Kramer Allrad Backhoe loader 616 Series 2 Parts Manual – PDF DOWNLOAD

Kramer Allrad Backhoe loader 616 Series 2 Parts Manual – PDF DOWNLOAD

FILE DETAILS:

Kramer Allrad Backhoe loader 616 Series 2 Parts Manual – PDF DOWNLOAD

Language : English
Pages : 385
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Kramer Allrad Backhoe loader 616 Series 2 Parts Manual – PDF DOWNLOAD

Introduction
Information for ordering spare parts
Signs and symbols
Vehicle specifications
Maintenance and sealing kits
Electrical plug and socket connections
Maintenance kit for “1st Inspection” 00-1
Maintenance kit for maintenance plan “C” and “2nd Inspection” 00-1
Maintenance kit for maintenance plan “D” 00-1
Sealing kits 00-2
Sealing kits for hydraulic control valve 00-2
List of O-rings on sealing cone screw connections (DKO) 00-3
O-rings for pipe fittings with UNF thread 00-3
Sealing rings for pipe fittings with metric thread 00-4
Electrical plug and socket connections 00-6
1-pole plug housings 00-10
2-pole plug housings 00-10
3-pole plug housings 00-12
4-pole plug housings 00-12
5-pole plug housings 00-14
6-pole plug housings 00-16
7-pole plug housings 00-16
8-pole plug housings 00-16
9-pole plug housings 00-18
11-pole plug housings 00-18
13-pole plug housings 00-18
17-pole plug housings 00-18
20-pole plug housings 00-18
21-pole plug housings 00-18
28-pole plug housings 00-18
37-pole plug housings 00-18
Other component parts 00-18
I-2 ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm
Table of contents
Engine
Mounting hardware – component parts 01-2
Engine 01-2
Engine mounting (left) 01-2
Fan bearing 01-2
Alternator 01-4
V-grooved pulley 01-4
Intake manifold 01-4
Fuel pump 01-4
Oil pan 01-4
Cylinder-head cover 01-6
Turbocharger 01-6
Engine mounting (right) 01-8
Clutch 01-8
Engine ventilation 01-8
Engine – component parts 01-10
Injection facility 01-12
Water pump 01-12
Engine – crankshaft – pistons – component parts 01-14
Engine: oil pump – component parts 01-14
Engine: cylinder head – component parts 01-16
Engine: tilt lever – component parts 01-16
Fuel lines
Fuel line – negative wheel castor 08-2
Fuel line – reflux 08-2
Air filter
Standard air filter 10-2
Air filter for operation in dusty environment 0641000099 10-2
Air filter with safety cartridge 0641000199 10-4
Engine cooling
Radiator: attachment – radiator lines – breather line 15-2
Radiator attachment 15-2
Expansion tank – engine breather line 15-4
Expansion tank – radiator line 15-4
Radiator line: engine – radiator (upper) 15-4
Radiator line: engine – radiator (lower) 15-4
Fuel feed system
Fuel feed system 16-2
Fuel tank attachment 16-2
Speed regulation
Speed regulation 17-2
Cutoff device (engine) 17-2
Manual throttle 17-4
Table of contents
ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm I-3
Frame
Floor pan
Rear axle attachment on frame 20-2
Front axle attachment on frame 20-2
Rear excavator attachment on frame 20-2
Oscillating axle lock 20-2
Cover plate 20-4
Cover plates – attachment 20-4
Hydrostatic drive
Variable displacement pump – variable displacement motor – cardan shaft 22-2
Variable displacement pump – variable displacement motor 22-2
Cardan shaft attachment 22-2
Variable displacement pump – variable displacement motor – hydraulic installation 22-4
Component parts for variable displacement pump 22-4
Component parts for variable displacement motor 22-8
Variable displacement pump – variable displacement motor – hydraulic installation 22-10
Suction line: oil tank – variable displacement pump 22-10
SHD- line: variable displacement pump – variable displacement motor 22-10
Control line: variable displace pump PS – variable displace motor X1 22-10
