TW7 TW9 TW10 Service-Manual en PDF

SERVICE - MANUAL
TL 65 - 80 - 80AS - 100 - 70S

List of Contents
1 General
2 Technical Data
3 Diesel Engine
4 Hydraulic System
5 Setting Instructions
6 Functioning Description
7 Electrical System
8 Maintenance
9 Operation
10 Options
11 Repair Instructions
12 Service-Bulletins
05.2010
SUBGROUP LIST
General
Foreword / Information for the User 1.100.01
Safety and Accident Prevention 1.200.01-05
Tightening torques, piston nuts 1.500.01
Pictograms 1.500.50-52
Test ports 1.600.01
Units 1.800.01
10/2008
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Foreword / Information for the User 1.100.01

The Service Manual is subdivided into This structuring will also facilitate the filing
main groups, subgroups and page of revised versions and supplements
numbers so that you can easily find within the framework of the technical
special groups and pages. alteration service.
E.g.
main group
subgroup
page no.
1. 01. 01
For the division of the main groups, please information referring to the repair you
refer to the list of contents. intend to do.
The subgroup division is done starting
from the main group. Any maintenance and repair work on
The page number follows the subgroup machines located in the field may only
and main group number. be performed when the work equipment
is lowered to the ground, the engine is
Please strictly follow the regulations for switched off, the machine is secured so
Accident Prevention valid in your country that it cannot roll, and the hydraulic
(see also 1.20). system is relieved.
The best safety measure to avoid If qualified personnel perform repair work
accidents is to be careful when carrying in the workshop, the relevant Accident
out repairs. We therefore recommend to Prevention Regulations also apply.
carefully study the corresponding
1.100.01/01.2007
Safety and Accident Prevention
If special attachments, such as Uni-shovel,

1 Introductory remarks
side dump shovel, sweeper, fork lift
attachment etc. are mounted, special jobs
Please read the operating instructions
can be done with the attachment.
carefully before putting an earth-moving
machine into operation and strictly follow
Another or additional application, e.g. for
the following remarks for a safe operation.
transportation of passengers or using the
National safety regulations - e.g. the lifting device as working platform etc. is
Accident Prevention Regulations, “Earth- not considered as correct use. The
Moving Machinery” (VBG 40) and supplier is not liable for subsequent
“Vehicles” (VBG 12) in the Federal damage. The enduser himself bears the
Republic of Germany - must also be full risk.
complied with.
It is part of the correct use to follow the
In addition to the operating instructions,
operating and maintenance instructions
legal regulations governing road traffic and
and to carry out the maintenance as well
road safety measures must also be
as to follow the maintenance intervals.
observed. Such requirements could also
apply in respect of handling hazardous
goods or the wearing of personal safety 3 General safety notes
equipment, for example.
It is important to refrain from any working
Furthermore, safety laws governing work methods which impair safety.
in particular locations (tunnels, adits,
quarries, pontoons, contaminated areas, The earth-moving machine may only be
etc.) must likewise be observed. used when it is in a safe, operational
condition.
2 Correct use The manufacturer’s operating instructions

must be complied with for operation,
maintenance, repair, assembly and
The earth-moving machine with normal
transportation.
shovel equipment is only to be used for
work which is suitable for the machine’s The plant operator must provide additional
functions and its attachment. special safety instructions, wherever
necessary, for specific local conditions.
Such work includes the digging, loading,
The operating instructions and any
displacing and dumping out of earth,
information pertaining to safety must be
stones or other materials and the loading
carefully kept in the driver’s cab.
of these materials onto lorries, conveyor
belts or other means of transportation. The The operating instructions and safety
transport of the loading material, however, notes must be complete and fully
is mainly carried out by moving the earth- readable.
moving machine.
Safety devices on earth-moving machines
must not be deactivated or removed.
General 01.2007
Safety and Accident Prevention 1.200.01

during operation. Rings, scarves and Operating equipment (controls) may only
unbuttoned jackets are to be avoided. be activated from the driver’s seat.
Protective goggles, protective boots,
The earth-moving machine may only be
helmets, gloves, reflecting jackets, ear-
ascended and entered using the entrances
muffs, etc. may be required.
and surfaces intended for this purpose.
Before commencing work, information
The operator has to ensure that the cab,
must be obtained on first aid and possible
steps and other walked-on surfaces of the
means of rescue (ambulance, fire brigade,
earth-moving machine are free of dirt,
helicopters).
grease, oil, ice and snow.
A check must be carried out to ensure that
the first aid box is at hand and that its
5 Danger zone
contents comply with regulations.
Personnel must be aware of the location •No one may enter the danger zone of
and method of operation of the fire earth-moving machines.
extinguishers on the earth-moving
machine as well as on-site fire-warning •The danger zone encompasses the area
and fire-fighting equipment. around the earth-moving machine in which
people may be injured by movements of
Loose parts such as tools or other the earth-moving machine during
accessories must be secured to the earth- operation, its working equipments and
moving machine. attachments, or by swinging out or falling
Open doors, windows, covers, flaps, etc. loads, or by falling working equipment.
must be secured so that they cannot slam •The machine operator may only work with
shut. the earth-moving machine when the
danger zone is free of personnel.
4 Operation •The machine operator must give a
warning signal to persons who may be in
Earth-moving machines may only be danger.
independently operated and serviced by
people who •The machine operator has to stop work
with the earth-moving machine if anyone
- are physically and mentally fit remains in the danger zone despite the
- have been instructed in the operation or warning.
maintenance of the earth-moving
machine and have demonstrated this •To ensure no danger of crushing, a
ability to the plant operator sufficient safety distance (min. 500 mm)
- can be expected to perform their must be kept from solid objects, e.g.
allocated duties reliably buildings, excavation slopes, scaffolding,
other machines, etc.
All these people must be of the legal
minimum age. If the above safety distance cannot be
maintained, the area between solid objects
They must be designated by the plant and the working zone of the earth-moving
operator to operate or service the earth- machine must be blocked off.
moving machine.
1.200.01/01.2007
quarries, pits, mounds and slopes to
•If conditions are such that the machine
ensure there is no risk of falling.
operator’s view of the driving and working
zone is restricted, he must be guided or Earth-moving machines must be secured
the driving and working zone must be so that they cannot roll or slip when in the
marked by a solid barricade. vicinity of excavations, shafts, ditches, pits
and slopes.
The windows must be clean and free of
ice.
8 Travel operation
Driving tracks must be designed so as to
ensure smooth, safe operation, i.e. they Before putting the earth-moving machine
must be sufficiently wide, on ground which into operation, the driver’s seat, mirrors
has sufficient carrying capacity and as few and controls must be so adjusted as to
slopes as possible. ensure safe working.
Downhill tracks must be set out in such a The carrying capacity of bridges, cellar
way that loading machines can be braked roofs, vaults, etc. must be verified before
safely. the earth-moving machine can drive over
them.
The internal dimensions of constructions
6 Transport of passengers must be noted before entering
underground passages, tunnels, etc.
Passengers must not be transported on
the machine. On steep drops and uphill gradients, the
load must be carried on the uphill side, if
possible, in order to increase stability.
7 Stability Before driving downhill, the appropriate
gear for the terrain must be selected and
Earth-moving machines must be used, the gear lever must not be moved during
driven and operated in such a manner that downhill travel (normal or crawler gear).
their stability against overturning is
ensured at all times. Earth-moving machines may only be
driven on the open road when both the
The machine operator must drive at machine and the driver have the
speeds which are suitable for local appropriate licence as required by the
conditions. country in question.
The permitted payload of the earth-moving Outside areas covered by general traffic
machine must not be exceeded. regulations, e.g. on construction sites,
Earth-moving machines must remain at a traffic regulations should be applied in the
sufficient distance from the edges of proper manner. This should also apply
with regard to drivers’ licences.
General 01.2007

9 Operation
Earth-moving machines may only be used
where there is a danger of falling objects if
The operator has to check the correct
the driver’s seat and operator consoles
fastening of the attachments and / or lock
have an overhead guard (FOPS). A front
of the quick exchange device daily before
guard must be employed if there is a risk
start of operation and after every
of materials breaking into the cab.
attachment change. Move the attachment
carefully at low height. Please ensure that In front of walls e.g. of stacked materials,
nobody is in the danger zone during these earth-moving machines must be
checks. positioned and operated in such a way
that the driver’s seat and entry to the
The machine operator may only swing the driver’s seat are not situated on the side
working equipment over occupied drivers’ facing the wall.
seats, operator consoles and workplaces
Demolition work may only be performed
of other machines if these are protected by
with earth-moving machines where there
overhead guards (FOPS).
is no danger to personnel.
If a cab does not have the required
protection, the driver of this vehicle must
leave the driver’s seat when the working
12 Working in the vicinity of
equipment has to be slewed overhead.
underground power lines
The vehicles must be loaded in such a
manner as to ensure that there is no Before commencing excavating work
overloading and no material can be lost using earth-moving machines, it must be
during travel. The vehicle must be loaded determined whether any underground
from the lowest possible height. power lines are present in the intended
working zone which may present a danger
At dumping points, earth-moving machines to personnel.
may only be operated when suitable
measures have been taken to prevent If underground power lines are present,
rolling or falling. their exact position and course must be
determined in consultation with the
proprietor or operator of the lines, and the
necessary safety precautions decided and
10 Guides implemented.
Guides must be easily recognizable, e.g. The course of power lines in the work area
by means of reflective clothing. They must must be clearly marked, under
remain within the machine operator’s field supervision, before commencing any
of sight. excavation work. If the position of lines
cannot be determined, search ditches
While guiding the machine, guides must must be dug - manually, if needed.
not be given other jobs which may distract
If underground power lines are
them from their task.
encountered unexpectedly or they or their
protective covers are damaged, the
machine operator must discontinue work
immediately and notify the supervisor.
11 Danger of falling objects
1.200.02/01.2007
13 Working in the vicinity of overhead
In the observation of safety distances, all
power lines
working movements of the earth-moving
machine, e.g. positions of the boom,
When the earth-moving machine is being
swinging ropes and the dimensions of
used in the vicinity of overhead power
attached loads must be taken into
lines and trolley wires, a safety distance
consideration. Uneven ground which
which varies depending upon the nominal
would cause the earth-moving machine to
voltage of the overhead line must be
be inclined and thus nearer to overhead
maintained between the lines and the
lines must also be taken into account.
earth-moving machine and its working
equipment, in order to prevent current During work in windy conditions, both
overspill. This also applies to the distance overhead lines and working equipment
between these lines and attached may swing out, thus reducing the safety
implements or loads. distance.
The safety distances specified below must If it is impossible to maintain sufficient
be complied with: distance from overhead power lines and
trolley wires, the plant operator must
Nominal voltage Safety distance consult with the proprietor or operator of
the overhead lines to find other safety
in metres precautions to prevent current overspill.
Such measures could be, e.g.
- 1000 V 1.0 m
- Switching off the current
over 1 kV - 110 kV 3.0 m
- Re-routing the overhead line
over 110 kV - 220 kV 4.0 m - Cabling, or
- Limiting the work zone of earth-moving
over 220 kV - 380 kV 5.0 m machines.
nom. voltage unknown 5.0 m
General 01.2007

14 Operation in closed rooms aid of a fixing device (rope, chain, etc.),
whereby the assistance of personnel is
If earth-moving machines are used in required to attach and release the load.
closed rooms, these areas must be
Such work covers, for example, the lifting
sufficiently ventilated and special
and lowering of pipes, heavy machine
regulations observed.
parts or containers with earth-moving
machines.
Earth-moving machines may only be used
15 Work stoppages for crane operations if the prescribed
safety devices are present and in full
Before rest periods and at the end of the working order. For earth-moving
working day, the driver of the earth-moving machines, these are:
machine must park the machine on ground - Safe fastening points for lifting device
with sufficient load capabilities and is as - Table of carrying capacity
even as possible, and must secure it - Overload warning device*
against movement. - Hose rupture safety valve for boom cy-
Before rest periods and at the end of the linder*
working day, the driver must lower the *only in case of an admissible carrying
working equipment onto the ground or capacity of more than 1000 kg
secure it so that it cannot move about. Loads must be attached in such a way that
The driver must not leave the earth- they cannot slip or fall out.
moving machine if the working equipment Personnel guiding the machine and
has not been lowered to the ground or attaching loads must always remain in the
secured. machine operator’s field of sight.
Earth-moving machines may only be The machine operator must carry loads as
parked in places where they do not close to the ground as possible and
present an obstacle, e.g. on the prevent them from swinging.
construction site or to plant traffic. Warning
devices, e.g. triangles, warning cordons, Earth-moving machines may only travel
flashing or hazard lights are to be used if with an attached load if the path of travel is
necessary. fairly level.
Before leaving the control console, the When earth-moving machines are used for
driver must bring all working equipment crane operations, personnel attaching
into home position and apply the brakes. loads may only approach the boom from
the side and with the machine operator’s
If the driver is leaving the earth-moving permission. The machine operator may
machine unattended, he must first turn off only give his permission if the earth-
the drive motors and ensure that they moving machine is standing still and the
cannot be started up by unauthorized working equipment is not in motion.
persons (remove ignition key for example).
Do not use fixing devices (ropes, chains)
16 Crane operations which are damaged or of inadequate
dimensions. Protective gloves must
Crane operations are the hoisting, always be worn when working with fixing
transporting and lowering of loads with the devices.
1.200.03/01.2007
17 Assembly, maintenance, repair case of maintenance or repair work which
cannot be performed without the engine/
Earth-moving machines may only be motor running.
assembled, converted or disassembled Depressurize the hydraulic system when
under the guidance of a suitable person carrying out maintenance and repair jobs.
designated by the plant operator and To do this, lower the working equipment to
following the manufacturer’s operating the ground with the engine turned off and
instructions. operate all hydraulic control levers until the
After every change of attachment, the hydraulic system is depressurized.
operator has to ensure the correct Before working on the electrics or when
fastening and / or lock of the quick performing arc-welding on the machine,
exchange device. the connection to the battery must be
Work on braking, steering, hydraulic and interrupted.
electric systems of the earth-moving When disconnecting the battery, first the
machine may only be carried out by expert negative pole then the positive pole must
personnel specially trained in these areas. be disconnected. The battery must be re-
Stability must be ensured at all times connected in reverse order.
during work on earth-moving machines. During repair work around the battery, the
The working equipment must be secured battery must be covered with insulating
against movement by lowering them to the material; tools should never be placed on
ground or equivalent measures, e.g. stays, or near the battery.
trestles. When the engine is running, the Protective devices of moving machine
insecured articulation area of loaders with parts may only be opened or removed
articulated steering must not be entered. when the drive has been switched off and
When jacking up earth-moving machines, cannot be switched on again by
jacking devices must be positioned so that unauthorized persons. Protective devices
they cannot slip. Jacks must be positioned are e.g. engine/motor covers, doors,
and applied absolutely straight, without protective grating, trim.
tilting. Upon completion of assembly,
Raised earth-moving machines must be maintenance or repair work, all protective
supported by suitable structures such as devices must once more be attached in
crosswise stacks of planks, square timbers the proper manner.
or steel trusses. Load-bearing parts of earth-moving
Earth-moving machines which are raised machines may only be welded following
with working equipment must be stabilized consultation with the manufacturer and in
by a supporting structure immediately after accordance with recognized welding
lifting. Do not work under earth-moving principles.
machines which are only supported by the
hydraulics.
Overhead guards (FOPS) must not be
The engine/motor must be turned off prior welded or drilled in any way which could
to all maintenance and repair work. These impair their sturdiness.
requirements may only be ignored in the
General 01.2007

