3410 3411 H179Service Training

Service Training
3410-3411
Release 2011-07-18
SERVICE TRAINING
H179
EN
2128428
3410-3411
SERVICE TRAINING
H179
EN
2128428
3410-3411
SERVICE TRAINING
EN
H179
2128428
3410-3411
01 - View
02 - Operator´s manual / maintenance
03 - Illustrations - mechanics
04 - Illustrations - electrics
05 - Illustrations hydraulics
06 - Electric circuit diagrams
07 - Hydraulic circuit diagrams
08 - Manuals
09 - Suppliers documentation
10 - Machine data
11 - Transportation data
12 - Appendix
a
Drive diagram – 3000 series
# 2067359
3205 – 3307
Hydraulic-Training 1/3
# 2067359
3410 – 3520 HT
# 2067359
3625 HT
View 3410-3411 – H179
# 2114845
List of types „Series 3000“

H188 H189 H179 H180 H176 H177
3205 3307 3410 3412 3516

STANDARD
3411 3414 3518

3520
3205 P 3307 P 3410 P 3412 P 3516 P
3411 P 3414 P 3518 P
3520 P
3307 VIO 3412 VIO
3414 VIO
3307 HT 3412 HT 3516 HT 3625 HT

HAMMTRONIC
3414 HT 3518 HT
3520 HT
3307 HT P 3412 HT P 3516 HT P

3414 HT P 3518 HT P
3520 HT P
3307 HT VIO 3412 HT VIO
3414 HT VIO
View 1 / 17
View 3410-3411 – H179
# 2114845
Type designation e.g. 3307
HAMMTRONIC
Operating weight [t]
Vibration- / Oscillation drum
Assembly
Series 3000
3307 HT VIO
P Padfoot
A Asphalt version
View 2 / 17
View 3410-3411 – H179
# 2114845
View of the machine from the left
Vibration drive
(optional vib.
frequency sensor)
View 3 / 17
View 3410-3411 – H179
# 2114845
Vibration motor
High pressure port A
High pressure port B
Leakage
Integrated
scavenge valve
View 4 / 17
View 3410-3411 – H179
# 2114845
View of the machine from the right

Drum drive motor (2 versions)
Axle drive -radial piston (2-speed)
motor (2-speed) -axial piston (2-speed) with
(optional speed sensor) reduction transmission
Axle with self
locking differential
Switch box
Battery box
View 5 / 17
View 3410-3411 – H179
# 2114845
Drum drive motors
Version 1 (radial piston motor) Version 2 (axial piston motor)
Scavenge valve in engine compartment Integrated

(next to brake release valve, page 12/17) scavenge valve
View 6 / 17
View 3410-3411 – H179
# 2114845
3410 - 3414
Diesel engine
Machinen type
3410-3414
Engine type TCD 2012 L04 2V

Cooling system Water
Engine output ISO 9249 100 kW
(136 HP)
Cubic capacity 4038 cm³
Max. torque 520 Nm
TCD 2012 L04 2V

Valves per cylinder
Number of cylinders
In-line engine
Stroke [cm]
Series
Diesel
Intercooled
Turbocharged
View 7 / 17
View 3410-3411 – H179
# 2114845
Engine (cooling air duct)
• Air intake on the highest Cooling air

point of the engine hood intake
• Long sound absorbing
distance
• No heat short circuit
Intercooler
• High cooling
performance
• Longevity of components Water cooler
• Low noise level
• Free access to the Exhaust
coolers Noise absorbing
bulkhead
Hydraulic oil cooler
View 8 / 17
View 3410-3411 – H179
# 2114845
Engine compartment (left side) 3410-3411 Coolant compensator tank
Coolant level sensor
Engine oil filter
Fuel pump
Engine oil filler neck
Twin fuel filter
Test port and refill connection

steering pump
Central plug for Steering and max. 175 bar
engine electric feed pump
View 9 / 17
View 3410-3411 – H179
# 2114845
Engine compartment (left side) 3410-3411

Filter indicator main filter
Manual pump / fuel
Main filter for drive

and vibration system
Fuel pre-filter with

water separator
Water level sensor

fuel pre-filter
Vibration Drive pump Test ports

feed pressure
pump
View 10 / 17
View 3410-3411 – H179
# 2114845
Engine compartment (right side) 3410-3411 Breather for fuel tank
Connection plugs
for cabin
Emergency-Stop-Solenoid
Main fuses (drive pump)
F1 (100A) – el system cl.30, starter relay
F2 (100A) – generator B+ Starter relay
F3 (150A) – cold start device
F4 – reserve Relay cold start device
View 11 / 17
View 3410-3411 – H179
# 2114845
Engine compartment (right side) 3410-3411 Bowden cable

Scavenge valve (drive) drive control
(valid for drum drive version
„radial piston motor“ only)
Drive pump Cooler bypass (2bar)
Brake release valve

Cold start valve (27bar)
Brake pressure Hydraulic oil
switch temp. sensor
Proximity switch
Backup Alarm
Brake solenoid
Vibration pump Collector block - hydraulic fluid

Solenoids: low pressure return and charge pressure system
Y1 – small Amp.
Y2 – big Amp.
View 12 / 17
View 3410-3411 – H179
# 2114845
Sensors on wire harness - machine (to mainboard plugs X19, X27→D1X1)
Water inside fuel Coolant level Air filter pollution

pre-filter
DEUTZ EMR3
Engine rpm director Atmospheric pressure sensor

View 13 / 17
View 3410-3411 – H179
# 2114845
Sensoren on wire harness - diesel engine (to EMR3 plug D1X2)
Eng. speed crankshaft Eng. speed camshaft Boost air pressure / temp. Oil pressure
Coolant temperature Low fuel pressure, FCU Rail pressure
View 14 / 17
View 3410-3411 – H179
# 2114845
Fuses, relays, connectors Wire harness

Wire harness engine dashboard
compartment X1, X2, X3
X5, X6, X7 Relay K1
Wire harness control unit diesel
cabin X10, X11 engine
Wire harness EMR3
Potentiometer
Relay K5 -
engine speed
driving light
Wire harness Relay K6 -
front roller X9 parking brake
Relay K7 -
Backup-Alarm Relay K10 -
start release
Connection plug and
mounting place for Relay K13 -
compaction meter vibration release
Wire harness Diagnose port

compaction meter DEUTZ SERDIA
X13, X21
Hand pump for
High current relay K15 –
Relay K100 - engine hood
main power supply EMR3 diagnose
heating fan Vibration
push-button with LED
relay on/off
EMR3 mounted on backside of PCB!
View 15 / 17
View 3410-3411 – H179
# 2114845
EMR3 error code Air filter polluted
Engine oil pressure Charge indicator lamp
Hydraulic oil filter
polluted
Water inside the Preheating
fuel pre-filter
Hazard warning lights
Low coolant level
Turn indicator
Hourmeter
Parking brake
Compaction
meter
Hydraulic oil
temperature
Engine
temperature Warning lamp
jump mode
Fuel level indicator Low hydraulic
Vibration frequency oil level
Dashboard completely populated with all options! Drive speed
Options see operator´s manual! Engine speed
View 16 / 17
View 3410-3411 – H179
# 2114845
Operating elements Hazard warning lights Traction control

Amplitude
pre-selection
Signal horn
Gear shifting
Dashboard (right side)

Dashboard (left side) Levelling blade up
Levelling blade down
Vibration (on / off)
Drop-arm switch – Drive lever Potentiometer –

Driving lights and turning signal engine speed adjustment
View 17 / 17
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
OPERATING MANUAL
3410 ● 3410 P ● 3411 ● 3411 P
H179 1207
Series valid from serial no.
20.01.2011
Date of first issue
2180528 en
Order number Language
© HAMM AG 2011 Version 00.1

Publisher HAMM AG
Postfach 1160
95633 Tirschenreuth
Germany
Phone: +49 (0) 96 31 / 80-0
http://www.hamm.eu
Name of the document 2180528_00_BAL_3410-11_H179_en

Original operating manual
Date of first issue 20.01.2011
Date of change 20.01.2011
Copyright © HAMM AG 2011
The disclosure as well as the duplication of this document, the use and
the forwarding of its contents, are forbidden as far as not expressively
permitted. Violations will cause indemnities. With respect to patent, utility
sample or design patent registration all rights reserved.
612-01
2 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

This operating manual is valid for the following roller types:
COMPACTOR 3410
3410 P
3411
3411 P
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 3

Table of contents
TABLE OF CONTENTS
1 General..................................................................................................................... 9
1.00 Introduction........................................................................................................9
1.00.01 Preface to the operating manual...........................................................................................9
1.00.02 Product information............................................................................................................... 9
1.00.03 Guarantee............................................................................................................................ 10
1.00.04 Modifications / reservations................................................................................................. 10
1.00.05 Packaging and storage....................................................................................................... 10
1.00.06 Signs and symbols.............................................................................................................. 10
1.00.07 Signal words........................................................................................................................ 11
1.01 Documentation.................................................................................................12
1.02 Use.................................................................................................................... 13
1.02.01 Intended use........................................................................................................................13
1.02.02 Reasonably forseeable misuse........................................................................................... 14
1.02.03 Residual risks...................................................................................................................... 14
1.02.04 Climatic conditions...............................................................................................................15
1.03 Environmental protection............................................................................... 16
1.04 Disposal............................................................................................................16
1.05 EC confirmity................................................................................................... 17
1.06 Type plate......................................................................................................... 18
1.07 Noise and vibration requirements.................................................................19
1.08 Personnel......................................................................................................... 21
1.08.01 Qualification and duties....................................................................................................... 21
1.09 General safety instructions............................................................................22
1.10 Danger zone.....................................................................................................23
1.11 Loading and transport.................................................................................... 24
1.12 Stickers on the machine................................................................................ 26

1.12.01 Warning labels..................................................................................................................... 26
1.12.02 Information sign................................................................................................................... 31
2 Description............................................................................................................. 36
2.00 Technical characteristics of the machine.....................................................36
4 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Table of contents
2.01 General view of machine................................................................................37

2.01.01 Chassis / safety devices......................................................................................................37
2.01.02 Control stand....................................................................................................................... 38
2.01.04 Drive unit / diesel engine.....................................................................................................40
2.01.05 Hydraulic oil supply............................................................................................................. 41
2.01.06 Electrical equipment............................................................................................................ 41
2.01.08 Drive.....................................................................................................................................42
2.01.09 Steering system...................................................................................................................42
2.01.26 Vibration............................................................................................................................... 43
2.02 General view of instruments and operating elements................................ 44

2.02.02 Control stand....................................................................................................................... 44
2.02.04 Drive unit / diesel engine.....................................................................................................50
2.02.05 Electrical system..................................................................................................................51
3 Operation................................................................................................................52
3.00 Instruments and operating elements............................................................ 52
3.00.01 Indicators, displays.............................................................................................................. 52
3.00.02 Pilot lights............................................................................................................................ 54
3.00.03 Switch.................................................................................................................................. 60
3.00.04 Sockets, lights..................................................................................................................... 67
3.00.05 Operation levers, adjustment handles.................................................................................68
3.01 Prior to machine start.....................................................................................72
3.02 Engine start......................................................................................................74
3.03 Driving.............................................................................................................. 76
3.04 Driving with vibration..................................................................................... 78
3.05 Stopping, switching off engine, leaving machine........................................80
3.06 Operation monitoring......................................................................................82
3.07 Scraper............................................................................................................. 83
3.08 Starting with jump leads................................................................................ 84
3.09 Towing...............................................................................................................85
3.10 Heating / ventilation / cooling........................................................................ 89
3.11 Open and close engine hood........................................................................ 91
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 5

Table of contents
4 Maintenance........................................................................................................... 93
4.00 General maintenance instructions................................................................ 93
4.00.01 Operation monitoring........................................................................................................... 93
4.00.02 Maintenance overview.........................................................................................................93
4.00.03 Running-in regulations.........................................................................................................96
4.00.04 Required maintenance parts............................................................................................... 97
4.00.05 Important information about maintenance works................................................................ 98
4.00.06 Safety strut........................................................................................................................ 100
4.00.07 Welding works on the machine.........................................................................................101
4.01 Chassis / safety features.............................................................................. 103

4.01.01 General.............................................................................................................................. 103
4.01.02 Checking the function of the parking brake...................................................................... 103
4.01.03 Checking the EMERGENCY STOP function.................................................................... 104
4.01.04 Lubricating hinges of the engine hood..............................................................................105
4.01.05 Lubricating hinges of the electric box............................................................................... 106
4.02 Control stand................................................................................................. 107

4.02.01 *Air conditioning.................................................................................................................107
4.02.02 Replacing fresh air filter of the operator's cabin............................................................... 108
4.02.03 Checking fill level of the windscreen washer.................................................................... 108
4.04 Drive unit - diesel engine............................................................................. 109

4.04.01 General.............................................................................................................................. 109
4.04.02 Maintenance points at the Diesel engine when changing oil............................................ 110
4.04.03 Changing the filter cartridge for the fuel pre-filter............................................................. 111
4.04.04 Replacing ventilation filter for fuel tank.............................................................................112
4.04.05 *Draining water separator..................................................................................................113
4.04.06 *Cleaning / replacing filter insert of the dirt and water separator...................................... 114
4.04.07 Checking and cleaning dust discharge valve....................................................................115
4.04.08 Checking and replacing the air filter................................................................................. 116
4.04.09 Changing the safety cartridge........................................................................................... 117
4.04.10 Checking radiator.............................................................................................................. 118
4.04.11 Checking coolant level...................................................................................................... 119
4.04.12 Changing coolant...............................................................................................................119
4.05 Hydraulic oil supply...................................................................................... 121

4.05.01 General.............................................................................................................................. 121
4.05.02 Checking hydraulic oil level...............................................................................................121
4.05.03 Replacing hydraulic oil...................................................................................................... 122
6 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Table of contents
4.05.04 Replacing ventilation filter for hydraulic oil tank................................................................123

4.05.05 Replacing filter insert of pressure filter for hydraulic system............................................ 123
4.05.06 Replacing filter insert of pressure filter for steering system.............................................. 124
4.08 Drive................................................................................................................125
4.08.01 Inspecting smooth drum scrapers..................................................................................... 125
4.08.02 Inspecting scrapers of stamping feet drum.......................................................................126
4.08.03 Checking the wheel nuts / wheel bolts for tightness.........................................................126
4.08.09 Checking the air pressure in the tyres..............................................................................127
4.08.10 Changing the tyres............................................................................................................ 128
4.08.11 Checking driving gear oil level.......................................................................................... 129
4.08.12 Changing driving gear oil.................................................................................................. 130
4.08.13 Checking differential gear oil level.................................................................................... 131
4.08.14 Changing differential gearbox oil.......................................................................................132
4.09 Steering system.............................................................................................133

4.09.01 General.............................................................................................................................. 133
4.09.02 Lubricating pivoted bearing............................................................................................... 133
4.09.03 Lubricating steering cylinder bolt...................................................................................... 134
4.26 Vibration / oscillation.................................................................................... 135

4.26.01 General.............................................................................................................................. 135
4.26.02 Checking vibrator oil filling level........................................................................................135
4.26.03 Changing vibrator oil......................................................................................................... 136
4.26.04 Checking damping elements............................................................................................. 137
5 Tables....................................................................................................................138
5.00 Technical data................................................................................................138
5.00.01 Lubrication indications....................................................................................................... 138
5.00.02 Use of biologic hydraulic oil.............................................................................................. 139
5.00.03 Wirtgen Group Lubricants................................................................................................. 140
5.00.04 Coolant conditioning.......................................................................................................... 143
5.00.05 Fuel.................................................................................................................................... 145
5.00.06 Starting torques................................................................................................................. 146
5.01 Technical data................................................................................................147

5.01.01 3410................................................................................................................................... 147
5.01.02 3410 P............................................................................................................................... 149
5.01.03 3411................................................................................................................................... 151
5.01.04 3411 P................................................................................................................................153
5.02 Dimension sheet............................................................................................155
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 7

Table of contents
5.02.01 3410, 3411......................................................................................................................... 155

5.02.02 3410 P, 3411 P..................................................................................................................155
5.03 Fuses.............................................................................................................. 156

5.03.01 Main fuses......................................................................................................................... 156
5.03.02 Fuses, electrical box..........................................................................................................156
5.03.03 Fuses, operator's cabin..................................................................................................... 157
6 Assembly instructions........................................................................................158
6.00 Instructions for installation and retrofitting............................................... 158
6.00.01 Safety device ROPS cabin................................................................................................158
6.00.02 Safety device ROPS roll-over bar.....................................................................................160
8 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

General
Introduction
1 GENERAL
When working at the machine please always adhere to the
instructions given in your Safety instructions!
000-01
1.00 Introduction
1.00.01 Preface to the operating manual
This chapter contains important instructions for the operating personnel
on how to operate the machine and to use this operating manual.
This operating manual helps you:

to become familiar with the machine.
to avoid malfunctions due to improper use.
Adhering to this operating manual:

helps to avoid risks.
increases the reliability when working on the construction site.
increases the life span.
reduces maintenance costs and downtimes.
It is absolutely necessary to adhere to this operating manual, the

instructions given in the safety instructions, supplementary information
and all regulations and provisions applying at the building site (e.g.
accident prevention regulations).
Maintenance and care of the diesel engine have to be performed
according to these motor instructions. Any safety notes have to be
followed.
609-08
1.00.02 Product information

You have purchased a HAMM Quality product. All parts of this machine
have been checked and tested carefully, thus corresponding to the
quality you expect.
The reliability of the machine is preserved through correct use and
careful maintenance. This includes the use of the specified operating
supply items and the use of original HAMM spare parts.
Our representations will help you to keep your roller in perfect operating
condition.
Our representations will be at your disposal whenever you need
consultation and service even after the warranty period. They will supply
you with our original HAMM spare parts which do not only meet the
technical requirements but also ensure exchangeability and quality.
The safety, operating and maintenance instructions given in this
operating manual are intended for the operating personnel. Thus, keep
this manual always at hand!
609-06
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 9

General
Introduction
1.00.03 Guarantee
No guarantee claims with:
operating errors.
in the case the spare parts used are no original HAMM spare parts.
in the case wrong operating supply items have been used.
in the case any additional devices have been refitted an/or installed
that have not been approved by HAMM.
in the case of deficient maintenance.
in the case of any processes that conflict with these operating
manual.
609-07
1.00.04 Modifications / reservations

We are committed to provide you with correct and updated operating
manual. However, we cannot guarantee the correctness of all data
given. To be able to keep pace with changing trends, it may be
necessary to amend or modify the product and/or its operating console
without prior notice. We assume no liability for malfunctions, downtimes
and resulting damage.
609-09
1.00.05 Packaging and storage

We have carefully packed our products to ensure proper protection in
transit. Please check both packaging and the goods yourselv for any
damage upon reception of your goods. In the case of damage, the
devices must not be put into operation. Damged cables and connections
are a safety risk and must not be used.
In such a case, please contact your supplier.
If the devices are not put into operation upon unpacking, they must be
protected against humidity and dirt.
609-10
1.00.06 Signs and symbols

The signs and symbols used in this operating manual are to help you
use this operating manual and the device in a safe and fast manner.
Note Informs about application hints and useful information. No

dangerous or harmful situation.
Enumeration Indicates a listing of issues or possibilities.
Operating steps Are listed according to their succession each starting from 1 for
each individual process.
Option Indicates special equipment which varies from the standard.
10 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

General
Introduction
Directions Information on directions contained in these instructions such as left or

right and/or front or rear always refer to the directions of the machine
driving forwards.
Cross-references Cross-references help you to find quickly sections in this operating

manual which supply you with additional important information. The
cross-reference shows you the page of the relevant section. The
abbreviation sqq. means "and the following pages".
Example: (see page 134 sqq.)
Positioning of illustrations The positions of illustrations are represented with letters and numbers.
The positions identified with letters in alphabetical order are only
explained in the corresponding text segment, beginning new for each
single figure. The positions marked with numbers apply to operating
elements, control units and switches. They are identical to the numbers
in the section Overview of Instruments and Operating Elements (see
page 44 sqq.). These numbers in squared brackets are used
as a reference in the description of the elements. Amongst others,
this ensures that important and additional information can be found
immediately and without difficulties in the descriptions of the elements.
The end of the positioning line is marked as dot or arrow. In the
illustration the dot marks a visible element and an arrow an invisible
element which is in arrow direction.
Example
Legend
[A] Driver [B] Engine compartment
Descriptive text
The drive lever [501] determines the direction of travel and the speed.
Using the lever [520] you can adjust the pretension of the attenuation
system to the driver's weight.
609-11
1.00.07 Signal words

A signal word identifies a source of dangers and residual risks.
609-12
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 11

General
Documentation
DANGER!
Identifies immediate danger. If this risk is not prevented, this causes
death or severe personal injuries.
001-01
WARNING!
Refers to situations that may be dangerous. If this situation is not
avoided, fatality or very serious injuries may be caused.
002-01
CAUTION!
Refers to situations that may be dangerous. If this situation is not
avoided, minor or light injuries may be caused.
003-01
NOTICE
Refers to a situation that may cause property damage.
004-01
1.01 Documentation
This operating manual is intended to make the operating personnel
familiar with basic work steps / activities of and with the machine.
The entire operating manual consists of:

Safety instructions
Operating manual of the machine
Operating manual of the diesel engine
If necessary, additional information
The entire operating manual must always be available at the machine

and be accessible to the authorized operating personnel at all times.
Prior to operating the machine, you must have carefully read und
understood this operating manual. In case you do not understand this
operating manual or individual chapters, please ask us prior to starting
these activities. The operating manual includes valuable information in
order to operate the machine safely, appropriately and economically.
613-00
12 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

General
Use
1.02 Use
1.02.01 Intended use
The machine represents state-of-the-art technology and complies with
all valid safety regulations concerning its intended use at the time the
machine was launched on the market.
When designing the machine it was not possible to avoid forseeable
misuse or residual risks without restricting the machine's intended
functionality.
The maschine's intended use is:

pave roads and traffic areas.
ramming and smoothing of loose earth, road bedding, pavement or
similar ramable subgrade in layers.
The machine may only be deployed on surfaces that can support it.
Subgrade not capable of bearing is e.g. high fillings, batters, roadside
ditches.
The machine must not be used with explosive areas, on landfill sites
and with mining.
The machine is only intended for commercial applications within fenced
construction sites.
The machine must be operated by authorised operating personnel only if
in proper technical condition and according to this operating manual.
All unintended uses and/or all machine-related activities not described in
this operating manual are to be deemed as unauthorised misuse outside
the legal limits of indemnity of the manufacturer.
611-01
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 13

General
Use
1.02.02 Reasonably forseeable misuse

In the case of reasonably forseeable misuse and/or improper use of the
machine, the manufacturer's warranty period will expire and the operator
will solely be responsible.
Reasonably forseeable misuse is:
Non-compliance with this operating manual.
Operating errors by operating personnel not qualified or instructed.
Conveyance of passangers.
Leaving the driver's position during operation.
Starting, using the machine outside the driver's position.
Errors due to "reflexive behaviour" and/or "chosing the easiest way".
Operating the machine if it is not in a proper technical condition.
Using the machine with improper ambient conditions (e.g.
temperature, gradient, cross slope).
Using the machine with the protective equipment removed.
Spraying with high-pressure cleaners or fire extinguishing equipment.
Towing trailing loads.
Non-compliance with maintenance intervals.
Omission of measurements and tests to detect damages early.
Omission of replacing wear parts.
In the case the spare parts used are no original HAMM spare parts.
Omission of maintenance and repair works.
Improper maintenance and repair works.
Unauthorised modifications of the machine.
611-02
1.02.03 Residual risks

Residual risks have been analysed and evaluated prior to starting the
construction and planning the machine. Existing residual risks are
referred to in the documentation. However, HAMM cannot forsee all
situations that may pose a risk in practice.
You can avoid existing residual risks if you comply with and
implement the following instructions:
Special warnings at the machine.
General safety instrucitons in this operating manual and in the safety
instructions.
special warnings in this operating manual.
Instructions contained in the safety instructions.
Operating instructions of the operator.
14 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

General
Use
Danger of life / risk of personal injury when operating the machine

due to:
Misuse.
Improper operation.
Transport.
Missing protective equipment.
Defective and/or damaged components.
Operation / usage by personnel not trained and/or instructed.
The machine may cause risk to the environment with:

Improper operation.
Operating supply items (lubricants etc.).
Noise emission.
Property damage may occur at the machine e.g. with:

Improper operation.
Non-compliance with operating and maintenance instructions.
Improper operating supply items.
Property damage may occur at additional assets within the

machine's operating area e.g. with:
Improper operation.
Reduction in performance and/or the machine's functionality may

occur at the machine with:
Improper operation.
Improper maintenance and/or repair works.
Improper operating supply items.
611-03
1.02.04 Climatic conditions

Low ambient temperature The diesel engine's starting behaviour and the machine's operation
depend on:
The fuel used.
The viscosity of the motor, gear and hydraulic oil.
The battery's charge state.
Please note:
The acceleration and braking behaviour of the machine are influenced
by viscous hydraulic oil. Prior to cold seasons (autumn, winter) please
adjust all operating supply items (coolants, oils etc.) to low temperatures.
Please use fuels suitable in winter or additives improving the flow with
temperatures below 0 °C (32 °F) (see page 145 sqq.). Do not charge
batteries with temperatures below 0 °C (32 °F) .
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 15

General
Environmental protection
WARNING!
Explosion!
Risk of injury due to burns and moving parts.
Do not use aerosol start-up aid (e.g. aether).
Do not use any liquids as start-up aid (e.g. alcohol).
002-02
Extensive ambient See operating manual of diesel engine.

temperature, extensive height 611-04
1.03 Environmental protection

Packing materials, cleaning agents and used or residual operating
supply items are to be disposed according to relevant environmental
provisions at the building site using the recycling systems provided.
614-00
1.04 Disposal
Conservation of nature is one of our major tasks. Properly disposed
devices avoid negative impacts on human beings and the environment
and allows re-using our precious resources.
Operating supply items Please dispose all operating supply items according to relevant
specifications and local regulations of the relevant country.
Materials (metal, plastics) To be able to dispose materials professionally, these materials need to
be correctly sorted. Cleanse materials of adhesive impurities.
Please dispose all materials as demanded by local provisions of the
relevant country.
Electical / electronical Electrical / electronical components are not subject to

system / battery Directive 2002/96/EC and relevant national regulations (in Germany e.g.
ElektroG).
Dispose electrical / electronic components directly at a specialised
recycling company.
615-00
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General
EC confirmity
1.05 EC confirmity
The declaration of conformity is part of the documentation provided
separately by HAMM and will be submitted to you togehter with the
machine.
The pictogram represents the machine's conformity with relevant
EU Directives. The CE mark of the machine is part of the type
plate.
In case the machine has been modified in a way that has

not been agreed by HAMM, the EC declaration of conformity
expires.
616-00
EC declaration of confirmity
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 17

General
Type plate
1.06 Type plate

The entire marking represents an official document and must not be
altered or effaced.
Please state the VIN and the type of your machine for every
spare part order.
Type plate of machine The type plate is fixed to the machine frame (see page 37).
[A] Description [B] Homologation

[C] Type [D] Year of construction
[E] Chassis number [F] Engine power
[G] Admissible total weight (only [H] Admissible axle load, front /
valid for public roads) rear (only valid for public
roads)
[J] Basic weight [K] Operating weight
[L] Maximum weight
The VIN [E] indicates the type series and the serial number of
the machine e.g. H1841234. The first four characters represent
the type series (H184), the following characters the serial
number of this type series (1234).
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General
Noise and vibration requirements
Type plate roll-over protection The roll-over protection, ROPS, approved by the manufacturer for this
ROPS machine is marked by a type plate attached at the cabin / roll-over bar
(see page 38).
[A] Type / type series (part of the [B] Cabin / ROPS identification
VIN) number
[C] Cabin / ROPS serial number [D] FOPS identification number
[E] Year of construction [F] Cabin / ROPS own weight
[G] Tested up to the machine's
maximum speed
602-05
1.07 Noise and vibration requirements

The sound emission of the machine was measured according to the EC
Sound Emission Directive in the version 2000/14/EC.
The sound and vibration indications on the driver's seat are in line
with the requirements of the EC Machinery Directive in the version
2006/42/EC.
Sound power level Sound indication of the machine

The guaranteed sound power level is specified in the machine's
Technical Details (see page 147 sqq.).
Sound intensity level Sound indication on operator panel

The noise level at the operator's seat is specified under Technical data
(see page 147 sqq.) (measurement uncertainty in accordance with
EN ISO 11201).
However, when working in the immediate vicinity of the machine,
values may exceed 85 dB(A). In this case wear always your
personal noise protection (ear protection).
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 19

General
Noise and vibration requirements
Vibration indication on the Whole body vibration

operator panel The weighted rms values of the acceleration with whole body vibrations
on the operator's seat have been accessed in accordance with EN1032
and do not exceed aw = 0.5 m/s².
Hand arm vibrations
The weighted rms values of the acceleration with hand arm vibrations
have been accessed in accordance with EN 1032 and do not exceed
ahw = 2.5 m/s².
602-06
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General
Personnel
1.08 Personnel
1.08.01 Qualification and duties
Operating personnel All activities at the machine must be carried out by authorised operating
personnel only. In this operating manual the term operating personnel
refers to all authorised persons that are responsible for operating,
maintaining, instaling, setting up, cleaning, repairing or transporting the
machine.
This comprises the following persons:
Machine operator
Maintenance personnel
Persons are deemed as authorised that have been trained, qualified

and instructed for carrying out relevant activities at the machine and that
have proven their skills to the contractor. The operating personnel must
be authorised by the contractor for those activities at the machine.
In addition to the qualifications specified in the safety instructions,

the operating personnel must:
Have read and understood the operating manual.
Be trained and instructed according to the rules of action in the case
of perturbation.
Please adhere to the following instructions:

Please drive the machine only if you are entirely familiarised with the
operating and control elements and the method of operation.
Please use this machine only according to its intended purpose.
In case you detect any defects, such as at the safety equipment, that
may affect the safe operation of the machine, please immediately
notify the supervising body.
With defects that may endanger persons, please stop operating the
machine immediately.
Please ensure that the machine is compliant with all requirements
concerning traffic law.
Banksman Only persons are to marshal independently that:

Have been trained in marshalling others (the machine).
Have successfully proven their participation in such a course.
Have proven their skills to the contractor.
Fulfil their tasks in a reliable manner.
Have been appointed by the contractor / company as a banksman.
The meaning of signals must be unambiguous between driver and

banksman.
To avoid ambiguities, clarify hand signal, such as specified by the
German BG Directive "Safety and Health Protection Signals at Work",
should be used.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 21

General
General safety instructions
Please adhere to the following instructions:

Please make yourself familiar with the machine's and the loading
vehicle's dimensions.
Wear reflective clothing.
For marshalling please use voice radio (e.g when loading with a
crane) or via hand signals (e.g. when reversing the machine).
602-07
1.09 General safety instructions

Safety instructions The safety instructions are part of the operating manual. Please make
yourself familiar with these safety instructions prior to working with the
machine.
Regulations and Provisions In addition to this operating manual, it is also necessary to adhere
to all laws, standards, regulations and provisions applicable in the
country of use and at the building site. The vandslism protection for the
lighting is not permitted by the StVZO (German Road Traffic Licensing
Regulations) and must be removed when travelling on public roads.
Additional information In case you should obtain additional technical and/or safety-relevant
information for the machine, they also must be adhered to and need to
be attached to the operating manual.
Electrical system During works at the electrical system, the machine must be de-
energised at the battery isolating switch or by disconnecting the negative
terminal (earthing strip) at the battery.
ROPS roll-over protection The machine frame must not be warped, bent or cracked in the ROPS
fixing area (deformation). The reinforcement elements of the cabin /
roll-over bar must not show rust, damage, fissures or open fractures.
All screwed connections of the reinforcement elements must comply
with the given specifications and must be screwed tightly to each other.
Observe starting torque values! Bolts and nuts must not be damaged,
bent or deformed. It is absolutely forbidden to modify or repair / level the
reinforcement elements in any way.
610-08
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General
Danger zone
1.10 Danger zone

The machine's danger zone is divided into the areas inactive and
moving.
Zone "inactive"
With the machine put out of operation and with the diesel engine
switched off, an area 1 metre around the machine is defined as danger
zone. Only authorised operating personnel is allowed to enter the
danger zone.
Zone "moving"
For a moving machine the danger zone is defined as follows:

10 metres In front of and in the rear of the machine
1 metre To the left and right of the machine
During compression and transport works no persons are allowed to be

within the danger zone.
610-06
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 23

General
Loading and transport
1.11 Loading and transport

Regulations and Provisions When loading rollers onto lorries, trailers or semitrailers, it is very
important to secure the load properly. The duty for tie-down on street
vehicles arises from StVO § 22, StVO § 23, HGB § 412 as well as from
VDI guideline 2700 or other local requirements. Sufficient knowledge
about the loading of vehicles as well as about their behaviour under load
are required for loading and transporting the machine. The machine may
only be loaded by trained loading staff. The machine must be fixed to
the vehicle in an form-locked or friction-locked and transport-safe way.
The machine must not change its position on the vehicle during normal
traffic loads. Emergency braking, change manoeuvres and uneven
grounds count among normal traffic loads. If it is impossible to secure
the machine properly onto the vehicle, or if the loading vehicle shows
visible defects which do not ensure safe transport, loading must not be
performed.
Basically, the relevant transport company is responsible for transporting
the machine and accessory.
Loading instructions When loading please observe the following instructions:

Adhere to section Transport as specified in the safety instructions.
Observe weight and dimensions (see page 147 sqq.).
Only use approved gantries or planks that are provided with an
antiskid coating. Never drive with metal on metal.
Gantries, planks and loading areas must be swept clean and free
of oil and ice. Clean roller drums and tyres prior to driving on the
gantries. Please ensure a friction factor or ≥0.6, e.g. by use of anti-
slide mats.
Drive the machine slowly onto the loading area with ¾ diesel engine
speed.
On rubber wheeled rollers with tyre filling system, the tyre filling
system must be set to 0.6 MPa (6 bar, 87 psi).
In case of rollers with articulated steering, the safety strut must
always be activated for transport.
Lash the machine with appropriate lashing devices onto the loading
area, using only the marked lashing lugs (see figure).
Pay attention to the admissible load on the lashing point of the
vehicle / loading area and that on the loaded good / roller. Do not
overload the lashing points with tensioning device.
In case of crane loading, only fix ropes to the marked lifting lugs.
Remove wedges and lashing devices completely before unloading.
Unblock steering system by unblocking the safety strut.
Drive the roller slowly and carefully from the loading area.
716-07
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General
Loading and transport
Load securing example
Park machine on a loading area with two clean strips of anti-slide

mats for each roller drum / tyre.
Position 2 wedges at each axis - as far to the outside as possible -
flush with roller drum or tyre, and fix each of them with 5 nails (Ø 3.8
mm) to the loading area. The nail must at least reach into the loading
area by 50 mm.
The lashing devices A and B must be fixed to the lashing point of the
machine and the vehicle.
The arrangement of the lashing devices shown in the figure must be

realised on both sides. The type of the lashing device, the number of
lashing devices and the min. tractive force at the lashing point can be
found in the table depending on the max. weight of the machine (type
plate).
Lashing devices must comply with the requirements according to
EN 12195:
Lashing straps according to EN 12195-2
Chains according to EN 12195-3, quality class 8
Max. weight (kg) Type of lashing de- Number

vice
0 - <5000 Lashing strap: 4
LC=2000 daN
0 - <5000 Chain 6 mm: 4
LC=2200 daN
5000 - <10000 Chain 8 mm: 4
LC=4000 daN
10000 - <18000 Chain 8 mm: 6
LC=4000 daN
18000 - <25000 Chain 10 mm: 6
LC=6300 daN
25000 - 30000 Chain 10 mm: 6
LC=6300 daN
716-08
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 25

General
Stickers on the machine
1.12 Stickers on the machine

Below you will find all used stickers. You will find the precise
arrangement of stickers in the spare parts catalogue.
1.12.01 Warning labels

Read documentation
Read operating manual and safety instrucions before you start working
with the machine or maintaining it. Ignoring this instructions can cause
serious injuries or fatality.
Seat belt obligatory (only with ROPS cabin or ROPS roll-over bar)
Risk of being thrown out of tipping machine can cause serious injuries
or fatality. Put on safety belt.
Hearing protection
Dangerous noise level! May cause damage to the hearing. Wear
personal safety equipment.
Water jets
Dangerous situation! Fluid may enter control units and cause injury and/
or damage to the machine. Do not spray components with water.
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General
Motor Stop
Hazard due to rotating parts! With the machine running, serious injuries
or fatality may be caused. Prior to maintenance work, shut down engine
and remove ignition key. Wait until all machine components have come
to a standstill.
Hot surface
Risk of burns! Surfaces can be very hot. Do not touch surface. Keep
away.
Air conditioning
Risk of burns! Coolant of the air-conditioning can cause serious injuries
or fatality. Follow operating and maintenance instructions.
Chip spreader
Hazard due to rotating parts! Moving machine components can cause
serious injuries or fatality. Prior to maintenance and adjustment works,
shut down machine and remove ignition key.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 27

General
Edge pressing assembly

Risk of crushing! Pinch point can cause serious injuries or fatality. Keep
away. Prior to maintenance and adjustment works, shut down machine
and remove ignition key.
Fan blade
Hazard due to rotating parts! With the machine running, serious injuries
or fatality may be caused. Prior to maintenance work, shut down engine
and remove ignition key. Wait until all machine components have come
to a standstill.
V-belt
Risk of trapping! Open belts or chains. With the machine running,
serious injuries or fatality may be caused. Prior to maintenance work,
shut down engine and remove ignition key. Wait until all machine
components have come to a standstill.
Accumulator
Tank under pressure. System contains accumulator. Prior to starting
service work, read operating and service manual.
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General
Folding joint
Risk of crushing! Pinch point can cause serious injuries. Keep away.
Running over hazard

Machine movements can cause serious injuries or fatality. Keep away.
Danger of overturning
Pay attention that there is sufficient stability when working with rollers of
small roller drum width. Pay attention to permitted machine tilt.
Risk of crushing
Pinch point can cause serious injuries. Keep away.
Lashing not allowed

Dangerous situation! Do not use as a lashing or lifting point. Lifting not
allowed.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 29

General
Battery isolating switch

Dangerous situation. Actuate the battery isolating switch only with
the enginge stopped. Before you start with service works, read the
operating and maintenance instructions.
12 V fuses
Diesel
Diesel tank! Use diesel with a sulphur content of less than 0.5%. Pay
attention to standards.
Safety strut
Marking of a safety strut.
Towing loop for crane loading
Lashing point
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General
Read documentation
Read operating manual before you start working with the machine or
maintaining it.
First-aid kit
Panolin
Biodegradable hydraulic oil in use.
1.12.02 Information sign

In the following you will find a list of all information signs. Illustrations
and values of the signs may vary depending on the machine type.
Put parking brake into / out of operation
Drive lever function
All-wheel lock
Engine speed
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 31

General
Sprinkling
Water tank filling
Water tank outlet
Additive sprinkling
Water tank inlet of additive sprinkling
Water tank outlet of additive sprinkling
Water pump
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General
Hydraulic oil filling level
Hydraulic oil reservoir inlet
Hydraulic oil reservoir outlet
Socket 12V
Engine oil outlet
Water sump fuel filter outlet
Coolant filling level
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 33

General
Coolant inlet
Inflation pressure
Tyre without water filling
Inflation pressure
Tyre with water filling
Guaranteed sound power level
Expert inspection test badge
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General
Maintenance overview
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 35

Description
Technical characteristics of the machine
2 DESCRIPTION
000-01
2.00 Technical characteristics of the machine

Drive Hydrostatic all-wheel drive
infinitely variable
Single lever operation
Vibration Direct hydrostatic drive
Steering Hydrostatic servo-assisted steering via centre pivot assembly

Large steering angle to both sides
Pendulum compensation upwards and downwards
Service brake During operation, the machine is braked with the hydrostatic drive.
Wear-free brakes
Parking brake Spring-operated brake acting upon each hydromotor of the drive
Manually and automatically
EMERGENCY STOP brake Machine is braked with spring-operated brakes and hydrostatic drive.
Electrical system Operating voltage 12 V

100-14
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Description
General view of machine
2.01 General view of machine

This operating manual applies to several types of this
series. Therefore it is possible that these instructions include
descriptions of operating elements not installed on your machine.
000-03
2.01.01 Chassis / safety devices
[A] Stickers indicating dangers [B] Towing eyes for crane loading
[C] Towing eye [D] Lashing point
[E] Safety strut [F] Steps
[G] Engine hood [H] Chassis
[J] Vehicle identification number [K] Machine type plate
(VIN)
[L] Operation mirror / rear-view
mirror
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 37

Description
2.01.02 Control stand

ROPS cabin
[A] Handles [B] Operator's seat console

[C] Operator's cabin [D] Steering console
[E] Stacker for operating manual / [F] ROPS cabin type plate
first aid kit
[G] Position for *fire extinguisher
ROPS roll-over bar
[A] Handles [B] Stacker for operating manual /

first aid kit
[C] Steering column [D] Operator's seat console
[E] Roll-over bar [F] ROPS roll-over bar type plate
[G] Position for *fire extinguisher
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Description
Operator's cabin roof section
[A] Switch unit [B] Roll-up sunshield

[C] Inside mirror [*D] Air conditioning ventilation
nozzles
[*E] Aspiration duct for air
conditioning
[A] Roll-up sunshield [B] Position for *radio

[C] Loudspeaker [D] Position for *tachograph
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 39

Description
2.01.04 Drive unit / diesel engine
[A] Fuel system [B] Oil dip stick

[C] Oil inlet [D] Diesel engine with drive units
[E] Oil outlet [F] Cooling system
[G] Coolant inlet / coolant filling
level
[A] Air filter [B] Dust discharge valve

[C] Exhaust system [D] Cooling system
[E] Fuel tank ventilation filter [F] Manual pump, parking brake
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Description
2.01.05 Hydraulic oil supply
[A] Oil inlet [B] Level indicator

[C] Hydraulic oil reservoir [D] Oil outlet
[E] Ventilation filter of hydraulic oil [F] Steering hydraulic oil filter
tank
[G] Hydraulic oil filter
2.01.06 Electrical equipment
[A] Battery isolating switch [B] Battery

[C] Fuses, electric box [D] Fuses, operator's cabin
[E] Main fuses
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 41

Description
2.01.08 Drive
[A] Scraper
2.01.09 Steering system
[A] Steering cylinder [B] Articulated pendulum joint

[C] Safety strut
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Description
2.01.26 Vibration
[A] Drum with vibrator [B] Oil inlet for vibrator

[C] Fill level indicator of vibrator [D] Oil outlet for vibrator
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 43

Description
General view of instruments and operating elements
2.02 General view of instruments and operating elements

All instruments and operating elements are marked by numbers.
You will find a description in chapter 3 under the corresponding
element.
000-04
2.02.02 Control stand

Operator platform
[302] EMERGENCY STOP switch [310] Switch, electrical system /

engine start
[405] Socket [501] Drive lever
[502] 0-position lock [503] Multifunction handle
[504] Engine speed
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Description
[*303] Switch, flashing lights switch / [353] Switch, parking brake

lighting monitoring
[528] Adjustment steering console
Instrument console
[301] Signal horn switch [*303] Switch, flashing lights / lighting

[*305] Warning flasher switch [312] Vibration switch
[314] Gear shifting switch [315] Traction control switch
[*319] Vibration mode switch
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 45

Description
Operator's cabin roof section
[*311] Rotating light switch [332] Front windscreen wiper switch

[333] Rear windshield wiper switch [336] Rear working lights switch
[337] Front working lights switch [338] Switch, windshield washer
[*361] Air conditioning switch [410] Cab lighting
Operator's seat
[520] Seat adjustment weight [521] Seat adjustment forward -

backward
[522] Seat backrest adjustment [524] Seat adjustment rotation
[526] Seat adjustment height
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Description
Cabin heating
[330] Cabin-heating switch [347] Switch, cabin temperature

regulation
Normal mode control unit
[101] Hourmeter display [106] Engine speedometer

[237] Fuel pilot light
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 47

Description
Driving control unit
[*108] Driving speed indicator [*211] Flashing indicator pilot lamp

[*217] Warning flasher pilot lamp [218] Front working floodlight pilot
lamp
[219] Rear working floodlight pilot [223] Function not existing
lamp
Vibration control unit
[*109] Indicator compression [*110] Vibration frequency indicator

[221] Small amplitude pilot lamp [222] Large amplitude pilot lamp
[*224] RMV indicator (jump
operation)
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Description
Warning lamps control unit
[201] Charge current pilot light [202] Oil pressure pilot light
[203] Air filter pilot light [204] Parking brake pilot light
[206] Coolant level pilot light [214] Pilot light, hydraulic oil filter
[215] Pilot light, hydraulic oil level [216] Pilot light, cold start assistance
[220] STOP pilot light [227] Pilot light, water sump fuel
prefilter
[228] Engine temperature pilot light [229] Oil temperature indicator,
hydraulic system
[234] Diesel engine pilot light
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 49

Description
2.02.04 Drive unit / diesel engine

Engine compartment
[530] Manual pump, parking brake
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Description
2.02.05 Electrical system

Electrical box
[351] Link plug jumper km/h - mph [356] Battery isolating switch
[530] Manual pump, engine hood [531] Actuating pipe
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 51

Operation
Instruments and operating elements
3 OPERATION
3.00 Instruments and operating elements
The instruments and operating elements are arranged in this
section in ascending order according to their number. These
numbers in squared brackets are used as a reference in the
description of the elements.
000-05
3.00.01 Indicators, displays

Electrical equipment When switching on the electrical system with the switch [310] all pilot
lights and indicators are activated for ca 2 seconds . Check whether
all elements are operable. You find further explanations in the section
Operational monitoring (see page 82 sqq.).
100-06
101 Hourmeter
After the electrical system is switched on, the operating hours of the
machine are shown in the display field. Maintenance work has to be
carried out according to the accumulated operating hours.
101-06
After switching on the electric system, an internal test code is

displayed for 2 seconds.
000-12
106 Engine speed

The actual engine speed is calculated from a multiplication of the
indicated value by 100.
106-08

000-12
Diagnostic codes
In the event of a fault, "ER" and a diagnostic code appear
alternately in the display.
If a diagnostic code is displayed, write down all messages and
contact your HAMM Customer Service. The diagnostic codes
can only be interpreted by a HAMM service partner.
000-13
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Operation
108 Driving speed

Indication of the driving speed in km/h or mph. The unit is set with a
jumper [351] and is also displayed.
108-11

000-12
109 Compression HMV

The magnitude of the indicated value depends on the material to be
compressed. In case of compression work with the vibration turned on,
increasing HMV values show an increasing material densification, or
carrying capacity. If the value remains constant at a pre-compressed
place, this place cannot be compressed further. Use is only permissible
with vibration in earthmoving applications
109-04
If the machine is not equipped with a computer unit for HMV, no

display appears.
000-14
110 Vibration frequency

Indication of the current frequency in Hz or vpm. The set unit appears in
the indicator. The actual value is calculated from a multiplication of the
indicated value by 100.
110-10

000-12
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 53

Operation
3.00.02 Pilot lights

201 Charge current
Flashing during operation indicates missing charging current.
201-06
202 Engine oil pressure

Flashing during operation indicates insufficient oil pressure.
202-07
203 Air filter

Flashing during operation indicates a clogged air filter cartridge.
203-04
204 Parking brake

The pilot light flashes when the parking brake is applied and after the
actuation of the EMERGENCY STOP switch [302]. A flashing pilot light
when driving indicates that the oil pressure is not sufficient for opening
the parking brake.
204-06
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Operation
206 Coolant level

Flashing during operation indicates that the coolant level in the cooling
system of the diesel engine is not sufficient.
206-02
211 Flashing lights

Pilot light illuminates if the direction indicator is switched on.
211-02
214 Hydraulic oil filter

Flashing during operation indicates a clogged filter cartridge of the
hydraulic oil filter.
214-01
215 Hydraulic oil level

Flashing during operation indicates, that the filling level of the hydraulic
system oil tank is insufficient.
215-00
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Operation
216 Cold start assistance

When the electric system is switched on (switch [310] in position I),
this indicator lights up. After reaching start temperature, the indicator
switches off; then start the diesel engine.
216-04
217 Warning flashers

Pilot light flashes when the warning flashes are switched on.
217-00
218 Front working spotlights

Pilot light illuminates if the front working lights are switched on.
218-00
219 Rear working spotlights

Pilot light illuminates if the rear working lights are switched on.
219-00
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Operation
220 STOP
Flashing during operation indicates a serious malfunction of the
machine. At the same time an acoustic signals sounds.
Further operation is inadmissible!
1. Park the machine out of the danger zone.
2. Shut down the diesel engine immediately
3. Rectify the cause immediately.
220-02
221 Small amplitude

Pilot light illuminates if vibration with small amplitude is activated.
221-00
222 Large amplitude

Pilot light illuminates if vibration with large amplitude is activated.
222-00
224 RMV (jump operation)

The vibrating drum must not be lifted from the ground (jump operation)
during compression in earth moving work.
A slow flashing of the display indicates that the drum is immediately
before jump operation.
A fast flashing of the display indicates that the drum is in jump operation.
No even compression measurement can be realised during jump
operation. In this case, the values of the compression display
[109] are not reliable any longer.
224-00
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Operation
227 Water sump fuel prefilter

Flashing during operation indicates an excessively high water sump in
the fuel pre-filter.
227-03
228 Engine temperature

Lighting up during operation indicates improper engine temperature.
Warm-up phase [A] — lights up YELLOW
Increased [B] — lights up RED
Overheating [C] — flashes RED
228-05
229 Oil temperature of hydraulic system

Lighting up during operation indicates improper hydraulic oil
temperature.
Warm-up phase [A] — lights up YELLOW
Increased [B] — lights up RED
Overheating [C] — flashes RED
229-05
234 Diesel engine

Lighting up during operation indicates a malfunction of the diesel engine.
1. Stop machine.
2. Contact your HAMM customer service.
As long as the engine works with normal speed, the machine can be
operated further.
Only if the diesel engine automatically limits its speed to emergency
operation, the machine must be parked outside of the danger area.
1. Stop machine.
2. Shut down the diesel engine.
3. Contact your HAMM customer service.
234-04
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Operation
237 Fuel filling level

The fuel tank filling level is displayed by an illuminated pilot light. A
luminous spot moves between 1/1 and 0 corresponding to the motion of
the level sensor. When the light point is flashing refuelling is necessary.
237-02
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Operation
3.00.03 Switch
301 Signal horn
The signal horn sounds as long as this switch is pressed.
301-03
302 EMERGENCY STOP
WARNING!
Full braking!
Danger of injuries due to strong braking force.
Activate EMERGENCY STOP only in the event of danger.
Do not use the EMERGENCY STOP as operation brake.
002-03
Pressing the switch:

Stops the hydraulic drive,
Switches off the diesel engine,
Activates the hydraulic brakes
On — position DOWN
To disengage EMERGENCY STOP, turn push button clockwise.
Off — position UP
After actuating the EMERGENCY STOP switch, the machine
must be brought into its start position.
Start position:
1. Switch off the electrical system [310].
2. Latch drive lever [501] in 0 position.
3. Release EMERGENCY STOP switch.
4. Start the diesel engine.
302-25
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Operation
303 Flashing lights

Flashing lights
Steer right — position I
(pilot light [211] flashes)
Off — position 0
Steer left — position II
(pilot light [211] flashes)
Parking light / driving light

Off — position
Parking light — position
Driving light — position
303-11
305 Warning flashers

On — position I
(push button flashes)
Off — position 0
305-02
310 Electrical system / engine start

The switch (ignition key) supplies the electrical components with power,
and starts and stops the diesel engine.
0-position
Electrical system — OFF
Diesel engine — STOP
(key released)
Position I
Electrical system — ON
Position II — PREHEAT
Position III — ENGINE START
Key turns back to position I after starting.
When the engine is at a standstill and the electrical
system is switched on for a longer period (position I), the
battery discharges rapidly. If the engine is started with the
EMERGENCY STOP switch pressed, the engine will not start for
safety reasons.
To activate the machine:
1. Latch drive lever [501] in 0-position.
2. Release EMERGENCY STOP switch [302].
310-06
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Operation
311 Rotating light

On — position I
Off — position 0
311-07
312 Vibration
The switch activates or deactivates the vibration. The vibration works
with small or large amplitude, according to switch position.
Activate the large amplitude position I
(pilot light [222] lights up)
Deactivating position 0
Activate the small amplitude position II
(pilot light [221] lights up)
When the vibration system is activated, the vibrator can be switched on
or off at the multifunction handle [503].
312-07
314 Gear shifting

Transport speed position I
(push button lights up)
Working speed position II
314-03
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Operation
315 Traction control

Toggling the traction force is only possible in the working speed.
The driving force of drum and rear wheels is set at the switch.
Depending on the switch position, a large portion of the traction power
is displaced to the drum or to the rear wheels, respectively. In 0 position
both drives have the same traction power.
Uphill, drum in front
Strong traction force on rear wheels — position I
Same traction power
on both drives — position 0
Uphill, rear wheel in front
Strong traction force on drum — position II
315-01
319 Vibration mode manual-automatic

The switch sets the operating mode for the vibration system. The
vibrator can be switched on or off manually or automatically.
Manual — position II
The vibration can be switched on or off at any time with the switch on the
multifunction handle [503].
Automatic — position I
(switch button lights up)
The switching on and off of the vibration is coupled to the road speed.
Vibration is switched off when at low or high speed.
The automatic mode must be activated with the switch on the
multifunctional handle [503] after initial switching on.
Also in automatic mode, the vibration can be switched on or off at any

time by means of the switch on the multifunctional grip.
319-10
330 Cabin heating blower

The switch regulates the blower for the cabin heating.
Air current Off — position OFF
Air current stage 1 — position 1
330-06
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Operation
332 Front windshield wiper

On — position I
Off — position 0
332-04
333 Rear windshield wiper

On — position I
Off — position 0
333-03
336 Rear working lights

Pressing the switch turns the rear working spotlights on the cabin on or
off.
On — position l
Off — position 0
336-04
337 Front working spotlights

Pressing the switch turns the front working spotlights on the cabin on or
off.
On — position l
Off — position 0
337-04
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Operation
338 Front windshield washer

By pressing the switch the pump of the washer system is switched on.
Only as long as the switch is pressed a moistening of the windscreen
takes place.
338-03
347 Cabin-heating temperature regulation

The heat exchanger for the cabin-heating is connected to the diesel
engine cooling circuit. The heat exchanger temperature is continuously
adjustable with the switch.
Minimum temperature — stop LEFT
Maximum temperature — stop RIGHT
347-02
351 Jumper link plug

The unit for the speed display is set with a jumper link plug [A].
km/h — jumper UP
mph — jumper DOWN
Perform the toggling only when the electrical system is switched
off (switch [310] position 0)
351-02
353 Parking brake inspection
WARNING!
Full braking!
Only inspect the parking brake when the engine is at a standstill.
Do not use the parking brake as the service brake.
002-04
The parking brake is applied only as long as the switch is pressed (pilot
light [204] flashes).
353-02
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Operation
356 Battery isolating switch
NOTICE
Voltage spikes!
Damage or destruction of electrical components.
Only interrupt the circuit at the battery isolating switch when the
engine is at a standstill and when the electrical system is switched
off!
004-03
The circuit to the minus terminal of the battery is interrupted at the

battery isolation switch. All electric components will be off.
Electrical circuit interupted — position 0
(key released)
Electrical circuit closed — position I
(key latched)
356-01
361 Air conditioning temperature

The switch regulates the cooling and the blower for the air conditioning
system. The air flow is cooled down through the heat exchanger of the
air conditioning system.
Off — position 0
Air current stage 1 — position I
Air current stage 2 — position II
Air current stage 3 — position III
361-05
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Operation
3.00.04 Sockets, lights

405 Socket 12 V
The maximum load on the socket is 100 W (8 A).
405-01
410 Cab lighting

This works even if the electrical system is switched off.
410-00
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Operation
3.00.05 Operation levers, adjustment handles

501 Drive lever
The drive lever determines the driving direction and speed.
Forwards travelling — push lever FORWARD
Reverse travelling — push lever BACKWARD
Braking — lever to CENTRE
Stop — lever in CENTRE
The driving speed is proportional to the magnitude of the lever
displacement. It is also influenced by the engine speed.
If the machine is equipped with a back-up alarm, an acoustic signal
sounds when travelling reverse.
501-18
502 0 position lock / parking brake

When the driving lever is in the central position, a spring pulls it into the
0-position lock. Two functions are assigned to this position. To drive off,
press the driving lever towards the driver's seat, and start the vehicle
moving with the driving lever pressed.
0-position lock
The 0-position lock is a safety device. It avoids unintended movement of
the machine.
Latched — drive lever position 0
(drive lever [501] is latched in central position)
Unlatched — drive lever position I
(drive lever is free)
Parking brake
If the drive lever is latched in the 0 position lock, the parking brake is
applied. If the parking brake is applied, the pilot light [204] flashes.
502-10
503 Multifunction handle

Vibration
If the vibration system [312] is activated, the vibrator can be switched on
or off at switch [A] at any time.
Vibrator on — PRESS
Vibrator off — PRESS again
Push plate
The push plate is lifted and lowered as long as one side of the switches
[B] or [C] is pressed. If both switches are pressed simultaneously for
about 2 seconds, the lifting and lowering movement of the push plate is
released. Then it can adapt to soil irregularities.
Pressing a switch [B] or [C] cancels the release of the push plate.
Lift push plate — PRESS switch [B]
Lower push plate — PRESS switch [C]
Push plate released — PRESS switch [B] and [C] for about 2 seconds
503-19
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Operation
504 Engine speed

The speed of the diesel engine can be regulated between idle speed
and maximum speed using the adjustment wheel.
Idle speed — MIN
max. speed — MAX
504-06
520 Seat adjustment weight
WARNING!
Uncontrolled movements!
Risk of injury due to uncontrolled movements when changing the seat
pedestral position.
Operate the machine only in an admissable seat position.
Only drive the machine with latched seat pedestal.
Do not adjust the seat pedestal during driving.
Adjust the seat pedestal only on an even surface.
002-41
In order to absorb impulsive machine movements using the installed

attenuation system, this must be adjusted to the weight of the driver.
The pretension of the attenuation system can be adjusted continuously
to a driver's weight between 50 kg and 120 kg by turning the hand wheel
to the left or to the right.
520-02
521 Seat adjustment forward - backward
WARNING!
pedestral position.
002-41
After lifting the lever, the upper part of the seat can be shifted in forward
or backward direction in increments of 15 mm.
521-00
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Operation
522 Seat backrest adjustment
WARNING!
pedestral position.
002-41
The inclination of the backrest can be adjusted after the lever has been
lifted by shifting the seat forward or backward.
522-03
524 Rotation seat adjustment
WARNING!
pedestral position.
002-41
After lifting the lever, the seat can be turned to the left or to the right in
increments of 10°. The seat can be rotated freely if the lever is pulled
upward into the latching position. For locking, the lever must be pushed
downwards over the latch.
524-04
526 Height seat adjustment
WARNING!
pedestral position.
002-41
By turning the hand wheel to the right or left the seat height can be
adjusted by about 60 mm upward or downward.
526-00
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Operation
528 Steering console adjustment
WARNING!
Risk of injury due to uncontrolled movements when changing the
steering console position.
Only drive the machine with latched steering console.
Do not adjust the steering console when the machine is driving.
Adjust the steering console only on an even surface.
002-25
After releasing the lock with the foot lever, the complete steering panel
can be rotated to the front or to the rear.
Locking device released — PRESS foot lever
Before driveaway latch steering console in the desired position.
528-02
530 Manual pump

Engine hood
The manual pump opens and closes the engine hood
Open engine hood — lever position ↑
Close engine hood — lever position ↓
530-09
530 Manual pump

Parking brake
The spring-operated brakes must be released using the manual pump in
order to tow the machine.
Screw position, normal operation
Screw [A] — OPEN
Screw position, towing operation
Screw [A] — CLOSED
530-10
531 Actuating pipe

The manual pump is actuated with the actuating pipe.
531-03
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Operation
Prior to machine start
3.01 Prior to machine start

General
WARNING!
Operating errors!
Risk of injury due to improper use.
Prior to every start-up:
Check the machine for operational and traffic safety.
Read and adhere to the Operating manual and the Safety
instructions.
Ensure that no persons or objects are in the danger zones of the
machine.
002-07
What must be done prior to 1. Battery isolating switch [356] — position I

start of work? 2. Perform inspection and maintenance work (see page 93 sqq.).
3. Check the flasher system [303] and the warning flasher system [305],
as well as the signal horn [301], the back-up alarm [501] and the
lighting [303].
4. Check the parking brake [353].
5. Adjust the operator's seat.
6. Adjust the rear and operation mirrors so that you can watch the traffic
in the rear.
701-20
Fuel
1. Never drive the machine until the fuel tank is empty. Check the
filling level of the fuel tank in time. Fill up the fuel tank already in the
evening. This avoids the formation of condensed water in the fuel
tank.
2. Fill up to the lower edge of the filler neck. Only use clean fuel!
Advice about fuel see page 145 sqq. See also Safety
instructions.
701-13
Air
1. Check the air pressure in the tyres.
701-16
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Operation
Prior to machine start
Control stand
WARNING!
pedestral position.
002-41
Operator platform
Machine may only be operated from the operator seat.
701-19
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Operation
Engine start
3.02 Engine start

General The starting process may last 20 seconds as a maximum; otherwise,
the starting motor will be overheated and destroyed. There must be
pauses between the individual starting processes in order to allow the
staring motor to cool down. If the engine doesn't start after two starting
attempts, find out and eliminate the cause. Observe the operating
manual of the engine. The engine cannot be started by means of towing.
Drive component damage would be the consequence.
When the battery is unloaded, the egine can be restarted by starting with
an external power source (see page 84 sqq.).
703-04
Start position before starting
Set the operating elements to their initial position prior to the start of the
engine.
1. Drive lever [501] — CENTRE
2. 0-position lock / parking brake [502] — position 0
3. Engine speed [504] — MIN
4. EMERGENCY STOP [302] — position UP
5. Vibration [312] — position 0
6. Gear shifting [314] — position II
Only when the 0-position lock is latched, is the starting motor

connected to the switch [310] via the starter protection device.
This is the only way to start the engine.
702-28
Engine start 1. Engine speed [504] — 1/4 after MAX

2. Key [310] — 0 → I
(electrical system ON)
If the key is turned to position I, all pilot lights light up shortly for
function control purposes.
3. Key [310] — I → III
704-24
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Operation
Engine start
Before driveaway
WARNING!
Long stopping distance!
Risk of fatal injury due to braking delay with viscous hydraulic oil.
In case of low external temperatures, in particular when below
freezing, wait a few minutes after starting the engine until driveaway.
Warm up the machine during the warming phase with moderate
speed and low load until the oil in the hydraulic system has heated to
approx. +20 °C (68 °F) .
002-15
The acceleration and braking behaviour of the machine are influenced

by viscous hydraulic oil. If the machine is frozen to the ground, take care
that no clods of earth stick to the roller drum / tyre, since these could
damage the scrapers. Therefore, park the machine on planks or dry
gravel if frost is likely!
705-05
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Operation
Driving
3.03 Driving
Driveaway
1. Engine speed [504] — MAX

2. 0-position lock / parking brake [502] — UNLATCHED
(pilot light [204] goes out)
3. Drive lever [501] — FORWARD
or — BACKWARD
If the machine is equipped with a back-up alarm, an acoustic signal

sounds when travelling reverse. In ascending or descending slopes,
reduce the driving speed at the drive lever and increase engine speed
[504].
Do not switch off the switch [310] when the machine is driving
(0-position).
706-26
Gear shifting
WARNING!
Full braking!
Danger of injuries by strong acceleration or braking
Shift gears only when the machine is at standstill.
Use transportion gear only to manoeuver on paved roads.
In case of visible obstacles reduce speed in good time.
Longer uphill or downhill slopes must always be driven in working
speed.
Work may only be performed in the working gear.
002-55
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Operation
Driving
Only operate the gear shift when the machine is at a standstill. If

the gear shift is operated when the machine is moving, it will be
essentially decelerated or accelerated.
The machine has a working gear and a transportation gear. These can
be toggled with the switch (314]. The driving speed can be regulated
variably with the driving lever [501].
708-03
Traction control
Traction control can influence the traction power for the drum or for the
rear wheels. Optimum climbing performance of the machine can only be
obtained if the axle directed downhill has a bigger drive torque. This can
almost completely prevent slipping. The driving force is adjusted with the
switch [315]. The three switching positions of the driving gear lever [501]
for the working gear each have a different final speed (see page 138
sqq.).
732-01
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Operation
Driving with vibration
3.04 Driving with vibration

General
WARNING!
Collapse or damage!
Risk of collaps or damage at buildings or on the pipe system in the
ground.
Do not switch on the vibration system near buildings!
Prior to switching on the vibration function, ensure that there are
no lines (e.g. gas, water, electricity, sewage lines) are laid in the
underground.
002-18
WARNING!
Explosion!
Risk of injury due to burns and moving parts.
Prior to switching on the vibration function, it must be ensured that
there are no lines laid in the underground.
002-19
WARNING!
Reduced road adhesion!
Risk of falling or tipping due to reduced lateral stability when having
switched in vibration.
Do not switch in vibration function when driving across inclines or on
hard underground.
002-20
When the vibration system is switched on, the roller drum will vibrate
according to the speed of the vibrator. This hammering will increase the
compacting force of the machine several times over. Vibration may only
be used at maximum diesel engine speed and can be operated as single
or double vibration. An elastic suspension of the roller drums prevents
the transfer of vibration oscillations to the machine frame.
Vibrations
Vibration oscillations can spread in the ground over a wide area. They
are generated in circles around the roller drum and effect also the
deeper ground. This may cause a damage to buildings or pipe systems
under the machine.
712-28
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Operation
Driving with vibration
Vibration
The switch [312] activates or desactivates the vibration. The pilot lights
[221] or [222] indicate the selected amplitude. When the vibration
system is activated, the vibrator can be switched on or off at the
multifunction handle [503].
712-37
Manual - automatic The operating mode for the vibration is set with the switch [319]. The
operating mode vibrator can be switched on or off manually or automatically.
712-30
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Operation
Stopping, switching off engine, leaving machine
3.05 Stopping, switching off engine, leaving machine

WARNING!
Uncontrolled driving behaviour!
Risk of fatal injury due to the machine's own driving movements.
Switch off diesel engine even if you leave the operator platform only
for short time.
002-22
Stop
1. Vibration [503] — OFF

The hydrostatic drive brings the machine to a stop.
Before switching off the 1. Vibration [312] — position 0

Diesel engine 2. Engine speed [504] — MIN
3. Fully lower attached accessory equipment.
713-33
Shut down the diesel engine Do not switch off engine directly after full load operation. Instead, let
it run for 1-2 minutes with idling speed for temperature compensation
purposes.
1. Key [310] — I → 0
The battery discharges rapidly if the engine is at a standstill and

the electrical system is switched on (switch [310] in position I).
000-02
Leaving the machine The driver may only leave the machine when orderly parked. Traffic
regulations have to be observed as well.
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Operation
Stopping, switching off engine, leaving machine
Before leaving the machine, the driver must ensure that

The driver's seat console is latched in the centre of the machine.
The ignition key is disconnected.
The machine is switched off at the battery isolating switch and the
key is removed.
The cabin doors resp. the instrument panel covering, as well as all
cladding covers are locked.
714-09
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 81

Operation
Operation monitoring
3.06 Operation monitoring
Keep an eye on the control and indication instruments on the instrument

board during operation. Pilot lights inform the driver about the operating
stages of the individual machine components and indicate faults. The
urgancy of taking action is subdivided into three stages.
Danger, important reminder The STOP pilot light [220] is active. In addition, you hear a permanent
acoustic signal. Further operation of the machine is inadmissible. The
cause of the fault is displayed by further active pilot lights.
1. Park the machine out of the danger zone and switch off the diesel
engine.
2. Rectify the cause immediately.
Warning, notice, malfunction A pilot light displays the fault. Further operation of the machine is
admissible for a short period of time.
1. Rectify the cause of the fault without delay, at least at the end of the
working shift.
Switch-in check A pilot light indicates that a machine component e.g. the vibration is
switched on. No action necessary.
Filling levels Pay attention to the filling level for operating supply items (fuel etc.).
1. Fill up tanks in good time.
2. Never drive the machine until the fuel tank is empty.
711-27
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Operation
Scraper
3.07 Scraper
General
The scrapers [A] are designed to remove clogging dirt from the surface
of the drum when working on soft, adhesive ground. With a padfoot
drum, the dirt can only be removed from between the padfoot segments.
Rinse out dirt embedded between roller drum and the scraper with water
jet. Remove strongly adhesive dirt e.g. with spatula or similar tool.
744-07
Scraper
The scrapers are mounted on a rigid console. Because the drum is

suspended elastically, the scraper must not touch the drum. Therefore a
clearance must be maintained between the scraper and the drum.
Smooth drum clearance — 10 mm
Padfoot drum clearance — 15 mm
744-08
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Operation
Starting with jump leads
3.08 Starting with jump leads

Preparation Observe precaution measures for handling batteries (see Safety
instructions).
Pay attention to the nominal voltage of the batteries.
A discharged battery can freeze already at 0 °C (32 °F). It is essential
that you defrost a frozen battery in a warm room before connecting it
with jump leads.
Use jump leads with an insulated terminal clamp and a cross section
of at least 25 mm².
The terminal clamps of one lead may not come in contact with those
of the other.
Do not disconnect the battery from the vehicle's supply system.
Charging vehicle and discharged vehicle may not come in contact
with each other.
Connecting leads
1. Connect one terminal clamp of one wire with the positive terminal of
the charged battery (plus sign).
2. Connect the other terminal clamp of this lead to the positive terminal
of the discharged battery (plus sign).
3. Connect one terminal clamp of the second wire with the negative
terminal of the charged battery (minus sign).
4. Connect the other terminal clamp of the second lead with the
discharged vehicle. e.g. at the engine block or at the fastening screw
of the engine suspension. Do not connect the terminal clamp with the
negative terminal of the discharged battery (risk of explosion) but as
far away from the discharged battery as possible.
5. Lay leads such that they are not drawn into rotating parts and that
they can be taken off even with a running diesel engine.
Starting process 1. Start the engine of the charging vehicle and let it run with medium
engine speed.
2. Start the diesel engine of the discharged vehicle after approx. 5 min.
3. For approx. 3 min let both engines run with medium engine speed
and the jump leads connected.
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Operation
Towing
Removing leads 1. To prevent overloads in the electrical system, switch on an electrical

component in the discharged vehicle (e.g. driving light) before
removing the jump leads.
2. Remove the jump leads in reverse order.
743-00
3.09 Towing
General
WARNING!
Brake out of order!
Risk of fatal injury due to unintentional rolling away of the machine.
Prior to releasing the brake, secure the machine against rolling away
with wedges.
002-23
Towing of the machine assumes sufficient knowledge of the functioning

of the hydrostatic drive and the operation of the multi-disc spring
operated brake. The preparations for towing may only be carried out by
experienced personnel who are aware of the dangers. The machine may
only be fastened at the lifting points [A] and only be towed with a towing
bar. Replace damaged pipes and hoses from which oil leaks before
towing (environment protection).
In dangerous situations: You can also use a towing rope or
towing chains when salvaging the machine on an uphill slope
(brakes not released).
717-10
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Operation
Towing
Before towing

2. 0-position lock [502] — position 0
3. Shut down diesel engine, if still functional..
4. Secure machine against rolling away with wedges or blocks.
5. Interrupt frictional connection of the hydrostatic drive (see text
below).
6. Disable parking brakes (see text below).
7. Tow using towing bar only (brakes not functional).
Towing Start, if possible, the engine (for steering hydraulics). The machine may
only be towed with low speed 1 km/h (0.6 mph) . The maximum towing
distance is 500 m.
If the diesel engine fails, the machine can only be steered in a
restricted way and with a high amount of force at the steering
wheel (emergency steering). Before moving, remove wedges or
blocks.
After towing 1. Shut down the diesel engine.

