-155




7.3.10 Replacing a bonded-in window 

WARNING 

Risk of injury from glass splinters. 

Wear protective gloves and safety goggles. 

WARNING 

Risk of injury by falling window. 

Windows can be very heavy and unwieldy. 

Use suitable lifting gear, or get a second person to assist you. 

Always follow the glass manufacturer's fitting instructions. 

Always follow the adhesive manufacturer's fitting instructions. 

This section describes replacement of a bonded-in window. 

All other bonded-in windows are replaced in the same way. 


Window 1 

Adhesive set 1 

Fig. 344 Remains of the window Fig. 345 Glass and residual beading 

Removing glass remains Remove and set aside fittings under which there are splinters, e.g. door 

handle (Fig. 344,1). 

Remove and clean the seals (Fig. 344,3) and place them aside. 

Remove loose glass splinters. 

DANGER 

Risk of injury from slipping with the cutting tool. 

Work very carefully and wear cut-resistant work clothing. 

Cut open the adhesive between the glass remains (Fig. 345,1) and the 

door. 

Remove the glass remains. 

Scrape off the residual beading (Fig. 345,2) so that it is smooth, leaving 

approx. 1 mm. 

If necessary, touch up minor paint damage on the frame. 

Clean the bonding surfaces on the door thoroughly. 

4-156 1000239425 - WDF-6001-00EN 


Preparation for bonding Place the window into the door to check the fit. 



Fig. 346 Adhesive dispenser Fig. 347 Primer and activator 

Clean the bonding surfaces of the window thoroughly. 

Cut off the end of the adhesive dispenser (Fig. 346) and make a notch (see 

the adhesive manufacturer's instructions). 

Touch up minor damage on the door's black UV protective coating with the 

primer (Fig. 347,1) and allow it to dry thoroughly. 

Break the small glass tube inside the activator (Fig. 347,2) to activate the 

activator. 

Using the yellow fleece, apply the activator to the bonding surfaces of the 

door and window, and allow it to dry. 

Fig. 348 Adhesive bead 

Bonding in the window Apply the adhesive in a bead (Fig. 348) along the bonding surface of the 

door. 

Do not touch the bonding surfaces of the window. 

When performing vertical installation, use spacers to the edge until the 

adhesive has hardened. 

When performing vertical installation, secure the window in place until the 

adhesive has hardened. 

Place the window onto the adhesive bead, align it and press it on until the 

window is flush against the door. 

Allow the adhesive to harden (see the adhesive manufacturer's instructions). 

Fit the seals and attachments, e.g. door handle. 

If necessary, seal individual points with sealant (e.g. silicone). 

4-157


7.3.11 Replacing the complete heater 




WARNING 








Heater 1 

Fig. 349 Lines Fig. 350 Grille attachment 

Dismantling the water lines Open the radiator cap briefly in order to depressurize the cooling system. 

Mark, disconnect and close off the lines (Fig. 349,2) of the heater. 




Remove the grille (Fig. 350,1) with the filter mat. 

Fig. 351 Heater attachment Fig. 352 Plug 

Removing the heater Unscrew the 4 screws (Fig. 351,1). 


Place the heater (Fig. 352,1) onto the floor of the cab. 

Unplug the plug (Fig. 352,2). 

4-158 1000239425 - WDF-6001-00EN 




Carefully pull the heater's lines inwards through the opening (Fig. 352,3). 

Remove the heater. 

Installing the heater Place the heater (Fig. 352,1) onto the floor of the cab. 

Carefully route the heater's lines outwards through the opening 

(Fig. 352,3). 


Place the heater into position, screw in and tighten 1 screw (Fig. 351,2). 


Connecting the water lines Place the grille (Fig. 350,1) into position with the filter mat. 




Connect the lines (Fig. 349,2) of the heater. 



Removing the cables at the 

front 

Final work Vent the heater (see operator's manual "Checking the coolant level/refilling 

the coolant") 



7.4 Steering column 

7.4.1 Replacing the instrument steering column 


Instrument steering column 1 

Fig. 353 Electrical cables Fig. 354 Horn 

Mark and disconnect all plugs (Fig. 353). 


Pull the 2 connectors (Fig. 354,3) off the horn and set the horn (Fig. 354,2) 

aside. 

4-159


Removing the grounding 

strip 



Removing the instrument 

steering column 

Fig. 355 Steering cover Fig. 356 Grounding point 



Unscrew the screw (Fig. 356,1) and remove the grounding cable. 

Fig. 357 Upper cladding Fig. 358 Lower cladding 



Carefully pull the upper steering column cladding (Fig. 357,4) apart so that 

the screws (Fig. 358,1) are freed. 



Remove the lower steering column cladding (Fig. 358,2). 

Carefully connect the upper steering column cladding and screw in 1 screw 

(Fig. 357,3) loosely. 

Fig. 359 Steering attachment 


Carefully set down the orbital steering valve (Fig. 359,3) to the rear. 

4-160 1000239425 - WDF-6001-00EN 


Installing the instrument 

steering column 



Installing the grounding 

cable 

Connecting the lines at the 

front 





At the same time, hold the instrument steering column firmly in place and 

unscrew the 4 screws (Fig. 359,2). 

Remove the instrument steering column, including the cable harness. 

Carefully put the instrument steering column into position and hold it in 

place. 


Carefully set down the orbital steering valve (Fig. 359,3) from the rear. 



Carefully pull the steering column cladding (Fig. 357,4) apart slightly. 

Place the lower steering column cladding (Fig. 358,2) into position. 



Carefully connect the upper steering column cladding, screw in the 

4 screws (Fig. 357,3) and tighten. 

Align the instrument panel (Fig. 357,1), screw in the 4 screws (Fig. 357,2) 

and tighten. 

Place the grounding cable into position, screw in the screw (Fig. 356,1) 

with the spring lock washer and disk, and tighten it. 



Connect the 2 plugs (Fig. 354,3) to the contact tabs of the horn. 

Place the horn (Fig. 354,2) into position, screw in the screw (Fig. 354,1) 

with the spring lock washer and disk, and tighten it. 

Connect and secure all plugs (Fig. 353). 

Final work Check the function of the instrument steering column. 

7.4.2 Replacing the steering wheel 

So as not to damage the underside of the steering wheel, to pull it off use 

two suitable half-shells (see Part 2, "Half-shells and pull-off fixture" section) 

and and a three-armed puller (see Fig. 362). 


Steering wheel 1 

4-161



wheel 

Fig. 360 Cover Fig. 361 Steering wheel attachment 



Remove the washer (Fig. 361,3). 

Carefully pull off the steering wheel (Fig. 361,1) with a suitable tool. 

Fig. 362 Pulling off the steering wheel Fig. 363 Position of the half-shells 

Insert the 2 half-shells (Fig. 363,4) from below and hold them in place. 

Position a three-armed puling device (Fig. 363,1) on the steering wheel. 

Carefully pull the steering wheel (Fig. 363,2) off the steering column 

(Fig. 363,3). 

