Wacker Neuson Dumper 3001 Service Manual_1000156004 – PDF DOWNLOAD

Wacker Neuson Dumper 3001 Service Manual_1000156004 – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson Dumper 3001 Service Manual_1000156004 – PDF DOWNLOAD

Language : English
Pages :214
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Wacker Neuson Dumper 3001 Service Manual_1000156004 – PDF DOWNLOAD

Important information on this service manual 1-1 3
Identification of warnings and dangers 1-2 3
Designated use and exemption from liability 1-3 3
Type labels and component numbers 1-4 3
Description of 3001F components (overview) 1-6 3
Description of 3001S components (overview) 1-7 3
Control stand overview 1-8 3
Instrument panel overview 1-9 3
Front skip maintenance prop 1-10 3
Swivel skip maintenance prop 1-10 3
Rollbar 1-11 3
Centre pivot prop 1-11 3
Locking the control levers 1-12 3
Battery master switch 1-12 3
Chassis 2-1 3
Engine 2-1 3
Travelling drive 2-2 3
Brakes 2-2 3
Steering system 2-2 3
Work hydraulics 2-3 3
Skip 2-3 3
Drive specifications 2-3 3
Vibration 2-3 3
Electric system 2-4 3
Tyres 2-5 3
Noise levels 2-5 3
Coolant compound table 2-5 3
General tightening torques 2-6 3
Dimensions model 3001 front skip 2-10 3
Dimensions model 3001 swivel skip 2-11 3
Fluids and lubricants 3-1 3
Maintenance plan (overview) 3-3 3
Service package 3-6 3
Introduction 3-6 3
Fuel system 3-7 3
Engine lubrication system 3-11 4
Cooling system 3-15 4
Air filter 3-18 4
V-belt 3-20 4
Hydraulic system 3-22 4
Lubrication points 3-26 4
Tyres 3-27 4
Changing wheels 3-28 4
Axles 3-29 4
Electric system 3-30 4
Battery master switch 3-33 4
General maintenance work 3-34 4
3TNV88-KNSV engine: overview 4-1 4
Fuel system (up to AB) 4-3 4
Fuel system (starting AC) 4-4 4
Checking the injection nozzles 4-7 4
Adjusting engine revs 4-9 4
Compression 4-9 4
Checking the coolant thermostat 4-10 5
Oil pressure switch 4-11 5
Checking the coolant circuit 4-11 5
Clutch 4-12 5
Engine 3TNV88-BKNSV overview (from serial no AE310242D) 4-13 5
Fuel system (from serial no AE310242D) 4-15 5
Checking the injection nozzles 4-18 5
Adjusting engine revs 4-20 5
Automatic revs setting option (Tier 3A from AE310242D) 4-20 5
Compression 4-22 5
Checking the coolant thermostat 4-22 5
Oil pressure switch 4-23 5
Checking the coolant circuit 4-23 5
Clutch 4-24 5
Engine trouble 4-24 5
Variable displacement pump A10VG45DA 5-1 5
A6VM80EZ hydraulic motor 5-7 5
Travelling drive overview (up to AB) 5-8 5
Travelling drive overview (starting AC) 5-8 5
Towing and transporting the machine 5-9 5
Test instruction 5-10 5
Adjustment 5-13 5
Axle type label 6-1 5
Drain, fill and check plug 6-2 5
Tightening torques 6-2 5
Articulated joint (up to AB) 6-4 5
Articulated joint (starting AC) 6-6 5
Transfer gearbox (up to AD) 6-8 5
Transfer gearbox (from AE310242D) 6-10 5
Semiaxles 6-12 5
Wheel hub 6-14 5
Front axle brake (up to AB) 6-16 5
Brake diagram 6-17 6
Front axle brake (starting AC up to AD) 6-20 6
Front axle brake (from AE310242D) 6-21 6
Differential (up to AB) 6-23 6
Cardan shaft 6-32 6
Brake circuit (up to AB) 7-1 6
Brake circuit (starting AC) 7-2 6
Steering circuit (up to AB) 8-1 6
Steering circuit (starting AC) 8-2 6
Steering unit: diagram 8-3 6
Steering unit connections 8-4 6
Steering unit overview 8-5 6
Manual spool connections: overview 9-1 6
Valves – differential lock (up to AB) 9-2 6
Dumping the skip: hydraulic diagram (up to AB) 9-3 6
Dumping the skip: hydraulic diagram (starting AC) 9-4 6
Swivelling the skip: hydraulics diagram (up to AB) 9-5 6
Swivelling the skip: hydraulics diagram (starting AC) 9-6 6
Test instructions 9-7 6
Diagram A4 (up to AB) 9-8 6
Diagram legend (up to AB) 9-9 6
Diagram A4 (starting AC) 9-10 6
Diagram legend (starting AC) 9-11 6
Ohm’s Law (current, voltage, resistance); power 10-1 6
Measuring equipment, measuring methods 10-1 6
Relays 10-2 6
Electric units 10-3 6
Control stand overview 10-4 6
Instrument panel overview 10-5 6
Wiring diagram (legend) 10-7 6
Wiring diagram version 1 A4 10-8 6
Wiring harness 1000115009 main wiring harness up to AB (legend) 10-9 6
Wiring harness 1000115009 main wiring harness up to AB 10-11 6
Wiring harness 1000173558 main wiring harness starting AC (legend) 10-12 6
Wiring harness 1000173558 main wiring harness starting AC 10-14 6