2. Secure machine against rolling away with wedges or blocks.
3. Reestablish frictional connection of the hydrostatic drive (see text
below)
4. Actuate parking brakes (see text below).
5. Remove towing bar.
717-07
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Operation
Towing
Separating the hydrostatic

drive power train
Only if the oil flow can circulate without pressure in the hydraulic system,
can the machine be towed.
1. Remove covering cap.
2. Loosen the hexagon socket screw [A] at both multifunctional valves
of the drive pump [B] by rotating counter-clockwise 2 turns.
Do not screw out the screw by more than 2 turns out of the
housing; otherwise, hydraulic oil may flow out between screw
and housing or air may enter into the system.
Activating the hydrostatic 1. Screw in the hexagon socket screw as far as possible.
drive power train 2. Mount cap.
718-06
Making the parking brakes

inoperational
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 87

Operation
Towing
Only for the purpose of towing in case of a defective diesel engine or

defective hydraulic system the pretension of the spring-loaded brakes
may be reduced using the manual pump [530].
1. Loosen counternut [A]
2. Screw in screw [B] up to the valve seat.
3. Aerate the spring-operated brakes by pumping at lever [C] (approx.
30 pump strokes).
4. During towing, the spring-operated brakes must be kept open by
constant and slow pumping due to interior leaks.
Making parking brake 1. Unscrew screw [B] with two turns.

operational 2. Tighten the lock nut [B].
Do not screw out the screw by more than 2 turns out of the
housing; otherwise, hydraulic oil may flow out between screw
and housing or air may enter into the system.
719-15
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Operation
Heating / ventilation / cooling
3.10 Heating / ventilation / cooling

General The comfort, well-being and good condition of the driver are largely
dependent on a properly set heating and ventilation. This especially
applies for the cold seasons. By opening the ventilation nozzles
required, a temperature distribution is achieved with the pleasant effect
of having warm feet but a cool head. A special heating and ventilation
system in conjunction with an air conditioning ensures an optimal
compartment climate. The cabin ventilation is achieved through mixer
operation, i.e. the exhaust flow simultaneously sucks air out of the
operator's cabin and draws in fresh outside air. Dirty filters must be
replaced depending on the dust load.
720-18
Cabin ventilation
[A] Ventilation nozzle [B] Aspiration duct for fresh air

[C] Aspiration duct for [330] Cabin heating switch
recirculating air
[347] Cabin heating temperature
regulation
The air flow enters the cabin through the ventilation nozzles [A] that
can be opened or closed by adjusting the discs. The direction is set by
turning the disc ring. For drying or de-icing of the front or rear window
the air flow must be directed to the windows.
760-01
Heating system The heat exchanger for the heating is connected to the engine cooling
circuit. After the ventilation fan [330] is switched on, the air flow which
passed through the heat exchanger is guided into the cabin. The heating
temperature [347] is infinitely variable.
761-01
Ventilation If the switch [347] is set to minimum (left stop), the system runs in
ventilation operation. Three ventilation steps [330] ensure an optimal air
circulation in the cabin.
762-01
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 89

Operation
Heating / ventilation / cooling
Cooling
[A] Vent [B] Aspiration duct for

recirculating air
[361] Air conditioning temperature
switch
If the machine is equipped with a air conditioning, the air flow for cabin
aerating can be cooled down at high outside temperatures. Doors and
windows should be closed in order to obtain a fast cooling of the cabin if
the air conditioning is turned on. This obtains a further cooling of already
cooled inside air.
Switch [361] is used to switch the system on and off. Several ventilation
steps ensure an optimal air circulation in the cabin. The air flow enters
the cabin through the ventilation nozzles [A] that can be opened or
closed by adjusting the discs.
Switch on air conditioning at least 1 per month (even in winter)
for ca. 15 minutes.
763-01
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Operation
Open and close engine hood
3.11 Open and close engine hood

General
WARNING!
Large swivel range of the engine hood!
Risk due to rotating parts.
Ensure that there are no persons or objects in the danger zone of the
machine.
Only open the engine hood when the engine is at a standstill.
Make sure that there is adequate space above and behind.
Only open and shut from the machine side, and only with the
actuating pipe.
Maintenance work may only be performed with the bonnet
completely opened and the ↑ lever position.
Keep all parts of the body (e.g. hands) away from moving parts when
closing it.
002-56
The motor hood may only be opened by one person. This person must
be familiar with the work, and have been instructed about the dangers.
Prior to opening the engine hood:
1. Switch off diesel engine and remove ignition key.
2. Close the cabin doors.
723-05
Opening the engine hood
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 91

Operation
Open and close engine hood
1. Turn the lever [A] in the direction of opening — lever position ↑.

2. Insert the actuating pipe [531] in the cutout on the manual pump
[530] and raise the hood to the tilting point by gradual pumping.
After passing the tilting point, the hood is opened to the stop by
its own weight.
3. Remove the actuating pipe.
Maintenance work may only be performed with the engine hood

completely opened and the ↑ lever position.
Closing the engine hood Completely remove all loose tools from the engine compartment,
replaced maintenance parts and other items not belonging to the
machine.
1. Turn the lever [A] in the direction of closing — lever position ↓.
2. Insert the actuating pipe [531] in the cutout on the manual pump
[530] and lower the hood to the tilting point by gradual pumping.
After passing the tilting point, the engine hood closes by itself
due to its basic weight. The automatic closing process can be
stopped by turning the lever [A] towards the direction of opening.
3. When the hood is in its final position, tighten it by continued pumping
to a notable resistance.
4. Remove the actuating pipe.
723-04
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Maintenance
General maintenance instructions
4 MAINTENANCE
000-01
4.00 General maintenance instructions

This machine requires care and maintenance like any other technical
device. The extent and the frequency of the maintenance work depends
essentially of the operating and deployment conditions, which are very
different in many cases. In case of more difficult operating conditions,
the machine must have maintenance in shorter intervals as scheduled
for normal operation.
The maintenance intervals are determined according to the running time
of the operation hours counter; for this, additional maintenance work has
to be performed during the running-in time according to the running-in
regulations. The works necessary for care and the conservation of the
operational safety of the machine are listed in the following sections.
The running-in regulations, the servicing intervals and the care
measures for the diesel engine can be found in the operating manual of
the engine manufacturer and must be observed.
800-06
4.00.01 Operation monitoring

Air filter The operability of the air filter cartridge and the safety cartridge is
monitored by an electric contamination indicator. Only if the pilot light
[203] flashes, must the air filter cartridge or the safety filter cartridge be
replaced.
810-16
Pressure filter hydraulics The pressure filters for the hydraulic system are monitored by an
electrical contamination display. Only if the pilot light [214] flashes, must
the filter insert of the hydraulic filters be replaced prematurely.
A prematurely contaminated filter can be a first hint for a damage
in the hydraulic system.
819-05
Preliminary fuel filter According to the water content in the fuel, more or less water
precipitates in the drain housing of the fuel pre-filter. If the pilot light [227]
flashes, the water sump must be drained.
837-17
Coolant of diesel engine The coolant level in the diesel engine's cooling system is monitored
electrically. If the pilot light [206] flashes, the coolant level in the cooling
system must be checked.
815-07
4.00.02 Maintenance overview
Engine maintenance: see Operating manual for engine ( )!
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 93

Maintenance
Every 10 operating hours

Checking the function of the parking brake see page 103 sqq.
Inspecting the EMERGENCY STOP see page 103 sqq.
function when engine at standstill
Checking hydraulic oil level see page 121 sqq.
Checking the air pressure in the tyres see page 125
Checking motor oil level
Checking coolant level see page 109 sqq.
Checking and cleaning air filter / dust valve see page 109 sqq.
Draining water separator see page 109 sqq.

Checking scrapers see page 125 sqq.
Checking vibrator oil filling level see page 135 sqq.

Checking filling level of driving gear oil see page 125 sqq.
Checking oil level of the differential gear see page 125 sqq.
Lubricating pivoted bearing see page 133

Lubricating steering cylinder bolt see page 133 sqq.
Lubricating hinges see page 103 sqq.
engine hood, electric box
Checking radiator see page 109 sqq.
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Maintenance

Replacing fresh air filter of the operator's see page 107 sqq.
cabin
Replacing filter insert of pressure filter for see page 121 sqq.
hydraulic system
Replacing filter insert of pressure filter for see page 121 sqq.
steering system
Checking damping elements see page 135 sqq.
Checking V-belt tension
Checking wheel nuts / wheel bolts for see page 125 sqq.
tightness
Changing engine oil
Exchanging lubrication oil filter of diesel

engine
Replacing filter cartridge for the fuel filter
Cleaning / Replacing filter insert of the dirt see page 109 sqq.
and water separator
Changing filter cartridge for the fuel pre- see page 109 sqq.
filter

Changing differential gearbox oil see page 125 sqq.
Changing vibrator oil see page 135

Inspecting the EMERGENCY STOP see page 103 sqq.
function when driving
Exchanging (driving) gear oil see page 125 sqq.
Replacing hydraulic oil see page 121 sqq.
Replacing V-belt
Changing coolant see page 109 sqq.
Replacing air filter cartridge see page 109 sqq.

Changing safety cartridge
Replacing ventilation filter for fuel tank see page 109 sqq.
Replacing ventilation filter of hydraulic oil see page 121 sqq.

tank
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 95

Maintenance
4.00.03 Running-in regulations
Engine maintenance: see Operating manual for engine ( )!
After 50 operating hours Axle maintenance

1. Check the wheel nuts for tightness.
Maintenance of hydraulic system

1. Replacing filter insert of pressure filter for hydraulic system.
2. Replace filter insert of pressure filter for steering system.
Drum maintenance
1. Exchanging (driving) gear oil.
After 500 operating hours Axle maintenance

1. Changing differential gearbox oil.
803-22
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Maintenance
4.00.04 Required maintenance parts

3410, 3411 all types (TCD 2012 L04 2V)
H1791207 →
Servicing intervals
first in operating hours
Quantity Maintenance part time
after every every every every
250 500 1000 2000
11.5 l Engine oil D
50.0 l Hydraulic oil D
14.0 l Coolant D
(2x) 1.6 l Vibrator oil A D
1.3 l Driving gear oil 50 D A D
14.0 l Differential gear oil 500 D A D

1 Poly-v-belt A D
1 V-belt Air condition- A D
ing system
1 Air filter cartridge A D
1 Safety cartridge D
1 Filter cartridge Lubricating oil D
2 Filter cartridge Fuel D
1 Filter cartridge Preliminary fu-
D
el filter
1 Filter insert Dirt and water D
separator
1 Seal Valve cover D
1 Filter insert Hydraulic sys- 50 D D
tem
1 Filter insert Steering 50 D D
2 Ventilation filter Oil tank, fuel D
1 Dryer Air condition- D
ing system
1 Filter insert Operator's D
cabin
Damping elements for the A
14
drum suspension
A = check, replace if necessary, D = replace
1 All required maintenance parts for the corresponding 2060088 2060092 2060094
maintenance intervals
All necessary maintenance parts for the corresponding maintenance interval are assembled in a service
kit. You find the current order numbers for individual service kits in the WIRTGEN GROUP document Parts
and more.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 97

Maintenance
4.00.05 Important information about maintenance works

Safety The following safety instructions apply for all maintenance works.
WARNING!
Unintentional movement!
Risk of injury due to unintentional movement during maintenance works.
Carry out maintenance work only when the engine is stopped.
Put machine on a safe surface (even, capable of bearing, horizontal).
Keep away from batters.
Secure machine against rolling away.
002-37
WARNING!
Inadmissable engine start!
Risk of injury due to starting engine during maintenance works.
Prior to maintenance works fasten a warning label on the operator
platform.
Prior to maintenance work, pull off the key from the battery isolating
switch (if applicable).
If no battery isolating switch exist, remove the ground strap from the
battery.
002-08
WARNING!
Uncovered, rotating parts!
Risk of injury due to rotating parts.
Only open the engine hood or engine room doors when the engine is
at a standstill.
002-09
WARNING!
Hot surface, hot fluids!
Risk of burns due to hot surfaces and fluids.
Prior to maintenance works, allow machine to cool down to a
temperature under 30 °C (86 °F) .
Do not touch hot machine parts.
Check filling levels only when machine is cooled down.
002-10
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Maintenance
WARNING!
Explosion, acid!
Risk of injury due to moving parts and caustic acids.
Do not put any tools on the battery.
002-11
WARNING!
Fluids under pressure!
Risk of injury due to fluids spurting out under pressure.
Carry out maintenance works only with depressurized hydraulic
systems.
Park the machine on level ground and secure against rolling away.
Put lifted machines on the ground.
Wait at least 1 minute after you switched off the motor until the
pressure is relieved.
002-12
WARNING!
Electrical voltage!
Risk of injury due to electric shock.
Prior to maintenance work, pull off the key from the battery isolating
switch (if applicable).
If no battery isolating switch exist, remove the ground strap from the
battery.
002-13
800-09
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 99

Maintenance
4.00.06 Safety strut

Applying safety strut
1. Align articulated joint for travelling straight ahead (no steering angle).
2. Remove the bolt retainer [A].
3. Lift the locking pin [B], turn it through 180°, and lock the articulated
joint.
800-13
Releasing safety strut
1. Lift the locking pin [B], turn it through 180°, and hook it into bracket
[C].
2. Mount the bolt retainer [A].
800-14
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Maintenance
4.00.07 Welding works on the machine

Preparation Observe the operating manual of the diesel engine.
In order to protect electronic components as e. g. central processing
unit, monitor unit, sensors, relays etc., all connectors must be pulled
out prior to welding work.
The negative terminal of the welding appliance must be applied in
the vicinity of the weld directly on the component to be welded. Pay
attention that it has good contact and remove insulating colour coats.
If possible, keep welding leads away from the leads of the machine
(induction). If not possible, the welding leads must cross the machine
leads.
Touch with live electrodes only the welds. Other components may be
damaged if coming in contact with the electrodes. Prior to welding
works remove components which may get damaged by heat or
welding work.
Ensure that there are no inlfammable or combustible materials /
gases (e.g. fuel, oil, etc.) can get into the vicinity of the welds.
885-00
Fusible board
Engine control unit at the

diesel engine
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 101

Maintenance
Procedure 1. Switch off diesel engine and remove ignition key.

2. Disconnect battery, first negative then positive terminal.
3. To disconnect fusible board:
Press catch [A] downwards.
Take all connectors [B] from the support by jiggling and pulling is
carefully.
4. To disconnect engine control unit [C] at the diesel engine:
Press catch [D] upwards with a screw driver.
Separate plug connection with screw [E] (anti-clockwise).
5. Connect negative terminal of the welding appliance in the vicinity of
the weld.
6. Pay attention to the components in the vicinity of the weld.
7. Reconnect all connection plugs after welding.
885-03
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Maintenance
Chassis / safety features
4.01 Chassis / safety features

4.01.01 General
Adhere to the following Check operating and safety instructions on the machine. Replace
instructions: damaged or non-legible signs.
Ensure that hinges and links move easily and lubricate lightly.
Check the warning devices (signal horn, reflectors, back-up alarm,
blinkers and warning flashers).
Check lighting.
Check heavily loaded screw connections for being properly tightened
e.g. pivoted links, roller drum suspensions, drum drives.
883-00
4.01.02 Checking the function of the parking brake
WARNING!
Uncontrolled driving behaviour!
Risk of fatal injury due to the machine's own driving movements.
machine.
Do not check functioning in case there is not enough space.
002-26
Only inspect the parking brake when engine at standstill.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 103

Maintenance
Function test 1. Start the diesel engine [310].

2. Engage working gear [314].
3. Keep the switch [353] pushed.
4. Push the drive lever [501] shortly in forward direction.
5. Bring the drive lever [501] into central position again before releasing
the switch [353].
If the switch [353] is pushed and the drive blocks, the parking brake
works properly. If the brake discs of the brakes are worn in a way that
driving is possible even if the switch is pushed, the parking brake must
be inspected or replaced.
Operation of the machine is inadmissible! Call the customer service!
813-16
4.01.03 Checking the EMERGENCY STOP function
WARNING!
Full braking!
Activate EMERGENCY STOP only in the event of danger.
Do not use the EMERGENCY STOP as operation brake.
002-03
Function test when engine at Carry out functional tests with the diesel engine running and the work
standstill (daily) functions (e.g. vibration) switched on.
1. Press EMERGENCY STOP [302] when engine at standstill.
The machine:
switches off the working functions.
shuts down the diesel engine.
813-20
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Maintenance
Function test during driving Carry out functional tests with the diesel engine running and the work
operation (yearly) functions (e.g. Vibration) switched on.
1. Press EMERGENCY STOP [302] with low speed 0.5 km/h (0.3 mph).
The machine:
Stops immediately.
Switches off the working functions.
Shuts down the diesel engine.
813-15
4.01.04 Lubricating hinges of the engine hood

2. Lubricate lubrication nipple [A] (2 nipples).
Only lubricant with this sign allowed (see page 138 sqq.).
821-04
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 105

Maintenance
4.01.05 Lubricating hinges of the electric box

821-04
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Maintenance
Control stand
4.02 Control stand

4.02.01 *Air conditioning
WARNING!
Fluids under pressure!
Risk of injury due to fluids spurting out under pressure.
Perform maintenance works only of the air conditioning is not under
pressure and empty.
Wear your safety equippment.
002-27
WARNING!
Refrigerating agent harmful to health!
Risk of injury due to frostbite and harmful vapours.
Do not touch air conditioning components.
Do not opern the pipe system of the air conditioning.
002-28
If the machine is equipped with an air conditioning, it must be

maintained according to the manufacturer's instructions. Only trained,
specialised staff with the corresponding workshop equipment is allowed
to perform these works.
886-00
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 107

Maintenance
Control stand
4.02.02 Replacing fresh air filter of the operator's cabin
Replace the filter depending on the dusty conditions.

2. Loosen screws [A] and remove with the cover [B].
3. Remove filter element [C] from the ventilation system and replace
with a new one.
4. Mount cover [B] and tighten screws [A].
887-00
4.02.03 Checking fill level of the windscreen washer
The tank [A] of the windscreen washer is located in the operator's cabin.
Fill up windscreen washer in good time.
Pure water can be used to wash the windscreen. Antifreeze must be
added when outdoor temperatures are below freezing point. Make sure
you use the mixing ratio specified by the manufacturer!
1. Open lid [B], and fill the tank with the appropriate windscreen
washing liquid.
2. Close the tank lid [B] again.
884-00
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Maintenance
Drive unit - diesel engine
4.04 Drive unit - diesel engine

4.04.01 General
WARNING!
Fuel under high pressure!
Risk of injury due to fluids spurting out under pressure. Fluids spurting
out under pressure may get on your skin or eyes.
Carry out maintenance works only with depressurized fuel systems.
Wait 1 minute after you switched off the diesel engine and the
pressure is relieved.
Special knowledge is necessary for works on the high pressure lines
of the injection system. Therefore only trained specialist personnel
are to carry out these works.
Wear your personal protective equipment (e.g. safety glasses,
protective suit) during test run of the diesel engine.
002-47
WARNING!
Inflamable fuel!
Risk of injury due to fire and explosion.
Do not smoke. No open fire.
Do not breathe in fuel vapours.
Catch spilling fuel or water sump, do not allow to seep away into the
ground!
002-29
NOTICE
Damage to engine due to soiling!
Soiling in the fuel system damages the engine.
Prior to work on the fuel system:
Clean components and their vicinity thoroughly (e.g. with high
pressure washer).
Ensure no soiling or dust enters the fuel system (cover soiled areas
with plastic film).
Dry cleaned, wet areas with compressed air.
004-08
The fuel system must be deaerated after all works on the open
fuel system or after the tank has run out of fuel. Performing a test
run check fuel system for leaks.
000-08
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 109

Maintenance
Adhere to running-in regulations, servicing intervals and care measures

for diesel engine as specified in the operating manual of the engine
manufacturer.
800-08
4.04.02 Maintenance points at the Diesel engine when changing oil
[A] Oil dip stick [B] Oil filler

[C] Oil drain screw
For engine maintenance see operating manual for diesel engine!
Lubricant only admissible if containing this marking (see page

138 sqq.).
872-01
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Maintenance
4.04.03 Changing the filter cartridge for the fuel pre-filter
WARNING!
Inflamable fuel!
ground!
002-29
Replacing filter cartridge 1. Switch off diesel engine and remove ignition key.
2. Allow machine to cool down to a temperature under 30 °C (86 °F) .
3. Open the drain valve [A] (screw conical nipple into housing).
4. Open the vent screw [D].
5. Drain the fuel and the water sump from the filter.
6. Unscrew filter cartridge [C].
7. Unscrew the drain housing [B] from the filter cartridge and clean it.
8. Remove contamination from drain valve [A] (check function).
9. Screw the drain housing [B] with a new gasket ring to the filter
cartridge [C] and tighten by hand. Close drain valve [A] (unscrew the
tightening cone from the housing until the stop).
10.Apply a thin coat of oil to the rubber seal and screw the new filter
cartridge [C] to the filter head until the seal makes contact. Tighten
the filter cartridge by hand further by half a turn.
11. Fill the filter with fuel using the hand pump [E] until fuel comes from
the purge bore.
12.Screw in and tighten the vent screw [D].
13.Open the vent screws [F] at the fuel filter cartridges [G].
14.Actuate the hand pump further until fuel comes out of the purge
bores.
15.Screw in and tighten the vent screw [F].
16.Continue to actuate the hand pump until there is a notable resistance
at the actuation button.
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 111

Maintenance
17.Check for tightness after assembly.
Purging of the fuel system is performed by starting the Diesel

engine. For this, several starting attempts may be necessary.
The starting process may last 20 seconds as a maximum;
otherwise, the starter winding will be overheated and destroyed.
There must be pauses of a minimum of 1 minute between the
individual starting processes in order to allow the starter to cool
down.
The fuel pre-filter must be drained at the drain valve [A] from time to time
depending on the water content in the fuel. If the pilot light [227] flashes,
the water sump must be drained immediately in order to avoid damage
on the diesel engine.
837-18
4.04.04 Replacing ventilation filter for fuel tank
WARNING!
002-32

2. Allow machine to cool down under a temperature of 30 °C (86 °F).
3. Unscrew ventilation filter [A] and replace by a new one.
809-00
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Maintenance
4.04.05 *Draining water separator
WARNING!
Inflamable fuel!
ground!
002-29
General To avoid damage to the diesel engine, the water separator must be
drained at the drain valve [A] depending on the water content in the
fuel. If the fuel has a high water content, the water separator must be
drained more often. If the pilot light [227] flashes, the water sump must
be drained immediately in order to avoid damage on the diesel engine.
Draining water sump 1. Open drain valve [A].

2. Allow water sump to drain off.
3. Close drain valve [A].
897-01
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 113

Maintenance
4.04.06 *Cleaning / replacing filter insert of the dirt and water separator
WARNING!
Inflamable fuel!
ground!
002-29
Changing filter insert 1. Switch off diesel engine and remove ignition key.
3. Close the fuel shutoff valve if existing (only if the fuel tank is installed
in high position).
4. Open drain valve [A].
5. Open the vent screw [D].
6. Drain the fuel and the water sump from the filter.
7. Loosen 4 screws [b] and remove (screws are spring-loaded at the
beginning).
8. Removing cover [C]
9. Remove internal spring cage.
10.Take the filter insert out of the casing, and clean it or replace it by a
new one.
11. Mount the spring cage and the lid [C] (tighten screws [B] diagonally).
12.Close drain valve [A].
13.Open the fuel stop cock if existing (only if the fuel tank is installed in
high position).
14.Fill the water separator with fuel using the manual pump [E] on the
fuel prefilter until fuel comes from the purge bore [D].
15.Screw in and tighten the vent screw [D].
16.Continue to actuate the manual pump until there is a notable
resistance at the actuation button.
17.Check for tightness after assembly.
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Maintenance
Purging of the fuel system is performed by starting the diesel

engine. For this purpose, several starting attempts may be
necessary. The starting process may last 20 seconds as a
maximum; otherwise, the starter winding will be overheated and
destroyed. There must be pauses of at least 1 minute between
the individual starting processes in order to allow the starter to
cool down.
882-00
4.04.07 Checking and cleaning dust discharge valve
Prior to start of work check whether the opening of the dust discharge
valve [A] is clogged with moist dirt deposits.
2. Squeeze the dust discharge valve [A] and clean the discharge slot.
810-18
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 115

Maintenance
4.04.08 Checking and replacing the air filter
WARNING!
Exposed, rotating parts!
Risk of injury due to rotating parts.
Start the diesel engine only with closed engine hood resp. closed
engine room doors.
machine.
002-30
NOTICE
Air filter cartridge / safety cartridge damaged or missing!
Engine damaged by dirt in the intake air.
Replace dirty air filter cartridge, do not clean it.
Replace damaged air filter cartridge immediately.
The safety filter cartridge may only be taken from the housing for
replacement purposes. The safety cartridge must not be cleaned.
Clean the interior parts of the casing only with a moist, fiber-free
cloth, never with compressed air.
Ensure that no dirt gets into the clean air side of the air filter.
The diesel engine must not be operated without air filter cartridge
and safety filter cartridge.
004-10
General
The operability control of the air filter cartridge and the safety cartridge
must be performed with the diesel engine running.
1. Start diesel engine and shortly rev up to maximum speed.
If the pilot light [203] does not light up, both filter cartridges are still
completely operable. If the pilot light flashes, the air filter cartridge [B]
resp. the safety cartridge [A] must be replaced.
810-19
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Maintenance
Replacing air filter cartridge 1. Switch off diesel engine and remove ignition key.
3. Pull out lock [C].
4. Turn the dust container [D] anti-clockwise (approx. 10°) and remove
it.
5. Clean the inside of the dust collectors.
6. Replace the air filter cartridge [B].
7. Re-assemble in reverse order.
The operability check for the safety filter cartridge [A] is performed
together with the replacement of the air filter cartridge [B]. To test that,
start the diesel engine when the filter housing is open and the new air
filter cartridge is inserted. If the pilot light [203] does not light up during
this process, the safety filter cartridge is still completely operable. If the
pilot light flashes, the safety filter cartridge must be replaced.
810-17
4.04.09 Changing the safety cartridge

Change the safety filter cartridge in the following intervals:
After having changed the air filter cartridge five times.
After 2000 operating hours at the latest.
If the pilot light [203] does not go out after having changed the air
filter cartridge.
If the air filter cartridge is defective.
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Maintenance
Changing the safety cartridge 1. Switch off diesel engine and remove ignition key.
3. Remove the air filter cartridge [B].
4. Pull out safety filter cartridge [A].
5. Insert a new safety filter cartridge.
6. Insert the air filter cartridge [B].
The safety filter cartridge may only be taken from the housing
for replacement purposes. The safety cartridge must not be
cleaned. The diesel engine must not be operated without air filter
cartridge and safety filter cartridge.
861-04
4.04.10 Checking radiator

3. Check the cooling fins of the radiators for contamination.
If the radiators are contaminated they must be cleaned thoroughly and

immediately.
4. Clean the radiator carefully with a high-pressure cleaner.
824-03
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Maintenance
4.04.11 Checking coolant level

2. Only check the coolant level when the engine is cold.
3. Correct coolant level: Between the Min. and Max. mark at the
compensation tank.
Do not exceed this level!
4. In case of a lack of coolant, only fill up coolant in the specified
concentration through filling opening [A] at the compensator tank.
5. In case of bigger coolant losses, find out and eliminate the cause.

138 sqq.).
815-03
4.04.12 Changing coolant

2. Open the sealing cap [A] at the compensator tank.
3. Remove the drain plug [B] from the radiator and discharge the
coolant in a provided receptacle.
4. Drain the engine block at the drain plug [C] according to the engine
operating manual.
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Maintenance
5. Screw in again the drain plug [B, C].

6. Open the hollow screw [D] of the purge line at the engine block by
three turns (do not remove).
7. Set the temperature regulator for the cabin heating to maximum
temperature.
8. Fill coolant into the filling opening [A] of the compensation tank, until
coolant spills from the hollow screw [D].
9. Tighten the hollow screw [D].
10.Top up coolant up to the max. mark of the compensation tank.
11. Close the filling opening with the sealing cap [A].
12.Start the diesel engine and bring it to operating temperature
(thermostat opens).
13.Switch off diesel engine and remove ignition key.
14.Check coolant level when the motor is cold, fill up as necessary.
15.Correct coolant level: Between the Min. and Max. mark at the
compensation tank.

138 sqq.).
866-04
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Maintenance
Hydraulic oil supply
4.05 Hydraulic oil supply

4.05.01 General
Check all lines, hoses and screwed connections regularly (at least 1x
yearly) for leaks and visible damage.
Damaged parts must be replaced immediately. Further operation is
inadmissible. Oil spurting out can lead to injuries and fire.
Avoid subsequent damage! After a damage to the hydraulic system,
with a foreign object having entered the oil circuit, the entire hydraulic
system must be cleaned. This work may only be performed by trained
specialised personnel! Call the customer service!
After that, replace all suction filters, return filters or pressure filters in the
hydraulic system after 50 and after 125 operating hours.
888-00
4.05.02 Checking hydraulic oil level

2. Check only when the engine is cooled down to approx. 20 °C (68 °F).
3. Correct oil level: Centre of inspection glass [A].
Do not exceed this level!
4. If the oil level is too low, fill in appropriate oil through filling opening
[B].
5. In case of bigger oil losses, find out and eliminate the cause.
811-03
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Maintenance
4.05.03 Replacing hydraulic oil

3. Unscrew oil drain screw [C] down on the oil tank and discharge the
used oil drain into a provided receptacle.
4. Screw in oil drain screw [C] and tighten.
5. Fill in specified oil through filling opening [B] to the centre of the
inspection glass [A].
6. Start the diesel engine, actuate drive lever [501] with low engine
speed until the drive activates, furthermore actuate the steering.
Pipes and hoses are filled with oil and purged.
7. Check the oil level of the diesel engine with the engine at a standstill.
If necessary fill up to the centre of the inspection glass [A].
8. Check the hydraulic system for leaks.

138 sqq.).
860-14
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Maintenance
4.05.04 Replacing ventilation filter for hydraulic oil tank

3. Unscrew ventilation filter [A] and replace by a new one.
809-00
4.05.05 Replacing filter insert of pressure filter for hydraulic system
WARNING!
002-32
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Maintenance

2. Allow machine to cool down below a temperature of 30 °C (86 °F).
3. Unscrew the cup-shaped housing [A].
4. Pull the filter insert [B] from the filter head and replace with a new
one.
5. Clean the inside of the cup-shaped housing, screw it back to the filter
head and tighten.
836-05
4.05.06 Replacing filter insert of pressure filter for steering system
WARNING!
002-32

2. Allow machine to cool down below a temperature of 30 °C (86 °F).
3. Unscrew the cup-shaped housing [A].
4. Pull the filter insert [B] from the filter head and replace with a new
one.
5. Clean the inside of the cup-shaped housing, screw it back to the filter
head and tighten.
836-05
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Maintenance
Drive
4.08 Drive
4.08.01 Inspecting smooth drum scrapers
General Only correctly adjusted scrapers ensure a clean roller drum surface.
Check the condition of the scrapers. Replace worn scrapers in good
time.
825-15
If the scrapers are worn to the extent that dirt adhering is no longer
removed from the drum while the machine is working, the scraper must
be readjusted to the correct clearance.
Smooth drum clearance — 10 mm
Basic setting of scraper 1. Switch off diesel engine and remove ignition key.
2. Loosen hexagonal screw [A].
3. Push scraper console to the clearance of the drum.
4. Tighten hexagonal screw [A].
Readjusting the scraper 1. Switch off diesel engine and remove ignition key.
2. Loosen clamp connection [C].
3. Push scraper [D] to the clearance of the drum.
4. Tighten clamp connection [C].
825-23
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Maintenance
Drive
4.08.02 Inspecting scrapers of stamping feet drum

General Only correctly positioned scraper teeth can remove the dirt from
between the stamping feet optimally.
825-24
Stamping feet drum clearance — 15 mm
Basic setting of scraper 1. Switch off diesel engine and remove ignition key.
2. Loosen hexagonal screw [A].
3. Push scraper tooth to the clearance of the drum.
4. Tighten hexagonal screw [A].
825-25
4.08.03 Checking the wheel nuts / wheel bolts for tightness

2. Tighten the wheel nuts / wheel bolts crosswise.
For starting torque see Technical data (see page 147 sqq.).
879-00
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Maintenance
Drive
4.08.09 Checking the air pressure in the tyres
WARNING!
Explosion, fluids under pressure!
Risk of injury due to flying parts and fluids spurting out under pressure.
Change damaged tyres.
When filling, do not exceed the values of the specified air pressure.
Use only suitable filling devices with a pressure indicator.
Fill tyres with water filling only in UPSIDE valve position.
When filling the tyres, be always next to the tyre, not in front of it.
002-43
Visually inspect the tyre pressure daily. In case of visible air deficiency
fill the tyres with suitable filling devices to the specified air pressure.
2. Fasten filling hose to the valve [A] and fill the tyre till it reaches the
specified air pressure (air pressure see page 147 sqq.).
898-00
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Maintenance
Drive
4.08.10 Changing the tyres

Preparation Only persons familiar with changing tyres and aware of dangers are
allowed to change the tyres.
Put machine on a safe surface (even, capable of bearing, horizontal).
Lift the machine only by the specified suspension points using
suitable hoisting gear and take into account the weights (see page
147 sqq.).
When jacking up the machine, use only stable liners capable of
bearing (e.g. squared timber of sufficient size)
Observe the weight of the tyres (see page 147 sqq.). Install if
possible with two persons.
Dismantling 1. Switch off diesel engine and remove ignition key.

2. Lift the machine until the tyres are clear from the ground.
3. Put machine on the machine frame on liners capable of bearing
(tyres may not be in contact with the ground).
4. Unscrew wheel nuts.
5. Remove the wheels from the wheel hub.
Installation 1. Put the wheels on the wheel hub (tyre bolts must align with the fixing
holes).
2. Screw the wheel nut on the tyre bolt and tighten with the starting
torque ( see page 147 sqq.).
3. Lift the machine and remove the liners.
896-03
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Maintenance
Drive
4.08.11 Checking driving gear oil level
WARNING!
002-32

3. Screw out the check plug [A]; if the oil level is correct, some oil must
flow out of the control bore.
4. If the oil level is insufficient, fill in oil through the filler bore [B].
5. Screw in and tighten the check plug [A].

138 sqq.).
827-03
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Maintenance
Drive
4.08.12 Changing driving gear oil
WARNING!
002-32

3. Remove filling screw [B] carefully for pressure compensation
purposes.
4. Screw out oil drain screw [C] and let the used oil drain into a provided
receptacle.
5. Screw in oil drain screw [C] and tighten.
6. Screw out the check plug [A].
7. Fill in the specified oil type though the filling bore [B] until oil comes
out of the control bore.
8. Screw in filler plug [B] and tighten the check plug [A].

138 sqq.).
862-07
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Maintenance
Drive
4.08.13 Checking differential gear oil level
WARNING!
002-32

2. Allow machine to cool down to a temperature under 30 °C (86 °F).
3. Unscrew filler / check plug [A]; if the oil level is correct, some oil must
flow out of the control bore.
4. If the oil level is insufficient, fill in oil through the filler / control bore
[A].
5. Screw in and tighten the check plug [A].

138 sqq.).
826-01
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Maintenance
Drive
4.08.14 Changing differential gearbox oil
WARNING!
002-32

2. Allow machine to cool down to a temperature under 30 °C (86 °F).
3. Remove filler / check plug [A] carefully for pressure compensation
purposes.
4. Screw out oil drain screws [B] (3 items) and let the used oil drain into
a provided receptacle.
5. Screw in and tighten oil drain screws [B].
6. Fill in the specified oil type though the filling /control bore [A] until oil
comes out of the bore.
7. Screw in and tighten filler / check plug [A].

138 sqq.).
864-01
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Maintenance
Steering system
4.09 Steering system

4.09.01 General
Any work in the danger zone of the articulated steering may only be
performed with the engine at a standstill and with the electrical system
switched off! Furthermore, the safety strut must be latched.
889-00
4.09.02 Lubricating pivoted bearing
WARNING!
Prior to maintenance works, apply the safety strut in the hazard area.
002-33

2. Lubricate lubrication nipple [A].
820-04
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Maintenance
Steering system
4.09.03 Lubricating steering cylinder bolt
WARNING!
Prior to maintenance works, apply the safety strut in the hazard area.
002-33

821-04
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Maintenance
Vibration / oscillation
4.26 Vibration / oscillation

4.26.01 General
Prior to maintenance works clean roller drums thoroughly.
WARNING!
Check filling levels only when machine is cooled down.
002-10
891-00
4.26.02 Checking vibrator oil filling level
Drive the machine slowly until the mark [A] is exactly perpendicular
below the axle.
3. Correct oil level: centre of inspection glass [B].
4. If the oil level is insufficient, fill in oil through the filler bore [C].
The check must be performed at the right and the left drum side.

138 sqq.).
814-03
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Maintenance
4.26.03 Changing vibrator oil
Drive the machine slowly until the mark [A] is exactly perpendicular
below the axle.
3. Remove filling screw [C] for pressure equalization purposes.
4. Screw out oil drain screw [D] and let the used oil drain into a provided
receptacle.
5. Screw in and tighten the oil drain screw [D] with gasket ring.
6. Fill in the specified oil type through the filler bore [C].
Correct oil level: centre of inspection glass [B].
7. Screw in and tighten the filling screw [C] with gasket ring.
The oil change must be performed at the right and the left drum
side.

138 sqq.).
838-07
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Maintenance
4.26.04 Checking damping elements

2. Check the damping elements [A] of the roller drum suspension for
cracks.
Replace damaged damping elements by new ones.

880-01
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Tables
Technical data
5 TABLES
000-01
5.00 Technical data

5.00.01 Lubrication indications
Viscosity - temperature range
The viscosity of lubricant oil changes with the temperature. The ambient temperature at the place of
utilisation determines the selection of the viscosity class (SAE class).
The following chart applies only for engine oil.
[A] Pre-heating only
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Tables
Technical data
Lubrication indications
Lubricant Quality Viscosity Identification
Engine oil API: CG-4
The oil quality must correspond to the or higher
See chart
API / ACEA classification. ACEA: E5-02
or higher
Hydraulic oil (mineral oil)
The viscosity is determined in accor- Conditions
HVLP ISO VG 22 arctic
dance with DIN standard 3448 (ISO-VG:
viscosity grade). ISO VG 32 winter
ISO VG 46 summer
Hydraulic oil (biological hydraulic oil) ISO VG 68 tropical
Synthetic, saturated ester HEES ISO VG 100 extreme heat
(ISO-VG: viscosity grade).
Special oil
Only HAMM special oil is admissible.
Gear oil with Limited Slip additions.
The oil quality must meet the API GL-5 SAE 85W-90
API classification.
Coolant for engine, liquid-cooled (free of nitrite, amine and phosphate).
Mixture: 40 % coolant concentrate, 60 % water.
Lubricating grease
Lithium-based multi-purpose grease with high-pressure additives.
Temperature application range from -25 °C (-13 °F) to +120 °C (248 °F).
For order numbers and packing size see WIRTGEN GROUP Document Parts and More and Wirtgen
Group lubricants (see page 140 sqq.).
804-02
5.00.02 Use of biologic hydraulic oil

The hydraulic system of the machine is generally filled with mineral oil in factory. All maintenance intervals
given in these maintenance instructions are related to mineral oil.
The use of biological hydraulic oil is admissible under the following circumstances:
Only biological hydraulic oil on the basis of special synthetic saturated complex esters may be used.
The products used and recommended by HAMM can be taken from the lubricant indications (see page
138 sqq.). Other oils used must correspond to the specifications of the oil above mentioned. The
neutralisation value (oil acid) may not exceed 2.
Hydraulic oil replacement (biological hydraulic oil replaces mineral oil; mineral oil replaces biological
hydraulic oil) may only be performed in accordance with special instructions. You can request for these
instructions at HAMM Customer service. All filters in the oil circuit are to be replaced 50 operating hours
after oil replacement. After that, the filter change intervals given in this instructions apply again.
Used biological oil must be disposed at a reliable place of disposal, just like mineral oil.
801-01
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 139

Tables
Technical data
5.00.03 Wirtgen Group Lubricants
General
Intensive testing and development work with leading mineral oil companies has analysed the complex and
high requirements of Wirtgen Group machines. The results have been translated into optimal specifications
and used for the first filling in the factory. The results are impressive:
a wide range of premium lubricants from one source augmented by highly functional accessories "Made in
Germany" for filling and lubrication. The new Wirtgen Group lubricants are the "elixir of life" for your fleet.
Premium lubricants
Wirtgen Group lubricants combine the best basic oils and unique additives in tailor-made specifications.
The advantages for you:
A longer oil change interval according to the oil analysis by the Wirtgen Group
Compatibility with the first filling
Optimal protection against wear
Perfect prevention of corrosion
Retracing in the event of damage
Wirtgen Group lubricants not only increase the performance and service life of your machines but also
permanently reduce your running costs. Why try to make savings in the wrong place?
Everything from one source

All Wirtgen Group machines – Wirtgen milling machines, Vögele pavers and HAMM rollers – can be filled
and lubricated with the Wirtgen Group lubricant appropriate for the particular area of application.* Together
with the sophisticated container mix, this leads to clearly optimized ordering, storage and filling.
*Exceptions are shown
Filling and lubricating accessories

We support you with highly functional accessories "Made in Germany" for filling and lubrication, such as
canister pumps and grease guns.
804-03
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Tables
Technical data
Wirtgen Group Engine Oil 15W40

Strong heavy-duty motor oil made from excellent basic oils and special additives. It increases the power
output of your engine and gives the highest operational reliability.
Packing size: 5 l, 20 l, 208 l

Classes: ACEA E7 / E5, API CI-4 / SL
Manufacturer standards: Daimler Chrysler MB 228.3, Caterpillar CAT ECF-1, Cummins CES
20078/7/6/2/1, Mack EO-M Plus, Volvo VDS-3, MAN M3275
804-04
Wirtgen Group Hydraulic Oil HVLP 46

High quality, multirange hydraulic oil with a high viscosity index for the best protection against wear under
the most difficult operating conditions. A new refined specification enables very long oil change intervals.
Guaranteed optimal cold start performance.
Packing size: 20 l, 208 l

Classes: Dension HF-0, Vickers M-2950-S, DIN 51524 part 3, HVLP, ISO6743/4 type HV
804-05
Wirtgen Group Gear Oil 85W90

Latest generation mineral gear oil for multi-purpose use in gearboxes and axle drives. It provides
impressive protection against wear and oxidation.

Classes: API GL-5
Manufacturer standards: Daimler Chrysler MB 235.0, ZF-TE-ML05A/07A/16C/17B/19B, MAN 342 type N
Do not use for Wirtgen milling drum gears, HAMM vibration bearings or drum drives, or Vögele
pump distributor gears or drive units.
804-06
Wirtgen Group Special Gear Oil

Special fully synthetic heavy-duty gear oil for HAMM vibration bearings and drum drives, as well as Vögele
pump distributor gears and drive units. Extremely pressure and temperature stable.
Do not mix with mineral gear oil. Do not use in Wirtgen milling drum gears.
804-07
Wirtgen Group Multipurpose Grease

The finest multipurpose grease for a wide range of lubricating tasks, such as pivot pins and wheel
bearings. State-of-the-art additive technology makes it especially suitable for use under shock and
vibrating conditions.
Packing size: 400 g cartridge

804-08
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 141

Tables
Technical data
Wirtgen Group Drum Bearing Grease

Exclusive grease for lubricating HAMM drum bearings. Extremely temperature-resistant and and pressure-
stable.
Packing size: 1 kg
804-09
Wirtgen Group Drive Bearing Grease

Special heavy-duty grease for use in HAMM drive bearings. Extremely pressure stable and water repellent.
Packing size: 1 kg
804-10
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Tables
Technical data
Overview of Wirtgen Lubricants

Designation Identification Packing size Order No.
5l 2065020
Wirtgen Group Engine Oil 15W40 20 l 2065025
208 l 2065026
5l 2112355
Wirtgen Group Engine Oil 10W40
20 l 2112354
20 l 2065028
Wirtgen Group Hydraulic Oil HVLP 46
208 l 2065029
5l 2065030
Wirtgen Group Gear Oil 85W90 20 l 2065031
208 l 2065032
5l 1238051
Wirtgen Group Special Gear Oil 20 l 2065037
208 l 2065038
Separator concentrate for combo and 5l 2117378

rubber-tyred rollers 20 l 2117379
Wirtgen Group Multipurpose Grease 400 g 2065035
Wirtgen Group Drum Bearing Grease 1 kg 1205757
Wirtgen Group Drive Bearing Grease 1 kg 1227114
5l 2120296
Radiator antifreeze agent
20 l 2120298
804-11
5.00.04 Coolant conditioning

For liquid-cooled diesel engines, special care must be taken for the conditioning and the inspection of
the coolant; otherwise, corrosion, cavitation and freezing can cause damage on the diesel engine. The
conditioning of the coolant is performed by adding a cooling system protection agent to the coolant.
The cooling system requires constant monitoring. Apart from the control of the coolant level, this also
implies the verification of the concentration of the cooling system protection agent.
The concentration of the cooling system protection agent can be checked with commercially available test
devices (e.g. gefo glycomat ®).
The concentration of the cooling system protection agent in the coolant should not exceed or fall
short of the following values:
Cooling system protection Water
agent
max. 45 Vol. % 55 %
min. 35 Vol. % 65 %
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 143

Tables
Technical data
The products used and recommended by HAMM (free from nitrites, amines and phosphates) can be taken
from the lubricating instructions (see page 138 sqq.). The factory-filled coolant mixture consists of 40 %
Cooling system protective agent and 60 % water. This guarantees freezing protection up to -25 °C (-13 °F).
The cooling system protectiv agent can be purchased from HAMM customer service.
802-01
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Tables
Technical data
5.00.05 Fuel
Use only the diesel fuel commercially available which contains a sulphur content below 0,5 % . The engine
oil replacement intervals specified here apply only for diesel fuel.
Approved diesel fuel specifications are:

DIN EN 590
ASTM D 975 Grade-No. 1-D and 2-D
JIS K 2204 Grade 1 Fuel and Grade 2 Fuel, with lubricating properties corresponding to diesel fuel
EN 590 (HFFR max. 460 micrometer in accordance with EN ISO 12156)
In case other fuels are used that do not comply with the afore mentioned requirements, we do not accept
any guarantee.
With diesel fuels with a sulfur content over 0,5 % to 1,0 % or permanent ambient air temperatures below
-10 °C (-14 °F) the change intervals of the motor oil need to be halved.
The certification measurements to measure the compliance with statutory emission limits are carried out
using the test fuels specified by law. These fuels comply with the diesel fuels specified in this operating
manual according to EN 590 and ASTM D 975. For all other fuels specified in this operating manual we
cannot guarantee any emission values.
[A] Exterior temperature [B] Admixture fraction petroleum

[C] Summer diesel fuel [D] Winter diesel fuel
Winter operation with diesel fuel

With lower ambient temperatures paraffin precipitations may result in congestions of the fuel system and,
thus, in malfunctions.
Below an ambient temperature of 0 °C (32 °F) it is necessary to use winter diesel fuel
(up to -20 °C (-4 °F)) (gas stations provide them early enough prior to winter time).
Below -20 °C (-4 °F) it is necessary to add petroleum.
For the mixture ration required please see diagram.
For arctic climate zones up to -44 °C (-47 °F) it is possible to use special diesel fuels.
In case it is necessary to use summer diesel fuels below 0 °C (32 °F) , it is also possible to add petroleum
up to 30 % as indicated in the diagram.
Sufficient cold resistance may be achieved by adding flow improver.
715-01
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 145

Tables
Technical data
5.00.06 Starting torques

The starting torques indicated within the tables apply to nuts in accordance with DIN 934 and screws with
headrest according to DIN 931 (frictional coefficient μtotal = 0.12) unless otherwise specified.
Check screws and nuts regularly for tight seat, if necessary, retighten.
Starting torques for regular type screw threads

Starting torques MA (Nm)
Threads
8.8 10.9 12.9
M4 2,7 4,0 4,7
M5 5,5 8,1 9,5
M6 9,5 14 16,5
M8 23 34 40
M10 46 68 79
M12 79 117 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1120
M27 1000 1400 1650
M30 1350 1900 2250
Starting torques for fine threads

Starting torques MA (Nm)
Threads
8.8 10.9 12.9
M8x1 24,5 36 43
M10x1.25 49 72 84
M12x1.25 87 125 150
M12x1.5 83 122 145
M14x1.5 135 200 235
M16x1.5 205 300 360
M18x1.5 310 440 520
M20x1.5 430 620 720
M22x1.5 580 820 960
M24x2 730 1040 1220
M27x2 1070 1500 1800
M30x2 1490 2120 2480
892-00
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Tables
Technical data
5.01 Technical data

5.01.01 3410
Designation Value Unit
Dimensions and weights
Basic weight without cab 9860 kg
Operating weight with cabin 10530 kg
Axle load front / rear 5690 / 4840 kg
Working width 2140 mm
Turning radius inside / outside 4005 / 6145 mm
Diesel engine
Manufacturer Deutz
Type TCD 2012 L04 2V
Number of cylinders 4
Power (ISO 14396) / rated speed 100,0 / 2300 kW / rpm
Emission level COM 3, EPA 3
Drive
Working gear speed 0-5,7 / (0-3,5) km/h / (mph)
0-7,6 / (0-4,7)
0-7,9 / (0-4,9)
Transport speed 0-12,0 / (0-7,4) km/h / (mph)
Climbing ability, vibration on / off 53 / 57 %
Max. longitudinal gradient allowed 30 °
Max. transverse gradient allowed 30 °
Tyres
Tyre size AW 23.1-26 12 PR
Number of tyres 2 items
Total weight per tyre 755 kg
Tyre with rim 225 kg
Water filling 455 l
Magnesium chloride 75 kg
Air pressure 0.17 / (1.7) / [24.5] MPa / (bar) / [psi]
Tightening torque, wheel nut 550 Nm
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 147

Tables
Technical data

Vibration
Vibration front
Level 1: Frequency / speed 30 / 1800 Hz / rpm
Level 1: Maximum amplitude 1.78 mm
Steering
Steering angle to both sides 33 °
Pendulum compensation upwards and downwards 10 °
Filling quantities
Fuel 290.0 l
Engine oil (for oil change) 11.5 l
Engine coolant 14.0 l
Hydraulic oil 50.0 l
Differential gear 14.0 l
Driving gear 1.3 l
Vibrator right / left 1.6 / 1.6 l
Air conditioning (R134a) 1.6 kg
Noise data
Guaranteed sound power level LWA 106 dB(A)
Measured noise level at operator platform with
ROPS cabin 80 dB(A)
ROPS roll-over bar 85 dB(A)
Electrical system
Operation voltage 12 V
148 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Tables
Technical data
5.01.02 3410 P
Padfoot, number 140 items
Padfoot, height 100 mm
Padfoot, end face 154 cm²
Diesel engine
Manufacturer Deutz
Drive
Working gear speed 0-5.8 / (0-3.6) km/h / (mph)
0-7.2 / (0-4.5)
0-8.4 / (0-5.2)
Tyres
Tyre size TR 23.1-26 12 PR
Water filling 455 l
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 149

Tables
Technical data

Vibration
Vibration front
Steering
Filling quantities
Fuel 290.0 l
Driving gear 1.3 l
Noise data
ROPS cabin 80 dB(A)
Electrical system
150 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Tables
Technical data
5.01.03 3411
Diesel engine
Manufacturer Deutz
Drive
Working gear speed 0-5,7 / (0-3,5) km/h / (mph)
0-7,6 / (0-4,7)
0-7,9 / (0-4,9)
Tyres
Tyre size AW 23.1-26 12 PR
Water filling 455 l
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 151

Tables
Technical data

Vibration
Vibration front
Steering
Filling quantities
Fuel 290.0 l
Driving gear 1.3 l
Noise data
ROPS cabin 80 dB(A)
Electrical system
152 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Tables
Technical data
5.01.04 3411 P
Padfoot, number 140 items
Padfoot, height 100 mm
Padfoot, end face 154 cm²
Diesel engine
Manufacturer Deutz
Drive
Working gear speed 0-5.8 / (0-3.6) km/h / (mph)
0-7.2 / (0-4.5)
0-8.4 / (0-5.2)
Tyres
Tyre size TR 23.1-26 12 PR
Water filling 455 l
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 153

Tables
Technical data

Vibration
Vibration front
Steering
Filling quantities
Fuel 290.0 l
Driving gear 1.3 l
Noise data
ROPS cabin 80 dB(A)
Electrical system
154 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Tables
Dimension sheet
5.02 Dimension sheet

5.02.01 3410, 3411
5.02.02 3410 P, 3411 P
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 155

Tables
Fuses
5.03 Fuses
5.03.01 Main fuses
Fuses
Position Fuse occupancy Fuse
F01 On-board electrical system (terminal 30) 100 A
F02 Alternator B+ 100 A
F03 Cold starting device 150 A
F04 not used
400-27
5.03.02 Fuses, electrical box

Fuses
F1 not used
F2 not used
F3 Sensors for: 5A
– Coolant level
– Air filter
F4 Sensors for: 5A
– Vibration frequency
– Driving speed
F5 Fuel level transmitter 5A
Filling pump control
F6 Multifunction handle 7.5 A
Push plate
F7 EMERGENCY STOP 7.5 A
Diesel engine controller (EMR) (terminal 15)
F8 Driving light, right 7.5 A
F9 Driving light, left 7.5 A
F10 Parking light, right 5A
F11 Parking light, left 5A
F12 Signal horn 10 A
F13 Warning flasher (terminal 15) 10 A
F14 Filling pump 25 A
F15 Backup alarm 7.5 A
F16 Fuel pre-heating 30 A
F17 Vibration 7.5 A
F18 Compaction meter (HCM) 7.5 A
F19 not used
F20 Alternator D+ 5A
F21 Display (terminal 15) 7.5 A
156 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Tables
Fuses

F22 not used
F23 Socket 10 A
F24 Gear shifting 10 A
F25 Diesel engine speed adjustment 7.5 A
F26 not used
F27 Heating, air conditioning (terminal 15) 15 A
F28 Seat contact switch 10 A
F29 Cabin (clamp 15) 30 A
F30 Electrical system (terminal 30) 10 A
F31 Diesel engine controller (EMR) (terminal 30) 25 A
F32 Lighting (terminal 30) 15 A
F33 Warning flasher (terminal 30) 10 A
F34 Cabin (clamp 30) 30 A
FL Receptacle for fusible test
When the green LED lights up, the fuse is operable.
400-28
5.03.03 Fuses, operator's cabin

Fuses
1 Illumination for control devices (terminal 58) 10 A
2 Interior cab lighting, tachograph (terminal 30) 10 A
3 Working lights at the cabin (terminal 15) 25 A
4 Windshield washer, beacon (terminal 15) 15 A
5 Windshield wiper front / back (terminal 15) 15 A
6 Radio (terminal 30) 10 A
7 Air conditioning system 40 A
8 Air conditioning system 40 A
403-09
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 157

Assembly instructions
Instructions for installation and retrofitting
6 ASSEMBLY INSTRUCTIONS
000-01
6.00 Instructions for installation and retrofitting

6.00.01 Safety device ROPS cabin
General The ROPS cabin is a safety device in the case the machine tilts or rolls
over. It avoids that the driver is crushed to death based on the high self-
weight of the machine. In case the ROPS cabin was demounted (from
the machine) due to transport or repair reasons, the ROPS cabin needs
to be remounted according to instructions prior to operating the machine
again.
158 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Assembly instructions ROPS

WARNING!
cabin
High self-weight of machine!
Risk for life: Machine may crush you to death if tilting or rolling over.
Operate machine only with the ROPS safety device installed
according to instructions.
With detectable defects of the ROPS safety device or of its fixation it
is not allowed to operate the machine.
002-34
Installation
1. Use appropriate lifting devices and hoisting equipment. Observe
weight (see type plate of ROPS safety device).
2. Lift ROPS cabin onto platform and align with fixing holes.
3. Screw ROPS cabin with operator platform. Observe specified starting
torque (see picture).
Visual test The machine frame must not be warped, bent or cracked in the ROPS
fixing area (deformation).
The reinforcement elements of the ROPS cabin must not show rust,
damage, fissures or open fractures.
All screw connections of the reinforcement elements must comply with
the given specifications and must be screwed tightly to each other
(observe starting torque values).
Bolts and nuts must not be damaged, bent or deformed.
It is absolutely forbidden to modify or repair / level the reinforcement
elements in any way.
619-00
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 159

6.00.02 Safety device ROPS roll-over bar
General The ROPS roll-over bar is a safety device in the case the machine tilts
or rolls over. It avoids that the driver is crushed to death based on the
high self-weight of the machine. In case the ROPS roll-over bar was
dismounted (from the machine) due to transport or repair reasons, the
ROPS roll-over bar needs to be remounted according to instructions
prior to operating the machine again.
Assembly instructions ROPS

WARNING!
roll-over bar
High self-weight of machine!
Risk for life: Machine may crush you to death if tilting or rolling over.
Operate machine only with the ROPS safety device installed
according to instructions.
With detectable defects of the ROPS safety device or of its fixation it
is not allowed to operate the machine.
002-34
Installation
1. Use appropriate lifting devices and hoisting equipment. Observe
weight (see type plate of ROPS safety device).
2. Lift ROPS roll-over bar onto platform and align with fixing holes.
3. Screw ROPS roll-over bar with operator platform. Observe specified
starting torque (see picture).
160 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

Visual test The machine frame must not be warped, bent or cracked in the ROPS
fixing area (deformation).
The reinforcement elements of the ROPS roll-over bar must not show
rust, damage, fissures or open fractures.
All screw connections of the reinforcement elements must comply with
the given specifications and must be screwed tightly to each other
(observe starting torque values).
Bolts and nuts must not be damaged, bent or deformed.
It is absolutely forbidden to modify or repair / level the reinforcement
elements in any way.
620-00
© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 161

01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Centre pivot assembly
# 853747
3 Radial rod end bearing
Plate for front part
Plate for rear part
Bolt for
transportation lock
Mechanical-Training 1/3
# 853747
16
7
17
6
15 13
14 12
11 11
20
10
20
1
2
20
11 5
# 853747
Pos Bezeichnung Description Designation
1 Pendel- und Knickgelenk Centre pivot assembly Articulation centrale

2 Pendel- und Knickgelenk Centre pivot assembly Articulation centrale
5 Radialgelenklager Radial rod end bearing Palier à bascule radiale
6 Blech Plate Tôle
7 Zylinderschraube Cheese-head screw Vis à tête cylindrique
8 Blech Plate Tôle
9 Deckel Cover Couvercle
10 Sechskantschraube Hexagon screw Vis hexagonale
11 Schmiernippel Lubrication nipple Nipple de graissage
12 Blech Plate Tôle
13 Radialgelenklager Radial rod end bearing Palier à bascule radiale
14 Flansch Flange Bride
15 Deckel Cover Couvercle
16 Sechskantschraube Hexagon screw Vis hexagonale
17 Sicherungsscheibe Locking washer Rondelle d'arrêt
18 Sicherungsscheibe Locking washer Rondelle d'arrêt
20 Dichtring Gasket ring Bague d'étanchéité
Diagram roller drum - vibration
# 873861
Driver Roller drum

Rubber buffer
screwed to the
drive transmission
Drive bearing
Suspension Suspension
roller drum roller drum
screwed to the right screwed to the
side of the left side part
front part of the front part
Vibration
Drive motor motor
roller drum
Vibration
Drive transmission Driver

screwed to the roller drum
# 873861
niedrige Frequenz hohe Frequenz

große Amplitude kleine Amplitude
low frequency high frequency

large amplitude small amplitude
fréquence réduite fréquence élevée

grande amplitude petite amplitude
Drehrichtung sense of rotation sense de rotation

Unwucht fest unbalance fixed balourd immobile
Unwucht lose unbalance loose balourd détaché
Amplitude amplitude amplitude
# 873861
Attention!
When switching on the big amplitude, the vibrator
must turn clockwise.
Danger of bearing damage !
View of machine from the left
Series HD / DV
Vibration
• Big amplitude
• Small amplitude
Direction of rotation
vibrator Series 3000
„clockwise“
Wheel gear – drum drive
# 1254758
Hydraulic variable displacement

motor
5-planet reduction
transmission with
integrated parking brake
Wheel gear – drum drive
# 1254758
5-planet reduction
transmission
Hydraulic variable
displacement
motor
Parking brake
(in oil bath moving
multi-disc spring operated
brake)
Rear axle
# 1298151
Hydraulic variable displacement motor
Differential housing with
self-locking differential O-ring
Connection flange
Coupling
Planetary gear
Parking brake
Air bleed
(in oil bath moving
multi-disc spring
Connection parking brake
operated brake))
Planetary gear
Caution!
When disassembling
the hydraulic
displacement motor,
oil may escape.
Rear axle
# 1298151
View of axle body
Rear axle
# 1298151
View of bevel and crown gear
Rear axle
# 1298151
View of self-locking differential
Rear axle
# 1298151
View of parking brake
Rear axle
# 1298151
View of planetary gear
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Display – Series 3000
# 2068669
engine oil EMR3 air filter hydraulic oil filter charge indicator preheating
pressure error code polluted polluted lamp
hazard warning lights

water inside the
fuel pre-filter turn indicator
low coolant hour meter

level
parking brake compaction

meter
hydraulic oil
temperature
low hydraulic
oil level
engine
temperature
vibration frequency
warning lamp
fuel level indicator engine rpm drive speed jump mode
Dashboard completely populated with all options!

Options see operator´s manual!
Electrical-Training 1/2
Display – Series 3000
# 2068669
adjustment of machine type / units

according to the sticker
Switchpoints for LEDs for standard machines without EMR3:

LED yellow LED red LED red (flashing)
Type Signal
temp. low temp. high temp. too high
Engine temp.,
0, 1, 8, 9 >4,030V <0,495V <0,265V
X2:2
Engine temp.,
3, 4, 5 >4,371V <1,109V <0,902V
X2:2
Engine temp.,
A, B >4,455V <0,987V <0,880V
X2:2
0-5, 8, 9, Hydraulic temp.,
>4,03V <1,00V <0,807V
A, B X2:1
Switchpoints for LEDs for HAMMTRONIC machines and machines with an

EMR3 installed:
LED yellow LED red LED red (flashing)
Type Signal
temp. low temp. high temp. too high
Engine temp.,
H159 <15°C >120°C >130°C
via CAN
H160-H162, Engine temp., connector - A1X2
<15°C >105°C >115°C
H169 via CAN
Engine temp.,
H188-H189 <15°C >110°C >115°C
via CAN
connector - A1X1
H176-H177, Engine temp.,
<15°C >112°C >115°C
H179-H180 via CAN
Hydraulic temp.,
all <15°C >90°C >100°C
via CAN
Mainboard
# 2038472
K1 Engine control unit X1 Dashboard (sz)
K2 Fuel preheating X2 Dashboard (bl)
K3 Flasher unit X3 Dashboard (ge)
K4 Fuelling pump X4 Jumper vibration system
K5 Driving light X5 Engine compartment (sz)
K6 Parking brake X6 Engine compartment (bl)
K7 Backup alarm X7 Engine compartment
K8 Levelling blade X8 Engine compartment (sz)
K9 Levelling blade X9 Front frame
K10 Start release X10 Cabin
K11 Pilot lamp - preheating X11 Cabin
K13 Vibration X12 Levelling blade
K15 High current relay – X13 HCM
main power supply X16 Controller for fuelling pump
X17 High current relay –
main power supply
X18 Standby/Cold start device (COM-2)
X19 Engine control unit EMR-3
X20 Standby/Lox.
X21 HCM
X22 Lighting front right
X23 Lighting front left
X26 Potentiometer engine rpm
X27 Engine control unit (standby)
X28 Engine control unit (standby)
XD2 Engine control unit (EMR-3)
EMR3 – Diagnostic plug

EMR3 – Diagnostic–LED
EMR3 – Diagnostic push-button
Capacitive proximity switch
# 892947
Plug arrangement:
1: br
2: bl
3: sw
Adjustment screw for sensitivity

(pre-adjusted ex works)
Scheme:
Check LED
(glowing when sensor is alive)
Mount to reservoir without clearance
Level sensor – fuel tank
# 886092
enable-signal for refuel pump

Display – fuel level indication
switch-point at 50mm
+12V power supply
Characteristic line - fuel level sensor
1
GND
Voltage on D-Out [V]
0,5
0
0 100 200 300 400 500
Symbol tank full Floater level [mm]
tank empty
Electric-Training 1/1
HCM - 3
# 2024303
Test points
2 2 3 3
3 1 2
2 4 2 4
1 3 3
1 4 51 6 5 7
1
4
6 5
I – Sensor (Speedometer) A – Sensor (Acceleration sensor)
1 = +U (12V/+24V) 1 = +9V
2 = GND (0V) 2 = GND (0V) AC: 100mV/g
+U
3 = I- Signal 3 = A- Signal
DC: 4,5V
0V
(roller must drive) 0V
4 = free (vibrator must turn around)
HCM - 3
# 2024303
Test points
Power CDS - Connector
1;2 = +U (12V/+24V) 1 = RMV- value (DC: 5V = 50 RMV)

3;4 = free 2 = Vibrator frequence (DC: 5V = 75Hz)
5;6 = GND (0V) 3 = big/small amplitude
(big. Ampl. < 0.8V; small. Ampl. > 4V)
4 = I- Signal
+U
Instruments 0V
(roller must drive)
1 = Speedometer (0...0.3V DC) 5 = +12V
2 = HMV - Instruments (0...0.3V DC) 6 = HMV- value (DC:5V = 180 HMV)
3 = GND (0V) 7 = GND
4 = RMV - Instruments
(0...5V DC,FM overlap 0...500Hz,
dependet from the amplitude)
5 = free
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Variable displacement pump - vibration
# 1255665
Test ports
Air bleed R Control pressure
Variable M 12x1.5 X1 = small amplitude
displacement X2 = big amplitude
pump / drive 5 – 22 bar
M 12x1.5
(in front of orifice)
Test port
PS = control pressure
M 14x1.5
(after orifice)
Test port
G = charge pressure
max. 22 bar
M 12x1.5
Charge pressure valve
is not installed !!!
Charge pressure is controlled
by drive pump
Test ports
MB = big amplitude
MA = small amplitude
Centring Frequency adjustment Case drain port T2 max. 423 bar
mechanic high frequency (from drive pump) Pressure cut-off
neutral position small amplitude M 22x1.5 max. 420 bar
M 12x1.5
Variable displacement pump - vibration
# 1255665
Variable displacement
Centring pump / drive
Proportional solenoid hydraulic neutral position
b = big amplitude
a = small amplitude
Pressure cut- off

max. 420 bar
High pressure port

B = small amplitude
SAE ¾“
Charge and high

pressure valves
small amplitude
big amplitude
max. 420 bar
Frequency adjustment
low frequency
big amplitude
Test ports
Charge pressure Charge pressure supply Fa Case drain port T1
M 18x1.5
High pressure port
(from drive pump port Fa1) (oil connector block)
A = big amplitude
M 18x1.5 M 22x1.5
SAE ¾“
Variable displacement motor - axle
# 1271482
Adjusting screw
absorbation capacity
V min.
Proportional solenoid
adjusting pump Connector
speed sensor
Test port G 80 - (new)
400 bar M
14x1.5
High pressure A
SAE 1“
Case drain port T

M 26x1.5
Test port M1 Adjusting screw

M 14x1.5 V max. High pressure B
SAE 1“
Variable displacement motor - drum
# 1271814
Adjusting screw
Proportional solenoid V min.
adjusting pump
Case drain port T
Test port G 80 - M 18x1.5
400 bar M
14x1.5
Connector
speed sensor
(new)
High pressure A
SAE 1“
High pressure B
SAE 1“
Adjusting screw
Test port M1 absorbation capacity
M 14x1.5 V max.
Shuttle Scavenge valve

Scavenge block
Fixed displacement motor - vibration
# 1259644
High pressure port B

small amplitude
Attention ! SAE 1“
After fitting check the Test port

direction of rotation small amplitude
of vibrator.
Test port
big amplitude
Scavenge valve
(below the scavenge
block)
Scavenge block
Shuttle
Port T1 High pressure port A

M 18x1.5 big amplitude
(closed) SAE 1“
Case drain port T2
M 18x1.5
Fixed displacement motor - vibration
# 1259644
Attention!
When switching on the big amplitude, the vibrator
must turn clockwise.
Danger of bearing damage !
View of machine from the left
Series HD / DV
Vibration
• Big amplitude
• Small amplitude
vibrator Series 3000
„clockwise“
Collecting block (hydraulic oil)
# 1488635
Pressure relief valve
# 1249479
Scheme:
O-ring Sealing
pin
pout
Adjusting screw
(pre-adjusted to 27bar ex works)
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
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
Circuit diagram 3410 - 3411

valid from serial-No. : H1790001 TIER-3
- Fehlende Ersatzteilnummern siehe Ersatzteilkatalog
- missing spare parts numbers see spare parts list
Revision Modification valid from serial-No.