Installing the steering wheel Fit the steering wheel (Fig. 361,1) to the steering column. 

Screw the nut (Fig. 361,2) with the washer (Fig. 361,3) onto the steering 

column and tighten it with a tightening torque of 15 Nm. 

Put the cap (Fig. 360,1) onto the steering wheel. 

4-162 1000239425 - WDF-6001-00EN 


8.1 Generator, battery and motors 

8.1.1 Replacing the generator 






WARNING 




WARNING 






hood"). 

The battery has been disconnected (see "Disconnecting and connecting 

the battery/changing the battery" in the operator's manual). 


Generator 1 

Fig. 364 Generator 

Removing the generator Unscrew the 3 nuts (Fig. 364,4) and remove the 3 cables. 




Screw the generator (Fig. 364,3) sufficiently far towards the engine that the 

V-belt (Fig. 364,1) is free. 



Lift out the generator. 

Installing the generator Insert the generator (Fig. 364,3). 

Screw the nut (Fig. 364,5) with the washer onto the bolt. 


Place the V-belt (Fig. 364,1) over the drive pulley. 

Pull the generator sufficiently far out so that the V-belt is taut and tighten 

the screw (Fig. 364,2). 

4-163



Connect the 3 cables, screw the 3 nuts (Fig. 364,4) with the washers onto 

the connections and tighten them. 

Final work Check the V-belt tension (see the engine manufacturer's workshop manual 

"Checking and adjusting the V-belt"). 


8.1.2 Replacing the starter 




WARNING 






The flue has been removed (see the section 2.5.1 "Replacing the flue"). 

The flexi-pipe has been removed (see the section 2.5.2 "Replacing the 

muffler and flexi-pipe"). 


Starter 1 

Fig. 365 Starter Fig. 366 Installation opening 

Removing the starter Disconnect the electrical cables from the starter (Fig. 365,1). 


Remove the starter. 

Installing the starter Insert the starter into the installation opening (Fig. 366). 

Screw and tighten the 2 nuts (Fig. 365,2) with spring lock washers onto the 

thread. 

Connect the electrical cables to the starter. 

Final work Install the flexi-pipe (see the section 2.5.2 "Replacing the muffler and flexipipe"). 

Install the flue (see the section 2.5.1 "Replacing the flue"). 

Connect the battery (see "Disconnecting and connecting the battery/ 

changing the battery" in the operator's manual). 

4-164 1000239425 - WDF-6001-00EN 


8.1.3 Replacing the rear windshield wiper motor 




Disconnecting the electrical 

cable 


wiper motor 


wiper motor 


cable 



The surround has been removed (see the section 8.2.4 "Replacing the 

switches in the cab"). 

The rear windshield wiper arm has been removed (see the section 7.3.3 

"Replacing the windshield wiper arms"). 


Windshield wiper motor 1 

Fig. 367 Installation console attachment Fig. 368 Electrical cable of the windshield 

wiper motor 


Remove the installation console (Fig. 367,2). 


Fig. 369 Windshield wiper motor attachment 



Open the rear window if necessary. 

Unscrew both nuts and remove the windshield wiper motor (Fig. 369,1). 

Insert the windshield wiper motor (Fig. 369,1). 

Screw the nut (Fig. 369,2) with the rubber washer onto the thread and 

tighten. 

Screw the nut (Fig. 369,3) onto the rigid part of the drive shaft and tighten it. 


4-165




Place the installation console (Fig. 367,2) into position. 


Switch the rear windshield wiper on and off in order to bring the windshield 

wiper motor into its end position. 

Final work Install the rear windshield wiper arm (see the section 7.3.3 "Replacing the 

windshield wiper arms"). 

Install the surround (see the section 8.2.4 "Replacing the switches in the 

cab"). 

8.1.4 Replacing the front windshield wiper motor 

Removing the cover Unscrew the 3 screws (Fig. 370,1). 



wiper motor 

Do not damage any wires or cables when fitting the installation console. 


Windshield wiper motor 1 

Fig. 370 Cover 

Fig. 371 Electrical wire and holder Fig. 372 Windshield wiper motor attachment 




Pull the rod (Fig. 372,6) off the shaft (Fig. 372,4). 

4-166 1000239425 - WDF-6001-00EN 



wiper motor 


Remove the windshield wiper motor (Fig. 372,2). 



Insert the windshield wiper motor (Fig. 372,2) into the holder (Fig. 372,3). 



Switch the front windshield wiper on and off in order to bring the windshield 

wiper motor into its end position. 

Attach the rod (Fig. 372,6) horizontally onto the shaft (Fig. 372,4). 


Place the holder (Fig. 371,2) into position. 


Check the function of the windshield wiper motor. 

Fitting the cover Place on the cover (Fig. 370,2). 




8.2 Switches and sensors 

8.2.1 Replacing the switches in the instrument panel 


Switch as req. 

Fig. 373 Rubber guard Fig. 374 Switches 

Carefully pull off the rubber guard (Fig. 373,1). 

Carefully pull the switches (Fig. 374,1) out of the installation frame 

(Fig. 374,2). 

Pull the connector off the switch. 

Attach the connector onto the new switch. 

Carefully insert the switch into the installation frame. 

Place the rubber guard over the switch and carefully insert it under the 

edge of the installation frame. 

4-167




Removing the combination 

switch 

Installing the combination 

switch 

8.2.2 Replacing the combination switch 

Carefully pull off the bellows (Fig. 375,1). 


Pull out the mounting plate (Fig. 376,1). 



Carefully insert the mounting plate (Fig. 376,1) into the instrument panel. 


Carefully insert the bellows (Fig. 375,1) under the edge of the mounting 

plate. 

8.2.3 Replacing the glow-plug indicator 





Combination switch 1 

Fig. 375 Bellows Fig. 376 Combination switch attachment 

Fig. 377 Electrical connection 

The instrument panel has been removed (see the section 8.4.5 "Replacing 

the engine-hour indicator"). 


Glow-plug indicator 1 

4-168 1000239425 - WDF-6001-00EN 






Pull out the glow-plug indicator towards the inside. 



Fig. 378 Electrical connection Fig. 379 Glow-plug indicator attachment 

Insert the new glow-plug indicator through the instrument panel from the 

inside. 

Screw the nut (Fig. 379,1) onto the glow-plug indicator and tighten it. 

Tighten the 2 wires with 2 nuts (Fig. 378,1). 

Final work Install the instrument panel (see the section 8.4.5 "Replacing the enginehour 

indicator"). 

8.2.4 Replacing the switches in the cab 


Switch as req. 

Fig. 380 Surround attachment 

Removing the surround Unscrew the 2 screws (Fig. 380,1). 

Remove the surround (Fig. 380,2). 

4-169


Replacing a switch Disconnect the plug (Fig. 381,1) from the switch. 

Press the switch (Fig. 381,2) out of the installation frame (Fig. 381,3) 

towards the front. 

Press the new switch into the installation frame from the front. 

Attach the plug (Fig. 381,1) onto the switch. 