Alterations, such as welding of the Before setting off, the route to be taken
hydraulic system, may only be undertaken must be examined to determine whether
with the manufacturer’s permission. the roads are wide enough, entrances and
passages under bridges are large enough
and that roads and bridges have sufficient
Before commencing work on the hydraulic carrying capacity.
system, the pilot pressure, back pressure
and pressure inside the tank must be let 19 Monitoring and inspections
off.
Lubricants cannot be taken internally and The machine must be thoroughly
repeated skin contact should be avoided. inspected by an authorized and trained
There is no special danger to health if person according to the safety regulations
lubricants are used correctly. Please follow valid in your country:
the safety recommendations issued by the
mineral oil companies. •prior to the first commissioning and prior
to re-commissioning after major changes
Only the hoses specified by the •at least once a year
manufacturer may be used. •periodically according to the operating
Hydraulic hoses must be routed and conditions and the conditions in the
operator’s company
assembled by expert personnel.
Never smoke or handle open flames near The inspection report is to be put in writing
or around the fuel tank and batteries. and kept for future reference.
Furthermore, prior to each work shift, the
machine operator must check the earth-
18 Towing, loading, transportation moving machine according to the
inspection chart.
The towing of earth-moving machines may Hydraulic hoses must be replaced as soon
only be done with towing devices as the following damages are recognized:
sufficiently dimensioned.
- Damages to the outer layer which reach
The fixing devices specified by the the intermediate layer
manufacturer must be employed. - Embrittled patches on the outer layer
For loading and transportation, earth- - Deformations when under pressure or
moving machines and all necessary without pressure which differ from the
auxiliary equipment must be secured original shape of the installed hose
against unwanted movement. - Leakages
- Damages to hose fittings or to the
The travelling gear and track-laying gear connection between the fitting and the
of earth-moving machines must be hose
sufficiently cleaned of mud, snow and ice
to ensure that ramps can be driven up The coolant level must only be checked
without risk of slipping. when it has cooled down; the cap must be
turned carefully in order to bleed off
When the earth-moving machine is excess pressure.
transported on lorries, flat-bed trailers or
by rail, it has to be carefully secured with Prior to operations, the machine operator
wheel chocks and tie-downs at the must check the function of the safety
fastening points. devices.
1.200.04/01.2007
The machine operator must advise the
21 Emergency exit
supervisor immediately - and the person
relieving him, should there be a change of
operators - with regard to any The windscreen acts as an emergency
shortcomings. exit. If a front guard is fitted or this exit can
no longer be used for any other reason, an
In the event of shortcomings which emergency hammer must be affixed at an
jeopardize the operating safety of the easily accessible place inside the driver’s
earth-moving machine, it must not be used cab.
until these have been eliminated.
20 Fire protection 22 Other dangers
Failure of the hydraulics

A fire extinguisher has to be
stored in the operator’s cab. A If the hydraulic system fails due to a
fire extinguisher symbol has to standstill of the diesel engine, a
be applied. defectiveness of the hydraulic pump or a
hydraulic oil leakage, only the emergency
functions „lower working equipment“ are
possible.
General 01.2007

Gewinde Kolbenmutter Anziehdrehmoment Nm
Thread of nut Tightening torques Nm
Filetage d’écrou Couples de serrage Nm
M 18x2 200
M 20x2 260
M 22x2 410
M 24x2 450
M 27x2 810
M 30x2 1050
M 35x1,5 730
M 36x2 1075
M 36x3 1550
M 39x3 1700
M 40x1,5 730
M 42x2 1400
M 42x3 1850
M 48x3 2050
M 56x2 1600
M 60x2 1800
M 70x2 2500
M 80x2 2900
M 90x2 3200
General 01.2007
Tightening torques, piston nuts 1.500.01
Führungsbüchse
Gland
Douille
Hydraulikzylinder ∅ Gewinde - Führungsbüchse Anziehdrehmomente Nm

Hydraulic cylinder ∅ Thread - Bushing Tightening torques Nm
Vérin hydraulique ∅ Filetage - Douille Couples de serrage Nm
35/45 M50x2 200 - 230

50 M56x2 230 - 265
55 M60x2 250 - 290
63 M68x2 290 - 335
70 M75x2 330 - 380
70 M80x2 360 - 415
80 M85x2 390 - 450
90 M95x2 450 - 520
95 M100x2 480 - 550
100 M105x2 520 - 600
105 M110x2 550 - 635
110 M115x2 590 - 680
115 M120x2 630 - 725
125 M130x2 690 - 795
1.500.01/01.2007
Pictograms
001 - 099 General control
100 - 119 Loader
120 - 139 Excavator
140 - 149 Backhoe excavator
150 - 159 Universal-mounted excavator / loader
160 - 179 Walking excavator
180 - 199 Tunnelling and mining machines / Rail-road excavator
200 - Maintenance, safety, etc. in general
Symbol Description Symbol Description

001 Battery charge 012 Hydraulic oil, hydraulic oil
indicator level
002 Pre-heat 013 Hydraulic oil temperature
003 Engine oil pressure 014 Hydraulic oil filter

clogging indicator
004 Engine oil temperature 015 Horn
005 Engine oil level 016 Operational status,

operating hours
006 Coolant temperature 017 Parking brake
007 Coolant level 018 Brake accumulator

pressure
008 Air filter 019 Excavator brake
009 Fuel, fuel level 020 Service brake
010 Fan, 021 Hazard warning system

Heater / ventilation
011 Windscreen wash/ 022 Direction indicator,

wipe system left/right
Pictograms 01.2007
General 1.500.50
023 Working floodlights 039 Speed control
024 Upper beam indicator 040 Oscillating axle lock
025 Direction of travel 041 Steering inversion

forward/reverse
026 Rotating beacon 042 All-wheel steering

crab / round steer
027 Light, lower beam 043 Rocker pedal for travel
028 Central grease system 044 Only shift when machine

is at standstill
029 Lashing points 045 High gear
030 Overload warning 046 Cabin lift / lower

device / Overload
warning indicator
031 Suspension point for 047 Steering control display
loading by crane
032 Travel speed, fast 048 First aid kit
033 Travel speed, slow 049 Fire extinguisher
034 Working hydraulics 050 Switch-over monitor for

cut-off, excavator; operating hours and time
loader / crane
035 Unlocked 051 Swing limitation, engine
stop override
036 Locked 052 Switch for all-wheel

steering
037 Float position 053 Interior lighting
038 Dozer blade 054 Reset hydraulic pulley

block (crane)
1.500.50/01.2007
055 Quick movement 071 Danger of crushing
hoisting winch
056 Cable uncoil limit switch 072 Danger of injury
057 Auxiliary winch 073 Observe notes in

operating instructions
058 Magnet system 074
059 Hydraulic rock breaker 075 Linde - no load

automatics
060 Electric boom height 076 Remote control

limitation
061 Undercarriage- 077 Warning - general

adjustment
062 Switch-over swing 078 Temperature - General

speed, engine speed
adjustment
063 Free fall mode 079
064 Grab rotation 080
065 Bucket return 100 Control by Joystick

positioning, lifting frame
height limitation
066 Ride control system 101
067 Bucket return 102 Quick mount-hitch lock

positioning
068 Hydraulic oil level 103
070 Safety distance, 104 Water pump for sweeper

see item 202
Pictograms 01.2007
General 1.500.51
105 Warning lamp gearbox 151 Universal-mounted
excavator/ loader (AL)
controls
ISO control system right
120 Control 152 Universal-mounted
ISO control system-left
controls
Schaeff control system-
right Schaeff control system left
ISO control system right
controls
Schaeff control system right
Schaeff control system
controls
left
Outrigger right
Intermediate boom
controls
(articulated boom type)
Outrigger left
124 Control 160 Control
telescopic stick in / out Outrigger leg left

articulation „Knickmatik“ Wheel outrigger - left
126 Switch-over rock 162 Control

breaker / grapple
Outrigger leg right

dozer blade Wheel outrigger - right
128 Switch-over (HR 12) 164 Steering

Bucket - rocker breaker
small / rock breaker big
140 Shifting of slide bearing 165 Wheel lock (HS 41)
150 Universal-mounted 166 Free wheel (HS 41 M)

controls
ISO control left
1.500.51/01.2007
167 Outriggers spread 200 Grease gun
168 Outriggers lift / lower 201 Danger
169 Steering mode switch 202 On the machine:

HS 41 MM caution, safety distance
In the operating manual:
warning
170 Outrigger left 203 Note
171 Outrigger right 204 Soot filter

R
180 Switch-over 205 Particle filter
diesel drive
181 Switch-over
electric drive
182 Diesel engine

ignition lock
183 Pony truck IN
184 Pony Truck OUT
185 Electric motor START
186 Electric motor

emergency OFF
187 Cable drum (cable

winch)
Pictograms 01.2007
General 1.500.52
Minimum basic equipment
test port 8 L
part no. 5 066 234 200 pilot pressure
“working hydraulics“
2X control pressure
“travel hydraulics“
screwed fitting ELSD 8 L etc.
part no. 1 919 060 351
test port 10 L
part no. 5 066 234 230
brake pressure
1X
etc.
screwed fitting ELSD 10 L
part no. 1 919 060 352
control pressure
test port M 12x1,5
regulation start
part no. 5 066 253 605
2X housing pressure
seal ring 18x12x1,5
“travel hydraulics“
part no. 1 636 815 453
etc.
nut 8 L
part no. 1 911 060 154 brake inching
plug 1X
part no. 1 928 000 944 etc.
screwed fitting G 8 L
part no. 1 915 000 418
Measuring hoses (Minimeß)
L = 2000mm part no. 5 066 253 600 L = 2500mm part no. 5 066 314 010
L = 3200mm part no. 5 066 314 040 L = 5000mm part no. 5 066 314 055
L = 6000mm part no. 5 066 314 070
General 01.2007
Test ports 1.600.01
Temp. °C Temp. °F Temp. °C Temp. °F Temp. °F Temp. °C Temp. °F Temp. °C
-19 -2,20 21 69,80 -19 -28,33 21 -6,11
-18 -0,40 22 71,60 -18 -27,78 22 -5,56
-17 1,40 23 73,40 -17 -27,22 23 -5,00
-16 3,20 24 75,20 -16 -26,67 24 -4,44
-15 5,00 25 77,00 -15 -26,11 25 -3,89
-14 6,80 26 78,80 -14 -25,56 26 -3,33
-13 8,60 27 80,60 -13 -25,00 27 -2,78
-12 10,40 28 82,40 -12 -24,44 28 -2,22
-11 12,20 29 84,20 -11 -23,89 29 -1,67
-10 14,00 30 86,00 -10 -23,33 30 -1,11
-9 15,80 31 87,80 -9 -22,78 31 -0,56
-8 17,60 32 89,60 -8 -22,22 32 0,00
-7 19,40 33 91,40 -7 -21,67 33 0,56
-6 21,20 34 93,20 -6 -21,11 34 1,11
-5 23,00 35 95,00 -5 -20,56 35 1,67
-4 24,80 36 96,80 -4 -20,00 36 2,22
-3 26,60 37 98,60 -3 -19,44 37 2,78
-2 28,40 38 100,40 -2 -18,89 38 3,33
-1 30,20 39 102,20 -1 -18,33 39 3,89
0 32,00 40 104,00 0 -17,78 40 4,44
1 33,80 50 122,00 1 -17,22 50 10,00
2 35,60 60 140,00 2 -16,67 60 15,56
3 37,40 70 158,00 3 -16,11 70 21,11
4 39,20 80 176,00 4 -15,56 80 26,67
5 41,00 90 194,00 5 -15,00 90 32,22
6 42,80 100 212,00 6 -14,44 100 37,78
7 44,60 110 230,00 7 -13,89 110 43,33
8 46,40 120 248,00 8 -13,33 120 48,89
9 48,20 130 266,00 9 -12,78 130 54,44
10 50,00 140 284,00 10 -12,22 140 60,00
11 51,80 150 302,00 11 -11,67 150 65,56
12 53,60 200 392,00 12 -11,11 200 93,33
13 55,40 300 572,00 13 -10,56 300 148,89
14 57,20 400 752,00 14 -10,00 400 204,44
15 59,00 500 932,00 15 -9,44 500 260,00
16 60,80 600 1112,00 16 -8,89 600 315,56
17 62,60 700 1292,00 17 -8,33 700 371,11
18 64,40 800 1472,00 18 -7,78 800 426,67
19 66,20 900 1652,00 19 -7,22 900 482,22
20 68,00 1000 1832,00 20 -6,67 1000 537,78
Datum/Edition/Date
Umrechnungstabelle / Conversion table
08/2008
Benennung/Descrition/Dénomination Blatt/Page/Feuille
Einheiten / Units 1.800.01

Kilometers Miles per Kilometers Miles per Miles per Kilometers Miles per Kilometers
per hour hour (mph) per hour hour (mph) hour (mph) per hour hour (mph) per hour
(km/h) (km/h) (km/h) (km/h)
1 0,6 110 68,3 1 1,6 110 177,1
2 1,2 120 74,5 2 3,2 120 193,2
3 1,9 130 80,7 3 4,8 130 209,3
4 2,5 140 87,0 4 6,4 140 225,4
5 3,1 150 93,2 5 8,1 150 241,5
6 3,7 160 99,4 6 9,7 160 257,6
7 4,3 170 105,6 7 11,3 170 273,7
8 5,0 180 111,8 8 12,9 180 289,8
9 5,6 190 118,0 9 14,5 190 305,9
10 6,2 200 124,2 10 16,1 200 322,0
20 12,4 210 130,4 20 32,2 210 338,1
30 18,6 220 136,6 30 48,3 220 354,2
40 24,8 230 142,9 40 64,4 230 370,3
50 31,1 240 149,1 50 80,5 240 386,4
60 37,3 250 155,3 60 96,6 250 402,5
70 43,5 260 161,5 70 112,7 260 418,6
80 49,7 270 167,7 80 128,8 270 434,7
90 55,9 280 173,9 90 144,9 280 450,8
100 62,1 290 180,1 100 161,0 290 466,9
bar PSI bar PSI

1 14,50 210 3045,79
2 29,01 220 3190,83
3 43,51 230 3335,87
4 58,02 240 3480,90
5 72,52 250 3625,94
6 87,02 260 3770,98
7 101,53 270 3916,02
8 116,03 280 4061,06
9 130,53 290 4206,09
10 145,04 300 4351,13
20 290,08 310 4496,17
30 435,11 320 4641,21
40 580,15 330 4786,24
50 725,19 340 4931,28
60 870,23 350 5076,32
70 1015,26 360 5221,36
80 1160,30 370 5366,39
90 1305,34 380 5511,43
100 1450,38 390 5656,47
110 1595,41 400 5801,51
120 1740,45 410 5946,55
130 1885,49 420 6091,58
140 2030,53 430 6236,62
150 2175,57 440 6381,66
160 2320,60 450 6526,70
170 2465,64 460 6671,73
180 2610,68 470 6816,77
190 2755,72 480 6961,81
200 2900,75 490 7106,85
1.800.01/08.2008
Cubic meter Cubic feet Cubic Cubic Cubic Cubic Cubic Cubic Cubic feet
(m³) (ft³) yards (yd ) feet (ft³) yards (yd ) meter (m³) yards (yd3) meter (m³)
3 3
(ft³)
0,1 3,53 0,13 1 0,04 0,03 0,1 0,08 2,70
0,2 7,06 0,26 2 0,07 0,06 0,2 0,15 5,40
0,3 10,59 0,39 3 0,11 0,08 0,3 0,23 8,10
0,4 14,13 0,52 4 0,15 0,11 0,4 0,31 10,80
0,5 17,66 0,65 5 0,19 0,14 0,5 0,38 13,50
0,6 21,19 0,78 6 0,22 0,17 0,6 0,46 16,20
0,7 24,72 0,92 7 0,26 0,20 0,7 0,54 18,90
0,8 28,25 1,05 8 0,30 0,23 0,8 0,61 21,60
0,9 31,78 1,18 9 0,33 0,25 0,9 0,69 24,30
1 35,31 1,31 10 0,37 0,28 1 0,76 27,00
2 70,63 2,62 20 0,74 0,57 2 1,53 54,00
3 105,94 3,92 30 1,11 0,85 3 2,29 81,00
4 141,26 5,23 40 1,48 1,13 4 3,06 108,00
5 176,57 6,54 50 1,85 1,42 5 3,82 135,00
6 211,89 7,85 60 2,22 1,70 6 4,59 162,00
7 247,20 9,16 70 2,59 1,98 7 5,35 189,00
8 282,52 10,46 80 2,96 2,27 8 6,12 216,00
9 317,83 11,77 90 3,33 2,55 9 6,88 243,00
10 353,15 13,08 100 3,70 2,83 10 7,65 270,00
20 706,29 26,16 200 7,41 5,66 20 15,29 540,00
30 1059,44 39,24 300 11,11 8,50 30 22,94 810,00
40 1412,59 52,32 400 14,81 11,33 40 30,58 1080,00
50 1765,74 65,40 500 18,52 14,16 50 38,23 1350,00
60 2118,88 78,48 600 22,22 16,99 60 45,87 1620,00
70 2472,03 91,56 700 25,93 19,82 70 53,52 1890,00
80 2825,18 104,64 800 29,63 22,65 80 61,16 2160,00
90 3178,33 117,72 900 33,33 25,49 90 68,81 2430,00
100 3531,47 130,80 1000 37,04 28,32 100 76,46 2700,00
Datum/Edition/Date
Umrechnungstabelle / Conversion table
08/2008
Benennung/Descrition/Dénomination Blatt/Page/Feuille
Einheiten / Units 1.800.02