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
01 Potentiometer Speed adjustment Diesel engine with SAP Modification 12795

sealed connectors (05.09.2007)
Relay (K100) Fan motor added , Page 10, 18, 42 SAP - Modification 13969
Instrument panel new , Page 13, 21 SAP - Modification 12794

02 Connection Control device Charge pump Fuel changed , Page 29, 48 H1790001
Connection Blade changed , Page 32 H1790001

Schutzvermerk nach DIN 34 beachten
Änderung Datum Name Datum Name Projektbez. Blatt

a Revision management Circuit diagram 3410-3411, TIER3
b
c
gez. 08.10.2003 Landstorfer
Zeichnungsnummer Rev. = 1
d
gepr.
02082937 02 + 66 Bl.
Plotdatum: 19.05.2008
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
P a g e l i s t
Page Page description
1 Revision management
2 Page list
3 Page list
4 Page list
5 Page list
6 Page list
7 Fuse box / Starting relay

Engine room
8 Fuse occupancy
Central electric
9 Fuse occupancy
Central electric
10 High current PCB

Central electric
11 Relay Central electric

12 Fuse box
Cab console
13 Display Plug occupancy
14 Control device Diesel engine

EMR-3

EMR-3

EMR-3
Electric plug

a Page list Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
P a g e l i s t
17 Power supply Supply system
18 Power supply Supply system

Ignition switch
19 Emergency control
Parking brake
20 Voltage supply EMR-3

21 Diagnose
Diesel engine
22 CAN-Bus Instrument panel
23 Diesel engine 1
Cold start equipment
Common-Rail
24 Diesel engine 2
Common-Rail
25 Diesel engine 3
Common Rail
26 Diesel engine 4
Common Rail
27 Pressure switch , Temperature sensor

Engine room ; Signal transmitter
Socket Supply system
28 Speed adjustment Diesel engine

Sensor Fuel prefilter
29 Level transmitter Fuel tank

Refuel pump
Fuel preheating
30 Jumper km/h - mph

Sensor Speed
Sensor Vibration frequency
31 Proximity switch Drive lever

b
c
d
gepr.
02082937 02 + 66 Bl.
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
P a g e l i s t
31 Multifunction handle
Relay Parking brake / Starting release
32 Back-up alarm
Schubschild
33 Lighting STVZO
34 Lighting STVZO
35 Vibration control
Gear shifting
Traction control
36 Working spotlights
Windshield washer
Rotating-beam light
37 Cab lighting
Windshield wiper
38 Radio assembly
Instrumentation lighting Cabin
39 Tachograph
40 Compactometer HCM
Acceleration sensor
41 CDS Display
42 Heating / Air conditioning
43 Special equipment
Sprinkling
44 Reserve
Central electric
45 Reserve
Central electric
46 Reserve

b
c
d
gepr.
02082937 02 + 66 Bl.
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
P a g e l i s t
46 Central electric
47 Electric plug
Central electric
48 Electric plug
Central electric
49 Electric plug
Central electric
50 Electric plug E-Box
51 Connector Diesel engine
52 Connector Engine room
53 Connector Engine room

Connector Front roller
54 Central plug Instrument panel
55 Connector Operator platform

Air conditioning Heating
Connector Cabin
56 Connector Cabin
57 Central plug Cabin
58 Connector Sprinkling
59 Spare parts list
60 Spare parts list
61 Spare parts list
62 Spare parts list

b
c
d
gepr.
02082937 02 + 66 Bl.
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
P a g e l i s t
63 Spare parts list
64 Spare parts list
100 Version
Lighting ROPS
101 Lighting ROPS

Connector

b
c
d
gepr.
02082937 02 + 66 Bl.
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
XF1: Fuse box Engine room
Retainer sheet Engine room

K17: Relay Cold start equipment
K17
1
100A 100A 150A

XF1
/17.8
K16
F01 F02 F03

Pos.: Fuse Page Function

5 K16X1
2 F01 100A /17.11 F01 - 100A: Supply system Terminal 30, Starting relay
85: /18.17
87 86: /18.17
3 F02 100A /17.13 F02 - 100A: Alternator B+
30: /17.4
85
86
87: /17.4
4 F03 150A /17.16 F03 - 150A: Cold start equipment
30
F04 F04 - Reserve Header Starting relay
( Engine room )

a Fuse box / Starting relay Circuit diagram 3410-3411, TIER3
b
c
Engine room Zeichnungsnummer Rev. = 7
d
gepr.
02082937 02 + 66 Bl.
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
F1 /45.4 F1 - Reserve
F2 /45.6 F2 - Reserve
7 F3 5A /27.16 F3 - 5A: Sensors : Sensor Coolant level
8 F4 5A /30.15 F4 - 5A: Sensors : Vibration frequency , Speed Rear axle
9 F5 5A /29.6 F5 - 5A: Level transmitter, fuel / Control circuit Refuel pump

10 F6 7.5A /31.12 F6 - 7,5A: Multifunction handle , Blade

Proximity switch Brake / Vibro automatic / Back-up alarm
11 F7 7.5A /19.3 F7 - 7,5A: Emergency control , Control device Diesel engine Terminal 15
12 F8 7.5A /34.16 F8 - 7,5A: Driving light right
13 F9 7.5A /34.5 F9 - 7,5A: Driving light left
14 F10 5A /34.20 F10 - 5A: Parking light right
15 F11 5A /34.8 F11 - 5A: Parking light left
16 F12 10A /35.3 F12 - 10A: Signal transmitter
17 F13 10A /33.6 F13 - 10A: Alarm system switch Terminal 15
18 F14 25A /29.15 F14 - 25A: Refuel pump

19 F15 7.5A /32.4 F15 - 7,5A: Back-up alarm
20 F16 30A /29.22 F16 - 30A: Fuel preheating
21 F17 7.5A /35.10 F17 - 7,5A: Vibration control

a Fuse occupancy Circuit diagram 3410-3411, TIER3
b
c
Central electric Zeichnungsnummer Rev. = 8
d
gepr.
02082937 02 + 66 Bl.
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
23 F18 7.5A /40.4 F18 - 7,5A: Compactometer HCM
F19 /44.14 F19 - Reserve
24 F20 5A /17.18 F20 - 5A: Terminal D+ Alternator
25 F21 7.5A /30.7 F21 - 7,5A: Display Terminal 15 , Rotary switch km/h - mp/h
F22 /45.8 F22 - Reserve

26 F23 10A /27.3 F23 - 10A: Socket Supply system
27 F24 10A /35.7 F24 - 10A: Gear shifting

Rocker switch Vibro automatic / Driving speed / Traction control
28 F25 7.5A /21.9 F25 - 7,5A: Potentiometer Engine speed
F26 /44.10 F26 - Reserve
29 F27 15A /42.3 F27 - 15A: Cabin-heating , Air conditioning
F28 /44.4 F28 - Reserve
30 F29 30A /36.3 F29 - 30A: Cabin Terminal 15
31 F30 10A /18.7 F30 - 10A: Ignition switch Terminal 30
32 F31 25A /20.3 F31 - 25A: Control device Diesel engine Terminal 30
33 F32 15A /33.21 F32 - 15A: Steering column switch Terminal 30
34 F33 10A /33.8 F33 - 10A: Alarm system switch Terminal 30
35 F34 30A /37.4 F34 - 30A: Cabin Terminal 30

a Fuse occupancy Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
X5 X6 X7 X1 X2 X3
X24
X16
X9 X27
J1
X10 X11
mph km/h
X8 X26
F1 F6 F20 X4
F2 F7 F21
X20
F3 F8 F22
F4 F9 F23 KL30.4
X28
F5 F10 F24
X19
KL30.5
F11 F25
X12
X15.6
F26 K1 X18
K4 V4
F12 F27 KL15.3
K9 K8 XD2
K3
F13 F28
A3 J2
F29
3 F14
37
2 K7 V1
F15
1
F16 F30 J4 K12 K5 K6 K10 K11
02
F17 F31
KL15.2
K2 V2
F18 F32
430 K100X1
F19 F33
X13 V5 F34
KL30.3 86: /18.14
K13
R1
85 87a 86
FL
02 85: /18.14
XD1
X21 87
30: /42.3
K15 30
R2
87a:
DIAGNOSE
KL31.1
X22 87: /42.3
R3
K100
KL31.2 D2 R4
R5
1
1 2 0W V7
2
X23
3
X17 S1
J3
X14_1 K100: Relay Fan motor

KL31.3
02038472 K L 1 5 . 1K L 3 0 . 2 KL30.1
A3: Central electric
K15: high current relay

Supply system
a 02 14.05.2008 Lan. High current PCB Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
General arrangement Relay Central electric
K1: Diesel engine K4: Charge pump

Control device K2: Fuel preheating K3: Flasher relay Fuel tank
K1 K2 K3 K4
86 86: /20.3 86 86: /29.18 31 49: /33.5 86 86: /29.11
87a 85: /20.3 85: /29.18 31: /33.5 85: /29.11
87a
87a
30 30: /20.5 30 30: /29.22 49a: /33.6 30 30: /29.15
87 87 49a 87
87: /20.5 87: /29.23 87: /29.15
87a: 87a: 87a:
85 85 49 85
K5: Driving light K6: Parking brake K7: Back-up alarm K8: Blade
K5 K6 K7 K8
1: /33.21 1: /31.13 1: /31.4 1: /32.19
2 4 1 2 4 1 2 4 1 2 4 1
2: /33.21 2: /31.13 2: /31.4 2: /32.19
3: /33.23 3: /19.16 3: /32.4 3: /32.21
5
5
4: /33.23 4: /19.16 4: 4: /32.20
3
3
5: 5: /19.17 5: /32.5 5:
K11: Pilot light

K9: Blade K10: Starting release Preheat K13: Vibration
K9 K10 K11 K13

1: /32.14 1: /19.19 1: /44.10 1: /19.21
2 4 1 2 4 1 2 4 1 2 4 1
2: /32.14 2: /19.19 2: /44.10 2: /19.21
3: /32.15 3: /18.17 3: /44.11 3: /35.13
5
5
4: /32.15 4: 4: 4:
3
3
5: 5: /18.17 5: /44.11 5: /35.13

a Relay Central electric Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Fuse box Cab console
/38.14
/36.21
/37.15
/37.8
/36.7
/38.6
3F1 - 10A: Instrumentation lighting Console , Terminal 58 Radio
A B C D E F Terminal 58 Speedometer
3F2 - 10A: Terminal 30 Cab lighting , Terminal 30 Speedometer
3F3 - 25A: Working spotlights

F1
F2
F3
F4
F5
F6
XF3
38 3F4 - 15A: Windshield washer , Rotating-beam light
1 2 3 4 5 6 3F5 - 15A: Windshield wiper
3F6 - 10A: Terminal 30 Radio


a Fuse box Circuit diagram 3410-3411, TIER3
b
c
Cab console Zeichnungsnummer Rev. = 12
d
gepr.
02082937 02 + 66 Bl.
c
d
b
a
1
02
39
A1
Änderung
2
02
Datum
14.05.08
/17.18 D+
X1:1
3
/22.8 CAN High 120W
X1:2
Lan.
4
Name
/22.4 CAN Low
X1:3
Speed sensor Diesel engine
X1:4
5
gez.
gepr.
/30.22 Vibration frequency
X1:5
6
Fuel filter Water Indicator
Datum
X1:6
/36.11 Working spotlights front
X1:7
7
A1X1
/36.18 Working spotlights rear
X1:8
Name
8
24.10.2003 Landstorfer
Preheat
X1:9
/30.7 Terminal 15
9
/30.4 GND
A1: Display Instrument panel
10
/18.21 Terminal 30
/27.5 Signal transmitter

11
Display
/30.17 Speed
12
/27.9 Hydraulic oil filter
Air filter
13
Coolant level
14
Oil pressure switch Diesel engine

X1:10 X1:11 X1:12 X1:13 X1:14 X1:15 X1:16 X1:17 X1:18
15
16
/27.12 Temperature indicator Hydraulic oil

X2:1
Display Plug occupancy

Temperature indicator Diesel engine
X2:2
17
/35.25 Amplitude, large

X2:3
18
Double jump (RMV)

X2:4
/19.24 Pilot light, brake

X2:5
19
Level Hydraulic oil

X2:6
A1X2
20
/30.10 Change-over km/h - mp/h

X2:7
/29.3 Level transmitter Fuel tank

X2:8
21
Projektbez.
GND (HCM)
X2:9
22
Zeichnungsnummer
/35.25 Amplitude, small

Rev.
02082937 02
Compaction data (HMV)

23
+
=
/33.18 Blinker left

24
/33.15 Blinker right
/21.20 Diagnostic lamp Diesel engine

X2:10 X2:11 X2:12 X2:13 X2:14
25
Circuit diagram 3410-3411, TIER3
66
Blatt
26
13
Bl.
c
d
b
a
1
D1X1
D1X1
D1.1
Änderung
2
/20.7
48
Terminal 30
2
/20.17
49
GND
Datum
3
3
/20.10
50
Terminal 30
4
/20.20
51
GND
4
Name
5
/20.13
52
Terminal 30
6
/20.23
53
GND
5
gez.
7
gepr.
54
8
/21.23
55
D-Out Diagnostic Lamp
6
/28.17
56
A-In. Engine speed setting
Datum
57
10
7
58
11
12
Name
59
8
13
/21.11
60
Diagnostic-CAN-Low
14
/21.15
61
CAN-Low (Customer-CAN)
9
15
/21.17
62
CAN-High (Customer-CAN)
16
/28.23
63
GND-Sensor Fuel prefilter
10
17
/28.25
64
A-In. Sensor Fuel prefilter
18
65
11
19
66
20
67
12
21
68
22
/28.19
69
+5V (U ref.)
13
23
70
24
71
EMR-3
14
25
/20.3 /21.9
72
D-Out. EMR - Relay ISO-K-Line
EMR3 / EDC16
26
73
15
27
74
28
/19.8
75
Terminal 15
16
29
76
30
/27.22 /28.15
77
D-In. Pressure switch, air filter GND (U ref.)

17
31
78
32
/27.19
79
Control device Diesel engine

D-In. Sensor Coolant level
18
33
80
34
81
19
35
/21.13
82
Diagnostic-CAN-High
36
83
20
37
84
38
85
21
39
86
Projektbez.
40
/31.10
87
D-In. Starting release

22
Zeichnungsnummer
41
88
42
89
Rev.
02082937 02
23
43
90
+
=
44
91
24
45
92
46
93
25

47
94
66
Blatt
26
14
Bl.
c
d
b
a
1
Änderung
2
Datum
3
4
Name
D1X2
D1X2
D1.2
5
gez.
1
gepr.
/26.21 /26.25
31
D-Out Injection valve Cylinder 5 GND Injection valve Cylinder 4-6
2
/26.23
32
D-Out Injection valve Cylinder 6
6
/26.11
33
Datum
4
/23.3
34
D-Out - Relay Preheat
7
35
6
Name
36
8
7
/25.23
37
Shield
8
/24.21
38
GND Pressure sensor Fuel Rail
9
39
/24.9 /25.11
40
10
A-In. charge-air pressure F-In. Speed sensor Camshaft

10
/23.25 /25.3
41
11
GND Temperature sensor, engine cooling GND Pressure sensor Fuel Low pressure
12
/25.21
42
GND Speed sensor Crankshaft
11
13
/24.23 /24.13
43
A-In. Pressure sensor Fuel Rail +5V Sensor
14
/24.3
44
+5V Sensor
12
15
/23.20
45
D-Out - Starting relay
16
/26.19 /26.15
46
D-Out Injection valve Cylinder 4 GND Injection valve Cylinder 1-3
13
17
/26.9
47
18
/26.13
48
EMR3 / EDC16
EMR-3
14
19
/26.5 /26.3
49
GND Fuel Valve Rail PWM-Out + Fuel Valve Rail
20
/25.13 50
GND Speed sensor Camshaft Shield /25.15
15
21
/24.17 /23.7
51
GND Sensor Engine oil pressure D-In. Relay Preheat

22
52
16
23
/24.7 /24.5
53
A-In. Temperature sensor Boost air GND Sensor Boost air

24
/25.7 /23.5
54
+5V Pressure sensor Fuel Low pressure D-Out + Relay Preheat

17
25
55
26
/24.15 /24.25
56

A-In. Engine oil pressure +5V Pressure sensor Fuel Rail
18
27
/25.5 /25.19
57
A-In. Pressure sensor Fuel Low pressure F-In. Speed sensor Crankshaft
28
/23.23
58
A-In. Temperature sensor, engine cooling

19
29
59
30
/23.18
60
D-Out + Starting relay

20
21
Projektbez.
22
Zeichnungsnummer
Rev.
02082937 02
23
+
=
24
25
66
Blatt
26
15
Bl.
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
EMR3
D1 EDC16
40
D1X2 D1X1
41 D1X1 42 D1X2
VIEW CONTACTS 1: /20.7 25: /21.9 49: 73: 1: /26.25 21: /23.7 41: /23.25
2: /20.17 26: 50: 74: VIEW CONTACTS 2: 22: 42:
3: /20.10 27: 51: 75: 3: 23: /24.5 43: /24.23
5 3 1 30 45
4: /20.20 28: /19.8 52: 76: 15 60 4: 24: /23.5 44:
6 4 2
5: /20.13 29: 53: 77: /27.22 5: 25: 45:
51 29
73 7 6: /20.23 30: /28.15 54: 78: 6: 26: /24.25 46: /26.19
7: 31: 55: /21.23 79: /27.19 7: /25.23 27: /25.19 47: /26.9
8: 32: 56: 80: 8: /24.21 28: 48: /26.13
9: /28.17 33: 57: 81: 9: 29: 49: /26.5
10: 34: 58: 82: /21.13 10: /25.11 30: /23.18 50: /25.13
11: 35: 59: 83: 11: /25.3 31: /26.21 51: /24.17
12: 36: 60: /21.11 84: 1 46 12: /25.21 32: /26.23 52:
16 31
13: 37: 61: /21.15 85: 13: /24.13 33: /26.11 53: /24.7
14: 38: 62: /21.17 86: 14: /24.3 34: /23.3 54: /25.7
15: 39: 63: /28.23 87: 15: /23.20 35: 55:
16: 40: /31.10 64: /28.25 88: 16: /26.15 36: 56: /24.15
94 28
72 50 17: 41: 65: 89: 17: 37: 57: /25.5
18: 42: 66: 90: 18: 38: 58: /23.23
19: 43: 67: 91: 19: /26.3 39: 59:
20: 44: 68: 92: 20: /25.15 40: /24.9 60:
21: 45: 69: 93:
22: /28.19 46: 70: 94:
23: 47: 71:
24: 48: 72: /20.3

a Control device Diesel engine Circuit diagram 3410-3411, TIER3
b
c
EMR-3
Electric plug
d
gepr.
02082937 02 + 66 Bl.
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
XF1: Fuse box Engine room

+ + + + +
XF1 F01 100A F02 100A F03 150A

/7.5 /7.4 /7.4 /7.4
+ 1 2 3 4
35 sw 30.1
/23.2
6 rt 16 sw 30
/18.2
95 sw
95 sw
10 rt
+ B+
K16X1 30 G
W D+
1.5 rt
150Ah
30 3
12V
G1 14V/95A
K16 46
G2 U
/18.17 87 47 31 X6 9
-
K16X1 87
F20 5A
/9.3
6 ge
95 sw
X1 3
0.75 rt
30 M 50a
0 1
12V/3kW
M1 S1
44 31 45 A1X1 1
X1:1
Display
A1
95 sw
/13.2
Pilot light
Charge current
Earth terminal Earth terminal Earth terminal Shield
/21.2
Diesel engine Chassis E-Box
31 3
31 02 95 sw 31 01 31 03 31 4 5 6 7 8 9 Stud bolt
31 2 Central electric
6 bn 31 1 31
/18.2
M1: Starting motor G1: Battery G2: Alternator

K16: Starting relay S1: Battery isolating switch A1: Display

a Power supply Supply system Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
30 30
/17.25 /20.2
15
/19.2
30 1
S2X1 1
30 30
F30 10A
S2
/9.3 0,1
49 123
30 2 17 17 54 15 50a 19 19
S2X2 5 7
Reserve
30
2.5 rt
1.5 rt
1.5 ws
0.75 rt
K15
.11 87
15 1 X1 16 X1 19 X19:11
X1 21
A1X1 12
X17 1 K10X1 3
X1:12
3
Display
K10
/19.19 A1
4 5 /13.2
Terminal 30
K10X1 5
X6 3
FL A
0.75 ws
0.75 ws
02 Sicherungstester
Fuse Tester
K15X1 1 K100X1 86 K16X1 86
FL E
86 1 86
-V6 K15 K100 K16
50 85 431 2 51 85
-R1
K15X1 2 K100X1 85 K16X1 85

0.75 br
0.75 br
-V5
X17 2
31 12
31 31
/17.25 /19.2
5
A1: Display
30
87
30
87
3
.3 /42.3 /17.4
4
K15: Power relay

Central electric
S2: Ignition switch K10: Relay Starting release
K16: Starting relay
a 02 14.05.08 Lan. Power supply Supply system Circuit diagram 3410-3411, TIER3
b
c
Ignition switch Zeichnungsnummer Rev. = 18
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/18.25 /20.2
J4 2 Pilot light
F7 7.5A A1 Brake
/8.3 J4 1 K6X1 3 /13.2 Display
3 X2:5
K6
/31.13 4 5 A1X2 5
X10 2 X10 7 X19 12 X20:4 K6X1 4 5
Reserve
0.75 ws
1.5 rt
1.5 ws
0.75 rt
X6 5 X6:1 X20:3 X6 6
D1X1 28
Reserve
28 X1 17
1 1
D1.1
0.75 ws
0.75 ws
S7 Terminal 15
/14.2
53 2 2 EMR-3 X5 3
0.75 ws
Y8X1 1 Y5X1 1 K10X1 1 K13X1 1
S12X1 2
2 4
1 1 58
Y8 Y5 K10 K13 S12 P
54 55 56 2 57 2 p=6bar
1
Y8X1 2 Y5X1 2 K10X1 2 K13X1 2 S12X1 1 PE
0.75 bn
0.75 br
0.75 bn
S12: Pressure switch

Parking brake
31 11 31 5
31 31
/18.25 /20.2
5
3
3
/18.17 /35.12
4
D1: EMR-3
S7: Emergency stop switch Y8: Magnet, drive pump K6: Relay Parking brake K10: Relay Starting release
Y5: Brake valve K13: Relay Vibration
a Emergency control Circuit diagram 3410-3411, TIER3
b
c
Parking brake Zeichnungsnummer Rev. = 19
d
gepr.
02082937 02 + 66 Bl.
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
30 30
/18.25 /33.2
15 15
/19.25 /21.2
F31 25A
/9.3
EMR-3 EMR-3 EMR-3
D1.1 GND D1.1 GND D1.1 GND
X30 4 /14.2 /14.2 /14.2
2 4 6
X30 5
D1X1 2 D1X1 4 D1X1 6
K1X1 86 30
86 30
K1
1.5 br
1.5 br
1.5 br
59 85 87a 87
K1X1 85 87
X19 5 X19 6 X19 15
X19 4 X19 1 X19 2 X19 3

0.75 ws
1.5 rt
1.5 rt
1.5 rt
D1X1 72 D1X1 1 D1X1 3 D1X1 5
72 1 3 5
D-Out.
D1.1 D1.1 Terminal 30 D1.1 Terminal 30 D1.1 Terminal 30
/14.2 EMR Relay /14.2 /14.2 /14.2
EMR-3 EMR-3 EMR-3 EMR-3
31 31
/19.25 /21.2
K1: Relay EMR-3 D1: EMR-3

a Voltage supply EMR-3 Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/20.25 /23.2
F25.1
/28.2
CAN-Low
/22.2
CAN-High
F25 7.5A /22.2
Reserve
Reserve
Reserve
/9.3
02
X19:17 X19:18 X28:3
Diagnostic lamp
XD1 A1 Diesel engine
A /13.2 Display
X2:14
M
A1X2 14
F
H G F
I M
E H
A K L
B C D
G
3
K EMR-3
2
D1.1 D-Out
0.75 ws
B
60W 120W 1 /14.2 Diagnostic
-S1 55
J3
-R2 -R3
D1X1 55
XD2 1 XD2 2 XD2 3 XD2 4 XD2 5
0.75 ws
3x0.75 X3 19
3x0.75
3x0.75
3x0.75
3x0.75
3x0.75
Schirm
Schirm
0.75 ws
XD2 8
ws
ws
br
br
-R5 4,7kW -R4 1kW

D1X1 25 D1X1 60 D1X1 82 D1X1 61 D1X1 62
25 60 82 61 62
Diagnostic Diagnostic Customer Customer -V7

D1.1 ISO-K-Line
/14.2 CAN-Low CAN-High CAN-Low CAN-High
EMR-3 EMR-3 EMR-3 EMR-3 EMR-3
XD2 6 XD2 7
Shield Shield
/17.25 /22.2
31 31
/20.25 /22.2
XD1: Diagnostic connector D1: EMR-3 V7: Diagnostic lamp

S1: Diagnostic push button switch Central electric

a 02 14.05.08 Lan. Diagnose Circuit diagram 3410-3411, TIER3
b
c
Diesel engine Zeichnungsnummer Rev. = 21
d
gepr.
02082937 02 + 66 Bl.
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
CAN-Low CAN-Low
/21.25 /28.2
CAN-High CAN-High
/21.25 /28.2
Shield(A1)
/30.2
X3 7 X3 10
3x0.75
3x0.75
3x0.75
Schirm
ws
br
A1X1 3 A1X1 2
X1:3 X1:2
Display Display
A1 A1
/13.2 /13.2
CAN-Low CAN-High
120W
Shield Shield
/21.25 /28.2
31 31
/21.25 /27.2
A1: Display

a CAN-Bus Instrument panel Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/21.25 /27.2
30.1
/17.25
EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3

D1.2 D-Out + D-Out - D-In. Relay D1.2 D-Out + D-Out - D1.2 A-In. GND
/15.5 Relay Relay Preheat /15.5 Starting relay Starting relay /15.5 Sensor Sensor
34 24 21 30 15 58 41
D1X2 0.75 sw
34 D1X2 24 D1X2 21 D1X2 30 D1X2 15 D1X2 58 D1X2 41
0.75 sw
0.75 sw
0.75 sw
0.75 sw
1.5 sw
1.5 sw
35 sw
K17X1 1
86 30
K17 K17 M1X1s 30 M1X1s 24
62 85 .3 87 M1X1b 30 M1X1b 24
K17X1 2
35 sw
0.75 sw
0.75 sw
M1X2 2 M1X2 1
E04 E05 E01 E02

64 64 64 64
B43X1 1
X34b 1 X34b 2 B43

65
Preparation
B43X1 2
30
87
.10
K17: Relay Heater plugs B43: Temperature sensor, engine cooling

E01-E05: Heater plugs

a Diesel engine 1 Circuit diagram 3410-3411, TIER3
b
c
Cold start equipment
Common-Rail
d
gepr.
02082937 02 + 66 Bl.
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
EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3
D1.2 +5V GND A-In. Boost air A-In. Boost air D1.2 +5V A-In. Pressure GND D1.2 GND A-In. Pressure +5V
/15.5 Sensor Thermosensor Pressure sensor /15.5 Engine oil Sensor /15.5 Sensor Fuel Rail
14 23 53 40 13 56 51 8 43 26
D1X2 14 D1X2 23 D1X2 53 D1X2 40 D1X2 13 D1X2 56 D1X2 51 D1X2 8 D1X2 43 D1X2 26
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
0.75 sw
M1X1s 22 M1X1s 28 M1X1s 29 M1X1s 23 M1X1s 33 M1X1s 26 M1X1s 27 M1X1s 31 M1X1s 25 M1X1s 32
M1X1b 22 M1X1b 28 M1X1b 29 M1X1b 23 M1X1b 33 M1X1b 26 M1X1b 27 M1X1b 31 M1X1b 25 M1X1b 32
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
B48X1 3 B48X1 1 B48X1 2 B48X1 4 B6X1 1 B6X1 2 B6X1 3 B49X1 1 B49X1 2 B49X1 3
+5V GND T P +5V P GND GND P +5V

0,5-4,5V 0,5-4,5V 0,5-4,5V 0,5-4,5V
B48 P T B6 P B49 P
67 U U 68 U 69 U
B48: Sensor charge-air pressure / B6: Sensor Engine oil pressure B49: Pressure sensor Fuel Rail
Boost air Thermosensor

b
c
Common-Rail Zeichnungsnummer Rev. = 24
d
gepr.
02082937 02 + 66 Bl.
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
EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3

D1.2 GND A-In Fuel +5V D1.2 F-In. GND Shield D1.2 F-In. GND Shield
/15.5 Sensor Low pressure /15.5 Speed sensor Sensor /15.5 Speed sensor Sensor
11 57 54 10 50 20 27 12 7
D1X2 11 D1X2 57 D1X2 54 D1X2 10 D1X2 50 D1X2 20 D1X2 27 D1X2 12 D1X2 7
0.75 sw
0.75 sw
0.75 sw
2x 0.75
2x 0.75
2x 0.75
2x 0.75
ws
ws
ws
ws
M1X1s 10 M1X1s 17 M1X1s 16 M1X1s 14 M1X1s 13 M1X1s 9 M1X1s 15 M1X1s 21 M1X1s 1
M1X1b 10 M1X1b 17 M1X1b 16 M1X1b 14 M1X1b 13 M1X1b 9 M1X1b 15 M1X1b 21 M1X1b 1
2x 0.75
2x 0.75
2x 0.75
2x 0.75
1.0 sw
1.0 sw
1.0 sw
ws
ws
ws
ws
B51X1 1 B51X1 2 B51X1 4 B40.1X1 1 B40.1X1 2 B40.1X1 3 B40.2X1 1 B40.2X1 2 B40.2X1 3
GND P +5V Sign. GND Shield Sign. GND Shield

0,5-4,5V
B51 P B40.1 n B40.2 n

72 U 73 U 74 U
B51: Pressure sensor Fuel Low pressure B40.1: Speed sensor Camshaft B40.2: Speed sensor Crankshaft

b
c
Common Rail Zeichnungsnummer Rev. = 25
d
gepr.
02082937 02 + 66 Bl.
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
EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3 EMR-3
D1.2 PWM-Out + GND D1.2 Injection valve + Injection valve + Injection valve + Injection valve - D1.2 Injection valve + Injection valve + Injection valve + Injection valve -
/15.5 MPROP MPROP /15.5 Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 1-3 /15.5 Cylinder 4 Cylinder 5 Cylinder 6 Cylinder 4-6
19 49 47 33 48 16 46 31 32 1
D1X2 19 D1X2 49 D1X2 47 D1X2 33 D1X2 48 D1X2 16 D1X2 46 D1X2 31 D1X2 32 D1X2 1
0.75 sw
0.75 sw
1.5 sw
1.5 sw
1.5 sw
1.5 sw
1.5 sw
1.5 sw
1.5 sw
1.5 sw
M1X1s 19 M1X1s 20 M1X1s 35 M1X1s 36 M1X1s 37 M1X1s 34 M1X1s 39 M1X1s 40 M1X1s 41 M1X1s 42
M1X1b 19 M1X1b 20 M1X1b 35 M1X1b 36 M1X1b 37 M1X1b 34 M1X1b 39 M1X1b 40 M1X1b 41 M1X1b 42
1.0 sw
1.0 sw
1.0 sw
1.0 sw
1.0 sw
2.5 sw
1.0 sw
1.0 sw
1.0 sw
2.5 sw
Y19X1 1
Y15.1 Y15.5 Y15.3 Y15.6 Y15.2 Y15.4

Y19
76 77 77 77 77 77 77
Y19X1 2
6- Cylinder 4- Cylinder
Y15.1 Injection valve Cylinder 1 Injection valve Cylinder 1
Y19: Fuel Valve Rail
Y15.5 Injection valve Cylinder 5
Y15.6 Injection valve Cylinder 6
b
c
Common Rail Zeichnungsnummer Rev. = 26
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/23.25 /29.2
F23 10A Signal transmitter Hydraulic oil filter Temp. F3 5A

/9.3 /8.3
A1 A1 A1 Hydraulic oil
/13.2 Display /13.2 Display /13.2 Display
X1:13 X1:15 X2:1
X5 21 X5 18 X7:3
A1X1 13 A1X1 15 A1X2 1 Preparation :
Level transmitter
Hydraulic oil
0.75 ws
0.75 ws
0.75 ws
0.75 rt
0.75 rt
X35b 1
H2X1 2 X35s 1
S17X1 1
+ +U
84
H2 SIGN
80 -
B12 NPN
S17 P
83 GND
p=50mbar
H2X1 1 S17X1 2
X35s 2 X35s 3
X1 5 X1 13
X35b 2 X35b 3
0.75 ws
0.75 ws
X1 15 X5 14 X6 16 X27:4
Reserve
X5 17 X5 7
1.5 rt
0.75 bn
0.75 ws
0.75 ws
X27 2 X1:1 X27 1 X1:14
S16X1 2
Reserve
Reserve
0.75 ws
0.75 ws
81
S16 P
D p=2,5 bar
S16X1 1 D1X1 79 D1X1 77
X27b 1 2
1.5 bn
0.75 bn
82 79 77
0.75 bn
X4. B8 D-In. Sensor D-In. Air filter

79
D1.1 D1.1
/14.2 Coolant level /14.2 Pressure switch
31 8 EMR-3 EMR-3
X5 5 X5 19
31 31
/22.25 /28.2
S16: Pressure switch B12: Sensor Coolant level

Hydraulic oil filter
X4: Socket Supply system
H2: Signal transmitter B8: Temperature sensor, hydraulic oil S17: Pressure switch Air filter
a Pressure switch , Temperature sensor Circuit diagram 3410-3411, TIER3
b
c
Engine room ; Signal transmitter
Socket Supply system
d
gepr.
02082937 02 + 66 Bl.
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
CAN-Low CAN-Low
/22.25 /40.2
CAN-High CAN-High
/22.25 /40.2
F25.1
/21.25
EMR-3 EMR-3
D1.1 GND A-In. Sensor
/14.2 Sensor Fuel prefilter
63 64
X26 2 7 1 4 5 6 8 3 X19 14 X19 8 X19 13 10 D1X1 63 D1X1 64

X19:7 X26:9
Reserve
3x0.75
3x0.75
3x0.75
3x0.75
Schirm
0.75 ws
0.75 ws
Reserve
Reserve
ws
gn
br
5x0.75
5x0.75
5x0.75
5x0.75
5x0.75
5x0.75
Schirm
X1:2 X1:18
0.75 br
0.75 rt
D1X1 D1X1 D1X1 X27 X27
ws
ge
gn
br
gr
30 9 22 3 5
30 9 22
GND A-In. Potentiometer +5V U ref.

D1.1
/14.2 Sensor Engine speed X6 10 X6 20
01 EMR-3 EMR-3 EMR-3
X45.1b 2 1 X45.2b 1 2 4 6 5 3
X45.1s 2 1 X45.2s 1 2 4 6 5 3
0.75 ws
0.75 ws
0.5 ws
0.5 ws
0.5 ws
0.5 ws
0.5 ws
0.5 ws
0.5 ws
0.5 ws B11X1 1 B11X1 2

GND +U CAN-H CAN-L +5V 0V Shield

0,5-4,5V 1MW
B2 U
120W B11
86 CAN 87
Shield Shield
/22.25 /30.2
31 31
/27.25 /29.2
B2: Potentiometer Speed adjustment B11: Sensor Water level

Diesel engine Fuel prefilter

a 01 10.04.08 Lan. Speed adjustment Diesel engine Circuit diagram 3410-3411, TIER3
b
c
Sensor Fuel prefilter Zeichnungsnummer Rev. = 28
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/27.25 /30.2
F5 5A Special equipment F14 25A F16 30A

/8.3 /8.3 /8.3
Fuel indicator
Heating Fuel filter

A1
/13.2 Display
optional Switch
X2:8 X16 2 X16 3
02
0.75 rt
0.75 gn
A1X2 J2 1
Jumper 2
8
K4X1 30 K2X1 30
D60X1 2 3 30 7,5A 30
0.75 ws K4 K2
+U +U .11 .18
87a 87 J2 2 3 87a 87
X2:4
D60 K4X1 87 K2X1 87
R
90
D-In GND nc no Trig.
D60X1 1 6 8 5
0.75 ws
0.75 gn
0.75 gn
0.75 ws
X8 4
X1 4 X16 6 1 X16 4 X16 5
2.5 ws
X5 11 X5 6 X8 6 X8 3
X5 12
0.75 ws
2.5 ws
X70b 1
X70s 1
X60b 1
X60s 1
>24°C
5x0.75
5x0.75
5x0.75
5x0.75
5x0.75
Schirm
K4X1 86 S60X1 5 K2X1 86

E70
bn
ge
gn
gr
86 86
M60 95
S60 M P=0,2kW
V4
V2
K4 K2
92 93
91 94
B1X1 2 1
4 3
85 S60X1 7 85
K4X1 85 K2X1 85 X70s 2
X60s 2 X70b 2
A-Out +U D-Out GND 0.75 br
X60b 2
B1
2.5 br
L
U
2.5 br
89
X5 13
31 14 31 13
31 31
/28.25 /30.2
A1: Display S60: Push button switch E70: Heating Fuel filter
B1: Level transmitter, fuel Refuel pump
D60: Control device Refuel pump M60: Refuel pump
a 02 14.05.08 Lan. Level transmitter Fuel tank Circuit diagram 3410-3411, TIER3
b
c
Refuel pump
Fuel preheating
d
gepr.
02082937 02 + 66 Bl.
87
87
30
30
.14 .22
7a
7a
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
15 15
/29.25 /31.2
Shield Shield
/28.25 /39.2
31 31
/29.25 /31.2
F21 10A F4 5A
/9.3 /8.3
I-Sign.
/40.2
B4-Sign.
/39.7
B3-Sign.
/39.7
J1
1
X9:2 X5 20 X5 10 X5 15 X5 9 X2 7 X9 7 X9 3 X9 5 X9 1 X2 21 X14:4
Vibration frequency
Reserve
Reserve
7.5A
J1
3x0.75
3x0.75
3x0.75
3x0.75
Schirm
2
ws
bn
gn
3x0.75
3x0.75
3x0.75
J1
ws
gn
bn
3x0.75
Schirm
3
+U GND Sign.
Jumper 1
1/2 = km/h A4
2/3 = mph 98
Sen. Sen. Schirm
X1 7 X2 15 X1 6 X2 3
Special equipment
Special equipment
B4X1 2 1
3
Shield(A1)
/22.11
GND +U Sign.
0.75 ws
0.75 rt
n n
B4 U B3 U
97 99
5x0.75
5x0.75
5x0.75
ws
bn
gr
A1X1 11 A1X1 10 A1X2 7 A1X1 14 A1X1 5
X1:11 X1:10 X2:7 X1:14 X1:5
Display Display Display Display Display

A1 A1 A1 A1 A1
/13.2 /13.2 /13.2 /13.2 /13.2
Earth Terminal 15 km/h - mph Speed Vibration frequency
A4: Electronic unit with housing

A1: Display J1: Jumper km/h - mph Change-over B4: Sensor Speed ( Signal Amplifier )
Rear axle
B3: Sensor Vibration frequency
a Jumper km/h - mph Circuit diagram 3410-3411, TIER3
b
c
Sensor Speed
Sensor Vibration frequency
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/30.25 /32.2
F6 10A
S1: Push button switch Vibration
/8.3
S2: Push button switch Blade lift
A7 S3: Push button switch Blade lower
R
106
X2 9 X10 3 -S1 -S2 -S3 2 sec. S2+S3: " Floating mode "
+U GND T2 T1 A1 A2
0.75 vio
0.75 rt
0.75 br
0.75 bl
0.75 gr
X43b 1 X44b 1 X42b 1
X43s 1 X44s 1 X42s 1

= Special equipment
0.75 ws
+ +
GND GND
B7 B9
102 SIGN
103 SIGN
3 +
GND
X43s 3 2 X44s 3 2 S14 B5
X43b 3 2 X44b 3 2 4 101 SIGN
EMR-3
D1.1 D-In. X42s 6 X42s 2 X42s 3 X42s 4 X42s 5
/14.2 Drive lever X42b 6 X42b 2 X42b 3 X42b 4 X42b 5
0.75 vio
0.75 bl
0.75 gr
40
D1X1 40
lower
Auto-Vib
/32.2
lift
/32.2
0.75 ws
0.75 ws
0.75 ws
0.75 ws
Vib.on
Reserve
/35.2
/35.13
X10 4 X19 16 X2 20 X10 10 X20:1
0.75 br
K7X1 1 K6X1 1
1 1
K7 Relay K6 Relay
104 2 Back-up alarm 100 2 Parking brake
X10 16
31 K7X1 2 K6X1 2
31
/30.25 /32.2
B7: Proximity switch S14: Push button switch

5
Back-up alarm Parking brake

3
/32.4 /19.16
B9: Proximity switch Vibro automatic B5: Proximity switch Parking brake
4

a Proximity switch Drive lever Circuit diagram 3410-3411, TIER3
b
c
Multifunction handle
Relay Parking brake / Starting release
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/31.25 /33.2
lower
/31.25
lift
/31.25
Y10 Y11 Y12 Y13

X11 6 X11 2 lift X X
lower X X
Floating mode X X
F15 7.5A
/8.3
K7X1 3 K9X1 1 3 K8X1 1 3
3 1 3 1 3
K7 K9 K8
/31.4 4 5
108 109
2 4 5 2 4 5
K7X1 5
Back-up alarm = Special equipment
K9X1 2 4 K8X1 2 4
Blade = Special equipment

X6 2 X12 2 X12 5 X12 6 X12 3
0.75 ws
0.75 ws
0.75 ws
0.75 ws
0.75 ws
02
X38b 1
X38s 1 Y10X1 1 Y11X1 1 Y12X1 1 Y13X1 1
H3 Y10 Y11 Y12 Y13

107 110 111 112 113
Valve block Connection "T"
Valve block Connection "A"
Valve block Connection "P"
Valve block Connection "B"

X38s 2 Y10X1 2 Y11X1 2 Y12X1 2 Y13X1 2
X38b 2
0.75 bn
0.75 bn
0.75 bn
0.75 bn
0.75 bn
31 6 31 9 31 9 31 9 31 9
31 31
/31.25 /33.2
Y10: Blade lift

Y12: Blade lower
H3: Back-up alarm Y11/Y13= Floating mode
Y10-Y13: Solenoid valve Blade
a 02 14.05.08 Lan. Back-up alarm Circuit diagram 3410-3411, TIER3
b
c
Schubschild Zeichnungsnummer Rev. = 32
d
gepr.
02082937 02 + 66 Bl.
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
30 30
/20.25 /37.2
15 15
/32.25 /35.2
F13 10A F33 10A F32 15A

/8.3 /9.3 /9.3
X3 12 X3 18 X3 15
Blinker Blinker
K5X1 3
3
A1 right A1 left
/13.2 Display /13.2 Display K5
1.5 rt
1.5 rt
.21 4 5
X2:13 X2:12
K5X1 4
2.5 rt
Lighting StVZO = Special equipment
A1X2 13 A1X2 12
S5X1 11 14
11 14
S5
0.75 ws
0.75 ws
115 X28b 4
3 13 5 18 17 10 X28s 4
S5X1 3
1.5 ws
13 5 18 17 10
117
S4
.11
0 1 2
58 56b
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
0.75 bn
X28s 5 6
56b
X28b 5 6 /34.2
31.8 58
/35.2 /34.2
58.1
/35.2
L
/34.2
R
/34.2
1.5 ws
X28b 3 X28b 2
X28s 3 X28s 2
L R
X3 21 X3 20 X3 3
117
S4
.21
K3X1 49
49a
K5X1 1
49 X28s 1
1
K3 X28b 1
K5
116 31 49a 118 2
K3X1 31 49a 31 8 K5X1 2
31 31
/32.25 /35.2
3
.23
S5: Alarm system switch S4: Steering column switch A1: Display
4
K3: Flasher relay K5: Relay Driving light

a Lighting STVZO Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
R 1.5 ws 58
/33.16 /38.2
58 1.5 ws
/33.25
L 1.5 ws
/33.16
X3 2 X3 9 X3 13 X10 1
56b
/33.25
F9 10A F11 5A F8 10A F10 5A

/8.3 /8.3 /8.3 /8.3
X9 9 X9 11 X9 15 X6 7 X6 8 X9 6 X9 10 X9 12
X6 4 X6 11
Lighting StVZO = Special equipment
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
1.5 ws
X32b 4 X32b 1 X32b 3 X37b 3 X37b 1 X29b 4 X29b 1 X29b 3 X36b 1 X36b 3
X32s 4 X32s 1 X32s 3 X37s 3 X37s 1 X29s 4 X29s 1 X29s 3 X36s 1 X36s 3
1.5 sw/rt
1.5 sw/ws
1.5 gr/rt
1.5 gr/rt
1.5 gr/rt
1.5 sw/ws
1.5 sw/rt
1.5 sw/ws
1.5 gr/rt
1.5 gr/rt
1.5 gr/rt
1.5 sw/gn
X23 2 X23 5 X23 4 X22 2 X22 5 X22 4
+ +
E1 E9 E3 E5 E10 E2 E11 E4 E6 E12

120 121 122
E7 124 125 126 127 128
E8 130 131
123 129
- -
X23 6 X22 6
1.5 bn
0.75 bn
1.5 bn
1.5 bn
1.5 bn
0.75 bn
1.5 bn
1.5 bn
X32s 2 X37s 2 X29s 2 X36s 2
X32b 2 X37b 2 X29b 2 X36b 2

1.5 bn
1.5 bn
1.5 bn
1.5 bn
31 8 31 6 31 8 31 6
E1: Driving light left E5: Parking light rear, left E2: Driving light right E6: Parking light rear, right
E9: Blinker front, left E10: Blinker rear, left E11: Blinker front, right E12: Blinker rear, right
E3: Parking light front, left E7: Side lamp front, left E4: Parking light front, right E8: Side lamp front, right
a Lighting STVZO Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/33.25 /36.2
31 31
/33.25 /40.2
Vib.on
/31.25
58.1 X14 2 3 6 1
/33.25
K13X1 5
4 5 +U 1 GND Auto
F12 10A F24 10A F17 10A Input
/8.3 /9.3 /8.3 K13
Trigger
D2 X2 5 X2 6
/19.21 3
144
K13X1 3 2 3
X9 14 X2 2 X10 11
0.75 ws
0.75 ws
X14 5 8
1.5 ws
1.5 rt
0.75 ws 0.75 ws 0.75 ws

1.5 ws 1.5 ws 1.5 ws 1.5 ws
V6X1
2 + 0
S8X1 2 5 8 10 S10X1 2 5 8 10 S13X1 2 5 8 10 S11X1 2 8
V6 H1
2 5 8 10 2 5 8 10 2 5 8 10 2 8 10
133 134 -
1
S8 S10 S13 S11
136 1 3 4 6 7 9 137 102 1 3 4 6 7 9 138 1 3 4 6 7 9 139 102 1 3 7 9
S8X1 1 4 7 9 S10X1 1 3 4 6 7 9 S13X1 1 3 4 6 7 9 S11X1 1 3 7

1.5 ws
0.75 ws
0.75 ws
0.75 bn 0.75 bn 0.75 bn

1.5 ws V7 0.75 ws 0.75 ws
X9 13 1.5 ws
1.5 ws 1.5 ws
0.75 ws
0.75 ws 0.75 ws 0.75 ws
1.5 ws
1.5 ws
0.75 ws
0.75 ws
X3 1
Switch position S8 = 2. Gear
X4 3 X4 2 X2 10 X2 11 X4 6 X4 1 X2 14 X4 5 X4 4
1.5 ws
0.75 bn
X2 12 X2 1
A1X2 10
X10 17 X6 13 X6 15
X2:10
X9 4 X6 17
Display
S3X1 2 8
A1
0.75 ws
0.75 ws
0.75 ws
0.75 ws
0.75 ws
0.75 ws
0.75 ws
2 8 10
/13.2
S3 Amplitude, small
135 3 1 7 9
S3X1 Y4X1 1 Y3X1 1 Y2X1 1 Y1X1 1
Amp.large
Amp.small
1 7
Auto-Vib A1X2 3
Y4 Y3 Y2 Y1
X2:3
0.75 bn
Display
Y4X1 2 Y3X1 2 Y2X1 2 Y1X1 2
A1
/39.10
/39.10
/31.8
/13.2
0.75 bn
0.75 bn
0.75 bn
0.75 bn
Amplitude, large
31.8
/33.16
31 8 31 6 31 5 31 5
S13: Switch Vibro automatic
H1: Signal horn D1: Relay ( Electronic system ) Y2: Magnet , Amplitude, large
S8: Switch 1./2. Gear S10: Switch Traction control S11: Switch Preselection of amplitudes
Y4: Magnet 2. Gear Roller drum Y3: Magnet 2. Gear Rear axle Y1: Magnet , Amplitude, small
a Vibration control Circuit diagram 3410-3411, TIER3
b
c
Gear shifting
Traction control
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/35.25 /40.2
15K
/37.2
XF3 3 XF3 4
Comfortable cabin =
F29 30A 3F3 25A
Special equipment 3F4 15A
/9.3 146 149
XF3 C XF3 D
X15 2
2.5 sw
2.5 sw
1.5 bl
1.5 or
6 rt
S43X1 5 S44X1 5 S45X1 5 S46X1 5
147 5 148 5 150 5 151 5

X39b A
S43 S44 S45 S46
X39s A /38.16 1 /38.14 1 /38.23 1
/38.25 1
S43X1 1 S44X1 1 S45X1 1 S46X1 1
1.5 gr/sw
1.5 gr/sw
1.5 gr/sw
1.5 or
1.5 sw
1.5 sw
1.5 sw
1.5 bl
Earth terminal Cabin
X102b 1 X103b 1 X40b 3 X104b 1 X105b 1 X40b 4 X109b 1
X102s 1 X103s 1 X40s 3 X104s 1 X105s 1 X40s 4 X109s 1
1.0 gr/ge
1.0 gr/bl
31 10
1.5 gr/sw
1.5 gr/sw
1.5 sw
1.5 sw
1.5 or
M42X1 1
6 bn
X10 14 X10 13
E40 E41 E42 E43 M42 M H40 M

152 153 154 155 156 157
X1 11 X1 10
X39s B M42X1 2 H40X1 1

1.5 bn
1.5 bn
1.5 bn
1.5 bn
0.75 ws
0.75 ws
X39b B
1.5 bn
X102s 2 X103s 2 X104s 2 X105s 2
X102b 2 X103b 2 A1X1 7

X104b 2 X105b 2 A1X1 8
X109s 2
X109b 2
2.5 bn
2.5 bn
X1:7 X1:8
1.5 bn
1.5 bn
1.5 bn
1.5 bn
1.5 bn
Display Display
A1 A1
1.5 bn
Working spotlights Working spotlights
/13.2 /13.2
front rear
31 7 31 7 31 10 31 10 31 10 31 10 31 10 31 10
S43: Switch Working spotlights front S44: Switch Working spotlights, rear S45: Push button switch Windshield washer
M42: Pump Windshield washer
E40: Working spotlights front, left E42: Working spotlights rear, left
S46: Switch Rotating-beam light
E41: Working spotlights front, right E43: Working spotlights rear, right H40: Rotating-beam light

a Working spotlights Circuit diagram 3410-3411, TIER3
b
c
Windshield washer
Rotating-beam light
d
gepr.
02082937 02 + 66 Bl.
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
15K 15K
/36.25 /38.2
30 30
/33.25 /44.2
30K.1
/38.2
30K.2
/39.2
XF3 2 XF3 5 Comfortable cabin =
1.5 sw
1.5 sw
159 160 Special equipment
F34 30A 3F2 10A 3F5 15A
/9.3
XF3 B XF3 E
0.75 bl/sw
X30 3
2.5 sw
2.5 sw
1.5 rt/ge
1.5 bl
X40b 1
X40s 1
S40X1 7 3 S41X1 1 5
162 7 3 163 1 5
161
E44 S40 S41
/38.21 012 5 1 /38.18 01 3 7
5 1 S41X1 3 7
31 10 31 10
1.5 bl/ws
0.75 bl/sw
1.5 bl/ws
1.5 bl
1.5 sw
1.5 gr
1.5 bn
1.5 gr
1.5 bn
X100b 3 1 2 4 6 X101b 1 4 3 2
1.5 bn
1.5 bn
1.5 bn
X100s 3 1 2 4 6 X101s 1 4 3 2
1.5 bl/ws
0.75 bl/sw
1.5 bl/ws
1.5 bl
1.5 bl
1.5 gr
1.5 bn
1.5 bl
1.5 bn
164 165
S47 S48
1.5 bn
1.5 bn
53a 31b 53 53b 31 53a 31b 53 31
166 167
M40 M41
M M
31 10 31 10 31 10
E44: Cab lighting

S47: Door contact switch left S40: Switch Windshield wiper front S41: Switch Windshield wiper rear
S48: Door contact switch right M40: Windscreen wiper motor front M41: Windscreen wiper motor rear
a Cab lighting Circuit diagram 3410-3411, TIER3
b
c
Windshield wiper Zeichnungsnummer Rev. = 37
d
gepr.
02082937 02 + 66 Bl.
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
15K 15K
/37.25 /43.2
58 58K
/34.25 /39.2
30K.1 X40b 2 58K.1
/37.25 /43.2
3F6.F X40s 2
/39.2
Comfortable cabin =
1.5 gr/rt
1.5 rt
XF3 6
172 XF3 1
Special equipment
3F6 10A 173
3F1 10A
XF3 F
XF3 A
Radio assembly = Special equipment
31 10
1.5 gr/rt
1.5 gr/rt
W1
1.5 sw
1.5 rt
1.5 bn
171
+U-Ant. GND
Instrumentation lighting Console
A40X1 4 7 1 5 8 1.5 gr/rt 1.5 gr/rt 1.5 gr/rt 1.5 gr/rt 1.5 gr/rt
S44X2 1 S43X2 1 S41X2 1 S40X2 1 S45X2 1 S46X2 1
30 15 n.c. Ant.+U GND
174 9 175 9 176 9 177 9 178 9 179 9
S44 S43 S41 S40 S45 S46

A40 Ant.In. /36.14 10
/36.7 10
/37.24 10
/37.14 10
/36.21 10
/36.24 10
170 S44X2 2 S43X2 2 S41X2 2 S40X2 2 S45X2 2 S46X2 2
+LF -LF +RF -RF 1.5 bn 1.5 bn 1.5 bn 1.5 bn 1.5 bn
A40X2 5 6 3 4
1 sw/rt
180
B40
1.5 bn
1 rt
1 rt
181
B41
31 10
1 sw/rt
A40: Radio B40: Loudspeaker right S44: Switch Working spotlights, rear S40: Switch Windshield wiper front
W1: Antenna B41: Loudspeaker left S43: Switch Working spotlights front S45: Push button switch Windshield washer
S41: Switch Windshield wiper rear S46: Switch Rotating-beam light

a Radio assembly Circuit diagram 3410-3411, TIER3
b
c
Instrumentation lighting Cabin Zeichnungsnummer Rev. = 38
d
gepr.
02082937 02 + 66 Bl.
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
Shield Shield
/30.25 /40.2
58K
/38.25
/30.25
/30.25
/35.17
/35.20
3F6.F
/38.9
30K.2
/37.25
B3-Sign.
B4-Sign.
Amp.large
Amp.small
Speedometer =
Special equipment
X10 9 5 18 X10 6 8
5x0.75
5x0.75
31 10
ws
gr
0.75 ws
0.75 ws
1.5 gr/rt
X40b 7 8 X40b 6 5 V 000

1.5 sw
1.5 bn
1.5 rt
X40s 7 8 X40s 6 5 184

P1
1.5 vio/ws
1.5 ge/gn
1.5 vio
1.5 ws
X50b 2 3 4 6 7 8 X51b 2 3
4
X50s 2 3 5 6 7 8 X51s 2 3 1
P1A 1 2 3 5 6 P1B 1 2 3 4 P1C 2 3 P1D 1 2
1.5 rt/bl
1.5 gr/rt
1.5 gr/rt
0.75 sw/ws
1.0 gr/ge
0.75 vio
0.75 rt
0.75 bn
0.75 sw
0.75 bl
0.75 ws
0.75 gn
0.75 ge
0.75 rt
0.75 sw
0.75 bn
0.75 ws
0.75 bl
0.75 ge
0.75 gn
183
A9
kl. Ampl. Dauer +12V

gr. Ampl. Licht
Tacho Inp. geschaltet +12V
Vib. imp. I GND
Licht Geber +U
Vib. Imp. II Geber -U
geschaltet +12V inv. Tachosignal
GND Tachosignal
Dauer +12V Vibroimp.
kl. Ampl.
gr. Ampl.
A9: Interface Speedometer P1: Speedometer

a Tachograph Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/36.25 /42.2
31 31
/35.25 /44.2
Shield Shield
/39.25 /44.2
CAN-High CAN-High
/28.25 /44.2
CAN-Low CAN-Low
/28.25 /44.2
I-Sign.
/30.25
F18 10A
/9.3
X13 X21
X22:6
X23:6
X22:4
X23:4
X22:5
X23:5
X22:2
X23:2
X22:3
X23:3
3 6 5 9 10 11 12 4 10 11 3 2 5 4 6 12
5x2x0,14
5x2x0,14
5x2x0,14
5x2x0,14
5x2x0,14
5x2x0,14
5x2x0,14
5x2x0,14
0.75 Schirm
0.75 Schirm
Schirm
0.75 bn
0.75 gr
0.75 gn
0.75 ge
0.75 gn
0.75 ws
vio
ws
gn
ge
br
gr
bl
A8X1 1 2 4 5 A8X2 2 3 A8X6 B C G H J K M
-X1 1 2 3 4 5 6 -X2 1 2 3 4 -X6 A B C D E F G H J K L M

HCM =
CAN-High
CAN-Low
Res-In
CAN-GND
USB-GND
Boot-In
GND
TP200
USB-
USB+
RxD
TxD
+U +U GND GND +U GND Sign.
Power I-Sensor Special equipment
A8 HCM-3 DIGITAL
185 a-Sensor
+9V GND Sign. CDS
-X4 1 2 3 -X5 1 2 3 4 5 6 7
A8X4 1 2 3 A8X5 1 2 3 4 5 6 7
Instruments
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
gnge
187
6
3x0.75
3x0.75
3x0.75
3x0.75
Schirm
A10
CDS2
ws
bn
gn
+12V /41.2
CDS7
GND /41.2
f CDS3
I-Signal /41.2
f/4
+U GND Sign.
RMV-Wert
186
Vibrofrequenz
B10 a gr/klAmpl.
CDS6
/41.2
U CDS5
HMV-Wert /41.2
CDS4
/41.2
CDS1
/41.2
B10: Acceleration sensor A8: Compactometer HCM A10: Interface CDS-Display

a Compactometer HCM Circuit diagram 3410-3411, TIER3
b
c
Acceleration sensor Zeichnungsnummer Rev. = 40
d
gepr.
02082937 02 + 66 Bl.
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
A11X2 10 11 12 13 14 15 16 17 18
RS232
Power Extern
CDS =
6
GND
Special equipment Display
5
n.c.
188
4
A11
+12V
A11X3
A11X1 12 13 14 15 16 17 18 19 20 22 21
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
gnge
2
6
1
X53s 1 2 3 4 5 6 7
X53b 1 2 3 4 5 6 7
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
7x0.5
gnge
2
6
1
X52s 1 2 3 4 5 6 7
X52b 1 2 3 4 5 6 7
CDS1 7x0.5
/40.25
CDS2 1 7x0.5
/40.25
CDS3 7x0.5 2
/40.25
CDS4 3 7x0.5
/40.25
CDS5 7x0.5 4
/40.25
CDS6 5 7x0.5
/40.25
CDS7 7x0.5 6
/40.25
gnge
A11: CDS Display

a CDS Display Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/40.25 /44.2
2.5 rt
F27 15A A30X1b 1 A30X1b 4
/9.3 A30X1s 1 A30X1s 4
X15 3 X41s 1
2.5 rt
X41b
2.5 rt
1.5 br
1
2.5 rt
2.5 br
B
190
02 -S2 -K1X1 30 85
1.5 rt
-S1
A30
0.75 gn
K100X1 30 192 30 85
1 2 3 L M H C
3
-K1
87 87a 86
K100 191
/18.14 4 5 -S3 -K1X1 87 86
1.5 ws
1.5 ge
1.5 bl
1.5 rt/ws
K100X1 87
0.75 gn
0.75 gn
A30X1s A30X1s A30X1s

2.5 rt
2.5 rt
2 5 3
A30X1b 2 A30X1b 5 A30X1b 3
1.5 rt/ws
0.75 gn
0.75 gn
X56b 4 3 1
X15.6b 1 X56s 4 3 1
Special equipment
X15.6s 1
1.5 ws
1.5 ge
1.5 bl
Air conditioning
X41b 2 X41b 5 X41b 3
X41s 2 X41s 5 X41s 3 X41s 4
X41b 4
0.75 ws
1.5 ws
0.75 ws
A31X1 1 4 5 2 3
X10 12 X11 3 X11 1

1.5 bl
R1 R2
F1
A31 X7 7 X7 9 X7 8
2.5 br
M
0.75 ws
1.5 ws
0.75 ws
193
S49X1 1 X57 1
195
S49 P
Y30
1.5 br
1.5 br
194
S49X1 2
X56s 2
X56b 2 31 15
A30: Control unit Air conditioning

A30-S1: Switch Fan motor A30-S3: Thermostat Air conditioning
A30-S2: Switch Air conditioning S49: Pressure switch Compressor
A31: Fan motor Ventilation / Heating Y30: Compressor
a 02 14.05.08 Lan. Heating / Air conditioning Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
58K.1
/38.25
15K 1.5 rt 1.5 rt
/38.25
Interval switch
0...9
t = 2,5-9sec. G
A200 i
4F2 15A 4F1 15A 202
INH. +10-30V +10-30V Output GND n.c.
1 2 3 4 5 6
A200X1 2 3 4 5
1.5 rt
1.5 rt
1.5 rt 1.5 rt 1.5 rt
S200X1 2 8 10 S201X1 2 8 10 P200X1 +

2 8 10 2 8 10
S200 S201
200 3 1 7 9 201 3 1 7 9
-H1
S200X1 P200
1 . 5 b rS 2 0 1 X 1
1 7 9 1 7 9
1.5 br 1.5 br 203 207
1.5 gr 1.5 gr
1.5 gr
P200X1 S GND
2.5 gr
1.5 gr
0.75 bl
1.0 gr/bl
X200b 3 X200b 2 X205 1 X200b 1
X200s 3 X200s 2 X200s 1
0.75 bl
1.5 br
2.5 gr
2.5 gr
2.5 br 2.5 br X201b 3
X203b 1 2 X201b 1 2 X201s 3
X203s 1 2 X201s 1 2
2.5 gr
2.5 br
2.5 gr
2.5 br
0.75 bl
X204b 1 2 X202b 1 2 B200X1 1
X204s 1 2 X202s 1 2
0.75 br
B200 L
M201 M M202 M 204
205 206
31 10 31 10 B200X1 2
S200: Push butt.switch, additive sprinkl. M202: Water pump P200: Water level indicator
M201: Water pump Additive sprinkling S201: Push button switch Water pump B200: Level transmitter, water
A200: Interval switch

a Special equipment Circuit diagram 3410-3411, TIER3
b
c
Sprinkling Zeichnungsnummer Rev. = 43
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/42.25 /45.2
30 30
/37.25
CAN-High
/40.25
CAN-Low
/40.25
X18:4
X18:2
F28 10A F26 7.5A F19 5A
/9.3 /9.3 /9.3
Reserve
Lox.
X20:12
X21:7
X22:7
X23:7
X21:8
X22:8
X23:8
X21:9
X22:9
X23:9
X4:10
X4:11
X7:11
X7:13
X22:10
X23:11
X23:10
X22:11
K11X1 1 3
Reserve Cold start equipment (COM-2)

X20:10
X20:2
X20:7
X20:9
X20:8
K11X1 2 5
HCN CAN-Bus
Reserve Reserve
X18:1
X1:20
X7:10
X11:5
X7:12
X3:6
X3:8
X21:12
X22:12
X23:12
X20:6
X18:6
X18:4
X18:3
X21:1
X22:1
X23:1
X4:12
X5:2
X6:19
Shield Shield
/40.25 /45.2
31 31
/40.25 /45.2

a Reserve Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/44.25 /46.2
F1 30A F2 15A F22 10A

/8.3 /8.3 /9.3
Reserve Reserve
Compactometer Instrument panel Engine room
X8:8
X8:8
X1:9
X10:15
X2:17
X2:16
X2:19
X2:18
X3:11
X3:14
X3:17
X3:16
X2:13
X3:5
X3:4
X1:8
X2:8
Reserve
Power supply
X13:2
X13:7
X13:1
X13:8
X4:9
X4:7
X4:8
X7:15
X6:14
X6:21
X11:4
X7:14
X7:5
X5:4
X8:1
X8:2
X5:16
X5:1
X5:8
X9:8
X7:4
X7:6
X7:1
Shield Shield
/44.25 /46.2
31 31
/44.25 /46.2

b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/45.25 /=SE/100.2
Reserve
X27:14
X27:15
X27:10
X27:11
X27:12
X27:13
X25:1
X24:1
X27:9
X27:8
X27:7
X27:6
X6:18
X6:12
X28:8
X28:4
X28:10
X28:1
X28:6
X28:2
X28:5
X28:11
X28:7
X28:12
XD2:9
X28:9
Shield Shield
/45.25
31 31
/45.25 /=SE/100.2

b
c
d
gepr.
02082937 02 + 66 Bl.
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
Electric plug Central electric
Wire harness Wire harness Wire harness Contact bridge

Instrument panel Instrument panel Instrument panel Vibration
210 X1 211 X2 212 X3 213 X4
21 18 15 12 9 6 3 1: 12: 21 18 15 12 9 6 3 1: /35.10 12: /35.8 21 18 15 12 9 6 3 1: /35.3 12: /33.6 12 9 6 3
1: /35.19
2: 13: /27.12 2: /35.7 13: 2: /34.7 13: /34.18 2: /35.14
3: /35.13
3: /17.18 14: 3: /30.10 14: /35.20 3: /33.21 14:
4: /35.22
1 4: /29.3 15: /27.3 1 4: 15: /30.5 1 4: 15: /33.21 1 5: /35.21
6: /35.18
5: /27.9 16: /18.11 5: /35.23 16: 5: 16:
7:
6: /30.7 17: /19.24 6: /35.25 17: 6: 17: 8:
9:
7: /30.4 18: 7: /30.17 18: 7: /22.4 18: /33.8
10:
8: 19: /18.17 8: 19: 8: 19: /21.20 11:
12:
9: 20: 9: /31.12 20: /31.12 9: /34.8 20: /33.8
10: /36.18 21: /18.7 10: /35.15 21: /30.22 10: /22.8 21: /33.5
black 11: /36.11 blue 11: /35.17 yellow 11:
Wire harness Wire harness Wire harness Supply line

Engine room Engine room Engine room Fan motor
02
214 X5 215 X6 216 X7 X15.6b
21 18 15 12 9 6 3 1: 12: /29.6 21 18 15 12 9 6 3 1: 12: 15 12 9 6 3 1:
2:
2: 13: /29.6 2: /32.5 13: /35.19 1: /42.3
3:
3: /19.24 14: /27.9 3: /18.17 14: 4:
5:
1 4: 15: /30.15 1 4: /34.24 15: /35.22 1 6:
5: /27.9 16: 5: /19.11 16: /27.12 7: /42.15
X15.6s
8: /42.20
6: /29.9 17: /27.19 6: /19.16 17: /35.10
9: /42.17
1 :/ 4 2 . 3
7: /27.22 18: /27.22 7: /34.12 18: 10:
11:
8: 19: /27.16 8: /34.14 19:
12:
9: /30.16 20: /30.13 9: /17.18 20: /28.25 13:
14:
10: /30.14 21: /27.16 10: /28.23 21:
15:
black 11: /29.3 blue 11: /34.25

a 02 14.05.08 Lan. Electric plug Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Wire harness Wire harness Wire harness Wire harness Wire harness
Engine room Front roller Cabin Cabin Blade
221 X9 222 X10 223 X11 224 X12
220
X8
15 12 9 6 3 1: /30.21 1: /34.20 10: /31.13 6 3 6 3
18 15 12 9 6 3
1: 2: 1: /42.20 1:
2: /19.3 11: /35.8
3: /30.19
2:
4: /35.8 3: /31.13 12: /42.15 2: /32.19 2: /32.15
3: /29.15 5: /30.20
1 4: /31.4 13: /36.18 1 1
6: /34.16 1 3: /42.17 3: /32.23
4: /29.23
7: /30.18 5: /39.7 14: /36.11
5: 8: 4: 4:
2 4 6 8 6: /39.10 15:
9: /34.5
6: /29.13
1 3 5 7 10: /34.18 7: /19.5 16: /31.17 5: 5: /32.18
7: 11: /34.7
8: /39.10 17: /35.13
12: /34.20 6: /32.14 6: /32.20
black 8:
13: /35.3 9: /39.7 18: /39.8
14: /35.3
15: /34.8
Potentiometer
Wire harness
Speed adjustment
Wire harness Wire harness high current relay Control device Refuel pump
Diesel engine 02
HCM HCM Supply system
225 X13 229 X21 226 X26 227 X17 230 X16 231 D60X1
12 9 6 3 12 9 6 3 9 6 3 1: /28.8 6 3 1 :/ 2 9 . 9
1: 1: 1: /18.11
1: /29.9 2 :/ 2 9 . 9
2: 2: /40.16 2: /28.5 4 3 2: /18.11
3 :/ 2 9 . 1 0
3: /40.3 3: /40.16 3:
3: /28.11 2 1 2: /29.9 4:
4: /40.9 4: /40.18 4: 6 7 8
5
5 :/ 2 9 . 1 1
1 5: /40.5 1 5: /40.17 1 4: /28.8 1 2 3 4
3: /29.10 1
6 :/ 2 9 . 9
6: /40.4 6: /40.19
5: /28.9 7:
7: 7: 228 K15X1 4: /29.11 8 :/ 2 9 . 1 1
8: 8: 6: /28.10
9: /40.6 9:
7: /28.6 5: /29.13
10: /40.7 10: /40.12 1 :/ 1 8 . 1 1
11: /40.8 11: /40.13 8: /28.10
1 2 6: /29.9
12: /40.8 12: /40.20 2 :/ 1 8 . 1 1
9:

a 02 14.05.08 Lan. Electric plug Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Wire harness Control device Diesel engine EMR-3
232 X19 233 X27 234 XD2

1: /20.5 10: /28.20 15 12 9 6 3 1: /27.22 9 6 3 1: /21.9
18 15 12 9 6 3
2: /27.19
2: /20.10 11: 2: /21.11
3: /28.23
3: /20.13 12: /19.8 4: 3: /21.13
5: /28.25
4: /20.3 13: /28.19 1 1 4: /21.15
1 6:
5: /20.17 14: /28.15 7: 5: /21.17
8:
6: /20.20 15: /20.23 6: /21.6
9:
7: 16: /31.10 10: 7: /21.19

11:
8: /28.17 17: 8: /21.23
12:
9: 18: 13: 9:
14:
15:

a Electric plug Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Electric plug E-Box
HCM Power HCM I-Signal HCM a-Signal HCM DIGITAL
235 A8X1 236 A8X2 237 A8X4 238 A8X6

3 2 A:
3 2 B: /40.12
4 2 1: /40.3 1: 1: /40.3
3 1 View Contacts C: /40.13
5 6 1 2: /40.4 4 1 2: /40.8 2: /40.4
D:
3: 3: /40.9 3: /40.4
E:
4: /40.5 4:
G F F:
5: /40.6 H M
E
D G: /40.16
6: L C
J H: /40.16
K A B
J: /40.17
K: /40.18
L:
M: /40.19
CDS-Display HCM CDS Electric plug
239 X52b 240 X52s 241 A8X5