Installing the surround Place the surround (Fig. 380,2) into position. 


8.2.5 Replacing the ignition lock 




Disconnecting the electrical 

connections 

Fig. 381 Switch connection 




Ignition lock 1 

Fig. 382 Upper cladding Fig. 383 Electrical connections 



Raise the instrument panel (Fig. 382,1) sufficiently far so that the upper 

cladding (Fig. 382,4) can be folded upwards. 

Fold the upper right cladding to the side sufficiently far so that the rear of 

the ignition lock (Fig. 383,1) is accessible. 

Mark the wires in order to avoid mix-ups. 

Unscrew 1 screw (Fig. 383,3) in each case and remove the respective wire 

(Fig. 383,3). 

4-170 1000239425 - WDF-6001-00EN 


Replacing the ignition lock Unscrew the nut (Fig. 384,1). 


connections 

Remove the metal plate (Fig. 384,2). 

Remove the ignition lock inwards. 



Insert the new ignition lock through the upper cladding from the inside. 

Put the metal plate (Fig. 384,2) onto the ignition lock. 

Screw the nut (Fig. 384,1) onto the ignition lock and tighten it. 

Secure each wire (Fig. 383,3) with 1 screw (Fig. 383,2). 

Push together the upper cladding (Fig. 382,4). 


Place the instrument panel (Fig. 382,1) onto the upper cladding. 


8.2.6 Replacing the battery disconnect switch 




Fig. 384 Ignition lock attachment 

During removal and installation, pay attention to the spacer sleeves located 

between the step plate and the battery disconnect switch. 








Switch 1 

4-171


Removing the battery 

disconnect switch 

Installing the battery 

disconnect switch 

Undo the 2 bolts (Fig. 385,1) and unscrew the 2 nuts on the rear side. 

Remove the battery disconnect switch (Fig. 386,1) out of the step plate 

from below. 

Remove the 2 caps (Fig. 386,4). 


Disconnect the cable (Fig. 386,2) from the battery disconnect switch. 

Connect the cable (Fig. 386,2) to the battery disconnect switch. 

Tighten the 2 nuts (Fig. 386,3). 

Fit the 2 caps (Fig. 386,4) onto the nuts. 

Insert the battery disconnect switch (Fig. 386,1) through the step plate from 

below. 

Fit 2 bolts (Fig. 385,1), each with 1 washer and 1 spacer sleeve, through 

the battery disconnect switch. 

Screw 1 nut and disk with a spring lock washer onto the 2 bolts (Fig. 385,1) 

from the rear and tighten. 


valve"). 

Connect the battery (see "Disconnecting and connecting the battery/ 

changing the battery" in the operator's manual). 



8.2.7 Replacing the parking brake switch 




Fig. 385 Battery disconnect switch 

attachment 

Fig. 386 Electrical connections 

Install the switch so that the parking brake indicator lamp lights up no later 

than after the third catch. 




Parking brake switch 1 

4-172 1000239425 - WDF-6001-00EN 




Remove the switch (Fig. 387,2). 

Put a new switch in place. 


Plug the plug onto the switch. 





8.2.8 Replacing the return filter overpressure switch 




Replacing the overpressure 

switch 

Fig. 387 Switch attachment 






Switch 1 

Fig. 388 Return filter 

Open the cap (Fig. 388,4). 

Briefly open the cap (Fig. 388,3) so that the fluid can flow out of the return 

filter and into the hydraulic fluid tank. 


4-173


Remove the 2 plugs (Fig. 388,2). 

Unscrew the overpressure switch (Fig. 388,1). 

Screw a new overpressure switch into the return filter (Fig. 388,5) and 

tighten it. 

Connect the 2 plugs (Fig. 388,2) onto the overpressure switch. 

8.2.9 Replacing the engine temperature sensor 




Replacing the engine 

temperature sensor 

WARNING 




WARNING 






hood"). 


Temperature sensor 1 


Fig. 389 Temperature sensor 

Open the radiator cap briefly in order to depressurize the cooling system. 


Unscrew the temperature sensor (Fig. 389,1) and close off the opening in 

the engine. 

Screw the new temperature sensor into the engine and tighten it. 



4-174 1000239425 - WDF-6001-00EN 




8.2.10 Replacing the temperature sensor of the hydraulic fluid tank 




Replacing the temperature 

sensor 








Temperature sensor 1 


Fig. 390 Connections on the hydraulic 

fluid tank 

CAUTION 

Hazard from escaping hydraulic fluid. 

Wear suitable protective clothing (e.g. gloves, protective goggles etc.) to 

protect yourself against the hydraulic fluid. 

Before starting work, wrap the thread of the new temperature sensor in 

sealant so that you can install it quickly. 


Unscrew the temperature sensor (Fig. 390,1) and close off the opening in 

the hydraulic fluid tank. 

Screw the new temperature sensor into the hydraulic fluid tank and tighten 

it. 




Check the hydraulic fluid level (see operator's manual "Checking the 

hydraulic fluid level"). 

4-175




Removing the fuel level 

sensor 

Installing the fuel level 

sensor 

8.2.11 Replacing the fuel level sensor 

WARNING 






If the fuel tank is too full, fuel can escape from the fuel level sensor opening. 

Empty the fuel tank until the fuel level is below the tank sensor opening. 


Fuel level sensor 1 

Fig. 391 Electrical cable Fig. 392 Fuel level sensor attachment 





Pull off the fuel lines. 


Pull out the fuel level sensor (Fig. 392,4). 

Insert the fuel level sensor (Fig. 392,4) into the fuel tank. 


Plug the fuel lines (Fig. 392,1) with clamps (Fig. 392,2) onto the fuel level 

sensor. 





4-176 1000239425 - WDF-6001-00EN 


8.3 Relays, coils and fuses 

8.3.1 Replacing the relays 




This section describes replacement of a relay. 

The other relays are replaced in the same way. 






Remove the relay (Fig. 393,2). 

Remove the plug (Fig. 3933). 

Connect the plug to the new relay. 

Place the relay in position. 

Screw in and tighten the screw with spring lock washer and disk. 



8.3.2 Replacing the solenoid valve drives on the variable 






Relay 1 

Fig. 393 Relay attachment 



The variable displacement motor has been removed (see the section 3.2.4 

"Replacing the variable displacement motor"). 


Coil 2 

Drive 2 

4-177


Removing the drives Unscrew the 2 nuts (Fig. 394,1). 

Pull off the 2 coils (Fig. 394,2). 

Unscrew the 2 drives (Fig. 395,1). 

Installing the drives Screw in and tighten the 2 drives (Fig. 395,1). 

Connect the 2 coils (Fig. 394,2) onto the drives. 

Screw the 2 nuts (Fig. 394,1), each with an O-ring, onto the drives and 

tighten hand-tight. 

Final work Install the variable displacement motor (see the section 3.2.4 "Replacing 

the variable displacement motor"). 