Newton per Pound per Pound per Pound per Pound per Newton per Pound per Newton per Pound per
meter (Nm) Inch (lbf/in) foot (lbf/ft) Inch (lbf/in) foot (lbf/ft) meter (Nm) foot (lbf/ft) meter (Nm) Inch (lbf/in)
1 8,86 0,74 1 0,08 0,11 1 1,36 12,00
2 17,71 1,48 2 0,17 0,23 2 2,71 24,00
3 26,57 2,21 3 0,25 0,34 3 4,07 36,00
4 35,42 2,95 4 0,33 0,45 4 5,42 48,00
5 44,28 3,69 5 0,42 0,56 5 6,78 60,00
6 53,13 4,43 6 0,50 0,68 6 8,13 72,00
7 61,99 5,16 7 0,58 0,79 7 9,49 84,00
8 70,84 5,90 8 0,67 0,90 8 10,85 96,00
9 79,70 6,64 9 0,75 1,02 9 12,20 108,00
10 88,55 7,38 10 0,83 1,13 10 13,56 120,00
20 177,10 14,75 20 1,67 2,26 20 27,12 240,00
30 265,65 22,13 30 2,50 3,39 30 40,67 360,00
40 354,20 29,50 40 3,33 4,52 40 54,23 480,00
50 442,75 36,88 50 4,17 5,65 50 67,79 600,00
60 531,30 44,25 60 5,00 6,78 60 81,35 720,00
70 619,86 51,63 70 5,83 7,91 70 94,91 840,00
80 708,41 59,00 80 6,67 9,03 80 108,47 960,00
90 796,96 66,38 90 7,50 10,16 90 122,02 1080,00
100 885,51 73,76 100 8,33 11,29 100 135,58 1200,00
200 1771,01 147,51 200 16,67 22,59 200 271,16 2400,00
300 2656,52 221,27 300 25,00 33,88 300 406,75 3600,00
400 3542,03 295,02 400 33,33 45,17 400 542,33 4800,00
500 4427,54 368,78 500 41,67 56,46 500 677,91 6000,00
600 5313,04 442,54 600 50,00 67,76 600 813,49 7200,00
700 6198,55 516,29 700 58,33 79,05 700 949,07 8400,00
800 7084,06 590,05 800 66,67 90,34 800 1084,65 9600,00
900 7969,57 663,81 900 75,00 101,64 900 1220,24 10800,00
1000 8855,07 737,56 1000 83,33 112,93 1000 1355,82 12000,00
Liter gal (US) gal (US) Liter

1 0,26 1 3,79
2 0,53 2 7,57
3 0,79 3 11,36
4 1,06 4 15,14
5 1,32 5 18,93
6 1,59 6 22,71
7 1,85 7 26,50
8 2,11 8 30,28
9 2,38 9 34,07
10 2,64 10 37,85
20 5,28 20 75,71
30 7,93 30 113,56
40 10,57 40 151,42
50 13,21 50 189,27
60 15,85 60 227,12
70 18,49 70 264,98
80 21,13 80 302,83
90 23,78 90 340,69
100 26,42 100 378,54
200 52,83 200 757,08
300 79,25 300 1135,62
400 105,67 400 1514,16
500 132,09 500 1892,71
600 158,50 600 2271,25
700 184,92 700 2649,79
800 211,34 800 3028,33
900 237,75 900 3406,87
1000 264,17 1000 3785,41 1.800.02/08.2008
SUBGROUP LIST
Technical Data
TL 65 2.22
TL 80 ( from 06-2010, from Se.No. TL08020100) 2.24
TL 80 AS 2.25
TL 100 2.26
TL 70 2.37
06/2010
DIESEL ENGINE Tier 3
Manufacturer: Deutz
Type: D 2011 L04
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 36,9 at 2,300 min-1
Construction: 4 cylinders in line
Cooling: external oil cooling
Injection: direct injection
Capacity: cm³ 3,100
High idle: min-1 2,450 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 216
Tappet clearance - inlet cold: mm 0.30
Tappet clearance - outlet cold: mm 0.50
Torque of cylinder head studs Nm 30 / 80 / 160
(only in case of repair): Tightening angle 90°
Further data: see engine instruction book or chapter 3
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 100 / 850 (EN)
Generator: V/A 14 / 95
Starter: V/kW/PS 12 / 2.3 / 3.1
Cold start aid: heater plug
Lighting: acc. to German motor vehicle construction and use
regulation (“StVZO”) and Euronorm.
H4 halogen headlamp.
Two working lights at the front.
TRANSMISSION
Travel pump: type A 4 VG 40 DA with pressure cut-off
Displacement: max. cm³/rev. 40
Travel motor 20/36 km/h version: type A 6 VM 55 DA 2
Displacement 20/36 km/h version: max. cm³/rev. 55
TRAVEL RANGE
Two/ four pre-selectable travel ranges, electro-hydraulically controlled:
TL 65: 20 km/h - version:
tortoise / rabbit km/h 0 to 7.0 / 0 to 20
TL 65 S: 36 km/h - version:
Gearbox position 1, tortoise / rabbit: km/h 0 to 6.5 / 0 to 18
Gearbox position 2, tortoise / rabbit: km/h 0 to 13 / 0 to 36
Cardan shaft rev. at 20 km/h - version adjustment at nominal speed

tortoise / rabbit
and standard tyres 365/70 R18: min-1 650 / 1,985
12,5-18: min-1 650 / 1,985
335/80 R18: min-1 650 / 1,940

tortoise / rabbit
1./2. gear / 1./2. gear
and standard tyres 365/70 R18: min-1 630 / 1,290 1,750 / 3,565
12,5-18: min-1 630 / 1,290 1,750 / 3,565
335/80 R18: min-1 630 / 1,290 1,710 / 3.490
TL 65 from s/n.: TL00650452 05.2009
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.22.22
PRESSURE AND SETTING VALUES travel
Suction pressure: max. bar 0.5 ±0.1
Charge pressure (high idle): bar 30 ±1
High pressure (SV): bar 480
Pressure cut-off: bar 450
Case pressure at + 50° C: max. bar 2.5
Regulation start, dynamic: min-1 2,200 -50 at 240 bar HP
(see setting instructions, chapter 5, measuring method 2)
Start-up speed: min-1 1,150
Engine stalling (rabbit) - dynamic: min-1 2,100 -100 at 260 bar HP
Brake inching beginning / end: bar 5 - 13
Pressure switch (hydrostatic brake): bar 22
STEERING
Steering unit: type Rexroth LAGC100-15/LD 240-1
Steering pump: make Cassappa
Displacement: cm³/rev: 17.8
Steering pressure (high idle): bar 175
Priority valve: type Rexroth LPS80RM/LD7-643-0
WORKING HYDRAULICS
Working pump: make Cassappa
Displacement: l/min. 41
Valve bank: type Bucher HDM19
Servo-controlled valve: type Brown PRSV
PRESSURE AND SETTING VALUES working
Main pressure relief valve (high idle): max. bar 250

Line relief pressures:
- lifting frame lift: bar 280
- lifting frame lower: bar anti-cavitation
- shovel dump in: bar 280
- shovel dump out: bar 130
- additional control circuit: bar 230 / 230
- pilot pressure (charge pressure): bar 30 ±1
WORKING CYCLES
Lifting frame lift: s 4.9
Lifting frame lower: s 3.4
Shovel dump in: s ---
Shovel dump out: s ---
AXLES
Front axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 715 or MT-L 3015
// 4472 004 204
Rear axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 715 or MT-L 3015
// 4472 004 205
Front axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 715 or MT-L 3015
// 4472 004 204
Rear axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 715 or MT-L 3015
// 4472 004 206
2.22.20/06.2008
BRAKE SYSTEM
Service brake: hydraulically operated drum brake,
front axle
Parking brake: drum brake at the front axle
Master cylinder: make ATE (mineral oil)
LUBRICANTS
Engine: see engine instruction book
Hydraulic oil: see hydraulic oil recommendation
table
Transmission oil: MIL-L 2105 B or API-GL 5 resp.,
SAE 85 W 90 LS or SAE 90 LS
Multi-purpose grease: acc. to DIN 51825. Dripping point over
170° C. Lithium-saponified.
Brake medium: ATF type A Suffix A or Dexron II D
MAINTENANCE PARTS see instruction book
CAPACITIES ltr.
Engine oil with oil filter and oil cooler - change: approx. 13.0 engine oil
Hydraulic oil (tank and system) - first filling: approx. 49.0 hydraulic oil
Hydraulic oil tank (change): approx. 40.0 hydraulic oil
Fuel tank: approx. 75.0 diesel
Front axle - central housing: approx. 3.5 transmission oil
Front axle - wheel hub: approx. 0.3 transmission oil, each
Rear axle - central housing and reduction gearbox: approx. 4.0 transmission oil
Rear axle - wheel hub: approx. 0.3 transmission oil, each
Service brake: approx. 0.25 ATF oil
TL 65 from s/n.: TL00650452 05.2009
DIESEL ENGINE
Manufacturer: Deutz
Type: F4M 2011
(ECE-R24/ISO1585/ISO9249): kW 44 at 2,400 min-1
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 80 / 720 (EN)
Starter: V/kW/PS 12 / 2.3 / 3.1
TRANSMISSION
Travel motor 20/36 km/h version: type/make 51D080 / Danfoss
TRAVEL RANGE

tortoise / rabbit
and standard tyres 405/70 R18: min-1 650 / 1,880
12,5-20: min-1 650 / 1,900
335/80 R20: min-1 650 / 1,850

tortoise / rabbit
1./2. gear / 1./2. gear
and standard tyres 405/70 R18: min-1 635 / 1,300 1,660 / 3,390
12,5-20: min-1 635 / 1,300 1,675 / 3,420
335/80 R20: min-1 635 / 1,300 1,625 / 3,320
TL 80 from s/n.: TL00800751 to 1180 01.2008
(SKL 834 / SKL 834 S)
Blatt/Page/Feuille
Regulation start: bar 230
Engine stalling (rabbit) - dynamic: min -1
2,200 -100 at 220 bar HP
STEERING
Steering unit: type Danfoss OSPC 250 LS dyn.
Displacement: cm³/rev: 27
Priority valve: type Danfoss OLS 80 dyn.
WORKING HYDRAULICS
Valve bank: type Parker P 70

WORKING CYCLES
AXLES
Front axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 715 // 4472 004 061
Rear axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 715 // 4472 004 060
2.24.03/01.2008
BRAKE SYSTEM
front axle
LUBRICANTS
Hydraulic oil: see Schaeff hydraulic oil recommendation
table
CAPACITIES ltr.
TL 80 from s/n.: TL00800751 to 1180 01.2008
(SKL 834 / SKL 834 S)
Manufacturer: Deutz
Type: D 2011 L04W
Cooling: water
Further data: see engine instruction book
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 80 / 720 (EN)
Starter: V/kW/PS 12 / 2.3 / 3.1
Two working lights at the front (option)
Two working lights at the rear (option)
TRANSMISSION
Travel motor ( 20 km/h ): type/make A 6 VM 80 DA 2
Displacement : max. cm³/rev. 80
TRAVEL RANGE 20 km/h :
Tortoise / rabbit km/h 0 to 7.0 / 0 to 20
Cardan shaft rev. adjustment at nominal speed

tortoise / rabbit
and standard tyres 12,5-20: min-1 650 / 1,865

340/80 R20: min-1 650 / 1,830
405/70 R18: min-1 650 / 1,850
TL 80 AS ab s/n 147 06.2008
Blatt/Page/Feuille
Regulation start: min-1 2100-50 at 180 bar HP
(see setting instructions,chapter 5,measuring method 2)
STEERING
Steering unit: type Rexroth LAGC100-15/LD240-1
Priority valve: type Rexroth LPS80RM/LD7-643/0
WORKING HYDRAULICS
Valve bank: type Walvoil SDM 100/3

WORKING CYCLES
Shovel dump in: s 3.0
Shovel dump out: s 3.8
AXLES
Front axle with self-locking differential - 20 km/h-version: make/type Dana 211/111
Rear axle with self-locking differential - 20 km/h-version: make/type Dana 311/211/174
2.25.20/06.2008
BRAKE SYSTEM
front axle
LUBRICANTS
table
CAPACITIES ltr.
Engine oil with oil filter - change: approx. 9.0 engine oil
Coolant fluid approx. 15,0 water with anti-corrosive
and anti-freeze agent
TL 80 AS ab s/n 147 06.2008
DIESEL ENGINE
Manufacturer: Deutz
Type: BF4M 2011 Turbo
Injection: direct injection, turbo charged
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 80 / 720 (EN)
Starter: V/kW/PS 12 / 2.3 / 3.1
TRANSMISSION
Travel motor 20/36 km/h version: type/make 51D080 / Danfoss
TRAVEL RANGE
tyres tortoise / rabbit
standard: 405/70 R20: min-1 600 / 1,990
option: 14,5-20: min-1 600 / 2,005
16/70-20: min-1 600 / 2,070
375/75 R20: min-1 600 / 2,040
tortoise / rabbit
tyres 1./2. gear / 1./2. gear
standard: 405/70 R20: min-1 580 / 1,190 1,750 / 3,570
option: 14,5-20: min-1 580 / 1,190 1,760 / 3,595
16/70-20: min-1 580 / 1,190 1,800 / 3,700
375/75 R20: min-1
DKD
580 / 1,190 1,775 / 3,660
TL 100 from s/n.: TL01000453 to 646 01.2008
(SKL 844 / SKL 844 S)
Blatt/Page/Feuille
Regulation start: bar 290
STEERING
Steering unit: type LAGU 400/130-11/LD240-175M01
Steering pump: make WSP 20.14-045
Priority valve: type LPS 80R11/LD7-643/01
WORKING HYDRAULICS
Working pump: make WSP 20.14-045
Valve bank: type Parker P 70
Servo-controlled valve: type Brown PRSV C01 S053 FO