3 4 4 3 4 3
2 5 5 2 5 2
1: /41.19 1: /41.19 1: /40.6

1 6 2: /41.19 6 1 2: /41.19 6 1 2: /40.7
3: /41.20 3: /41.20 3: /40.7
4: /41.21 4: /41.21 4: /40.8
5: /41.21 5: /41.21 5: /40.9
6: /41.22 6: /41.22 6: /40.9
/41.23 /41.23 /40.10

a Electric plug E-Box Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Central plug Diesel engine
242 M1X1s 243 M1X1b
1: /25.23 22: /24.3 1: /25.23 22: /24.3

VIEW CONTACTS 2: 23: /24.9 VIEW CONTACTS 2: 23: /24.9
16 28 3: 24: /23.25 3: 24: /23.25
1 10 22 34 4: 25: /24.23 28 16 4: 25: /24.23
5: 26: /24.15 5: 26: /24.15
34 22 10 1
6: 27: /24.17 6: 27: /24.17
7: 28: /24.5 7: 28: /24.5
8: 29: /24.7 8: 29: /24.7
9: /25.15 30: /23.23 9: /25.15 30: /23.23
10: /25.3 31: /24.21 10: /25.3 31: /24.21
11: 32: /24.25 11: 32: /24.25
12: 33: /24.13 12: 33: /24.13
13: /25.13 34: /26.15 13: /25.13 34: /26.15

14: /25.11 35: /26.9 14: /25.11 35: /26.9
15: /25.19 36: /26.11 15: /25.19 36: /26.11
16: /25.7 37: /26.13 16: /25.7 37: /26.13
17: /25.5 38: 17: /25.5 38:
9 15 27 18: 39: /26.19 18: 39: /26.19
19: /26.3 40: /26.21
42 27 15 9 19: /26.3 40: /26.21
21 33 42
20: /26.5 41: /26.23 33 21 20: /26.5 41: /26.23
21: /25.21 42: /26.25 21: /25.21 42: /26.25
Sensor Sensor Water level Speed sensor Speed sensor Temperature sensor Relay
Engine oil pressure Fuel prefilter Camshaft Crankshaft Coolant Cold-start aid
244 B6X1 245 B11X1 246 B40.1X1 247 B40.2X1 248 B43X1 249 K17X1
1 2
3 3
1: /24.13 1: /28.23 1
2 1: /25.11 1
2 1: /25.19
1 :/ 2 3 . 2 3
1 :/ 2 3 . 3
2
1
1
2
3
2: /28.25
2: /24.15 2: /25.13 2: /25.21 2 :/ 2 3 . 2 3
1 2 2 :/ 2 3 . 3
1 2 3 3: /24.17 3: /25.15 3: /25.23 1 2
Sensor Pressure sensor Low pressure Valve Reserve

Boost air Fuel RAIL Fuel Fuel RAIL Starting relay
250 B48X1 251 B49X1 252 B51X1 253 Y19X1 255 X34b
1: /24.5 1: /24.21 1: /25.3 1 :/ 2 3 . 1 8

1 :/ 2 6 . 3
2
1
1
2
3
2
2
3
1
2: /24.7 1 4 2: /25.5 1 2 :/ 2 3 . 2 0
2: /24.23 2 :/ 2 6 . 3
3: /24.3 3 2 3:
1 2 3 3: /24.25 1 2
1 2 3 4 4: /24.9 4: /25.7

a Connector Diesel engine Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Connector Engine room

Magnet Magnet Magnet Magnet
Amplitude, small Amplitude, large Gear shifting Brake valve Drive pump
260 Y1X1 261 Y2X1 262 Y3X1 263 Y5X1 264 Y8X1
1 1 1 1 1
1 :/ 3 5 . 2 2 1 :/ 3 5 . 1 9 1 :/ 3 5 . 1 0 1 :/ 1 9 . 1 6 1 :/ 1 9 . 1 1
4 3 2 :/ 3 5 . 2 2 4 3 2 :/ 3 5 . 1 9 4 3 2 :/ 3 5 . 1 0 4 3 2 :/ 1 9 . 1 6 4 3 2 :/ 1 9 . 1 1
3: 3: 3: 3: 3:
2 4: 2 4: 2 4: 2 4: 2 4:
Coupler socket, black Coupler socket, grey Coupler socket, black Coupler socket, black Coupler socket, black
Level transmitter Sensor Filter indicator Pressure switch Sensor

Fuel Speed Hydraulic oil filter Air filter Coolant level
265 B1X1 266 B4X1 267 S16X1 268 S17X1 269 X35b 270 X35s
1 :/ 2 9 . 4 1 :/ 3 0 . 1 5 2
1 :/ 2 7 . 9 1 :/ 2 7 . 2 2
1 :/ 2 7 . 1 6 1 :/ 2 7 . 1 6
2 :/ 2 9 . 3 2 :/ 3 0 . 1 4 3
2 :/ 2 7 . 9
1 2 :/ 2 7 . 2 2 1
3 :/ 2 9 . 5 3 :/ 3 0 . 1 6 : 1 2 :/ 2 7 . 1 6 2 :/ 2 7 . 1 6
2
3
4 :/ 2 9 . 5 4: 2 3
3 :/ 2 7 . 1 9 3 :/ 2 7 . 1 9
Pressure switch Lighting Lighting

Parking brake Back-up alarm rear, right rear, left
271 S12X1 272 X38b 273 X38s 274 X36b 275 X36s 276 X37b 277 X37s
1 :/ 3 4 . 2 4 1 :/ 3 4 . 2 4 1 :/ 3 4 . 1 4 1 :/ 3 4 . 1 4
1: /19.24 1 :/ 3 2 . 5 1 :/ 3 2 . 5
2 :/ 3 4 . 2 4 2 :/ 3 4 . 2 4 2 :/ 3 4 . 1 2 2 :/ 3 4 . 1 2
1 2: /19.24
2
1 2 :/ 3 2 . 5 1 2
2 :/ 3 2 . 5
3 4 4 3
3 4 4 3
2
3 :/ 3 4 . 2 5 2 1 3 :/ 3 4 . 2 5 2
3 :/ 3 4 . 1 2 2 1 3 :/ 3 4 . 1 2
1 1
4 4: 4: 4: 4: 4:
2 : /19.25 Heating
Fuel filter
278 X70b 283 X70s
Push button switch Charge pump
Fuel tank 1 :/ 2 9 . 2 3 1 :/ 2 9 . 2 3
2 2 :/ 2 9 . 2 3 1 2
2 :/ 2 9 . 2 3
1
279 S60X1
1:
Proximity switch Proximity switch
4
2:
Charge pump Fuel tank Back-up alarm Vibro automatic
5 3
3:
4:
280 X60b 281 X60s 325 X43b 326 X43s 327 X44b 328 X44s
6 2
5 :/ 2 9 . 1 3
1 :/ 2 9 . 1 5 1 :/ 2 9 . 1 5 1 :/ 3 1 . 4 1 :/ 3 1 . 4 1 :/ 3 1 . 8 1 :/ 3 1 . 8
6:
7 1 2 1 2 1 1
7 :/ 2 9 . 1 3 1 2 :/ 2 9 . 1 5 2 :/ 2 9 . 1 5 1 2 :/ 3 1 . 5 2 :/ 3 1 . 5 1 2 :/ 3 1 . 9 2 :/ 3 1 . 9
2 2
3 3 3 3
2 2
3 :/ 3 1 . 4 3 :/ 3 1 . 4 3 :/ 3 1 . 8 3 :/ 3 1 . 8
a Connector Engine room Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Connector Front roller
Lighting Lighting
front, left front, right
285 X32b 286 X32s 287 X23 288 X29b 289 X29s 290 X22
1 :/ 3 4 . 7 1 :/ 3 4 . 7 1: 1 :/ 3 4 . 1 8 1 :/ 3 4 . 1 8 1:
2 :/ 3 4 . 5 2 :/ 3 4 . 1 6
2 :/ 3 4 . 5 2 :/ 3 4 . 5 2 :/ 3 4 . 1 6 2 :/ 3 4 . 1 6
4 4 3 6
3: 4 4 3 6
3:
3 4 5 3 4 5
2
3 :/ 3 4 . 8 2 1 3 :/ 3 4 . 8 3
4 :/ 3 4 . 8 2
3 :/ 3 4 . 2 0 2 1 3 :/ 3 4 . 2 0 3
4 :/ 3 4 . 2 0
1 1 2 1 1 2
5 :/ 3 4 . 7 5 :/ 3 4 . 1 8
4 :/ 3 4 . 5 4 :/ 3 4 . 5 4 :/ 3 4 . 1 6 4 :/ 3 4 . 1 6
6 :/ 3 4 . 5 6 :/ 3 4 . 1 6
Magnet
Signal horn Gear shifting
291 V6X1 292 Y4X1
1
1 :/ 3 5 . 8
1 :/ 3 5 . 2
4 3 2 :/ 3 5 . 8
2 2 :/ 3 5 . 2
1 3:
2 4:
Coupler socket, black
Plug Blade
293 Y10X1 294 Y11X1 295 Y12X1 296 Y13X1

1 1 1 1
1 :/ 3 2 . 1 5 1 :/ 3 2 . 1 8 1 :/ 3 2 . 2 0 1 :/ 3 2 . 2 3
4 3 2 :/ 3 2 . 1 5 4 3 2 :/ 3 2 . 1 8 4 3 2 :/ 3 2 . 2 0 4 3 2 :/ 3 2 . 2 3
3: 3: 3: 3:
2 4: 2 4: 2 4: 2 4:
Coupler socket, black Coupler socket, grey Coupler socket, grey Coupler socket, black

a Connector Engine room Circuit diagram 3410-3411, TIER3
b
c
Connector Front roller Zeichnungsnummer Rev. = 53
d
gepr.
02082937 02 + 66 Bl.
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
Display Display Ignition lock Ignition lock
300 A1X1 301 A1X2 302 S2X1 303 S2X2

1: /27.12
1: /17.18 1 :/ 1 8 . 1 1 5: /18.13
2: 8
2: /22.8 3 2: 6:
3: /35.25 4 10 9
3: /22.4 3: 7: /18.14
4: 1 2
4: 4: 7 8:
5: /19.24
5: /30.22 5 6 9:
14 6:
6: 13 10:
12 7: /30.10
7: /36.11
11 8: /29.3
18 8: /36.18 10
17 9 7 9:
9: 6
16 8 10: /35.25
15 10: /30.7 5
14 4 11:
11: /30.4
13 9 3 12: /33.18
12 8 12: /18.21 2
7 1 13: /33.15
11 13: /27.5
6
10 14: /21.20
5 14: /30.17
4 15: /27.9 Alarm system switch
3
2 16:
1 17: 308 S5X1
18:
Steering column switch 3: /33.5
10 18 4:
Socket 306 X28s 307 X28b 5: /33.8
3
Signal transmitter Supply system 1 :/ 3 3 . 1 1 1 :/ 3 3 . 1 1
17 7:
14 8:
1 2 3 4 5 6 7 8
8 7 6 5 4 3 2 1
2 :/ 3 3 . 1 1 2 :/ 3 3 . 1 1 5
304 H2X1 305 X27b 3 :/ 3 3 . 1 0 3 :/ 3 3 . 1 0
10: /33.12
13 11: /33.6
4 :/ 3 3 . 2 1 4 :/ 3 3 . 2 1
1 :/ 2 7 . 5 1 :/ 2 7 . 3 4 13: /33.7
5 :/ 3 3 . 2 1 5 :/ 3 3 . 2 1 11
2 14: /33.7
1 2 :/ 2 7 . 5 1 2 :/ 2 7 . 4 6 :/ 3 3 . 2 1 6 :/ 3 3 . 2 1
8 7 17: /33.11
2 3
7: 7:
3: 18: /33.9
8: 8:
Push button switch Switch Switch Switch

Signal horn Switch Gear Traction control Preselection of amplitudes Vibro automatic
309 S3X1 310 S8X1 311 S10X1 312 S11X1 313 S13X1
1: /35.4 1: /35.6 1: /35.12 1: /35.24 1: /35.18

10 9 10 9 10 9 10 9 10 9
2: /35.3 2: /35.7 2: /35.13 2: /35.25 2: /35.18
3 6 3: 3 6 3: 3 6 3: /35.13 3 6 3: /35.25 3 6 3: /35.19
4: 4: /35.8 4: /35.14 4: 4: /35.19
5: 5: /35.8 5: /35.14 5: 5: /35.20
2 5 2 5 2 5 2 5 2 5
6: 6: 6: /35.14 6: 6: /35.20
7: /35.4 7: /35.9 7: /35.15 7: /35.26 7: /35.21
1 4 8: /35.4 1 4 8: /35.9 1 4 8: /35.15 1 4 8: /35.26 1 4 8: /35.21
9: 9: /35.10 9: /35.16 9: 9: /35.21
8 7 10: 8 7 10: /35.10 8 7 10: /35.16 8 7 10: 8 7 10: /35.21

a Central plug Instrument panel Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Wire harness
Potentiometer Speed adjustment Diesel engine Seat pedestal
314 X45.1b 315 X45.1s 316 X45.2b 317 X45.2s 323 X42b 324 X42s
1 :/ 2 8 . 8 1 :/ 2 8 . 8 1 :/ 3 1 . 1 3 1 :/ 3 1 . 1 3
1
1: /28.6
2
2 :/ 2 8 . 8 2 :/ 2 8 . 8 2 :/ 3 1 . 1 7 2 :/ 3 1 . 1 7
1 :/ 2 8 . 6
3 :/ 2 8 . 1 1 3 :/ 2 8 . 1 1 3 :/ 3 1 . 1 8 3 :/ 3 1 . 1 8
2: /28.5 4 5 6
4
1 2 4 :/ 2 8 . 9 4 :/ 2 8 . 9 4 :/ 3 1 . 2 0 6 5 4 :/ 3 1 . 2 0
2 :/ 2 8 . 5 1 2 3
2 1
5 :/ 2 8 . 1 0 5 :/ 2 8 . 1 0 5 :/ 3 1 . 2 1 3 5 :/ 3 1 . 2 1
6 :/ 2 8 . 1 0 6 :/ 2 8 . 1 0 6 :/ 3 1 . 1 3 6 :/ 3 1 . 1 3
CDS Display
Cabin 334 X53b 335 X53s

Plug Terminal 15 332 X40b 333 X40s 3 4 4 3

2 5 5 2
Cabin 1 :/ 3 7 . 4 1 :/ 3 7 . 4
1: /41.19 1: /41.19
2 :/ 3 8 . 1 4 2 :/ 3 8 . 1 4 1 6 6 1
330 X39b 331 X39s 3 :/ 3 6 . 1 1 3 :/ 3 6 . 1 1
2: /41.19 2: /41.19
3: /41.20 3: /41.20
4 :/ 3 6 . 1 8 4 :/ 3 6 . 1 8
A :/ 3 6 . 3 A :/ 3 6 . 3 6 7 8
7 6 5 4: /41.21 4: /41.21
5
5 :/ 3 9 . 1 0 8
1
5 :/ 3 9 . 1 0
2 3 4
4 3
2 5: /41.21 5: /41.21
1
6 :/ 3 9 . 1 0 6 :/ 3 9 . 1 0
B :/ 3 6 . 3 B :/ 3 6 . 3 6: /41.22 6: /41.22
7 :/ 3 9 . 7 7 :/ 3 9 . 7
B A /41.23 /41.23
A B 8 :/ 3 9 . 7 8 :/ 3 9 . 7
Control unit Relay

Heating / Air conditioning Heating / Air conditioning Compressor Pressure switch
Air conditioning
336 X41b 337 X41s 338 A30X1b 339 A30X1s 340 -K1X1
1 :/ 4 2 . 5 1 :/ 4 2 . 5 1 :/ 4 2 . 1 7 1 :/ 4 2 . 1 7
282 S49X1
85: /42.19 1 2
2 :/ 4 2 . 1 5 2 :/ 4 2 . 1 5 2 :/ 4 2 . 1 5 2 :/ 4 2 . 1 5
87 86: /42.19 1: /42.15
3 :/ 4 2 . 2 0 3 :/ 4 2 . 2 0 3 :/ 4 2 . 2 0 3 :/ 4 2 . 2 0
4 5 6
4 4 5 6
4 30: /42.17
4 :/ 4 2 . 2 2 4 :/ 4 2 . 2 2 4 :/ 4 2 . 1 9 4 :/ 4 2 . 1 9 2: /42.15
85
86
5 5
6 6
1 2 3
2 1 1 2 3
2 1 87a 87: /42.17
5 :/ 4 2 . 1 7 3 5 :/ 4 2 . 1 7 5 :/ 4 2 . 1 7 3 5 :/ 4 2 . 1 7
87a:
30
6: 6: 6: 6:
Electric plug
Fan motor Heating / Air conditioning
341 A31X1 342 X56b 343 X56s

1 :/ 4 2 . 7 1 :/ 4 2 . 8 1 :/ 4 2 . 8
2 :/ 4 2 . 9 2 :/ 4 2 . 8 2 :/ 4 2 . 8
6
3 :/ 4 2 . 1 1 6
3 :/ 4 2 . 7 3 :/ 4 2 . 7
4 5 4 5 4
3
4 :/ 4 2 . 7 3
4 :/ 4 2 . 7 6 5 4 :/ 4 2 . 7
1 2 1 2 1
2
5 :/ 4 2 . 8 5: 3 5:
6: 6: 6:

a 01 10.04.08 Lan. Connector Operator platform Circuit diagram 3410-3411, TIER3
b
c
Air conditioning Heating
Connector Cabin
d
gepr.
02082937 02 + 66 Bl.
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
Connector Cabin
Windshield wiper, front Windshield wiper, rear Working spotlights, front left
345 X100b 346 X100s 347 X101b 348 X101s 349 X102b 350 X102s
1 :/ 3 7 . 1 4 1 :/ 3 7 . 1 4 1 :/ 3 7 . 2 1 1 :/ 3 7 . 2 1
1 :/ 3 6 . 6 1 :/ 3 6 . 6
2 :/ 3 7 . 1 5 2 :/ 3 7 . 1 5
2 :/ 3 7 . 2 5 2 :/ 3 7 . 2 5 2 1 2
6
3 :/ 3 7 . 1 4 3 :/ 3 7 . 1 4 4 4 3 1 2 :/ 3 6 . 6 2 :/ 3 6 . 6
4 5 4 3
3
4 :/ 3 7 . 1 7 6 5 4 :/ 3 7 . 1 7 2
3 :/ 3 7 . 2 4 2 1 3 :/ 3 7 . 2 4
1 2 1 1
2
5: 3 5:
4 :/ 3 7 . 2 2 4 :/ 3 7 . 2 2
6 :/ 3 7 . 1 7 6 :/ 3 7 . 1 7
Working spotlights, front right Working spotlights, rear left Working spotlights, rear right
351 X103b 352 X103s 353 X104b 354 X104s 355 X105b 356 X105s
1 :/ 3 6 . 8 1 :/ 3 6 . 8 1 :/ 3 6 . 1 4 1 :/ 3 6 . 1 4 1 :/ 3 6 . 1 6 1 :/ 3 6 . 1 6
2 2 :/ 3 6 . 8 1 2
2 :/ 3 6 . 8 2 2 :/ 3 6 . 1 4 1 2
2 :/ 3 6 . 1 4 2 2 :/ 3 6 . 1 6 1 2
2 :/ 3 6 . 1 6
1 1 1
Rotating-beam light Interface Speedometer mounting Interface Speedometer mounting
357 X109b 358 X109s 359 X50b 360 X50s 361 X51b 362 X51s
1: 1: 1: 1 :/ 3 9 . 1 1
1 :/ 3 6 . 2 4 1 :/ 3 6 . 2 4
2 :/ 3 9 . 3 2 :/ 3 9 . 3
2 1 2 2 :/ 3 9 . 1 0 2 :/ 3 9 . 1 0
1 2 :/ 3 6 . 2 4 2 :/ 3 6 . 2 4 3 :/ 3 9 . 4 3 :/ 3 9 . 4 4 4 3
3
8
4 :/ 3 9 . 5 5
4 :/ 3 9 . 5 2
3 :/ 3 9 . 1 0 2 1 3 :/ 3 9 . 1 0
6 7 7 6 1
5
5: 8
1
5 :/ 3 9 . 5
2 3 4
4 3
2 4: 4:
1
6 :/ 3 9 . 6 6 :/ 3 9 . 6
7 :/ 3 9 . 7 7 :/ 3 9 . 7
8 :/ 3 9 . 7 8 :/ 3 9 . 7
Radio Radio
Pump, windshield washer Power supply Loudspeaker
363 M42X1 364 A40X1 365 A40X2
1: /38.5 1:
1 :/ 3 6 . 2 1
2: 2:
2 2 :/ 3 6 . 2 1 1 2 3: 3: /38.6
1 1 2
3 4 4: /38.4
3 4 4: /38.6
5 6 5: /38.6 5: /38.4
5 6
6: 6: /38.5
7 8 7 8
7: /38.5 7:
8: /38.7 8:

a Connector Cabin Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Central plug Cabin
366 S40X1 367 S41X1 368 S43X1 369 S44X1 370 S45X1 371 S46X1
1: /37.15 1: /37.24 1: /36.7 1: /36.14 1: /36.21 1: /36.24

2: 2: 2: 2: 2: 2:
3: /37.15 3: /37.24 3: 3: 3: 3:
4: 4: 4: 4: 4: 4:
5: /37.15 5: /37.24 5: /36.7 5: /36.14 5: /36.21 5: /36.24
6: 6: 6: 6: 6: 6:
7: /37.14 7: /37.24 7: 7: 7: 7:
8: 8: 8: 8: 8: 8:
372 S40X2 373 S41X2 374 S43X2 375 S44X2 376 S45X2 377 S46X2
1 2 1: /38.21 1 2 1: /38.18 1 2 1: /38.16 1 2 1: /38.14 1 2 1: /38.23 1 2 1: /38.25

2: /38.21 2: /38.18 2: /38.16 2: /38.14 2: /38.23 2: /38.25

a Central plug Cabin Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
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
Water sprinkling unit
380 X200b 381 X200s 382 X201b 383 X201s 384 X202b 385 X202s
1 :/ 4 3 . 1 8 1 :/ 4 3 . 1 8
1 :/ 4 3 . 2 3 1 :/ 4 3 . 2 3 1 :/ 4 3 . 1 8 1 :/ 4 3 . 1 8
1 2 :/ 4 3 . 1 9 2 :/ 4 3 . 1 9 2 1 2
1 2 :/ 4 3 . 1 8 2 :/ 4 3 . 1 8 4 4 3 1 2 :/ 4 3 . 1 9 2 :/ 4 3 . 1 9
2 3
3
2 3
3 :/ 4 3 . 2 3 2 1 3 :/ 4 3 . 2 3
3 :/ 4 3 . 5 3 :/ 4 3 . 5 1 2
4: 4:
386 X203b 387 X203s 388 X204b 389 X204s

1 :/ 4 3 . 5 1 :/ 4 3 . 5 1 :/ 4 3 . 5 1 :/ 4 3 . 5
2 2 :/ 4 3 . 6 1 2
2 :/ 4 3 . 6 2 2 :/ 4 3 . 6 1 2
2 :/ 4 3 . 6
1 1
390 A200X1 391 P200X1 392 B200X1 393 S200X1 394 S201X1
1
1: 1 :/ 4 3 . 2 3
+: /43.22
2 :/ 4 3 . 1 3 4 3 2 :/ 4 3 . 2 3 1: /43.5 1: /43.9
10 9 10 9
3 :/ 4 3 . 1 5 S: /43.23 3: 2: /43.4 2: /43.9
4 5 6 S +
4 :/ 4 3 . 1 8 2 4: 3 6 3: 3 6 3:
1 2 3
GND: /43.24
5 :/ 4 3 . 1 9 4: 4:
Coupler socket, grey
6: 5: 5:
2 5 2 5
6: 6:
7: /43.5 7: /43.10
1 4 8: /43.5 1 4 8: /43.10
9: /43.6 9: /43.11
8 7 10: /43.6 8 7 10: /43.11

a Connector Sprinkling Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

Pos. Component Page Spare part No. Description useable for Machine type
1 XF1 7.5 01293028 Fuse-holder 4-pol.

2 F01 7.4 01293001 Fuse
3 F02 7.4 01293001 Fuse
4 F03 7.4 01286919 Fuse
5 K16X1 7.20 00880043 Header
7 F3 8.3 00386197 Blade fuse
8 F4 8.3 00386197 Blade fuse
9 F5 8.3 00386197 Blade fuse
10 F6 8.3 00384046 Blade fuse
11 F7 8.3 00384046 Blade fuse
12 F8 8.3 00384046 Blade fuse
13 F9 8.3 00384046 Blade fuse
14 F10 8.3 00386197 Blade fuse
15 F11 8.3 00386197 Blade fuse
16 F12 8.3 00384054 Blade fuse
17 F13 8.3 00384054 Blade fuse
18 F14 8.3 00384070 Blade fuse
19 F15 8.3 00384046 Blade fuse
20 F16 8.3 01243705 Blade fuse
21 F17 8.3 00384046 Blade fuse
23 F18 9.3 00384046 Blade fuse
24 F20 9.3 00386197 Blade fuse

25 F21 9.3 00384046 Blade fuse
26 F23 9.3 00384054 Blade fuse
27 F24 9.3 00384054 Blade fuse
28 F25 9.3 00384046 Blade fuse
29 F27 9.3 00384062 Blade fuse
30 F29 9.3 01243705 Blade fuse
31 F30 9.3 00384054 Blade fuse
32 F31 9.3 00384070 Blade fuse
33 F32 9.3 00384062 Blade fuse
34 F33 9.3 00384054 Blade fuse
35 F34 9.3 01243705 Blade fuse
37 A3 10.5 02038472 Central electric
38 XF3 12.3 00880957 Fuse box 6-pol.
39 A1 13.2 02068669 Instrument panel
40 D1 16.9 02051927 Control deviceDiesel engine
41 D1X1 16.2 02054219 Central plug
42 D1X2 16.15 02054218 Central plug
44 M1 17.2 02043678 Starting motor
45 S1 17.9 00394319 Battery switch
46 G1 17.9 00207330 Battery
47 G2 17.13 01294768 Alternator
49 S2 18.11 00380296 Ignition switch
49 S2 18.11 00367125 Ignition key
50 K15 18.11 01289829 Relay
51 K16 18.17 02035291 Relay
53 S7 19.3 01238795 Push button switch
53 S7 19.3 01240447 Switch
53 S7 19.3 01238817 Switch
54 Y8 19.11 01289047 Control magnet

55 Y5 19.16 01237640 Solenoid
56 K10 19.19 01263986 Relay
57 K13 19.21 01263986 Relay
58 S12 19.24 01301020 Pressure switch, parking brake
59 K1 20.3 00331686 Relay
62 K17 23.3 01289829 Relay
64 E01 23.9 01224603 Heater plug
64 E02 23.10 01224603 Heater plug
64 E04 23.4 01224603 Heater plug
64 E05 23.5 01224603 Heater plug
65 B43 23.23 02062293 Temperature sensor
67 B48 24.3 02073575 Sensor Pressure , Temperature
68 B6 24.13 02062291 Pressure sensor
73 B40.1 25.11 02062292 Speed sensor
74 B40.2 25.18 02073584 Speed sensor
76 Y19 26.3 02073573 FCU Valve
77 Y15.1 26.9 02075175 Injection nozzle

a Spare parts list Circuit diagram 3410-3411, TIER3
b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

79 X4. 27.3 00207705 Built-in socket
80 H2 27.5 01220314 Signal transmitter
81 S16 27.9 01276689 Filter indicator , electrical
82 B8 27.12 01217429 Temperature sensor
83 B12 27.16 00892947 Sensor
84 S17 27.22 00233366 Pressure switch
86 B2 28.6 02085709 Potentiometer Speed adjustment
87 B11 28.22 02065058 Filter body
89 B1 29.3 00886092 Level transmitter Fuel tank
90 D60 29.8 00898813 Control device
91 K4 29.11 01263986 Relay
93 M60 29.15 01243438 Pump
94 K2 29.18 01263986 Relay
95 E70 29.22 01292439 Heating , Fuel filter
97 B4 30.13 00881899 Speed sensor
98 A4 30.19 00865168 Signal Amplifier

99 B3 30.19 00865222 Sensor
100 K6 31.13 01263986 Relay
101 B5 31.13 02024147 Proximity switch
102 B7 31.4 00874698 Wire harness with Proximity switch
103 B9 31.8 00874698 Wire harness with Proximity switch
104 K7 31.4 01263986 Relay
106 A7 31.17 00806463 MFG electronic system only with Blade
106 A7 31.17 00806447 MFG electronic system without Edge pressing assembly , Blade
107 H3 32.5 00840696 Back-up alarm
108 K9 32.14 01263986 Relay
109 K8 32.19 01263986 Relay
110 Y10 32.15 01227637 Solenoid
111 Y11 32.18 01201409 Solenoid
112 Y12 32.20 01227637 Solenoid
113 Y13 32.23 01201409 Solenoid
115 S5 33.6 01264524 Alarm system switch
116 K3 33.5 00282618 Flasher relay
117 S4 33.21 00869392 Steering column switch
117 S4 33.11 00869392 Steering column switch
118 K5 33.21 01263986 Relay
120 E1 34.5 01277499 Halogen lamp
121 E9 34.7 00283150 Lamp
122 E3 34.8 00209635 Lamp
123 E7 34.10 02029166 LED Side lamp left
124 E5 34.12 00283142 Lamp
125 E10 34.14 00283150 Lamp
126 E2 34.16 01277499 Halogen lamp

127 E11 34.18 00283150 Lamp
128 E4 34.20 00209635 Lamp
129 E8 34.21 02029266 LED Side lamp right
130 E6 34.24 00283142 Lamp
131 E12 34.25 00283150 Lamp
133 V6 35.2 00821136 Diode
134 H1 35.3 00207365 Signal horn
135 S3 35.3 01267752 Rocker
136 S8 35.7 01268686 Switch
136 S8 35.7 01267744 Rocker
137 S10 35.13 01268678 Switch
137 S10 35.13 01497774 Rocker
138 S13 35.18 01268686 Switch
138 S13 35.18 01497766 Rocker
139 S11 35.25 01268678 Switch
139 S11 35.25 01497804 Rocker
144 D2 35.16 01706217 Relay
146 3F3 36.7 00384070 Blade fuse
147 S43 36.7 01272241 Switch Working spotlights

b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

147 S43 36.7 01249215 Symbol, working spotlights front
148 S44 36.14 01272241 Switch Working spotlights
148 S44 36.14 01249223 Symbol, working spotlights rear
149 3F4 36.21 00384062 Blade fuse
150 S45 36.21 01272217 Push button switch Windshield washer
150 S45 36.21 01272225 Symbol, windshield washer
151 S46 36.24 01240773 Switch
151 S46 36.24 01272233 Symbol Rotating-beam light
152 E40 36.6 00366528 Halogen lamp
153 E41 36.8 00366528 Halogen lamp
154 E42 36.14 00366528 Halogen lamp
155 E43 36.16 00366528 Halogen lamp
156 M42 36.21 01272195 Windshield washer
157 H40 36.24 00342505 Rotating-beam light
157 H40 36.24 00355283 Lamp
159 3F2 37.8 00384054 Blade fuse
160 3F5 37.15 00384062 Blade fuse
161 E44 37.7 00283142 Lamp
161 E44 37.7 00283142 Lamp
162 S40 37.14 01240773 Switch
162 S40 37.14 01240781 Symbol, wiper front
163 S41 37.24 01240803 Switch Windshield wiper, rear

163 S41 37.24 01240811 Symbol, wiper rear
164 S47 37.8 01240854 Door contact switch
165 S48 37.10 01240854 Door contact switch
166 M40 37.13 01270036 Windscreen wiper motor
167 M41 37.21 01270044 Windscreen wiper motor
170 A40 38.4 02031076 Radio
171 W1 38.9 00384836 Antenna
172 3F6 38.6 00384054 Blade fuse
173 3F1 38.14 00384054 Blade fuse
174 S44 38.14 01272284 Lamp
174 S44 38.14 01272268 Header
175 S43 38.16 01272284 Lamp
175 S43 38.16 01272268 Header
176 S41 38.18 01272284 Lamp
176 S41 38.18 01272268 Header
177 S40 38.21 01272284 Lamp
177 S40 38.21 01272268 Header
178 S45 38.23 01272284 Lamp
178 S45 38.23 01272268 Header
179 S46 38.25 01272284 Lamp
179 S46 38.25 01272268 Header
180 B40 38.10 01236849 Loudspeaker
181 B41 38.10 01236849 Loudspeaker
183 A9 39.11 00850063 Interface Speedometer
184 P1 39.16 02076714 Tachograph 3410, 3411
185 A8 40.2 02028559 Compactometer HCM-3 3410
186 B10 40.3 02025018 Acceleration sensor
187 A10 40.13 02038452 Interface HCM-3 3205-3625
188 A11 41.18 00466905 Display CDS

190 A30 42.8 01261150 Control unit
191 A30-S3 42.15 01270834 Thermostat
192 A30-K1 42.19 00331686 Relay
193 A31 42.6 01284118 Blower
194 S49 42.15 01278304 Pressure switch
195 Y30 42.17 01270850 Compressor
200 S200 43.4 01267752 Rocker
201 S201 43.9 01267752 Rocker
202 A200 43.12 00843008 Interval switch
203 P200 43.22 00382515 Water level indicator
204 B200 43.23 00871133 Level transmitter, water
205 M201 43.5 00851124 Water pump
206 M202 43.18 00877131 Water pump
207 D61-H1 43.25 00231746 Tubular lamp
210 X1 47.1 00898872 Connector
211 X2 47.8 00898082 Connector
212 X3 47.16 00898287 Connector

b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

213 X4 47.23 00898570 Connector
214 X5 47.1 00898872 Connector
215 X6 47.9 00898082 Connector
216 X7 47.16 00898678 Connector
220 X8 48.1 00898384 Connector
221 X9 48.8 00898678 Connector
222 X10 48.13 00898775 Connector
223 X11 48.20 00898376 Connector
224 X12 48.23 00898376 Connector
225 X13 48.1 00898570 Connector
226 X26 48.10 00898473 Connector
227 X17 48.14 02031349 Connector
228 K15X1 48.14 00892823 Connector 2-pol.
229 X21 48.5 00898570 Connector
230 X16 48.19 00898376 Connector
231 D60X1 48.22 00880124 Connection plug, 8-pole
232 X19 49.2 00898775 Connector
233 X27 49.9 00898678 Connector
234 XD2 49.14 00898473 Connector
235 A8X1 50.2 00351970 Electric plug
236 A8X2 50.8 00350680 Electric plug
237 A8X4 50.13 00351962 Electric plug

238 A8X6 50.19 02014722 Female cable connector
239 X52b 50.2 00369683 Round connector 7-pol.
240 X52s 50.8 00369691 Electric plug
241 A8X5 50.13 00369691 Electric plug
242 M1X1s 51.4 02039764 Connector male
243 M1X1b 51.12 02052010 Connector male
244 B6X1 51.1 02040578 Connector
245 B11X1 51.6 02071870 Electric plug
246 B40.1X1 51.10 00892130 Electric plug
247 B40.2X1 51.14 00892130 Electric plug
248 B43X1 51.19 00880698 Electric plug 2-pol.
249 K17X1 51.23 00892823 Connector 2-pol.
250 B48X1 51.1 02040579 Connector
251 B49X1 51.6 02040578 Connector
252 B51X1 51.11 02040580 Circular connector
253 Y19X1 51.15 00880698 Electric plug 2-pol.
255 X34b 51.23 00880116 Connection plug, 2-pole
260 Y1X1 52.1 00272116 Coupler socket
260 Y1X1 52.1 00284351 Diode
261 Y2X1 52.6 00284351 Diode
262 Y3X1 52.10 00284351 Diode
263 Y5X1 52.15 00284351 Diode
264 Y8X1 52.20 00284351 Diode
265 B1X1 52.1 00880744 Connector 4-pol.
266 B4X1 52.6 00880744 Connector 4-pol.

267 S16X1 52.10 01269372 Coupler socket 3-pol.
268 S17X1 52.15 00880647 Central plug
270 X35s 52.23 00880213 Fishing box, 3-pole
271 S12X1 52.1 01301543 Plug
273 X38s 52.9 00880310 Connection plug, 3-pole
279 S60X1 52.1 00880531 Electric plug 7-pol.
282 S49X1 55.23 00880442 Electric plug
287 X23 53.9 00880817 Connection plug, 6-pole

b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

290 X22 53.21 00880817 Connection plug, 6-pole
291 V6X1 53.2 00880116 Connection plug, 2-pole
292 Y4X1 53.6 00284351 Diode
293 Y10X1 53.4 00284351 Diode
294 Y11X1 53.9 00284351 Diode
295 Y12X1 53.14 00284351 Diode
296 Y13X1 53.20 00284351 Diode
300 A1X1 54.2 00880450 Central plug 18-pol.
301 A1X2 54.10 00880353 Central plug 14-pol.
304 H2X1 54.2 00880310 Connection plug, 3-pole
305 X27b 54.7 00880213 Fishing box, 3-pole
306 X28s 54.13 00880035 Connector 8-pol.
307 X28b 54.16 00880523 Connector 8-pol.

308 S5X1 54.22 00880159 Central plug 10-pol.
314 X45.1b 55.1 00892823 Connector 2-pol.
315 X45.1s 55.4 02084038 Connector
316 X45.2b 55.8 00893080 Connection - Bush
317 X45.2s 55.13 00893072 Electric plug
330 X39b 55.1 00880655 Connector 2-pol.
331 X39s 55.4 00880558 Connector 2-pol.
334 X53b 55.16 00369683 Round connector 7-pol.
335 X53s 55.22 00369691 Electric plug
338 A30X1b 55.9 00880817 Connection plug, 6-pole
339 A30X1s 55.13 00880612 Fishing box, 6-pole
340 A30-K1X1 55.18 00880930 Header
341 A31X1 55.1 00880817 Connection plug, 6-pole


b
c
d
gepr.
02082937 02 + 66 Bl.
1 2 3 4 5 6 7 8 9 10 11 12
Spare parts list

363 M42X1 56.2 00880116 Connection plug, 2-pole
364 A40X1 56.9 02041142 Central plug
365 A40X2 56.14 02041143 Central plug

390 A200X1 58.2 00880817 Connection plug, 6-pole
391 P200X1 58.6 00898465 Central plug
392 B200X1 58.10 00392839 Coupler socket
400 -F29 100.3 01243705 Blade fuse
401 -5F1 100.9 00384062 Blade fuse
402 -5F2 100.16 00384054 Blade fuse
403 -S46 100.9 00347701 Push button switch
404 -S44 100.13 00385395 Pushbutton
405 -S43 100.16 00385387 Pushbutton
406 -H40 100.9 00355283 Lamp
406 -H40 100.9 00342505 Rotating-beam light
407 -E42 100.13 01272209 Working spotlights
407 -E42 100.13 00366528 Halogen lamp
408 -E43 100.14 00366528 Halogen lamp
409 -E40 100.16 00366528 Halogen lamp
410 -E41 100.18 00366528 Halogen lamp
411 -X39b 101.1 00880655 Connector 2-pol.
412 -X39s 101.5 00880558 Connector 2-pol.
413 -X102b 101.9 00880515 Connection plug, 4-pole
414 -X102s 101.12 00880418 Fishing box, 4-pole

417 -XF5 101.2 00898651 Fuse box
422 -S43X1 101.1 00880531 Electric plug 7-pol.
425 -E40X1 101.1 00892815 Electric plug
426 -E41X1 101.5 00892815 Electric plug
427 -E42X1 101.8 00892815 Electric plug
428 -E43X1 101.11 00892815 Electric plug
430 K100X1 10.21 00898767 Relay base
431 K100 18.14 01263986 Relay

b
c
d
gepr.
02082937 02 + 66 Bl.
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
15 15
/46.25
-XF5 1 -XF5 2 Lighting ROPS =

Special equipment
-F29 30A -5F1 15A -5F2 10A
400 401 402
-XF5 A -XF5 B
-X15 2
1.5 or
1.5 sw
6 rt
1.5 br 1.5 br 1.5 br 1.5 br 1.0 gr/ge
-S46X1 5 6 -S44X1 5 6 -S43X1 5 6 1.0 gr/bl
S 31 S 31 S 31
-X39b A
-X102s 1 -S46 -S44 -S43 -X102s 4 -X102s 3
-X39s A
-X102b 1 403 S1 C 404 S1 C 405 S1 C
-X102b 4 -X102b 3
-S46X1 7 3 -S44X1 7 3 -S43X1 7 3
1.0 gr/bl
1.0 gr/ge
6 rt
1.5 sw/ws
1.5 or
1.5 sw
-X40s 4 -X40s 3
-X40b 4 -X40b 3
-X109b 1 -X103b 2 -X103b 1
0.75 ws
0.75 ws
-X109s 1 -X103s 2 -X103s 1
1.5 sw/ws
1.5 sw/ws
1.5 or
1.5 sw
1.5 sw
-X10 13 -X10 14
-E42X1 1 -E43X1 1 -E40X1 1 -E41X1 1
-H40 M 1 1 1 1
406 -E42 1 2 V- E 4 3 12V -E40 1 2 V- E 4 1 12V -X1 10 -X1 11

6 br
407 2 55W 408 2 55W 409 2 55W 410 2 55W
0.75 ws
0.75 ws
-H40X1 1 -E42X1 2 -E43X1 2 -E40X1 2 -E41X1 2
-X39s B -X102b 2
1.5 br
1.5 br
1.5 br
1.5 br
1.5 br
-X39b B -X102s 2
-A1X1 8 -A1X1 7
6 br
X1:8 X1:7
-X109s 2 -X103s 3 -X103s 4
Display Display
-X109b 2 -X103b 3 -X103b 4
-A1 -A1
Working spotlights Working spotlights
rear front
-X31 7 1.5 br
1.5 br
31 31
/46.25
S46: Push button switch S44: Push button switch S43: Push button switch
Rotating-beam light Working spotlights, rear Working spotlights, front
H40: Rotating-beam light E42: Working spotlights, rear left E40: Working spotlights, front left
E43: Working spotlights, rear right E41: Working spotlights, front right

a Version Circuit diagram 3410-3411, TIER3
b
c
Lighting ROPS Zeichnungsnummer Rev. = SE 100
d
gepr.
02082937 02 + 66 Bl.
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
411 -X39b 412 -X39s 413 -X102b 414 -X102s 415 -X103b 416 -X103s
1 :/ 1 0 0 . 6 1 :/ 1 0 0 . 6 1 :/ 1 0 0 . 1 6 1 :/ 1 0 0 . 1 6
A :/ 1 0 0 . 3 A :/ 1 0 0 . 3
2 :/ 1 0 0 . 6 2 :/ 1 0 0 . 6 2 :/ 1 0 0 . 1 3 2 :/ 1 0 0 . 1 3
3 3
B :/ 1 0 0 . 3 B :/ 1 0 0 . 3 3 4 4
3 4 4
2
3 :/ 1 0 0 . 2 4 2 1 3 :/ 1 0 0 . 2 4 2
3 :/ 1 0 0 . 1 3 2 1 3 :/ 1 0 0 . 1 3
B A 1 1
A B
4 :/ 1 0 0 . 2 1 4 :/ 1 0 0 . 2 1 4 :/ 1 0 0 . 1 6 4 :/ 1 0 0 . 1 6
/100.16
/100.9
418 -X109b 419 -X109s 420 -X40b 421 -X40s

A B 1: 1:
1 :/ 1 0 0 . 9 1 :/ 1 0 0 . 9
2: 2:
2 2
1
1 2 :/ 1 0 0 . 9 2 :/ 1 0 0 . 9 3 :/ 1 0 0 . 2 4 3 :/ 1 0 0 . 2 4
417
8
4 :/ 1 0 0 . 2 1 5
4 :/ 1 0 0 . 2 1
7 6
F1
F2
6 7
-XF5 5
3 4
5: 8
2 1
5:
2 4 3
1
6: 6:
7: 7:
8: 8:
1 2
422 -S43X1 423 -S44X1 424 -S46X1

4 1: 4 1: 4 1:
5 3 2: 5 3 2: 5 3 2:
3 :/ 1 0 0 . 1 7 3 :/ 1 0 0 . 1 3 3 :/ 1 0 0 . 1 0
4: 4: 4:
6 2 6 2 6 2
5 :/ 1 0 0 . 1 6 5 :/ 1 0 0 . 1 3 5 :/ 1 0 0 . 9
6 :/ 1 0 0 . 1 7 6 :/ 1 0 0 . 1 3 6 :/ 1 0 0 . 1 0
7 1 7 1 7 1
7 :/ 1 0 0 . 1 6 7 :/ 1 0 0 . 1 3 7 :/ 1 0 0 . 9
425 -E40X1 426 -E41X1 427 -E42X1 428 -E43X1
1: /100.16 1: /100.18 1: /100.13 1: /100.14
2: /100.16 2: /100.18 2: /100.13 2: /100.14

2 1 2 1 2 1 2 1

a Lighting ROPS Circuit diagram 3410-3411, TIER3
b
c
Connector Zeichnungsnummer Rev. = SE 101
d
gepr.
02082937 02 + 66 Bl.
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
Control device EMR-3 to DEUTZ-TCD Diesel engine
EMR3
EDC16
HAMM DEUTZ
D1X2 D1X1 Wire harness (engine) Wire harness (engine)
M1X1s M1X1b
D1X2 D1X1
16 28 28 16
30 45 1 10 22 34
15 60 5 3 1 34 22 10 1
6 4 2
51 29
73 7
1 46
16 31
94 28 42 27 15 9
72 50 9 15 27
21 33 42 33 21
View Connector : Contact side

a Electric circuit diagram EMR-3
b
c
d
gepr.
02100004 02 + 4 Bl.
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
7.5A
Ignition switch
17 17 54 15 50a 19 19 XD1
123
B K G H F M A
15-Ubat.
0,1
Customer CAN-High
Customer CAN-Low
Emergency stop switch

30 30
Diagn. CAN-High
Diagn. CAN-Low
ISO K-Line
+U + 1
25A
GND
31-GND
GND XD1
P
Diagnostic push button switch

2
Diagnostic lamp
SIGN SIGN
86 30
NPN PNP H G F
I M
E
85 A K L
87a 87 B C D
01
D1X1
72 1 3 5 43 77 79 40 28 62 61 82 60 25 55
Customer CAN-High
Diagnostic lamp
D-Out Relay
D-In. Kl.50
Engine start
Coolant level
Automatic stop
Air filter
Drive lever
Terminal 15
C-CAN-High
C-CAN-Low
D-CAN-High
D-CAN-Low
ISO K-Line
Kl.30
Kl.30
Kl.30
D-In.
D-In.
D-In.
Customer CAN-Low
D1.1
EMR 3, EDC 16
A-In. 0,5-4,5V
D1X1
GND Sensor
A-In.
D-Out
GND
GND
GND
+5V
5 3 1
0V
2 4 6 22 9 30 63 64 48 6 4 2
51 29
D1X1 73 7
+
View Contact side

Battery
12V
Battery isolating switch
1MW Output
Engine speed
0 1
60 pulses/revolution
( only HD90-130 ) 94 28
72 50
Potentiometer Fuel filter

Speed adjustment
- Setpoint Engine speed via CAN-Bus (Costumer-CAN)

- If CAN-Bus is out of function,
value of potentiometer speed adjustment is valid.

a 01 03.03.08 Lan. Control deviceDiesel engine Electric circuit diagram EMR-3
b
c
Customer-side (HAMM) Zeichnungsnummer Rev. = 2
d
gepr.
02100004 02 + 4 Bl.
c
d
b
a
1
D1.2
02
M1X1
D1X2
Änderung
Injection nozzle 34
2
Cylinder 1
16 47
35
Datum
16.06.08
Injection nozzle
3
Cylinder 5
31
40
Injection nozzle
Lan.
4
Name
Cylinder 3
48
37
Injection nozzle
5
gez.
gepr.
Cylinder 6
32
41
Injection nozzle
EMR 3, EDC 16
6
Cylinder 2
33
Datum
36
Injection nozzle 42
7
Cylinder 4
1 46
39
Y15.1 Y15.2 Y15.3 Y15.4 Y15.5 Y15.6
Name
8
14
Signal-In.
1
Speed sensor GND
2
13
3
Camshaft Shield
10 50 20
9
9
1 2 3
B40.1X1
15
Signal-In.
10
1
Speed sensor GND
2
21
3
27 12 7
Crankshaft
1 2 3
1
Shield
B40.2X1
11
19
PWM-Out
Fuel Valve
GND
19 49
20
1 2
Rail FCU
12
Y19X1
28
GND
13
1
2 29
A-In. Temp.
Sensor Boost air 3
+5V
1 2 3 4
4 22
Pressure +
B48X1
A-In. Pressure
23 53 14 40
23
1 2 3 4
14
GND
6 - Cylinder
1
31
15
Pressure sensor 2 A-In. Pressure

25
1 2 3
3
Fuel Rail +5V
8 43 26
B49X1
32
1 2 3
16
Diesel engine (DEUTZ)

30
A-In. Temp.
Temperature sensor
GND
58 41
24
1 2
Engine cooling fluid

17
B43X1
33
+5V
1
18
Sensor 2 A-In. Pressure

26
1 2 3
3
Engine oil pressure GND
B6X1
13 56 51
27
1 2 3
19
10
+5V
3
1
A-In.Pressure
11 57
17
1 2
Sensor Low pressure

20
2
4
B51X1
Fuel
GND
54
16
4
02
21
Projektbez.
2
Preparation D-Out +
1
Starting relay D-Out -

30 15
1 2
22
Zeichnungsnummer
Rev.
02100004 02
D-Out -
23
D-Out +
+12V U-Bat.
+
=
D-In.
24 34 21
24
30
F03
Electric circuit diagram EMR-3

25
4
Heater plugs
150A
Blatt
26
3
Bl.
c
d
b
a
1
D1.2
02
M1X1
D1X2
Änderung
Injection nozzle 34
2
Cylinder 1
16 47
35
Datum
16.06.08
Injection nozzle
3
Cylinder 3
31
40
Injection nozzle
Lan.
4
Name
Cylinder 4
48
37
Injection nozzle 41
5
gez.
32 1
gepr.
Cylinder 2 42
Y15.1 Y15.2 Y15.3 Y15.4

EMR 3, EDC 16
36
6
33 46
Datum
39
7
Name
8
14
Signal-In.
1
Speed sensor GND
2
13
3
Camshaft Shield
10 50 20
9
9
1 2 3
B40.1X1
15
Signal-In.
10
1
Speed sensor GND
2
21
3
27 12 7
Crankshaft
1 2 3
1
Shield
B40.2X1
11
19
PWM-Out
Fuel Valve
GND
19 49
20
1 2
Rail FCU
12
Y19X1
28
GND
13
1
2 29
A-In. Temp.
Sensor Boost air 3
+5V
1 2 3 4
4 22
Pressure +
B48X1
A-In. Pressure
23 53 14 40
23
1 2 3 4
14
GND
4 - Cylinder
1
31
15
Pressure sensor 2 A-In. Pressure

25
1 2 3
3
Fuel Rail +5V
8 43 26
B49X1
32
1 2 3
16
Diesel engine (DEUTZ)

30
A-In. Temp.
Temperature sensor
GND
58 41
24
1 2
Engine cooling fluid

17
B43X1
33
+5V
1
18
Sensor 2 A-In. Pressure

26
1 2 3
3
Engine oil pressure GND
B6X1
13 56 51
27
1 2 3
19
10
+5V
3
1
A-In.Pressure
11 57
17
1 2
Sensor Low pressure

20
2
4
B51X1
Fuel
GND
54
16
4
02
21
Projektbez.
2
Preparation D-Out +
1
Starting relay D-Out -

30 15
1 2
22
Zeichnungsnummer
Rev.
02100004 02
D-Out -
23
D-Out +
+12V U-Bat.
+
=
D-In.
24 34 21
24
30
F03
Electric circuit diagram EMR-3

25
4
Heater plugs
100A
Blatt
26
4
Bl.
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
10 8 15
D B
2bar
M
C
22 N
27bar
F G
175 bar A B
K H
24
L J 16bar
240 bar 240 bar E

P T L R 7
23 29 3
10μm delta_p =
160bar 3,1 bar
10μm
499bar/Δ477bar 395/Δ370bar L
ohne Stopfen
L1
14
ohne Stopfen G
R T1 T2 PS Fa Fa1 Fe MB R T1 T2
b a
PS Fe MB U D
B B
1 B
Deutz Vg min
BF4M 2012 C 22bar Vg max
A
A A
X1 X2 G MH S Fs MA X1 X2 G S MA T2
i= 1.189
499bar/Δ477bar
395bar/Δ370bar 360bar 4
450bar
20.1
250bar
2.1 2.2 5
20
28
U
A B
27
7μm
25 6
18 M C
G
200μm
T
25
Diese Zeichnung darf weder kopiert noch dritten Personen ohne unsere
Erlaubnis mitgeteilt werden.Schutzvermerk nach ISO 16016.
T P
13
15
gültig für 3410 / 3411 TEIL
TOLERANZEN
BENENNUNG
THERMISCHES SCHNEIDEN ISO 9013-331

DIN WERKSTOFF BEZEICHNUNG, BESTELL-NR.
UMFORMEN/STANZEN/SPANEN ISO 2768-M

STUECK
SCHWEISSEN EN ISO 13920-BE

HAMM-WERKSNORM
GIESSEN ISO 8062-CT11
ladeluftgekühlter Turbomotor, TIER 3- EMR 3, Commonrail 2007

GEWALZT, GEZOGEN RZ 100 W
= GEGOSSEN,VORBEARBEITET = = RZ 63 DATUM NAME
X
= RZ 16 Y
= RZ 4 Z
= RZ 1 GEZEICHN. 13.12. Weihs
+$00$*
Exportversion 05
04
GEPRUEFT
NORM-GEP.
D-95643 TIRSCHENREUTH
H 179
gültig ab November 2009
TYP:
-:-
Glattbandage / Stampffußbandage mit Getriebe-Bandagen-Antrieb -(Lohmann)
03 MASSTAB
Blatt 1-4
15733 Version Getriebe wieder hinzu 02.10.
02
Pos. 5 und Pos. 6 geändert durch
2009
05.12.
Weihs Hydraulik-Schema 02058002
01
AE.NR.
Fahrantrieb mit Poclain-Mot
AENDERUNGS-VERMERK01537202 DATUM NAME

2008 Becker
PASSMASS ABMASSE
3410 / 3411 ORDN.
NR : 6063 02
Pos. Hamm-Nr. Bezeichnung Bemerkung
1 02043451 Dieselmotor TCD 2012 L04 2V---TIER 3 Version-100 kW - 2300 U/min-1(Kraftstoff-Doppelfilter 3μ)
2 ------------ Tandemaggregat **********************************************
2.1 01297449 Verstellpumpe -FAHR- A4VG71 HW
2.2 01298437 Verstellpumpe -VIBRO- A10VG45 EZ, ohne Speisepumpe
3 02054909 Planetenachse MT-C 3065, i = 46,6, mit Federspeicherbr., Selbstsperrdifferential
4 01297481 Verstellmotor Achse A6VM107 EZ
5 02024034 Planetengetriebe GFT 17 T2, mit Federspeicherbremse
6 01297457 Verstellmotor Bandage A6VE55 EZ
7 01298445 Konstantmotor -VIBRO- A10FM37, mit Spülventil
8 01488635 Anschlußblock
10 01480901 Hydraulikölkühler
13 00891940 Hydrauliköltank 50 l
14 02141319 Vibrobandage (glatt) ø1504x2140 (VMG mit Getriebe-Lohmann)
14 02141322 Vibrobandage (stampf) ø1684x2140 (VMG mit Getriebe-Lohmann)
15 02025734 AW-Profil Reifen 23.1/26 - 12PR (bei Glattbandage)
15 02025735 TR-Profil Reifen links 23.1/26 - 12PR (bei Stampfbandage)
02025736 TR-Profil Reifen rechts
18 01204491 Bremslöseventil
20 00240974 Zahnradpumpe 19 cm³
20.1 02030383 Ventilblock mit DBV 250bar
22 01238930 Lenkeinheit LAGC 320
23 02031491 Hochdruckfilter (Lenkung) 10 μm, delta_p = 160bar

24 01535188 Lenkzylinder ø80/40, Hub 285
25 01301020 Druckschalter Feststellbremse am Bremslöseventil

27 01236199 Saugfilter AS 025-12, 200 μm
28 01259334 Entlüftungsfilter am Hydrauliköltank, 10 μm
29 01285475 Leitungsfilter -absolut- mit BY-PASS und Verschmutzungsanzeige, 10 μm
Blatt 2-4
TEIL BENENNUNG DIN WERKSTOFF BEZEICHNUNG, BESTELL-NR. STUECK HAMM-WERKSNORM
TOLERANZEN THERMISCHES SCHNEIDEN ISO 9013-331 UMFORMEN/STANZEN/SPANEN ISO 2768-M SCHWEISSEN EN ISO 13920-BE GIESSEN ISO 8062-CT11
GEWALZT, GEZOGEN
= GEGOSSEN,VORBEARBEITET = RZ 100 W
= RZ 63
2007 DATUM NAME
zu 2.2 Einstellung der Vibropumpe siehe Arbeitsanweisung 247 X
= RZ 16 Y
= RZ 4 Z
zu 6 Einstellung der Bandagenmotore siehe Arbeitsanweisung 463 05 GEPRUEFT +$00$*
zu 4 Einstellung der Achsmotore siehe Arbeitsanweisung 463 04 NORM-GEP. D-95643 TIRSCHENREUTH
03 MASSTAB
-:- TYP:
H 179
gültig ab November 2009 02

2009
05.12.
01
AE.NR.

2008 Becker
PASSMASS ABMASSE
3410 / 3411 ORDN.
NR : 6063 02
10 8 15
D B
2bar
M
C
22 N
27bar
F G
175 bar A B
K H
24
L J 16bar
240 bar 240 bar E 3

P T L R 7
29
23
10μm delta_p = 3,1 bar

160bar 10μm
499bar/Δ477bar L
395/Δ370bar L1
14
G
R T1 T2 PS Fa Fa1 Fe MB R T1 T2
b a
PS Fe MB U D
B B
1
B
Deutz Vg min
Dieselmotor 22bar Vg max
A
A A
X1 X2 G MH S Fs MA X1 X2 G S MA T2
i= 1.189
499bar/Δ477bar
2.1 395bar/Δ370bar 360bar 4
450bar
20.1
ohne Stopfen ohne Stopfen
250bar
2.2
20
28
27 R A
7μm 1 Y
25 X
G
18 M C 5
200μm b
Y
25
6
c a
S L
17bar
Ø3,0
T P
13
MA MB
15 TEIL BENENNUNG DIN WERKSTOFF BEZEICHNUNG, BESTELL-NR. STUECK HAMM-WERKSNORM
gültig für 3410 / 3411 TOLERANZEN

GEWALZT, GEZOGEN
THERMISCHES SCHNEIDEN ISO 9013-331
= RZ 63
UMFORMEN/STANZEN/SPANEN ISO 2768-M
2007 DATUM
SCHWEISSEN EN ISO 13920-BE
NAME
GIESSEN ISO 8062-CT11
ladeluftgekühlter Turbomotor, TIER 3- EMR 3, Commonrail 13.12. Weihs

X RZ 16 Y Z RZ 1
= = RZ 4 = GEZEICHN.
05 GEPRUEFT +$00$*
D-95643 TIRSCHENREUTH
Exportversion
04 NORM-GEP.
H 179
ungültig ab November 2009
TYP:
03 MASSTAB
-:-
Blatt 3-4
02
Hydraulik-Schema 02058002
Glattbandage / Stampffußbandage mit Poclain-Bandagen-Antrieb
2009 Weihs
Pos. 5 und Pos. 6 geändert durch 05.12.
01
AE.NR.

2008 Becker
PASSMASS ABMASSE
3410 / 3411 ORDN.
NR : 6063 02
Pos. Hamm-Nr. Bezeichnung Bemerkung
1 02043451 Dieselmotor TCD 2012 L04 2V---TIER 3 Version-100 kW - 2300 U/min-1(Kraftstoff-Doppelfilter 3μ)
2 ------------ Tandemaggregat **********************************************
2.1 01297449 Verstellpumpe -FAHR- A4VG71 HW
2.2 01298437 Verstellpumpe -VIBRO- A10VG45 EZ, ohne Speisepumpe
ungültig 01298151 Planetenachse MT-C 3075, i = 46,6, mit Federspeicherbr., Selbstsperrdifferential
3 02054909 Planetenachse MT-C 3065, i = 46,6, mit Federspeicherbr., Selbstsperrdifferential
4 01297481 Verstellmotor Achse A6VM107 EZ
5 02107404 Ausspeiseventilblock STEUERBLOCK-LO-08036--Z-NR-1490300
6 02058232 Radialkolbenmotor MOTOR-MSE18-2-D21-F12-1840-7DFJP-A22459M
7 01298445 Konstantmotor -VIBRO- A10FM37, mit Spülventil
8 01488635 Anschlußblock
10 01480901 Hydraulikölkühler
13 00891940 Hydrauliköltank 50 l
14 00891924 Vibrobandage (glatt) ø1504x2140
14 00891932 Vibrobandage (stampf) ø1684x2140
15 02025734 AW-Profil Reifen 23.1/26 - 12PR (bei Glattbandage)
15 02025735 TR-Profil Reifen links 23.1/26 - 12PR (bei Stampfbandage)
02025736 TR-Profil Reifen rechts
18 01204491 Bremslöseventil
20 00240974 Zahnradpumpe 19 cm³
20.1 02030383 Ventilblock mit DBV 250bar
22 01238930 Lenkeinheit LAGC 320

23 02031491 Hochdruckfilter (Lenkung) 10 μm, delta_p = 160bar
24 01535188 Lenkzylinder ø80/40, Hub 285

25 01301020 Druckschalter Feststellbremse am Bremslöseventil
27 01236199 Saugfilter AS 025-12, 200 μm
28 01259334 Entlüftungsfilter am Hydrauliköltank, 10 μm
29 01285475 Leitungsfilter -absolut- mit BY-PASS und Verschmutzungsanzeige, 10 μm
Blatt 4-4
TEIL BENENNUNG DIN WERKSTOFF BEZEICHNUNG, BESTELL-NR. STUECK HAMM-WERKSNORM
zu 2.2 Einstellung der Vibropumpe siehe Arbeitsanweisung 247 TOLERANZEN THERMISCHES SCHNEIDEN ISO 9013-331 UMFORMEN/STANZEN/SPANEN ISO 2768-M SCHWEISSEN EN ISO 13920-BE GIESSEN ISO 8062-CT11
zu 6 Einstellung der Bandagenmotore siehe Arbeitsanweisung 463 GEWALZT, GEZOGEN

= RZ 63
2007 DATUM NAME
zu 4 Einstellung der Achsmotore siehe Arbeitsanweisung 463

X
= RZ 16 Y
= RZ 4 Z
05 GEPRUEFT +$00$*
NORM-GEP. D-95643 TIRSCHENREUTH
04
03 MASSTAB
-:- TYP:
H 179
ungültig ab November 2009 02

2009
05.12.
01
AE.NR.

2008 Becker
PASSMASS ABMASSE
3410 / 3411 ORDN.
NR : 6063 02
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Vibrator 3412-3625HT
Reparaturanleitung / Repair instructions
Vibrator 3412-3625
Reparaturanleitung / Repair instructions
47
45
31
30
33
32
100
21
22
20
23 70
10 69
57
91
90
94
70
40 96
69
41 95
41 68
40 65
67
66
71
31
56
HAMM AG 1/56 # 1298119

09/07/2009
Inhaltsverzeichnis / Table of contents
Inhaltsverzeichnis / Table of contents
Inhaltsverzeichnis / Table of contents ......................................... 2

1. Benutzerhinweise / User guide .................................................. 3
1.1 Wichtige Kennzeichen in der Reparaturanleitung / Important symbols in the
repair instructions.......................................................................................................... 3
2. Montageanleitung / Mounting instruction ................................. 4
2.1 Was ist was ? / What is what? ................................................................................ 4
2.2 Montage Vibrator / Assembly of the vibrator ........................................................ 5
2.2.1 Vormontage der Unwuchten / Pre-assembly of the unbalances .................. 5
2.2.2 Vormontage der Vibratorgehäuse / Pre-assembly of the vibrator housings
10
2.2.3 Vormontage der Flanschplatten / Pre-assembly flange bearing ................ 15
2.2.4 Montage Vibrator rechts / Assembly of the right vibrator ........................... 18
2.2.5 Montage Vibrator links / Assembly of the left vibrator ................................ 22
2.2.6 Montage Fahrlager / Assembly of drive bearing .......................................... 27
2.3 Vibratoreinbau in Bandage / Vibrator installation into roller drum ................... 43
2.3.1 Montageschema Vibratoreinbau / Vibrator installation scheme................. 43
2.3.2 Montageanleitung Vibratoreinbau / Mounting instruction vibrator
installation scheme .................................................................................................. 45
3. Anhang ....................................................................................... 53
3.1 Datenblatt „Anzugsdrehmomente“ / Data sheet „torque wrench settings“ ..... 53
3.2 Datenblatt und Richtlinien für den Einsatz von Flüssigkunststoffen,
Dichtungen, Fetten und Ölen ...................................................................................... 54
3.3 Data sheet and recommendation for the use of liquid plastics, sealants,
greases and oils. .......................................................................................................... 55
HAMM AG 2/56 # 1298119

09/07/2009
Benutzerhinweise / User guide
1. Benutzerhinweise / User guide

Diese Anleitung dient für Monteure zur Reparatur des Vibrators bei HAMM – Walzen.
Die allgemeinen Richtlinien zur Sicherheit und zur Unfallverhütung sind zu beachten.
Die Hamm AG kann nicht für Vorfälle haftbar gemacht werden, die auf die Anwen-
dung der in diesem Dokument empfohlenen Verfahren zurückgehen.
This manual is for service engineers to repair the vibrator of HAMM rollers. Attention
should be paid to the general rules for safety and accident prevention. This manual
should assist service technicians with the repair of the vibrator of HAMM rollers. The
general safety and accident prevention regulations apply. Company HAMM AG can-
not be made liable for occurrences caused by the application of the steps recom-
mended in this document.
1.1 Wichtige Kennzeichen in der Reparaturanleitung / Important sym-

bols in the repair instructions.
! Sicherheitshinweise / Safety instructions
9 Notwendige Informationen / Essential instructions
; Allgemeine Informationen / General information
HAMM AG 3/56 # 1298119

09/07/2009
Montageanleitung / Mounting instruction
2. Montageanleitung / Mounting instruction

Bei Reparaturen am Vibrator und an der Bandage ist auf äußerste Sau-
berkeit zu achten. Alle Bauteile sind gründlich zu reinigen. Bauteile die mit Flüs-
sigkunststoff gesichert werden müssen öl- und fettfrei sein. Gewinde und Schrau-
ben nacharbeiten, um den alten Flüssigkunststoff zu entfernen. Schrauben die mit
Flüssigkunststoff eingesetzt werden, umgehend mit dem angegeben Drehmoment
anziehen. Es dürfen nur Original Hamm Ersatzteile verwendet werden.
Nur wenn alle diese Punkte beachtet werden ist eine hohe Lebensdauer ge-
währleistet.
Pay attention for extreme cleanness when repairing the vibrator and
the roller drum. Carefully clean all components. Components which are secured
with liquid plastic have to be free of oil and grease. Touch up threads and screws
to remove the liquid plastic. Screws which are screwed in with liquid plastic
have to be tightened immediately with the indicated torque. Only use original
Hamm spare parts.
Only if all these points are observed long service life is guaranteed.
2.1 Was ist was ? / What is what?

Ersatzteilbild
parts picture
47
45
31
30
33
32
100
21
22
20
23
70
10
69
57
91
90
70 94
40 69 96
41 95
41 68
40 65
67
66
71
31
56
HAMM AG 4/56 # 1298119

09/07/2009
2.2 Montage Vibrator

33 / Assembly of the vibrator
2.2.1 Vormontage der Unwuchten / Pre-assembly of the unbalances
Bild 1 / figure 1
Sämtliche Gewindebohrungen an
der Unwuchtwelle 30 mit Kaltrei- 32
30und fettfrei
niger und Druckluft öl-
machen.
All thread borings on the unbal-

ance shaft 30 must be cleaned
from oil and grease with cold
30
cleaner and compressed air.
Bild 2 / figure 2
Unwucht 32 in Schraubstock
einspannen. Unwuchtwelle 30 in
Unwucht einsetzen.
Clamp unbalance 32 into vice.

Insert unbalance shaft 30 into un-
balance.
30
32
HAMM AG 5/56 # 1298119

09/07/2009
Bild 3 / figure 3
Befestigungsschrauben 33 mit
Flüssigkunststoff + benetzen und + 33
einschrauben.
Moisten fastening screws 33 with

liquid plastic + and screw them
in.
32
Bild 4 / figure 4
Die Befestigungsschrauben 33
festziehen. 33
Anzugsdrehmomente: siehe
3.1
Tighten fastening screws 33.