8.3.3 Replacing the solenoid valve of the variable displacement 

pump 




Fig. 394 Coil attachment Fig. 395 Drives 








Solenoid valve 1 

4-178 1000239425 - WDF-6001-00EN 


Removing the solenoid 

valve 

Mark the connectors in order to prevent mix-ups. 

Unscrew 1 screw on each of the connectors (Fig. 396,1). 

Remove the 2 connectors. 



Remove the solenoid valve (Fig. 396,3). 



Installing the solenoid valve Clean the contact surfaces of the variable displacement pump. 

Place the solenoid valve (Fig. 396,3) with new O-rings onto the variable 

displacement pump and press it into place. 

Screw in the screw (Fig. 396,2). 

Screw in the 4 screws (Fig. 396,4). 

Tighten the screws evenly. 

Plug the 2 connectors (Fig. 396,1) onto the connections on the solenoid 

valve and secure with 1 screw for each. 



8.3.4 Replacing the coil on the variable displacement pump 




Fig. 396 Securing the solenoid valve 

Tighten the retaining screws alternately so that both contact surfaces are 

sealed. 




Coil 1 

4-179


Removing the coil Unscrew the screw (Fig. 397,2) on the connector. 

Disconnect the plug. 


Pull off the coil (Fig. 397,3). 

Installing the coil Attach the new coil (Fig. 397,3) onto the solenoid valve drive. 

Screw the nut (Fig. 397,1) with the O-ring onto the solenoid valve drive and 

tighten it hand-tight. 

Pull the plug (Fig. 397,2) into the connections on the coil. 

Tighten the screw on the plug. 



8.4 Indicator lamps, audible warning generators and 

instruments 

8.4.1 Replacing the indicator lamp in the instrument panel 




Fig. 397 Variable displacement pump 

solenoid valve 




Indicator lamp as req. 

4-180 1000239425 - WDF-6001-00EN 


Replacing the indicator 

lamp 




Pull the bulb out of the indicator lamp. 


Pull the indicator lamp forwards out of the instrument panel. 

Installing the indicator lamp Insert the indicator lamp into the instrument panel from the front. 

Screw the nut (Fig. 398,1) with the ring onto the indicator lamp and tighten. 

Insert the bulb into the indicator lamp. 

Plug the connector (Fig. 398,2) onto the bulb. 


indicator"). 

8.4.2 Replacing the instrument lights 




Fig. 398 Indicator lamps 



This section describes replacing the instrument lights of an analog device. 

The other instrument lights are replaced in the same way. 


Bulb as req. 

4-181




Fig. 399 Rear side of the engine-hour 

indicator 

Rotate the locking mechanism (Fig. 399,1) counter-clockwise and remove 

it. 

Pull out the bulb. 

Insert a new bulb. 

Carefully insert the locking mechanism (Fig. 399,1) into the engine-hour 

indicator and rotate it clockwise until it is locked. 


indicator"). 

8.4.3 Replacing the horn 


Horn 1 

Fig. 400 Horn 



Connect the 2 plugs (Fig. 400,2) to the new horn. 

Screw in and tighten the screw (Fig. 400,1) with the spring lock washer and 

disk. 

4-182 1000239425 - WDF-6001-00EN 


8.4.4 Replacing the audible warning generator 










Remove the audible warning generator (Fig. 401,1). 

Put a new audible warning generator into place. 



8.4.5 Replacing the engine-hour indicator 





Audible warning generator 1 

Fig. 401 Audible warning generator 

Always follow the manufacturer's installation instructions. 

This section describes the replacement of an analog device. 

The other analog devices are replaced in the same way. 

The steering wheel has been removed (see the section 7.4.2 "Replacing 

the steering wheel"). 

The battery disconnect switch is switched off (see the operator's manual 

"Battery disconnect switch"). 


Engine-hour indicator 1 

4-183


Removing the instrument 

panel 

Removing the engine-hour 

indicator 

Installing the engine-hour 

indicator 

Fig. 402 Instrument panel attachment 


Carefully lift the instrument panel (Fig. 402,1) and tilt it towards the driver's 

seat. 

Fig. 403 Engine-hour indicator attachment 

Fig. 404 DIP switch 



Remove the bar (Fig. 403,4). 

Carefully push the engine-hour indicator (Fig. 403,3) to the front side and 

out of the instrument panel (Fig. 403,1). 

Carefully insert the new engine-hour indicator (Fig. 403,3) into the instrument 

panel (Fig. 403,1) from the front side. 

Place the bar (Fig. 403,4) into position. 

Screw the 2 nuts (Fig. 403,2) with spring lock washers onto the thread. 

Align the engine-hour indicator in the instrument panel so that it can be 

read easily. 

Tighten the 2 nuts (Fig. 403,2). 

Transfer the coding of the DIP switch from the old engine-hour indicator 

(Fig. 404). 

Attach the connector (Fig. 403,5) onto the engine-hour indicator. 

Do not damage any wires or cables when fitting the instrument panel. 

Carefully pull the instrument panel (Fig. 402,1) over the steering column. 

Screw in and tighten the 4 screws (Fig. 402,2) hand-tight. 

4-184 1000239425 - WDF-6001-00EN 






Final work Install the steering wheel (see the section 7.4.2 "Replacing the steering 

wheel"). 

8.5 Lighting system 

8.5.1 Replacing a complete headlamp with indicator 

Replacing a headlamp Remove the plug (Fig. 405,3). 


Remove the headlamp (Fig. 405,2). 

Place a new headlamp into position. 

Screw the nut (Fig. 405,1), with the washer, onto the thread and tighten. 

Connect the plug (Fig. 405,3) to the connection on the headlamp. 

Adjusting the headlamp Drive the loader (parallel) to 10 m in front of a flat wall (Fig. 406). 

Switch on the dipped beam. 


Align the headlamp so that the light/dark border of the dipped beam is 1 m 

above the ground (Fig. 406). 





Headlamp 1 

Fig. 405 Headlamp attachment Fig. 406 Alignment dimensions 

8.5.2 Replacing a complete tail lamp 


Lamp 1 


as req. 

4-185


Removing the tail lamp Carefully push the 2 tabs (Fig. 407,2) outwards and remove the lamp glass 

(Fig. 407,1). 

Remove the bulbs. 



Remove the tail lamp. 

If necessary, replace the electric cable. 

Installing the tail lamp Thread the electric cable through the hole in the tail lamp. 

Coat the thread of the 2 screws (Fig. 408,2) with locking agent. 


Connect the 3 plugs (Fig. 408,1) onto the contact tabs. 

Install the bulbs. 

Carefully push on the lamp glass (Fig. 407,1) until the 2 tabs (Fig. 407,2) 

engage. 



Fig. 407 Tail lamp Fig. 408 Connections 

Final work Check that the lighting system is working. 

8.5.3 Replacing the headlight 

This section describes replacement of a suspended headlight. 

The vertically mounted headlight is replaced in the same way. 


Headlight 1 

4-186 1000239425 - WDF-6001-00EN 


Fig. 409 Rear headlight 

Removing the headlight Remove the plug (Fig. 409,5). 


Remove the headlight. 