Filter line: variable displace pump Fe – pressure filter – variable displace pump Fa 22-10
Reflux line: case flushing – variable displacement motor T2 – reflux line: steering 22-12
Pressure line: brake pedal – variable displacement pump Z (inching) 22-12
Short circuit line: temperature controller – suction line: variable displacement pump 22-12
Tow away line 22-12
Reflux line: variable displace pump – variable displace motor – oil temp controller 22-12
Reflux line from oil temperature controller to the radiator and to the tank 22-14
Gearbox block – gearbox housing – gearbox parts 22-16
Gearbox (standard) 20 kph SO 1342/1 22-16
Gearbox block: gearbox housing – gearbox components –
Gear shift mechanism for high speed 22-22
Gearbox (high speed gearbox) 39 kph SO 1342 22-22
High speed circuit 22-28
Pressure line: variable displacement pump – solenoid valve A/P 22-28
Pressure line: solenoid valve – ram 22-28
Reflux line: solenoid valve – reflux line – differential lock 22-28
I-4 ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm
Table of contents
Parking brake
Service brake
Brake pedal – brake disc – component parts 24-2
Parking brake – component parts 24-2
Attachment: hand brake-cable pull 24-2
Brake valve – brake line – valves – pressure accumulator – pressure switch 24-6
Brake valve – cut-off valve 24-6
Pressure line: cut-off valve A2 – brake valve A11 – pressure accu and pressure switch 24-6
Pressure line: brake valve A 21 – var displace pump (inching) – double non-return valve 24-8
Pressure line: Double non-return valve – front axle (left and right) 24-8
Pressure line: output screw connection evT – brakes – rear axle (left and right) 24-10
Reflux line: brake valve A 51 – oil tank 24-10
Reflux line: hand brake valve – brake valve 24-10
Pressure line: hand brake valve – brake valve 24-12
Pressure line: double non-return valve – hand brake valve 24-12
Planetary steering axles
Component parts: axle – differential lock – steering ram 26-2
Rear axle – front axle 26-2
Component parts: axle – differential lock – steering ram 26-4
Component parts (bevel gear set) 26-4
Component parts (differential case) 26-8
Component parts: axle – differential lock – steering ram 26-10
Components parts: axle casing 26-10
Component parts for front axle only 26-14
Component parts – joint housing 26-16
Component parts for double cardan shaft 26-16
Component parts: axle – differential lock – steering ram 26-18
Component parts: output and brake 26-18
Component parts: steering ram 26-22
Differential lock control – hydraulic installation 26-24
Differential lock control 26-24
Pressure line – output pressure filter: solenoid valve – differential lock – front axle 26-24
Pressure line – output screw connection evT – differential lock – rear axle 26-24
Reflux line: solenoid valve – reflux line – oil tank 26-24
Table of contents
ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm I-5
Steering
Hydrostatic steering: hydraulic pump – solenoid valve – valves – oil pipes 27-2
Steering – component parts 27-2
Suction line: hydraulic oil tank – steering pump 27-2
Hydraulic pump for steering 27-2
Pressure line: steering pump – cut-off valve – steering 27-4
Pressure line: steering (output L) to check valve L 27-6
Pressure line: steering (output R) – to check valve R 27-6
Check valve A – change-over valve P – steering ram (rear right ) 27-6
Check valve S – change-over valve T – steering ram (rear left) 27-6
Anticavitation – steering ram – rear axle 27-8
Pressure line: check valve B – steering ram front axle L 27-8
Pressure line: check valve S – steering ram – front axle R 27-8
Hydrostatic steering: hydraulic pump – solenoid valve – valves – oil pipes 27-10