Torques: see 3.1
Bild 5 / figure 5
Lagerinnenringe der Zylinderrol-
lenlager 31 auf ca. 80°C erwär-
men. Anschließend bis auf An-
schlag auf die Unwuchtwelle 30
aufschieben. 31
Preheat the inner bearing rings
of the cylindrical roller bearing
31 to approx 80°C. Then put
them onto the unbalance shaft
30 up to the limit stop
HAMM AG 6/56 # 1298119

09/07/2009
9 Anordnung der Unwucht zur Montage der Mitnehmer / correct mounting of the
driver to the assembly of the unbalance
Mitnehmer 45
Driver 45 Bild 6 / figure 6
Deckel 54
Zahnwelle 56 Cover 54
Involute spli-
ne shaft 56
Ansicht in Fahrtrichtung
Unwucht links View in direction of motion Unwucht rechts
Left unbalance Right unbalance
Unwucht
rechts / Right
unbalance Bild 7 / figure 7
Deckel 54 auf Unwuchtwelle
der rechten Unwucht aufset-
zen. Befestigungsschrauben 55
mit Flüssigkunststoff + benet-
54
zen, eindrehen und festziehen.
Anzugsmoment: siehe 3.1
Put cover 54 onto the unbalance

shaft of the right unbalance. Moisten
fastening screws 55 with liquid plastic
+. Screw them in and tighten them.
Torques: see 3.1
55
HAMM AG 7/56 # 1298119

09/07/2009
Unwucht rechts
Right unbalance
Bild 8 / figure 8
Mitnehmer 45 auf Unwuchtwelle 45

der Unwucht aufsetzen. Befesti-
gungsschrauben 47 mit Flüssig-
kunststoff + benetzen, eindre-
hen und festziehen.
! Beim Aufsetzen der Mitnehmer 47

auf Position der Kontrollbohrungen
achten!
(siehe Pfeile Bild 8)
Put driver 45 onto the unbalance Unwucht links /

shaft of the unbalance. Moisten Left unbalance
fastening screws 47 with liquid Bild 9 / figure 9
plastic +. Screw them in and
tighten them. 45
Torques: see 3.1
! During mounting the driver, pay

attention for the correct position of the
check bores!
(see arrows in figure 8)
47
HAMM AG 8/56 # 1298119

09/07/2009
Unwucht links /
Zahnwelle 56 auf Unwuchtwelle Left unbalance
der linken Unwucht aufsetzen. Bild 10 / figure 10
Befestigungsschrauben 57 mit
Flüssigkunststoff + benetzen,
eindrehen und festziehen.
Anzugsmomente: siehe 3.1
Put involute spline shaft 56 onto
the unbalance shaft of the left
unbalance. Moisten fastening
screws with liquid plastic +.
Screw them in and tighten them.
Torques: see 3.1
56
57
HAMM AG 9/56 # 1298119

09/07/2009
2.2.2 Vormontage der Vibratorgehäuse / Pre-assembly of the vibrator

housings
Bild 1 / figure 1
Vibratorgehäuse 10 gründlich
reinigen. Gewindebohrungen
müssen öl- und fettfrei sein.
Lagersitz auf ca. 100 -120°C an-
wärmen.
Carefully clean vibrator housing

10. Thread bores have to be free
of oil and grease. Heat up bear- 10
ing fit to approx. 100 -120 °C.
Bild 2 / figure 2
Flansch 20 auf Vibratorgehäuse
10 aufsetzen.
20
! Bei Montage auf richtige Position
der Ölbohrung bzw. -nut achten!
Put flange 20 onto vibrator hous-

ing 10. 10
! Pay attention for the correct posi-

tioning of oil bore and oil
channel!
(see arrow in figure 2)
HAMM AG 10/56 # 1298119

09/07/2009
Bild 3 / figure 3
Flansch 20 mit drei Befesti-
gungsschrauben 21 anschrau-
ben. Mit Schraubenschlüssel 21
leicht festziehen.
! (Flansch wird als Anschlag für
20
Lagermontage verwendet.)
Tighten the flansch 20 with three

fastening screws 21. Then
slightly tighten the fastening
screws with a ring spanner.
! (Use the flange as limit stop for
the bearing mounts)
23
Bild 4 / figure 4
Zylinderrollenlager 31 einsetzen
und Vibratorgehäuse abkühlen
lassen.
! Nur Original-Hamm-Lager ver-

wenden!
31
Insert cylindrical roller bearing
31 and let the vibration housing cool
down.
! Only use original Hamm bear- 10
ings!
Nach Abkühlen des Vibrator- Bild 5 / figure 5

gehäuses 10 die Schrauben
21 lösen, und Flansch 20 ab-
21
nehmen.
After the cooling-down of the

20
vibrator housing 10 unscrew
the screws 21, and remove
flange 20.
10
HAMM AG 11/56 # 1298119

09/07/2009
Bild 6 / figure 6
Flansch 20 gründlich reinigen.
Dann O-Ring 23 in Flanschnut ein-
setzen. 23
Carefully clean flange 20. Then

insert o-ring 23 into the flange 20
channel.
Bild 7 / figure 7
Flansch 20 auf Vibratorgehäuse
10 aufsetzen. 20
! Bei Montage auf richtige Position
der Ölbohrung bzw. -nut achten!
10
Put flange 20 onto vibrator hous-
ing 10.
! Pay attention for the correct posi-

tioning of oil bore and oil
channel!
(see arrow in figure 7)
HAMM AG 12/56 # 1298119

09/07/2009
Bild 8 / figure 8
Schrauben 76 mit Flüssig-
kunststoff + benetzen, Schei-
be 80 beilegen, und ein-
schrauben 76
Moisten screws 76 with liquid
plastic +, add shim 80 and
screw them in.
Torques: see 3.1 80
Bild 9 / figure 9
Gewindebohrungen M6 mit Flüs-
sigkunststoff , benetzen
Moisten thread bores M6 with

,
liquid plastic ,.
HAMM AG 13/56 # 1298119

09/07/2009
Bild 10 / figure 10
Ölleitbleche 40 mit Schrauben
41 befestigen.
Fasten oil guide plates 40 with 40

screws 41.
Torques: see 3.1
41
Verschlussschraube 69 mit Dicht-

ring 70 einschrauben.
Screw in screw plug 69 with seal Bild 11 / figure 11

ring 70.
70 69
HAMM AG 14/56 # 1298119

09/07/2009
2.2.3 Vormontage der Flanschplatten / Pre-assembly flange bearing
Bild 1 / figure 1
Flanschlager 65 gründlich rei-
nigen.Gewindebohrungen
müssen öl- und fettfrei sein.
Lagersitz auf ca. 100 -120°C
anwärmen.
Carefully clean flange bearing

65. Thread bores have to be
free of oil and grease. Heat up
bearing fit to approx. 100 -120
°C. 65
Bild 2 / figure 2
Deckel 75 auf Flanschlager 65
aufsetzen.
75
Put cover 75 onto flange bear-
ing 65.
65
HAMM AG 15/56 # 1298119

09/07/2009
Deckel 75 mit sechs Befesti-

gungsschrauben 76 an- Bild 3 / figure 3
schrauben. Mit Schrauben-
schlüssel leicht festziehen.
! (Deckel wird als Anschlag für

75
Lagermontage verwendet.) 76
Tighten cover 75 with six fas- 65

tening screws 76. Then
slightly tighten the fastening
screws with a ring spanner.
! (Use the cover as limit stop

for the bearing mounts)
Bild 4 / figure 4
Zylinderrollenlager 31 in
Flanschlager 65 einsetzen.
! Nur Original-Hamm-Lager ver-

wenden!
Insert cylindrical roller bearing

31 into flange bearing 65. 31
! Only use original Hamm bear-

65
ings!
Bild 5 / figure 5
Nach Montage des Flanschla-
gers 31 die Schrauben 76 lö- 76
sen und Deckel 75 abnehmen.
76
After the mounting of the
flange bearing 31 unscrew the 75
screws 76, and remove the
cover 75.
HAMM AG 16/56 # 1298119

09/07/2009
Bild 6 / figure 6
Verschlussschraube 79 mit
Dichtring 70 einschrauben und 70
79
festziehen.
Schauglas 71 einschrauben 71
und festziehen.
Screw in screw plug 79 with

seal ring 70 and tighten them.
Screw in inspection glas 71
and tighten it.
Bild 7 / figure 7
76
Gewindebohrungen M6 mit
41
Flüssigkunststoff , benetzen.
Ölleitbleche 40 mit Schrauben
41 befestigen. 75
Moisten thread bores M6 with 40

liquid plastic ,. Fasten oil
guide plates 40 with screws
41.
Bild 8 / figure 8
O-Ring 68 aufziehen. Radial- 68

sitz mit O-Ring leicht einfetten.
Put on o-ring 68. Slightly

grease radial fit and o-ring.
HAMM AG 17/56 # 1298119

09/07/2009
2.2.4 Montage Vibrator rechts / Assembly of the right vibrator
Vibrator rechts
Right vibrator
Flanschlager
Flange bearing
View in direction of motion
HAMM AG 18/56 # 1298119

09/07/2009
Bild 1 / figure 1
Vormontierte Unwucht rechts Unwucht rechts
in Vibratorgehäuse 10 einfüh- Right unbalance
ren.
!
75
Unwucht nicht verkanten!
Unwucht muss leicht eingeführt
werden können.
Insert the pre-assembled right

unbalance into the vibrator
housing. 10
! Do not tilt the unbalance!

The rotor has to be inserted eas-
ily.
Bild 2 / figure 2
Vormontiertes Flanschlager
auf Vibratorgehäuse aufset-
zen.
! Aussparrung am Flanschlager
muss Verschlussstopfen einfas-
sen.
Mount the pre-assembled

flange bearing onto the vibra-
tor housing.
! Sparing on the flange bearing

must surround screw plug.
HAMM AG 19/56 # 1298119

09/07/2009
Bild 3 / figure 3
be 67 beilegen, und ein- 66
schrauben. 75

screw them in. 67
Torques: see 3.1
Bild 4 / figure 4
! Unwucht auf Leichtgängigkeit

prüfen. 75
! Check the unbalance for smooth

running.
Bild 5 / figure 5
Deckel 75 gründlich reinigen.
Dann O-Ring 78 in Flanschnut einset-
zen.
75
Carefully clean cover 75. Then in-
sert o-ring 78 into the flange channel.
75
78
HAMM AG 20/56 # 1298119

09/07/2009
Deckel 75 auf Flanschlager 65 65

Bild 6 / figure 6
aufsetzen. 76 75
! Bei Montage auf richtige Positi- 75 68 75
on der Ölbohrung bzw. -nut achten!
Put flange 75 onto flange

bearing 65.
! Pay attention for the correct po- 65
sitioning of oil bore and oil

channel!
Schrauben 76 mit Flüssig- Bild 7 / figure 7

be 77 beilegen, eindrehen und
festziehen. Verschlussschrau-
be 79 mit Dichtring 80 montie-
ren.
79
Anzugsmoment : siehe 3.1
plastic + , add shim 77.
Screw in and tighten them.
Mount screw plug 79 with seal 77
ring 80. 76
Torques: see 3.1
Bild 8 / figure 8
Axialspiel der Unwuchtwelle
überprüfen! Unwuchtwelle hin
und her schieben und jeweils
in der Endlage messen.
Check end play of the unbal-

ance shaft! Move unbalance
shaft back and forth and
check play in both limit stops.
HAMM AG 21/56 # 1298119

09/07/2009
2.2.5 Montage Vibrator links / Assembly of the left vibrator
Vibrator links
Fahrlager Left vibrator
Drive bearing
Flanschlager
Flange bearing
View in direction of motion
47
45
31
30
33
32
100
21
22
20
23
70
10
69
57
91
90
70 94
40 69 96
41 95
41 68
40 65
67
66
71
31
56
Bild 1 / figure 1
HAMM AG 22/56 # 1298119

09/07/2009 75
Vormontierte Unwucht links in Unwucht links

Vibratorgehäuse 10 einführen. Left unbalance
! Unwucht nicht verkanten! Un-
wucht muss leicht eingeführt werden
können.
Insert the pre-assembled left un-

balance into the vibrator housing.
! Do not tilt the unbalance!

The rotor has to be inserted easily. 10
Vormontiertes Flanschlager auf Bild 2 / figure 2

Vibratorgehäuse aufsetzen.
! Aussparrung am Flanschlager
muss Verschlussstopfen einfassen.
Mount the pre-assembled flange

bearing onto the vibrator housing.
! sparing on the flange bearing

must surround screw plug.
Bild 3 / figure 3
Schrauben 66 mit Flüssigkunst-
stoff + benetzen, Scheibe 67 bei-
legen, und einschrauben.

plastic +, add shim 67 and screw 66
them in.
Torques: see 3.1
67
HAMM AG 23/56 # 1298119

09/07/2009
Bild 4 / figure 4
! Unwucht auf Leichtgängigkeit

prüfen. 75
! Check the unbalance for smooth

running.
Bild 4 / figure 4
Konusflansch 90 gründlich reinigen.
Dann O-Ring 91 in Konusflansch ein-
setzen.
75
Carefully clean cone flange 90. 90
Then insert o-ring 91 into the flange
channel.
91
HAMM AG 24/56 # 1298119

09/07/2009
Konusflansch 90 auf Flansch-

Bild 5 / figure 5
lager 65 aufsetzen.
! Bei Montage auf richtige Positi- 90

on der Ölbohrung bzw. -nut achten!
Put cone flange 90 onto flange

bearing 65.
! Pay attention for the correct po- 65

sitioning of oil bore and oil
channel!
Bild 6 / figure 6
Ring 94 von Öl und Fett reini-
gen. Flächendichtung / auftragen.
The ring 94 must be free from

oil and grease.Then apply liq-
uid plastic /.
94
HAMM AG 25/56 # 1298119

09/07/2009
Ring 94 auf Konusflansch 90

Bild 7 / figure 7
setzen. Befestigungsschrau-
ben 66 mit Flüssigkunststoff
90
benetzen, Scheibe 67 beile-
gen, eindrehen und festzie-
hen. 66
94
67
Put the ring 94 onto the cone
flange 90. Moisten the fasten-
ing screws 66 with liquid plas-
tic, add the shim 67,screw
them in and tighten them.
Torques: see 3.1
HAMM AG 26/56 # 1298119

09/07/2009
2.2.6 Montage Fahrlager / Assembly of drive bearing
Montageschema Fahrlager 3412 – 3516 / Drive bearing assembly scheme 3412 – 3516
3412 - 3414
3516
HAMM AG 27/56 # 1298119

09/07/2009
HAMM AG 28/56 # 1298119

09/07/2009
Bild 1 / figure 1
Flanschlager 106 säubern, alle Ge-
windebohrungen müssen öl- und fett- 101
frei sein! Rillenkugellager 101 in
großen des Flanschlagers einset-
zen.
Clean flange bearing 106, all thread

bores have to be free of oil and
grease! Insert deep groove ball bea-
ring 101 into the big diameter of
the flange bearing.
 106
Bild 2 / figure 2
Eine Hälfte der Gleitringdichtung

97 mit Silikonemulsion ein-
streichen.
Apply silicone emulsion onto

one half of the axial face seal 97
97
Bild 3 / figure 3
Gleitringdichtung 97 vorsichtig in 97
Flanschlager 106 eindrücken.
Press axial face seal 97 carefully

into the flange bearing 106.
106
HAMM AG 29/56 # 1298119

09/07/2009
Bild 4 / figure 4
Gewindebohrungen M10 (siehe
Pfeil) reinigen. Gleitringnut am
Konusflansch 90 einfetten. 90
Clean thread borings M10 ( see

arrow). Grease the axial face
channel on the cone flange 90.
Bild 5 / figure 5
Die zweite Hälfte der Gleit-
ringdichtung 97 mit Silikon-
emulsion einstreichen.

the second half of the axial
face seal 97.
97
Bild 6 / figure 6
Gleitringdichtung 97 vorsichtig
in die Gleitringnut des Konus-
flansches 90 eindrücken. 97
90
Press axial face seal 97 care-
fully into axial face channel of
the cone flange 90.
HAMM AG 30/56 # 1298119

09/07/2009
Bild 7 / figure 7
Gleitflächen der Gleitringdich-
tung 97 reinigen und mit Fett
bestreichen. 97
Clean sliding surfaces of the

axial face seal 97 and put on
grease.
Bild 8 / figure 8
Flanschlager 106 auf Konus- 90
flansch 90 aufsetzen. 106
Put flange bearing 106 onto

cone flange 90.
Bild 9 / figure 9
Flanschlager gleichmäßig mit

Kunststoffhammer bis auf An-
schlag klopfen.
Push flanged bearing with a

plastic hammer constantly un-
til the limit stop.
HAMM AG 31/56 # 1298119

09/07/2009
Distanzring 102 einsetzen. Bild 10 / figure 10
Insert distance ring 102. 102
Bild 11 / figure 11
Rillenkugellager 102 aufset-
zen. 102
Place deep groove ball bear-

ing 102.
Bild 12 / figure 12
Lager gleichmäßig mit Kunst-

stoffhammer einschlagen.
Push in bearing constantly
HAMM AG 32/56 # 1298119

09/07/2009
Bild 13 / figure 13
Gewindebohrungen M10 mit
Flüssigkunststoff + benetzen.
Moisten thread bores M10

with liquid plastic +.
Bild 14 / figure 14
Deckel 103 aufsetzen und mit
Schrauben 104 befestigen. 103
Place cover 103 and fasten it

102
with screws 104.
Torques: see 3.1
Bild 15 / figure 15
Flansch 110 von Öl und Fett
reinigen. Flächendichtung /
auftragen.
Flange 110 must be free from 110

oil and grease. Then apply
liquid plastic /.
HAMM AG 33/56 # 1298119

09/07/2009
Bild 16 / figure 16
Flansch 110 aufsetzen.
Schrauben 104 mit Flüssig- 110
kunststoff + benetzen, Schei- 104
be 112 beilegen, eindrehen
und festziehen.
112
Place cover 103.
Moisten screws 104 with liquid plas-
tic +, add shim 112, screw them in
and tighten it.
Torques: see 3.1
HAMM AG 34/56 # 1298119

09/07/2009
Montageschema Fahrlager 3518 – 3625HT / Drive bearing assembly scheme 3518 – 3625
HAMM AG 35/56 # 1298119

09/07/2009
9 Bilder zeigen teilw. 3412-3516 und können daher abweichen!!! /

Figures partially show 3412-3516 and may vary!!!
Bild 1 / figure 1
Flanschlager 106 säubern, alle Ge-
windebohrungen müssen öl- und fett- 197
frei sein! Sicherungsring in das
Flanschlager einsetzen.
Clean flange bearing 106, all thread

bores have to be free of oil and
grease! Insert the locking ring into
the flange bearing.
 106
Außenringe der Kegelrollenlager auf

beiden Seiten des Sicherungsringes
montieren.
Mount the outer rings of the taper

roller bearings on both sides of the
locking ring.
Bild 2 / figure 2
Eine Hälfte der Gleitringdichtung 97

mit Silikonemulsion einstreichen.
Apply silicone emulsion onto one

half of the axial face seal 97
97
HAMM AG 36/56 # 1298119

09/07/2009
Gleitringdichtung 97 vorsichtig in 97
Flanschlager 106 eindrücken.
Press axial face seal 97 carefully

into the flange bearing 106.
106
Bild 4 / figure 4
Gewindebohrungen (siehe Pfeil)
reinigen. Gleitringnut am Konus-
flansch 90 einfetten. 10
Clean thread borings (see arrow).

Grease the axial face channel on
the cone flange 90.
Bild 5 / figure 5
Die zweite Hälfte der Gleit-
ringdichtung 97 mit Silikon-
emulsion einstreichen.

the second half of the axial
face seal 97.
90
HAMM AG 37/56 # 1298119

09/07/2009
Bild 6 / figure 6
Gleitringdichtung 97 vorsichtig
in die Gleitringnut des Konus-
flansches 90 eindrücken. 90
97
Press axial face seal 97 care-
fully into axial face channel of
the cone flange 90.
Bild 7 / figure 7
Lagerinnenring des ersten
Kegelrollenlagers auf dem
Konusflansch montieren. 97
Gleitflächen der Gleitringdich-
tung 97 reinigen und mit Fett
bestreichen.
Mount the inner ring of the first

taper roller bearing to the
cone flange. Clean sliding sur-
faces of the axial face seal 97
and put on grease.
Bild 8 / figure 8
HAMM AG 38/56 # 1298119

09/07/2009
Flanschlager 106 auf Konus- 90

flansch 90 aufsetzen. 106
Put flange bearing 106 onto

cone flange 90.
Bild 9 / figure 9
Flanschlager gleichmäßig mit

Kunststoffhammer bis auf An-
schlag klopfen.
Push flanged bearing with a

plastic hammer constantly un-
til the limit stop.
Bild 10 / figure 10
102 Bild 11 / figure 11
HAMM AG 39/56 # 1298119

09/07/2009
Innenring des zweiten Kegel-

rollenlagers spielfrei montie- 102
ren.
Mount the inner ring of the

second taper roller bearing
free of play.
Lagerüberstand am Konus-
flansch messen (x). x
Measure the bearing over-
hang at the cone flange (x).
Absatzlänge des Deckels

messen (y).
Measure the length of the cap y
shoulder (y).
Bild 13 / figure 13
Gewindebohrungen mit Flüs-

sigkunststoff + benetzen.
Moisten thread bores with li-

quid plastic +.
HAMM AG 40/56 # 1298119

09/07/2009
Laminumringe auf Gesamt-

maß a=y-x+0,1mm schälen
und auf den Innenring aufset-
zen. Damit wird das Lager um
0,1mm vorgespannt
Peel laminum rings to a over-

all dimension of a=y-x+0,1mm
and place them on top of the
inner ring of the bearing. This
means the bearing will obtain
a pretension of 0,1mm.
Bild 14 / figure 14
Deckel 103 aufsetzen und mit
Schrauben 104 befestigen. 104
Place cover 103 and fasten it

102
with screws 104.
Torques: see 3.1
Bild 15 / figure 15
Flansch 110 von Öl und Fett
reinigen. Flächendichtung /
auftragen.
Flange 110 must be free from 110

oil and grease. Then apply
liquid plastic /.
HAMM AG 41/56 # 1298119

09/07/2009
Bild 16 / figure 16
Flansch 110 aufsetzen.
Schrauben 104 mit Flüssig- 110
kunststoff + benetzen, Schei- 104
be 112 beilegen, eindrehen
und festziehen.
112
Place cover 103.
Moisten screws 104 with liquid plas-
tic +, add shim 112, screw them in
and tighten it.
Torques: see 3.1
HAMM AG 42/56 # 1298119

09/07/2009
2.3 Vibratoreinbau in Bandage / Vibrator installation into roller drum
2.3.1 Montageschema Vibratoreinbau / Vibrator installation scheme
Schritt 1
Step 1
Schritt 2
Step 2
3518 – 3625 HT
3412 - 3516
HAMM AG 43/56 # 1298119

09/07/2009
Schritt 3 / Step 3
Schritt 4 / Step 4
Schritt 5 / Step 5
HAMM AG 44/56 # 1298119

09/07/2009
2.3.2 Montageanleitung Vibratoreinbau / Mounting instruction vibrator

installation scheme
Bandage säubern. Bandagen-

Vibrogehäusesitz muss metal-
lisch blank sein. Gewindeboh- Bild 1 / figure 1
rungen M16 müssen öl- und
fettfrei sein.
! Bandage mit Markierungs-

blech senkrecht zum Untergrund
aufstellen (siehe Pfeil) und gegen
wegrollen sichern.
Clean drums. Vibrator housing

fit of drum has to be polished.
Thread bores M16 have to be
free of oil and grease.
! The roller drum must stand

with the marking plate verticaly to
the underground (see arrow) and
save it to turn around.
Bild 2 / figure 2
Radial-sitz leicht einfetten.
Slightly grease radial fit.

75
HAMM AG 45/56 # 1298119

09/07/2009
Bild 3 / figure 3
Sitzflächen der Schrauben-
köpfe am Vibratorgehäuse
müssen blank sein (siehe
Pfeil).
The fitting surface of the

screw heads on the vibrator
housing have been blank (see
arrow).
Bild 4 / figure 4
Radialsitz des Vibrogehäuses
ebenfalls leicht einfetten.
Slightly grease radial fit of the

vibrator housing.
Bild 5 / figure 5
Montagehilfe zum Einsetzen des
rechten Vibrators benutzen.
Use mounting aid for inserting

the right vibrator.
HAMM AG 46/56 # 1298119

09/07/2009
!Bei Montage des Vibroge-

Bild 6 / figure 6
häuses darauf achten, dass das

Ölschauglas senkrecht zum Mar-
kierungsblech steht (siehe Pfeile).
! By mounting the vibrator

housing into the roller drum, you
have to attend the oil control glas
have to be verticaly to the marking
plate (see arrows).
Bild 7 / figure 7
schrauben.
plastic +, add shim 12 and 12
screw them in.
Torques: see 3.1
Bild 8 / figure 8
9 3518 – 3625 HT: 3 O –
Ring 24 auf Zwischenrohr 25 montie-
ren.
Beide Enden mit den O-Ringen ein- 24
fetten . 25
9 3518 – 3625 HT: Mount 3

o-rings 24 onto the intermediate tube
25.
Grease both ends and o-rings.
HAMM AG 47/56 # 1298119

09/07/2009
Bild 9 / figure 9
9 3412 – 3516 : 4 O-Ring 52 auf
Zwischenrohr 51 montieren Beide En-
den mit den O-Ringen einfetten . 52
9 3412 – 3516 : Mount 4 o-rings 51
52 onto the intermediate tube 51.
Grease both ends with the o-rings.
Bild 10 / figure 10
Zwischenrohr in Vibratorgehäuse
einsetzen.
Insert intermediate tube into vi-

brator housing.
Bild 11 / figure 11
Zwischenrohr mit Kunststoff-
hammer bis auf Anschlag klopfen.
Push intermediate tube with a

plastic hammer until the limit stop.
HAMM AG 48/56 # 1298119

09/07/2009
Bild 12 / figure 12
Sitzflächen der Schraubenköpfe
am Vibratorgehäuse müssen
blank sein (siehe Pfeil).
The fitting surface of the screw

heads on the vibrator housing
have been blank (see arrow).
Bild 13 / figure 13
Radialsitz des Vibrogehäuses
ebenfalls leicht einfetten.
Slightly grease radial fit of the

vibrator housing.
O–Ringe 49 (3412–3516) od. 44 Bild 14 / figure 14

(3518–3625HT) auf beiden Seiten der 49 od. 44
Vierkantwelle 50 (3412 – 3516) od. 45 49 or 44
(3518-3625HT) aufziehen.
Beide Enden mit den O–Ringen einfet-
ten.
Mounting the o–rings 49 (3412- 50 od. 45

3516) or 44 (3518-3625HT) on both 50 or 45
sides of the square bar shaft 50 (3412-
3516) or 45 (3518-3625HT). Grease
both ends with the o–rings.
HAMM AG 49/56 # 1298119

09/07/2009
Bild 15 / figure 15
Vierkantwelle in Mitnehmer des
linken Vibrators einführen, dann
mit Kunststoffhammer bis auf An-
schlag einschlagen.
Insert the square bar shaft into

the driver of the left vibrator and
push it with a plastic hammer un-
til the limit stop.
50 od. 45
50 or 45
Bild 16 / figure 16
Montagehilfe A zum Einsetzen
des linken Vibrators benutzen.
Use mounting aid A for inserting A

the left vibrator.
Bild 17 / figure 17
Vibrator links bis auf Anschlag

einführen, gleichzeitig Montage-
hilfe B leicht nach links od. rechts
verdrehen (10°) bis Vierkant-  102
welle einrastet.
Put in the vibrator left until the

limit stop. At the same time turn
the mounting aid B left or right
(10°) until the square bar shaft
lock in.
HAMM AG 50/56 # 1298119

09/07/2009
!Bei Montage des Vibrators

Bild 18 / figure 18
darauf achten, dass das Ölschau-

glas senkrecht zum Markierungs-
blech steht (siehe Pfeile).
! By mounting the vibrator

into the roller drum, you
have to attend the oil control glas
have to be verticaly to the marking
plate (see arrows).
Bild 19 / figure 19
schrauben.
Moisten screws 11 with liquid 12

screw them in.
Torques: 3.1
Bild 20 / figure 20
Vibrator rechts und links mit
spezial Vibratoröl % befüllen.
Füllmengen: siehe „War-
tungsinformationen“.
Fill vibrator right and left with

special vibrator oil %.
Fuel quantity: see “Mainte-
nance information”
HAMM AG 51/56 # 1298119

09/07/2009
Bild 21 / figure 21
Fahrlager mit spezial Vibra-
toröl % befüllen.
Füllmenge: = 0,4l
Fill drive bearing with special

vibrator oil %.
Fuel quantity = 0,4l
HAMM AG 52/56 # 1298119

09/07/2009
Anhang
3. Anhang
3.1 Datenblatt „Anzugsdrehmomente“ / Data sheet „torque wrench set-
tings“
Für Schrauben mit metrischem Regelgewinde in Stahl und Kopfauflagen -

maßen wie in DIN 931; 912; 934 ...
Die Anzugsmomente gelten mit und ohne Flüssigkunststoff als Schrauben-
sicherung
For screws with metric thread in steel like in DIN 931; 912; 934 ...
The torque wrench settings valid with and without Loctite
Drehmomente (Nm)
Torque (Nm)
Abmessung 8.8 10.9 12.9
Verzinkte Schrauben Dimension
Galvanized screws M4 2,7 3,8 4,6

M5 5,5 8 9,5
Reibungszahl 0,125 – für M6 9,5 13 16
verzinkte Schrauben M8 23 32 39
M10 46 64 77
Sliding friktion 0,125 – for M12 80 110 135
M14 125 180 215
galvanized screws M16 195 275 330
M18 270 390 455
M20 385 540 650
M22 510 720 870
M24 660 930 1100
M27 980 1400 1650
M30 1350 1850 2250
M
Drehmomente (Nm)
Torque (Nm)
Abmessung 8.8 10.9 12.9
Unverzinkte (schwarze) Schrauben
Dimension
Non-galvanized (black) screws
M4 2,9 4,1 4,9
M5 6 8,5 10
Reibungszahl 0,14 - für
M6 10 14 17
unverzinkte Schrauben M8 25 35 41
M10 49 69 83
Sliding friktion 0,14 – for M12 86 120 145
non-galvanized screws M14 135 190 230
M16 210 295 355
M18 290 405 485
M20 410 580 690
M22 550 780 930
M24 710 1000 1200
M27 1050 1500 1800
M30 1450 2000 2400
HAMM AG 53/56 M
# 1298119
09/07/2009
Anhang
3.2 Datenblatt und Richtlinien für den Einsatz von Flüssigkunststoffen,

Dichtungen, Fetten und Ölen
Kenn- Hamm Norm- oder Firmen- Anwendungshinweise Festigkeit

zeichen Ident-Nr. bezeichnung
00 382 620 Flüssigkunststoff für demontierbar
+ (50 ml)
00 263 397
Schraubenverbindungen aller Größen
außer verzinkten Schrauben
(250 ml)
00 393 037 Flüssigkunststoff für verzinkten demontierbar
(50 ml) Schrauben aller Größen
00 393 029
(250 ml)
, 00 382 639
(50 ml)
Flüssigkunststoff für Fügeverbindungen,
z.B. Nabe-Welle Mitnehmerbuchse,
schwer lösbar
00 263 419 Mitnehmerflächen, Reperaturen

(250 ml)
- 01 234 188
(50 ml)
Flüssigkunststoff für Fügeverbindungen
mit engem Spalt, z.B. Wälzlager
demontierbar
01 234 196
(250 ml)
/ 00 382 604
(50 ml)
Flüssigkunststoff zur Abdichtung von
Flächen (Klebespalt max. 0,5 mm)
leicht
demontierbar
00 323 705
(250 ml)
0 00 231 347
(500 ml)
Epple Dichtungskit 4012 wird nicht mehr verwendet
1 01 205 757
(1 kg)
Bechem FA67 II Hochleistungsfett, druck- und
temperaturbeständig für schnellaufende
Niedrige
Grund-
Wälzlager ölviskosität
2 01 227 114
(1 kg)
Bechem FA50 Hochleistungsfett, druckbeständig,
wasserabweisend für langsam laufende
Hohe Grund-
ölviskosität
Wälzlager, Zahnbuchsen, Steckwellen
3 00 392 693
(250 ml)
Flüssigkunststoff zur Abdichtung von
Rohrgewinde bis 3“
leicht
demontierbar
4 01 215 809
(300 ml)
Dichtmittel zur Flächenabdichtung von
Wasser-, Öl- und Kraftstoffdeckeln
leicht
demontierbar
" 00 261 866

Patrone
Fina Marson EPL2 Mehrzweckfett
00 261 858
(200 kg)
# 00 261 149 siehe Motor-

wartungsanleitung
Motoröl
$ 00 261 165

Fina Hydran AF 46
DIN 51 524 Teil 2, HLP
Hydrauliköl, zink-,silikon- und aschefrei
 ISO 6743/4-HM
 ISO TC 28/SC 4-HM
 CETOP RP 91H-HM
 AFNOR NF 460-203-HM
% 01 238 051
(5 L)
Spezial Getriebeöl Vibratoröl
( 00 261 157 Fina Pontonic

MP SAE 85 W-90W
Hypoidöl für Planeten- und Radgetriebe
00 341 940 Cleo -Trennmittelkonzentrat Trennmittel
00 313 238 Fina Termidor Frostschutzmittel; Mischungsverhältnis:

Frostschutz / Wasser 60% / 40% bis -
26°C
HAMM AG 54/56 # 1298119

09/07/2009
Anhang
3.3 Data sheet and recommendation for the use of liquid plastics, seal-
ants, greases and oils.
Identifi- Hamm Norm- or Firm- Applications Solidity
cation Ident-No. designation
+ 00 382 620
(50 ml)
Liquid plastic for bolt connecting
all sizes besides galvanized
removable
00 393 037 Liquid plastic for bolt connecting removable

(50 ml) all sizes
, 00 382 639
(50 ml)
Liquid plastic for joints, e.g. hub-
shaft bushing, carrier surfaces,
hardly
removable
- 01 234 188
(50 ml)
Liquid plastic for joints with narrow
gaps, e.g. roller bearing
removable
/ 00 382 604
(50 ml)
Liquid plastic to tighten surfaces
(adhesive gab max. 0.5 mm)
easily
removable
0 00 231 347
(500 ml)
Epple seal kit 4012 is no longer used
1 01 205 757
(1 kg)
Bechem FA67 II High-grade grease, resistant to
pressure and temperatures, for
Low base oil
viscosity
2 01 227 114
(1 kg)
Bechem FA50 High-grade grease, resistant to
pressure, water-repellent for low-
High base oil
viscosity
3 00 392 693
(250 ml)
Liquid plastic for tightening pip
threads up to 3“
easily
removable
4 01 215 809
(300 ml)
Sealants to tighten water, oil and
fuel tanks
easily
removable
" 00 261 866

cartridge
Fina Marson EPL2 Mulit-purpose grease
# 00 261 149 Fina Kappa

Supra SAE 15 W-40W
Engine oil for all Diesel engines
$ 00 261 165 Fina Hydran AF 46 Hydraulic oil, free from zinc,

silicone and ashes
 DIN 51 524 Teil 2, HLP
 ISO 6743/4-HM
 ISO TC 28/SC 4-HM
 CETOP RP 91H-HM
 AFNOR NF 460-203-HM
% 01 238 051
(5 L)
Special gear oil Vibrator oil
( 00 261 157 Fina Pontonic

MP SAE 85 W-90W
Hypoid oil for planetary and wheel
gear
00 341 940 Cleo - Separating agent Separating agent
00 313 238 Fina Termidor Antifreeze; mixture ratio:

antifreeze / water 60% / 40%
up to -26°C
HAMM AG 55/56 # 1298119

09/07/2009
Anhang
HAMM AG 56/56 # 1298119

09/07/2009
Adjustment of vibration frequencies
Adjustment of the
maximum vibration
frequencies
Series 3000
HAMM AG 1/18 #2118297

04/12/2009
Table of contents
TABLE OF CONTENTS:
1. Instructions for use ..................................................................... 3
1.1 Liability exclusion ................................................................................................... 3
1.2 Validity...................................................................................................................... 3
1.3 Important symbols in this manual ......................................................................... 3
1.4 Special tools ............................................................................................................ 3
2. Preparations on the machine ..................................................... 4
3. Frequency adjustment 3410-3411 .............................................. 5
3.1 Frequency adjustment small amplitude ................................................................ 5
3.2 Frequency adjustment big amplitude .................................................................... 7
4. Frequency adjustment 3412-3520 standard ............................. 9
4.1 Frequency adjustment small amplitude ................................................................ 9
4.2 Frequency adjustment big amplitude .................................................................. 11
5. Frequency adjustment 3412-3625 HAMMTRONIC .................. 13
5.1 Frequency adjustment small amplitude .............................................................. 13
5.2 Adjustment of the big amplitude .......................................................................... 15
6. Annex ......................................................................................... 17
6.1 Allowed maximum frequencies ............................................................................ 17
6.2 Adjustment table HAMMTRONIC.......................................................................... 17
Notes.............................................................................................. 18
HAMM AG 2/18 #2118297

04/12/2009
Instructions for use
1. Instructions for use

1.1 Liability exclusion
This manual should support service technicians with the adjustment of the maximal
vibration frequencies in our compactors of the Series 3000. The general safety and
accident prevention regulations apply. Company HAMM AG cannot be made liable for
occurrences caused by the application of the steps recommended in this document.
1.2 Validity
This document is valid for all Series 3000 rollers without the option “HAMMTRONIC”.
1.3 Important symbols in this manual
! Security advices
9 Necessary information
; General information
1.4 Special tools
Frequency measuring device (SIROMETER)

278548
to test and adjust the vibration system
Lifting pad
versatile. Especially suited to test the
vibration in closed rooms.
HAMM AG 3/18 #2118297

04/12/2009
Preparations on the machine
2. Preparations on the machine
!
Prior to the start of work, warm up the machine and place it on
an appropriate and even ground. Furthermore, please make
sure that the drum is vibration isolated (refer to 1.4).
Vibration isolation:
 Place drum on lifting pad

 Alternatively on an even
sandy ground
!
Always make sure that the diesel engine is not running and the
battery isolation switch is not applied when working on the
machine!
HAMM AG 4/18 #2118297

04/12/2009
Frequency adjustment 3410-3411
3. Frequency adjustment 3410-3411

3.1 Frequency adjustment small amplitude
1. Preselect “small amplitude“
luminous indication in display
2. Start diesel engine
3. Speed-up diesel engine to max.

speed
4. Activate vibration with push-

button V
HAMM AG 5/18 #2118297

04/12/2009
5. Determine vibration frequency

with Sirometer
6. Switch off diesel engine

!
7. Open engine bonnet
A B
8. Loosen counter nut A and
simultaneously hold adjusting
screw B
9. Frequency reduction = screw-in
adjusting screw B
10. Hold adjusting screw B and re-
tighten counter nut A
Adjusting chamber upper left

11. Close engine bonnet
12. Repeat steps 2 to 12 until the
allowed maximum frequency
(Annex 6.1) has been reached.
HAMM AG 6/18 #2118297

04/12/2009
3.2 Frequency adjustment big amplitude
1. Pre-select “big amplitude“
Luminous indication in display

speed

button V
HAMM AG 7/18 #2118297

04/12/2009

with Sirometer

!
8. Loosen counter nut C and

screw D
9. Frequency reduction = Screw-in
adjusting screw D C
10. Hold adjusting screw D and re-
tighten counter nut C D
Adjustment chamber lower right

HAMM AG 8/18 #2118297

04/12/2009
standard
4. Frequency adjustment 3412-3520 standard

13. Preselect “small amplitude“
luminous indication in display

speed

button V
HAMM AG 9/18 #2118297

04/12/2009
standard

with Sirometer

!
A
screw B
21. Frequency reduction = screw-in
adjusting screw B
B
Adjusting chamber down right
HAMM AG 10/18 #2118297

04/12/2009
standard
4.2 Frequency adjustment big amplitude
13. Pre-select “big amplitude“
Luminous indication in display

speed

button V
HAMM AG 11/18 #2118297

04/12/2009
standard

with Sirometer

!
D
screw D
21. Frequency reduction = Screw-in C
adjusting screw D
tighten counter nut C
Adjustment chamber top left

HAMM AG 12/18 #2118297

04/12/2009
HAMMTRONIC
5. Frequency adjustment 3412-3625 HAMMTRONIC

1. Detach the plugs from both
solenoids of the vibration pump.
3. Speed-up diesel engine

according to the adjustment
table (Annex 6.2).
4. Apply 12V to the solenoid for the

small Amplitude (upper one).
HAMM AG 13/18 #2118297

04/12/2009
HAMMTRONIC

with Sirometer.
6. Switch off diesel engine!

!
7. Open engine bonnet.
A
screw B
9. Frequency reduction = Screw-in
adjusting screw B
B
11. Close engine bonnet.
according adjustment value
(Annex 6.2) is reached.
HAMM AG 14/18 #2118297

04/12/2009
HAMMTRONIC
5.2 Adjustment of the big amplitude
1. Detach the plugs from both

solenoids of the vibration pump.
3. Speed-up diesel engine

according to the adjustment
table (Annex 6.2).
4. Apply 12V to the solenoid for the

big Amplitude (lower one).
HAMM AG 15/18 #2118297

04/12/2009
HAMMTRONIC

with Sirometer.
6. Switch off diesel engine!

!
7. Open engine bonnet.

screw D
9. Frequency reduction = Screw-in C
adjusting screw D
tighten counter nut C

11. Close engine bonnet.
according adjustment value
(Annex 6.2) is reached.
HAMM AG 16/18 #2118297

04/12/2009
Annex
6. Annex
6.1 Allowed maximum frequencies
Machine Vibration frequency [Hz]

Type Series Drum Small amplitude Big Amplitude
3205 H158; H188 Standard 42 30
Standard 42 30
3307 H159; H189
VIO 36 36
3410-3411 H169; H179 Standard 40 30
Standard 40 30
3412-3414 H160; H180
VIO 30 30
3516 Standard 40 30
3518 H161; H176 Standard 30 27
3520 Standard 30 27
6.2 Adjustment table HAMMTRONIC
Machine Adjustment data (rpm, frequency)

Type Series Drum Diesel rpm small ampl. big ampl.
[Hz] [Hz]
Std. / P 42 30
3307 HT H159; H189 2080+100
VIO 34 34
3412 HT Std. / P 35 30
H160; H180 1700+100
3414 HT VIO 30 30
3516 HT 35 30
3518 HT H161; H176 Std. / P 1700+100 28 27
3520 HT 28 27
3625 HT H162; H177 Std. 1700+100 25 25
HAMM AG 17/18 #2118297

04/12/2009
Notes
Notes
HAMM AG 18/18 #2118297

04/12/2009
Readout of DEUTZ EMR3 Blink-Code
Readout of DEUTZ
Blink Codes
(for machines equipped with a EMR3)
HAMM AG 1/10 # 2138392

30.11.2009
INDEX
INDEX:
1. INSTRUCTIONS FOR USE 3
1.1 LIABILITY EXCLUSION 3

1.2 IMPORTANT SYMBOLS IN THE MANUAL: 3
1.3 SECURITY ADVICE 3
2. SERIES 3000 4
2.1 PREPARATIONS 4
2.2 READOUT OF BLINK-CODES 5
3. SERIES HD 7
3.1 PREPARATIONS 7
3.2 READOUT OF BLINK-CODES 8
NOTES 10
HAMM AG 2/10 # 2138392

30.11.2009
Instructions for use
1. Instructions for use

1.1 Liability exclusion
This manual should assist service technicians with the readout of the Deutz Diagnostic
Trouble codes via Blink-Code. The general safety and accident prevention regulations ap-
ply. Company HAMM AG cannot be made liable for occurrences caused by the application
of the steps recommended in this document.
1.2 Important symbols in the manual:
! Security advices
9 Necessary information
; General information
1.3 Security advice
! Prior to starting work make sure that the battery isolation switch has been
disconnected!
HAMM AG 3/10 # 2138392

30.11.2009
Series 3000
2. Series 3000
2.1 Preparations
8 Ignition switched off!
 Open switchbox (right side of

machine)
 Disassemble four knurled nuts to

remove plastic cover
 Remove plastic cover from main-

board
HAMM AG 4/10 # 2138392

30.11.2009
Series 3000
 Mainboard with diagnose LED

and pushbutton
2.2 Readout of Blink-Codes
9 Ignition on!
8 Diesel engine switched off!!!
The blink code will appear in three flashing sequences with short breaks in
between.
9 Example:
flashing sequence = blink code
D_DD_DDD = 1-2-3
 Switch ignition on!
HAMM AG 5/10 # 2138392

30.11.2009
Series 3000
 Localize pushbutton and LED for

the readout of the EMR3 error
memory.
 Apply pushbutton until red LED

glows
 Release pushbutton and wait for
the blink code
 The blink code will appear. Example:

Please pay attention, count the flashing sequence = blink code
flashes and write down the error
codes D_DD_DDD = 1-2-3
 Apply pushbutton only for a short

click to go to the next error (if pre-
sent)
HAMM AG 6/10 # 2138392

30.11.2009
Series HD
3. Series HD
3.1 Preparations
8 Ignition switched off!
 Open switchbox (cabin floor right

side)
 Loosen two allen screws
HAMM AG 7/10 # 2138392

30.11.2009
Series HD
 Remove cover
 Mainboard with diagnose LED

and pushbutton
3.2 Readout of Blink-Codes
9 Ignition on!
8 Diesel engine switched off!!!
The blink code will appear in three flashing sequences with short breaks in
between.
9 Example:
flashing sequence = blink code
D_DD_DDD = 1-2-3
HAMM AG 8/10 # 2138392

30.11.2009
Series HD
 Switch ignition on!
 Localize pushbutton and LED for the

readout of the EMR3 error memory.
 Apply pushbutton until red LED glows

 Release pushbutton and wait for the
blink code
Beispiel:
 The blink code will appear. Please
pay attention, count the flashes and Blinksequenz = Blink-Code
write down the error codes D_DD_DDD = 1-2-3
 Apply pushbutton only for a short

click to go to the next error (if pre-
sent)
HAMM AG 9/10 # 2138392

30.11.2009
Notes
Notes
HAMM AG 10/10 # 2138392

30.11.2009
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Operation Manual
TD/TCD 2012 L04/06 2V
TD/TCD 2013 L04/06 2V
Notes
Notes gine, the use of DEUTZ original parts is pre-
scribed. These are specially designed for your
This engine is defined exclusively for purpose
engine and guarantee perfect operation.
according to the scope of delivery and built by
Non-compliance results in the expiry of the war-
the equipment manufacturer (use for the intend-
ranty!
ed purpose). Any other use above and beyond
this will be considered as misuse. The manufac- Maintenance/cleaning work on the engine may
turer will not accept any liability for damages re- only be carried out when the engine is not run-
sulting from this. The user bears the sole risk. ning and has cooled down.
Use for the intended purpose also includes ob- When doing this, make sure that the electrical
servance of the operating, maintenance and re- system is switched off (remove ignition key).
pair conditions specified by the manufacturer. The specifications for accident prevention with
The engine should only be operated, serviced electrical systems (e.g. VDE-0100/-0101/-0104/-
and repaired by personnel trained in its use and 0105 Electrical protective measures against dan-
the hazards involved. gerous contact voltages) must be observed.
The pertinent rules for the prevention of acci- Cover all electrical components tightly when
dents and other generally recognised safety and cleaning with liquids.
industrial medicine rules must be observed. Do not work on the fuel system while the engine
When the engine is running there is a danger of is running - Danger to life!
injury caused by: Wait for the pressure to drop after the engine has
– rotating and hot components come to a standstill (in engines with DEUTZ
– on motors with external ignition (high electri- Common Rail about 5 minutes, otherwise
cal voltage). Contact must be avoided! 1 minute) because the system is under high
Unauthorised engine modifications will invalidate pressure - Danger to life!
any liability claims against the manufacturer for During the first trial run do not stand in the dan-
resultant damage. ger area of the engine.
Equally, manipulations to the injection and con- Danger due to high pressure in case of leaks -
trol system can affect the engine's performance Danger to life!
and the exhaust characteristics. Adherence to – In case of leaks immediately contact work-
legislation on pollution can no longer be guaran- shop.
teed under such conditions. – When working on the fuel system, make sure
Do not change the cooling air feed area to the that the engine is not started inadvertently
blower of fan. An unobstructed cooling air supply during repairs - Danger to life!
must be guaranteed.
The manufacturer will accept no liability for dam-
age resulting from this.
When carrying out maintenance work on the en-
2 © 2007
Foreword
Dear customer, Engine serial number
Congratulations on the purchase of your DEUTZ en- Please enter the engine serial number here. This will
gine. simplify the handling of customer service, repair and
DEUTZ air/liquid-cooled engines are developed for a spare parts queries.
broad spectrum of applications. Consequently, a
wide range of variants is offered to meet the require-
ments of specific cases.
The engine is equipped accordingly for the particular Notes
installation situation, i.e. not all the components de-
We reserve the right to make technical changes to
scribed in the operating manual are installed in your the descriptions and data in this operating manual in
engine. the interest of further development of the engines.
We have endeavoured to highlight any differences This document may only be reprinted and repro-
so that you will be able to locate the operating and duced, even in part, with our express permission.
maintenance instructions applicable to your engine
more quickly and easily. Order number
Please make sure that this operating manual is avail- 0312 3459 en
able to everyone involved in the operation, mainte-
nance and repair of the engine and that they have
understood the contents.
If you have any queries, please contact us, we'll be
happy to advise you.
Sincerely,
DEUTZ AG
© 2007 3
Table of contents
Notes . . . . . . . . . . . . . . . . . . . . . . . 2 Belt drives . . . . . . . . . . . . . . . . . . 54
Foreword. . . . . . . . . . . . . . . . . . . . . 3 Setting work . . . . . . . . . . . . . . . . . 56
1 General. . . . . . . . . . . . . . . . . . . . 5 Electrical system . . . . . . . . . . . . . . . 60
2 Engine description . . . . . . . . . . . . . 7 7 Faults. . . . . . . . . . . . . . . . . . . . . 62
Type . . . . . . . . . . . . . . . . . . . . . 7 Fault table . . . . . . . . . . . . . . . . . . 62
Engine illustration. . . . . . . . . . . . . . . 9 Engine management . . . . . . . . . . . . . 65
Lubricating oil circuit . . . . . . . . . . . . . 19 8 Transport and storage . . . . . . . . . . . 68
Fuel schematic . . . . . . . . . . . . . . . . 20 Transport . . . . . . . . . . . . . . . . . . . 68
Coolant schematic . . . . . . . . . . . . . . 21 Protecting the engine against corrosion . . . 69
Electrics/Electronics . . . . . . . . . . . . . 23 9 Technical data . . . . . . . . . . . . . . . . 71
3 Operation . . . . . . . . . . . . . . . . . . 26 Engine and setting data . . . . . . . . . . . 71
Ambient conditions . . . . . . . . . . . . . . 26
First time commissioning . . . . . . . . . . . 27
Start procedure . . . . . . . . . . . . . . . . 29
Operation monitoring . . . . . . . . . . . . . 31
Stop procedure . . . . . . . . . . . . . . . . 33
4 Operating media. . . . . . . . . . . . . . . 34
Lubricating oil . . . . . . . . . . . . . . . . . 34
Fuels . . . . . . . . . . . . . . . . . . . . . 36
Coolant . . . . . . . . . . . . . . . . . . . . 37
5 Maintenance . . . . . . . . . . . . . . . . . 38
Maintenance schedule . . . . . . . . . . . . 38
6 Care and maintenance work . . . . . . . . 41
Lubricating oil system. . . . . . . . . . . . . 41
Fuel system. . . . . . . . . . . . . . . . . . 44
Cooling system . . . . . . . . . . . . . . . . 48
Engine cleaning. . . . . . . . . . . . . . . . 50
Suction system . . . . . . . . . . . . . . . . 51
4 © 2007
General notes General
DEUTZ diesel engines
DEUTZ diesel engines are the product of years of re-
velopments for improving the engines are also intro-
duced in the original DEUTZ parts of course. Only
ity with notes on product responsibilities and servic-
es. Or you can use another fast, convenient way via 1
the use of original DEUTZ parts manufactured ac- the Internet under www.deutzshop.de. The DEUTZ
search and development. Profound know-how com-
cording to the state-of-the-art can guarantee perfect P@rts Online parts catalogue gives you a direct con-
bined with high quality requirements are the functioning and high reliability. tact to your nearest local service partner.
guarantee for the production of engines with a long
life, high reliability levels and low fuel consumption. DEUTZ Xchange components
Obviously the high requirements for the protection of
the environment are also met. DEUTZ replacement parts are a low-cost alternative.
California
Of course, the quality standards here are just as high
Safety precautions when the engine is as for new parts. DEUTZ replacement parts are Proposition 65 Warning
Diesel engines and some of its constituents are
running equal to the original DEUTZ parts in function and re-
known to the State of California to cause cancer,
Maintenance work or repairs may only be performed liability.
birth defects and other reproductive harm.
on the shut-down engine. Make sure that the engine Asbestos
cannot be started inadvertently - Danger of acci- Masthead
dent! The gaskets used in this engine contain no asbestos.
Please use the appropriate spare parts for mainte- DEUTZ AG
When the work is complete, be sure to refit any pan- nance and repair work. Ottostraße 1
els and guards that have been removed.
Service 51149 Cologne
Observe industrial safety regulations when running
the engine in an enclosed space or underground. Telephone:+49 (221) 822-0
We want to preserve the high performance of our en-
When working on the running engine, work clothing gines, and with it the confidence and satisfaction of Fax: +49 (221) 822-5850
must be close fitting. our customers. We are therefore represented world- www.deutz.com
Never fill the fuel tank while the engine is running. wide by a network of service branches.
info@deutz.com
The DEUTZ name does not merely stand for engines
Service and Maintenance that are the products of extensive development
Service and maintenance are also decisive for work, DEUTZ also stands for complete service pack-
whether the engine satisfactorily meets the set de- ages that ensure optimum operation of our engines,
mands. Recommended service intervals must there- and for customer services operations that you can
fore be observed and service and maintenance work count on.
must be carried out conscientiously. Please contact your service partner in case of mal-
Special care should be taken under abnormally de- functions and sare parts inquiries. Our specially
manding operating conditions. trained personnel will ensure fast, professional re-
pairs using original DEUTZ spare parts in case of
Original DEUTZ parts damage.
Original DEUTZ parts are subject to the same strict The DEUTZ home page gives you a continuously up-
quality demands as the DEUTZ engines. Further de- to-date overview of the service partners in your vicin-
© 2007 5
General General notes
1 Danger
This symbol is used for all safety instruc-

tions which, if not observed, present a di-
rect danger to life and limb for the person
involved. Observe these carefully. The at-
tention of operating personnel should be
drawn to these safety instructions. Further-
more, the legislation for "general regula-
tions for safety and the prevention of
accidents" must be observed.
Caution
This symbol indicates a danger to the part

and engine. The relevant instructions must
be observed, failure to do so can lead to de-
struction of the part and the engine.
Notes
This symbol accompanies notes of a gen-

eral kind.
6 © 2007
Type Engine description
2
Rating plate Location of the rating plate

The engine type A, engine number B and the power The rating plate C is mounted on the cylinder head
data are stamped on the rating plate. cover or crankcase.
The engine type and number must be stated when
purchasing spare parts.
© 2007 7
Engine description Type
Engine serial number Cylinder numbering

The engine number is stamped onto the crankcase Cylinder arrangement
(arrow) and onto the rating plate. The cylinders are counted consecutively starting
from flywheel (1).
Looking at the power transmission side.
rotating to the left: counter-clockwise.
Engine sides
Looking at the power transmission side.
8 © 2007
Engine illustration Engine description
Engine TCD 2013 L04 2V with mech. in-
jection system PLD and mech./electr. 2
control, view from right (example)
1 Lubricating oil filling
2 Charge air line
3 Coolant outlet to the cooler
4 Transport device
5 Ventilation line to the compensation tank
6 Fan hub
7 Fuel pump
8 V-rib belt
9 Tension pulley
10 Coolant pump
11 Engine mounting
12 Lubricating oil drain plug
13 Lube oil replacement filter
14 Lube oil cooler
15 Generator
16 Hydraulic pump or compressor mounting (op-
tional)
17 Spin-on fuel filter (transport position)
18 Electrical motor shutdown
19 Crankcase ventilation valve
20 Cover for cable harness mount
21 Cylinder head cover
22 Injection pump
23 Control canister (exhaust turbocharger pressure
regulation)
© 2007 9
Engine description Engine illustration
2 Engine TCD 2013 L04 2V with mech. in-

jection system PLD and mech./electr.
control, view from left (example)
1 Turbocharger
2 Transport device
3 Mechanical speed control
4 Gear connection (SAE housing)
5 Engine mounting
7 Lubricating oil return line from the exhaust turbo-
charger
8 Starter
9 Lubricating oil filling (optional)
10 Coolant inlet
11 Exhaust manifold line
10 © 2007
Engine TCD 2012 L04 2V with DEUTZ
Common Rail (DCR), view from right (ex- 2
ample)
2 Combustion air inlet
3 Cover for cable harness mount
4 Fan
5 Generator
6 Coolant pump
7 Tension pulley
8 Lube oil cooler
9 Lubricating oil filter
10 Fuel filter
11 Hydraulic pump or compressor mounting (op-
tional)
12 Flywheel
13 Transport bracket (only for transport)
15 Transport device
17 Control block FCU (Fuel Control Unit)
© 2007 11
2 Engine TCD 2012 L04 2V with DEUTZ

Common Rail (DCR), view from left (ex-
ïï ample)
1 Transport device
3 Turbocharger
4 Transport bracket (only for transport)
ïð charger
6 Relay (starter)
7 V-rib belt
8 Coolant inlet
í 9 Coolant outlet
10 Fan mounting
11 Compensation line connection to tank
12 Ventilation line connection
12 © 2007
îï îî îí
ample)
îð 3 Transport device
4 Generator
5 Fan hub
6 Fuel supply pump
ïç 7 Belt pulley with torsional vibration damper on
crankshaft
8 V-rib belt
9 Tension pulley
10 Coolant pump
ïè
13 Lube oil cooler
14 Cab heating supply flow line
15 Exchangeable fuel filter
16 Lubricating oil dipstick
17 Engine mounting
18 Hydraulic pump or air compressor mounting (op-
ïé tional)
20 Central plug (for engine control)
ïê
22 High-pressure pump
23 Rail
24 Injector
ïë
ïì
© 2007 13

ample)
2 Charge air line
3 Transport device
5 Engine mounting
7 Starter cover
charger
9 Turbocharger
10 Charge air connection to the charge air cooler
11 Coolant inlet
12 Coolant outlet
14 © 2007
ample)
1 Combustion air inlet (heating flange mounting,
optional)
2 Cab heating return flow connection
5 Fan
6 Generator
7 Belt pulley with torsional vibration damper on
crankshaft
8 V-belts
9 Fuel supply pump drive
12 Lube oil cooler
13 Hydraulic pump or air compressor mounting (op-
tional)
14 Lubricating oil return line for crankcase ventila-
tion
15 Cab heating supply flow line
20 Injector
© 2007 15

ample)
3 Engine mounting
5 Starter
charger
7 Turbocharger
8 Coolant inlet
9 Charge air connection to the charge air cooler
10 Coolant outlet
13 Transport device
16 © 2007
ample)
3 Generator
4 Coolant pump
7 Lubricating oil dipstick
9 Lubricating oil return line for crankcase ventila-
tion
10 Engine mounting
14 Rail
15 Transport device
17 Injector
© 2007 17

ample)
1 Turbocharger
3 Starter
4 Lubricating oil pipe to the turbocharger
5 Coolant drain plug
6 Coolant inlet
7 Engine mounting
8 V-rib belt
9 Fan
10 Tension pulley
11 Transport device
14 Coolant outlet
18 © 2007
Lubricating oil circuit Engine description
Lubricating oil schematic (example)
1 Lubricating oil sump
2
2 Lubricating oil suction intake pipe
3 Lubricating oil pump
3.1 Overpressure valve (only for 2013)
4 Lube oil cooler
4.1 Return flow shutoff valve (only for 2012)
4.2 Bypass valve
4.3 Bypass valve for lubricating oil filter
4.4 Pressure control valve
5 Lubricating oil filter
6 Main lubricating oil lines
6a Internal connected exhaust gas recirculation
(optional, only for 6-cyl. engines)
7 Crankshaft bearing
8 Big-end bearing
9 Camshaft bearing
10 Line to injector nozzle
11 Piston cooling nozzle with pressure holding
valve
12 Tappet with impulse lubrication of the rocker arm
13 Tappet rod, lubricating oil feed to the rocker arm
lubrication
14 Rocker arm
15 Return flow to the lubricating oil pan
16 Lubricating oil pipe to the turbocharger
17 Turbocharger
18 Return line from the compressor/hydraulic pump
to the crankcase
19 Air compressor or hydraulic pump
20 Lubricating oil line to the air compressor/hydrau-
lic pump
21 Return line from the turbocharger
© 2007 19
Engine description Fuel schematic
2 Fuel schematic of the DCR engine (exam-

ple)
1 Fuel container
A= minimum distance 500 mm
2 Fuel pre-filter with manual supply pump for filling
the low-pressure area (mounted on device side)
3 Line to the fuel supply pump
4 Fuel supply pump
5 Line to the spin-on fuel filter
7 Fuel line to the control block
9 Fuel line from the control block to the high-pres-
sure pumps and the rail
11 Rail
12 Fuel line to the injector
13 Injector
14 Fuel return line at the cylinder head
15 Fuel return to fuel tank
20 © 2007
Coolant schematic Engine description
2
© 2007 21
Engine description Coolant schematic
2 Coolant schematic (example)

1 Coolant outlet at the cooler
2 Thermostat
3 Coolant supply line to the pump
4 Coolant pump
5 Lube oil cooler
6 Cylinder cooling
7 Cylinder pipe/head cooling
8 Coolant supply flow to the cab heating
9 Cab heating (optional)
10 Coolant for the thermostat
11 Coolant return flow from the cab heating
12 Compensation line
13 Ventilation line to the compensation tank
14 Coolant outlet to the cooler
15 Compensation tank
16 Compensation line to the cooler
17 Cooler
22 © 2007
Electrics/Electronics Engine description
Electrics (example)
2
Engine side
1 Fuel pressure transducer in the FCU

2 Coolant temperature
3 Charge air pressure/temperature transmitter
– A=TCD 2012/2013L06
– B=TCD 2012/2013L04
4 Engine adapter plug
5 Engine control unit
6 Speed transmitter via crankshaft
7 Rail pressure, laterally on the rail
8 Lubricating oil level transmitter (optional)
9 Lubricating oil pressure transmitter
10 Fuel transducer
11 Speed transmitter via camshaft
Equipment side
13 Power supply (battery)
14 Multifunction displays
15 Outputs (configurable, e.g. for lamps, torque
(PWM), speed, engine running signal, etc.)
16 Inputs (configurable)
17 Accelerator
18 Hand throttle (optional)
19 Switch functions (optional, e.g. for P-factor, reg-
ulator type, peak curves, fixed speeds etc. also
multi-step switches)
20 Detachable key switch Start/Stop
21 Diagnostic button
22 Error lamp with blink code
23 Diagnostic interface/CAN bus
© 2007 23
Engine description Electrics/Electronics
2 Other application side components (de-

pending on the application)
Water trap fuel filter
Override key (for temporary bypassing of the en-
gine protection functions)
Coolant level transmitter
Separate engine stop switch
Fan control
Switch for brake contact, engine brake, clutch
Drive speed sensor, drive speed control unit, +-
keys for increasing/decreasing speed
Cold start aid indicator lamp
This lamp flashes in the case of a serious fault,
e.g. the heating flange is drawing current al-
though the control unit is not controlling it. The
power supply to the heating flange must then be
disconnected separately (overheating protection
heating flange)
24 © 2007
Electrics/Electronics Engine description
Information about the engine electronics
This engine is equipped with an electronic DEUTZ
It is strictly prohibited:
a) to make changes or connections to the
Supply voltage
DEUTZ diesel engines must be operated with a 12 V
2
control unit. wiring of the electrical control devices and or 24 V supply. An adequate charging condition of
The equipping of the respective system depends on the data transmission cable (CAN lines). the battery must be ensured. Interruption of the pow-
the desired scope of function and the planned type of b) to switch control units. er supply when the engine is running can lead to
engine application. Diagnostic and maintenance work may damage to the electrics/electronics. Failure of the
only be carried out by authorised personnel supply voltage leads to engine standstill.
The resultant wiring with pin assignment can be seen using equipment approved by DEUTZ.
in the appropriate wiring diagram. Voltages above 32 Volt will destroy the control unit.
The installation regulations of the DEUTZ AG must Installation instructions Diagnostics
also be taken into account. The control units are calibrated to the respective en- DEUTZ control units are equipped with self-diagno-
Precautions gine and identified by the engine number. Every en- sis. Active and passive error entries are saved in the
gine may only be operated with the appropriate error memory. Active errors are displayed by error
control unit. lamp/diagnostic lamp ( 65 ). The active errors can
The connections of the control units are
only dust and water proof when the mating Setpoint transmitters (pedal value transmitters) nec- be called by blink codes or by the DEUTZ diagnostic
plugs are plugged (protection class IP69K)! essary for vehicle operation must be connected to program SERDIA. Passive errors must be deleted by
The control units must be protected against the vehicle side cable harness and calibrated with SERDIA.
spray water and moisture until plugging in the DEUTZ diagnostic program SERDIA (SERvice with error lamp (optional).
the mating plugs! DIAgnosis). Wiring and cable assignment of the ve- – See blink codes for details.
Reverse polarity can lead to failure of the hicle side cable harness must be taken from the con-
control unit. nection diagram of the DEUTZ installation via diagnostic socket (SERDIA).
To avoid damaging the control units, all the consulting.
connections on the control unit must be dis-
connected before electric welding work.
Interventions in the electrical system con-
trary to the DEUTZ regulations or by un-
qualified personnel can permamently
damage the engine electronics and have
serious consequences which are not cov-
ered by the manufacturer's guarantee.
© 2007 25
Operation Ambient conditions
3 can be used as cold starting aids.( 29)

Coolant
Mixing ratio anti-freeze/cooling water.
High ambient temperatures, high altitude
Under the operating conditions listed be-

low, the amount of fuel is reduced automat-
ically, controlled by the electronic control
unit.
Under the following application and operating condi-

tions, the amount of fuel must be reduced.
above 1000 m altitude
above 30 °C ambient temperature
Low ambient temperatures
Reason: Air density decreases as altitude or ambient
Lubricating oil temperature increase. This reduces the amount of
oxygen in the engine intake air and the fuel-air mix-
Select lubricating oil according to ambient tem-
perature ture would be too rich if the injected amount of fuel
were not reduced.
If cold starting occurs frequently cut the lube oil
changing interval by half. The results would be:
– black smoke in the exhaust
Fuel – high engine temperature
Use Winter fuel below 0 °C ( 36 ). – reduction in engine performance
Battery – possible impairment of starting behaviour
Consult your equipment supplier or DEUTZ partner if
A good charging condition of the battery ( 60 ) you have any other questions.
is the prerequisite for starting the engine.
Heating up the battery to approx. 20°C improves
the starting behaviour of the engine. (Remove
and store the battery in a warm room).
Cold start aid
Depending on the type of engine, glow plugs,
heating plugs, heating flange, flame glow system
26 © 2007
First time commissioning Operation
Preparations for initial commissioning
(Maintenance schedule E 10)
3
Remove engine corrosion protection
Remove any transport devices.
Check the battery and cable connections and
mount if necessary.
Checking the belt tension ( 54 ).
Have the engine monitor or warning system
checked by authorised personnel.
Check the engine mounting.
Check that all hose unions and clips fit properly.
The following additional work must be carried
out on generally overhauled engines:
Check the fuel pre-filter and main filter and
change if necessary. Fill with engine lube oil. Pour in fuel
Check the intake air cleaner (if available, main- The fuel low pressure system must be vented be-
tain according to maintenance indicator). Low lubricating oil level and overfilling lead fore the first start-up after filling with the manualy
to engine damage.
Drain lubricating oil and condensation water from supply pump.
the charge air cooler.
Fill with engine lube oil. The engines are generally supplied without Only re-fuel when the engine is not running.
lubricating oil filling. Ensure cleanliness.
Select lubricating oil quality and viscosity Do not spill fuel.
before filling. Additional venting of the fuel system by a 5
Order DEUTZ lubricating oils from your minute trial run at idle speed or on low load
DEUTZ partner is absolutely essential.
Fill the engine with lubricating oil via the lubricat- Only use clean commercially available brand diesel
ing oil filler neck. fuel. Observe fuel quality ( 36).
Observe the lubricating oil filling level ( 71 ). Use summer or winter-grade fuel, depending on the
Check lubricating oil level, if necessary top up. ambient temperature.
© 2007 27
Operation First time commissioning
3 Start engine and run up until the thermostat

opens ( line 1 heats up ).
Engine operation with open thermostat 2 - 3 min-
utes.
Check the coolant level in the compensation tank
and top up coolant if necessary.
If required, repeat procedure with engine start.
Fill up coolant to the MAX mark on the compen-
sation tank and close the cooling system cap.
Switch on any available heating and set to the
highest level so that the heating circuit is filled
and vented.
Observe the filling volume of the cooling system
( 71).
Trial run
Fill oil-bath air filter with lubricating oil. Filling the coolant system
Venting of the fuel system by operating for
No lubricating oil may be filled in the cy- The coolant must have a prescribed con- 5 minutes on no load or with low load is ab-
clone pre-separator that may be connected centration of cooling system corrosion pro- solutely essential.
upstream. tection agent.
Never operate the engine without coolant, Carry out a brief trial run up to operating temperature
Fill lubricating oil pan (1) of the oil-bath filter with even for a short time! (approx. 90 °C) after preparations.
lubricating oil as far as the marking arrow.
Do not load the engine if possible.
Order coolant corrosion protection agent Work with the engine not running:
from your DEUTZ partner. – Check engine for tightness.
– Check the lubricating oil level and top up lu-
Connect coolant outlet (1) and coolant inlet (2) to bricating oil if necessary.
the cooling system. Connect supply line from the
– Check the coolant level and top up coolant if
compensation tank to the water pump or to the
necessary.
coolant inlet line (2).
Work during the trial run:
Connect ventilation line from the engine and, if
– Check engine for tightness.
necessary, from the cooler to the compensation
tank.
Fill cooling system via the compensation tank.
Close compensation tank with valve.
28 © 2007
Start procedure Operation
Starting If the engine does not start and the error
lamp blinks, the EMR3 system has activat-
if the engine fails to start.
3
Before starting, make sure that nobody is ed the start lock to protect the engine.
standing in the immediate vicinity of the en- The start lock is released by switching off
gine or work machine. the system with the ignition key for about 30
After repair work: Check that all guards seconds.
have been replaced and that all tools have Separate the engine if possible by disen-
been removed from the engine. gaging driven units.
When starting with the flame glow plug/ Do not actuate the starter for more than
glow plug/heating flange system do not use 20 seconds. If the engine does not start up,
any other starting aid (e.g. injection with wait for one minute and then repeat the
start pilot). Risk of accident! starting process.
Attention: The engine may never be started If the engine does not start up after two at-
with the mechanical speed transmitter re- tempts, determine the cause as per fault ta-
moved. Disconnect the battery connec- ble ( 62 ).
tions! Do not run up the engine immediately to
If the engine does not start properly when high idling speed / full load operation from
the heating flange is automatically actuated cold.
(starter does not receive current as a result
of a fault in the equipment/customer electri-
Disconnect the engine by uncoupling de-
cal control system) the starting procedure vices to be driven where possible.
must be abandoned (set the ignition switch
to OFF, disconnect the power supply to the
heating flange). If the starter is connected to the EMR3 by a relay,
the maximum starting time is limited by the
EMR3.
The pause between two start attempts is preset
by the EMR3.
If the touch start function is programmed, a short
start command with the ignition key in position 2 or a
start button, if available, suffices.
The start is then continued automatically by the
EMR3.
The EMR3 can be programmed for special appli-
cations by data record so that the control unit can
also carry out further start attempts automatically
© 2007 29
Operation Start procedure
w îêîìëóï w îëéìëóð
Start for mech. injection system (exam- Without cold start aid Glow plugs with cold start aid
ple)
Insert key. Insert key
Disconnect the engine by uncoupling devices to Turn key to the right. – Position 0 = no operating voltage.
be driven (where possible). – Position 1 = operating voltage.
The speed adjusting lever (1) must be at the limit Turn key to the right.
– Pilot lamps (1) and (2) light up.
stop of the low idling (arrow). – Position 1 = operating voltage.
Push the key in and turn further clockwise
The stop lever (2) must have been brought to the – Pilot lamps (1) and (2) light up.
against spring pressure.
normal position as a result of its spring force (di- – Preheat until glow display goes out.
– Level 2 = no function.
rection of arrow). Push the key in and turn further clockwise
– Level 3 = start.
against spring pressure.
Release key as soon as the engine starts up.
– Level 2 = no function.
– The pilot lamps will go out.
– Level 3 = start.
Release key as soon as the engine starts up.
– The pilot lamps will go out.
30 © 2007
Operation monitoring Operation
Operation monitoring by EMR3
The EMR3 system monitors the engine condition
ment panel to avoid critical situations. This
brief deactivation of the engine protection 3
functions is logged in the control unit.
and itself.
The engine protection functions are released in
The statuses are displayed by the error lamp. co-operation with the equipment manufacturer
Lamp test: and the DEUTZ installation consulting and may
– The error lamp lights up for approx. 2 s after be designed individually. It is therefore absolute-
switching on the ignition (ignition lock stage ly essential to observe the operating instructions
1) of the equipment manufacturer.
Steady light:
– There is a system error or an engine variable
(temperature, pressure etc.) is in the warning
range.
The EMR3 can reduced the engine perform-
ance depending on the error to protect the
engine. Display instrument
Fast flashing: Possible displays:
– Attention, the engine is in danger and must Colour scale
be switched off. – Display of the operating state by coloured ar-
– The control unit switches the engine off auto- ears (green = OK/red = take suitable action).
matically depending on the application.
– The control unit can preset a forced engine Measured value scale
operation with low idling speed to cool down – Actual value can be read off directly. The
the engine before switching off, automatic nominal value should be taken from the
switch-off if necessary. Technical Data ( 73).
– There may be a start lock after engine stop.
– The start lock is released by switching off the
system with the ignition key for about 30 sec-
onds.
– Additional control lamps, e.g. for lubricating
oil pressure or lubricating oil temperature,
are switched on if necessary.
– The power reduction can be bypassed, the
automatic switch-off delayed or a start lock
bypassed with the override key on the instru-
© 2007 31
Operation Operation monitoring
3 Instruments and symbols
Instruments / symbols Designation Possible display: Measure