Fitting the headlight Place the new headlight into position. 

Screw the nut (Fig. 409,4) onto the thread and tighten it. 

Attach the connector (Fig. 409,5) onto the headlight. 

Aligning the lamp glass Unscrew the 4 screws (Fig. 409,1). 

Remove the frame (Fig. 409,2). 

Rotate the lamp glass (Fig. 409,3) into the desired position. 

Place the frame into position. 


Final work Check that the lighting system is working. 



The lamp glass (Fig. 409,3) must be aligned so that the lettering is not 

upside down. Align the lamp glass as necessary. 

4-187


4-188 1000239425 - WDF-6001-00EN 




9.1 Replacing the earth bucket digging tooth 


Digging tooth 1 

Fig. 410 Digging tooth attachment 


Remove the digging tooth (Fig. 410,1). 

Put a new digging tooth into place. 


Attachments 9 

Screw the 2 nuts (Fig. 410,2) with spring lock washers onto the bolts and 

tighten. 

9Attachments 

4-189

9 Attachments 

4-190 1000239425 - WDF-6001-00EN 


A 

Additional weight 

Replacement . . . . . . . . . . . . . . . . . . . . . . 4-104 

Air filter 

Replacing complete . . . . . . . . . . . . . . . . . . 4-25 

Replacing the housing . . . . . . . . . . . . . . . . 4-26 

Alternator 

See generator . . . . . . . . . . . . . . . . . . . . . 4-163 

Annular shaft seal, replacement 


Audible warning generator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-183 

Auxiliary hydraulics 

Replacing the cover . . . . . . . . . . . . . . . . . 4-77 

B 

Base plate 

Replacement . . . . . . . . . . . . . . . . . . . . . . 4-104 

Battery disconnect switch 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-171 

Bearings, replacing 

Drawbar, long . . . . . . . . . . . . . . . 4-131, 4-132 

Drawbar, short . . . . . . . . . . . . . . . . . . . . . 4-127 

Lower bearing . . . . . . . . . . . . . . . . . . . . . 4-116 

Reversing lever, long . . . . . . . . . . . . . . . 4-129 

Reversing lever, short . . . . . . . . . . . . . . . 4-128 

Self-aligning bearing . . . . . . . . . . . . . . . . 4-115 

Belt buckle 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

Brake cylinder 

see Main brake cylinder . . . . . . . . . . . . . . 4-55 

Brake drum 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 

Brake fluid 

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57 

Brake hydraulics 

Replacing the tank . . . . . . . . . . . . . . . . . . 4-56 

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 

Brake shoes 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 

C 

Cab 

Removing complete . . . . . . . . . . 4-144, 4-146 


Cardan shaft 

see Drive shaft . . . . . . . . . . . . . . . . . . . . . 4-85 

Center joint 

Connecting . . . . . . . . . . . . . . . . . . . . . . . 4-111 

Detaching . . . . . . . . . . . . . . . . . . . . . . . . 4-109 

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

WL 30 - - (WDF-7022-00) 1000239425 - WDF-6001-00EN 

Index 

Clutch hub 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 

Clutch PA flange 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-168 

Control valve 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 

Installing the catch . . . . . . . . . . . . . . . . . . 4-70 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-63 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 

Cover, replacing 

Auxiliary hydraulics control lever . . . . . . . 4-78 

Cross controller 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-70 

D 

Depressurize the hydraulic system . . . . . . . . 4-37 

Digging tooth, replacing 

Earth bucket . . . . . . . . . . . . . . . . . . . . . . 4-189 

Document compartment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-142 

Door 


Door lock 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-151 

Door stay 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-152 

Drawbar, long 

Lower bearing, replacing . . . . . . . . . . . . 4-132 

Upper bearing, replacing . . . . . . . . . . . . 4-131 

Drawbar, short 


Drive shaft 

Disassembling . . . . . . . . . . . . . . . . . . . . . 4-85 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 

Temporary securing . . . . . . . . . . . . . . . . . 4-86 

Driver's canopy 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-139 

Driver's seat 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-137 

Driving motor 


E 

Engine 

Cleaning after toppling . . . . . . . . . . . . . . . 4-19 

Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-13 

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 


4-191

Index 

Engine hood 

Emergency release . . . . . . . . . . . . . . . . 4-109 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-107 

Replacing the lock . . . . . . . . . . . . . . . . . 4-108 

Engine temperature gauge, replacing 


Engine-hour indicator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-183 

F 

Fender 

Replacing front . . . . . . . . . . . . . . . . . . . . 4-103 

Replacing rear . . . . . . . . . . . . . . . . . . . . 4-103 

Flue 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

Front axle 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 

Relieving the load . . . . . . . . . . . . . . . . . . 4-87 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 

Fuel feed pump 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 

Fuel filter 



Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-176 

Fuel tank gauge, replacing 


G 

Gear pump 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 

Generator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-163 

Glow-plug indicator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-168 

H 

Handbrake 

see Parking brake . . . . . . . . . . . . . . . . . . 4-99 

Headlamp 


Headlight 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-186 

Heater 


Horn 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-182 

see Audible warning generator . . . . . . . 4-183 

Hydraulic cylinder 

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 

Hydraulic fluid tank 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 


Hydraulic line 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 

Hydraulic motor 


Hydraulic pump 

see Gear pump . . . . . . . . . . . . . . . . . . . . . 4-59 


I 

Ignition lock 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-170 

Indicator lamp 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-180 

Instrument lights 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-181 

Instrument panel 


Instrument steering column 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-159 

Insulation mat 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-124 

L 

Lifting cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-71 

Load arm 


Locking agent . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

Locking cylinder 

Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-79 

Locking pin 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-134 

Lower bearing 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-116 

M 

Main brake cylinder 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 

Main fuel filter 


Muffler 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

4-192 1000239425 - WDF-6001-00EN 

WL 30 - - (WDF-7022-00)

O 

Operator's platform 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . 4-120 

Removing . . . . . . . . . . . . . . . . . . . . . . . . 4-117 

Orbital steering valve 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 

Overpressure switch, replacing 

Return filter . . . . . . . . . . . . . . . . . . . . . . . 4-173 

P 

Parking brake 

Fitting the Bowden cable . . . . . . . . 4-89, 4-100 

Removing the Bowden cable . . . . 4-87, 4-100 

Replacing the Bowden cable . . . . . . . . . . . 4-99 

Switch, replacing . . . . . . . . . . . . . . . . . . . 4-172 

Pivot bearing 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 

Pressure filter 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 

Priority valve 

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 

Protective stickers 

Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

R 

Radiator 

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 

Rear axle 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 

Rear muffler 

see Muffler . . . . . . . . . . . . . . . . . . . . . . . . 4-33 

Rear weight 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-105 

Relay 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-177 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 