WORKING CYCLES
AXLES
2.26.03/01.2008
BRAKE SYSTEM
front axle
LUBRICANTS
Hydraulic oil: see Schaeff hydraulic oil recommendation
table
CAPACITIES ltr.
TL 100 from s/n.: TL01000453 to 646 01.2008
(SKL 844 / SKL 844 S)
Manufacturer: Deutz
Type: D 2011 L04W
Cooling: water
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 100 / 850 (EN)
Starter: V/kW/PS 12 / 2.3 / 3.1
TRANSMISSION
Travel motor 20/36 km/h version: type 51D080 Danfoss
TRAVEL RANGE

tyres tortoise / rabbit
standard: 12,5-20: min-1 650 / 2,100
option: 335/80 R20 SPT 9: min-1 650 / 2,050
335/80 R20 XM 27TL: min-1 650 / 2,080
tortoise / rabbit
tyres 1./2. gear / 1./2. gear
standard: 12,5-20: min-1 635 / 1,300 1.860 / 3,780
option: 335/80 R20 SPT 9: min-1 635 / 1,300 1.800 / 3,680
335/80 R20 XM 27TL: min-1 635 / 1,300 1.840 / 3,750
TL 70 from s/n.: TL00700363 05.2009
Blatt/Page/Feuille
Regulation start, dynamic: min-1 2,300 -50 at 230 bar
STEERING
Steering unit: type Rexroth LAGC100-15/LD240-1
Displacement: cm3/rev. 29
Priority valve: type Rexroth LPS80RM/LD7-643-0
WORKING HYDRAULICS
Displacement: l/min 65
( = slewing 28 l/min and steering 37 l/min summation)
Oil flow divider type Kracht KM1/14+KM1/11
Valve bank: type Bucher HDM19
PRESSURE AND SETTING VALUES working (at high idle)

Main pressure relief valve I: max. bar 250
- lifting frame lift: (B2) bar 280
- lifting frame lower: (A2) bar anti-cavitation
- shovel dump in: (B3) bar 280
- shovel dump out: (A3) bar 130
- additional control circuit: (A1+Y9 / B1+Y8) bar 230 / 230
Main pressure relief valve II: max. bar 250
- slewing left: (A1+Y31) bar 230
- slewing right: (B1+Y32) bar 230
WORKING CYCLES
Slewing right / left: s 3.2 to each side
AXLES
Front axle: with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 720 or MT-L 3020
// 4472 025 200
Rear axle: with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 720 or MT-L 3020
// 4472 025 201
Front axle: with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 720 or MT-L 3020
// 4472 025 200
Rear axle : with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 720 or MT-L 3020
// 4472 025 202
2.37.20/06.2008
BRAKE SYSTEM
front axle
LUBRICANTS
table
CAPACITIES ltr.
Engine oil with oil filter - change: approx. 9.0 engine oil
Coolant fluid approx. 15,0 water with anti-corrosive
and anti-freeze agent
TL 70 from s/n.: TL00700363 05.2009
SUBGROUP LIST
DIESEL ENGINES
TL 65 / TL 70 DEUTZ F4M 2011 3.250

TL 80 / TL100
TL80AS
10/2008
Specification data 3.250.01
Schematic for valve clearance adjustment 3.250.02
Key to Symbols 3.250.03
Engine DEUTZ F-4M 2011 - overview 3.250.04
Valve clearance checking and adjusting 3.250.05-3.250.06
Compression pressure checking and adjusting 3.250.07-3.250.08
Injector checking and adjusting 3.250.09-3.250.11
Injector, repair of components 3.250.12-3.250.14
Typ Motor Datum

Model DEUTZ Engine Edition
Moteur
01.2007
Type F - 4M 2011 Date
Tipo Motor Fecha
Benennung INHALTSVERZEICHNIS Blatt
Description TABLE OF CONTENTS Page
3.250.00
Dénomination SOMMAIRE INDICE Feuille
Denominación INDICE Página
Deutsch English Français Español
Technische Daten Specification data Caractéristiques Datos técnicos

techniques
F – 4M 2011 F – 4M 2011 F – 4M 2011 F – 4M 2011

ohne Kühlsystem Without cooling system sans système de refroid sin sistema de refrige
Motorgewicht ohne Engine weight without Poids du moteur sans Peso del motor sin
Starter, mit Generator starter with generator démarreur avec arrancador, con
ca. 248 kg approx. 248 kg génératrice generador aprox. 248 kg
approx. 248 kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindradea total

3108 cm3 3108 cm3 3108 cm3 3108 cm3
Bohrung 94mm Bore 94mm Alésage 94mm Calibre 94mm
Hub 112mm Stroke 112mm Course 112mm Carrera 112mm
Drehrichtung: Direction of rotation: Sens de rotation: Sentido de giro:

Auf Schwungrad gesehen When facing flywheel Vu sur volant à gauche Visto sobre el volante a
links counter-clockwise izquierdas
Nenndrehzahl: Rated speed: Régime nominal: Régimen nominal:

max. 2800/min max. 2800 rpm max.2800 tr/mn máx. 2800 r/min
Niedrigste Leerlauf- Minimum idle speed: Ralenti extrême: Régimen min. en vacío:
drehzahl: 900/min 900 rpm 900 tr/mn 900 r/min
Arbeitsweise: Working cycle: Principe de Sistema de trabajo:

Viertakt - Diesel four-stroke diesel fonctionnement: Diesel a 4 tiempos
Diesel 4 temps
Verbrennungsverfahren Combustion system: Principe de Sistema de

: Direct injection combustion: compustión:
Direkteinspritzung Injection directe Inyección directa
Verdichtungsverhältnis: Compression ratio: Taux de compression: Relación de

19 19 19 compresión:19
Kompressionsdruck: Compression pressure: Compression: Pressión de

25-30 bar 25-30 bar 25-30 bars compresión:
25-30 bar
Zündfolge: Firing order: Ordre d’allumage: Orden de encendido:

1–3–4-2 1–3–4-2 1–3–4-2 1–3–4-2
Typ Motor Datum

Moteur
01.2007
Tipo Motor Fecha
Benennung Technische Daten Blatt
Description Specification data Page
3.250.01
Dénomination Caractéristiques techniques Feuille
Denominación Datos técnicos Página
Technische Daten Specification data Caractéristiques Datos técnicos

techniques
F – 4M 2011 F – 4M 2011 F – 4M 2011 F – 4M 2011

ohne Kühlsystem Without cooling system sans système de refroid sin sistema de refrige
Steuerzeiten ohne Valve timing without Calage distribution Cotas de reglaje sin
Stößel- und Ventilspiel valve clearance sans jeux des juegos de válvula y de
poussoirs st soupapes empujadores
Einlaß öffnet Inlet opens Admission ouvre Admisión abre

45 Grad vor OT 45 degrees before TDC 45 degrés avant PMH 45 drados a. PMS
Einlaß schließt Inlet closes Admission ferme Admisión cierra

65 Grad nach UT 65 degrees after BDC 65 degrés après PMB 65 grados t. PMI
Auslaß öffnet Exhaust opens Échappement ouvre Escape apre

76 Grad vor UT 76 degrees before BDC 76 degrés avant PMB 76 grados a. PMI
Auslaß schließt Exhaust closes Échappement ferme Escape cierra

44 Grad nach OT 44 degrees after TDC 44 degrés après PMH 44 grados t. PMS
Mindestöldruck bei Minimum oil pressure Pression d’huile Presión min. de aceite a
warmem Motor, during warm motor, minimum sur moteur motor caliente,
Öltemperatur 110 °C Oil temperature 110 °C chaud, temperatura del aceite
Öl SAE 20/20 bei: Oil SAE 20/20 during: température d’huile 110 110 °C, SAE 20/20, a:
°C, huile SAE 20/20, à :
900/min (niederer 900 rpm 900 tr/mn 900 r/min (régimen bajo
Leerlauf) 1,4 bar (lower no-load) 1,4 bar (ralenti minimum)1,4 bars en vacìo) 1,4 bar
1800/ min 2,2 bar 1800 rpm 2,2 bar 1800 tr/mn 2,2 bars 1800 r/min 2,2 bar
max. 2800/min 3,0 bar max. 2800 rpm 3,0 bar 2800 tr/mn maxi 3,0 bars máx. 2800 r/min 3,0 bar
Angaben für Motoren Data related to motors Indications pour moteurs Datos para motores sin
ohne Motoröl-Heizung without motor oil heating sans chauffage par huile calefacción por el aceite
moteur del motor
Absteuerventil Pressurestat Clapet de décharge Válvula reguladora final

7 bar 7 bar 7bar 7 bar
3.250.01/01.2007
Ventilspieleinstell- Schematic for valve Schema de reglage Esquema para el

schema clearance adjustment des soupapes ajuste de holgura de
v81vulas
Kurbelwellen- Crankshaft Position de Posición dei

stellung position I'arbre à cames cigüeñal
Motor bis zum Erreichen der Turn engine until valves Virer le moteur jusqu'au Gírese el motor, hasta
Ventilüberschneidung am of cylinder No.1 overlap chevau-chement des que las válvulas del
Zyl. Nr. 1 durchdrehen soupapes au cylindre 1 cilindro N° 1 coincidan en
su posición momentánea
Kurbelwellen- Crankshatt Position de Posición dei

stellung 2 position 2 I'arbre à cames 2 cigüeñal 2
Motor um eine volle Turn engine further by Taurner le mateur d'un Continuese girando el
Umdrehung (360°) one complete revolution taur complet (360°) motor por una rotación
weiterdrehen (360°). completa (360°)
nicht einstellbar einstellbar

not ready for adjustment ready for adjustment
non réglable réglable
no ajustable ajustable
Typ Motor Datum

Moteur
01.2007
Tipo Motor Fecha
3.250.02
Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening order for cylinder head bolts
Ordre à respecter lors du serrage d'approche et définitif des vis de cul.
Sucesión de los trabajos al apretar los tornillos de culata
Krümmerseite
Mainfold side
Coté coudes
Lado codo
4-Zylinder
4-cylinder
4-cylindres
4-cilindros
3.250.02/01.2007
Bildzeichen- Key to Explication des Leyenda de

erklärung Symbols symboles símbolos
Zerlegen Disassembly Déassemblage Desarmer

von Baugruppen of assembly groups d’ensemble constructifs grupos de constucción
Zusammenbauen Reassembly Assemblage Ensamblar

zu einer Baugruppe to form assembly group d’un ensemble constructif un grupo de construcción
Démontage – Dépose
Abbauen – Ausbauen Remove Desmontar
de pièces entravant
behindernder Teile obstructing parts elementos estorbantes
l’accès
Remontar
Einbauen – Anbauen Reinstall – Remount Remontage – repose
elementos que habían
Teile, die beim parts which had de pièces qui entravaient
estorbado en el
Ab-/Ausbauen hinderten obstructed disassembly la dépose
desmontaje
Atención:
Achtung, Attention! Attention,
Indicación
wichtiger Hinweis Important notice! remarque importante
importante
Prüfen – Einstellen Check – Adjust Contrôler – régler Verificar – ajustar
z.B. Drehmomente, e. g. torque dimensions, p. ex. couples, cotes, p. ej. pares motor,
Maße, Drücke usw. pressures, etc. pressions etc. medidas, presiones, etc.
Spezialwerkzeug Special tool Outillage spécial Herramienta especial
Einbaurichtung Note direction of Respecter le sens de

Dirección de montaje
beachten installation montage
Kontrollieren –
Contrôle – Vérifier
Prüfen Visual inspection Inspección visual
contrôle visuel
Sichtprüfung
Réutilisation Reutilizable en
Bedingt Possibly still
conditionnelle determinadas
wiederverwendbar serviceable
Bei Bedarf auswechseln renew if necessary
Remplacer le cas condiciones
échéant Sustitur, si es necesario
Beim
Renew at each Toujours remplacer Renovar en cada
Zusammenbauen
reassembly au remontage montaje
immer erneuern
Quitar – colocar
Entsichern – Sichern Unlock – Lock Débloquer – Arrêter elementos de
z. B. Splint, e. g. split pin, p. ex. goupille, tôle d’arrêt seguridad
Sicherungsbleche usw. locking plate, etc. etc. p. ej. pasador de aletas,
chapa de seguridad, etc.
Freiner – Coller Frenar – pegar
Sichern – Kleben Lock – Adhere
p. ex. produit d’étanchéité p. ej. utilizando pasta
z. B. Dichtmittel flüssig e. g. with liquid sealant
liquide sellante
Typ Motor Datum

Moteur
01.2007
Tipo Motor Fecha
3.250.03
Bildzeichen- Key to Explication des Leyenda de

erklärung Symbols symboles símbolos
Personenschäden
Guard against Prévention de Prevención de daños
verhüten
personal injury dommages corporels personales
Hinweis auf
Indication of hazard Signalisation de danger Aviso a puntos de peligro
Gefahrenstelle
Prévention de
Materialschaden Guard against Prevención de daños
dommages matériels
verhüten material damage materiales
Endommagement de
Teilbeschädigung Damage to parts Daños en partes o piezas
pièces
colocar sobre
Unterbauen – Prop up - Support -
Supporter – Étayer caballeta – apoyar –
Abstützen - Abfangen Hold
sostener – retener
Einölen Oil Huiler Aceitar
Einfetten Grease Graisser Lubricar con grasa
Markieren Mark Repérer Marcar

Vor dem Zerlegen, before disassembly, avant désassemble, antes de desarmar,
beachten beim observe marks when respecteur au observar la marcas al
Zusammenbauen reassembly réassemblage remontar
Wuchten
Balance Equilibrer Equilibar
Ausgleichen von
Eliminate any imbalance éliminer le balourds Eliminar desequilibrios
Unwuchten
Filling – Topping up – Remplir – Faire Llenar – reponer -
Einfüllen – Auffüllen
Refilling l’appoint rellenar
– Nachfüllen
e. g. oil, p. ex. huile, eau de p. ej. aceite, agua de
z. B. Öl, Kühlwasser usw.
cooling water, etc. refroidissement refrigeración, etc.
Ablassen Drain off Vidange Evacuar
z. B. Öl, Kühlwasser e. g. oil, p. ex. huile, eau de p. ej. aceite, agua de
usw. cooling water, etc. refroidissement refrigeración, etc.
Lösen Loosen – Release Desserrer Soltar
z. B. Lockern einer e. g. loosening a p. ex. desserrer un p. ej. aflojar un dispositivo
Spanneinrichtung clamping device dispositif de tension de sujeción
Spannen Tighten – Clamp Serrer Fijar
z. B. Anziehen einer e. g. tightening a p. ex. serrer un dispositif p. ej. apretar un
Spanneinrichtung clamping device de tension dispositivo de sujeción
Entlüften Vent Purge d’air Purgar de aire
Usinage par
Spanabhebende Mecanizado con
machining process enlèvement de
Bearbeitung arranque de virutas
copeaux
3.250.03/01.2007
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12
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27
26 14
15
25
16
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F:\ServHB\Kap03\4-sprachig-deut-eng-fran-span \390004-Deutz-F4M-2011
Typ Motor Datum