Reflux line: steering (output T) – to hydraulic oil filter 27-10
Reflux line: case flushing – variable displacement motor T2 – reflux line steering 27-10
Anticavitation line for steering 27-10
Reflux line: check valve – reflux line – brake valve 27-10
Steering synchronization 27-12
Component parts for check valve and solenoid valve 27-14
Component parts for check valve 27-14
Component parts for solenoid valve 27-14
Operator’s seat
Component parts: operator’s seat 29-2
Operator’s seat 29-2
Operator’s seat – component parts 29-2
Operator’s seat – optional component parts 29-2
Operator’s seat – leatherette upholstery 29-2
Operator’s seat – lower part 29-4
Component parts: seat adjustment 29-6
Seat adjustment – component parts 29-6
Sheet-metal parts
Cover plates – wheel cover (front and rear) 30-2
Sheet-metal parts 30-2
Rubber cover between wheel covers 30-4
Parts as per German road use registration for high speed gearbox SO 1067/4
(possibly necessary depending on the legal regulations of your country) 30-6
Tyres – snow chains
Standard tyres 31-2
Optional tyres 31-2
Snow chains SO 1295 09 for tyres 16/70-24 31-2
Exhaust system
Exhaust silencer – rear silencer – cover plate 32-2
Exhaust system – component parts 32-2
Attachment: exhaust silencer on the cab 32-2
I-6 ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm
Table of contents
Electrical system
Instrument panel – side console – telltales – switch 33-2
Front instrument panel – component parts 33-2
Instrument panel: side console – component parts 33-8
Headlight: switch – starter – alternator – battery cable 33-10
Vehicle lighting 33-10
Rear light on cab – SO 1380/00 33-10
Counterweight SO 580/04 33-10
Starter – alternator – battery 33-12
Steering synchronization 33-14
Wiring harnesses – component parts 33-16
Wiring harness: instrument panel (side console) 33-16
Wiring harness: instrument panel (front) 33-18
Main wiring harness 33-20
Front wiper 33-26
Washer system (front) 33-26
Wiper on the rear window 33-26
Washer system (rear) 33-26
Rotating beacon 33-28
Rotating beacon attached on the cab SO 01206/15 33-28
Additional light attached on the cab (front) – SO 01382/00 33-28
Electric equipment for front implement 33-30
Socket for external auxiliary starting 33-30
Engine preheater 220 V 33-30
Table of contents
ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm I-7
Cab
Cab: cab parts 34-2
Front window – rear window – exterior rearview mirror 34-2
Cab: component parts 34-2
Sealing on the cab (front) – mount 34-2
Rear window (upper) 34-4
Rear window (lower) 34-4
Cab doors 34-6
Cab doors (lower) 34-6
Cab doors (upper) 34-8
Detent for cab door (upper) 34-8
Component parts: cab – centre console – side console 34-10
Cab: component parts 34-10
Cab: roof 34-12
Cab – roof 34-12
Special roof with window and protective screen for fork lift truck SO 596 01 34-12
Roof with protective FOPS screen and aluminium roof hatch SO 596 02 34-12
Engine cover – component parts – attachment 34-14
Engine cover: attachment 34-14
Sheet-metal parts – insulating mat 34-16
Floor panels – insulating mat 34-16
Interior lining 34-20
Interior lining (rear – excavator desk and leg room) 34-20
Cab: attachment 34-22
Attachment: cab 34-22
Passenger’s seat (left) – SO 579 01 34-22
Folding seat 00579-03 34-22
I-8 ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm
Table of contents
Hydraulic system
Hydraulic pump drive – hydraulic pump for loader unit 36-2
Oil tank 36-2
Reflux filter 36-2
Breather 36-4
Suction line: oil tank – hydraulic pump for loader unit 36-4
Pressure line from hydraulic pump to control valve 36-4
Reflux line from control valve to oil tank 36-4
Micro port line: control valve 36-6