Lubricating oil pressure dis- Lubricating oil pressure below minimum Switch off engine
play
Lubricating oil pressure dis- Lubricating oil pressure in the red area Switch off engine
play
Coolant temperature Coolant temperature too high Switch off engine
Lubricating oil pressure pilot If the pilot lamp lights up after starting the engine or while Switch off engine
lamp the engine is running, the lubricating oil pressure is too
low
Lube oil level If the pilot lamp lights up after starting the engine or while Check lubricating oil level / if necessary top up
the engine is running, the lubricating oil level is too low
Coolant level If the control lamp lights up after the engine starts or Switch off the engine, allow to cool down and top up
while the engine is running, the coolant level is too low coolant
Operating hours counter Indicates the previous operating time of the engine Observe the maintenance intervals
Horn With acoustic signal See fault table ( 62).
32 © 2007
Stop procedure Operation
Shutting off
3
Avoid switching off from full load (coking/
blockage of the remaining lubricating oil in
the turbocharger bearing housing). The lu-
bricating oil supply of the turbocharger is
then no longer guaranteed! This shortens
the life of the turbocharger.
Run the engine in low idling speed for ap-
proximately one minute after relieving the
load.
The control unit remains active for about
another 40 seconds to save the system
data (lag) and then switches off automati-
cally.
Electrical shutdown (optional) Stopping for mechanical speed control

Move the key to position 0. Move speed adjustment lever (1) to slow idle.
Control lamps A+B+C go out. Activate stop lever (2) until the engine comes to
A = charge pilot light a stop. Charge current pilot lamp and lubricating
B = lube oil pressure pilot light oil pressure pilot lamp light up after the engine
C = pilot light for pre-heating system has stopped.
P = gear position: park Turn key to the left (to level 0= and pull out. Pilot
0 = gear position: switch off engine lamps go out.
1 = gear position: pre-heat engine Move the key to position 0.
2 = gear position: start engine Control lamps A+B+C go out.
A = charge pilot light
B = lube oil pressure pilot light
C = pilot light for pre-heating system
P = gear position: park
0 = gear position: switch off engine
1 = gear position: pre-heat engine
2 = gear position: start engine
© 2007 33
Operating media Lubricating oil
4 General
Modern diesel engines place very high demands on
perature and oxidation stability as well as a relatively
low cold viscosity. Since some processes relevant to
Recommended quality class
DEUTZ ACEA API
the definition of the lube oil change intervals are not
the lubricating oil to be used. The specific engine
essentially dependent on the lube oil quality (such as DQC III - See TR 0199-99-3002
performances which have increased constantly over the incorporation of soot and other contaminations), 05 Please contact your DEUTZ partner
the last few years lead to an increased thermal load
the lube oil change interval when using synthetic DQC IV -
on the lubricating oil. The lubricating oil is also more lube oils may not be increased in relation to the spec-
exposed to contamination due to reduced oil com- 05
ifications of the lube oil change intervals.
sumption and longer oil change intervals. For this
reason it is necessary to observe the requirements Biodegradable lubricating oils may be used in DEUTZ lubricating oils DQC II-05
and recommendations described in this operating DEUTZ engines if they meet the requirements of this TLS - 15W40 D
manual in order not to shorten the life of the engine. operating manual.
Container Order number
Lubricating oils always consist of a base oil and an Quality 5 litre container 0101 6331
additive package. The most important tasks of a lu-
bricating oil (e.g. wear protection, corrosion protec- Lubricating oils are classified by DEUTZ according 20 litre container 0101 6332
tion, neutralisation of acids from combustion to their efficiency and quality class (DQC: DEUTZ 209 litre barrel 0101 6333
products, prevention of coke and soot deposits on Quality Class). It basically applies that: with increas-
the engine parts) are assumed by the additives. The ing quality class (DQC I, II, III, IV) the lubricating oils
are more efficient and higher quality. The appended DEUTZ lubricating oils DQC III-05
properties of the base oil are also decisive for the TLX - 10W40 FE
quality of the product, e.g. with regard to thermal quality class designation (- 02 / - 05) indicates in
load capacity. which year the classification was made. Container Order number
In principle, all engine oils of the same specification Lubricating oils according to other comparable spec- 5 litre container 0101 6335
can be mixed. However, mixing of engine oils should ifications can be used as long as they meet DEUTZ 20 litre container 0101 6336
be avoided because the worst properties of the mix- requirements. In regions in which none of these
qualities are available, please contact your responsi- 209 litre barrel 0101 6337
ture are always dominant.
ble DEUTZ partner.
The lubricating oil quality has a considerable influ- DEUTZ lubricating oils DQC IV-05 synthetic
ence on the life, performance and thus also on the The following lubricating oils are specified for the en-
gines described in this operating manual. DEUTZ-Oil DQC IV-5W30 synthetic
costs-effectiveness of the engine. It basically applies
that: The better the lubricating oil quality, the better Container Order number
these properties. Recommended quality class 20 litre container 0101 7849
DEUTZ ACEA API
The lubricating oil viscosity describes the flow be- 209 litre barrel 0101 7850
haviour of the lubricating oil depending on the tem- DQC II - E3-96 / E5-02 / E7- CG-4 / CH4 / C I-4
perature. The lubricating oil viscosity has no 05 04
influence and effect on the lubricating oil quality.
Synthetic lubricating oils are used increasingly
and have advantages. These oils have a better tem-
34 © 2007
Lubricating oil Operating media
Lubricating oil change intervals
The intervals depend on:
purpose lubricating oils should be used basically.
Single-purpose lubricating oils can also be used in 4
enclosed, heated spaces at temperatures >5 ° C.
– lubricating oil quality
Depending on the ambient temperature we recom-
– sulphur content in the fuel
mend the following common viscosity classes:
– type of application of engine
The lubricating oil change interval must be
halved if at least one of the following conditions
applies:
– Constant ambient temperature below -10 °C
(14 °F) or lube oil temperature below 60 °C
(84 °F).
– sulphur content in the diesel fuel of 0.5 - 1
weight %.
– operation with bio-diesel fuel
If the oil change intervals for vehicle engines are
to be carried out according to operating hours,
the oil change intervals for built-in engines apply.
If the lubricating oil change intervals are not
reached within a year, the oil should be changed
at least once a year.
Viscosity
The prescribed lubricating oil quality must

be observed when selecting the viscosity
class!
The ambient temperature at the installation site or in
the application area of the engine is decisive for
choosing the right viscosity class. Too high a viscos-
ity can lead to starting difficulties, too low a viscosity
can endanger the lubrication effect and cause a high
lubricating oil consumption. At ambient temperatures
below -40 °C, the lubricating oil must be pre-heated
(e.g. by storing the vehicle or the machine in a hall).
The viscosity is classified according to SAE. Multi-
© 2007 35
Operating media Fuels
4 Permissible fuels
The following fuel specifications / standards are ap-
Winter operation with diesel fuel
Only carry out mixing in the tank. Fill with

proved:
the appropriate amount of paraffin first,
Diesel fuels according to DIN EN 590 then add the diesel fuel. Normal and high
– Nato F-54 (equivalent to diesel fuel in ac- grade fuels may not be mixed.
cordance with DIN EN 590)
At low ambient temperatures paraffin discharges can
US diesel fuel according to ASTM D 975 Grade- lead to blockages in the fuel system and cause oper-
No.1-D and 2-D ating faults. Below 0 °C ambient temperature use
Japanese diesel fuel JIS K 2204 Grade 1 Fuel winter diesel (down to -20 °C) (filling stations provide
and Grade 2 Fuel with lubricating properties ac- this in good time before the cold season starts).
cording to diesel fuel EN 590 (HFFR max. 460
Below -20 °C paraffin should be added. The rel-
micrometer according to EN ISO 12156) evant percentages are given in the adjacent dia-
Biodiesel per EN 14214 (only permissible for gram.
engines with mechanical injection system).
Special diesel fuels can be used for arctic cli-
Use commercially available fuels with a sulphur con- mates to -44 °C. I Summer-grade diesel fuel
tent below 0.5 %. The lubricating oil change intervals II Winter-grade diesel fuel
If it is necessary to use summer diesel fuel below
must be halved at a higher sulphur content. A Outdoor temperature
0°C, paraffin can also be added by up to 30 % as per
If other fuels are used which do not meet the require- the diagram on the right. B Percentage of paraffin to be added
ments of the operating manual, the warranty will be Usually a sufficient cold resistance can be achieved
voided. by adding a flow improver. Ask your DEUTZ partner.
The certification measurements to satisfy the legal
emission limits are performed with the test fuels de-
fined by law. These correspond to the diesel fuels
according to EN 590 and ASTM D 975 described in
this operating manual. No emission values are guar-
anteed with the other fuels described in this operat-
ing manual.
36 © 2007
Coolant Operating media
General Total hardness or carbonate hardness too
low:
Please contact your DEUTZ partner if the DEUTZ
cooling system corrosion protection agent is not 4
Never operate the engine without coolant Mixing with harder water (harder water is usually available.
(even for a short time)! available in the form of drinking water). The cooling system must be monitored regularly.
Chlorides and/or sulphates too high: This also includes checking the coolant system cor-
In liquid-cooled engines, the coolant must be condi- Mixing with softened water (pH neutralized con- rosion protection agent concentration in addition to
tioned and monitored, otherwise the engine could be densate or water softened by ion exchanger). checking the coolant level.
damaged by:
Cooling system corrosion protection The cooling system corrosion protection agent con-
corrosion agent centration can be checked with conventional test in-
cavitation struments (e.g. refractometer).
freezing Health damaging nitrous amines form
Cooling sys- Water percent- Cold protec-
when nitrite-based cooling system corro-
Water quality tem corrosion age tion up to
sion protection agents are mixed with
protection
The right water quality is important for conditioning amine-based agents!
agent percent-
the coolant. Clear, clean water within the following
age
analysis values should always be used: Cooling system corrosion protection agents
must be disposed of in an environmentally min. 35 % 65 % -22 °C
Analysis values min max friendly way. 40 % 60 % -28 °C
ph value at 20 °C 6,5 8,5 max. 45 % 55 % -35 °C
The conditioning of the coolant for liquid-cooled
Chloride ion content [mg/dm 3] - 100
DEUTZ compact engines is performed by mixing an At temperatures below -35 °C, please contact your
Sulphate ion content [mg/dm 3] - 100 anti-freeze with corrosion protection inhibitors based responsible DEUTZ partner.
Total hardness [°dGH] 3,0 12,0 on ethylene glycol into the water.
It is possible to use other cooling system corrosion
(carbonate hardness
DEUTZ cooling system corrosion protection protection agents (e.g. chemical corrosion protection
percentage of the total
agent agents) in exceptional cases. Consult your DEUTZ
hardness min. 3 dGH) partner.
Container Order number
Specifications of the water quality are made by the
local water board. 5 litre container 0101 1490
pH value too low: 20 litre container 0116 4160
Addition of diluted sodium or potassium lye. 210 litre barrel 1221 1500
Small trial mixtures are advisable.
This cooling system corrosion protection agent is
Total hardness too high:
free from nitrite, amine and phosphate and is adapt-
Mixing with softened water (pH neutralized con- ed to the materials in our engines. Order from your
densate or water softened by ion exchanger). DEUTZ partner.
© 2007 37
Maintenance Maintenance schedule
5 Assignment of the DEUTZ maintenance and service schedules to maintenance intervals
Standard maintenance schedule Standard and EPA 1) certified engines

TD/TCD 2012 L04/06 2V and TD/TCD 2013 L04/06 2V
Stage Activity see To be carried Industrial engines/Agricultural technology
out by (every .... oh)
E10 Initial commissioning Authorised spe- For measures to be taken during the run-in phase or commissioning of new or overhauled
cialists engines, see ( 27)
E20 Daily inspection Customer 1x daily or ev ery 10 operating hours in continuous operation
E30 Maintenance 2) 4) 500 oh 3)
E40 Extended maintenance I 1,000 oh
E45 Interim stage 2,000 oh
E50 Extended maintenance II Authorised spe- 3,000 oh
E60 Intermediate overhaul cialists (only for EPA) 6,000 oh
E70 General overhaul 12,000 oh
1) EPA (Environmental Protection Agency).

2) The oil load may be high depending on the application. Shorter maintenance intervals are necessary for this 250 oh.
3) Data for lubricating oil change interval, in relation to lubricating oil quality DQC III.
4) For engines TD/TCD 2012 L04 2V with mechanical injection system, which are predominantly operated at a high load and a high s peed, the lubricating oil change
interval is reduced to 250 h.
*If the water level warning system (lamp/siren) responds, the fuel pre-filter must be emptied immediately.
Changing the pre-filter cartridge depends on the degree of dirt contamination of the fuel being used. If other fuels are used w hich do not meet the requirements of the
operating manual, the warranty will be voided.
38 © 2007
Maintenance schedule Maintenance
Maintenance measures
A self-adhesive maintenance diagram is provided with every engine. This should be stuck to the engine or device in a prominent position.
5
Order number: 0312 2450 (TCD 2012 2V) and 0312 2451 (TCD 2013 2V)
Stage Measure Page

E10 The measures are listed in chapter 3. 27
E20 Check Lubricating oil level (if necessary top up) 41
Coolant level (top up if necessary) 48
Engine tightness (visual inspection for leaks) 27
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 51
E30 Clean Fuel pre-filter with water trap (renew the filter insert if necessary). If the warning system responds (lamp/horn), the 47
water trap bowl must be emptied immediately.
Check V-belts (retension or renew if necessary) 54
Coolant (additive concentration) 48
Coolant level (top up if necessary) 48
Replace Lubricating oil (lubricating oil change intervals depending upon the engine application). xxxxxxxx 35
Lubricating oil filter/insert (every time the lubricating oil is changed) 42
E40 Check Charge air cooler (drain lubricating oil and condensation) 48
Check glow plugs and heating flange for functioning. 30
Check valve in the injection pump (only for mechanical injection system) 33
Battery and cable connectors 60
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel 31
Filter cartridge of the crank space ventilation valve
Tighten engine mountings, if necessary (renew in case of damage) 75
Fastenings, hose unions / clips (renew if damaged)
Replace Fuel filter insert (main filter) 47
Suction air filter/dry air filter (maintain in accordance with maintenance indicator) 51
Fuel pre-filter with water trap (renew the filter insert if necessary). If the warning system responds (lamp/horn), the 47
water trap bowl must be emptied immediately.
© 2007 39
Maintenance Maintenance schedule
5 Stage
E45 Check
Measure
if necessary, set control piston clearance for exhaust gas recirculation (optional).
Page
59
Valve clearance (set if necessary, earlier if there is any noise) 56
E50 Check V-rib belt and tensioning pulley (replace if wear limit is fallen below) 55
Replace V-belt, V-rib belt and tensioning pulley 54
Injection valve (only for EPA and only for mechanical injection system)
E60 Check Electronic injector test via EMR3 (only for DEUTZ Common Rail System) 65
Replace V-rib belt and tensioning pulley 54
Injection valve (only for EPA and DCR)
Crankcase ventilation valve (only for EPA)
annually Clean Charge air cooler inlet area (drain condensation), (only for EPA) 48
Replace Fuel pre-filter (renew the filter insert if necessary). 47
Engine monitor, warning system Maintenance only to be carried out by authorised service personnel 31
Every 2 Replace Coolant (additive concentration) 48
years V-belt, V-rib belt and tensioning pulley 55
Check Crankcase breather valve
40 © 2007
Lubricating oil system Care and maintenance work
Regulations for working on the lubricat-
ing oil system
Checking the lubricating oil level Pour in lube oil.
– Quality/viscosity data. 6
Low lubricating oil level or overfilling lead to – Filling volume ( 71 ).
Do not work when the engine is running! engine damage! Check engine lubricating oil level (see previous
Smoking and naked lights prohibited! The lubricating oil level may only be chapter).
Danger of scalding from hot lubricating oil! checked with the engine in a horizontal po-
sition and switched off.
Original DEUTZ filters must be used when If the engine is warm, switch off the engine
changing filters. and check the lubricating oil level after 5
Pay attention to utmost cleanliness when minutes. If the engine is cold you can check
working on the lubricating oil system. Clean it immediately.
the area around the components con-
cerned carefully. Blow damp parts dry with Be careful of hot lubricating oil. Danger of
compressed air. scalding!
Observe the safety regulations and nation-
al specifications for handling lube oils. Pull out the lubricating oil dipstick and wipe off
Dispose of leaking lubricating oil and filter with a lint-free, clean cloth.
elements properly. Do not allow used oil to Insert the lubricating oil dipstick as far as it will
seep away into the ground. go.
Perform a trial run after all work. Pay atten-
Extract the lubricating oil dipstick and read off the
tion to tightness and lubricating oil pressure
oil level.
and then check the engine oil level.
In case of fuels containing more than 1% The oil level must always be between the MIN
and MAX marks! Top up to the MAX mark if nec-
sulphur, contact your service representa-
tive. essary.
Changing the lubricating oil
Warm up the engine (lubricating oil temperature
> 80 °C).
Ensure that the engine or vehicle is in a level po-
sition.
Switch off the engine.
Place a collecting receptacle underneath the
lube oil drain screw.
Unscrew the lube oil drain screw, drain oil.
Fit a new sealing ring to the lube oil drain screw,
insert and tighten. (tightening torque 100 Nm).
© 2007 41
Care and maintenance work Lubricating oil system
Change lubricating oil filter Oil the gasket of the new DEUTZ original filter
cartridge lightly.
The filter cartridge should never be pre- Screw on new filter by hand until the gasket is in
filled. There is a danger of dirt contamina- place and then tighten with a torque of 15-17 Nm.
tion! If necessary, fix the clips of the anti-rotation lock.
Remove the clips if an anti-rotation lock is fitted.
Loosen and unscrew the filter cartridge with the
tool (order no. 170050) .
Collect draining lubricating oil
Clean the sealing surface of the filter support
with a lint-free, clean cloth.
42 © 2007
Lubricating oil system Care and maintenance work
6
Replace lubricating oil filter cartridge Collect any lubricating oil that may escape. Replace round sealing ring (2) and grease light-
Bend the paper filter cartridge (5) in the collecting ly.
The filter cartridge should never be pre- vessel slightly sideways until the cartridge Press new paper filter cartridge (5) into the clamp
filled. There is a danger of dirt contamina- comes off the clamp (6). (6) and carefully insert into the guide (4).
tion! Clean any dirt from the sealing area of the filter Screw in lubricating oil filter cap (1) clockwise (25
media and lubricating oil filter cap (1) as well as Nm).
Switch off the engine. guide (4). Start engine.
Loosen lubricating oil filter cap (1) with 2 to 3
turns and wait 30 seconds.
Unscrew lubricating oil filter cap (1) with paper fil-
ter cartridge (5) anticlockwise.
Carefully loosen paper filter cartridge (5) up-
wards from the guide (4) located in the housing
(3).
Collect any lubricating oil that escapes.
© 2007 43
Care and maintenance work Fuel system
6 Specifications when working on the fuel

system
Pay attention to utmost cleanliness due to
the high production accuracy of the system!
The fuel system must be tight and closed.
Engine must be switched off! Make a visual inspection for leaks/damage
Smoking and naked lights prohibited! in the system.
No injection/high pressure pipes may be Clean and dry the engine and engine com-
disconnected while the engine is running. partment thoroughly before beginning
Caution when handling hot fuel! work.
Pay attention to utmost cleanliness when Areas of the engine compartment from
refuelling and working on the fuel system. which dirt could be loosened must be cov-
Clean the respective affected parts careful- ered with a fresh, clean foil.
ly. Blow damp areas dry with compressed Work on the fuel system may only be car-
air. ried out in an absolutely clean environment.
Observe the safety regulations and nation- Contamination of the air such as dirt, dust,
al specifications for handling fuels. moisture etc. must be avoided.
Dispose of leaking fuel and filter elements
properly. Do not allow fuel to seep away Change the fuel filter cartridge
into the ground.
After all work on the fuel system, the sys- The filter cartridge should never be pre-
tem should be vented, a trial run performed filled. There is a danger of dirt contamina-
and the tightness checked. tion!
It will be necessary to vent the fuel system
when commissioning for the first time, after Remove the clips if an anti-rotation lock is fitted.
maintenance work or if the tank has been Loosen and unscrew the filter cartridge with the
run dry. tool (order no. 170050) .
Catch any escaping fuel.
Original DEUTZ filters must be used when Clean the sealing surface of the filter support
changing filters. with a lint-free, clean cloth.
Oil the gasket of the new DEUTZ original filter
cartridge lightly.
Additional venting of the fuel system by a 5 Screw on new filter by hand until the gasket is in
minute trial run at idle speed or on low load place and then tighten with a torque of 15-17 Nm.
is absolutely essential.
If necessary, fix the clips of the anti-rotation lock.
Vent the fuel system.
44 © 2007
Fuel system Care and maintenance work
6
Replace fuel filter cartridge Collect any fuel oil that escapes. Replace round sealing ring (2) and grease light-
Bend the paper filter cartridge (5) in the collecting ly.
The filter cartridge should never be pre- vessel slightly sideways until the cartridge Press new paper filter cartridge (5) into the clamp
filled. There is a danger of dirt contamina- comes off the clamp (6). (6) and carefully insert into the guide (4).
tion! Clean any dirt from the sealing area of the filter Screw in fuel filter cap (1) clockwise (25 Nm).
media and fuel filter cap (1) as well as guide (4). Start engine.
Switch off the engine.
Loosen lubricating oil filter cap (1) with 2 to 3
turns and wait 30 seconds.
Unscrew fuel filter cap (1) with paper filter car-
tridge (5) anticlockwise.
Carefully loosen paper filter cartridge (5) up-
wards from the guide (4) located in the housing
(3).
Catch any escaping fuel.
© 2007 45
Care and maintenance work Fuel system
6 Empty emulsion in the water collection vessel

and clean the vessel.
Connect connectors of the water level sensor
(9).
– The special tool can be ordered under part Open the fuel supply to the engine.
number 8192 ( 77). Vent the fuel system.
Screw together the filter insert (2) and water col- Vent the fuel pre-filter.
lection vessel (3). Wet the sealing surfaces (8) of
the filter insert (2) and the water collection vessel Loosen the venting screw (7) slightly.
(3) with fuel. Operate the pump until fuel emerges without
Assembly in clockwise direction. bubbles.
Open the fuel shutoff tap and vent the system, Tighten the venting screw (7).
see venting the fuel system. Vent engine
Check for leaks after starting the engine.
Bring engine control to stop position.
Change the fuel pre-filter insert Position fuel collecting vessel below the con-
Shut off the fuel supply to the engine (with high- stant-pressure valve in the crankcase/filter hous-
Clean/Replace/Vent fuel pre-filter (for me- level tank). ing.
chanical injection system) Place water collection vessel (3) underneath the Open constant-pressure valve in the crankcase/
pre-filter. fuel stopcock in the filter housing.
1 Fuel pre-filter holder
Disconnect the plug of the optional water level Turn over the engine with starter (max. 20 Sec.)
2 Filter insert until bubble-free fuel emerges at the constant-
3 Water collecting vessel (bowl) sensor (4).
pressure valve in the crankcase/filter housing.
4 Electrical connection Open the drain tap (5) and drain off the liquid.
Screw in ventilation screws (tightening torque
5 Drain plug Unscrew the filter insert (2) together with the wa-
25-5 Nm) and constant-pressure valve.
6 Fuel manual supply pump ter collection vessel (3).
Unscrew the water collection vessel (3) from the Bring engine control to the start position and
7 Venting screw start.
filter insert (2).
8 Sealing surface Check for leaks after starting the engine.
Clean the water collection vessel (3) and all the
9 Connection for electrical water level sensor
existing sealing surfaces with a brush and diesel
warning lamp/horn
fuel.
Close fuel shutoff tap (with high-level tank). Oil the gaskets of the new DEUTZ original filter
Place fuel collection vessel underneath the fuel insert (2) lightly or wet with diesel fuel.
pre-filter. Screw the water collection vessel (3) to the filter
Release the water drain tap (5) and drain the fuel insert (2).
completely. Screw new filter insert (2) to the filter holder
Unscrew the filter insert (2) with water collection (tightening torque 17-18 Nm).
vessel (3) in anticlockwise direction and remove.
46 © 2007
Fuel system Care and maintenance work
pre-filter.
Release the water drain tap (7) + drain the fuel
Lock bayonet lock of the fuel manual pump (3) by
pressing and turning clockwise at the same time. 6
completely. Start the engine and operate approx. 5 minutes
Unscrew the filter insert (5) with water collection in idling mode or at low load. Check the pre-filter
vessel (8) in anticlockwise direction and remove. for leaks while doing this.
Close fuel shutoff tap (with high-level tank).
Loosen water collecting vessel (8) anticlockwise
from the old filer cartridge (5) and remove.
– The special tool can be ordered under part
number 8192 ( 77).
Drain remaining fuel into the fuel collecting ves-
sel and clean water collecting vessel (8).
Screw water collecting vessel (8) clockwise onto
ïï the new filter cartridge (5).
Clean any dirt from the sealing area of the new
Clean/purge or change the fuel pre-filter filter cartridge (5) and opposite side of the filter
(for the DCR system) head.
1 Fuel supply flow to the pump Lightly moisten sealing areas of the filter car-
2 Fuel return flow from the control block FCU (Fuel tridge (5) with fuel and screw onto the filter head
Control Unit) again clockwise (17-18 Nm).
3 Fuel manual pump with bayonet lock for locking Open the fuel shutoff tap and vent the system,
and unlocking see venting the fuel system.
4 Thermostat valve with stop lever (optional) Properly dispose of the collected fuel and old fil-
5 Filter insert ter cartridge (5).
6 Connection option for electrical water level sen- Vent the fuel system
sor
7 Water drain tap Unlock bayonet lock of the fuel manual pump (3)
8 Water collecting vessel (bowl) by pressing and turning anticlockwise at the
same time. The pump piston is now pressed out
9 Fuel inlet from the fuel tank
by the spring.
10 Fuel return to fuel tank
Keep pumping until a very strong resistance can
11 Connection for electrical warning lamp/horn
be felt and the pumping only progresses very
Filter replacement slowly.
Now continue pumping several times. (The re-
Close fuel shutoff tap (with high-level tank). turn line must be filled).
Place fuel collection vessel underneath the fuel
© 2007 47
Care and maintenance work Cooling system
6 Specifications when working on the cool-

ing system
Danger of scalding from hot coolant!

Cooling system under pressure! Only open
the cap when cool!
The coolant must have a prescribed con-
centration of cooling system corrosion pro-
tection agent!
Observe safety regulations and national
specifications when handling cooling me-
dia.
Observe the manufacturer's specifications
for an external cooler.
Dispose of leaking liquids properly and do
not allow them to seep into the ground.
Order coolant corrosion protection agent Check coolant additive concentration Emptying the cooling system
from your DEUTZ partner.
Never operate the engine without coolant Open the cooling system cap (1) carefully. Open the cooling system cap (1) carefully.
(even for a short time)! Check the coolant additive concentration in the Ensure that the engine or vehicle is in a level po-
cooler/compensation tank (2) with a convention- sition.
Checking the coolant level with an exter- al freeze protection measuring instrument (1) Remove the locking screw (1) in the crankcase.
nal cooler (e.g. hydrometer, refractometer).
Drain coolant.
Fill in new coolant and vent the system according Necessary coolant additive concentration Cool-
Tighten locking screw (1) again.
to the specifications of the cooling system manu- ant mixing ratio ( 37).
If the locking screw (1) is not accessible, the
facturer. You can order the appropriate test instrument from drainage can be carried out at the engine oil
Open the cooling system cap (1) carefully. your DEUTZ partner under order number 1824. cooler (coolant duct).
The coolant level must always be between the
MIN and MAX marks of the compensation tank!
Fill up to the MAX mark if necessary.
48 © 2007
Cooling system Care and maintenance work
6
Fill the cooling system Fill and ventilate cooling system
Open the cooling system cap (1) carefully. Open cooler locking cap.
Fill up coolant to the MAX mark on the compen- Remove locking screw.
sation tank and close the cooling system cap (1). Fill with coolant as far as the max. marking or fill-
Switch on any available heating and set to the ing limit (heating valve of the system must be
highest level so that the heating circuit is filled opened, if necessary).
and vented. Screw in locking screw again and tighten.
Run engine up to operating temperature (open- Start the engine and warm up until the thermo-
ing temperature of the thermostat). stat opens.
Switch off the engine. Check coolant level when the engine is cold and
Check coolant level in cooled engine and top up refill if necessary.
to the MAX mark on the compensation tank if Close cooler locking cap.
necessary. The cooling system (insofar as installed in com-
pliance with our installation guidelines) is auto-
matically drained after filling.
© 2007 49
Care and maintenance work Engine cleaning
6 Cleaning work Cleaning with cold cleaner

Spray the engine with cold cleaner and leave it
For all cleaning work, make sure that no
for about 10 minutes to take effect.
parts are damaged (e.g. bent cooler mesh).
Cover electrical/electronic parts and con- Spray the engine clean with a high pressure wa-
nections to clean the engine (e.g. control ter jet.
units, generator, solenoid valves etc.). Do Warm up the engine so that the water residues
not aim the water/steam jet directly at them. evaporate.
Allow engine to warm up. Cleaning with a high pressure cleaner
Always clean the cooler and cooling fins from the
Only carry out cleaning work on the engine
exhaust air side to the fresh air side.
when it is not running!
Remove the engine cover and cooling air Warm up the engine so that the water residues
cover if available and remount after clean- evaporate.
ing.
General
The following causes of soiling make it necessary to
clean the engine:
High dust content in the air.
Chaff and chopped straw in the area of the en-
gine.
Coolant leaks
Lubricating oil leakage
Fuel leaks
Because of the different application conditions,
cleaning depends on the degree of dirt contamina-
tion.
Cleaning with compressed air
Blow dirt off or out. Always blow out the cooler
and cooling fins from the exhaust air side to the
fresh air side.
50 © 2007
Suction system Care and maintenance work
Regulations for working on the intake
system 6
Do not work when the engine is running!
Pay attention to utmost cleanliness when

working on the intake system, close intake
openings if necessary.
Dispose of old filter elements properly.
Maintenance indicators for dry air filter

The dry air filter is maintained according to a
maintenance switch or maintenance indicator.
Maintenance is necessary when:
– the yellow warning light of the maintenance
switch lights up when the engine is running.
– the red field (1) of the maintenance indica-
tor is fully visible.
After carrying out maintenance work, reset the
signal by pressing the button on the mainte-
nance indicator. The maintenance indicator is
now ready for operation again.
© 2007 51
Care and maintenance work Suction system
6 Renewing the safety cartridge of the dry

air filter
Never clean the safety cartridge (4).
Renew safety cartridge (4) according to the inter-

val in the maintenance schedule
To do this:
– Unscrew hexagon nut (5), pull out safety car-
tridge (4).
– Insert new safety cartridge, screw on hexag-
onal nut.
Insert filter element (3), mount hood (2) and fix
with clamping yoke (1).
Clean the dust discharge valve of the dry Maintaining the dry air filter
air filter
Empty the dust discharge valve (1) by pressing Do not clean the filter element (3) with pet-
together the discharge slit. rol or hot liquids!
Renew damaged filter elements.
Remove any caked dust by pressing together the
upper section of the valve. Maintain the filter element (3) according to the in-
Clean the discharge slit. terval in the maintenance schedule
Lift up the clamping yoke (1).
Remove the filter hood (2) and pull out the filter
element (3).
Filter element (3):
– blow out with dry compressed air (max. 5
bar) from the inside to the outside if soiling is
only slight,
– renew if heavily soiled.
52 © 2007
Suction system Care and maintenance work
renew if damaged.
Fill the lubricating oil pan (3) of the oil bath air fil- 6
ter with engine oil up to the mark (arrow).
Mount the lubricating oil pan (3) with filter insert
(4) on the filter housing (1) and close the quick
release clamps (2).
Start engine and check for tightness.
Emptying the cyclone precleaner Cleaning oil bath air filter
Never fill the dust container (3) with lubri- Never clean the filter with petrol!
cating oil!
Loosen wing nut (1) and lift off housing cover (2).
Dispose of the old lubricating oil in accord-
Remove the dust container (3) from the base (4) ance with the regulations. Select the en-
and empty it. Clean the container using a brush gine lubricating oil according to the
and clean diesel fuel. Then dry.
requirements before filling the filter.
Place the dust container (3) on the base (4) and
tighten the housing cover (2) with wing nut (1). Shut down engine and wait about 10 minutes un-
til the lubricating oil has collected in the lubricat-
ing oil pan (3).
Loosen the quick release clamps (2) and remove
the lubricating oil pan (3) with filter insert (4).
Dispose of dirty lubricating oil.
Clean lubricating oil pan (3), filter cartridge (4)
and filter housing (1) with a brush and clean die-
sel fuel.
Visually inspect the rubber gaskets (5), (6) and
© 2007 53
Care and maintenance work Belt drives
Checking the belt drive Checking the belt tension Replace V-rib belt
Lower indicator arm (1) into the measuring de- Press tensioning pulley (1) with pin wrench (3) in
Only carry out work/function check on the vice.
belt drive when the engine is not running! the direction of the arrow until a holding pin
Only check / change V-belts when the en- Place guide (3) between two belt pulleys on the Ø 6 mm (4) can be fixed in the assembly bore.
V-belt (2). The stop have to be at the side. The V-rib belt (2) is now free of tension.
gine is not running! Refit the V-belt guard!
Retension the new V-belts after 15 minutes Press the button (4) at right angles to the V-belt First remove the V-rib belt (2) from the smallest
running time. In the event of wear of the (2) evenly until you hear or feel the spring snap pulley or from the tensioning pulley.
double belts or damage to one of the V- in. Mount V-rib belt (2).
belts always replace both belts as a pair. Lift the measuring device carefully without alter- Retain tensioning pulley using the pin wrench
The difference in length of the new V-belts ing the position of the indicator arm (1). and remove the holding pin.
must not exceed 0.15 % one to the other. Read the measured value at the point of inter- Re-tension using the tensioning pulley and pin
section (arrow), scale (5) and indicator arm (1). wrench (3). Check whether the V-rib belt is cor-
Check the whole belt drive visually for damage. If necessary, re-tension belt and measure again. rectly in its guide.
Renew damaged parts.
Remount protective devices if necessary. Tools
Pay attention to correct fit of new belts, check the Belt tension measuring device (order number:
tension after running for 15 minutes. 8115) can be obtained from your DEUTZ partner.
54 © 2007
Belt drives Care and maintenance work
6
Check belt length

Spacing between the nose of the moving ten-
sioning arm and the limit stop of the fixed ten-
sioning housing.
If gap "a" is less than 3 mm, the belt must be re-
placed.
© 2007 55
Care and maintenance work Setting work
6 Setting schematic for the valve and con-

trol piston clearance
Engine TCD 2012/2013, L04 2V
Valve overlap: Exhaust valve is not yet closed, inlet
valve begins to open.
Valve overlap Settings

1 4
3 2
4 1
2 3
Engine TCD 2012/2013, L06 2V
Valve overlap Settings

Check valve clearance, adjust if neces-
sary 1 6
Let the engine cool down for at least 30 minutes 5 2
before setting the valve clearance: Lubricating oil 3 4
temperature below 80 °C. 6 1
Place turning gear over fastening screws of the
belt pulleys. 2 5
Turn the crankcase until reaching valve overlap. 4 3
Outlet valve is not yet closed, inlet valve begins
to open.
The cylinders to be set can be seen in the setting
schematic.
56 © 2007
Setting work Care and maintenance work
6
Set valve clearance (inner exhaust recir- Turn rotation angle disc (3) anticlockwise until
culation) reaching the specified rotation angle:
Engine TCD 2012
This engine is equipped with an internal ex- IN = inlet valve 75°
haust feedback system. EX = outlet valve 120°
4-cylinder: The outlet valve opens briefly in
Engine TCD 2013
the discharge stroke:
IN = inlet valve 90°
6-cylinder: The outlet valve opens briefly in
the suction intake stroke: EX = outlet valve 150°
Do not confuse this with the valve over- Secure the rotation angle disc (3) against twist-
lap! ing.
Tighten locking nut (1).
Loosen locking nut (1) with special tool (order Then set the second valve on the rocker arm as
no.: 8199). described above.
Loosen rotation angle disc (3) (order no.: 8190) Perform the setting procedure on every cylinder.
and place pin wrench insert (4) (order no.: 8193)
on valve clearance setting screw (2).
Fix magnet (5) of the rotation angle disc (3).
Turn rotation angle disc (3) clockwise to the stop
(rocker arm without clearance) and set scale to
zero.
© 2007 57
Care and maintenance work Setting work
Set valve clearance (with internal exhaust Turn rotation angle disc (3) anticlockwise until
gas recirculation EGR connected) reaching the specified rotation angle:
The same setting regulation applies for the outlet Engine TCD 2012
valves as for engines without exhaust gas recircula- IN = inlet valve 75°
tion. Engine TCD 2013
Set inlet valve IN = inlet valve 90°
Secure the rotation angle disc (3) against twist-
Loosen locking nut (6).
ing.
Loosen rotation angle disc (3) (order no.: 8190)
Tighten locking nut (6).
and insert crow foot wrench (8) (order no.: 8199)
Then set the second valve on the rocker arm as
in valve clearance setting screw (7) on inlet
described above.
valve.
Perform the setting procedure on every cylinder.
Fix magnet (5) of the rotation angle disc (3).
Turn rotation angle disc (3) clockwise to the stop
(rocker arm without clearance) and set scale to
zero.
58 © 2007
Setting work Care and maintenance work
6
Set control piston clearance (with inter- Loosen locking nut (1).
nal exhaust gas recirculation EGR con- Place rotation angle disc and pin wrench insert
nected) (order number: 8194) on setting screw (2).
After setting the valve clearance, the control pis- Fix magnet of the rotation angle disc.
ton clearance must be set as follows: Turn rotation angle disc clockwise to the stop
Turn the crankcase until reaching valve overlap (control piston without clearance) and set scale
of the first cylinder. to zero.
Outlet valve is not yet closed, inlet valve begins Turn rotation angle disc anticlockwise until
to open. reaching the specified rotation angle.
The cylinders to be set can be seen in the setting Control piston clearance x: 144°
schematic. Tighten locking nut (1).
Perform the setting procedure on every control
piston.
© 2007 59
Care and maintenance work Electrical system
6 Regulations for working on the electrical

system
Battery
Electronically stored data could be lost if

Do not touch the voltage conducting parts, the battery is disconnected.
faulty warning lamps should be immediate- Keep battery clean and dry.
ly replaced. Make sure the battery is fitted correctly and
securely.
Pay attention to correct polarity of the con- Dispose of old batteries in an environmen-
nections. tally friendly way.
Cover electrical/electronic parts and con-
nections before cleaning the engine (e.g. Danger of explosion! The gases emitted by
control units, generator, solenoid valves the battery are explosive!
etc.) Do not aim the water/steam jet directly Fire, sparks, smoking and naked lights are
at them. Run the engine warm afterwards prohibited!
to evaporate moisture residues. Danger of acid burns! Wear protective
Touching a lead against the frame to check gloves and glasses! Avoid contact with skin
whether it is live must not, under any cir- and clothing! Check acid level
cumstances, be carried out. Danger of short circuit! Do not rest tools on Unscrew caps.
For electrical welding work, the ground ter- the battery! Note the manufacturer’s specifications concern-
minal of the welding gear must be clamped
directly to the part being welded. ing the liquid level.
Three-phase current generator: Never dis- The liquid should normally be 10-15 mm above
connect the cables between battery, gener- the top edge of the plate or reach up to any avail-
ator and regulator while the engine is able control device.
running. Only use distilled water to top up the battery.
Screw in caps.
Checking the voltage
Check the battery voltage with a conventional
voltmeter. The voltage indicates the charging
state. It should be between 12 and 14.4 Volt de-
pending per battery.
Check acid density
Unscrew caps.
Measure the electrolyte density of individual cells
with a commercial hydrometer. Hydrometer
60 © 2007
Electrical system Care and maintenance work
reading indicates battery’s state of charge. The
acid temperature when measuring should be 20
Installing the battery
Insert new or charged battery and attach the fas-
6
°C if possible.
tenings.
Check the acid level before recharging.
Clean the terminals and battery poles with fine
Screw in caps.
emery paper.
Acid density [kg/ l] Charge Measure Connect the plus pole first and then the minus
Normal Tropical status pole. Otherwise there is a danger of short-circuit!
Make sure the terminals have good contact.
1,28 1,23 good none Tighten clamp bolts hand-tight.
1,20 1,12 half charge Grease the assembled terminals with an acid-
1,12 1,08 empty charge free, acid-resistant grease.
Removing the battery

Always disconnect the minus pole first when re-
moving the battery. Otherwise there is a danger
of short-circuit!
Remove the fastenings and take out the battery.
Charging the battery
Unscrew caps.
Charge the battery with a conventional battery
charger. Observe the manufacturer specifica-
tions!
Screw in caps.
© 2007 61
Faults Fault table
7 Faults and remedies
Faults Causes Measures

Engine does not start or is diffi- Not disconnected (if possible) Check coupling
cult to start Engine stop lever still in stop position/Shut-off magnet defective (for mech. Check/replace
injection system)
Below starting limit temperature Check
Lube oil level too high Check lube oil level, if necessary drain off.
Exhaust gas backpressure too high Check
Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Fuel quality does not comply with operating manual Change the fuel
Air in fuel system Vent fuel system
Battery defective or discharged Check battery
Cable connection to starter loose or oxidized Check cable connections
Starter defective or pinion does not engage Check starter
Too high a base load Reduce load
Engine does not start and diag- Engine electronics prevents starting Check error according to error code and eliminate error if
nostic lamp flashes necessary
Engine starts, but runs irregu- Belt/V-rib belt (fuel pump in belt drive) Check whether torn or loose
larly or fails Incorrect valve clearance Settings
Injector defective Change
Injection valve defective Change
Glow plugs defective Change
Air in fuel system Vent
Fuel filter contaminated Clean
Injection line leaks Check injection line
Injection valve defective Check fuel injector / change if necessary
62 © 2007
Fault table Faults
Faults
Speed changes are possible
Causes
Engine electronics has detected a system error and activates an equivalent
Measures
Check error according to error code and eliminate error if
7
and diagnostic lamp lights up speed necessary
Engine becomes excessively Low coolant Fill up
hot. Temperature warning sys- Vent line blocked Clean
tem activates
Coolant heat exchanger soiled Clean
Coolant pump defective (V-rib belt torn or loose) Check whether torn or loose
Lubricating oil level too low Fill up lube oil
Lube oil level too high Check lube oil level, if necessary drain off.
Fan defective/V-rib belt torn or loose Check fan/V-belt, change if necessary
Heat short-circuit in the cooling system Check the cooling system
Resistance in cooling system is too high / flow volume too low Check the cooling system
Engine output is deficient Lube oil level too high Check lube oil level, if necessary drain off.
Lube oil filter contaminated on the air or lube oil side Change
Engine stop lever still in stop position/Shut-off magnet defective (for mech. Check/replace
injection system)
Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
Charge air cooler soiled Clean
Injection line leaks Check injection line
Injection valve defective Check fuel injector
Engine performs poorly and Engine electronics reduce performance Check error according to error code and eliminate error if
diagnostic lamp lights necessary
© 2007 63
Faults Fault table
7 Faults Causes
Engine does not run on all cylin- Injection line leaks
Measures
Check injection line
ders Injection valve defective Check fuel injector / change if necessary
Engine lubricating oil pressure Lubricating oil level too low Fill up lube oil
is non-existant or excessively Excessive inclination of engine Check engine mounting / reduce inclination
low
Wrong SAE viscosity class of the engine lubricating oil Change the lubricating oil
Engine lubricating oil consump- Lube oil level too high Check lube oil level, if necessary drain off.
tion excessive Excessive inclination of engine Check engine mounting / reduce inclination
Too long an operation in low idle or too low a load Load change
Engine producing blue smoke Lube oil level too high Check lube oil level, if necessary drain off.
Excessive inclination of engine Check engine mounting / reduce inclination
Too long an operation in low idle or too low a load Load change
Engine producing white smoke Below starting limit temperature Check
Engine producing black smoke Air filter clogged / turbocharger defective Check/replace
Air filter maintenance switch / maintenance indicator defective Check/replace
Charge air line leaking Check charge air line
64 © 2007
Engine management Faults
Engine protection function of the EMR3
system
Use of the diagnostic key
With the diagnostic key (1), it is possible to read out
7
the existing errors as blink codes. The diagnostic key
The error lamp goes out when all the errors
have been eliminated. For some errors, it is (1) and the error lamp (2) are accommodated in the
vehicle drive stand.
necessary to switch off the ignition, wait 30
s and only then switch back on the ignition. The occurrence of errors is indicated by flashing or
steady lighting of the error lamp (2). To get more de-
Depending on the design of the monitoring functions, tailed information about all the existing errors, these
the EMR3 can protect the engine from damage in can be read out in the following way in the form of
certain error situations by monitoring important limit blink codes only when the engine is at a standstill:
values during operation and checking the correct After pressing the diagnostic key (1) for at least one
functioning of the system components. second, the error lamp (2) goes out and the first error
is output after releasing the key as a blink code.
The appropriate monitoring functions are Evaluate blink code according to the table overleaf.
switched off when a sensor fails. Only the After outputting the error blink code, the error lamp
sensor failure is documented in the error (2) goes out for five seconds.
memory. Table of error blink codes
Then the next error (i.e. the following one in the error
The possible blink codes, their meanings and meas-
Depending on the severity of a detected error, the memory) can be displayed by pressing the diagnos-
tic key (1) again. If the last error was displayed, the ures for eliminating the errors can be taken from the
engine can continue to run with restrictions, whereby table on the next page. The blink code values in the
the error lamp lights permanently or the error lamp first error is displayed again on pressing the diagnos-
first column indicate the number of short blink signals
indicates a serious system error by flashing. In this tic key (1) again.
to be initiated (duration alight approx. 0.4 s), the
case, the engine must be switched off as soon as it number of subsequent long blink signals (duration
is safe to do so. The flashing error lamp may have alight approx. 0.8 s) and the number of short termi-
the following meaning depending on the motor con- nating blink signals. The code 2-1-4 of the "over-
figuration: speed" error is made up of two short, one long and
Switch off prompt for the operator. Attention: two short blink signals for example. If an error cannot
Failure to do so will lead to loss of guarantee! be eliminated by the measures listed in the table,
Automatic shutdown of the engine after a short please contact your responsible DEUTZ partner.
warning time, possibly in connection with a start
lock.
Engine forced to run at low idle speed to cool the
engine, with automatic shutdown if necessary.
Start lock
© 2007 65
Faults Engine management
7 Error code table
Blink code Function/component Error

Short (0.4 s) Long (0.8 s) Short (0.4 s)
1 2 3 Output to coolant temperature lamp Signal defective, control unit overtemperature
1 2 6 Speed manual setting Faulty/implausible signal
1 2 8 Intake air temperature sensor Signal defective
1 3 3 Transmission oil temperature sensor Signal defective
1 3 4 Rail pressure monitoring Signal implausible, pressure/pressure deviation outside the permissi-
ble range
1 3 5 Output to lubricating oil pressure warning lamp Signal defective, control unit overtemperature
Output to valve of the fuel metering unit Signal defective, control unit overtemperature
1 3 6 Monitoring air filter Air pressure after filter too low
1 3 7 Output to actuators Short-circuit to battery
1 3 8 Output to actuators Short-circuit to earth
1 4 2 Output to engine operation lamp Signal defective, control unit overtemperature
1 4 3 Multistage switch 1 / 2 / 3 Faulty/implausible signal
1 4 4 Lubricating oil temperature sensor Faulty/implausible signal
Monitoring of lubricating oil temperature Temperature outside nominal range
1 4 5 Override switch monitoring Signal implausible
1 4 6 Rail pressure reducing valve Valve open/Pressure surge necessary/No opening after pressure
surge
1 4 7 Rail pressure sensor Signal defective, pressure deviation outside the permissible range
2 3 1 Monitoring lubricating oil pressure Pressure pressure outside the nominal range
2 3 2 Monitoring coolant temperature Temperature above the nominal range
2 3 3 Monitoring suction intake air temperature Temperature above the nominal range
2 3 5 Monitoring coolant level Level below nominal range
2 3 7 Monitoring fuel temperature Temperature outside nominal range
66 © 2007
Engine management Faults
Blink code
Short (0.4 s) Long (0.8 s) Short (0.4 s)
Function/component Error
7
2 3 8 Output to fan actuator 1 / 2 Signal defective, control unit overtemperature
Monitoring fan speed Speed outside the nominal range
2 4 1 Monitoring combustion Misfiring detected in one or more cylinders
2 6 1 Monitoring of output to actuators Relay does not open or opens with delay, short-circuit to earth
2 6 3 Output to cold-start aid Signal defective, relay defective, jams or wrongly connected, short-
circuit
2 7 1 CAN bus Timeout of one or several send messages, bus inactive
2 8 2 Sensor supply voltage 1 / 2 / 3 Voltage outside the nominal range
2 9 2 Atmospheric pressure sensor Faulty/implausible signal
3 1 4 Hydraulic oil temperature sensor Signal defective
Monitoring hydraulic temperature Temperature outside nominal range
3 1 8 Monitoring battery Voltage outside the nominal range
3 2 8 Output to cold-start aid pilot lamp Signal defective, control unit overtemperature
4 1 4 Output to external EGR actuator Signal defective
4 1 5 Output to external EGR actuator Signal defective, control unit overtemperature
4 1 6 Output to external EGR actuator Signal defective
4 1 7 Lubricating oil wear time measuring device Critical time reached
5 1 2 Output to starter relay Signal defective, control unit overtemperature
5 1 3 Output to error lamp Signal defective, control unit overtemperature
5 1 4 Monitoring terminal 15 No signal detected
5 1 5 Monitoring terminal 50 Permanent signal detected
5 2 1 Speed measurement Travelling speed implausible
5 2 8 Output to internal engine brake Signal defective
All other blink codes: Please consult your DEUTZ partner.
Behaviour in case of error Signal faulty/implausible: Carry out function test on the parts concerned; check wiring and plugs for short-circuits, breaks and corrosion. Output
to external EGR actuator.
© 2007 67
Transport and storage Transport
Suspension equipment
Danger to life!
Always use proper suspension equipment when The engine may tip over or fall down if sus-
transporting the engine. pended incorrectly!
The suspension device (1) must be adjustable
for the engine's centre of gravity. The fastening attachment cannot be fixed se-
After transportation and before commissioning of curely above the centre of gravity (1).
engine: remove attachment eyes (2). The fastening attachment can slip, the engine
swings backwards and forwards (1).
Too short a fastening attachment causes bend-
ing torques in the transport device (2) and can
damage it.
68 © 2007
Protecting the engine against corrosion Transport and storage
General
Engines contain the following types of corrosion pro-
rosion protection agent in a corrosion protection
run of the engine.
fluid system (cooling water with cooling system
protection agent). 8
The corrosion protection run can be performed Cooling air system, see section Exterior corro-
tection:
once to protect the different systems: sion protection.
Interior corrosion protection In engines of the oil-cooled series the circulating
Exterior corrosion protection Fuel system
lubricating oil serves simultaneously for cooling.
Fill the fuel tank with a mixture of: The cooling chambers are protected automati-
Your DEUTZ partner has the right corro-
– 90 % distilled fuel cally against corrosion with the lube oil system.
sion protection agent for your needs.
– 10 % corrosion protection oil SAE 20W-20 If a coolant with corrosion protection properties is
Perform a corrosion protection run with no load poured into liquid-cooled engines, no further ac-
The following measures for corrosion protection af-
ter taking the engine out of operation meet the re- for at least 5 minutes. tion is necessary after draining.
quirements for 12 months corrosion protection. If not, the coolant must be drained and, to ensure
Lubricating oil system the formation of a covering layer on the inside
The following corrosion protection work may only be surfaces of the cooling system, a corrosion pro-
carried out by persons familiar with it and instructed Drain lubricating oil from warm engine.
tection run performed with a mixture of:
in the potential dangers. Thoroughly clean lube oil tray, cylinder head with
– 95 % treated water
If these measures are deviated from by exposing the rocker arms, valves, valve springs with diesel
fuel or cleaning agent. – 5 % corrosion protection agent
corrosion-protected engines or parts to unfavourable The duration of the corrosion protection run and
conditions (installation outdoors or storage in damp, Fill the engine with corrosion protection oil SAE
20W-20 up to the MAX mark and perform a cor- the concentration of the corrosion protection
badly aired places) or damage to the corrosion pro- agent are specified by the manufacturer of the
tection layer, a shorter corrosion protection duration rosion protection run for at least 5 minutes so
that all the components of the lubricating oil sys- corrosion protection agent.
is to be expected.
tem are wetted or wet all accessible parts with Then drain the coolant.
The engine corrosion protection should be checked corrosion protection oil and pump corrosion pro-
about every 3 months by opening the covers. If cor- Air intake pipes
tection oil through the engine with a separate
rosion is detected, the corrosion protection should pump until all bearings and bearing liners are After the corrosion protection run, remove the
be renewed. wetted. cylinder head cover and deinstall injectors. The
At the end of the corrosion protection work the crank respective piston must be set to LT.
drive may no longer be turned so that the corrosion Air compressor
The accessible part of the cylinder liner should
protection agent in the bearings, bearing liners and If a compressor is installed, a corrosion protec- be coated with corrosion protection oil with a
cylinder liners is not scraped off. tion agent must be sprayed into the compressor spray lance through the opening.
Before operating a corrosion protected engine, the suction system after shutting down the engine Spray corrosion protection oil SAE 20W-20 into
corrosion protection must be removed. until it emerges visibly from the pressure nozzle. the suction air intake line.
Interior corrosion protection Cooling system Exterior corrosion protection

Interior corrosion protection is always provided Depending on the series the engines are The engine must be cleaned thoroughly with a
by wetting of the walls with the implemented cor- equipped with cooling air, cooling oil or cooling cleaning agent before exterior corrosion protec-
© 2007 69
Transport and storage Protecting the engine against corrosion
8 tion. Any signs of corrosion and damage to the

paintwork must be removed.
Also close the fuel/tank/supply line to the
engine so that the sensitive rail system is
should be purged with fresh water for about 15
minutes before filling.
Cooling air system in air-cooled engines protected against dirt and dust. Protect the Removal of exterior corrosion protection
electronics against moisture/corrosion.
The air guidance compartment of the engines is All areas and components coated with corrosion
unpainted and must be sprayed with a corrosion Storage and packaging protection agent must be washed off with dis-
protection agent. After being protected against corrosion, the en- tilled fuel or a suitable cleaning agent.
gine must be stored in a dry, ventilated hall and Wash out grooves of V-belt pulleys if necessary.
Bare exterior surfaces and parts
suitably covered. Mount V-belts or V-rib belts as specified.
Coat or spray all bare exterior parts and surfaces The cover must be placed loosely over the en- Fill with coolant.
(e.g. flywheel, flange faces) with corrosion pro- gine so that the air can circulate around it to pre- Connect fuel/tank/supply line to the engine. Pay
tection agent. vent condensation from forming. Use a desiccant attention to cleanliness.
if necessary. Start the engine.
Rubber parts
Rubber parts (e.g. muffs) which are not painted Removal of corrosion protection
over must be rubbed down with talcum powder. The corrosion protection must be removed from
Belt drive the corrosion protected engine before starting.
The packaging and all covers over the closed
Remove V-belts and V-rib belts and store openings must be removed.
packed. Any corrosion deposits and paint damage should
Spray V-belt pulleys and tension rollers with cor- be remedied.
rosion protection agent.
Toothed belts for engine control may not be re- Fuel system
moved. If there is a mixture of diesel fuel/corrosion pro-
tection oil in the fuel tank, drain it.
Engine openings
Fill the fuel tank and fuel system with the proper
All engine openings must be fitted with air-tight, fuel.
water-tight covers to delay the vapourisation
process of the corrosion protection agents. Coolant system
With installed air compressor, the suction and If the implemented corrosion protection agent is
pressure connection must be sealed by a cap. compatible with the intended cooling system pro-
Air should be excluded to avoid ventilation of the tection agent, this can be filled directly into the
engine (chimney effect) for the suction from an coolant system as specified.
air supply pipe. If it is uncertain whether the implemented corro-
sion protection agent is compatible with the cool-
ing system protection agent, the cooling system
70 © 2007
Engine and setting data Technical data
General technical data
9
Engine type TD/TCD 2012 L04 2V TCD 2012 L06 2V
No. of cylinders 4 6
Cylinder arrangement upright in row
Bore [mm] 101
Stroke [mm] 126
3
Engine swept volume [cm ] 4038 6067
Compression ratio 18
Functional principle/combustion method Four-stroke diesel with charging and direct injection
Charge air cooler without/with with
Charge air temperature outlet at rated power [°C] 50
Direction of rotation looking onto the flywheel left
Injection system
Deutz Common Rail (DCR) DCR/PLD DCR
Mechanical injection system Pumpe Leitung Düse (PLD pump line nozzle)
Weight excluding cooling system to DIN 70020-A [approx. kg] 410 530
Engine power rating according to ISO 3046 [kW] Engine performance, speed and start of pumping, among other things, are
stamped on the engine rating plate.
Speed (nominal revolutions) [rpm] 2400
Valve clearance: inlet/outlet [°] Angular degree 75/120
Setting with special tool
Ignition pressure [kPa (bar)] 16000 (160)
Start of pumping [°KW v. OT] Engine performance, speed and start of pumping, among other things, are
Firing order of the engine 1-3- 4- 2 1-5-3-6-2-4
V-belt tension Pre-tensioning/Re-tensioning
Generator [N] 650/400 ± 50
Fuel pump/Coolant pump [N] 650/400 ± 50
© 2007 71
Technical data Engine and setting data
9 Engine type
V-rib belt tensioning
TD/TCD 2012 L04 2V TCD 2012 L06 2V
Spring-loaded tensioning pulley
The V-rib belt has an automatically tensioning spring-loaded tensioning pulley
and is not re-tensioned.
Cooling Liquid-cooled/cooling system protection
Coolant volume (engine content only without cooler) [approx. ltr.] 5,6 7,3
Permissible continuous coolant temperature [°C] max. 110
Temperature difference between coolant inlet/outlet [°C] 4 to 8
Start of thermostat opening [°C] 86
Thermostat fully open [°C] 102
Coolant preheating Only necessary in winter operation.
Lubrication Pressure lubrication
Lubricating oil SAE ( 34 )
Lube oil temperature in the lube oil tray, maximum [°C] 125
Lubricating oil pressure in warm state (114°C) and low idle, minimum [kPa (bar)] 80 (0,8)
Lube oil first fill quantities
Specified lubricating oil filling volumes apply for the standard versions. The lubricating oil filling volume may vary in engines which deviate from the standard, e.g. different
lubricating oil pan/lubricating oil dipstick variants and/or special inclined versions. The lubricating oil dipstick mark is always decisive.
Lube oil first fill quantity without filter, minimum / maximum [approx. ltr.] 12,5/15,0 23,5/26,0
Lube oil first fill quantity with filter, minimum / maximum [approx. ltr.] 13,0/15,5 24,0/26,5
72 © 2007
General technical data
9
Engine type TD/TCD 2013 L04 2V TCD 2013 L06 2V
No. of cylinders 4 6
Cylinder arrangement upright in row
Bore [mm] 108
Stroke [mm] 130
3
Engine swept volume [cm ] 4761 7142
Compression ratio 18
Functional principle/combustion method Four-stroke diesel with charging and direct injection
Charge air cooler without/with with
Charge air temperature outlet at rated power [°C] 50
Direction of rotation looking onto the flywheel left
Injection system
Deutz Common Rail (DCR) DCR + PLD DCR
Mechanical injection system Pumpe Leitung Düse (PLD pump line nozzle)
Weight excluding cooling system to DIN 70020-A [approx. kg] 450 500
Engine power rating according to ISO 3046 [kW] Engine performance, speed and start of pumping, among other things, are
Speed (nominal revolutions) [rpm] 2300
Valve clearance: inlet/outlet [°] Angular degree 90/150
Setting with special tool
Ignition pressure [kPa (bar)] 16000 (160)
Start of pumping [°KW v. OT] Engine performance, speed and start of pumping, among other things, are
Firing order of the engine 1-3- 4- 2 1-5-3-6-2-4
V-belt tension Pre-tensioning/Re-tensioning
Generator [N] 650/400 ± 50
Fuel pump/Coolant pump [N] 650/400 ± 50
© 2007 73
9 Engine type
V-rib belt tensioning
TD/TCD 2013 L04 2V TCD 2013 L06 2V
Spring-loaded tensioning pulley
The V-rib belt has an automatically tensioning spring-loaded tensioning pulley
and is not re-tensioned.
Cooling Liquid-cooled/cooling system protection
Coolant volume (engine content only without cooler) [approx. ltr.] 7,2 9,8
Permissible continuous coolant temperature [°C] max. 105
Temperature difference between coolant inlet/outlet [°C] 4 to 8
Start of thermostat opening [°C] 86
Thermostat fully open [°C] 102
Coolant preheating Only necessary in winter operation.
Lubrication Pressure lubrication
Lube oil SAE ( 34)
Lube oil temperature in the lube oil tray, maximum [°C] 125
Lubricating oil pressure in warm state (114°C) and low idle, minimum [kPa (bar)] 80 (0,8)
Lube oil first fill quantities
Specified lubricating oil filling volumes apply for the standard versions. The lubricating oil filling volume may vary in engines which deviate from the standard, e.g. different
lubricating oil pan/lubricating oil dipstick variants and/or special inclined versions. The lubricating oil dipstick mark is always decisive.
Lube oil first fill quantity without filter, minimum / maximum [approx. ltr.] 12,5/15,0 23,5/26,0
Lube oil first fill quantity with filter, minimum / maximum [approx. ltr.] 13,0/15,5 24,0/26,5
74 © 2007
Tool ordering
The special tools described in this chapter can be or-
9
dered from:
Fa. Wilbär
Taubenstrasse 5
D-42826 Remscheid
Tel.: 0049 (0) 2191-9339-0
Fax: 0049 (0) 2191-9339-200
E-mail: info@wilbaer.de
http://www.deutz-tools.com
Torx tool V-belt tension measuring instrument

Order no.: 8189 Order number: 8115
The Torx screw system is used in engines in this se- Measuring instrument for checking the specified V-
ries among other things. This system was introduced belt tensions.
for a number of reasons:
Excellent accessibility
High force transmission when loosening and
tightening
Slipping or breaking of the key and risk of injury
are practically excluded.
© 2007 75
Rotaqtion angle disc Pin wrench insert Crow foot wrench

Order no.: 8190 Order no.: 8193 (5 mm) valve clearance Order no.: 8199
Rotation angle disc for setting the valve and control Order no.: 8194 (4 mm) control piston clearance Crow foot wrench for rotation angle disc 8190 in con-
piston clearance Pin wrench inserts for rotation angle disc nection with conventional square bar extension.
76 © 2007
9
Turning gear Bowl key Closing plugs and caps

Order no.: 100 330 Order no.: 8192 Order no.: 170 160
For turning over the engine as an attachment for the Special tool for removing the water collection vessel A set of closing plugs and caps for sealing fuel lines.
torsional vibration damper in the fuel pre-filter (Racor type)
© 2007 77
Filling aid
Order no.: 170 150
Aid for filling the coolant in engines with external
cooling system.
78 © 2007
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Köln
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-mail: info@deutz.com
Printed in Germany
All rights reserved
1st edition, © 05/2007
The engine company. Order no.: 0312 3459 en
DEUTZ EMR 3 Training
Engine Management System EMR3
Comparison of new Electronic Control Units
Electronic
EDC 16 EDC 7 EMR2
Characteristics
Supply voltage 12/24V 12/24V 12/24V
Main relays External Internal (electronics) not needed

mecha.Up and
CR max. 6 Cylinder CR max. 6 Cylinder
Injection system Inline pump 2 to 16
UP max. 6 Cyl. UP max. 8 Cylinder
Cyl.
MPC562 „Silver Oak“ MPC562 „Silver Oak“ Mitsubishi M16
CPU
32 Bit, f=56MHz 32 Bit, f=56MHz 16 Bit, f=16 MHz
Flash memory 2MB 2MB 512 KB

34 kB 34 kB 8 KB
RAM
CAN-Interface 2x CAN J1939 2x CAN J1939 1x CAN J1939

1x 1x 1x ISO
K-Line (ser. Bus) ISO9141/KWP2 ISO9141/KW 9141
2000 P2000 K500
VS-CS, Schmickler/Philipps 17.03.2006 2

Engine Management System EMR3
Comparison of new Electronic Control Units (ECU)
Mecha.
EDC7 EDC16 EMR2
Characteristics
Mounting on engine No No No
Cooling Air (convection) Air (convection) Air (convection)

Operating -40 …+80° -40 …+80° -40 …+80°
temperature
3 2 2
Connector
81 + 16 + 16 pins 94 + 60 pins 25 + 25
Protection level IP 6K9K IP 6K9K IP 66K

Status of Electronic Systems for Tier III Engines
EMR3-S (EDC 16)

Series: TCD 2012 2V and TCD 2013 2V /4V
Injection System: DCR
Operating Voltage: 12 and 24 V
Installation: Chassis, Cabin
EMR3-E (EDC 7)
Series : TCD 2015
Injection System : Electro. unit pump, (PLD)
Operating Voltage : 12 and 24 V
Installation : Chassis, Cabin
EMR2
Series: 2011, 2012, 1013, 2013, 1015
Injection System: Mecha. unit pump and Inline pump
Operating Voltage : 12 and 24 V
Installation : Chassis, Cabin

Injection Technology
Fuel System – DEUTZ Common Rail
ECU
2 Pressure sensor
Injector
3 MProp (FCU)
p = 0,5 ... 1,1 bar

p = 6 bar (+/- 1 bar)
p = 300 ... 1600 bar
Pressure
p = 1 ... 1,5 bar sensor
Rail
DBV
3
Prefilter with HP-pump
water separator 2
FCU
Supply Main
pump filter
Hand-
primer
ECU:ElectronicControlUnit
FCU: Fuel ControlUnit
DBV:Pressure limiter valve

EMR 3
Service
DEUTZ Customer Service
Manual
ECU
Software
SERDIA
Interface
Engine with actuator, sensors

and wiring harness
EMR 3
Functions 1
 Governor
 All speed Governor
 Min- / Max-Governor
 Fix Speed
 Freeze speed
Torque limitation
 Torque limitation via CAN
 Different Top curves
Droop
 Droop switch
 Speed limitation
Communication
 ISO9141 (diagnostic software SERDIA)
 CAN-bus (SAE J1939)

EMR3
Functions 2
Set point input:

 Analog
 CAN-bus
 Fix speed
 Digital up/down
Engine start/stop
 Starter Function
 Stop function via CAN or switch
Temperature dependant start / Cold start aid

 Cold start function
 Other temperature depending functions
 Engine brake

EMR3
Sensors
 Speed sensor at cam- and crankshaft

 Rail pressure, Rail pressure regulation by fuel metering unit
 Coolant temperature sensor
 Boost pressure and temperature (included in one sensor)
 Oil pressure
 Low fuel pressure sensor
 fuel temperature sensor (only TCD2015V06/8)
 Altitude correction (Included in the ECU
 water in fuel ( at the fuel pre filter)
 coolant level
 air filter differential pressure

EMR3
wiring harness and sensors
Boost air temperature and pressure

Ladelufttemp. und -druck
Connecting injectors
Anschluss Einspritzventle
1FCU (MPROP)
Coolant temperature Rail pressure

Kühlmitteltemperatur Raildruck
Engine connector
Zentralstecker Crankshaft speed
Kurbelwellendrehzahl
Camshaft speed
Nockenwellendrehzahl Oil pressure
Öldruck
Start relay, left side

Anlasserelais, linke Seite Low fuel pressure
Kraftstoffniederdruck

EMR3
wiring diagram engine side (EDC 16) / customer connections
Connections to
vehicle wiring
94 pol .
Extension line
(2,5m oder 5 m)
42 pol. plug
Engine harnest

EMR3
wiring diagram vehicle side (EDC 16 page 1 )
94 pin. EDC plug
Each EMR 3 Functionality does have a different wiring

EMR3
wiring diagram vehicle side (EDC 16 Seite 2 )
Wiring
High power harness
The preheat sense. Wire is only
used together with heating
flange

EMR3
engine harness
Boost air temperature and pressure

Connecting injectors
FCU (MPROP)
Coolant temperature Rail pressure
Crankshaft speed
Low fuel Oil pressure

Engine connector pressure
Starter relay
Camshaft speed

Crankshaft speed sensor
TN: 0419 9447
TCD 2012/2013/2015
R = 915 Ohm+/-10%
Camshaft speed sensor

TN: 0419 4021
TCD 2012/2013/2015
R = 3,8kOhm +/-10%
L = 2,1 H +/-10% Measured Value: (94|2)Eng_nAvrg (97|59) EngM_stSync
Low fuel sensor
Fuel low pressure Sensor
8000
7000
6000
Fue llow pres sure Sensor Output [hPa]

5000
4000
3000
2000
1000
TN: 0421 3326 0

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
TCD 2012/2013
Fuel low pressure Voltage [mV]
Measured Value : (110|11) FlPSCD_pAct

Measurement of low fuel pressure (TCD 2013 L06-2V) without load

Fuel Temperature Sensor
Fuel Temperature Sensor
160
140
120
100
Fue l Te mpe ra ture Sensor Output [°C ]

80
60
40
20
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
-20
TN: 0421 3839

-40
-60
TCD 2015
Fuel Sensor Voltage [mV]
Measured Value : (127|7) FTSCD_tFuel

R(20°C) = 2,5 kOhm +/- 6%
R(100°C) = 0,186 +/- 2%
Rail pressure sensor
Rail Pressure Sensor
200000
180000
160000
R ail Pr es sur e Sens or Output [hPa]

140000
120000
100000
80000
60000
40000
20000
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
TN: 0421 3470 Rail Pressure Voltage [mV]
TCD 2012/2013
Measured Value : (180|1) RailCD_pAct

Measurement of rail pressure (TCD 2013 L06-2V)

Combined sensor: Boost pressure and –temperature
Boost Pressure Sensor
4500
4000
3500
Boost Pre ssure Sensor Output [hPa ]
3000
2500
2000
1500
1000
TN: 0421 3838 500
TCD 2012/2013/2015 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Boost Pressure Voltage [mV]
Measured Value : (26|1) BPSCD_pOutVal

R(1 bar) = 5,1 kOhm +/- 8%

Intake Air Temperature Sensor
140
120
100
Intak e Air Temper atur e Se ns or Output [°C ]

80
60
40
20
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
-20
TN: 0421 3838 -40
-60
TCD 2012/2013/2015 Intake Air Sensor Voltage [mV]
Measured Value : (136|7) IATSCD_tAir

R(20°C) = 2510Ohm +/- 10%
R(50°C) = 851Ohm +/- 10%
Coolant temperature sensor
Coolant Temperature Sensor
160
140
120
Coolant Temp erature S ensor Output [°C] 100
80
60
40
20
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
-20
-40
TN: 0421 3839 -60

Coolant Sensor Voltage [mV]
TCD 2012/2013/2015
Measured Value : (51|10) CTSCD_tClnt
R(20°C) = 2,5 kOhm +/- 6%
R(100°C) = 0,186 +/- 2%
Engine Oil Pressure
Lubrification Oil Pressure Sensor
12000
10000
Lubrification Oil Sensor Output [hP a]

8000
6000
4000
2000
TN: 0421 3020

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Lubrification Oil Pressure Voltage [mV]
TCD 2012/2013/2015
Measured Value : (166|2)OPSCD_pOutVal

Measurement of oil pressure (TCD 2013 L06-2V)

Coolant level sensor
TN: 0118 2228

TCD 2012/2013/2015

Fuel Control Unit
TN: 0429 0102

TCD 2012/2013
Measured Value : (154|6) MeUnCD_iAct
R 3 Ohm
Signal from fuel Control Unit at high idle speed
Injector
TCD 2012/2013
R 0,5 Ohm
Signal from Injector at low idle speed (with pilot injection)

Serdia EMR 3
Status:
 At the Moment Serdia for EMR 3 is still not fully integrated into Serdia 2000
At the Moment it is still necessary to have a parallel installation of both Versions, but
SERDIA for EMR 3 does need a Serdia 2000 Installation to operate
 In the Future Serdia for EMR 3 will be fully integrated into Serdia 2000, which will
make the installation much easier as now
 In contrast to today also Serdia Level 3a will not have any access to power or
emission related Parameters. Level 3a will only allow access to all Application
Parameters
 Serdia EMR 3 is able to handle EDC 7 (for 2015 and as an option for 2012/2013)
EDC 16 for (for 2012/2013)

EMR3
Parameters
 Parameters
The Names of the Parameters are based on the Bosch Parameter Names, which are
totally different to the former Parameters in EMR 1 and EMR 2
(see file Parameter Names for Serdia EMR 3 for more Information)
The Structure is as follows:
 <Component>_<type><identifier>_<expansion>
examples:
1. Eng_nAvrg
Identifier: Avrg = average
type_ n = engine speed
Component : Eng = engine
2. CTSCD_tClnt
 Coolant Temperature Sensor Component Driver _ temperature Coolant

Serdia EMR 3
 Main Software download
It is possible to load a new Main Software via “ECU Selection\Download”
You need two files to do that, the Main Program ( ECU and engine Typ specific)
and a specific file for the engine application and power data. Don’t use this
transaction to load partly data sets.
1. Select main file (operating
software) must be approx 5 MB
2.Select engine specific data set
3. Select „All areas“ to get the

complete file to the ECU
4. Do not use a higher speed than
67280kB !
Than push the Programming button
Serdia EMR 3
 Programming an engine specific dataset within the same softwareversion
1. 2.
3. 4.4.
5.