Model Deutz Engine Edition
Type F - 4M 2011 Moteur Date 06.2002
Tipo Motor Fecha
3.250.04
Pos.
Item
Rep. Deutsch English Français Español
No.
Motor Engine Moteur Motor
01
DEUTZ F - 4M 2011 DEUTZ F - 4M 2011 DEUTZ F - 4M 2011 DEUTZ F - 4M 2011
02 Starter Starter Démarreur Arrancador
03 Lüfter Fan Ventilateur Ventilador
04 Motorabstellung Shutdown device Arrêt du moteur Parada del motor
05 Keilriemen V-belt Courroie trapézoïdale Correa trapezoidal
06 Einspritzventile Injectors Injecteurs Inyectóres
07 Luftansaugrohr Air intake manifold Collecteur d’admis. d’air Colector de admisión
08 Glühwendelkerze Glow plug Bougie de réchauffage Bujía de incandescente
09 Abgassammelrohr Exhaust manifold Collecteur d’échappement Colector de escape
10 Generator Alternator Alternateur Alternador
Raccords de Racores para el
11 Ölkühleranschlüsse Oil cooler connections
refroidisseur d’huile refrigeradore de aceite
Oil temperature Transmetteur de Transmisor de
12 Öletmperaturgeber
regulator température d’huile temperatura de aceite
13 Einspritzpumpen Injection pumps Pompes d’injection Bombas de inyección
Verschlussdeckel für Closure cover for oil Bouchon de Tapa en la boca de
14
Öleinfüllung filling remplissage d’huile Ilendo de aceite
Varilla medidora de
15 Ölmessstab Oil dipstick Jauge d’huile
nivel de aceite
Interruptor de presión
16 Öldruckschalter Oil pressure switch Manocontact d’huile
de aceite
Bomba de aceite
17 Schmierölpumpe Lube oil pump Pompe à huile
lubricante
Pompe d’alimentation Bomba de alimentación
18 Kraftstoffförderpumpe Fuel feed pump
en combustible de combustible
19 Kraftstofffilter Fuel filter Filtre à combustible Filtro de combustible
20 Ölfilter Oil filter Filtre à huile Filtro de aceite
21 Ölwanne Oil pan Carter d’huile Cárter de aceite
Bouchon de vidange Tornillo de salida de
22 Ölablasschraube Oil drain plug
d’huile aceite provisto
Oil pressure control Soupape de régulation de Válvula reguladora de
Öldruckventil mit
23 valve with heater pression d’huile avec presión de aceite con
Heizungsanschluß branchem. de chauffage conexión para calefacción
connection
Oil pressure control Soupape de régulation Válvula reguladora de
24 Öldruckventil
valve de pression d’huile presión de aceite
Starterkranz, Starter ring gear, Couronne de Corona del volante,
25
Schwungrad flywheel démarrage, volant volante
26 Thermostat Thermostat Thermostat Termostato
27 Zylinderkopfdichtung Cylinder head gasket Joint de culasse Juanta de culata
28 Zylinderkopf Cylinder head Culasse Culata
29 Zylinderkopfhaube Cylinder head cover Cache-culbuteurs Tapa de culata
30 Einspritzventile Injectors Injecteurs Inyectores
31 Entlüftungsventil Vent valve Soupape de purge d’air Válvula de ventilacón
3.250.04/01.2007
Typ Motor Datum
06.2002
Type F - 4M 2011 Moteur Date
Tipo Motor Fecha
Benennung Ventilspiel - prüfen und einstellen Blatt
Description Valve clearance - checking and adjusting Page
3.250.05
Dénomination Jeu des soupapes - contrôle et réglage Feuille
Denominación Juego de válvulas - verificación y ajustes Página
Ventilspiel prüfen und Valve clearance Jeu des soupapes Juego de válvulas
einstellen checking and contrôle et réglage verificación y ajustes
adjusting
Die Standard- The standard valve Un réglage standard du EI juego estándar de
Ventilspieleinstellung ist clearance can be jeu des soupapes válvulas se puede
möglich: adjusted: peut se faire: ajustar:
Am kalten- oder am with engine cold or warm sur moteur froid ou A motor frio o a motor
warmen Motor nach einer after cooling down for at chaud après une durée caliente tras un período
Abkühlzeit von mindestens least 0.5 h. de refroidissement d'au de enfriamiento de, por
0,5 h. Oil temperature ≤ 80°C. moins 0,5 h. lo menos,
Öltemperatur ≤ 80 °C Température d'huile media hora (0,5 h).
≤ 80 °C. Temperatura dei aceite:
≤ 80 °C
Hinweis: Note: Nota: Nota:

Bei jedem Zylinderkopf- The valve clearance is to Après chaque Cada vez que se cambia
Dichtungswechsel ist das be increased by 0.1 mm remplacement de joint de la junta de culata, es
Ventilspiel um 0,1 mm zu at every cylinder head culasse, le jeu des necesario aumentar el
erhöhen. gasket renewal. soupapes est a juego de válvulas en
Nach 1000 Bh ist das After 1000 Bh , the augmenter de 0, 1 mm. 0,1 mm.
Standard-Ventilspiel standard valve clearance Après 1000 h de marche, Tras 1000 horas de
einzustellen. is to be adjusted. régler le jeu de soupape funcionamiento hay que
standard. ajustar el juego estándar
de válvulas.
Zylinderkopfhaube ist Cylinder head cover La cache-culbuteurs La tapa de culata está

abgebaut has been removed. est déposé desmontada.
1. Motor durchdrehen bis 1. Turn engine until 1. Virer le moteur jusqu'à 1. Girar el cigüeñal hasta
zum Erreichen der valves of ce que les soupapes que se crucen las
Ventilüberschneidung, cylinder No.1 overlap. du cylindre n° 1 soient válvulas en el cilindro
Zyl. Nr. 1. en bascule. No.1.
Ventilspieleinstellschem For valve clearance Schéma de réglage du Para el esquema de

a siehe Technische adjustment schematic jeu des soupapes, voir ajuste del juego de
Daten see Specification Data. Caractéristiques válvulas, ver Datos
techniques. técnicos.

Ventilüberschneidung Valves overlapping Soupapes en bascule Por cruce de válvulas se
bedeutet: means: signifie: soupape entiende: La válvula de
Auslassventil ist noch nicht Exhaust valve about to d'échappement pas escape aún no está
geschlossen, Einlassventil close. encore fermée, soupape cerrada y la de admisión
beginnt zu öffnen. Dabei Inlet valve about to open. d'admission commence à empieza a abrirse, sin
sind beide Stoßstangen Neither pushrod can be s'ouvrir. Les deux tiges que se puedan girar las
nicht drehbar. turned in this position. de culbuteur ne se dos varillas de empuje
laissent pas tourner en esta posición.
alors.
3.250.05/06.2002
Typ Motor Datum
06.2002
Type F - 4M 2011 Moteur Date
Tipo Motor Fecha
Benennung Ventilspiel - prüfen und einstellen Blatt
Description Valve clearance - checking and adjusting Page
3.250.06
Dénomination Jeu des soupapes - contrôle et réglage Feuille
Denominación Juego de válvulas - verificación y ajustes Página
Ventilspiel prüfen und Valve clearance Jeu des soupapes Juego de válvulas
einstellen checking and contrôle et réglage verificación y ajustes
adjusting
2. Ventilspieleinstellung am 2. Adjust valve clearance 2. Régler le jeu des 2. Ajustar el juego de
entsprechenden Zylinder on respective cylinder soupapes du cylindre válvula en el cilindro
mit Fühlerlehrenblatt with feeler gauge. correspondant avec correspondiente
einstellen une jauge d'épaisseur. mediante la galga de
espesores.

Ventilspiel Einlass: Inlet valve clearance: Jeu de soupape Juego de válvula
0,3 mm 0.3 mm Admission 0,3 mm admisión: 0,3 mm
Ventilspiel Außlaß: Exhaust valve clearance: Jeu de soupape Juego de válvula
0,5 mm 0.5 mm Échappement 0,5 mm escape: 0,5 mm
3. Kontermutter 3. Tighten locknut. 3. Serrer le contre-écrou. 3. Apretar la

festdrehen. contratuerca.
Anziehvorschrift: Tightening specification: Prescription de serrage: Prescripción de apriete:

20 ± 2 Nm 20 ± 2 Nm 20 ± 2 Nm 20 ± 2 Nm
Einstellung nochmals mit Recheck the adjustment Vérifier encore une fois Verificar otra vez el
Fühlerlehrenblatt with feeler gauge. le réglage avec la jauge ajuste efectuado,
überprüfen. d'épaisseur. mediante la galga de
espesores.
4. Dichtung aufsetzen. 4. Put gasket in place. 4. Mettre en place le 4. Colocar la junta.

joint.
5. Neue Gummischläuche 5. Insert New rubber 5. Emmancher des 5. Colocar mangueras de

an Überströmleitung und tubes at the cross- flexibles en goma nuevas sobre la
Einspritzventile bis over caoutchouc neufs sur tuberìa de rebose y los
Anschlag aufschieben. pipe and injection la rampe de décharge inyectores hasta el
Zylinderkopfhaube und valves until the end et les injecteurs tope. Montar la tapa
Überströmleitung mon- stop. Mount the jusqu'en butée. Monter de culata y la tubería
tieren. Schrauben cylinder head cover le cache-culbuteurs et de rebose. Apretar los
festdrehen. and the cross-over la rampe de décharge. tornillos.
pipe. Tighten bolts. Serrer les vis.
Anziehvorschrift: 8,5 Nm Tightening specification: Prescription de serrage: Prescripcion de apriete:

8.5 Nm 8,5 Nm 8,5 Nm
3.250.06/06.2002
Typ Motor Datum
Type Moteur Date
06.2002
F - 4M 2011
Tipo Motor Fecha
Benennung Kompressionsdruck - prüfen und einstellen Blatt
Description Compression pressure - checking and adjusting Page
3.250.07
Dénomination Pression de compression - controle et réglage Feuille
Denominación Presión de comprsión - verificación y ajustes Página
Kompressionsdruck Compression Pression de Presión de

prüfen und einstellen pressure compression compresión
checking and adjusting contrôle et réglage verificación y ajustes
Handelsübliche Commercial tools Outillage standard: Herramientas
Werkzeuge: required: comerciales:
Kompressionsdruckprüfer Compression tester Compressiomètre Compresímetro
Klauenschlüssel Glaw key Clé à griffes Llave de garra
Torx-Werkzeugsatz Torx tool kit Jeu d'outils Torx Juego de herramientas
Torx
Spezialwerkzeuge: Special tools required: Outillage spécial: Herramientas
especiales:
Anschlussstück 100120 Connector 100120 Élément raccord Pieza de ernpalme
100120 100120
Einspritzventile sind Injectors have been Les injecteurs sont Los inyectores están
ausgebaut, removed, déposés, desmontados,
Ventilspiel ist valve clearance has le jeu des soupapes est el juego de válvulas
kontrolliert. been checked. contrôlé. está verificado.
1. Anschlussstück mit 1. Insert connector with 1. Insérer I'élément 1. Introducir la pieza de

Spezialdichtung new special seal. raccord avec le joint empalme con una
einsetzen. spécial. junta especial.
2. Spannpratze aufsetzen. 2. Fit clamping pad. 2. Mettre en place la 2. Colocar la garra de

Schraube festdrehen. Tighten bolt. patte de serrage. sujeción. Apretar el
Serrer la vis.. tornillo.
3. Falls notwendig Adapter 3. If necessary, screw on 3. Si nécessaire, visser 3. De ser necesario,

für Anschlussstück adapter for connector. une pièce d'adaptation enroscar el adaptador
aufschrauben. pour I'élément raccord para la pieza de
empalme.
3.250.07/06.2002
Typ Motor Datum
Type Moteur Date
06.2002
F - 4M 2011
Tipo Motor Fecha
Benennung Kompressionsdruck - prüfen und einstellen Blatt
Description Compression pressure - checking and adjusting Page
3.250.08
Dénomination Pression de compression - controle et réglage Feuille
Denominación Presión de comprsión - verificación y ajustes Página
Kompressionsdruck Compression Pression de Presión de

prüfen und einstellen pressure compression contrôle compresión
checking and adjusting et réglage verificación y ajustes
4. Kompressions- 4. Connect compression 4. Brancher le 4. Conectar el
druckprüfer tester. Turn engine with compressiomètre. Virer compresímetro. Girar el
anschließen. starter. le moteur à I'aide du motor mediante el
Motor mit Starter démarreur. arrancador.
durchdrehen. Compression pressure: Pression de Presión de compresión:
Kompressionsdruck: 25 - 30 bar compression: 25 - 30 bar
25 - 30 bar 25 à 30 bars
Der gemessene The measured La pression de La presión de

Kompressionsdruck ist compression pressure is compression mesurée compresión medida
abhängig von der dependent on the starting dépend de la vitesse de depende de la velocidad
Anlassdrehzahl während speed during the démarrage durant le de arranque al hacer la
des Messvorganges und measuring process and relevé et de I'altitude du medición y de la altitud
der Höhenlage des also on the altitude of the site d'installation du dellugar de instalación
Motoraufstellortes. engine site. moteur. del motor.
Therefore it is difficult to Des valeurs limites
Grenzwerte sind daher specify precise limit précises ne peuvent donc Por eso, no se pueden
nicht genau festlegbar. values. pas être fixées. fijar valores límite
It is recommended to use Le relevé de la pression exactos.
Empfohlen wird die Kom- the compression de compression doit Se recomienda
pressionsdruckmessung pressure measure-ment uniquement être considerar la medición de
nur als Vergleichsmes- only for comparison of considéré comme relevé la compresión tan sólo
sung aller Zylinder eines compression pressures of comparatif pour como una medición de
Motors untereinander all cylinders in one lensemble des cylindres comparación entre todos
anzusehen. Sind mehr engine. If a difference in d'un moteur. Si l'ecart los cilindros de un motor.
als 15% Abweichung pressure in excess of relevé est supérieur à Si las diferencias son
ermittelt worden, sollte 15% is determined, the 15%, il faut en déterminer superiores aI 15%, es
durch die Demontage der cylinder unit concerned la cause par démontage conveniente. buscar la
betrof-fenen should be dismantled to des unités de cylindre en causa desmontando la
Zylindereinheit die establish the cause. question unidad de cilindro
Ursache ermittelt werden. afectada.

Einspritzventile mit neuer Fit injector with new Remonter les injecteurs Introducir los inyectores
Spezialdichtung special seal and tighten avec un joint spécial neuf con una junta especial
einsetzen und et les serrer. nueva y apretar.
festdrehen. Tightening specification: Prescription de serrage: Prescripción de apriete:
21 Nm 21 Nm 21 Nm
Anziehvorschrift: 21 Nm
Attach the injection pipes Remonter les tuyauteries Montar las tuberias de
Einspritzleitungen and fix them firmly. d'injection et les serrer. inyección y apretar.
anbauen und festdrehen.
Tightening specification: Prescription de serrage: Prescripción de apriete:
Anziehvorschrift: 25 ± 2.5 Nm 25 ± 2,5 Nm 25 ± 2,5 Nm
25 ± 2,5 Nm Insert New rubber tubes Emmancher des flexibles Colocar mangueras de
Neue Gummischläuche at the cross-over pipe en caoutchouc neufs sur goma nuevas sobre la
an Überströmleitung und and injection valves until la rampe de décharge et tubería de rebose y los
Einspritzventile bis An- the end stop. les injecteurs jusqu'en inyectores hasta el tope.
schlag aufschieben. Attach the cross-over butée. Monter la rampe Montar la tubería de
Überströmleitung pipe. de décharge. rebose.
anbauen.
Tightening specification: Prescription de serrage: Prescripción de apriete:
Anziehvorschrift: 8,5 Nm 8,5 Nm 8,5 Nm 8,5 Nm:
3.250.08/06.2002
Typ Motor Datum
Moteur
01.2007
Tipo Motor Fecha
Benennung Einspritzventil – prüfen und einstellen Blatt
Description Injector – checking and adjusting Page
3.250.09
Dénomination Injecteur – contrôle et réglage Feuille
Denominación Inyector – verificatión y ajustes Página
Einspritzventil Injector Injecteur Inyector

prüfen und einstellen checking and adjusting contrôle et réglage verificación y ajustes
Handelsübliche Commercial tools Outillage standard: Herramientas
Werkzeuge: required: Pompe d'essai des comerciales:
Düsenprüfgerät Nozzle tester injecteurs Comprobador para
Lange Stecknuss SW 15 Long socket a/flats 15 Douille longue de 15 inyectores
Llave de vaso
largo de 15
Spezialwerkzeug: Special tool required: Outillage spécial: Herramientas
Halter für Einspritzventil Retainer for injector Dispositif de blocage especiales:
110 110 110110 d'injecteur 110110 Retenedor para inyector
110110

Bei Arbeiten an der Utmost cleanliness must Lors de travaux sur le Para cualquier trabajo a
Einspritzausrüstung auf be ensured when working système d'injection, realizar en el equipo de
größte Sauberkeit achten. on the injection veiller a la plus grande inyección se observara la
Zur Prüfung der Einspritz- equipment. For testing propreté. Pour le maxima limpieza. Para la
ventile nur reines Prüföl the injector use only pure contr61e des injecteurs, comprobación de los
nach ISO 4113 oder test oil to ISO 4113 or n'utiliser que du fuel inyectores se utilizará
sauberen Dieselkraftstoff clean diesel fuel. d'essai pur selon IS0 solamente aceite de
verwenden 4113 ou du gasoil propre. prueba puro según IS0
4113 ó combustible
diesel limpio.
Achtung! Caution Attention! Atención:

Hände weg vom Beware of injection Tenir les mains hors du No acercar nunca las
Düsenstrahl. Der nozzle fuel jet. The! fuel jet des injecteurs. Le manos al chorro del
Kraftstoff dringt tief in das penetrates deeply into the combustible peut inyector, pues el combus-
Fleisch ein und kann zur skin tissue and may pénétrer profondément tible penetra profunda-
Blutvergiftung führen. cause blood poisoning. dans la chair et mente en los tejidos y
provoquer un puede causar una
empoisonnement du intoxicación de la sangre.
sang.
1. Einspritzventil an das 1. Connect injector to 1. Monter I'injecteur sur la 1. Montar el inyector en el
Düsenprüfgerät nozzle tester. pompe d'essai des comprobador.
anbauen. injecteurs.
2. Prüfung des 2. Checking opening 2. Contr61e de la 2. Comprobación de la

Öffnungsdruckes pressure pression d'ouverture presión de apertura
Hebel des Düsenprüfge- With pressure gauge Le manomètre étant Con el manómetro
rätes bei zugeschaltetem switched on, slowly press branche, abaisser conectado, tirar de la
Manometer langsam down lever of nozzle lentement le levier de la palanca del comprobador
niederdrücken. tester. The pressure at pompe d'essai. La lentamente hacia abajo.
Der Druck bei dem der which the gauge pointer pression a laquelle La presión a la que la
Zeiger stehe bleibt oder stops or suddenly drops, I'aiguille s'immobilise ou aguja se detenga o caiga
plötzlich abfällt, ist der is the opening pressure. chute brusquement est la bruscamente es la
Öffnungsdruck. pression d'ouverture. presión de apertura.
Öffnungsdruck für die Opening pressure for Pression d'ouverture pour Presión de apertura para
Neueinstellung: initial setting: un nouveau réglage: el nuevo ajuste:
210 + 8 bar 210 + 8 bar 210 + 8 bars 210 + 8 bar
3.250.09/01.2007
Typ Motor Datum
Moteur
01.2007
Tipo Motor Fecha
3.250.10

3. Einstellen des 3. Adjusting the 3. Réglage de la 3. Ajuste de la presión
Öffnungsdruckes am opening pressure on pression d'ouverture de apertura en el
Einspritzventil the injector sur I'injecteur inyector
Überwurfmutter Unscrew cap nut and Dévisser I'écrou- raccord, Desenroscar la tuerca de
abschrauben, alle Teile remove all parts démonter toutes les unión y desmontar todas
ausbauen. pièces. las piezas
Folge der Sequence of parts Ordre de démontage Secuencia del despiece

Einzeldemontage disassembly des pièces
1. Überwurfmutter 1. Cap nut 1) Écrou - raccord 1. Tuerca de unión
2. Einspritzdüse 2. Injection nozzle 2) Injecteur 2. Inyector o tobera
3. Zwischenstück 3. Adapter 3) Pièce intermédiaire 3. Pieza intermedia
4. Druckbolzen 4. Thrust pin 4) Poussoir 4. Perno de presión
5. Druckfeder 5. Compression spring 5) Ressort 5. Resorte de presión
6. Ausgleichscheibe 6. Shims 6) Rondelles de réglage 6. Arandelas de reglaje
4. Durch Auswahl der 4. Adjust pressure by 4. Régler la pression en 4. Ajustar la presión

erforderlichen Scheibe selecting appropriate choisissant la rondelle eligiendo la arandela
Druck einstellen. shim. A thicker shim adéquate. Une rondelle adecuada. Una
Stärkere Scheibe ergibt increases the opening plus épaisse donne arandela más gruesa
höheren Öffnungs- pressure. Reassemble une pression aumenta la presión de
druck. Einspritzventil injector. Tighten cap d'ouverture plus apertura. Ensamblar el
zusammenbauen. nut. élevée. Remonter inyector. Apretar la
Überwurfmutter I'injecteur. Serrer tuerca de unión.
festdrehen. I'écrou - raccord.
Anziehvorschrift: Tightening specification: Prescription de serrage: Prescripción de apriete:
45 ± 5 Nm 45 ± 5 Nm 45 ± 5 Nm 45 ± 5 Nm
Einspritzventil auf dem Recheck injector on Contr61er a nouveau Comprobar el inyector de
Düsenprüfgerät erneut nozzle tester. I'injecteur sur la pompe nuevo sobre el
prüfen. d'essai comprobador.
5. Prüfung auf Dichtheit 5. Checking for 5. Contrôle d'étanchéité 5. Comprobación de

tightness estanqueidad
Düse und Düsenhalter Dry nozzle and nozzle Sécher I'injecteur et le Secar el inyector (tobera)
abtrocknen mit Luft holder -blow out with porte-injecteur au jet y portainyector,
trockenblasen. compressed air. Press d'air. Abaisser lentement soplándolos con aire
Handhebel des down handlever of nozzle le levier de la pompe comprimido. Tirar de la
Prüfgerätes langsam tester slowly until a d'essai jusqu'a env. 20 palanca del comprobador
niederdrücken, bis pressure of about 20 bar bars au-dessous de la lentamente hacia abajo
ca. 20 bar unterhalb des below the previous pression d'ouverture hasta que se alcance una
vorher abgelesenen opening pressure reading relevée précédemment. presión en aprox. 20 bar
Öffnungsdruckes erreicht is attained. inferior a la de apertura
werden. leída anteriormente.
3.250.10/01.2007
Typ Motor Datum
Moteur
01.2007
Tipo Motor Fecha
3.250.11

6. Düse ist dicht, wenn 6. Nozzle is tight if there 6. L'injecteur est étanche 6. EI inyector es estanco
innerhalb 10 Sekunden is no dripping within a si aucune goutte ne si, pasados
kein Tropfen abfällt. period of 10 seconds. s'écoule pendant 10 segundos, no sale
10 secondes. ni una gota.
7. Fällt ein Tropfen ab, ist 7. In case of a drip, the 7. Si I'injecteur goutte, il 7. Si sale una gota, es
das Einspritzventil zu injector must be doit être démonte et la necesario despiezar y
zerlegen und die dismantled and cleaned fuite éliminée par limpiar el inyector para
Undichtigkeit durch to remedy the leak. If nettoyage. En cas eliminar la falta de
Reinigen zu beseitigen. this does not cure the d'échec, remplacer estanqueidad. Si esto
Ist das nicht erfolgreich, leak, the injector must I'injecteur. no surte el efecto
muss die Einspritzdüse be replaced. deseado, hay que
erneuert werden. sustituir el inyector por
otro nuevo.
Nacharbeit ist nicht Reworking is not Ne jamais rectifier No está permitido
zulässig. permissible. I'injecteur. rectificar el inyector.
8. Schnarr- und 8. Buzzing and spray 8. Contrôle du 8. Comprobación del

Strahlprüfung pattern test crissement et du jet ronquido y la
pulverización
Manometer des Switch off pressure Débrancher le Desconectar el
Prüfgerätes abschalten. gauge of tester. manomètre de la pompe manómetro del
d'essai. comprobador.
Die Schnarrprüfung The buzzing test permits Le contrôle du crissement La comprobación del
ermöglicht eine hörbare an audible check of the est un contrôle ronquido permite verificar
Prüfung der Leichtgängig- ease of movement of the acoustique du audiblemente el fácil
keit der Düsennadel im nozzle needle in the mouvement de I'aiguille movimiento de la aguja
Düsenkörper. Neue Ein- nozzle body. New dans le corps de dentro del cuerpo del
spritzventile haben ge- injectors emit a different I'injecteur. Les injecteurs inyector. Un inyector
genüber gebrauchten ein buzzing sound as neufs présentent un nuevo tiene un ronquido
geändertes Schnarr- compared to used comportement de distinto del de un inyector
verhalten. injectors. It deteriorates crissement différent par usado.
Durch Verschleiß im due to wear in the needle rapport aux injecteurs EI ronquido disminuye
Nadelsitzbereich ver- seat area. If an injection usages. Par suite de con el desgaste en la
schlechtert es sich. nozzle does not buzz I'usure du logement zona de asiento de la
Schnarrt eine Einspritz- despite cleaning, it must d'aiguille, il se détériore. aguja. Si un inyector deja
düse trotz Reinigung be renewed. Si malgré nettoyage, un de emitir el ronquido
nicht, muss sie durch injecteur ne crisse plus, il característico pese a su
eine neue ersetzt werden. doit être remplace par un limpieza anterior, hay que
injecteur neuf. sustituirlo por otro nuevo.
Ein gebrauchtes A used injector should Un injecteur usage doit A rápido accionamiento
Einspritzventil muss bei buzz clearly during rapid présenter un crissement de la palanca, un inyector
schneller Hebeltätigkeit actuation of the audible lorsque le levier usado debe roncar de
hörbar schnarren und handlever, while est actionne rapidement forma audible y dar un
dabei gut zerstäubt exhibiting a well atomized et bien pulvériser alors. chorro bien pulverizado,
abspritzen. Das Strahlbild spray pattern. The spray La forme du jet peut alors pudiendo variar la
kann dabei gegenüber pattern may differ être nettement différente pulverización claramente
dem eines neuen noticeably from that of a de celle d'un injecteur de la de un inyector
Einspritzventils deutlich new injector. neuf. nuevo.
unterschiedlich sein.
3.250.11/01.2007
SUBGROUP LIST
Hydraulic system
Diagrams – schemes
TL 65 4.22
TL 80 from Se. No. TL08020100 4.24
TL 80 AS 4.25
TL 100 4.26
TL 70 4.37
06/2010
3rd add circuit
Service Brake Traveldrive Steering Lifting frame Shovel Option : Ride control Option: Fast
(Front Axle) Z70/30 H270 Option: Hydr. 19 Z90/45 H455 travel version
Quick attach Z105/60 H570
28 17
19
T G X1 X3 B U Option:Load 27 Working
10 retaining valve 18
70bar
12 Y6
21 Road
P1 C2 P1 C2 23
R
10
240bar
20 P1 V2 ACC
R L 21 P1 V2 Y15
240
240 bar
Y2 bar B Y11 24
M1 A 8 110bar
A6VM55DA
LS T
9
3 x 0,75l
P 175 T
bar /16bar 25
CF EF T1
7
LS
16
A
Z R
55°C T3
H2 add. circuit Frame Shovel
S B2
H1 A B
1 bar
Y16
A Y12 Y13
5
C1
1
Y9 A3
S26
P T
A4VG40DA 1 T 22
Z 26
11 2
4 Y8
Y3
2 T
S25 T1 Y4 PS FA FE MB T 4
13 P
3 Y7
B 3,2 - 18,1 bar
2 3
Engine 4
Deutz P1 0,35bar J
P1
D2011 L04 2,5bar 0,75l/10bar Y5 14
37KW - 2200U/min 41
P2 l/min
A SP
0,5bar 3
7753
30 S MA 15
T2 X1 X2 G G S F
1 B1 B2
Typ Hydraulik Datum

29 Model Hydraulic Edition
Type TL 65 ab/from Se. No. TL00650452 Hydraulique Date 08.2009
Tipo Hidráulico Fecha
Benennung Hydraulikschaltplan Blatt
Description Hydraulic diagramm Page
Dénomination Plan hydraulique Feuille 4.22.12
Página
Denominación Plano hidráulico
Pos.
Item Deutsch English Fran ais
Rep.
No.
1 Verstellpumpe Variable displacement pump Pompe à débit variable

2 Zahnradpumpe Gear pump Pumpe à engrenage
3 Rücklauffilter, Saugfilter Return filter, suction filter Filtre de retour, filtre d’aspiration
4 Belüftungsfilter Vent filter Filtre d’aération
5 Öltemperaturregler Oil temperature regulator Régulateur de température d’huile
6 Ölkühler Oil cooler Refroidisseur d’huile
7 Prioritätsventil Priority valve Valve prioritaire
8 Lenkaggregat Steering unit Ensemble direction
9 Verstellmotor - Fahren Variable displacement Moteur à cylindrée
motor - travel variable - translation
10 Hydraulikzylinder - Lenken Hydraulic cylinder - steering Vérin hydraulique - direction
11 Hauptbremszylinder Master cylinder (brake) Maître - cylindre (frein)
12 Betriebsbremse (Vorderachse) Service brake (front axle) Frein de service (essieu AV)
13 Vorsteuergerät Joy stick Distributeur à commande assistèe
14 Vorsteuereinheit Pilot - operated unit Système pilotage
15 Hydrospeicher Hydraulic accumulator Accumulateur hydraulique
16 Blocksteuergerät Valve bank Bloc distributeur
17 Hydraulikzylinder - Hubrahmen Hydraulic cylinder - lifting frame Vérin hydraulique - bras de levage
18 Hydraulikzylinder - Hydraulic cylinder - Vérin hydraulique -
Schaufel kippen dump shovel basculement godet
19 Zusatzsteuerkreis Additional control circuit Circuit supplémentaire
20 Umschalthahn Ball cock Robinet - inverseur
21 Lasthalteventil Load check valve Clapet de sécurité
22 3/2 Wegeventil 3/2 Solenoid valve electrovanne 3/2
23 Lastschwingungsdämpfventil Ride control valve bloc anti-tangage
24 Hydrospeicher (3x) Hydraulic accumulator (3x) Accumulateur hydraulique (3x)
25 Speicherblock Accumulator bloc Bloc d’accumulateurs
26 3/2 Wegeventil 3/2 Solenoid valve Electrovanne 3/2
(schnell / langsam) (low / high speed) (petite / grande vitesse)
Schaltgetriebe gearbox boîte de vitesses
28 Schnellwechselaufhängung Quick mount hitch suspension Suspension attache rapide
29 Hydrauliköltank Hydraulic oil tank Réservoir hydraulique
30 Dieselmotor Diesel engine Moteur diesel
Typ HYDRAULIKSCHALTPLAN Datum

Model HYDRAULIC DIAGRAMM Edition
Type TL 65 PLAN HYDRAULIQUE Date 08.2009
Tipo PLANO HIDRAULICO Fecha
Benennung Legende Blatt

Description Legend Page
Dénomination Légende Feuille 4.22.13
Denominación Leyenda Página
Option
Option
Option LASTHALTEVENTILE
S-Version
BETRIEBSBREMSE HYDR. SCHNELLWECHSLER
FAHRANTRIEB LENKEN Option SCHALTGETRIEBE
V-ACHSE 19 HEBEN KIPPEN
3.KREIS SCHWINGUNGSDÄMPFUNG
28 17
19 2x
27 ARBEIT
10 18
70bar 21
12 21
STRASSE
P1 C2 P1 C2 23
T G X1 X3 B R
U
240bar
R L 20 P1 V2 P1 V2 ACC
Y6 Y15
240
240 bar 24
bar B Y11
8 110bar
LS T
Y2
3 x 0,75l
P 175 T
bar /16bar 25
M1 A6VM80DA A
9
6
CF EF T1
7
LS
16
A
Z R
55°C T3
H2 Zusatz- Heben Kippen
steuer-
S kreis B2
H1 A B
1 bar
Y16
A Y12 Y13
5
C1
1
Y9 A3
S26
P T
A4VG56DA 1 T 22
Z 26
11 2
4 Y8
Y3
2 T
13 P
3 Y7
B 3,2 - 18,1 bar
2 3
Dieselmotor 4
DEUTZ P1 0,35bar J
P1
D2011 L04W 2,5bar 0,75l/10bar Y5 14
44KW - 2200U/min 64
P2 l/min
A SP
0,5bar 3
7753
30 S MA 15
T2 X1 X2 G G S F
1 B1 B2
Typ Hydraulik Datum

Type TL 80z ab/from Se. No. TL08020100 Hydraulique Date 08.2010
Página
Pos.
Rep.
No.