Control valve (component parts see page 36-18) 36-6
Hydraulic pump for rear excavator 36-8
Suction line: oil tank – hydraulic pump – rear excavator 36-10
Pressure line: hydraulic pump rear excavator – control valve rear excavator 36-10
Attachment: pressure line to the vehicle 36-10
Pressure transmission: control valve – pressure line rear excavator 36-10
Reflux line: rear excavator – oil tank 36-10
Component parts for control valves 36-12
Control valve actuation 36-12
Attachment: control valve 36-14
Component parts for control lever 36-16
Control valve – component parts 36-18
Pressure line: control valve – lift ram (raise) – solenoid valve B 36-20
Pressure line: control valve – lift ram (lower) – solenoid valve A 36-20
Pressure line: solenoid valve PB – pressure accumulator 36-22
Output: line – pressure accumulator – pressure relief valve 36-22
Reflux line: solenoid valve PA – pressure relief valve – reflux steering 36-22
Control: load stabilizer – with rocker switch on the instrument panel 36-22
Pressure line: control valve – tilt ram (tilt in) 36-24
Pressure line: control valve – tilt ram (dump out) 36-24
Pressure line: control valve – 3rd control circuit 36-26
Lift frame, tilt lever, tilt rod, bearings 36-28
Lift frame, lift frame bearing, lift and tilt ram bearing 36-28
Bearing: lift frame on vehicle frame 36-28
Attachment: lift ram on vehicle frame 36-28
Attachment: tilt ram on vehicle frame 36-28
Attachment: tilt rod on the tilt lever 36-30
Attachment: tilt ram on the rocker lever 36-30
Attachment: tilt lever and lift ram on the lift frame 36-30
Attachment: quickhitch facility on the lift frame 36-30
Attachment: quickhitch facility on tilt rod 36-30
Lift ram: tilt ram 36-32
Lift ram: component parts 36-32
Tilt ram – component parts 36-34
Quickhitch – hydraulic ram – hydraulic installation 36-36
Quickhitch 36-36
Hydraulic installation (control ram – quickhitch facility – lift frame) 36-36
Hydraulic ram on quickhitch facility Üy approximately March 2000 36-38
Hydraulic ram on quickhitch facility yÜ approximately April 2000 36-38
Table of contents
ET 616 66 En * Edition 1 0 * 61666e0100IVZ fm I-9
Restrictor unit on tilt ram 01388-00 36-40
Hose burst valve for lift ram 36-42
Hose burst valve for tilt ram 36-42
Hose burst valve with ball-type cock and cover for lift ram 36-44
Hose burst valve with ball-type cock and cover for tilt ram 36-44
Attachments for fork lift mast model 0126611 36-46
Cab heating
Heating and ventilation
Component parts for heater fan – feed and reflux line to engine 41-2
Cab heating 41-2
Cab heating D1L C Eberspächer 41-6
Vehicle heater 41-6
Buckets for
quickhitch facility
Bucket for Kramer quickhitch facility SO 01339-13/14 41/3-2
Bucket for Kramer quickhitch facility SO 10049-00 41/3-2
Lightweight material bucket for Kramer quickhitch facility SO 01339-15 41/3-2
Component parts of multipurpose bucket 41/3-4
Multipurpose bucket for Kramer quickhitch facility SO 01339-03/04 41/3-4
Hydraulic installation – hydraulic ram 41/3-6
Hydraulic installation: multipurpose bucket for Kramer quickhitch facility 41/3-6
Lift ram: version A 41/3-8
Lift ram, version B 41/3-10
Lifting devices for quickhitch facility
Pallet forks for Kramer quickhitch facility SO 01339-09/12 41/4-2
Pallet forks for Kramer quickhitch facility SO 01339-29 41/4-2
Pallet forks for Kramer quickhitch facility SO 10094-00 41/4-2
Tools, additional equipment and keys
Labels, trim strips 43-2
Labels for special oils 43-2
Tool kit 43-4
Key (state key no for all spare parts orders) 43-4
Safety package SO 1151/1 43-6
Antitheft protection 43-6
Additional equipment for application in an agressive environment 43-6