Wiring diagram A3 up to AB (legend) 10-16 6
Wiring diagram A3 (up to AB) 10-17 7
Wiring harness 1000115009 main wiring harness up to AB (legend) 10-18 7
Wiring harness 1000115009 main wiring harness up to AB 10-19 7
Wiring harness 1000173558 main wiring harness starting AC (legend) 10-20 7
Wiring harness 1000173558 main wiring harness starting AC 10-21 7
Wiring harness 1000115414 engine wiring harness (legend) 10-22 7
Wiring harness 1000115414 engine wiring harness 10-23 7
Wiring harness 1000075039/1000079012 telltale/indicator base – ignition lock base up to AB (legend) 10-24 7
Wiring harness 1000075039 telltale/indicator base (up to AB) 10-25 7
Wiring harness 1000173351 ignition lock base starting AC 10-26 7
Light switch connector assignment 10-27 7
Legend and STVO wiring harness (Austrian road traffic regulations) 1000166512 (starting AC) 10-28 7
Extension cable (front skip) 1000166698 10-29 7
Operation 9
1 Operation 11
11 Important information on this service manual 11
12 Identification of warnings and dangers 12
13 Designated use and exemption from liability 13
14 Type labels and component numbers 14
15 Description of 3001F components (overview) 16
16 Description of 3001S components (overview) 17
17 Control stand overview 18
18 Instrument panel overview 19
19 Front skip maintenance prop 20
110 Swivel skip maintenance prop 20
111 Rollbar 21
112 Centre pivot prop 21
113 Locking the control levers 22
114 Battery master switch 22
Specifications 23
2 Specifications 25
21 Chassis 25
22 Engine 25
Engine capacities 26
Engine tightening torques 26
23 Travelling drive 26
24 Brakes 26
25 Steering system 26
26 Work hydraulics 27
27 Skip 27
28 Drive specifications 27
29 Vibration 27
210 Electric system 28
Fuse box 28
Relays 28
211 Tyres 29
212 Noise levels 29
213 Coolant compound table 29
214 General tightening torques 30
Tightening torques for hydraulic screw connections (dry assembly) 30
Tightening torques for high-resistance screw connections 32
Tightening torques for Nordlock lock washers 33
215 Dimensions model 3001 front skip 34
216 Dimensions model 3001 swivel skip 35
Maintenance 37
3 Maintenance 39
31 Fluids and lubricants 39
32 Maintenance plan (overview) 41
33 Service package 44
Up to serial no 44
From serial no AE310242D 44
34 Introduction 44
35 Fuel system 45
Specific safety instructions 45
Refuelling 45
Stationary fuel pumps 46
Diesel fuel specification 46
Bleeding the fuel system 46
Fuel prefilter with water separator 47
Replacing the fuel filter 48
36 Engine lubrication system 49
Checking the oil level 49
Filling up engine oil 50
Changing engine oil 51
Replacing the engine oil filter cartridge 52
37 Cooling system 53
Specific safety instructions 53
Checking/filling up coolant 54
Draining coolant 55
38 Air filter 56
Replacing the filter 57
Functional check once a week of the dust valve 57
39 V-belt 58
Checking V-belt tension 58
Retightening the V-belt 59
310 Hydraulic system 60
Specific safety instructions 60
Checking the hydraulic oil level 61
Filling up hydraulic oil 61
Changing hydraulic oil 62
Fouling indicator for hydraulic oil filter 62
Replacing the hydraulic oil filter element 62
Checking hydraulic pressure lines 63
311 Lubrication points 64
312 Tyres 65
Inspection work 65
313 Changing wheels 66
Removing the wheels 66
Fitting the wheels 66
314 Axles 67
Checking the oil level and filling up oil 67
Draining oil 67
315 Electric system 68
Specific safety instructions 68
Service and maintenance work at regular intervals 68
Instructions concerning specific components 69
Alternator 69
Battery 70
316 Battery master switch 71
317 General maintenance work 72
Cleaning 72
General instructions for all areas of the machine 72
Screw connections and attachments 72
Pivots and hinges 72
Engine 73
4 Engine 75
41 3TNV88-KNSV engine: overview 75
42 Fuel system (up to AB) 77
43 Fuel system (starting AC) 78
Checking and adjusting valve clearance 79
Tightening order for cylinder head bolts 80
44 Checking the injection nozzles 81
Pressure check 81
Checking the nozzle jet 81
Injection time 82
45 Adjusting engine revs 83
46 Compression 83
47 Checking the coolant thermostat 84
Checking the thermal switch 84
48 Oil pressure switch 85
49 Checking the coolant circuit 85
410 Clutch 86