EMR3
Serdia
You can select measured values by typing in the name of the value:

EMR3
warning strategy
Which values will be observed

 Coolant temperature
 Coolant level (option*)
 Oil pressure
 Boost air temperature
 Water in fuel
 Air differential pressure (option*)
 Heating flange (only used at 4V-engines)
 There are other monitored functions which will become active in case of a problem
Failure indication by warning light

 All values could be connected to a warning light in addition to the error light
*) – not all combinations are available

Applikation EMR3 - Überprüfung und Einstellung
Vom Fahrerwunsch zur Einspritzmenge
Despriction of the structure “Driver‘s Demand to injection mass “
AccPed_nDrvSetpoint Setpoint engine speed (Variable engine speed governor) [ 1/ min ]

VesGov_ntargetSetpoint Setpoint engine speed (Fix engine speed governor) [ 1/ min ]
LiGov_nSetpointLo Setpoint engine speed (Low idle governor) [ 1/ min ]
AccPed_trqDrvNGov Setpoint engine torque (Variable engine speed governor) [ Nm ]
EisGov_trq Setpoint engine torque (Min/Max- or fix engine speed governor) [ Nm ]
CoEng_trqinrLim Actual torque limitation (minimal) [ Nm ]
CoEng_trqSlpLim Engine torque from smoke limitation [ Nm ]
EngPrt_trqLim Maximal possible torque (Top curve) [ Nm ]
CoEng_prcPwrRdcMin Reducing factor for limitation curve [%]
CoEng_trqInrSet Engine torque before convertation to Injection mass [ Nm ]
InjCtl_qSetUnBal Setpoint injection mass [mg / cyl ]

EMR3
Structure throttle pedal
Vehicle side ECU
Throttle or [V]
APPCD_uRawAPP1
footpedal
[V]
O
APPCD_rLinAPP1_CUR
R
[%]
AccPed_nDrvSetpoint_CUR
[ rpm ]
Throttle via [ rpm ]
AccPed_nDrvSetpoint
“CAN-Bus“

Application EMR3 – Testing and Adjustments
From the Driver‘s Demand to Injection Mass
Setpoint by Setpoint by Setpoint by

a. Accelaration pedal Fix speed governor Low Idle governor
b. CAN-Bus
AccPed_nDrvSetpoint VESGov_ntargetSetPoint LIGov_nSetPointLo
Accped_trqDrvNGov EisGov_trq
M
Limitation by
A
Smoke limitation
X
CoEng_trqSlpLim
M M Limitation by
Top curve
I CoEng_trqInrLim I
N N x EngPrt_trqLim
Limitation by
Power Reduction
CoEng_trqInrSet (Monitoring strategy)
CoEng_prcPwrRdcMin
InjCtl_qSetUnBal

Serdia EMR 3
Tasks: foot pedal and hand throttle adjustment
Error Range
Acceleration
Pedal

Serdia EMR 3
Acceleration Pedal Adjustment
Map for combination of

percentage Acceleration pedal
and resulting speed

Serdia EMR 3
Page 1 Acceleration Pedal
Working range
pedal 1
pedal 2

Applikation EMR3
CAN Setpoint
´Customer EMR3
CAN-BUS FrmMng_TSC1TEByte1Raw_mp Byte1 from Message
FrmMng_TSC1TEByte2Raw_mp Byte2 from Message
TSC1 FrmMng_TSC1TEByte3Raw_mp Byte3 from Message
Message FrmMng_TSC1TEByte4Raw_mp Byte4 from Message
FrmMng_nTEDes Demanded Engine speed by CAN
CoVeh_nTSEASpdReq Demanded Engine speed in Coordinator
EisGov_CurrFu = 1 Accped_nDrvSetpoint Demanded Engine speed (output)

Govenor Path must be
O.K.
In the measured value AccPed_nDrvSetpoint you can simply notice, if the value is
taken from the CAN-Message or from the acceleration pedal.

Application EMR3 - Testing and Adjustments
The following values in the Reference-KLUs are variabel. You can change them locally or be
ordered:
Low idle adjustment: Example Old New

 Frmmng_nReqLoLim_C 600rpm 700rpm
 LiGov_nSetPointWarm_C 600rpm 700rpm
 LiGov_nSetPointDriveAway_C 600rpm 700rpm
 VESGov_nMin_C 600rpm 700rpm
 VESGov_nMod1_C 600rpm 700rpm
 AccPed_nDrvSetpoint_Cur Explained in the chaptre calibration acceleration pedal
Limp home speed: Example Old New

 AccPed_nErr_C 1200rpm 1500rpm
 LiGov_nLimHigh_C 1200rpm 1500rpm
 LiGov_nLimHighTrm_C 1200rpm 1500rpm
 CoVeh_nErr_C 1200rpm 1500rpm
Digital up and down-steps: Example Old New

 VESGov_nTipStp_C 50rpm 20rpm

Application EMR3 - Testing and Adjustments
The following values can be changed, but not being ordered:
Fix speed 1: Example Old New

 VESGov_nMode2_C 1200rpm 1500rpm
Fix speed 2: Example Old New

 VESGov_nMode3_C 1200rpm 1500rpm
Droop 1 and 2: Example Old New

 Droop 1
 HIGov_rSpdDrp1CAN_C 5% 2%
 HIGov_rSpdDrp0MSS_C 5% 2%
 VESGov_rSpdDrp1_CUR 2% introduising in the curve
 FrmMng_rDrpValDfl_C 5% 2%
 Droop 2
 HIGov_rSpdDrp2CAN_C 5% 10%

EMR3
parameters for warning strategy
Parameters for engine monitoring

CTSCD_stSelSysReac_C coolant temperature
CLSCD_stSelSysReac_C coolant level
OPSCD_stSelSysReacLo_C oil pressure
IATSCD_stSelSysReac_C boost air temperature
not existing – only warning water in fuel
AirFlt_stSelSysReac_C air differential pressure
Codes for the warning strategy

1 warning
2 warning / power reduction
8 warning and engine stop
9 warning and engine stop if engine stop is with a delay
10 warning/ power reduction / engine stop
example:
CTSCD_stSelSysReac_C = 10  warning/ power reduction / engine stop
EMR3
parameters for warning strategy
There are only 3 measured values which could cause a power reduction
PR by coolant temperature
CTSCD_prcPwrRdc
M
PR by oil pressure Actual power reduction
I
OPSCD_prcPwrRdcLo CoEng_prcPwrRdcMin
N
PR by boost air temperature
IATSCD_prcPwrRdc

Active Limiting State CoEng_stCurrLimActive
Limitingcodes ín Hex

Serdia EMR 3
Page 2 Air differential pressure
System
reaction

Serdia EMR 3
Page 3 Coolant Level
System
reaction

EMR3
Serdia
If you have made a Software

update and you will get a
permanent EEPROM error
in the error memory, you
must change this value to
1 and push the function
PC->ECU after that, you
must change to 0 again
and push PC->ECU again.
After that, you could erase
the error in the error
memory
With this operation you
will put also the running
hours and load cycle
to 0

EMR3
Initial Start Trouble Shooting
You need to do the following steps before the initial start of the engine:
Check the wiring and all connectors.
Switch on the ignition
Start SERDIA communication
Save the actual Data set on your computer
Check the error memory, it must be empty
If you have made a software upgrade, you can get a EEPROM error. You can solve that
with the following parameter: EEPCD_InitAfterProg_C (see page 27)
-start the engine-
Check error lamp and error memory

EMR3
engine start 10000
1000.. 2000.. 3000.. 4000.. 5000.. 6000.. 7000.. 8000.. 9000.. 1000.. 1100.. 1200.. 1300.. 1400.. 1500..
1000
1.000
10
Linienf Name Einhei Pro- Start Measured values:
1 Eng_nAvrg\KWP2000:rpm 100 0
90
2 FlPSCD_pAct\KWP20 hPa 1000 0

Eng_nAvrg
9000
90 0
900
9
4 RailCD_pPeak\KWP20 hPa 1,50E+ 0
5 5 InjCtl_qSetUnBal\KWP mg/c 9,5942 -
FlPSCD_pAct
80
8000
800
800
8
Rail_pPeak
70
7000
700
700
7
InjCtl_qSetUnBal
InjCtl_qSetUnBal\KWP2000:1 mg/cyc
60
R ail CD _pPeak\KWP2000:1 hPa

F lPSCD_pAct\KWP2000:1 h Pa
Eng_nAvrg\KWP20 00 :1 rpm
600 0
600
600
6
50
5000
500
500
5
4
1
40
40 00
400
400
4
30
3000
300
300
3
5
2
20
2000
200
200
2
1
1000
10
100
100
1
2
4
0
0
0
0
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 31 32 33034
1020
A B C D Zeit s A
1. Motorstart Datum: Objekt: TCD2013L06-2V

System noch nicht vollständig entlüftet Zeit: Projekt:
Langsamer Aufbau Kraftstoff vordruck Anw ender: Grohmann Messdatei:
Ab ca. 900mbar baut sich Raildruck auf Einheit: VS-TA2
Motor startet bei ca. 125bar Raildruck
15.08.2006 13:42:07 1/1

EMR3
engine start 10000
1000.. 2000.. 3000.. 4000.. 5000.. 6000.. 7000.. 8000.. 9000.. 1000.. 1100.. 1200.. 1300.. 1400.. 1500..
1000
1.000 I: 1 t1 [s]: 2,621696 t2 [s]: 3,201503 * t2-t1 [s]: 0,579808
10
Linien Name Cu Curso Curso Einh Pro- Star Measured values:
Eng_nAvrg\KWP20 0 183 183 rpm 100 0
90
FlPSCD_pAct\KWP 12 5059 3812 hPa 1000 0

Eng_nAvrg
9000
90 0
900
9
RailCD_pPeak\KWP87 3,71E 3,63E hPa 1,50E 0
InjCtl_qSetUnBal\K 57, 57,2 0 mg/c 9,594 -
1
FlPSCD_pAct
80
8000
800
800
8
Rail_pPeak
70
7000
700
700
7
2
InjCtl_qSetUnBal
InjCtl_qSetUnBal\KWP2000:1 mg/cyc
60
R ail CD _pPeak\KWP2000:1 hPa

F lPSCD_pAct\KWP2000:1 h Pa
Eng_nAvrg\KWP20 00 :1 rpm
600 0
600
600
6
50
5000
500
500
5
40
40 00
400
400
4
30
4
3000
300
300
3
4
20
2000
200
200 5
2
5
1000
10
100
100
1
1 2
0
0
0
0
1 2 3 4 5 6 7 8 9 0 1020
A B C D Zeit s A
Motorstart Datum: Objekt: TCD2013L06-2V

schneller Aufbau Kraftstoff vordruck Zeit: Projekt:
Start nach 0.5s Anw ender: Grohmann Messdatei:
Einheit: VS-TA2
15.08.2006 13:59:41 1/1

EMR3
engine will not start
Serdia: check error memory and solve the active errors
If you have errors from all sensors, check main plugs
Is the engine speed and injection amount monitored (InjCtl_qSetUnbal)?

 Eng_nAvrg engine speed
 InjCtl_qSetUnbal injection amount
Is the fuel pressure rising up?

 FlPSCD_pAct fuel pre pressure (only inline engines)
Is the rail pressure rising up?

 Railcd_pPeak rail pressure

EMR3
engine is missing power and dynamic response
Is the right top curve active?
 MSSCD_stSwt3 = 0 for max power curve (switch for different top curves not active)
Is the power reduced by monitoring functions?

 Coeng_prcPwrRdcMin < 100%
Is the power reduced by a big error?

 CoEng_trqLimRawErr (actual limit by an error) < EngPrt_trqLim (actual limit by the top curve)
Is the power reduced by CAN?

 FrmMng_prcEngPrtPowRed < 100%
Is the engine working at the smoke limitation?

 CoEng_trqInrSet (actual torque setpoint)= CoEng_trqSlpLim (actual smoke limitation)
Is the engine running at the top curve?

 CoEng_trqInrSet (actual torque setpoint) = EngPrt_trqLim (actual limit by top curve)
Is the boost pressure o.k.?

 BPSCD_pDfl_C (absolut amount)

EMR3
acceleration
3 00 0
1.000
10
1 00 0
2300
Linienf Name Ein Pro- Start

1 Eng_nAvrg\KWP2000:1 rp 146, 870,
2
2200
2 AccPed_nDrvSetpoint\KW rp 146, 870,

2800
900
9
900
3 CoEng_trqInrSet\KWP200 Nm 107, -48,7

4
4 4 EngPrt_trqLim\KWP2000:1 Nm 107, -48,7
2100
3
5 CoEng_trqSlpLim\KWP200 Nm 107, -48,7
2600
800
800
8
7 BPSCD_pOutVal\KWP200 hP 198, 1015
2000
1
1900
2400
700
700
7
5
1400 1500 16 00 17 00 1800
BPSCD_pO utVal\KWP2000:1 hPa

CoEng_trqInrSe t\KWP2000:1 Nm
Eng_nAvrg\KWP2000:1 rpm
600
2 20 0
600
6
500
2000
500
5
400
7
1800
400
4
3
300
1300
1600
300
3
1200
200
7
200
1400
2
1100
1 00
1 2
100
1200
10 00
1
0
900
0
76 78 80 82 84 86 88 90 92 94 96 98 0 1020
A B C Zeit s A
Beschleunigungsf ahrt unter Last Datum: Objekt: TCD2013L06-2V

Motor ist and Rauchbegrenzung Zeit: Projekt:
Ladeluftdruck w ird nur langsam auf gebaut Anw ender: Gr Messdatei:
Einheit: VS-TA2
16.08.2006 15:41:29 1/1

EMR3
Governor
EMR 3 does have several Governors working together

low speed governor (PID-Regler) LiGov Nominal speed
(HiGov)
max speed governor (PID-Regler) HiGov Fix speed (VesGov)
fix speed Governor (PID-Regler) VesGov Übergangsbereiche Variable speed
all speed governor (PI-Regler) Ngov (NGov)
Low idle
(LiGov)
Each Governor does have different parameters for small and big signal response
There are main parameters and maps to optimise the governors locally
Actual speed
Wenn SollDrehzahl - Ist Drehzahl < 0
Big signal area ...neg
Fenster
{ small signal area
Small signal area

Big signal area ...pos
Speed Setpoint
Wenn SollDrehzahl - Ist Drehzahl > 0 Iactual speedl

EMR3
Governor structure EMR3 ( LiGov / HiGov)
The Governing is always done by the No Grip governor

The Governor for the low idle does have the name ...Lo_C, the one for high speed ...Hi_C
The LiGov-parameters will be put to the main Governor the, EisGov for the governing
Parameters for governor optimising:
P-Part
LiGov_NoGripPKpLo_C [Nm/rpm] small signal parameter P-part
LiGov_NoGripPKpNegLo_C [Nm/rpm] negative big signal parameter P-part
LiGov_NoGripPKpPosLo_C [Nm/rpm] positive big signal parameter P-part
LiGov_NoGripPWinNegLo_C [rpm] negative speed window for small signal response
LiGov_NoGripPWinPosLo_C [rpm] positives speed window for small signal response
LiGov_KpCorTrqFac_MAP [Factor] speed and torque depending map for P-part
I-part
LiGov_NoGripIKiLo_C [Nm/rpm] small signal parameter I-part
LiGov_NoGripIKiNegLo_C [Nm/rpm] negative big signal parameter I-part
LiGov_NoGripIKiPosLo_C [Nm/rpm] positive big signal parameter I -part
LiGov_NoGripIWinNegLo_C [rpm] negative speed window for small signal response
LiGov_NoGripIWinPosLo_C [rpm] positives speed window for small signal response
LiGov_KICorTrqFac_MAP [Factor] speed and torque depending map for I-part
D-part
LiGov_NoGripDKd_C [Nm/rpm]

EMR3
governor structure EMR3 (all speed governor NGov)
The N-Gov does not have a D part!
Parameters for Governor optimizing

P-part
AccPed_DrvPKp_C [Nm/rpm] small signal parameter P-part
AccPed_DrvPKpNeg_C [Nm/rpm] negative big parameter P-part
AccPed_DrvPKpPos_C [Nm/rpm] positive big parameter P-part
AccPed_DrvPWinNeg_C [rpm] negative window for small signal response
AccPed_DrvPWinPos_C [rpm] positive window for small signal response
AccPed_facDrvLdKpCor_MAP[Factor] speed and torque depending map for P-part
I-part
AccPed_DrvIKi_C [Nm/rpm] small signal parameter I-part
AccPed_DrvIKiNeg_C [Nm/rpm] negative big parameter I-part
AccPed_DrvIKiPos_C [Nm/rpm] positive big parameter I-part
AccPed_DrvIWinNeg_C [rpm] negative window for small signal response
AccPed_DrvIWinPos_C [rpm] positive window for small signal response
AccPed_facDrvLdKiCor _MAP[Factor] speed and torque depending map for I-part

EMR3
governor structure EMR3 (fix speed governor VesGov)
.
The Ves Gov parameters will be pushed to the EisGov for governing
Parameters for governor optimizing:
P-Part
 VesGov_Par0PKpLo_C [Nm/rpm] small signal parameter P-part
VesGov_Par0PKpNegLo_C [Nm/rpm] negative big parameter P-part
VesGov_Par0PKpPosLo_C [Nm/rpm] positive biglparameter P-part
VesGov_Par0nPWinNegLo_C [rpm] negative speed window for small signal response
VesGov_Par0nPWinPosLo_C [rpm] positive speed window for small signal response
VesGov_KpCorTrqFac_MAP [Faktor] speed and torque depending map for P-part
I-Part
VesGov_Par0IKiLo_C [Nm/rpm] small signal parameter I-part
VesGov_Par0IKiNegLo_C [Nm/rpm] negative big parameter I-part
VesGov_Par0IKiPosLo_C [Nm/rpm] positive big parameter I-part
VesGov_Par0nIWinNegLo_C [rpm] negative speed window for small signal response
VesGov_Par0nIWinPosLo_C [rpm] positive speed window for small signal response
VesGov_KICorTrqFac_MAP [Faktor] speed and torque depending map for I-part
D-Part
VesGov_Par0DKd_C [Nm/rpm]

Referenced ECU Software
DTC - List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Fehlercodes P491_: 220, 310, 400, 501 P513_: 214, 300
Error Path DEUTZ SPN Blink Error Path DEUTZ SPN Blink Error Path DEUTZ SPN Blink
AirFltSysReac 11 107 1-3-6 CTLpCD 54 704 1-2-3 FrmMngTOSwtOut 117 523238 1-1-5
APP1 12 91 2-2-6 CTSCD 55 110 2-2-5 FrmMngTOTCO1 118 523222 1-1-6
APPPwm 14 91 2-2-2 CTSCDSysReac 56 110 2-3-2 FrmMngTOTSC1AE 120 523605 1-1-8
APPPwmPer 15 91 2-2-2 Dummy1CD_Max 57 701 1-0-0 FrmMngTOTSC1AR 121 523606 1-1-9
APSCD 16 108 2-9-2 Dummy1CD_Min 58 701 1-0-0 FrmMngTOTSC1DE 122 523607 1-1-8
ArHt1 17 729 2-6-3 Dummy1CD_SigNpl 59 701 1-0-0 FrmMngTOTSC1DR 123 523608 1-1-9
ArHt2 18 730 2-6-3 Dummy2CD_Max 60 702 1-0-0 FrmMngTOTSC1PE 124 523609 1-1-8
ArHtCD_NoLd 19 676 2-6-3 Dummy2CD_Min 61 702 1-0-0 FrmMngTOTSC1TE 125 898 1-1-8
ArHtCD_RlyErr 20 676 2-6-3 Dummy2CD_SigNpl 62 702 1-0-0 FrmMngTOTSC1TR 126 520 1-1-9
BattCD 22 168 3-1-8 EGRCD_Max 69 2791 4-1-4 FrmMngTOTSC1VE 127 523610 1-1-8
BattCDSysReac 23 168 3-1-8 EGRCD_Min 70 2791 4-1-4 FrmMngTOTSC1VR 128 523611 1-1-9
BIPCyl1 24 523561 5-3-1 EGRCD_SigNpl 71 2791 4-1-5 FrmMngTxTO 131 523500 2-7-1
BIPCyl2 25 523562 5-3-2 EGRCDIntEGR 72 2791 4-1-6 FTSCD 133 174 2-2-7
BIPCyl3 26 523563 5-3-3 EngCDTrqCalcOut 74 923 5-5-5 FTSCDSysReac 134 174 2-3-7
BIPCyl4 27 523564 5-3-4 EngMBackUp 75 190 2-1-2 GOTSCD 136 523618 1-3-3
BIPCyl5 28 523565 5-3-5 EngMCaS1 76 190 2-1-2 GOTSCDSysReac 137 523619 1-3-3
BIPCyl6 29 523566 5-3-6 EngMCrS1 77 190 2-1-2 HdThrt 138 29 1-2-6
BIPCyl7 30 523567 5-3-7 EngMOfsCaSCrS 78 190 2-1-3 HOTSCD 139 1638 3-1-4
BIPCyl8 31 523568 5-3-8 EngPrtSysReacFOC 79 190 2-1-4 HOTSCDSysReac 140 1638 3-1-4
BPSCD 32 102 2-2-3 EngPrtSysReacORC 80 190 2-1-4 HWEMonCom 141 523617 5-5-5
BPSCDSysReac 33 102 2-2-3 ESLpCD 81 703 1-4-2 HWEMonEEPROM 142 630 2-8-1
CLSCDSysReac 37 111 2-3-5 ExFlCD 82 1074 2-1-9 HWEMonRcyLocked 143 523612 5-5-5
CmbChbMisfire1 38 1323 2-4-1 FanCD 83 975 2-3-8 HWEMonRcySuppressed 144 523612 5-5-5
CmbChbMisfire2 39 1324 2-4-1 FanCDEval 85 1639 2-3-8 HWEMonRcyVisible 145 523612 5-5-5
CmbChbMisfire3 40 1325 2-4-1 FanCDSysReac 86 523602 2-3-8 HWEMonUMaxSupply 146 523612 5-5-5
CmbChbMisfire4 41 1326 2-4-1 FlFCD 87 97 2-2-8 HWEMonUMinSupply 147 523612 5-5-5
CmbChbMisfire5 42 1327 2-4-1 FlFCD_WtLvl 89 97 2-2-8 IATSCDk 149 105 1-2-8
CmbChbMisfire6 43 1328 2-4-1 FlPSCD 90 94 2-1-6 IATSCDSysReac 150 105 2-3-3
CmbChbMisfire7 44 1450 2-4-1 FlPSCDSysReac 91 94 2-1-6 InjVlvBnk1A 153 523350 1-5-1
CmbChbMisfire8 45 1451 2-4-1 FrmMngDecV1 94 523239 5-2-6 InjVlvBnk1B 154 523351 1-5-1
CmbChbMisfireMul 46 1322 2-4-1 FrmMngFunModCtl 95 523240 5-2-7 InjVlvCyl2A 155 523352 1-5-2
CmbChbSysReac 47 1346 2-4-1 FrmMngTOEngPrt 106 523212 3-3-3 InjVlvBnk2B 156 523353 1-5-2
CoEngShOffDemIgr 48 1109 3-4-1 FrmMngTOPrHtEnCmd 110 523216 3-3-7 InjVlvChipA 157 523354 1-5-3
CRERCD 52 1072 5-2-8 FrmMngTORxCCVS 112 523218 1-1-1 InjVlvChipB 158 523355 1-5-3
CSLpCD 53 1081 3-2-8 FrmMngTORxEngTemp 113 523604 1-1-2 InjVlvCyl1A 159 651 1-5-4
DEUTZ AG, VS-TA, Fi, Su Page 1 von 67 Rev. 2.0

DTC - List P490_: 220, 310, 501 P492_: 213
Error Path DEUTZ SPN Blink Error Path DEUTZ SPN Blink Error Path DEUTZ SPN Blink
InjVlvCyl1B 160 651 1-5-4 OPSCDSysReacHi 198 100 2-3-1 RailMeUn8 245 523010 2-5-4
InjVlvCyl2A 161 652 1-5-5 OPSCDSysReacLo 199 100 2-3-1 FlSys_FLPFMSysReac 246 523650 5-4-1
InjVlvCyl2B 162 652 1-5-5 OSwCD 200 1237 1-4-5 FlSys_FTSFMSysReac 247 523651 5-4-2
InjVlvCyl3A 163 653 1-5-6 OTSCD 201 175 1-4-4 FlSys_FlushStateEngineOff 248 523652 5-4-3
InjVlvCyl3B 164 653 1-5-6 OTSCDSysReac 203 175 1-4-4 FlSys_RapeOilHeatEx 249 523653 5-4-4
InjVlvCyl4A 165 654 1-6-1 PRVMon 208 523470 1-4-6 FrmMngDieselLvl 250 523654 5-4-5
InjVlvCyl4B 166 654 1-6-1 RailCD 209 157 1-4-7 FrmMngFuelTemp 251 523655 5-4-6
InjVlvCyl5A 167 655 1-6-2 RailCDOfsTst 210 157 1-4-7 FrmMngLowPressureDiesel 252 523656 5-4-7
InjVlvCyl5B 168 655 1-6-2 RailMeUn0 211 523613 1-3-4 FrmMngRapeOilIn 253 523657 5-6-1
InjVlvCyl6A 169 656 1-6-3 RailMeUn1 212 523613 1-3-4 FrmMngRapeOilLvl 254 523658 5-6-2
InjVlvCyl6B 170 656 1-6-3 RailMeUn2 213 523613 1-3-4 FrmMngRapeOilVlv1 255 523659 5-6-3
InjVlvCyl7A 171 657 1-6-4 RailMeUn3 214 523613 1-3-4 FrmMngRapeOilVlv2 256 523660 5-6-4
InjVlvCyl7B 172 657 1-6-4 RailMeUn4 215 523613 1-3-4 FrmMngRapeOilVlv3 257 523661 5-6-5
InjVlvCyl8A 173 658 1-6-5 RailMeUn7 216 523613 1-3-4 FrmMngRapeOilVlv4 258 523662 5-6-6
InjVlvCyl8B 174 658 1-6-5 SOPTst 218 523490 1-4-9 FrmMngRapeOilVlv5 259 523663 5-6-7
InjVlvErrDet 175 523370 5-5-5 SSpMon1 219 1079 2-8-2 FrmMngSTIN1RX 260 523664 5-6-8
MeUnCD_ADC 176 523615 1-3-5 SSpMon2 221 1080 2-8-2 FrmMngStEKP 261 523665 5-6-9
MeUnCDNoLoad 177 523615 1-3-5 SSpMon3 222 523601 2-8-2 FrmMngStLmp 262 523666 5-7-1
MeUnCDSCBat 178 523615 1-3-5 StrtCDHS 223 677 5-1-2 FrmMngStOutRx 263 523667 5-7-2
MeUnCDSCGnd 179 523615 1-3-5 StrtCDLS 224 677 5-1-2
MnRly1_SCB 182 2634 1-3-7 SysLamp 225 624 5-1-3
MnRly1_SCG 183 2634 1-3-8 T15CD 226 158 5-1-4
Montr 184 523420 1-3-9 T50CD 227 523550 5-1-5
MRlyCD 186 2634 2-6-1 TPUMon 228 523550 5-5-5
MRlyCDMnRly2 187 563 2-6-1 VSSCD1 232 84 5-2-1
MRlyCDMnRly3 188 2634 2-6-1 WdCom 235 523600 5-5-5
MSSCD1 189 523450 1-4-3 PRVMonSysReac 236 523470 1-4-6
MSSCD2 190 523451 1-4-3 APPCDSwtnSel 237 523006 2-4-2
MSSCD3 191 523452 1-4-3 FrmMng_TORxEngPress 238 523007 2-1-5
NetMngCANAOff 192 639 2-7-1 MplCtl 239 523008 4-2-4
NetMngCANBOff 193 1231 2-7-1 OLSCD 240 98 2-1-1
NetMngCANCOff 194 1235 2-7-1 OLSCDSysReacHi 241 98 2-5-1
OPLpCD 195 705 1-3-5 ADPSCDAna 242 107 1-3-6
OPSCD 196 100 2-2-4 OLSCDSysReacLo 243 98 2-5-2
OPSCD1 197 100 2-3-1 PrvMonWear 244 523009 2-5-3

DTC - List P490_: 220, 310, 501 P492_: 213
AirFltSysReac APP1 APPPwm

Error Description Error Description Error Description
Air filter differential pressure: the pressure difference of the Analog accelerator pedal sensor 1 or double accelerator Digital accelerator pedal sensor (PWM): the signal
intake air between the filter inlet and outlet calculated by pedal sensor: the voltage measured by ECU is out of the received by ECU is defective or implausible or the pulse-
ECU is above the target range and the ECU activates a target range or the calculated pedal position is implausible duty factor is out of the target range
system reaction compared with the position of the second pedal
Error Codes
Error Codes Error Codes DEUTZ: 14, Blink: 2-2-2, SPN: 91,
DEUTZ: 11, Blink: 1-3-6, SPN: 107, DEUTZ: 12, Blink: 2-2-6, SPN: 91, FMI (Bit 0,1,2,3):
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 8: unusual frequency, pulse or period.
0: data valid, but above normal working area 3: Voltage to high or short circuit to +Ubatt 8: unusual frequency, pulse or period.
11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
11: Errormode not identifiable 11: Errormode not identifiable 8: unusual frequency, pulse or period.
11: Errormode not identifiable 2: data stream is defective
Error Detection
Error Detection Error Detection Continuous light of the fault lamp, registered in the error
Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error memory of the ECU.
memory of the ECU. memory of the ECU.
Possible Error Reason
Possible Error Reason Possible Error Reason Duty cycle outside target range, signal erroneous or
Pressure loss above target range with system reaction, air Voltage outside target range, signal implausible compared implausible (pedal 1), sensor defective, onnection cable
filter clogged or defective, sensor not working, connection to signal of redundant pedal (analog pedal 1), sensor demaged
cable demaged defective, connection cable demaged
Corrective Action
Corrective Action Corrective Action Check cabling, check accelator pedal sensor and if
Check airfilter and if necessary clean or renew it, check Check cabling, check accelator pedal sensor and if necessary replace it, check connection cable and if
cabling, check air filter and if necessary replace the filter necessary replace it, check connection cable and if necessary repair or replace it
component, check sensor and if necessary replace it, necessary repair or replace it
check connection cable and if necessary repair or replace Others Error Properties
it Others Error Properties Priority 4, self healing, as measured value a current value
Priority 4, not self healing, as measured value a current will be showed.
Others Error Properties value will be showed.
Priority 2, self healing, as measured value a current value To First Page
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
APPPwmPer APSCD ArHt1

digital accelerator pedal sensor (PWM): the frequence of Ambient air pressure sensor (in ECU): the voltage Air heater relay: the current drain measured by ECU is out
the signal received by ECU is out of the target range measured by ECU is out of the target range or the of the target range
calculated ambient air pressure is implausible compared
Error Codes with the charge air pressure Error Codes
DEUTZ: 15, Blink: 2-2-2, SPN: 91, DEUTZ: 17, Blink: 2-6-3, SPN: 729,
FMI (Bit 0,1,2,3): Error Codes FMI (Bit 0,1,2,3):
8: unusual frequency, pulse or period. DEUTZ: 16, Blink: 2-9-2, SPN: 108, 3: Voltage to high or short circuit to +Ubatt
8: unusual frequency, pulse or period. FMI (Bit 0,1,2,3): 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 5: current to low or broken wire
11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable
11: Errormode not identifiable
Error Detection 2: data stream is defective Error Detection
Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
memory of the ECU. Error Detection memory of the ECU.
Continuous light of the fault lamp, registered in the error
Possible Error Reason memory of the ECU. Possible Error Reason
Pulse frequency outside target range (pedal 1), sensor Cable break or short circuit at EDC output, relay defective,
defective, connection cable demaged Possible Error Reason connection cable demaged
Ambient air pressure sensor defective, ECU defective
Corrective Action Corrective Action
Check cabling, check accelator pedal sensor and if Corrective Action Check cabling, if sensor not working, check relay and if
necessary replace it, check connection cable and if Change ECU necessary replace it, check connection cable and if
necessary repair or replace it necessary repair or replace it
Others Error Properties
Others Error Properties Priority 4, self healing, as measured value a default value Others Error Properties
Priority 4, self healing, as measured value a current value will be showed. Priority 2, self healing, as measured value a shutoff value
will be showed. will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
ArHt2 ArHtCD_NoLd ArHtCD_RlyErr

Air heater magnet valve: the current drain measured by Air heater relay: the ECU detects no switching operation at Air heater relay: the ECU detects an implausible signal at
ECU is out of the target range the input of a readback process the input of a readback process
Error Codes Error Codes Error Codes
DEUTZ: 18, Blink: 2-6-3, SPN: 730, DEUTZ: 19, Blink: 2-6-3, SPN: 676, DEUTZ: 20, Blink: 2-6-3, SPN: 676,
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable 5: current to low or broken wire
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
5: current to low or broken wire 11: Errormode not identifiable 11: Errormode not identifiable
11: Errormode not identifiable 11: Errormode not identifiable 11: Errormode not identifiable
Error Detection Error Detection Error Detection
Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
memory of the ECU. memory of the ECU. memory of the ECU.
Possible Error Reason Possible Error Reason Possible Error Reason
Cable break or short circuit, valve defective, connection Relay energized, but no feedback on sense line, relay Relay not energized, but working voltage on sense line,
cable demaged defective or wrong wired, preheat component defective, relay defective (can not disconnect or switch off), preheat
connection cable demaged component defective, connection cable demaged
Corrective Action
Check valve and if necessary replace it, check connection Corrective Action Corrective Action
cable and if necessary repair or replace it Check cabling of preheat component, if relay not Check cabling of preheat component, if relay not
working,check relay and if necessary replace it, check working,check relay and if necessary replace it, check
Others Error Properties preheat component and if necessary replace it, check preheat component and if necessary replace it, check
Priority 2, self healing, as measured value a shutoff value connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it
will be showed.
Others Error Properties Others Error Properties
Priority 3, not self healing, as measured value a nominal Priority 3, not self healing, as measured value a nominal
value for output status will be showed. value for output status will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
BattCD BattCDSysReac BIPCyl1

Battery voltage: the voltage measured by ECU is out of the Battery voltage: the voltage measured by ECU is out of the Begin of injection of cylinder 1: the ECU can not identify
target range target range; the ECU activates a system reaction the magnet valve or the injection pump with the measured
value of current drain at the begin of the injection
Error Codes Error Codes
DEUTZ: 22, Blink: 3-1-8, SPN: 168, DEUTZ: 23, Blink: 3-1-8, SPN: 168, Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): DEUTZ: 24, Blink: 5-3-1, SPN: 523561,
0: data valid, but above normal working area 2: data stream is defective FMI (Bit 0,1,2,3):
1: data valid, but below normal working area 2: data stream is defective 2: data stream is defective
11: Errormode not identifiable 11: Errormode not identifiable 2: data stream is defective
2: data stream is defective
Error Detection Error Detection
Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error Error Detection
memory of the ECU. memory of the ECU. Continuous light of the fault lamp, registered in the error
memory of the ECU.
Possible Error Reason Possible Error Reason
Voltage below target range, battery defective, too high Above target range with system reaction, too high power Possible Error Reason
power supply voltage, too high contact resistance, wiring supply voltage, parametering inaccurate, ECU defective Value outside target range or missing (cylinder 1), magnet
demaged, energie system overloaded, parametering valve or injection pump defective
inaccurate, ECU defective Corrective Action
Check dataset of calibration of working voltage for Corrective Action
Corrective Action application, check LIMA? Check voltage of generator, Check magnetic valve or injection pump
Check LIMA?, ECU, cabling, contact resistance, safety check the parameters and if necessary correct them, and if necessary change them
fuses, too high load in energy system, check battery and if replace ECU
necessary replace it, check battery pole and if necessary Others Error Properties
clean it, check connection cable and if necessary repair or Others Error Properties Priority 3, self healing, as measured value a current value
replace it, check volta Priority 4, self healing, as measured value a current value will be showed.
will be showed. To First Page
Priority 3, self healing, as measured value a current value
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
BIPCyl2 BIPCyl3 BIPCyl4

Begin of injection of cylinder 2: the ECU can not identify Begin of injection of cylinder 3: the ECU can not identify Begin of injection of cylinder 4: the ECU can not identify
the magnet valve or the injection pump with the measured the magnet valve or the injection pump with the measured the magnet valve or the injection pump with the measured
value of current drain at the begin of the injection value of current drain at the begin of the injection value of current drain at the begin of the injection
2: data stream is defective 2: data stream is defective 2: data stream is defective
Value outside target range or missing (cylinder 2), magnet Value outside target range or missing (cylinder 3), magnet Value outside target range or missing (cylinder 4), magnet
valve or injection pump defective valve or injection pump defective valve or injection pump defective
Corrective Action Corrective Action Corrective Action
Check magnetic valve or injection pump Check magnetic valve or injection pump Check magnetic valve or injection pump
and if necessary change them and if necessary change them and if necessary change them
Others Error Properties Others Error Properties Others Error Properties
Priority 3, self healing, as measured value a current value Priority 3, self healing, as measured value a current value Priority 3, self healing, as measured value a current value
will be showed. will be showed. will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
BIPCyl5 BIPCyl6 BIPCyl7

Begin of injection of cylinder 5: the ECU can not identify Begin of injection of cylinder 6: the ECU can not identify Begin of injection of cylinder 7: the ECU can not identify
the magnet valve or the injection pump with the measured the magnet valve or the injection pump with the measured the magnet valve or the injection pump with the measured
value of current drain at the begin of the injection value of current drain at the begin of the injection value of current drain at the begin of the injection
Value outside target range or missing (cylinder 5), magnet Value outside target range or missing (cylinder 6), magnet Value outside target range or missing (cylinder 7), magnet
valve or injection pump defective valve or injection pump defective valve or injection pump defective
Check magnetic valve or injection pump Check magnetic valve or injection pump Check magnetic valve or injection pump
and if necessary change them and if necessary change them and if necessary change them
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
BIPCyl8 BPSCD BPSCDSysReac

Begin of injection of cylinder 8: the ECU can not identify Charge air pressure sensor: the measured voltage of Charge air pressure: the charge air pressure calculated by
the magnet valve or the injection pump with the measured sensor by ECU is out of the target range; the calculated ECU is above the target range; the ECU activates a
value of current drain at the begin of the injection charge air pressure is implausible or the received value via system reaction
CAN is defective
DEUTZ: 31, Blink: 5-3-8, SPN: 523568, Error Codes DEUTZ: 33, Blink: 2-2-3, SPN: 102,
FMI (Bit 0,1,2,3): DEUTZ: 32, Blink: 2-2-3, SPN: 102, FMI (Bit 0,1,2,3):
2: data stream is defective FMI (Bit 0,1,2,3): 2: data stream is defective
2: data stream is defective 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
2: data stream is defective 4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable
2: data stream is defective 2: data stream is defective 11: Errormode not identifiable
Continuous light of the fault lamp, registered in the error Error Detection Continuous light or blink of the fault lamp, registered in the
memory of the ECU. Continuous light of the fault lamp, registered in the error error memory of the ECU.
memory of the ECU.
Value outside target range or missing (cylinder 8), magnet Possible Error Reason Outside target range with system reaction, air system
valve or injection pump defective Cable break or short circuit, sensor defective, onnection demaged, sensor defective, onnection cable demaged
cable demaged
Check magnetic valve or injection pump Corrective Action Check air system, inspect air system and if necessary
and if necessary change them Check cabling, if LDF6T sensor not working, check sensor repair it, check sensor and if necessary replace it, check
and if necessary replace it, check connection cable and if connection cable and if necessary repair or replace it
Others Error Properties necessary repair or replace it
Priority 3, self healing, as measured value a current value Others Error Properties
will be showed. Others Error Properties Priority 4, self healing, as measured value a current value
Priority 4, self healing, as measured value a default value will be showed.
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
CLSCDSysReac CmbChbMisfire1 CmbChbMisfire2

Coolant level: the coolant level calculated by ECU is Misfire at cylinder 1: the number of the misfire detected by Misfire at cylinder 2: the number of the misfire detected by
underneath the allowed minimum ECU is out of the allowed limit value ECU is out of the allowed limit value
1: data valid, but below normal working area 12: Defective component 12: Defective component
1: data valid, but below normal working area 11: Errormode not identifiable 11: Errormode not identifiable
Continuous light or blink of the fault lamp, registered in the Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
error memory of the ECU. memory of the ECU. memory of the ECU.
Outside target range with system reaction, cooling system Misfire detected (cylinder 1), magnet valve or injection Misfire detected (cylinder 2), magnet valve or injection
untight, sensor defective, onnection cable demaged pump defective, fuel system defective, motor engineering pump defective, fuel system defective, motor engineering
demaged demaged
Corrective Action
Check coolant level, check cabling, inspect cooling system Corrective Action Corrective Action
and if necessary repair it, check sensor and if necessary Check magnetic valve or injection pump and if necessary Check magnetic valve or injection pump and if necessary
replace it, check connection cable and if necessary repair replace them, check fuel system and if necessary repair it, replace them, check fuel system and if necessary repair it,
or replace it check motor engineering and if necessary repair it check motor engineering and if necessary repair it
Priority 3, not self healing, as measured value a current Priority 0, not self healing, as measured value a current Priority 0, not self healing, as measured value a current
value will be showed. value will be showed. value will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
CmbChbMisfire3 CmbChbMisfire4 CmbChbMisfire5

Misfire at cylinder 3: the number of the misfire detected by Misfire at cylinder 4: the number of the misfire detected by Misfire at cylinder 5: the number of the misfire detected by
ECU is out of the allowed limit value ECU is out of the allowed limit value ECU is out of the allowed limit value
12: Defective component 12: Defective component 12: Defective component
Misfire detected (cylinder 3), magnet valve or injection Misfire detected (cylinder 4), magnet valve or injection Misfire detected (cylinder 5), magnet valve or injection
pump defective, fuel system defective, motor engineering pump defective, fuel system defective, motor engineering pump defective, fuel system defective, motor engineering
demaged demaged demaged
Check magnetic valve or injection pump and if necessary Check magnetic valve or injection pump and if necessary Check magnetic valve or injection pump and if necessary
replace them, check fuel system and if necessary repair it, replace them, check fuel system and if necessary repair it, replace them, check fuel system and if necessary repair it,
check motor engineering and if necessary repair it check motor engineering and if necessary repair it check motor engineering and if necessary repair it
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
CmbChbMisfire6 CmbChbMisfire7 CmbChbMisfire8

Misfire at cylinder 6: the number of the misfire detected by Misfire at cylinder 7: the number of the misfire detected by Misfire at cylinder 8: the number of the misfire detected by
ECU is out of the allowed limit value ECU is out of the allowed limit value ECU is out of the allowed limit value
Misfire detected (cylinder 6), magnet valve or injection Misfire detected (cylinder 7), magnet valve or injection Misfire detected (cylinder 8), magnet valve or injection
pump defective, fuel system defective, motor engineering pump defective, fuel system defective, motor engineering pump defective, fuel system defective, motor engineering
demaged demaged demaged
Check magnetic valve or injection pump and if necessary Check magnetic valve or injection pump and if necessary Check magnetic valve or injection pump and if necessary
replace them, check fuel system and if necessary repair it, replace them, check fuel system and if necessary repair it, replace them, check fuel system and if necessary repair it,
check motor engineering and if necessary repair it check motor engineering and if necessary repair it check motor engineering and if necessary repair it
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
CmbChbMisfireMul CmbChbSysReac CoEngShOffDemIgr

Misfire at more cylinders: the number of the misfire Misfire at more cylinders: the number of the misfire Request of engine off: the operator ignors the engine off
detected by ECU is out of the allowed limit value detected by ECU is out of the allowed limit value; the ECU request within an allowed period.
activates a system reaction
12: Defective component FMI (Bit 0,1,2,3): 2: data stream is defective
11: Errormode not identifiable 0: data valid, but above normal working area 11: Errormode not identifiable
Continuous light of the fault lamp, registered in the error Error Detection Continuous light of the fault lamp, registered in the error
memory of the ECU. Continuous light of the fault lamp, registered in the error memory of the ECU.
memory of the ECU.
Misfire detected, magnet valve or injection pump defective, Possible Error Reason Shut-off request ignored by operator
fuel system defective, motor engineering demaged Misfire detected with system reaction, magnet valve or
injection pump defective, fuel system defective, motor Corrective Action
Corrective Action engineering demaged Warranty relevant
Check magnetic valve or injection pump and if necessary
replace them, check fuel system and if necessary repair it, Corrective Action Others Error Properties
check motor engineering and if necessary repair it Check magnetic valve or injection pump and if necessary Priority 4, not self healing, as measured value a current
replace them, check fuel system and if necessary repair it, value will be showed.
Others Error Properties check motor engineering and if necessary repair it To First Page
Priority 0, not self healing, as measured value a current
value will be showed. Others Error Properties
value will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
CRERCD CSLpCD CTLpCD

Engine brake actuator (internal): the current drain Indicator lamp of air heater relay: the current drain Warning lamp for coolant temperature: the current drain
measured by ECU is out of the target range or the measured by ECU is out of the target range or the measured by ECU is out of the target range or the
maximum permissble temperature of the ECU component maximum permissble temperature of the ECU component maximum temperature of the ECU component for power
for power supply of the actuator is exceeded. for power supply of the lamp is exceeded supply of the lamp is exceeded
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable
5: current to low or broken wire 5: current to low or broken wire 11: Errormode not identifiable
11: Errormode not identifiable 2: data stream is defective 11: Errormode not identifiable
cable break or short circuit, sensor defective, connection Cable break or short circuit, lamp defective, connection Cable break or short circuit, lamp defective, connection
cable demaged cable demaged cable demaged
Check actuator and if necessary replace it, check Check cabling and load, check lamp and if necessary Check cabling and load, check lamp and if necessary
connection cable and if necessary repaire or replace it replace it, check connection cable and if necessary repair replace it, check connection cable and if necessary repair
or replace it or replace it
Priority 2, not self healing, as measured value a nominal Others Error Properties Others Error Properties
value for output status will be showed. Priority 1, not self healing, as measured value a nominal Priority 1, not self healing, as measured value a nominal
value for output status will be showed. value for output status will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
CTSCD CTSCDSysReac Dummy1CD_Max

Coolant temperature sensor: the voltage of the sensor Coolant temperature: the coolant temperature calculated Reserve output 1: the ECU detects a short circuit to battery
measured by ECU is out of the target range; the coolant by ECU is above the target range; the ECU activates a
temperature calculated by ECU is implausible compared system reaction Error Codes
with the oil temperature or the received value via CAN is DEUTZ: 57, Blink: 1-0-0, SPN: 701,
defective Error Codes FMI (Bit 0,1,2,3):
DEUTZ: 56, Blink: 2-3-2, SPN: 110, 11: Errormode not identifiable
Error Codes FMI (Bit 0,1,2,3): 11: Errormode not identifiable
DEUTZ: 55, Blink: 2-2-5, SPN: 110, 0: data valid, but above normal working area 11: Errormode not identifiable
FMI (Bit 0,1,2,3): 0: data valid, but above normal working area 11: Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable Error Detection
2: data stream is defective Continuous light of the fault lamp, registered in the error
2: data stream is defective Error Detection memory of the ECU.
Continuous light or blink of the fault lamp, registered in the
Error Detection error memory of the ECU. Possible Error Reason
Continuous light of the fault lamp, registered in the error Short circuit to Ubatt (output 1), connection cable demaged
memory of the ECU. Possible Error Reason
Outside target range with system reaction, cooling system Corrective Action
Possible Error Reason not enough to be filled, clogged or demaged, cooling Check connection cable and if necessary repair or replace
Cable break or short circuit, lamp defective, connection compressor dropped out, sensor defective, onnection it
cable demaged cable demaged Others Error Properties
Corrective Action Corrective Action Priority 1, not self healing, as measured value a shutoff
Check cabling, sensor defect, check sensor and if Check cycle cooling system and compressor, inspect value will be showed.
necessary replace it, check connection cable and if cooling system and if necessary repair it, check cooling To First Page
necessary repair or replace it compressor and if necessary replace it, check sensor and
if necessary replace it, check connection cable and if
Priority 4, self healing, as measured value a default value
will be showed. Others Error Properties
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
Dummy1CD_Min Dummy1CD_SigNpl Dummy2CD_Max

Reserve output 1: the ECU detects a short circuit to Reserve output 1: the ECU detects no load or excess Reserve output 2: the ECU detects a short circuit to battery
ground temperature of the ECU component for power supply of
the connected components Error Codes
Error Codes DEUTZ: 60, Blink: 1-0-0, SPN: 702,
DEUTZ: 58, Blink: 1-0-0, SPN: 701, Error Codes FMI (Bit 0,1,2,3):
FMI (Bit 0,1,2,3): DEUTZ: 59, Blink: 1-0-0, SPN: 701, 11: Errormode not identifiable
11: Errormode not identifiable FMI (Bit 0,1,2,3): 11: Errormode not identifiable
11: Errormode not identifiable 11: Errormode not identifiable
11: Errormode not identifiable Error Detection
Error Detection Continuous light of the fault lamp, registered in the error
Continuous light of the fault lamp, registered in the error Error Detection memory of the ECU.
memory of the ECU. Continuous light of the fault lamp, registered in the error
Possible Error Reason Short circuit to Ubatt (output 2), onnection cable demaged
Short circuit to ground (output 1), connection cable Possible Error Reason
demaged Cable break or ECU internal error (output 1), connection Corrective Action
cable demaged, connected components defective, Check connection cable and if necessary repair or replace
Corrective Action parametering of the output inaccurate, ECU defective it
Check connection cable and if necessary repair or replace
it Corrective Action Others Error Properties
Check connection cable and if necessary repair or replace Priority 1, not self healing, as measured value a shutoff
Others Error Properties it, check parameters and if necessary correct it, replace value will be showed.
Priority 1, not self healing, as measured value a shutoff ECU
value will be showed. To First Page
Priority 1, not self healing, as measured value a shutoff

DTC - List P490_: 220, 310, 501 P492_: 213
Dummy2CD_Min Dummy2CD_SigNpl EGRCD_Max

Reserve output 2: the ECU detects a short circuit to Reserve output 2: the ECU detects no load or excess Actuator of the external EGR valve: the ECU detects a
ground temperature of the ECU component for power supply of short circuit to battery
the connected components
11: Errormode not identifiable FMI (Bit 0,1,2,3): 3: Voltage to high or short circuit to +Ubatt
memory of the ECU.
Short circuit to ground (output 2), connection cable Possible Error Reason Short circuit to Ubatt, connection cable demaged
demaged Cable break or ECU internal error (output 2), connection
cable demaged, connected components defective, Corrective Action
Corrective Action parametering of the output inaccurate, ECU defective Check cabling, sensor defect, check sensor and if
Check connection cable and if necessary repair or replace necessary replace it, check connection cable and if
it Corrective Action necessary repair or replace it
Check connection cable and if necessary repair or replace
Others Error Properties it, check parameters and if necessary correct it, replace Others Error Properties
Priority 1, not self healing, as measured value a shutoff ECU Priority 3, not self healing, as measured value a shutoff
value will be showed. value will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
EGRCD_Min EGRCD_SigNpl EGRCDIntEGR

Actuator of the external EGR valve: the ECU detects a Actuator of the external EGR valve: the ECU detects no Actuator of the internal EGR valve: the ECU detects no
short circuit to ground load or excess temperature of the ECU component for load or excess temperature of the ECU component for
power supply of the connected components power supply of the actuator
Error Codes
DEUTZ: 70, Blink: 4-1-4, SPN: 2791, Error Codes Error Codes
FMI (Bit 0,1,2,3): DEUTZ: 71, Blink: 4-1-5, SPN: 2791, DEUTZ: 72, Blink: 4-1-6, SPN: 2791,
11: Errormode not identifiable FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
11: Errormode not identifiable 11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
2: data stream is defective 2: data stream is defective
Error Detection
Continuous light of the fault lamp, registered in the error Error Detection Error Detection
memory of the ECU. Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
Short circuit to ground, connection cable demaged Possible Error Reason Possible Error Reason
Cable break or excess temperature, sensor defective, Cable break, short circuit or excess temperature, sensor
Corrective Action connection cable demaged defective, connection cable demaged
Check cabling, sensor defect, check sensor and if
necessary replace it, check connection cable and if Corrective Action Corrective Action
necessary repair or replace it Check cabling, sensor defect, check sensor and if Check cabling, sensor defect, check sensor and if
necessary replace it, check connection cable and if necessary replace it, check connection cable and if
Others Error Properties necessary repair or replace it necessary repair or replace it
value will be showed. Others Error Properties Others Error Properties
Priority 3, not self healing, as measured value a shutoff Priority 3, not self healing, as measured value a shutoff
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
EngCDTrqCalcOut EngMBackUp EngMCaS1

Output with PWM signal of the engine power: the current Crankschaft speed sensor: the ECU receives no signal Camschaft speed sensor: the ECU receives no signal or
drain measured by ECU is out of the target range or the and uses the signal from camschaft speed sensor as the signal is defective
maximum permissible temperature of the ECU component alternative to calculate the engine speed
to control the output is exceeded Error Codes
Error Codes DEUTZ: 76, Blink: 2-1-2, SPN: 190,
Error Codes DEUTZ: 75, Blink: 2-1-2, SPN: 190, FMI (Bit 0,1,2,3):
DEUTZ: 74, Blink: 5-5-5, SPN: 923, FMI (Bit 0,1,2,3): 12: Defective component
FMI (Bit 0,1,2,3): 11: Errormode not identifiable 8: unusual frequency, pulse or period.
3: Voltage to high or short circuit to +Ubatt 12: Defective component 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable 11: Errormode not identifiable
5: current to low or broken wire 11: Errormode not identifiable
2: data stream is defective Error Detection
Error Detection Continuous light of the fault lamp, registered in the error
Error Detection Continuous light of the fault lamp, registered in the error memory of the ECU.
Continuous light of the fault lamp, registered in the error memory of the ECU.
Possible Error Reason Speed signal from cam-shaft defectiveiv or missing,
Possible Error Reason Engine running only with cam-shaft speed signal, transmitter defective, connection cable demaged,
Engine Power output: cable break or short circuit, output transmitter defective, connection cable demaged parametering of the sensor wheel inaccurate
defective, connection cable demaged
Corrective Action Check cabling of crankschaft sensor, check crankschaft Check cabling, check camschaft sensor and if necessary
Check cabling, sensor defect, check sensor and if sensor and if necessary replace it, check connection cable replace it, check configuration of sensor wheel, check
necessary replace it, check connection cable and if and if necessary repair or replace it connection cable and if necessary repair or replace it,
necessary repair or replace it check parameters and if necessary correct them
Others Error Properties Priority 3, self healing, as measured value a - will be Others Error Properties
Priority 1, not self healing, as measured value a shutoff showed. Priority 4, self healing, as measured value a 0 will be
value will be showed. showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
EngMCrS1 EngMOfsCaSCrS EngPrtSysReacFOC

Crankschaft speed sensor: the ECU receives no signal or Speed sensor of crankschaft and camschaft: the received Engine speed: the engine speed calculated by ECU is
the signal is defective signals are out of phase above the target range; the ECU activates a system
reaction
12: Defective component 2: data stream is defective FMI (Bit 0,1,2,3):
8: unusual frequency, pulse or period. 11: Errormode not identifiable 0: data valid, but above normal working area
memory of the ECU. memory of the ECU. Blink of the fault lamp, registered in the error memory of
the ECU.
Speed signal from crankshaft defectiveiv or missing, Speed signals of crank-shaft and cam-shaft are phase- Possible Error Reason
transmitter defective, connection cable demaged, sensor shifted, sensor wheel installed in wrong position, sensor Engine overspeed detected with system reaction,
wheel installed inaccurately wrong wired maximum engine speed exceeded
Check cabling, check camschaft sensor and if necessary Check position from crankschaft sensor wheel to
replace it, check configuration of sensor wheel, check camschaft sensor wheel, polarisation crankschaft or
connection cable and if necessary repair or replace it, camschaft sensor, check position of sensor wheel and if Others Error Properties
check the position of sensor wheel and if necessary necessary correct it, check cabling and if necessary Priority 5, not self healing, as measured value a current
correct it correct it value will be showed.
Others Error Properties Others Error Properties To First Page

Priority 4, self healing, as measured value a 0 will be Priority 4, not self healing, as measured value a - will be
showed. showed.