Replacing the rubber buffers 

Engine, front . . . . . . . . . . . . . . . . . . . . . . . 4-16 

Engine, rear . . . . . . . . . . . . . . . . . . . . . . . . 4-17 

Return filter 

Overpressure switch, replacing . . . . . . . . 4-173 

Replacing the complete . . . . . . . . . . . . . . . 4-82 

Reversing lever, long 

Replacing the bearings . . . . . . . . . . . . . . 4-129 

Reversing lever, short 

Replacing the bearings . . . . . . . . . . . . . . 4-128 

Roof grille 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-154 

WL 30 - - (WDF-7022-00) 1000239425 - WDF-6001-00EN 

Index 

ROPS bar 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-139 

Rubber buffer, replacing 

Step plate . . . . . . . . . . . . . . . . . . . . . . . . 4-123 

S 

Seat belt 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-138 

Self-aligning bearing 

Replacing bearings . . . . . . . . . . . . . . . . 4-115 

Small parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 

Solenoid valve, replacing . . . . . . . . . . . . . . . 4-177 

Variable displacement pump . . . . . . . . . 4-178 

Solenoid valve, replacing the coil . . . . . . . . . 4-179 

Solenoid valve, replacing the drive 

Variable displacement motor . . . . . . . . . 4-177 

Starter 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-164 

Steering cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 

Steering wheel 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-161 

Step plate 

Rubber buffer, replacing . . . . . . . . . . . . 4-123 

Stickers 

see Protective stickers . . . . . . . . . . . . . . . . 4-9 

Storage compartment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-143 

Switch, replacing 

Parking brake . . . . . . . . . . . . . . . . . . . . . 4-172 

Switches, replacing 

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-169 

Instrument panel . . . . . . . . . . . . . . . . . . 4-167 

T 

Tail lamp 

Replacing the complete . . . . . . . . . . . . . 4-185 

Tank lock 

Drilling open . . . . . . . . . . . . . . . . . . . . . . . 4-32 

Emergency opening . . . . . . . . . . . . . . . . . 4-32 

Temperature sensor, replacement 

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-174 

Hydraulic fluid tank . . . . . . . . . . . . . . . . . 4-175 

Tipping cylinder 

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 

Removing . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 

Replacing the rod-end bearing . . . . . . . . . 4-76 

Tool attachment 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-133 

4-193

Index 

Tool attachment (US) 

Lock, replacing . . . . . . . . . . . . . . . . . . . . 4-135 

Transmission pump 


Turning the bearing 

see Engine, cleaning after toppling . . . . . 4-19 

Twin tires 

Changing the wheel . . . . . . . . . . . . . . . . . 4-95 

V 


Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 

Solenoid valve, replacement . . . . . . . . . 4-177 


Annular shaft seal, replacement . . . . . . . 4-45 

Coil, replacement . . . . . . . . . . . . . . . . . . 4-179 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 

Solenoid valve, replacing . . . . . . . . . . . . 4-178 

W 

Water separator 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 

Window, replacing 

Bonded-in window . . . . . . . . . . . . . . . . . 4-156 

Window with rubber clamping profile . . . 4-154 

Windshield washer container 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-150 

Windshield wiper arms 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-149 

Windshield wiper motor, front 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-166 

Windshield wiper motor, rear 

Replacing . . . . . . . . . . . . . . . . . . . . . . . . 4-165 

4-194 1000239425 - WDF-6001-00EN 

WL 30 - - (WDF-7022-00)


1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 5 

Circuit diagrams and technical descriptions 


1000239425 - WDF-6001-00EN 



Circuit diagrams and descriptions 


This part of the repair manual contains circuit diagrams and drawings that are 

required for fault searches and troubleshooting. 

Additional features Some of the circuit diagrams contain additional functions that are not installed 

in all loaders. 

5-3


5-4 1000239425 - WDF-6001-00EN 


1 Hydraulic circuit diagram . . . . 5-7 

2 Electrical circuit diagram. . . . . 5-9 

3 Plug assignments / 

contact assignments . . . . . . . . 5-19 

4 Technical description . . . . . . . 5-21 


Contents 

5-5

Contents 

5-6 1000239425 - WDF-6001-00EN 



Hydraulic circuit diagram 1 

1Hydraulic circuit diagram 

5-7

1 Hydraulic circuit diagram 

5-8 1000239425 - WDF-6001-00EN 



Electrical circuit diagram 2 

2Electrical circuit diagram 

5-9

2 Electrical circuit diagram 

Component list WL 30 Date: 06.08.08 P1 

ID Component Path ID Component Path ID Component Path 

K16 Release relay 2, Kl. 15 138-139 

Controll unit, radio F2-1 Fuse, Blinker Kl. 15 72 

A1 Control unit, travelling drive, hydraulics 86-88 F2-2 Fuse, Right side lamp 58 

A3 Control lever 83-84 F2-3 Fuse, Left side lamp 57 Engine 

A4 Radio 127 F2-4 Fuse, Dipped beam left & right 63 M1 Starter 11 

F2-5 Fuse, Main beam left & right 66 M2 Front windscreen wiper 114 

F2-6 Fuse, Free 22 M3 Rear windscreen wiper 118 

Converters M4 Front windscreen washer pump 116 

B1 Fuel gauge sensor 40 F3-1 Fuse, Front work light 123 M6Heater fan, max. 18A 133-134 

B2 Cooling water / engine oil temperatur emitter 42 F3-2 Fuse, Front windscreen wiper 115 

B3 Horn 86 F3-3 Fuse, Rear windscreen wiper 119 

F3-4 Fuse, Rear work light 121 Instrument 

F3-5 Fuse, Rotating beacon, radio 125 P1 Fuel gauge 40 

Lights - headlights F3-6 Fuse, Cab inside light, radio 129 P2Time meter, tachometer 32-33 

E1 Front left headlight 112, 168 P3 Engine temperature display 42 

E2 Front right headlight 123, 168 F30c Main fuse cab 7 

E3 Left rear work light 120, 170 

E4 Right rear work light 121, 170 Resistance 

Power supply R1 Heater plug indicator, 12V 28A (Perkins) 19 

E5 Left front headlight acc. to the Road Traffic Licensing Regulations 56,63,70 G1 Generator, 12V 65A 2 R2 Heater plugs (Perkins); heater coil 1 (Deutz) 20 

E6 Right front headlight acc. to the Road Traffic Licensing Regulations 59,66,73 G2 Starter battery, 12V 74Ah 4 R3 Resistance, exciter circuit 30 

E7 Left rear light acc. to the road Traffic Licensing Regulations 57,71 

E8 Right rear light acc. to the Road Traffic Licensing Regulations 58,72 

Indicator light Switch 

E9 Cab inside light 129 H1 Preheat 29 S1 Battery cut-off switch 7 

E10 Rotating beacon 124-126, 172 H3 Hydraulic oil contamination 44 S2 Heater start switch 15-19 

H5 Fuel reserve 39 S3 Fittings, warning blinker 73-75 

H6 Cooling water / Hydraulic oil temperatur 37 S7 Fittings, light, windscreen wiper, horn, blinker 57-70 