Allwheelsteering OPTION 3rd CIRCUIT
22 VA
ABS 060502sd TILTCYLINDER LIFTCYLINDER HYDR. QUICK-MOUNT HITCH

SERVICE BRAKE
TRAVEL DRIVE 10 bar
28
FRONT AXLE A2 B2
18 19 19
17
0,5 bar
10
10 bar
T G X1 X3 B U
A1 0,5 bar B1
12 Y6
R L
70bar
240 bar HA
8
LAGC 100-15/LD240-175
Y2
20
M1 A6VM80DA A LS
9
175 bar 15
P T
6
7
CF EF
LPS 80
T B3 A3 B2 A2 B1 A1 P T
LS 280 bar 125 bar 280 bar 230 bar 230 bar
Z R
P
55°C
H2
13
S 26
H1
1 bar
27 14
A
C
5
T1 P1
16 250 bar
S26
Z
A4VG56DA
11 SDM100/3
Y3
T1 2
S25 Y4 PS FA FE MB
4
B
64
0,35 bar
ENGINE l/min
KHD 28l
/min P1
P1
F4M2011 2,5bar
44KW - 2400U/min
P2
A
0,5bar 3
30 T2 X1 X2 G S MA
1 B1 B2
Typ Hydraulik Datum
(1) Travel drive adjustment setting look at chapter 2 29 Model
Type
TL 80 AS ab 0100 Hydraulic
Hydraulique
Edition
Date
01.2008

Description Hydraulic diagramm Page 4.25.01
Dénomination Feuille
Plan hydraulique
Pos.
Rep.
1 Verstellpumpe - Fahren Variable displacement pump Pompe à débit variable

2 Zahnradpumpe Gear pump Pompe à engrenage
10 Lenkzylinder mit integriertem Steering cyl. with integrated Vérin de direction avec
Parallelausgleich parallel compensation compensation en parallel
13 Y9 Magnet Schieberarretierung Y9 Spool solenoid lock devise Y9 Electrovanne blocage tiroir
14 Y10 Magnet Schieberarretierung Y10 Spool solenoid lock devise Y10 Electrovanne blocage tiroir
15 Auskippdrossel Dump throttle Etrangleur de basculement
21
22
23
24
25
26
27
28 Schnellwechselzylinder Quick mount hitch cylinders Vérins attache rapide


Model
Type TL 80 AS HYDRAULIC DIAGRAMM
PLAN HYDRAULIQUE
Edition
Date
01.2008

Description Legend Page 4.25.02
Légende
Option
Option HOSE RUPTURE VALVE
Option
HYDR. QUICK ATTACH FAST SPEED Version
TRAVELDRIVE STEERING Option
BRAKE FRONT AXLE LIFTING
19
SHOVEL RIDE CONTROL 2-GEAR-GERABOX
ADD CIRCUIT Frame
28 17
19
27 Working
10 18
70bar
12
21 Road travel
P1 C2 P1 C2 23
T G X1 X3 B R
U
240bar
20 P1 V2 ACC
Y6 R L 21 P1 V2 Y15
240
240 bar 24
bar B Y11
8 110bar
LS T
Y2
3 x 0,75l
P 175 T
bar /16bar 25
M1 A6VM80DA A
9
6
CF EF T1
7
LS
16
A
Z R
55°C T3
H2 Zusatz- Heben Kippen
steuer-
S kreis B2
H1 A B
1 bar
Y16
A Y12 Y13
5
C1
1
Y9 A3
S26
P T
A4VG56DA 1 T 22
Z 26
11 2
4 Y8
Y3
2 T
13 P
3 Y7
B 3,2 - 18,1 bar
2 3
Engine 4
DEUTZ P1 0,35bar J
P1
TD2011 L04W 2,5bar 0,75l/10bar Y5 14
54KW - 2200U/min 72
P2 l/min
A SP
0,5bar 3
7753
30 S MA 15
T2 X1 X2 G G S F
1 B1 B2
Typ Hydraulik Datum

Type TL 100 ab/from Se. No. TL01001006 Hydraulique Date 07.2009
Página
Pos.
Rep.
No.



Option
HYDR. QUICK ATTACH
Fast-Version
SERVICE BRAKE COOLER AND FILTER LOADING FRAME SWING STEERING 3rd add. CIRCUIT LIFTING FRAME SHOVEL OSCILLATING AXLE GEARBOX
TRAVELDRIVE
FRONT-AXLE 2x Z70/35 H420 Z70/30 H270 2x Z80/40 H470 Z90/40 H420
LOCK
2x Z50 H210
Work
T G X1 X3 B U 70bar Road travel

12L
Y6 R L
240 bar
LS 12L 12L 12L

12L 8L 8L 8L
Y2
OSPC250LS 175 bar
LAGC250 P T
M1 A6VM80DA A
18L
T3
P
12L 8L P b1 B1 A1 b2 B2 A2 b3 B3 A3 T T1
22L P1 E E P1
HPC
CF EF T3
LS
250 bar 250

22L 22L 230 bar OLS80
LPS80
P
bar
230 280 280
Z R bar
230
bar bar
130
T T 230 bar T
bar bar
HDS15/1
55°C T4
28L B A
H2 S 22L a1 a2 a3
HDM19WL/3
H1 1 bar
MFE200-01
A
B A Y34 Y12 B A Y13
8L 22L 25S 15L 15L 15L
B2 Y33
P T P T
S26 1 3
C A
Z A4VG56DA 8L
1 8L 8L
Y9
MB T
Y3 Y4 PS FA FE
2
Y8
S25 T1
T
B
28 36 4
Y7
123 l/min l/min
l/min 3
E198-278 J
25 A
HPV1/PD1310 1
30 l/min P1 P1
bar 2,5bar SP
Y5
KM1/14/11 2 4
P2 0,75l/10bar 7753
A
T G S F
T2
0,5bar
64 5,7 - 18,7 bar P
X1 X2 G S 0,35 3
bar
8L 28L MA l/min
B1 B2
35L
Typ Datum
ab Fz.-Id.Nr. - from s/n: TL00700374 Edition
09.2009
Model
Type
TL 70S bis Fz.-Id.Nr.- to s/n: Date
Fecha
Benennung Blatt
Hydraulikschema Page
Description
Hydraulic diagram Feuille
Página
4.37.40
Dénomination
SUBGROUP LIST
Setting instructions
TL Tightening torque hydraulic 5.200

transmission
TL 65/70/80/100/120 Bucher HDM19 Control valve 5.227
TL 160 - 260 Brake system general 5.228
TL 65 - 120 Travelhydraulic 5.300
TL 65/80/100 Working- and steeringhydraulic 5.301
TL 70 Working- and steeringhydraulic 5.305
TL 65 - 120 Drum brake 5.308
04/2010
Anziehdrehmomente Hydromatikpumpen /-motore
Tightening torques Hydromatikpumps /-motors
Anziehdrehmomente für Schaftschrauben Tightening torques for shaft bolts

(Metrisches ISO-Regelgewinde) (Metric ISO Standard Thread)
Festigkeitsklassen Strength Classes
Die nebenstehenden Werte für An- Gewinde 8.8 10.9 12.9 The values for tightening torques
Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur für shown in the table are valid only for
größe Anziehdrehmoment(Nm) size Tightening Torque (lb.ft)
Schaftschrauben mit metrischem ISO- shaft bolts with metric ISO- standard
M3 1,1 1,6 1,9 M3 0,8 1,2 1,4
Regelgewinde und Kopfauflagemaßen threads and head support surface
M4 2,9 4,1 4,9 M4 2,1 3,0 3,6
nach DIN 912, DIN 931 und DIN 933. dimensions in accordance with DIN
M5 6 8,5 10 912, DIN 931 and DIN 933. These M5 4,4 6,3 7,4
Außerdem gelten diese Werte nur für
leicht oder nicht geölte, unbehandelte M6 10 14 17 values are also valid only for light or M6 7,4 10,3 12,5
Oberflächen, sowie nur bei Verwen- M8 25 36 41 unoiled, untreated surface as well as M8 18,4 25,8 30,2
dung von Drehmoment- und Kraftbe- M10 49 69 83 for use only with torque-indicating M10 36,1 50,9 61,2
grenzungsschlüsseln. M12 86 120 145 wrenches and force limiting tools. M12 63,4 88,4 106,9
M14 135 190 230 M14 99,5 140,0 169,5
M16 210 295 355 M16 154,8 217,4 261,6
M18 290 405 485 M18 213,7 298,5 357,4
M 20 410 580 690 M 20 302,2 427,5 508,5
M 22 550 780 930 M 22 405,4 574,9 685,4
M 24 710 1000 1200 M 24 523,5 737,0 884,4
M 27 1050 1500 1800 M 27 773,9 1105,5 1326,6
M 30 1450 2000 2400 M 30 1068,7 1474,0 1768,8
Anziehdrehmomente für Verschlußschrauben VSTI Tightening torques for locking screws VSTI
(Metrisches Feingewinde) (Metric ISO fine thread)
Gewindegröße Bezeichnung Anziehdrehmoment(Nm) Thread size Designation Tightening torques (lb.ft)
M8x1 VSTI 8 x 1 -ED/SA =5 M8x1 VSTI 8 x 1 -ED/SA =4
M 10 x 1 VSTI 10 x1 -ED = 10 M 10 x 1 VSTI 10 x1 -ED =7
M 12 x 1,5 VSTI 12 x 1,5 -ED = 20 M 12 x 1,5 VSTI 12 x 1,5 -ED = 15
M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 30 M 16 x 1,5 VSTI 16 x 1,5 -ED/SA = 22
M 27 x 2 VSTI 27 x 2 -ED = 90 M 27 x 2 VSTI 27 x 2 -ED = 66
M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 100 M 30 x 1 ,5 VSTI 30 x 1,5 -ED/SA = 74
M 33 x 2 VSTI 33 x 2 -ED/SA = 120 M 33 x 2 VSTI 33 x 2 -ED/SA = 88
M 42 x 2 VSTI 42 x 2 -ED/SA = 200 M 42 x 2 VSTI 42 x 2 -ED/SA = 147
M 48 x 2 VSTI 48 x 2 -ED = 300 M 48 x 2 VSTI 48 x 2 -ED = 220
Anziehdrehmomente für Seal-Lock Bundmuttern Tightening torques for seal-lock nuts

(Metrisches ISO-Regelgewinde) (Metric ISO-Standard Thread)
Festigkeitsklassen Strength classes
Die nebenstehenden Werte für An- Gewinde 8.8 10.9 12.9 The values for tightening torques Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur für Seal- größe Anziehdrehmoment (Nm) shown in the table are valid only for size Tightening torque (lb.ft)
Lock Bundmuttern der Festigkeits- M6 10 seal-lock nuts of the strength class 8.8 M6 7,4
klasse 8.8 mit metrischem ISO-Regel- and with metric ISO-standard thread.
M8 22 M8 16,2
gewinde.
M 10 40 M 10 29,5
M 12 69 M 12 50,9
M 14 110 M 14 81,1
M 16 170 M 16 125,3
Anziehdrehmomente für Linsenschrauben mit Kreuz- Tightening torques for cross-slotted lens head screws
schlitz DIN 7985 DIN 7985
(Metrisches ISO-Regelgewinde) (Metric ISO- Standard Thread)
Festigkeitsklassen Strength classes
Die nebenstehenden Werte für An- The values for tightening torques
Gewinde 8.8 10.9 12.9 Thread 8.8 10.9 12.9
ziehdrehmomente gelten nur für Lin- shown in the table are valid only for
größe Anziehdrehmoment(Nm) size Tightening torques (lb.ft)
senschrauben mit Kreuzschlitz DIN cross-slotted lens head screws DIN
M3 1,1 M3 0,8
7985 der Festigkeitsklasse 8.8 mit 7985 of the strength class 8.8 and with
M4 2,9 M4 2,1
metrischem ISO-Regelgewinde metric ISO-standard thread.
M5 6 M5 4,4
M6 10 M6 7,4
M8 25 M8 18,4
M10 49 M10 36,1
Typ Datum
Model
Type General Edition
Date 01.2007
Tipo Fecha
Benennung Blatt
Description Page
Dénomination Tightening torques Hydromatik Feuille 5.200.02
Denominación Página
Typ Hydraulik Datum
Model Hydraulic Edition
Type TL 120 (SKL 854) Hydraulique Date 01.2007
Benennung
Steuerventil Bucher HDM 19WL Blatt
Description Page
Dénomination
Control valve Feuille 5.227.01
Denominación
Distributeur Página
Ref. Benennung Description Note Q.ty
Control valve
1 Steuerventil kpl. COMPLEWTE WITH CHECK VALVE 1
HDM19WL/3 K302 ½”
Main relief valve
2 Hauptüberdruckventil 1
VMP02 T.100-270 MAX VALVE
Check valve
3 Lasthalte-Rückschlagventil 3
HDS10
4 Dichtscheibe Washer (sealed) 21.3X27.5X1.50 3
5 Stopfen Plug TCEI 1/2” G DIN908ST ZG 3
Type Spool
6 Steuerschieber (Zusatz) 1
HDM19WL A5S
O-ring
7 O - Ring 6
3118 029.82X2.62 NBR90
Pilot control cap (complete)
8 Vorsteuerkappe kpl. 2
HDM19WL POSIT. 50 HP
Type Spool
9 Steuerschieber (Hubrahmen) 1
HDM19WL W5P
Pilot control cap (floating position)
10 Vorsteuerkappe kpl. (Schwimmst.) 1
HDM19WL POSIT. 52 HP
Type Spool
11 Steuerschieber (Schaufel) 1
HDM19WL R5RB
Secondary (safety) valve 230 bar
12 Sekundärventil (230 bar Zusatz) 2
HDM19WL T.230
Secondary valve 280 bar
13 Sekundärventil (280 bar heben, einkippen) Lifting, shovel in 2
HDM19WL T.280
Secondary valve 130 bar
14 Sekundärventil (130 bar auskippen) Dump out 1
HDM19WL T.130
Anticavitation valve
15 Nachsaugventil (Hubrahmen senken) 1
C/A-C/B HDM19WL
TL 120 ab Fz.-Id.-Nr.: TL01200100 (SKL 854) 01.2007
Control valve Bucher HDM 19 WL 5.227.02
Speisepumpe
A4VG ... DAD Charge pump
X2 7
X1
Baureihe / Series 32
PS 4
Verstellpumpe NG 40/56
Variable pump Size 40/56
MA
PS- Blende 1
Pp- Orifice
6 G
X1 - X2 2
7 MB
5
T- Blende
7 4 6 Orifice
PS- Blende
Pp- Orifice
Ansteuergerät und Inchventil

Control device and inching
Bremsdruck Inchfeder
PS Brake pressure Inching spring
11
G 1
2
B
Einstellscheiben für Speisedruck

Shims to adjust charge pressure
5
Hochdruck Niederdruck Saugdruck Lecköldruck Steuerdruck Stelldruck

A
High pressure Return line press. Suction pressure Case drain press. Pilot pressure Control press.
T S
SKL - TL 65 / 70 / 80 / 80AS / 100 01.2008

Fahrhydraulik
5.300.01
Travel drive
Pompe de translation
Fahrpumpe A4VG56DA Travel pump A4VG56DA
A4VG56DA
1 DA Regelventil Control valve Soupape de régulation
2 Speisedruckventil Charge pressure relief valve Clapet pression de gavage
3
4 Hochdruck-Sicherheitsventil HP - safety relief valve Clapet de securité HP
Einstellschraube für Adjusting bolt for mechanic neutral Vis de réglage positionement
6 mechanische Nulllage positioning au neutre
7 Druckabschneidung Pressure cut - off Cupure de pression
8
9
10
Einstellschraube für Adjusting bolt for Vis de réglage debut
11 Inchbeginn u.- ende inching start and -end et fin coupure
Messpunkt Hochdruck und Test port HP and Prise de pression
MA Speisedruck charge pressure HP et gavage
MB Speisedruck charge pressure HP et gavage
Prise de pression
X1 Messpunkt Stelldruck Test port control pressure pression de commande
Prise de pression
Messpunkt Steuerdruck Test port control pressure
PS nach der PS -Blende after Pp orifice
Après orifice PS
Anschluss Speisedruck- Charge pressure and Raccord pression de