DTC - List P490_: 220, 310, 501 P492_: 213
EngPrtSysReacORC ESLpCD ExFlCD

Engine speed: under overrun conditions, the engine speed Indicator lamp for engine running: the current drain Engine brake flap actuator: the current drain measured by
calculated by ECU is above the target range; the ECU measured by ECU is out of the target range or the ECU is out of the target range or the maximum permissible
activates a system reaction maximum permissible temperature of the ECU component temperature of the ECU component for power supply of
for power supply of the lamp is exceeded the actuator is exceeded
Error Codes
14: Special Instructions FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
2: data stream is defective 11: Errormode not identifiable
Error Detection
Continuous light of the fault lamp, registered in the error Error Detection Error Detection
memory of the ECU. Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
Overrun conditions detected with system reaction, Possible Error Reason Possible Error Reason
maximum engine speed exceeded Cable break or internal ECU error, lamp defective, Engine brake flap actuator: cable break or short circuit,
connection cable demaged sensor defective, connection cable demaged
Corrective Action
Check cabling and load, check lamp and if necessary Check cabling, sensor defect, check sensor and if
Others Error Properties replace it, check connection cable and if necessary repair necessary replace it, check connection cable and if
Priority 4, self healing, as measured value a current value or replace it necessary repair or replace it
will be showed.
Priority 1, not self healing, as measured value a shutoff Priority 2, not self healing, as measured value a shutoff
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FanCD FanCDEval FanCDSysReac

Fan power stage: the current drain measured by ECU is Fan speed sensor: the current drain measured by ECU is Fan speed: the fan speed calculated by ECU is above the
out of the target range or the maximum permissible out of the target range target range; the ECU activates a system reaction
temperature of the ECU component for power supply of
the actuator is exceeded Error Codes Error Codes
Error Codes FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
DEUTZ: 83, Blink: 2-3-8, SPN: 975, 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
FMI (Bit 0,1,2,3): 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable 11: Errormode not identifiable
5: current to low or broken wire
2: data stream is defective Error Detection Error Detection
Error Detection memory of the ECU. memory of the ECU.
memory of the ECU. Possible Error Reason Possible Error Reason
Sensor defective, connection cable demaged, fan speed Above target range with system reaction
Possible Error Reason outside the target range
cable break or short circuit, sensor defective, connection Corrective Action
cable demaged Corrective Action
Check sensor and if necessary replace it, check
Corrective Action connectionn cable and if necessary repair or replace it, Others Error Properties
Check cabling, sensor defect, check sensor and if check fan Priority 3, self healing, as measured value a current value
necessary replace it, check connection cable and if will be showed.
necessary repair or replace it Others Error Properties
Priority 2, self healing, as measured value a current value To First Page
Others Error Properties will be showed.
Priority 2, not self healing, as measured value a nominal

DTC - List P490_: 220, 310, 501 P492_: 213
FlFCD FlFCD_WtLvl FlPSCD

Fuel filter water level sensor: the voltage of sensor Water in fuel: the water level calculated by ECU is above Low fuel pressure sensor: the voltage of sensor measured
measured by ECU is out of the target range the allowed limit value by ECU is out of the target range
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
cable break or short circuit, sensor defective, connection Above target range, excess of maximum permissible water cable break or short circuit, sensor defective, connection
cable demaged level in fuel filter cable demaged
Check cabling, if sensor not working, check sensor and if flush water seperator Check cabling, if sensor not working, check sensor and if
necessary replace it, check connection cable and if necessary replace it, check connection cable and if
necessary repair or replace it Others Error Properties necessary repair or replace it
Others Error Properties value will be showed. Others Error Properties
Priority 1, self healing, as measured value a default value Priority 3, self healing, as measured value a default value
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FlPSCDSysReac FrmMngDecV1 FrmMngFunModCtl

Low fuel pressure: the low fuel pressure calculated by CAN message DecV1 (Pseudo Pedal): the message can CAN message FunModCtl (Function Mode Control): the
ECU is underneath the target range; the ECU activates a not be received by ECU or the received value is above the message can not be received by ECU
system reaction target range
Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 12: Defective component
2: data stream is defective 12: Defective component 11: Errormode not identifiable
2: data stream is defective 12: Defective component 11: Errormode not identifiable
11: Errormode not identifiable 12: Defective component 11: Errormode not identifiable
11: Errormode not identifiable 2: data stream is defective
Error Detection
Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error memory of the ECU.
Possible Error Reason Possible Error Reason Missing message "FunModCtl" = function mode control,
Below target range with system reaction, interruption in Missing or value above target range (message "DecV1" = CAN bus wrong cabled, wiring is demaged, receiver
cycling process of low fuel pressure (for example, fuel pseudo pedal), CAN bus wrong cabled, wiring is demaged, (sender of the message) work inaccurately, parametering
pump defective), sensor defective, connection cable receiver (sender of the message) work inaccurately, inaccurate
demaged parametering inaccurate
Corrective Action
Corrective Action Corrective Action Check CAN Bus cabling (Bus sheduling, polarity, short
Check low fuel pressure loop system, Check fuel pump, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check
inspect fuel system and if necessary repair it, check sensor circuit, power interrupt), test protocol of receiver, check CAN functional range
and if necessary replace it, check connection cable and if CAN functional range
Others Error Properties Priority 1, self healing, as measured value a default value
Others Error Properties Priority 1, self healing, as measured value a default value will be showed.
Priority 3, self healing, as measured value a current value will be showed. To First Page
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTOEngPrt FrmMngTOPrHtEnCmd FrmMngTORxCCVS

CAN message EngPrt (Engine Protection): the message CAN message PrHtEnCmd (Preheat and Engine CAN message RxCCVS (Cruise Control): the message
can not be received by ECU Command): the message received can not be received by can not be received by ECU
ECU
12: Defective component FMI (Bit 0,1,2,3): 11: Errormode not identifiable
12: Defective component 11: Errormode not identifiable 12: Defective component
memory of the ECU.
Missing message "EngPrt" = engine protection, CAN bus Possible Error Reason Missing message "RxCCVS" = cruise control; CAN bus
wrong cabled, wiring is demaged, receiver (sender of the Missing message "PrHtEnCmd" = preheat and engine wrong cabled, wiring is demaged, receiver (sender of the
message) work inaccurately, parametering inaccurate command; CAN bus wrong cabled, wiring is demaged, message) work inaccurately, parametering inaccurate
receiver (sender of the message) work inaccurately,
Corrective Action parametering inaccurate Corrective Action
Check CAN Bus cabling (Bus sheduling, polarity, short Check CAN Bus cabling (Bus sheduling, polarity, short
circuit, power interrupt), test protocol of receiver, check Corrective Action circuit, power interrupt), test protocol of receiver, check
CAN functional range Check CAN Bus cabling (Bus sheduling, polarity, short CAN functional range
circuit, power interrupt), test protocol of receiver, check
Others Error Properties CAN functional range Others Error Properties
will be showed. Others Error Properties will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTORxEngTemp FrmMngTOSwtOut FrmMngTOTCO1

CAN message RxEngTemp (Engine Temperature): the CAN message SwtOut (Switching Output): the message CAN message "TCO1" (Speedo Signal): the message can
message can not be received by ECU can not be received by ECU not be received by ECU
12: Defective component 12: Defective component 11: Errormode not identifiable
11: Errormode not identifiable 11: Errormode not identifiable 12: Defective component
Missing message "RxEngTemp" = engine temperature, Missing message "SwtOut" = switch outputs, CAN bus Missing message "TCO1" = speedo signal, CAN bus
CAN bus wrong cabled, wiring is demaged, receiver wrong cabled, wiring is demaged, receiver (sender of the wrong cabled, wiring is demaged, receiver (sender of the
(sender of the message) work inaccurately, parametering message) work inaccurately, parametering inaccurate message) work inaccurately, parametering inaccurate
inaccurate
Corrective Action Check CAN Bus cabling (Bus sheduling, polarity, short Check CAN Bus cabling (Bus sheduling, polarity, short
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check circuit, power interrupt), test protocol of receiver, check
circuit, power interrupt), test protocol of receiver, check CAN functional range CAN functional range
CAN functional range
Others Error Properties Priority 1, self healing, as measured value a default value Priority 1, self healing, as measured value a default value
Priority 1, self healing, as measured value a default value will be showed. will be showed.
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTOTSC1AE FrmMngTOTSC1AR FrmMngTOTSC1DE

CAN message TSC1-AE (Torque/Speed Control #1 from CAN message TSC1-AR (Torque/Speed Control #1 from CAN message TSC1-DE (Torque/Speed Control #1 from
Automatic Traction Control to Engine): the message can Automatic Traction Control to Retarder): the message can Driveline to Engine): the message can not be received by
not be received by ECU not be received by ECU ECU
Missing message "TSC1-AE", CAN bus wrong cabled, Missing message "TSC1-AR", CAN bus wrong cabled, Missing message "TSC1-DE", CAN bus wrong cabled,
wiring is demaged, receiver (sender of the message) work wiring is demaged, receiver (sender of the message) work wiring is demaged, receiver (sender of the message) work
inaccurately, parametering inaccurate inaccurately, parametering inaccurate inaccurately, parametering inaccurate
Check CAN Bus cabling (Bus sheduling, polarity, short Check CAN Bus cabling (Bus sheduling, polarity, short Check CAN Bus cabling (Bus sheduling, polarity, short
circuit, power interrupt), test protocol of receiver, check circuit, power interrupt), test protocol of receiver, check circuit, power interrupt), test protocol of receiver, check
CAN functional range CAN functional range CAN functional range
Priority 1, not self healing, as measured value a default Priority 1, not self healing, as measured value a default Priority 1, not self healing, as measured value a default
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTOTSC1DR FrmMngTOTSC1PE FrmMngTOTSC1TE

CAN message TSC1-DR (Torque/Speed Control #1 from CAN message TSC1-PE (Torque/Speed Control #1 from CAN message TSC1-TE (Torque/Speed Control #1 from
Driveline to Retarder): the message can not be received by Power Take Off to Engine): the message can not be Traction Control to Engine): the message can not be
ECU received by ECU received by ECU
Missing message "TSC1-DR", CAN bus wrong cabled, Missing message "TSC1-PE", CAN bus wrong cabled, Missing message "TSC1-TE", CAN bus wrong cabled,
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTOTSC1TR FrmMngTOTSC1VE FrmMngTOTSC1VR

CAN message TSC1-TR (Torque/Speed Control #1 from CAN message TSC1-VE (Torque/Speed Control #1 from CAN message TSC1-VR (Torque/Speed Control #1 from
Traction Control to Retarder): the message can not be Vehicle Control to Engine): the message can not be Vehicle Control to Retarder): the message can not be
received by ECU received by ECU received by ECU
Missing message "TSC1-TR", CAN bus wrong cabled, Missing message "TSC1-VE", CAN bus wrong cabled, Missing message "TSC1-VR", CAN bus wrong cabled,
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngTxTO FTSCD FTSCDSysReac

CAN message: the ECU detects a timeout for one or more Fuel temperature sensor: the voltage measured by ECU is Fuel temperature: the fuel temperature calculated by ECU
posted message out of the target range is above the target range; the ECU activates a system
reaction
11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt FMI (Bit 0,1,2,3):
11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area
12: Defective component 11: Errormode not identifiable 0: data valid, but above normal working area
memory of the ECU. memory of the ECU. Continuous light or blink of the fault lamp, registered in the
error memory of the ECU.
Timeout for sent messages Fuel temp. sensor: cable break or short circuit, sendor Possible Error Reason
defective, connection cable demaged Above target range with system reaction, interruption of
Corrective Action fuel loop (for example, rail pressure relief valve defective),
Corrective Action sensor defective, connection cable demaged
Check cabling, if sensor not working, check sensor and if
Others Error Properties necessary replace it, check connection cable and if Corrective Action
Priority 1, self healing, as measured value a - will be necessary repair or replace it Check fuel system and if necessary repair it, check sensor
showed. and if necessary replace it, check connection cable and if
will be showed. Others Error Properties
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
OTSCD GOTSCDSysReac HdThrt

Customer specific temperature sensor 1: the voltage of Customer specific temperature 1: the temperature Hand throttle pedal sensor: the voltage measured by ECU
sensor measured by ECU is out of the target range or the calculated by ECU is above the target range; the ECU is out of the target range or the calculated pedal position is
received value of temperature via CAN is defective activates a system reaction implausible compared with the position of accelerator
pedal 1
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective FMI (Bit 0,1,2,3):
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
Continuous light of the fault lamp, registered in the error Continuous light or blink of the fault lamp, registered in the Error Detection
memory of the ECU. error memory of the ECU. Continuous light of the fault lamp, registered in the error
memory of the ECU.
Cable break or short circuit (sensor 1), sensor defective, Outside target range with system reaction (temperature 1), Possible Error Reason
connection cable demaged, CAN bus wrong cabled, wiring dependant on the application Cable break or short circuit, signal implausible compared
demaged, receiver (sender of the message) work to signal of idle sensor, transmitter defective, connection
inaccurately, parametering inaccurate Corrective Action cable demaged
Customer specific bugfixing, denpendant on application
Customer specific bugfixing, check sensor and if Others Error Properties Check cabling, check sensor and if necessary replace it,
necessary replace it, check connection cable and if Priority 3, self healing, as measured value a current value check connection cable and if necessary repair or replace
necessary repair or replace it, Check CAN Bus cabling will be showed. it
(Bus sheduling, polarity, short circuit, power interrupt), test
protocol of receiver, check CAN fun Others Error Properties
Priority 2, self healing, as measured value a default value To First Page
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
HOTSCD HOTSCDSysReac HWEMonCom

Customer specific temperature sensor 2: the voltage of Customer specific temperature 2: the temperature Internal hardware monitoring: the ECU detects a
sensor measured by ECU is out of the target range or the calculated by ECU is above the target range; the ECU communication distrubance
received value of temperature via CAN is defective activates a system reaction
Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 12: Defective component
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 11: Errormode not identifiable
12: Defective component 11: Errormode not identifiable 11: Errormode not identifiable
Error Detection
Continuous light of the fault lamp, registered in the error Continuous light or blink of the fault lamp, registered in the memory of the ECU.
memory of the ECU. error memory of the ECU.
Possible Error Reason Possible Error Reason Communication with chip CJ 940 disturbed, ECU defective
Cable break or short circuit (sensor 2), sensor defective, Outside target range with system reaction (temperature 2),
connection cable demaged, CAN bus wrong cabled, wiring dependant on the application Corrective Action
demaged, receiver (sender of the message) work If cannot delete the error, change ECU
inaccurately, parametering inaccurate Corrective Action
Customer specific bugfixing, denpendant on application Others Error Properties
Corrective Action Priority 4, not self healing, as measured value a - will be
Customer specific bugfixing, check sensor and if Others Error Properties showed.
necessary replace it, check connection cable and if Priority 3, self healing, as measured value a current value
necessary repair or replace it, Check CAN Bus cabling will be showed. To First Page
(Bus sheduling, polarity, short circuit, power interrupt), test
protocol of receiver, check CAN fun
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
HWEMonEEPROM HWEMonRcyLocked HWEMonRcySuppressed

Internal hardware monitoring: the ECU finds an error Internal hardware monitoring: the CPU of the ECU is reset Internal hardware monitoring: the CPU of the ECU is reset
during the access to ist EEPROM memory or works with and the cause is logged internally; no item will be created and the cause is logged internally; no item will be created
an alternative value in error memory in error memory
12: Defective component 14: Special Instructions 14: Special Instructions
Continuous light of the fault lamp, registered in the error Blink of the fault lamp, registered in the error memory of Blink of the fault lamp, registered in the error memory of
memory of the ECU. the ECU. the ECU.
Error during EEPROM memory access or EEPROM works A recovery occurred which is stored as protected A recovery occurred which is not stored
with substitute value, programming error, ECU defective
Corrective Action Recoverey occured which is stored as protected Recoverey occured which is stored as protected
If not programmed, EEPROM is defect --> ECU is With parameter HWEMon_numRexxxxxxx the recovery With parameter HWEMon_numRexxxxxxx the recovery
defect, reprogram ECU and if necessary replace it nummer and the subsequent position can be identified. nummer and the subsequent position can be identified.
See especially SW-Doku _rcy_auto.pdf See especially SW-Doku _rcy_auto.pdf
Priority 4, not self healing, as measured value a - will be Others Error Properties Others Error Properties
showed. Priority 5, not self healing, as measured value a - will be Priority 5, not self healing, as measured value a - will be
showed. showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
HWEMonRcyVisible HWEMonUMaxSupply HWEMonUMinSupply

Internal hardware monitoring: the CPU of the ECU is reset Internal hardware monitoring: the ECU detects an excess Internal hardware monitoring: the ECU detects an
and an item will be created in error memory of the target range for the power supply of ist undershooting of the target range for the power supply of
communication module ist communication module
Error Codes
11: Errormode not identifiable FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
14: Special Instructions 11: Errormode not identifiable 11: Errormode not identifiable
Error Detection
Blink of the fault lamp, registered in the error memory of Error Detection Error Detection
the ECU. Continuous light of the fault lamp, registered in the error Continuous light of the fault lamp, registered in the error
A recovery occurred which is visible in the error memory Possible Error Reason Possible Error Reason
Overvoltage at CJ940, power supply voltage too high, ECU Undervoltage at CJ940, power supply voltage too low,
Corrective Action defective ECU defective
Recoverey occured which is stored as protected
With parameter HWEMon_numRexxxxxxx the recovery Corrective Action Corrective Action
nummer and the subsequent position can be identified. Check working voltage and if necessary correct it, Check Check working voltage and if necessary correct it, Check
See especially SW-Doku _rcy_auto.pdf ECU and if necessary replace it ECU and if necessary replace it
Priority 5, not self healing, as measured value a - will be Priority 4, not self healing, as measured value a - will be Priority 4, not self healing, as measured value a - will be
showed. showed. showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
IATSCD IATSCDSysReac InjVlvBnk1A

Charge air temperature sensor: the voltage of sensor Charge air temperature: die charge air temperature Injector cylinder bank 1: the current drain measured by
measured by ECU is out of the target range or the calculated by ECU is above the target range; the ECU ECU is above the target range
received value of temperature via CAN is defective activates a system reaction
Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 3: Voltage to high or short circuit to +Ubatt
3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area 4: Voltage to low or short circuit to -Ubatt
4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area 13: out of calibrated range
2: data stream is defective 11: Errormode not identifiable 11: Errormode not identifiable
Error Detection
Continuous light of the fault lamp, registered in the error Continuous light or blink of the fault lamp, registered in the memory of the ECU.
memory of the ECU. error memory of the ECU.
Possible Error Reason Possible Error Reason Short circuit (cylinder bank 1), injector defective,
Cable break or short circuit, sensor defective, connection Above target range with system reaction, air system connection cable demaged
cable demaged, CAN bus wrong cabled, wiring demaged, demaged, sensor defective, connection cable demaged
receiver (sender of the message) work inaccurately, Corrective Action
parametering inaccurate Corrective Action Check cabling, check injectors and if necessary replace
Check construction of LDF6T , check suction parts, check them, check connection cable and if necessary repair or
Corrective Action air system and if necessary repair it, check sensor and if replace it
Check cabling, LDF6T-sensor not working, check sensor necessary replace it, check connection cable and if
and if necessary replace it, check connection cable and if necessary repair or replace it Others Error Properties
necessary repair or replace it, Check CAN Bus cabling Priority 4, self healing, as measured value a current value
(Bus sheduling, polarity, short circuit, power interrupt), test Others Error Properties will be showed.
protocol of receiver, check CAN functional range Priority 4, self healing, as measured value a current value
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvBnk1B InjVlvBnk2A InjVlvBnk2B

Injector cylinder bank 1: the current drain measured by Injector cylinder bank 2: the current drain measured by Injector cylinder bank 2: the current drain measured by
ECU is underneath the target range ECU is above the target range ECU is underneath the target range
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 4: Voltage to low or short circuit to -Ubatt 13: out of calibrated range
5: current to low or broken wire 13: out of calibrated range 5: current to low or broken wire
13: out of calibrated range 11: Errormode not identifiable 13: out of calibrated range
Cable break (cylinder bank 1), injector defective, Short circuit (cylinder bank 2), injector defective, Cable break (cylinder bank 2), injector defective,
connection cable demaged connection cable demaged connection cable demaged
Check cabling, check injectors and if necessary replace Check cabling, check injectors and if necessary replace Check cabling, check injectors and if necessary replace
them, check connection cable and if necessary repair or them, check connection cable and if necessary repair or them, check connection cable and if necessary repair or
replace it replace it replace it
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvChipA InjVlvChipB InjVlvCyl1A

Internal hardware monitoring: the ECU detects an error of Internal hardware monitoring: the ECU detects a Injector 1: the current drain measured by ECU is above the
ist injector high current output disturbance in its injector high current output target range
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12: Defective component 13: out of calibrated range
14: Special Instructions 12: Defective component 4: Voltage to low or short circuit to -Ubatt
12: Defective component 12: Defective component 11: Errormode not identifiable
Blink of the fault lamp, registered in the error memory of Blink of the fault lamp, registered in the error memory of Continuous light of the fault lamp, registered in the error
the ECU. the ECU. memory of the ECU.
High power stage Injector A, ECU defective High power stage Injector B, ECU defective Short circuit (cylinder 1), injector defective, connection
cable demaged
If error is not removable, change ECU If error is not removable, change ECU Corrective Action
Check cabling, check injectors and if necessary replace
Others Error Properties Others Error Properties them, check connection cable and if necessary repair or
Priority 5, not self healing, as measured value a current Priority 5, not self healing, as measured value a current replace it
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvCyl1B InjVlvCyl2A InjVlvCyl2B

Injector 1: the current drain measured by ECU is Injector 2: the current drain measured by ECU is above the Injector 2: the current drain measured by ECU is
underneath the target range target range underneath the target range
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
Cable break (cylinder 1), injector defective, connection Short circuit (cylinder 2), injector defective, connection Cable break (cylinder 2), injector defective, connection
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvCyl3A InjVlvCyl3B InjVlvCyl4A

Injector 3: the current drain measured by ECU is above the Injector 3: the current drain measured by ECU is Injector 4: the current drain measured by ECU is above the
target range underneath the target range target range
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 13: out of calibrated range 11: Errormode not identifiable
Short circuit (cylinder 3), injector defective, connection Cable break (cylinder 3), injector defective, connection Short circuit (cylinder 4), injector defective, connection
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213

To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvCyl6A InjVlvCyl6B InjVlvCyl7A

Injector 6: the current drain measured by ECU is above the Injector 6: the current drain measured by ECU is Injector 7: the current drain measured by ECU is above the
target range underneath the target range target range
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 13: out of calibrated range 11: Errormode not identifiable
Short circuit (cylinder 6), injector defective, connection Cable break (cylinder 6), injector defective, connection Short circuit (cylinder 7), injector defective, connection
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213

To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
InjVlvErrDet MeUnCD_ADC MeUnCDNoLoad

Rail pressure monitoring: the monitoring of the rail Fuel volume flow rate: the fuel volume rate calculated by Valve at outlet of the fuel metering unit: the ECU detects
pressure will be deactivated by ECU because of the ECU at outlet of the fuel metering unit is out of the target no load or temperature excess of the ECU component for
activation of the function "compression test" by user range power supply of the valve
14: Special Instructions 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
11: Errormode not identifiable 11: Errormode not identifiable 5: current to low or broken wire
0 of the fault lamp, registered in the error memory of the Continuous light of the fault lamp, registered in the error Continuous light, 15s blink before shut off of the fault lamp,
ECU. memory of the ECU. registered in the error memory of the ECU.
Compression test active: rail-pressure monitoring is going Flow rate outside target range wiring error or ECU output is switched off because of
to be disabled overtemperature, fuel metering unit defective, connection
Corrective Action cable demaged
Corrective Action Check cabling , if necessary check FCU, check fuel
not correct metering unit and if necessary replace it, check connection Corrective Action
cable and if necessary repair or replace it Check cabling , if necessary check FCU, check fuel
Others Error Properties metering unit and if necessary replace it, check connection
Priority 1, not self healing, as measured value a 0 will be Others Error Properties cable and if necessary repair or replace it
showed. Priority 4, not self healing, as measured value a current
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
MeUnCDSCBat MeUnCDSCGnd MnRly1_SCB

Valve at outlet of the fuel metering unit: the current drain Valve at outlet of the fuel metering unit: the current drain Main relay 1: the current drains measured by ECU is
measured by ECU is above the target range measured by ECU is above the target range above the target range
12: Defective component 11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
Continuous light, 15s blink before shut off of the fault lamp, Continuous light, 15s blink before shut off of the fault lamp, Continuous light of the fault lamp, registered in the error
registered in the error memory of the ECU. registered in the error memory of the ECU. memory of the ECU.
Short circuit to Ubatt, fuel metering unit defective, Short circuit to ground, fuel metering unit defective, Short circuit to Ubatt (relay 1), relay defective, connection
connection cable demaged connection cable demaged cable demaged
Check cabling , if necessary check FCU, check fuel Check cabling , if necessary check FCU, check fuel Check cabling, check ECU, check relay and if necessary
metering unit and if necessary replace it, check connection metering unit and if necessary replace it, check connection replace it, check connection cable and if necessary repair
cable and if necessary repair or replace it cable and if necessary repair or replace it or replace it
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
MnRly1_SCG Montr MRlyCD

Main relay 1: the current drains measured by ECU is Internal hardware monitoring: the ECU detects an Main relay: during the switching off, main relay does not
above the target range disturbance in ist monitoring module (Wachtdog) switch on within an allowed time
11: Errormode not identifiable 11: Errormode not identifiable 7: Mechanical system not OK
4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable 12: Defective component
11: Errormode not identifiable 14: Special Instructions 11: Errormode not identifiable
Continuous light of the fault lamp, registered in the error Blink of the fault lamp, registered in the error memory of Continuous light of the fault lamp, registered in the error
memory of the ECU. the ECU. memory of the ECU.
Short circuit to ground (relay 1), relay defective, connection Watchdog counter exceeds maximum, ECU defective EDC16: main relay not open in allowed time or main relay
cable demaged open too early; EDC7: main relay not open in allowed time
Corrective Action or short circuit of main relay to ground; EDC16: main relay
Corrective Action If error is not removable, change ECU defective, connection cable demaged; generally: rapid
Check cabling, check ECU, check relay and if necessary shut-off of the ECU (without waiting till the end of the
replace it, check connection cable and if necessary repair Others Error Properties
afterrun), ECU defective
or replace it Priority 5, not self healing, as measured value a - will be
showed.
Others Error Properties Corrective Action
Priority 3, not self healing, as measured value a current EDC16: check external main relay, check cabling
value will be showed. EDC7: if error is not removable, change ECU, EDC16:
Check main relay and if necessary replace it, check
connection cable and if necessary repair or replace it;
both: if error is not removable, change ECU
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
MRlyCDMnRly2 MRlyCDMnRly3 MSSCD1

Main relay 2 (in ECU): during the switching off, main relay Main relay 3 (in ECU): during the switching off, main relay Multi state switch 1: the voltage measured by ECU is out of
does not switch on within an allowed time does not switch on within an allowed time the target range or the swith setting is not plausible
7: Mechanical system not OK 7: Mechanical system not OK 3: Voltage to high or short circuit to +Ubatt
12: Defective component 12: Defective component 4: Voltage to low or short circuit to -Ubatt
rapid shut-off of the ECU (without waiting till the end of the Short circuit to ground or emergency shut-off (relay 3 Cable break or short circuit, input voltage outside target
afterrun), ECU defective internal), rapid shut-off of the ECU (without waiting till the range (switch 1), switch defective, connection cable
end of the afterrun), ECU defective demaged
Corrective Action
If error not removable, change ECU Corrective Action Corrective Action
Check cabling, check ECU, if error not removable, change Check cabling and sensor, check switch and if necessary
Others Error Properties ECU replace it, check connection cable and if necessary repair
Priority 3, not self healing, as measured value a current or replace it
Priority 3, not self healing, as measured value a current Others Error Properties
value will be showed. Priority 2, self healing, as measured value a default value
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
MSSCD2 MSSCD3 NetMngCANAOff

Multi state switch 2: the voltage measured by ECU is out of Multi state switch 3: the voltage measured by ECU is out of CAN bus A: the ECU is not allowed to send messages,
the target range or the swith setting is not plausible the target range or the swith setting is not plausible because the status "BusOff" is detected
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 14: Special Instructions
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 11: Errormode not identifiable
2: data stream is defective 2: data stream is defective 11: Errormode not identifiable
Cable break or short circuit, input voltage outside target Cable break or short circuit, input voltage outside target Cable break or short circuit, off-state (CAN bus A), CAN
range (switch 2), switch defective, connection cable range (switch 3), switch defective, connection cable bus deactivated, connection cable demaged
demaged demaged
Corrective Action
Corrective Action Corrective Action Check cabling of CAN bus and if necessary repair it, check
Check cabling and sensor, check switch and if necessary Check cabling and sensor, check switch and if necessary connection cable and if necessary repair or replace it
replace it, check connection cable and if necessary repair replace it, check connection cable and if necessary repair
or replace it or replace it Others Error Properties
Priority 2, self healing, as measured value a 0 will be
Others Error Properties Others Error Properties showed.
will be showed. will be showed. To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
NetMngCANBOff NetMngCANCOff OPLpCD

CAN bus B: the ECU is not allowed to send messages, CAN bus C: the ECU is not allowed to send messages, Warning lamp for oil level: the current drain measured by
because the status "BusOff" is detected because the status "BusOff" is detected ECU is out of the target range or the maximum
temperature of the ECU component for power supply of
Error Codes Error Codes the lamp is exceeded
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): Error Codes
14: Special Instructions 14: Special Instructions DEUTZ: 195, Blink: 1-3-5, SPN: 705,
11: Errormode not identifiable 11: Errormode not identifiable FMI (Bit 0,1,2,3):
11: Errormode not identifiable 11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
5: current to low or broken wire
Error Detection Error Detection 2: data stream is defective
memory of the ECU. memory of the ECU. Error Detection
Possible Error Reason Possible Error Reason memory of the ECU.
Cable break or short circuit, off-state (CAN bus B), CAN Cable break or short circuit, off-state (CAN bus C), CAN
bus deactivated, connection cable demaged bus deactivated, connection cable demaged Possible Error Reason
Cable break or short circuit, lamp defective, connection
Corrective Action Corrective Action cable demaged
Check cabling of CAN bus and if necessary repair it, check Check cabling of CAN bus and if necessary repair it, check
connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it Corrective Action
Check cabling and load, check lamp and if necessary
Others Error Properties Others Error Properties replace it, check connection cable and if necessary repair
Priority 2, self healing, as measured value a 0 will be Priority 2, self healing, as measured value a 0 will be or replace it
showed. showed.
Priority 1, not self healing, as measured value a default
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
OPSCD OPSCD1 OPSCDSysReacHi

Oil pressure sensor: the voltage of sensor measured by Oil pressure: the oil pressure calculated by ECU is Oil pressure: the oil pressure calculated by ECU is above
ECU is out of the target range or the received value of oil implausibly low the target range; the ECU activates a system reaction
pressure via CAN is implausible (Oil pressure is above the
target range with higher oil temperature at the same time) Error Codes Error Codes
Error Codes FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
DEUTZ: 196, Blink: 2-2-4, SPN: 100, 11: Errormode not identifiable 0: data valid, but above normal working area
FMI (Bit 0,1,2,3): 11: Errormode not identifiable 0: data valid, but above normal working area
3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 1: data valid, but below normal working area 11: Errormode not identifiable
0: data valid, but above normal working area Error Detection Error Detection
Continuous light of the fault lamp, registered in the error Continuous light or blink of the fault lamp, registered in the
Error Detection memory of the ECU. error memory of the ECU.
memory of the ECU. Possible Error Reason Possible Error Reason
Oil pressure implausible low, sensor defective, connection Above target range, oil volume too large, sensor defective,
Possible Error Reason cable demaged oil pump defective, connection cable demaged
Cable break or short circuit, sensor defective, connection
cable demaged, CAN bus wrong cabled, wiring demaged, Corrective Action Corrective Action
receiver (sender of the message) work inaccurately, Check cabling, if sensor not working, check sensor and if Check oil level and if necessary correct it, check oil pump
parametering inaccurate necessary replace it, check connection cable and if and if necessary replace it, check sensor and if necessary
necessary repair or replace it replace it, check connection cable and if necessary repair
Corrective Action or replace it
Check cabling, if sensor not working, check sensor and if Others Error Properties
necessary replace it, check connection cable and if Priority 2, self healing, as measured value a current value Others Error Properties
necessary repair or replace it, Check CAN Bus cabling will be showed. Priority 4, self healing, as measured value a current value
(Bus sheduling, polarity, short circuit, power interrupt), test will be showed.
protocol of receiver, check CAN functional range
To First Page
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
OPSCDSysReacLo OSwCD OTSCD

Oil pressure: the oil pressure calculated by ECU is Bridgeover switch: the ECU receives a permanent signal Oil temperature sensor: the voltage of sensor measured by
underneath the target range; the ECU activates a system ECU is out of the target range; the oil temperature
reaction Error Codes calculated by ECU is implausible compared with coolant
DEUTZ: 200, Blink: 1-4-5, SPN: 1237, temperature or the received value via CAN is defective
Error Codes FMI (Bit 0,1,2,3):
DEUTZ: 199, Blink: 2-3-1, SPN: 100, 11: Errormode not identifiable Error Codes
FMI (Bit 0,1,2,3): 11: Errormode not identifiable DEUTZ: 201, Blink: 1-4-4, SPN: 175,
1: data valid, but below normal working area 11: Errormode not identifiable FMI (Bit 0,1,2,3):
1: data valid, but below normal working area 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable Error Detection 2: data stream is defective
Continuous light of the fault lamp, registered in the error 2: data stream is defective
Error Detection memory of the ECU.
Continuous light or blink of the fault lamp, registered in the Error Detection
error memory of the ECU. Possible Error Reason Continuous light of the fault lamp, registered in the error
Switch is blocked, taster locked, connection cable memory of the ECU.
Possible Error Reason demaged
Below target range, oil volume too small, sensor defective, Possible Error Reason
oil pump defective, connection cable demaged Corrective Action Cable break or short circuit, sensor defective, connection
Check cabling, if sensor not working, check switch and if cable demaged
Corrective Action necessary replace it, check connection cable and if
Check oil level and if necessary correct it, check oil pump necessary repair or replace it Corrective Action
and if necessary replace it, check sensor and if necessary Check cabling, if sensor not working, check switch and if
replace it, check connection cable and if necessary repair Others Error Properties necessary replace it, check connection cable and if
or replace it Priority 2, self healing, as measured value a current value necessary repair or replace it
will be showed.
Priority 4, self healing, as measured value a current value Priority 4, self healing, as measured value a default value
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
OTSCDSysReac PRVMon RailCD

Oil temperature: the oil temperature calculated by ECU is Rail pressure relief valve: is open, will be forced to open, Rail pressure sensor: the voltage of sensor measured by
above the target range; the ECU activates a system the forced-open failed ECU is out of the target range
reaction
Error Codes DEUTZ: 208, Blink: 1-4-6, SPN: 523470, DEUTZ: 209, Blink: 1-4-7, SPN: 157,
DEUTZ: 203, Blink: 1-4-4, SPN: 175, FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
FMI (Bit 0,1,2,3): 14: Special Instructions 3: Voltage to high or short circuit to +Ubatt
0: data valid, but above normal working area 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
0: data valid, but above normal working area 12: Defective component 11: Errormode not identifiable
Error Detection Continuous light, 15s blink before shut off of the fault lamp, Continuous light, 15s blink before shut off of the fault lamp,
Continuous light or blink of the fault lamp, registered in the registered in the error memory of the ECU. registered in the error memory of the ECU.
error memory of the ECU.
Possible Error Reason Rail pressure relief valve open or forced open abortive Cable break or short circuit, sensor defective, connection
Above target range with system reaction, oil volume too (interpretation of the rail pressure gradient), operating cable demaged
small, oil loop disturbed, sensor defective, connection voltage too low, rail pressure sensor defective, fuel
cable demaged metering unit defective, rail pressure relief valve defective, Corrective Action
air in fuel system Check cabling, check rail pressure sensor and if necessary
Corrective Action replace it, check connection cable and if necessary repair
Check cycle cooling system and compressor, check oil Corrective Action or replace it
level and if necessary correct it, check sensor and if Check working voltage and if necessary correct it, check
necessary replace it, check oil loop and if necessary repair rail-pressure sensor and if necessary replace it, check Others Error Properties
it, check connection cable and if necessary repair or FCU and if necessary replace it, check rail pressure relief Priority 4, not self healing, as measured value a default
replace it valve and if necessary replace it, bleed the fuel-system value will be showed.
Others Error Properties Others Error Properties To First Page

Priority 4, self healing, as measured value a current value Priority 4, not self healing, as measured value a current
will be showed. value will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
RailCDOfsTst RailMeUn0 RailMeUn1

Rail pressure sensor: the change of the voltage measured Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
by ECU during the engine start or the after-run is out of the above the target range which is dependant on the engine above the target range which is dependant on the volume
target range speed flow rate
0: data valid, but above normal working area 0: data valid, but above normal working area 0: data valid, but above normal working area
1: data valid, but below normal working area 11: Errormode not identifiable 11: Errormode not identifiable
Continuous light of the fault lamp, registered in the error Continuous light or blink of the fault lamp, registered in the Continuous light or blink of the fault lamp, registered in the
memory of the ECU. error memory of the ECU. error memory of the ECU.
Deviation of signal during start or after-run above target 1) Leakage in high pressure system (external) , 1) Leakage in high pressure system (external) ,
range, sensor defective 2) Leakage at rail pressure relief valve (internal), 2) Leakage at rail pressure relief valve (internal),
3) Needle clampt in open position, 3) Needle clampt in open position,
Corrective Action 4) Abrasion at injector, 4) Abrasion at injector,
Replace sensor 5) Abrasion at high pressure pump, 5) Abrasion at high pressure pump,
Others Error Properties 6) Too low primary pressure on low pressure side, sensor 6) Too low primary pressure on low pressure side, sensor
defective, fuel system disturbed defective, fuel system disturbed
will be showed. Corrective Action Corrective Action
(A) Check for leakage (A) Check for leakage
(B) Chek fuel-primary pressure (B) Chek fuel-primary pressure
(C) Change components, check sensor and if necessary (C) Change components, check sensor and if necessary
replace it, check fuel system and if necessary repair it replace it, check fuel system and if necessary repair it
Priority 4, self healing, as measured value a current value Priority 4, self healing, as measured value a current value
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
RailMeUn2 RailMeUn3 RailMeUn4

Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
underneath the target range which is dependant on the underneath the target range which is dependant on the above the absolute target range
engine speed volume flow rate
Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 0: data valid, but above normal working area
0: data valid, but above normal working area 1: data valid, but below normal working area 11: Errormode not identifiable
Error Detection
Error Detection Error Detection Continuous light or blink of the fault lamp, registered in the
Continuous light or blink of the fault lamp, registered in the Continuous light or blink of the fault lamp, registered in the error memory of the ECU.
error memory of the ECU. error memory of the ECU.
Possible Error Reason Possible Error Reason 1) No power supply in FCU,
1) No power supply in FCU, 1) Leakage in high pressure system (external) , 2) ZME clamped in open position,
2) ZME clamped in open position, 2) Leakage at rail pressure relief valve (internal), 3) Too high pressure nach Nullförderdrossel (FCU),
3) Too high pressure nach Nullförderdrossel (FCU), 3) Needle clampt in open position, 4) Nullförderdrossel clogged,
4) Nullförderdrossel clogged, 4) Abrasion at injector, 5) Too high primary pressure on low pressure side, sensor
5) Too high primary pressure on low pressure side, sensor 5) Abrasion at high pressure pump, defective, fuel system disturbed
defective, fuel system disturbed 6) Too low primary pressure on low pressure side, sensor
defective, fuel system disturbed Corrective Action
Corrective Action (A) Check return-pressure FCU
(A) Check return-pressure FCU Corrective Action (B) Check flow-pressure
(B) Check flow-pressure (A) Check for leakage (C) Change FCU, check sensor and if necessary replace it,
(C) Change FCU, check sensor and if necessary replace it, (B) Chek fuel-primary pressure check fuel system and if necessary repair it
check fuel system and if necessary repair it (C) Change components, check sensor and if necessary
replace it, check fuel system and if necessary repair it Others Error Properties
Others Error Properties Priority 4, self healing, as measured value a current value
Priority 4, self healing, as measured value a current value Others Error Properties will be showed.
will be showed. Priority 4, self healing, as measured value a current value

DTC - List P490_: 220, 310, 501 P492_: 213
RailMeUn7 SOPTst SSpMon1

Rail pressure: the fuel pressure in rail calculated by ECU is Internal hardware monitoring: the ECU finds an Internal hardware monitoring: the ECU detects a deviation
implausible compared with the setpoint setting of the fuel disturbance in the redundant switch off path through a test of the target range of the power supply voltage of sensor 1
metering unit during the ramp up phase
Error Codes
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3): 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 11: Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
Error Detection
Continuous light or blink of the fault lamp, registered in the Continuous light of the fault lamp, registered in the error memory of the ECU.
error memory of the ECU. memory of the ECU.
Possible Error Reason Possible Error Reason 5V sensor supply voltage 1 outside target range, operating
1) Leakage in high pressure system (external) , Test of redundant shut-off paths voltage too high or to low, connection cable demaged,
2) Leakage at rail pressure relief valve (internal), ECU defective
3) Needle clampt in open position, Corrective Action
4) Abrasion at injector, Could be triggered by over/undervoltage or external Corrective Action
5) Abrasion at high pressure pump, Watchdog If error not removable, change ECU, check cabling of
6) Too low primary pressure on low pressure side, sensor external components, check working voltage and if
Others Error Properties necessary correct it, check connection cable and if
defective, fuel system disturbed
Priority 4, not self healing, as measured value a - will be necessary repair or replace it
Corrective Action showed.
(A) Check for leakage Others Error Properties
(B) Chek fuel-primary pressure Priority 3, self healing, as measured value a current value
(C) Change components, check sensor and if necessary will be showed.
replace it, check fuel system and if necessary repair it
To First Page
will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
SSpMon2 SSpMon3 StrtCDHS

Internal hardware monitoring: the ECU detects a deviation Internal hardware monitoring: the ECU detects a deviation Start relay (high side power stage): the current drain
of the target range of the power supply voltage of sensor 2 of the target range of the power supply voltage of sensor 3 measured by ECU is above the target range
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
5V sensor supply voltage 2 outside target range, operating Wrong voltage of internal 5V reference source 3, operating Start relay (high side): short circuit, relay defective,
voltage too high or to low, connection cable demaged, voltage too high or too low, connection cable demaged, conncection cable defective
ECU defective ECU defective
Corrective Action
Corrective Action Corrective Action Check cabling and start relay and if necessary replace it,
If error not removable, change ECU, check cabling of If error not removable, change ECU, check cabling of check connection cable and if necessary repair or replace
external components, check working voltage and if external components, check working voltage and if it
necessary correct it, check connection cable and if necessary correct it, check connection cable and if
necessary repair or replace it necessary repair or replace it Others Error Properties
Priority 1, not self healing, as measured value a default
Others Error Properties Others Error Properties value will be showed.
Priority 3, self healing, as measured value a current value Priority 3, self healing, as measured value a current value
will be showed. will be showed. To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
StrtCDLS SysLamp T15CD

start relay (low side power stage): the current drain Error lamp (diagnositic lamp): the current drain measured Terminal 15: ECU receives no signal
measured by ECU is out of the target range by ECU is out of the target range or the maximum
permissble temperature of the ECU component for power Error Codes
Error Codes supply of the lamp is exceeded DEUTZ: 226, Blink: 5-1-4, SPN: 158,
DEUTZ: 224, Blink: 5-1-2, SPN: 677, FMI (Bit 0,1,2,3):
FMI (Bit 0,1,2,3): Error Codes 11: Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt DEUTZ: 225, Blink: 5-1-3, SPN: 624, 11: Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt FMI (Bit 0,1,2,3): 12: Defective component
5: current to low or broken wire 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
5: current to low or broken wire Error Detection
Error Detection 2: data stream is defective Continuous light of the fault lamp, registered in the error
memory of the ECU. Error Detection
- of the fault lamp, registered in the error memory of the Possible Error Reason
Possible Error Reason ECU. Ignition ON not detected, ignition switch defective,
Start relay (low side): cable break or short circuit, disabled connection cable demaged
by ECU, relay defective, connection cable demaged Possible Error Reason
Cable break or short circuit, disabled by ECU, lamp Corrective Action
Corrective Action defective, connection cable demaged Check cabling, if sensor not working, check ignition switch
Check cabling and start relay and if necessary replace it, and if necessary replace it, check connection cable and if
check connection cable and if necessary repair or replace Corrective Action necessary repair or replace it
it Check cabling and load, check lamp and if necessary
replace it, check connection cable and if necessary repair Others Error Properties
Others Error Properties or replace it Priority 2, not self healing, as measured value a current
Priority 1, not self healing, as measured value a default value will be showed.
Priority 2, not self healing, as measured value a nominal To First Page
value of diagnostic lamp will be showed.

DTC - List P490_: 220, 310, 501 P492_: 213
T50CD TPUMon VSSCD1

Terminal 50: ECU receives a permanent signal Internal hardware monitoring: ECU detects a deviation Vehicle speed: over the maximum, signal invalid or
between the signal of time module and the system time implausible compared with the injection quantity and the
Error Codes engine speed, offset factors unlearned
DEUTZ: 227, Blink: 5-1-5, SPN: 523550, Error Codes
FMI (Bit 0,1,2,3): DEUTZ: 228, Blink: 5-5-5, SPN: 523550, Error Codes
12: Defective component FMI (Bit 0,1,2,3): DEUTZ: 232, Blink: 5-2-1, SPN: 84,
11: Errormode not identifiable 11: Errormode not identifiable FMI (Bit 0,1,2,3):
11: Errormode not identifiable 11: Errormode not identifiable 0: data valid, but above normal working area
2: data stream is defective 8: unusual frequency, pulse or period.
Error Detection 14: Special Instructions
Continuous light of the fault lamp, registered in the error Error Detection
memory of the ECU. Blink of the fault lamp, registered in the error memory of Error Detection
the ECU. Continuous light of the fault lamp, registered in the error
Possible Error Reason memory of the ECU.
Engine start switch stuck, start switch clamped, connection Possible Error Reason
cable demaged Time processing unit (TPU) defective, ECU defective Possible Error Reason
Speed above target range, signal invalid or implausible
Corrective Action Corrective Action compared to injection volume and engine speed, distance
Check cabling, if sensor not working, check start switch If error not removable, change ECU factor not learned, sensor defective, connection cable
and if necessary replace it, check connection cable and if demaged
Priority 5, not self healing, as measured value a - will be Corrective Action
Others Error Properties showed. Check cabling, if sensor not working, check sensor and if
Priority 1, not self healing, as measured value a current necessary replace it, check connection cable and if
value will be showed. necessary repair or replace it
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
WdCom PRVMonSysReac APPCDSwtnSel

Internal hardware monitoring: the ECU detects a Rail pressure relief valve: is open, will be forced to open, Controller mode switch: the signal received by ECU is
disturbance in internal communication the forced-open failed; the ECU activates a system defective or implausible.
reaction
11: Errormode not identifiable FMI (Bit 0,1,2,3): 3: Voltage to high or short circuit to +Ubatt
11: Errormode not identifiable 12: Defective component 4: Voltage to low or short circuit to -Ubatt
11: Errormode not identifiable 12: Defective component 2: data stream is defective
Blink of the fault lamp, registered in the error memory of Error Detection Continuous light of the fault lamp, registered in the error
the ECU. Continuous light, 15s blink before shut off of the fault lamp, memory of the ECU.
registered in the error memory of the ECU.
Communication disturbed, ECU defective Possible Error Reason Cable break, signal implausible, switch defective,
Rail pressure relief valve open or forced open abortive connection cable demaged
Corrective Action (interpretation of the rail pressure gradient), power supply
If error not to removable, change ECU voltage too low, rail pressure sensor defective, fuel Corrective Action
metering unit defective, rail pressure relief valve defective, Check switch and if necessary replace it, check connection
Others Error Properties cable and if necessary repair or replace it
air in fuel system
Priority 5, not self healing, as measured value a - will be
showed. Corrective Action Others Error Properties
Check working voltage and if necessary correct it, check Priority 2, self healing, as measured value a current value
rail-pressure sensor and if necessary replace it, check will be showed.
FCU and if necessary replace it, check rail pressure relief To First Page
valve and if necessary replace it, bleed the fuel-system

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMng_TORxEngPress MplCtl OLSCD

CAN message EngPress (Engine Pressure): the message Data monitoring: the torque curve does not match the Oil level sensor: the voltage of sensor measured by ECU is
cannot be received by ECU specification out of the target range or the received value of oil level via
CAN is defective or the signal value is implausible
12: Defective component 1: data valid, but below normal working area FMI (Bit 0,1,2,3):
11: Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
Continuous light of the fault lamp, registered in the error 0 of the fault lamp, registered in the error memory of the Error Detection
memory of the ECU. ECU. Continuous light of the fault lamp, registered in the error
memory of the ECU.
Missing message "RxEngPress" = engine pressure; CAN Manipulation of Topcurve detected, data manipulation, too Possible Error Reason
bus wrong cabled, wiring is damaged, receiver (sender of slow changed curve Voltage outside target range, CAN signal error, signal
the message) work inaccurately, parametering inaccurate implausible, sensor defective, connection cable demaged,
Corrective Action CAN bus wrong cabled, wiring demaged, receiver (sender
Corrective Action of the message) work inaccurately, parametering
Check CAN Bus cabling (Bus scheduling, polarity, short inaccurate
circuit, power interrupt), test protocol of receiver, check Others Error Properties
CAN functional range Priority 3, not self healing, as measured value a 0 will be Corrective Action
showed. Check cabling, if sensor not working, check sensor and if
Others Error Properties necessary replace it, check connection cable and if
Priority 1, self healing, as measured value a default value necessary repair or replace it, Check CAN Bus cabling
will be showed. (Bus sheduling, polarity, short circuit, power interrupt), test
protocol of receiver, chec
will be showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
OLSCDSysReacHi ADPSCDAna OLSCDSysReacLo

Oil level: the oil level calculated by ECU is above the target Air filter differential pressure sensor: the voltage of sensor Oil level: the oil level calculated by ECU is underneath the
range; the ECU activates a system reaction measured by ECU is out of the target range target range; the ECU activates a system reaction
0: data valid, but above normal working area 3: Voltage to high or short circuit to +Ubatt 1: data valid, but below normal working area
Oil level too high with system reaction, oil volume too Voltage outside target range, sensor defective, connection Oil level too low with system reaction, oil volume too small,
large, sensor defective, connection cable demaged, CAN cable demaged sensor defective, connection cable demaged, CAN data
data error error
Corrective Action
Corrective Action Check cable harness, check sensor and if necessary Corrective Action
Check oil level and if necessary correct it, check sensor replace it, check connection cable and if necessary repair Check oil level and if necessary correct it, check sensor
and if necessary replace it, check connection cable and if or replace it and if necessary replace it, check connection cable and if
necessary repair or replace it necessary repair or replace it
Others Error Properties Priority 3, self healing, as measured value a default value Others Error Properties
Priority 4, self healing, as measured value a current value will be showed. Priority 4, self healing, as measured value a current value
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
PrvMonWear RailMeUn8 FlSys_FLPFMSysReac

Rail pressure relief valve: is open more frequently or for a Wenn the engine is in idle running, the metering unit
longer time than what the technical specification allows compares its output and rail pressure with the default value
(Parameter) and calculates a correction factor-it calibrates Error Codes
Error Codes itself then DEUTZ: 246, Blink: 5-4-1, SPN: 523650,
DEUTZ: 244, Blink: 2-5-3, SPN: 523009, FMI (Bit 0,1,2,3):
FMI (Bit 0,1,2,3): Error Codes 2: data stream is defective
9: Abnormal update rated DEUTZ: 245, Blink: 2-5-4, SPN: 523010, 2: data stream is defective
10: Abnormal rate of change FMI (Bit 0,1,2,3): 11: Errormode not identifiable
14: Special Instructions 0: data valid, but above normal working area 11: Errormode not identifiable
11: Errormode not identifiable Error Detection
Error Detection 11: Errormode not identifiable Continuous light of the fault lamp, registered in the error
memory of the ECU. Error Detection
Continuous light of the fault lamp, registered in the error Possible Error Reason
Possible Error Reason memory of the ECU.
Rail pressure relief valve open more frequently than the
technical specification allowed, rail pressure relief valve Possible Error Reason Corrective Action
open longer than the technical specification allowed, rail
pressure relief valve defective Others Error Properties
Corrective Action
Corrective Action Priority 4, self healing, as measured value a default value
Change rail pressure relief valve and remove the error will be showed.
through Serdia command Others Error Properties
Priority 3, not self healing, as measured value a current To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FlSys_FTSFMSysReac FlSys_FlushStateEngineOff FlSys_RapeOilHeatEx


2: data stream is defective 11: Errormode not identifiable 11: Errormode not identifiable

Priority 3, self healing, as measured value a default value Priority 3, self healing, as measured value a - will be Priority 3, self healing, as measured value a - will be
will be showed. showed. showed.
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngDieselLvl FrmMngFuelTemp FrmMngLowPressureDiesel

CAN message DieselLvl (Diesel tank level): the message CAN message FuelTemp (Fuel Temperature): the CAN message LowPressureDiesel (Low fuel pressure
can not be received by ECU message can not be received by ECU diesel): the message can not be received by ECU
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
CAN bus wrong cabled, wiring is demaged, receiver CAN bus wrong cabled, wiring is demaged, receiver CAN bus wrong cabled, wiring is demaged, receiver
(sender of the message) work inaccurately, parametering (sender of the message) work inaccurately, parametering (sender of the message) work inaccurately, parametering
inaccurate inaccurate inaccurate
Priority 3, self healing, as measured value a default value Priority 3, self healing, as measured value a default value Priority 3, self healing, as measured value a default value
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngRapeOilIn FrmMngRapeOilLvl FrmMngRapeOilVlv1

CAN messageRapeOilln (Rape oil input): the message can CAN message RapeOilLvl (Rape oil tank level): the CAN message OilVlv1 (Valve 1): the message can not be
not be received by ECU message can not be received by ECU received by ECU
12: Defective component 3: Voltage to high or short circuit to +Ubatt 11: Errormode not identifiable
12: Defective component 11: Errormode not identifiable 12: Defective component
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngRapeOilVlv2 FrmMngRapeOilVlv3 FrmMngRapeOilVlv4

CAN message OilVlv2 (Valve 2): the message can not be CAN message OilVlv3 (Valve 3): the message can not be CAN message OilVlv4 (Valve 4): the message can not be
received by ECU received by ECU received by ECU
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngRapeOilVlv5 FrmMngSTIN1RX FrmMngStEKP

CAN message OilVlv5 (Valve 5): the message can not be CAN message STIN1 (State Inputs 1): the message can CAN message StEKP (State Electrical Fuel Supply Pump):
received by ECU not be received by ECU the message can not be received by ECU
To First Page

DTC - List P490_: 220, 310, 501 P492_: 213
FrmMngStLmp FrmMngStOutRx
Error Description Error Description
CAN message StLmp (State Lamp): the message can not CAN message StOut (State Outputs): the message can
be received by ECU not be received by ECU
FMI (Bit 0,1,2,3): FMI (Bit 0,1,2,3):
11: Errormode not identifiable 12: Defective component
12: Defective component 12: Defective component
CAN bus wrong cabled, wiring is demaged, receiver CAN bus wrong cabled, wiring is demaged, receiver
(sender of the message) work inaccurately, parametering (sender of the message) work inaccurately, parametering
inaccurate inaccurate
Check CAN Bus cabling (Bus sheduling, polarity, short Check CAN Bus cabling (Bus sheduling, polarity, short
circuit, power interrupt), test protocol of receiver, check circuit, power interrupt), test protocol of receiver, check
CAN functional range CAN functional range
will be showed. will be showed
To First Page

01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
17901003.TXT
Technical data 3410 TCD 2012 L04 H179

Valid from Serial-No. 1207 22.03.2011
Machine dimensions
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5695 mm
Wheel base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3005 mm
Total width with cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2250 mm
Loading width, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2250 mm
Working width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Max. working width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Lateral overhang, left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55/55 mm
Total hight without cab.(steer.wh.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2320 mm
Total hight with cabin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3020 mm
Total hight with ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2945 mm
Loading hight, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2320 mm
Curb clearance, left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465/465 mm
Ground clearance, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375 mm
Turning radius, inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005 mm
Turning radius, outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6145 mm
Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .950 mm
Drum dimensions
Drums, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Drum type, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .smooth/nondivided
Drum width, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Drum diameter, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1504 mm
Shell thickness, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm
Wheel dimensions
Width over tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2130 mm
Number of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Size of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AW 23.1-26 12 PR
Diameter of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1565 mm
Tire width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 mm
Inflation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,7 bar
Ballast per tire, water/MGCL2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455/75 kg
Weights
Basic weight without cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9860 kg
Basic weight w. ROPS-cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10330 kg
Basic weight without cab, with ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10110 kg
Cab weigth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 kg
ROPS weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 kg
Operating weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10530 kg
Operating weight with ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10310 kg
Maximum weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11000 kg
Axle load, front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5690/4840 kg
Load per tire, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2420 kg
Static linear load, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26,6 kg/cm
Static surface drum load, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,18 kg/cm²
Linear load with vibr., front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127,1/101,9 kg/cm
Mass of vibrating parts, front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3340 kg
Mass of elast. mounted parts, front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2350 kg
Spring mounted:vibrat. mass, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,7
Compaction force, front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267/214 kN
Compaction force, rear, I/II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47/47 kN
French classification, value/class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35,5/VM2
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Diesel engine
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DEUTZ
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TCD 2012 L04 2V
Power rating ISO 14396, kW/PS/rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,0/136,0/2300
Power rating SAE J1349, kW/HP/rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,0/134,0/2300
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cooling, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4038 cm³
Bore/stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101/126 mm/mm
Torque max./speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .520/1600 Nm/UpM
Injection system, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Common Rail
Speed adjustment, actuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EMR3
Fuel consumption, 100 % eng. output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28,3 l/h
Fuel consumption, average . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9,2 l/h
Operating hours per tank filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Std.
Engine oil consumption, average . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,01 l/h
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 V
Alternator, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01294768
Alternator, capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14/95 V/A
Starting motor, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2043678
Starting motor, capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12/3000 V/W
Battery, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00207330
Battery, capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12/155 V/Ah
Vibration control
Frequency setting, function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .electro-hydraulic
Vibration system
Vibrating mode, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circular vibrator
Vibration
Vibration frequency, front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30/40 Hz
Amplitude, front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,78/0,75 mm
Centrifugal force, front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211/158 kN
Theor. centrif. force, front, I/II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171/135 kN
Drive
Hydrostatic drive, front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic motor/axle
Speed, working gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-5,7/0-7,6/0-7,9 km/h
Speed, transportation gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-11,7 km/h
Climbing ability, vibration on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48/53 %
Theor. climb. abil., with/no vibr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64/69 %
Static lateral inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Grad
Permissible longitudinal tilt, dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 °
Permissible lateral inclination, di . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 °
max.perm.ambient temp. by full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Hydraulic pump, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01297449
Hydraulic motor, front, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01297457
Hydraulic motor, rear, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01297481
Wheel gear, front, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2024034
Axle, rear, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2054909
Differential lock, type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Self-locking differential
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Vibrator drive
Steering
Steering, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Articulated steering
Steering, actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .hydrostatic, steer. wheel
Steering unit, hydr., Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238930
Steering pump, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00240974
Steering lock +/- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Grad
Oscillation angle +/-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Grad
Tank capacity/Filling amount

Engine oil-capacity (oil change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,5 L
Engine oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CH-4, SAE 10W40
Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,0 Ltr.
Engine coolant, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant emulsion
Coolant water/protective agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60/40 %
Fuel tank, capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 Ltr.
Fuel tank, material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet steel
Hydr. reserv., capac. (oil change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Ltr.
Hydraulic oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HLP-VG46
Hydraulic oil reservoir, material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sheet steel
Vibrator oil, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238051
Vibrator, left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,6/1,6 Ltr.
Drum gear, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3 L
Gear oil, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238051
Axle differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,0 L
Gear oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .API GL-5 SAE 85W90
Brake system
Service brake, mode of action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .hydrostatic
Service brake, application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive lever
Parking brake, mode of action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring-loaded/mechanical
Parking brake, application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .electr. a. autom.
Emergency brake, mode of action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .hydr./mech.
Emergency brake, application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency stop
Service parts
Engine oil filter, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00234486
Fuel filter, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2043673
Fuel prefilter, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01292404
Air filter, type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .dry + prefractionator
Air filter cartridge, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2051200
Safety filter cartridge, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2051202
Hydraulic oil filter, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01285491
Hydr. oil filter, steer., Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2031492
Poly-V-belt, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01290991
Operating data
Output*, 1 pass/2 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3200 m²/h
Output*, 1 pass/8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12800 m²/h
Output*, 3 pass./5 km/h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 m²/h
Output*, 1pass/2km/h 20cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 m³/h
Ref. 17901003_00 3
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Output*, 1pass/2km/h 40cm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1280 m³/h

* =work.factor=0.83/work.width=90% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound level
Acoustic pressure LP(A) cabin, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 db(A)
Acoustic power LW(A), measured. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 dB(A)/1p
Acoustic power LW(A), sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 dB(A)/1p
Acoustic power LW(A), lim. val. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 dB(A)/1p
Measuring data diesel engine

Idling speed/rated speed/max. speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950/2300/2415 UpM
Operating temperature from-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 - 105 °C
Maximum temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 °C
Measuring data hydraulic

Filling circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 bar
High-pressure limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 bar
Angle of adjusting lever from-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 35 °
Leakage press. pump max. warm/cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,5/1,5 bar
Leakage oil motor front maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8,1 Ltr./Min
Leak.press. motor fr max. warm/cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Leakage oil motor rear maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13,9 Ltr./Min
Leak.press. motor re max. warm/cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Operating temp. hydr. oil tank max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Operating temperature pump max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Operating temper. motor front max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Operating temper. motor rear max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Measuring data vibration hydraulic

Turn-on voltage/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12/26 V/W
Wor.press. la.ampl. single from*-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Work.press. la.ampl. doub. from*-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Wor.press. sm.ampl. single from*-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Wor.press. sm.ampl. doub. from*-to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Leakage oil motor maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,2 Ltr./Min
Leak. pressure motor max. warm/cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Operating temperature pump max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Operating temperature motor max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
Temperature vibr. bear. cover max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grad
* = on resilient base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring data steering hydraulic

Pressure relief steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 bar
Pressure relief shock valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 bar
Working pressure steering* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
* = on dry asph. surface in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring data brake

Service brake stopping distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m
Parking brake blocks in 2. gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .yes J/N
Emergency stop/stopping distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m
Ref. 17901003_00 4
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Opening pressure parking brake min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar
Ref. 17901003_00 5
17902003.TXT
Technical data 3410 P TCD 2012 L04 H179

Machine dimensions
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5695 mm
Total length with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6514 mm
Wheel base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3005 mm
Total width with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2440 mm
Working width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Drum dimensions
Drums, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Drum type, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Padfoot
Padfoot, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Height of the padfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm
Front area of padfoot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 cm²
Wheel dimensions
Size of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TR 23.1-26 12 PR
Tire width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 mm
Weights
Basic weight without cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10350 kg
Basic weight with cab, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12220 kg
Basic weight no cab, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11750 kg
Basic weight with ROPS, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12000 kg
Cab weigth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 kg
ROPS weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 kg
Blade, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00864579
Blade weigth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1400 kg
Operating weight with cabin, blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12415 kg
Operating weight with ROPS, blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12195 kg
Ref. 17902003_00 1
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Load per tire, rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2482,5 kg
French classification, value/class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35,9/VPM2
Diesel engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TCD 2012 L04 2V
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4038 cm³
Bore/stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101/126 mm/mm
Fuel consumption, 100 % eng. output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28,3 L/h
Fuel consumption, average . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9,2 L/h
Operating hours per tank filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 h
Engine oil consumption, average . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,01 L/h
Battery, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00207330
Vibration control
Vibration system
Vibration
Drive
Static lateral inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 °
max.perm.ambient temp. by full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Ref. 17902003_00 2
17902003.TXT


Axle, rear, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2054909
Vibrator drive
Steering
Steering lock +/- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 °
Oscillation angle +/-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 °

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,0 L
Fuel tank, capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 L
Hydr. reserv., capac. (oil change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 L
Vibrator, left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,6/1,6 L
Drum gear, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3 L
Gear oil, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238051
Brake system
Service parts
Ref. 17902003_00 3
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Operating data
Sound level


Leakage oil motor front maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8,1 L/Min
Leakage oil motor rear maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13,9 L/Min
Operating temp. hydr. oil tank max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Operating temperature pump max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Operating temper. motor front max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Operating temper. motor rear max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C

Leakage oil motor maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,2 L/Min
Operating temperature motor max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C
Temperature vibr. bear. cover max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C

Ref. 17902003_00 4
17902003.TXT


Ref. 17902003_00 5
17903003.TXT

Machine dimensions
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5695 mm
Wheel base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3005 mm
Working width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Drum dimensions
Drums, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Drum type, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .smooth/nondivided
Wheel dimensions
Size of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AW 23.1-26 12 PR
Tire width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 mm
Weights
Cab weigth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 kg
ROPS weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 kg
Static linear load, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29,2 kg/cm
Static surface drum load, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,19 kg/cm²
Linear load with vibr., front, I/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129,7/104,5 kg/cm
French classification, value/class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38,9/VM2
Ref. 17903003_00 1
17903003.TXT

Diesel engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TCD 2012 L04 2V
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4038 cm³
Bore/stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101/126 mm/mm
Battery, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00207330
Vibration control
Vibration system
Vibration
Drive
Hydraulic motor, front, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2058232
Axle, rear, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2054909
Ref. 17903003_00 2
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Vibrator drive
Steering
Steering lock +/- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 °

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,0 L
Vibrator, left/right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,6/1,6 Ltr.
Drum gear, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3 L
Gear oil, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238051
Brake system
Service parts
Operating data
Ref. 17903003_00 3
17903003.TXT


Sound level





Ref. 17903003_00 4
17903003.TXT


Ref. 17903003_00 5
17904003.TXT

Machine dimensions
Total length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5695 mm
Total length with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6514 mm
Wheel base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3005 mm
Total width with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2440 mm
Working width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2140 mm
Drum dimensions
Drums, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Drum type, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Padfoot
Padfoot, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Height of the padfoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm
Front area of padfoot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 cm²
Wheel dimensions
Size of tires, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TR 23.1-26 12 PR
Tire width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 mm
Weights
Basic weight with cab, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13000 kg
Basic weight no cab, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12530 kg
Basic weight with ROPS, with blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12780 kg
Cab weigth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470 kg
ROPS weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 kg
Blade, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00864579
Blade weigth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1400 kg
Operating weight with cabin, blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13195 kg
Operating weight with ROPS, blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12975 kg
Ref. 17904003_00 1
17904003.TXT


French classification, value/class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39,2/VPM2
Diesel engine
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TCD 2012 L04 2V
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4038 cm³
Bore/stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101/126 mm/mm
Battery, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00207330
Vibration control
Vibration system
Vibration
Drive
Ref. 17904003_00 2
17904003.TXT


Axle, rear, Hamm No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2054909
Vibrator drive
Steering
Steering lock +/- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 °

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14,0 L
Drum gear, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,3 L
Gear oil, Hamm No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01238051
Brake system
Service parts
Ref. 17904003_00 3
17904003.TXT

Operating data
Sound level




Ref. 17904003_00 4
17904003.TXT


Ref. 17904003_00 5
01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Transportdaten / Transportation data
# 2055076
3205
Gewichte / Weights
Leergewicht ohne Kabine
[kg] 4850
Tare weight without cab
Betriebsgewicht
[kg] 5475
Oper. weight
Höchstgewicht
[kg] 6600
Tare weight total
Achslast vorne
[kg] 2680
Front axle load
Achslast hinten
[kg] 2795
Rear axle load
Transportdaten / Transportation data 1 / 15

# 2055076
3205 P
Gewichte / Weights
[kg] 5190
Betriebsgewicht
[kg] 5815
Oper. weight
Höchstgewicht
[kg] 6600
Tare weight total
Achslast vorne
[kg] 3020
Front axle load
Achslast hinten
[kg] 2795
Rear axle load

# 2055076
3307 – 3307 HT VIO
Gewichte / Weights
[kg] 6215
Betriebsgewicht
[kg] 6840
Oper. weight
Höchstgewicht
[kg] 7800
Tare weight total
Achslast vorne
[kg] 3960
Front axle load
Achslast hinten
[kg] 2880
Rear axle load

# 2055076
3307 P /..HT P
Gewichte / Weights
[kg] 6215
Betriebsgewicht
[kg] 6840
Oper. weight
Höchstgewicht
[kg] 7800
Tare weight total
Achslast vorne [kg] 3960
Front axle load
Achslast hinten
[kg] 2880
Rear axle load

# 2055076
3412 /..HT /..VIO
Gewichte / Weights
[kg] 11530
Betriebsgewicht
[kg] 12200
Oper. weight
Höchstgewicht
[kg] 14200
Tare weight total
Achslast vorne
[kg] 6705
Front axle load
Achslast hinten
[kg] 5495
Rear axle load

# 2055076
3412 P / 3412 HT P
Gewichte / Weights
[kg] 11630
Betriebsgewicht
[kg] 12300
Oper. weight
Höchstgewicht
[kg] 14200
Tare weight total
Achslast vorne
[kg] 6805
Front axle load
Achslast hinten
[kg] 5495
Rear axle load

# 2055076
3414 /..HT /..VIO
Gewichte / Weights
[kg] 13570
Betriebsgewicht
[kg] 14240
Oper. weight
Höchstgewicht
[kg] 15100
Tare weight total
Achslast vorne
[kg] 8215
Front axle load
Achslast hinten
[kg] 6025
Rear axle load

# 2055076
3414 P / 3414 HT P
Gewichte / Weights
[kg] 13670
Betriebsgewicht
[kg] 14340
Oper. weight
Höchstgewicht
[kg] 16100
Tare weight total
Achslast vorne
[kg] 8315
Front axle load
Achslast hinten
[kg] 6025
Rear axle load

# 2055076
3516 / 3516 HT
Gewichte / Weights
[kg] 15085
Betriebsgewicht
[kg] 15755
Oper. weight
Höchstgewicht
[kg] 16200
Tare weight total
Achslast vorne
[kg] 9305
Front axle load
Achslast hinten
[kg] 6450
Rear axle load

# 2055076
3516 P / 3516 HT P
Gewichte / Weights
[kg] 15185
Betriebsgewicht
[kg] 15855
Oper. weight
Höchstgewicht
[kg] 17800
Tare weight total
Achslast vorne
[kg] 9405
Front axle load
Achslast hinten
[kg] 6450
Rear axle load

# 2055076
3518 / 3518 HT
Gewichte / Weights
[kg] 17155
Betriebsgewicht
[kg] 17825
Oper. weight
Höchstgewicht
[kg] 20000
Tare weight total
Achslast vorne
[kg] 10785
Front axle load
Achslast hinten
[kg] 7040
Rear axle load

# 2055076
3518 P / 3518 HT P
Gewichte / Weights
[kg] 17355
Betriebsgewicht
[kg] 18025
Oper. weight
Höchstgewicht
[kg] 20000
Tare weight total
Achslast vorne
[kg] 10985
Front axle load
Achslast hinten
[kg] 7040
Rear axle load

# 2055076
3520 / 3520 HT
Gewichte / Weights
[kg] 19130
Betriebsgewicht
[kg] 19800
Oper. weight
Höchstgewicht
[kg] 22500
Tare weight total
Achslast vorne
[kg] 12490
Front axle load
Achslast hinten
[kg] 7310
Rear axle load

# 2055076
3520 P / 3520 HT P
Gewichte / Weights
[kg] 19330
Betriebsgewicht
[kg] 20000
Oper. weight
Höchstgewicht
[kg] 22500
Tare weight total
Achslast vorne
[kg] 12690
Front axle load
Achslast hinten
[kg] 7310
Rear axle load

# 2055076
3625 HT
Gewichte / Weights
[kg] 24115
Betriebsgewicht
[kg] 24785
Oper. weight
Höchstgewicht
[kg] 25000
Tare weight total
Achslast vorne
[kg] 16115
Front axle load
Achslast hinten
[kg] 8670
Rear axle load

01 - View
08 - Manuals
10 - Machine data
12 - Appendix
a
Tightening torques
# 2020568
For screws with metric thread in steel like in DIN 931; 912; 934...
The torque wrench settings are valid with and without Loctite.
Metric screws
Metric screws with fine thread
Torque (Nm)
Torque (Nm)
Dimension 8.8 10.9 12.9
Dimension 8.8 10.9 12.9
M5 5,5 8,1 9,5

M8x1 24,5 36 43
M6 9,5 14 16,5
M10x1,25 49 72 84
M8 23 34 40
M12x1,25 87 125 150
M10 46 68 79
M12x1,5 83 122 145
M12 79 117 135
M14x1,5 135 200 235
M14 125 185 215
M16x1,5 205 300 360
M16 195 280 330
M18x1,5 310 440 520
M18 280 390 460
M20x1,5 430 620 720
M20 390 560 650
M22x1,5 580 820 960
M22 530 750 880 M24x2 730 1040 1220
M24 670 960 1120 M27x2 1070 1500 1800
M27 1000 1400 1650 M30x2 1490 2120 2480
M30 1350 1900 2250
Appendix 1/2
Tightening torques
# 2020568
Tightening torques for screwed

hydraulic connections – Tightening torques for wheel mounting
whitworth-pipe thread
Dimension Torque in Nm
Thread in steel in aluminum 8.8 10.9
Spherical collar nut
G1/8 20 Nm 15 Nm M16x1,5 240 340
G1/4 40 Nm 25 Nm M18x1,5 330 460
G3/8 80 Nm 45 Nm M20x1,5 500 640
G1/2 110 Nm 80 Nm Tightening torques VSTI – steel/aluminum M22x1,5 640 750
G3/4 200 Nm Thread Torque Thread Torque Shouldered nut with lockwasher
G1 370 Nm M16x1,5 180 260
G1¼ 600 Nm G1/8 10 Nm M 10 x 1 10 Nm M18x1,5 260 360
G 1 1/2 800 Nm G1/4 20 Nm M 12 x 1,5 20 Nm M20x1,5 350 450
G3/8 40 Nm M 14 x 1,5 30 Nm M22x1,5 450 550
G1/2 60 Nm M 16 x 1,5 35 Nm
G3/4 90 Nm M 18 x 1,5 40 Nm
G1 140 Nm M 20 x 1,5 50 Nm
M 22 x 1,5 60 Nm
M 26 x 1,5 70 Nm
M 27 x 2 90 Nm
M 33 x 2 140 Nm
Appendix 2/2
Sealants, lubricants, liquid plastics
# 2071621
Identifi- Hamm Ident-No. Gebindegröße Description Solidity
cation
+ 382620
263397
50ml
250ml
Liquid plastic for bolt connecting all sizes besides
galvanized screws
removable
393037 50ml Liquid plastic for bolt connecting all sizes removable
393029 250ml
, 382639
263419
50ml
250ml
Liquid plastic for joints, e.g. hub-shaft bushing, carrier
surfaces, repairs
hardly
removable
- 1234188
1234196
50ml
250ml
Liquid plastic for joints with narrow gaps, e.g. roller
bearing
removable
/ 382604
323705
50ml
250ml
Liquid plastic to tighten surfaces (adhesive gab max. 0.5
mm)
easily
removable
0 231347 500ml is no longer used
1 1225757
1204025
1kg
200kg
High-grade grease, resistant to pressure and
temperatures, for high-speed roller bearings
Low base oil
viscosity
2 1227114 1kg High-grade grease, resistant to pressure, water-repellent

for low-speed roller bearings, couplings, shafts
High base oil
viscosity
3 392693 250ml Liquid plastic for tightening pip threads up to 3“ easily

removable
4 1215809 300ml Sealants to tighten water, oil and fuel tanks easily
removable
" 2065035 400g Wirtgen Group multi-purpose grease
# 2065020
2065025
5l
20l
Wirtgen Group engine oil 15W40
2065026 208l
2112355 5l Wirtgen Group engine oil 10W40

2112354 20l
$ 2065028
2065029
20l
208l
Wirtgen Group hydraulic oil HVLP 46
% 1238051
2065037
5l
20l
Wirtgen Group special gear oil
( 2065030
2065031
5l
20l
Wirtgen Group gear oil 85W90
2117378 5l Separating agent

2117379 20l
&
2120296 5l Antifreeze
20l
Appendix 1/1
Service Training
Questionnaire for your training!
In order to improve the quality of our trainings to your favour, we kindly ask you to fill
in this questionnaire.
However, only honest and constructive criticism is useful.
Date:
Topic of the training:
Trainer:
1. Assessment of the training

excellent good satisfactory insufficient poor
Overall impression of the training
Related to practice
Quantity of the training matter
Training progress
Structure of the training documents
Content of the training documents
Comprehensibility of the training documents
Positive aspects of the training:
Negative aspects of the training

(short description why)
Following topics should be

added:
Following topics should be left

out:
Seite 1 von 2
Service Training
2. Assessment of the speaker
Overall impression
Expertise
Content of the speech
Style of the speech
Use of media
Linguistic qualities
Remarks regarding the

speaker:
3. Assessment of the surroundings

Premises
Media / technology
Meals
Organisation
4. Information of the training participant

Field of duty in your company/subsidiary?
How long have you been working with HAMM products?
In how many trainings have you already participated at

company HAMM?
5. Proposals, ideas, helpful suggestions
Seite 2 von 2
List of participants
Trainer: Place/ Date:
Topic:
Family name: First name: Company: Position Signature:

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

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3410 3411 H179Service Training

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Service Training

02 - Operator´s manual / maintenance

06 - Electric circuit diagrams

07 - Hydraulic circuit diagrams

List of types „Series 3000“

3205 3307 3410 3412 3516

3411 3414 3518

3307 HT 3412 HT 3516 HT 3625 HT

3307 HT P 3412 HT P 3516 HT P

Type designation e.g. 3307

View of the machine from the left

High pressure port A

High pressure port B

View of the machine from the right

Drum drive motors

Version 1 (radial piston motor) Version 2 (axial piston motor)

Scavenge valve in engine compartment Integrated

Engine type TCD 2012 L04 2V

TCD 2012 L04 2V

Engine (cooling air duct)

• Air intake on the highest Cooling air

Hydraulic oil cooler

Engine compartment (left side) 3410-3411 Coolant compensator tank

Coolant level sensor

Engine oil filter

Engine oil filler neck

Twin fuel filter

Test port and refill connection

Engine compartment (left side) 3410-3411

Manual pump / fuel

Main filter for drive

Fuel pre-filter with

Water level sensor

Vibration Drive pump Test ports

Engine compartment (right side) 3410-3411 Breather for fuel tank

Engine compartment (right side) 3410-3411 Bowden cable

Drive pump Cooler bypass (2bar)

Brake release valve

Vibration pump Collector block - hydraulic fluid

Sensors on wire harness - machine (to mainboard plugs X19, X27→D1X1)

Water inside fuel Coolant level Air filter pollution

Engine rpm director Atmospheric pressure sensor

Sensoren on wire harness - diesel engine (to EMR3 plug D1X2)

Coolant temperature Low fuel pressure, FCU Rail pressure

Fuses, relays, connectors Wire harness

Wire harness Diagnose port

Operating elements Hazard warning lights Traction control

Dashboard (right side)

Drop-arm switch – Drive lever Potentiometer –

02 - Operator´s manual / maintenance

06 - Electric circuit diagrams

07 - Hydraulic circuit diagrams

3410 ● 3410 P ● 3411 ● 3411 P

© HAMM AG 2011 Version 00.1

Name of the document 2180528_00_BAL_3410-11_H179_en

Date of first issue 20.01.2011

Date of change 20.01.2011

Copyright © HAMM AG 2011

2 2180528_00_BAL 3410_3411_H179_en © HAMM AG 2011

© HAMM AG 2011 2180528_00_BAL 3410_3411_H179_en 3

1.03 Environmental protection............................................................................... 16

1.06 Type plate......................................................................................................... 18

1.07 Noise and vibration requirements.................................................................19

1.09 General safety instructions............................................................................22