H7 Battery, generator 31 S15 Cab roof, front headlights 123 

H8 Blinker 79 S16 Cab roof, rear work lights 121 

Fuses H9 Main Beam 67 S17 Cab roof, rear windscreen wiper/washer 117-119 

F1-1 Fuse, Control unit 90 H10 Engine oil pressure 34 S19 Cab roof, rotating beacon 125 

F1-2 Fuse, indicator, instrument lights 39 H11 Parking brake 46 S21 Parking brake, handbrake 46 

F1-3 Fuse, heater, Release relay 134, 170 H13 Overdrive 93 S23 Cooling water/engine oil temperature 36 

H14 Crawler gear 95 S24 Engine oil pressure 34 

F1-4 Fuse, Horn 68 H15 Forward gear 99 S25 Fuel reserve 39 

F1-5 Fuse, Shut-off valve, fuel pump 14 H16 Reverse gear 97S27 Hydraulic oil filter, positve pressure 44 

F1-6 Fuse, Socket, warning blinker 25 H18 Dipped beam 58 S29 Hydraulic oil temperature 37 

F1-3 Fuse, Work light, Rotating beacon 170 S34 Belt lock switch 153 

S36 Fittings, rotating beacon 172 

F1-4 Fuse, Horn 68 Relay S39 Cab roof, front windscreen wiper/washer 113-116 

F1-5 Fuse, Shut-off valve, fuel pump 14 K1 Relief relay, lighting, 20A 56-57 S40 Fittings, rear work lights 168 

F1-6 Fuse, Socket, warning blinker 25 K3 Blinker interval relay 77 S41 Fittings, front headlights 170 

K13 Safety switching 152-153 

K14 Comfort hydro connection 109-110 

K15 Release relay 1 KL 15 111-113 

5-10 1000239425 - WDF-6001-00EN 


Component list WL 30 Date: 06.08.08 P2 

ID Component Path ID Component Path ID Component Path 

Diode 

V1 Free-wheeling diode, heater fan12V 31 

V2 Diode 12V 134 

V3 Diode 12V 149 

Socket 

X1 Socket, cigarette lighter, 12V 5A 25 

X2 3 pole plug, 12V, max. 5 amps 104 

Solenoid valve/pump 

Y1 Shut-off valve, injection pump 13 

Y2 Fuel pump 14 

Y3 Forward gear 99 

Y4 Reverse gear 97 

Y5 Overdrive 93 

Y6 Drive direction detector 95 

Y7 Locking differential 102 

Y13 By-pass, lowering brake valves, lifting cylinder left 165 

Y14 By-pass, lowering brake valves, right lifting cylinder 167 

Y23 Lifting cylinder block 151 

Y24 Tipping cylinder block 152 

Y25 Comfort hydro connection 122 

Y26 Wacker hydro connection 106 

Y27 Wacker hydro connection 108 



5-11


5-12 1000239425 - WDF-6001-00EN 




5-13


5-14 1000239425 - WDF-6001-00EN 




5-15


5-16 1000239425 - WDF-6001-00EN 




5-17


5-18 1000239425 - WDF-6001-00EN 


Plug assignment, 

multi-function lever 

Ignition lock contact 

assignment 


contact assignment 

Windshield wiper 

switch contact 

assignment 


Plug assignments / contact assignments 3 

No. Assignment 

1 Common foot contact for the switches and buttons 

2 Driving direction switch "Reverse" 

3 Driving direction switch "Forwards" 

4 "Overdrive" button 

5 "E-connection" button 

6 "Differential lock" button 

7 Not assigned 










15 Switched output 

17 Glow plugs / glow check (starting) 

19 Glow plugs / glow check (pre-heating) 

30a Positive pole (via battery disconnect switch) 

50 Starter 

(GR) Positive pole (via battery disconnect switch - 30b) 

56a Main beam, main headlights 

56b Dipped beam, main headlights 

58 Sidelight 

L Indicator, left 

R Indicator, right 

(VI/BK) Horn 

(WH/BK) Indicator relay 

1 Intermittent operation 

2 Continuous operation 

3 Positive pole (via relay K3) 

4 Washer pump 

3Plug assignments / contact assignments 

5-19

3 Plug assignments / contact assignments 

5-20 1000239425 - WDF-6001-00EN 



Technical description 4 

4Technical description 

The loader consists of the vehicle frame, the drive and the axles. The vehicle 

frame houses all drive and control units in the loader's standard configuration. 

The vehicle frame consists of the front carriage with the lift frame and the rear 

carriage, which houses the drive unit. The front and rear carriages are connected 

by an articulated pendulum link. 

Engine A Diesel engine provides the necessary power. The Diesel engine drives both 

the variable displacement pump for the driving hydraulics, as well as the gear 

pump for the working and steering hydraulics. 

The figure below shows the engine's control and output end (example). 

Fig. 1 Control and output end of the engine 

1 Elastic clutch 

2 Flywheel with starter ring gear 

3 Injection line 

4 Oil filler neck 

5 Oil dipstick 

6 Cutoff solenoid 

7 Injection pump 

8 Attachment flange 

9 Heater connection 

10 Oil filter 

11 Oil drainage screw 

5-21

4 Technical description 

The figure below shows the engine's exhaust and fan side (example). 

Fig. 2 Exhaust and fan side of the engine 

1 Fan wheel 

2 Oil pressure switch 

3 Thermostat housing 

4 Temperature sensor 

5 Exhaust manifold 

6 Generator 

7 Installation opening for starter 

8 Oil sump 

9 Attachment flange 

10 V-belt 

Hydraulic systems The loader has two hydraulic systems that are supplied from a hydraulic fluid 

tank: 

Hydrostatic drive 

Steering and working hydraulics 

The hydrostatic drive consists of an axial piston variable displacement pump 

that drives an axial piston variable displacement motor. The axial piston variable 

displacement pump is mounted on the Diesel engine, and the axial piston 

variable displacement motor is mounted on the pto gear. 

5-22 1000239425 - WDF-6001-00EN 




The figures below show the connections and adjustment devices of the variable 

displacement pump. 

Fig. 3 Drive end of the variable displacement 

pump 

1 Control valve 

2 Measuring point, high pressure MB 3 Solenoid valve connector 

4 Measuring point, positioning pressure 

X1 5 Measuring point, positioning pressure 

X2 6 Attachment flange 

7 Drive 

8 Transposition 

9 Measuring point, high pressure MA 10 Supply pressure valve 

Fig. 4 Output end of the variable displacement 

pump 

1 High-pressure connection B 

2 Solenoid valve connector 

3 Pressure cut-off 

4 High-pressure valve (B) 

5 High-pressure valve (A) 

6 High pressure connection A 

5-23


The figure below shows the configuration of the pressure cut-off. 

Fig. 5 Pressure cut-off configuration 

5-24 1000239425 - WDF-6001-00EN 




The adjustment is performed automatically and steplessly, but is dependent 

on the speed and load. The driving speed depends on the engine speed and 

the unit's load. Driving begins with the setpoint speed and ends with the max. 

engine speed by pressing the accelerator pedal. Depending on the loader's 

load, the variable displacement pump is automatically reduced, so that the 

most favorable speed is maintained. The greater the load on the loader (during 

loading work or driving uphill), the more the driving speed is reduced. This regulation 

makes optimum use of the entire power range. Pressing the inching 

pedal (inching delay, pedal in the left driving direction) enables the regulation 

to be additionally influenced, with the result that at any engine speed, the 

loader can be gradually slowed down until it comes to a standstill. 