411 Engine 3TNV88-BKNSV overview (from serial no AE310242D) 87
412 Fuel system (from serial no AE310242D) 89
Checking and adjusting valve clearance 90
Tightening order for cylinder head bolts 91
413 Checking the injection nozzles 92
Pressure check 92
Checking the nozzle jet 92
Injection time 93
414 Adjusting engine revs 94
415 Automatic revs setting option (Tier 3A from AE310242D) 94
Function 94
Installation 95
416 Compression 96
417 Checking the coolant thermostat 96
Checking the thermal switch 97
418 Oil pressure switch 97
419 Checking the coolant circuit 97
420 Clutch 98
421 Engine trouble 98
Travelling drive 99
5 Travelling drive101
51 Variable displacement pump A10VG45DA101
Variable displacement pump: diagram103
Variable displacement pump: design104
Travelling drive overview105
Connecting plate with valves106
52 A6VM80EZ hydraulic motor107
53 Travelling drive overview (up to AB)108
54 Travelling drive overview (starting AC)108
55 Towing and transporting the machine109
Safety instructions109
Towing109
Opening the high-pressure circuit109
56 Test instruction110
High pressure check110
Check: boost pressure111
Check: setting pressure112
57 Adjustment113
Setting: control initiation113
Axles115
6 Axles117
61 Axle type label117
62 Drain, fill and check plug118
63 Tightening torques118
Wheel screws118
General tightening torques119
64 Articulated joint (up to AB)120
65 Articulated joint (starting AC)122
66 Transfer gearbox (up to AD)124
67 Transfer gearbox (from AE310242D)126
68 Semiaxles128
69 Wheel hub130
610 Front axle brake (up to AB)132
611 Brake diagram133
612 Front axle brake (starting AC up to AD)136
613 Front axle brake (from AE310242D)137
614 Differential (up to AB)139
Front axle (up to AB)141
Front axle (starting AC up to AD)143
Rear axle146
615 Cardan shaft148
7 Brakes151
71 Brake circuit (up to AB)151
72 Brake circuit (starting AC)152
Parking brake152
Service brake154
Steering system155
8 Steering system157
81 Steering circuit (up to AB)157
82 Steering circuit (starting AC)158
83 Steering unit: diagram159
Function159
84 Steering unit connections160
85 Steering unit overview161
Priority valve overview161
Priority valve (legend)161
Steering unit162
Steering unit (legend)163
9 Hydraulic system167
91 Manual spool connections: overview167
92 Valves – differential lock (up to AB)168
Check valve168
93 Dumping the skip: hydraulic diagram (up to AB)169
94 Dumping the skip: hydraulic diagram (starting AC)170
95 Swivelling the skip: hydraulics diagram (up to AB)171
96 Swivelling the skip: hydraulics diagram (starting AC)172
97 Test instructions173
Check: work hydraulics173
98 Diagram A4 (up to AB)174
99 Diagram legend (up to AB)175
910 Diagram A4 (starting AC)176
911 Diagram legend (starting AC)177
10 Electric system183
101 Ohm’s Law (current, voltage, resistance); power183
102 Measuring equipment, measuring methods183
103 Relays184
Use, mode of function184
104 Electric units185
Fuse box185
Relays185
105 Control stand overview186
106 Instrument panel overview187
107 Wiring diagram (legend)189
108 Wiring diagram version 1 A4190
109 Wiring harness 1000115009 main wiring harness up to AB (legend)191
1010 Wiring harness 1000115009 main wiring harness up to AB193
1011 Wiring harness 1000173558 main wiring harness starting AC (legend)194
1012 Wiring harness 1000173558 main wiring harness starting AC196
107 Wiring diagram A3 up to AB (legend) 0
108 Wiring diagram A3 (up to AB) 0
109 Wiring harness 1000115009 main wiring harness up to AB (legend) 0
1010 Wiring harness 1000115009 main wiring harness up to AB 0
1011 Wiring harness 1000173558 main wiring harness starting AC (legend) 0
1012 Wiring harness 1000173558 main wiring harness starting AC 0
1013 Wiring harness 1000115414 engine wiring harness (legend) 0
1014 Wiring harness 1000115414 engine wiring harness 0
1015 Wiring harness 1000075039/1000079012 telltale/indicator base – ignition lock base up to AB (legend) 0
1016 Wiring harness 1000075039 telltale/indicator base (up to AB) 0
1017 Wiring harness 1000173351 ignition lock base starting AC 0
1018 Light switch connector assignment 0
1019 Legend and STVO wiring harness (Austrian road traffic regulations) 1000166512 (starting AC) 0
1020 Extension cable (front skip) 1000166698 0

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