The figures below show the connections and adjustment devices of the variable 

displacement motor. 

The steering and working cylinders are supplied with fluid by a hydraulic gear 

pump. The gear pump is mounted on the variable displacement pump of the 

drive. 

The hydraulic system is equipped with pressure control valves, filters and an 

oil cooler. 

The steering is designed as fully-hydraulic articulated pendulum steering via a 

dual-action cylinder. 

Drive and axles The pto gear, which transfers the power to the rear axle and (via a drive shaft) 

to the front axle, is driven via the driving hydraulics. 

The axles are configured as rigid axles. 

Vehicle frame and load 

arm 

Fig. 6 Underside of the variable displacement 

motor 


2 Measuring point, driving pressure G 

3 Output 

4 Cross flushing connection 

5 Volume adjustment in overdrive 

6 Measuring point, reversing pressure 

M1 Fig. 7 Topside of the variable displacement 

motor 

1 Cross flushing connection 

2 Volume adjustment in working gear 


4 High-pressure connection B 

5 Gear selection solenoid valve 

6 Driving direction recognition 

Brakes The drive also functions as the service brake. The service brake acts on the 

front and rear axle, and is actuated via the braking inching pedal. The drum 

brake on the differential is also actuated via the braking inching pedal. The 

parking brake acts mechanically on the drum brake via a Bowden cable. 

The loading equipment consists of the lift frame with an integrated mechanical 

or hydraulic quick-change attachment, lifting and tipping cylinders and the corresponding 

attachments. 

The loader has a rollover protective structure (ROPS structure). 

5-25


Electrical system The electrical system has an operating voltage of 12 Volts. The loads and their 

supply cables are protected by fuse elements. 

5-26 1000239425 - WDF-6001-00EN 


A 

Assignment 

Combination switch . . . . . . . . . . . . . . . . . . 5-19 

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . 5-19 

Multi-function lever . . . . . . . . . . . . . . . . . . 5-19 

Windshield wiper switch . . . . . . . . . . . . . . 5-19 

C 

Circuit diagram 

Electrical circuit diagram . . . . . . . . . . . . . . . 5-9 

Hydraulic circuit diagram . . . . . . . . . . . . . . . 5-7 

Contact assignment . . . . . . . . . . . . . . . . . . . . . 5-19 

D 

Description 

see Technical description . . . . . . . . . . . . . 5-21 

E 

Electrical circuit diagram . . . . . . . . . . . . . . . . . . 5-9 

H 

Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . 5-7 

P 

Plug assignment . . . . . . . . . . . . . . . . . . . . . . . 5-19 

T 

Technical description . . . . . . . . . . . . . . . . . . . . 5-21 


Index 

5-27

Index 

5-28 1000239425 - WDF-6001-00EN 



1000239425 - WDF-6001-00EN 

2008 

Edition 10/2008-1 


Part 6 

Supplier service manuals 


1000239425 - WDF-6001-00EN 



Supplier documentation 


This part of the repair manual lists the documents of the assembly or component 

suppliers. 

Add to the list of documents as necessary, and keep the list up to date. 

If you require additional documents, consult the loader manufacturer's or the 

supplier's Customer Service department (see "Service Address"). 

Recommended documents are: 

The engine manufacturer's workshop manual 

The variable displacement pump manufacturer's repair instructions 

The variable displacement motor manufacturer's repair instructions 

The axle manufacturer's workshop manual 

Installation instructions for the electrical components 

6-3


6-4 1000239425 - WDF-6001-00EN 


1 Engine workshop manual 

(example) . . . . . . . . . . . . . . . . . . . . 6-7 

2 Variable displ. pump repair 

instructions (example) . . . . . . . 6-9 

3 Variable displ. motor repair 

instructions (example) . . . . . . 6-11 

4 Planetary axle workshop 

manual (example) . . . . . . . . . . . 6-13 


Contents 

6-5

Contents 

6-6 1000239425 - WDF-6001-00EN 



Engine workshop manual (example) 1 

1Engine workshop manual (example) 

6-7

1 Engine workshop manual (example) 

6-8 1000239425 - WDF-6001-00EN 


Electric Drives 

and Controls 

Hydraulics 

Verstellpumpe A4VG 28 

Variable Pump A4VG 28 

Baureihe/Series 32 

Reparaturanleitung / Repair Manual 

Baugruppen / Assembly Groups 

Variable displ. pump repair instructions (example) 2 

Linear Motion and 

Assembly Technologies Pneumatics 

Service 


RDE 92003-41-R/02.08 

ersetzt/replaces 03.06 

R1 

2Variable displ. pump repair instructions (example) 

6-9

2 Variable displ. pump repair instructions (example) 

6-10 1000239425 - WDF-6001-00EN 


Electric Drives 

and Controls 

Hydraulics 

Variable displ. motor repair instructions (example) 3 

Linear Motion and 

Assembly Technologies Pneumatics 

Service 

Verstellmotor A6VM NG 28–200 

Variable Displ. Motor A6VM NG 28–200 

Baureihe/Series 63 

Reparaturanleitung / Repair Manual 

Baugruppen / Assembly Groups 


RDE 91 604-11-R/03.06 

R1 

3Variable displ. motor repair instructions (example) 

6-11

3 Variable displ. motor repair instructions (example) 

6-12 1000239425 - WDF-6001-00EN 



Planetary axle workshop manual (example) 4 

Bestell-Nr.: 5871 419 001 

ZF-PLANETENACHSE 

ZF Passau GmbH 

Donaustr. 25 - 71 

D- 94 034 Passau 

AP-R 715 

Ausgabe: 2001/07 

4Planetary axle workshop manual (example) 

6-13

4 Planetary axle workshop manual (example) 

Bestell-Nr.: 5871 419 901 

Schmier- und Wartungsvorschrift 

ZF - PLANETENACHSE 

ZF Passau GmbH 

Donaustr. 25 - 71 

D- 94034 Passau 

AP-R 715 

6-14 1000239425 - WDF-6001-00EN 



Planetary axle workshop manual (example) 4 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x 

 

 

 

 

 

6-15

4 Planetary axle workshop manual (example) 

6-16 1000239425 - WDF-6001-00EN 


E 

Engine 

Workshop manual (example) . . . . . . . . . . . 6-7 

P 

Planetary axle 

Workshop manual (example) . . . . . . . . . . 6-13 

V 


Repair instructions (example) . . . . . . . . . . 6-11 


Repair instructions (example) . . . . . . . . . . . 6-9 


Index 

6-17

Index 

6-18 1000239425 - WDF-6001-00EN

Repair Manual for Wheel Loader WL 30 - Wacker Neuson

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?