G Vorsteuerdruck pilot pressure port gavage et de pilotage
5.300.01 01.2008
Speisepumpe X1 X2
Charge pump
A4VG ... DAD
8
Baureihe / Series 32
Verstellpumpe NG 71...180
Variable pump Size 71...180
6 MA
PS
1
X1 - X2 MB
3
7 9
G
T- Blende
6 Orifice
7 Ansteuergerät und Inchventil

Control device and inching
8 PS
PS- Blende
Pp- Orifice
Inchfedern Bremsdruck
Inching springs Brake pressure
1 11
G 3
B
Hochdruck Niederdruck Saugdruck Lecköldruck Steuerdruck Stelldruck A

High pressure Return line press. Suction pressure Case drain press. Pilot pressure Control press.
T S
TL 120 01.2008
Einstellanweisung Fahrhydraulik 5.300.02

Pompe de translation
Fahrpumpe A4VG71DA Travel pump A4VG71DA
A4VG71DA
1 DA Regelventil Control valve Soupape de régulation
2
3 Speisedruckventil Charge pressure relief valve Clapet pression de gavage
4
5
Einstellschraube für Adjusting bolt for mechanic neutral Vis de réglage positionement
6 mechanische Nulllage positioning au neutre
7 Druckabschneidung Pressure cut - off Cupure de pression
10
Einstellschraube für Adjusting bolt for Vis de réglage debut
11 Inchbeginn u.- ende inching start and -end et fin coupure
MA Speisedruck charge pressure HP et gavage
MB Speisedruck charge pressure HP et gavage
Prise de pression
Prise de pression
Messpunkt Steuerdruck Test port control pressure
PS nach der PS -Blende after Pp orifice
Après orifice PS
Anschluss Speisedruck- Charge pressure and Raccord pression de

G Vosteuerdruck pilot pressure port gavage et de pilotage
5.300.02 01.2008
A6VM ... DA3 /63
DAD DA Mobilgetriebe
Mobile transmissions
PS
Y6
Y2
DA Regelkolben
Regulator piston
Rückschlagventile
Check valves
Q min
U
14
15
Q max
Hochdruck Niederdruck Saugdruck Lecköldruck Steuerdruck Stelldruck

Shuttledrossel High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure
Haute pression Basse pression Pression d'aspiration Pression de drainage Pression de pilotage Pression de commande
Shuttle throttle Alta pressione Bassa pressione Pressione d'aspirazione Pressione di trafilamento Pressione di pilotaggio Pressione di posizionamento
Alta presión Baja presión Presión de aspiratión Presión de drenaje Presión de pilotaje Presion de taraje
SKL - TL 65 / 70 / 80 / 80AS / 100 / 120 01.2008

Fahrhydraulik
5.300.03
Travel drive
When doing any tests or/and adjustments please respect the general safety and
accident prevention regulations! See page 1.200.01-05
1. Check and adjustment of the charge pressure

- connect 60 bar - gauge to high pressure port (MA) or (MB) of the travel pump
- attention, do not select any travel direction!

- read the value at the gauge. Desired value: see technical data
If the desired value is not reached:
TL 65 / 70 / 80 / 100:
Unscrew plug of the charge pressure valve (2) and correct the pressure by
adding or removing shims.
Shims: 10 X 16 X 0.3 1.309.412.107 = approx. 0.9 bars
10 X 16 X 0.5 1.309.412.217 = approx. 1.5 bars
10 X 16 X 1.0 1.309.412.117 = approx. 3.0 bars
TL 120:
Adjustment of the charge pressure by adjustment bolt (3)
2. M Check and adjustment of the travel pump neutral position

− connect gauge to the high pressure port (MA) and (MB) of the travel pump
− set the engine to increased idle running speed
watch the gauge. Both values have to be identical (charge pressure).
If the values are different, the neutral position can be corrected via the
setscrew (6) at the travel pump.
− 3. Check and adjustment of the start-up speed

− park machine on even ground
− connect engine rpm tachometer
− set travel range selector switch to „tortoise“
− set travel direction lever to „forward“ or „reverse“
− slowly actuate accelerator pedal
− read the engine rpm when the machine starts moving. Desired value: see technical data
If the desired value is not reached, turn the setscrew (1) at the regulator
cartridge in or out .
Screwing in: machine starts later

Screwing out: machine starts earlier
TL 65 / 70 / 80 / 80AS / 100 / 120 01.2008

Setting instructions travel hydraulics 5.300.04

4. Check and adjustment of the engine stall rpm
This check has to be carried on the road or in the field (A slope would be
favourable). Beware of the road traffic! If possible, carry out this check with 2 people.
− - load the bucket, if the incline is not sufficient.
− connect 600 bar gauge to high pressure port (MA) forward of the travel pump
− connect engine rpm tachometer
− screw in the regulation start setscrew by 1 turn, travel motor must not regulate
− remove brake inching hose from the travel pump and plug
− set travel range selector switch to „rabbit“
− set travel direction lever to „forward“
− start up, fully accelerate
− operate the service brake when driving in order to obtain high pressure value, (see
technical data). Read the engine rpm (see technical data) when this value is achieved.
the adjustment can be corrected by turning the setscrew (1), regulator

cartridge at the travel pump, in or out resp. (Attention: Start-up speed must be
within the tolerance range).
Turning in: Machine starts later

Turning out: Machine starts earlier
Afterwards reconnect the brake hose and de-aerate the brake at the inching block.
Adjust the regulation start as per the instructions, item 7.
5. Check and adjustment of the pressure cut-off
− connect 600 bar - gauge to gauge port (MA) or (MB) resp. of the travel pump
− set travel range selector switch to position „rabbit“
− set travel direction lever to „forward“ or „reverse“ resp.
− drive the vehicle against a solid object
− fully accelerate
− read the value on the gauge. Desired value: see technical data
if the desired value is not reached, turn the setscrew (7) for the pressure cut-off in
or out resp.
Screwing in: pressure increase

Screwing out: pressure decrease
5.300.04/01.2008
6. Check and replacement of the travel high pressure valves
It is only checked whether the travel high pressure valves are approx. 30 bars
above the pressure cut-off
− connect 600 bar - gauge to gauge port (MA) or (MB) resp. of the travel pump
− increase pressure cut-off by approx. 30 - 40 bar
− set travel direction lever to „forward“ or „reverse“ resp.
− drive the vehicle against a solid object (wheels must lock up)
− read the value on the gauge. Desired value: 30 bar above the pressure cut-off
if the desired value is not reached, remove the high pressure valve (4) or (5)
resp. at the travel pump of the TL 65 / TL 70 / TL 80 / TL 100, adjust, re-install and
check pressure, re-adjust if necessary.
On the TL 120 adjust the high pressure valves - without removing them - via the
setscrew.
− reset pressure cut-off to the desired value (see technical data)
7. Check and adjustment of the regulation start
The regulation start of the travel motor is also influencing the engine stall.
Diesel engine can be overheated during long uphill travel when regulation
start is set too high!
TL80 until s/n 0750 / TL100 until s/n 0452
TL 65 / 70 / 80 / 80AS / 100 / 120 01.2008

Method 1: Test at slope
The high pressure is simulated by uphill travel. The regulation start will be achieved
automatically at a corresponding gradient (dynamic measuring).
− connect 600 bar - gauge to gauge port (9) (regulation start) at the travel motor
− connect 600 bar - gauge to gauge port (MA) = (high pressure forward) of the travel pump
− set travel range selector switch to „rabbit“
− set travel direction lever to „forward“
− start up, fully accelerate. Attention: Beware of the road traffic

(if possible, carry out this check with 2 people)
− both gauges increase slowly. The gauge at the regulation start gauge port has to
decrease after having reached the desired value (see technical data)
− if the gradient is not steep enough (high pressure too low), use the service brake, to do
this, first remove the brake inching hose from the travel pump and plug.
the adjustment can be corrected by turning in or out resp. the setscrew (10)
at the travel motor
Turning in: Regulation start later

Turning out:Regulation start earlier
Afterwards re-connect the brake hose and de-aerate the brake at the inching
block.
−
Method 2: Test on even ground
− interchange the pressure hoses charge pressure (G) and pilot pressure (Pst) at the travel
pump, thus there is charge pressure at the travel motor regulation
− connect 600 bar - gauge to the travel pump MA = high pressure forward
− connect 60 bar - gauge to the travel pump MB = high pressure reverse (charge
pressure in this case)
− connect 600 bar gauge to the travel motor, regulation start gauge port
− drive the machine forward against a solid object
− select fast travel range (rabbit)
- slowly accelerate
5.300.05/01.2008
− watch all three gauges - if the gauge of the travel motor decreases, read the values on
the other gauges and compare them with the following table (adjust the regulation start
in case of excessive deviations)
TL 65 Charge pressure Regulation start

30 bar 345 bar
31 bar 355 bar
32 bar 365 bar
33 bar 370 bar
TL 70 / TL 80 Charge pressure Regulation start

28 bar 215 bar
30 bar 240 bar
32 bar 270 bar
34 bar 300 bar
TL100 Charge pressure Regulation start

30 bar 300 bar
31 bar 310 bar
32 bar 320 bar
33 bar 325 bar
TL 120 Charge pressure Regulation start

26 bar 220 bar
28 bar 250 bar
30 bar 280 bar
32 bar 300 bar
Tolerance range, regulation start: ± 10 bar
TL 65 / 70 / 80 / 80AS / 100 / 120 01.2008


8. Check and adjustment of the regulation start against mechanical stop
TL 80 ab Fz.id.Nr. 0751 / TL 100 ab 0453
Sauer Danfoss travel motors type 51D080
- connect 600 bar - gauge to the existing gauge port MA (high pressure forward) of the
travel pump
- connect a 600 bar gauge at the travel motor regulation start gauge port
- drive machine forward against mechanical stop
- select fast speed (rabbit) slowly accelerate
- the gauges at the pump and at the travel motor increase slowly.
When the regulation start value is reached (see technical data) the gauge
at the regulation start port (M3) must drop
-
The adjustment can be corrected by turning in or out resp. the setscrew (20) at the
travel motor
Turning in: Regulation start later

Turning out: Regulation start earlier
TL 80 ab Fz.id.Nr. 0751
M3
20
Y6
Y2
TL100 ab Fz.id.Nr. 0453 L2 N

A
Spülventil
Y2 Flush valve n
Y2
Q max. Q min.
Y6
20 M3
M3
B
L1 M4
5.300.06/01.2008
L2 N
A
Spülventil
Flush valve
Y2 n
Q max. Q min.
Y6
M3
B
L1 M4
Sauer Danfoss axial piston displacement motor series 51-1 size 080
Diagram situation:
Travel direction forward, solenoid valve Y2 not energized.
Travel range “high”, solenoid valve Y6 not energized.
Example: Machine runs on even ground, high pressure “B” side below regulation start value.
The piston of the solenoid valve Y6 is kept in the left position by the spring (20).
Both servo- cylinder chambers are pressurized by high pressure.
The servo- piston bottom side (21) compared to the piston side is more powerful.
The travel motor strokes into Q min (high speed) and is kept in this position.
Hochdruckanschluss High pressure port

A Fahren rückwärts travel reverse L2 N
Hochdruckanschluss High pressure port
B Fahren vorwärts travel forward A
Messanschluss Test port travel motor
M3 Fahrmotor Regelbeginn regulation start
Messanschluss Fahrmotor Test port travel

M4 Fahrtrichtungserkennung direction recognition Spülventil
Flush valve n
Magnetventil Fahrmotor Solenoid valve travel motor Y2
Y2 Fahrtrichtungserkennung travel direction recognition
Magnetventil Fahrmotor Solenoid valve travel motor Q max. Q min.
Y6 Fahrgeschwindigkeit travel speed
Einstellbare Feder Adustable spring travel
20 Fahrmotor Regelbeginn motor regulation start
21
21 Verstellzylinder Servo piston
20
Verzögerungsblende Orifice travel motor
T3 Fahrmotorverstellung regulation
Y6
Drehzahlaufnehmer RPM sensor
N (Option) (option)
Leckölanschluss M3
L1 Case drain
L2 Leckölanschluss Case drain B

L1 M4
Sauer Danfoss axial piston displacement motor series 51-1 size 080
Diagram situation:
Travel direction forward, solenoid valve Y2 not energized.
Travel range “high”, solenoid valve Y6 not energized.
Example: Machine drives uphill, high pressure at “B” side increases.
Beginning at the regulation start, the piston of the solenoid valve Y6 is pushed by the acting high pressure
against the spring (20), the bottom side of the servo- piston (21) is connected to the tank.
The permanent acting high pressure at the rod side of the servo- piston (21) shifts the motor into Q max position.
Example: Travel range low, solenoid valve Y6 energized.
The regulation will be overridden, the piston of the solenoid valve Y6 is shifted by the energized solenoid
against the spring (20).
The servo- piston (21) keeps the motor in Q max position.
TL 65 / 70 / 80 / 80AS / 100 / 120 01.2008


9. Check and adjustment of the inching
− open the engine bonnet
− connect 600 bar - gauge to the existing gauge port MA (high pressure forward) of the travel
pump
− connect 60 bar - gauge to gauge port „brake pressure at the inching valve“
− drive the machine forward against a solid object so that the wheels lock up
− slowly actuate the foot brake pedal
− watch both gauges: At approx. 5 bar brake pressure the inching must begin, i.e. the 600 bar -
gauge decreases. At approx. 13 bar brake pressure the inching must be finished, i.e. the 600
bar - gauge decreases to the charge pressure value
The inching range can be changed or corrected resp. via the setscrew (11) at the
inching valve
Turning in: inching later

Turning out: inching earlier
10. Check of pressure switch (hydrostatic brake)
− open the engine bonnet
− connect 60 bar - gauge to gauge port „brake pressure at the inching valve“(10)
− connect a test lamp to the current less cable of the brake pressure switch
the test lamp has to light up at the brake pressure value (see technical data)
if the pressure value does not correspond to the desired value,

adjust the pressure switch or replace it
10
Druckschalter S26
Pressure switch S26
5.300.07 / 01.2008
Description A 6 VM DA 5
with switching solenoids
Electrical travel direction valve and Q min - circuit
Travel range rabbit (road travel), forward
Electrical switching solenoid (a) current less in connection with travel direction switch
The high pressure side A is pressurized, so the high pressure can, on the one hand, act on
the regulator piston (ring surface) via the check valve and the switching solenoid (a) and, on
the other hand, on the control spool ring surface.
Electrical switching solenoid (b) current less in connection with quick / slow switch
Thus the corresponding speed-dependent control pressure can act on the big regulator
piston surface. This effects that the travel motor is set to Q min (small swash plate angle)
(rabbit) as with any other DA-regulation. When charged (increasing high pressure), the travel
motor automatically regulates back to Q max (big swash plate angle) (tortoise) from the
regulation start adjusted.
Travel range rabbit (road travel), reverse
Switching solenoid (a) under current
The high pressure side B is pressurized. So the description given under travel range rabbit
(road travel) forward applies.
Travel range tortoise (working), forward
Switching solenoid (a) current less
Functioning as described under travel range rabbit (road travel)
Switching solenoid (b) under current
The control pressure is not switched on the big surface of the regulator piston; solenoid
valve (b) is closed. The travel motor remains in Q max. position (big swash plate angle).
TL65 / TL70s / TL80 / TL80AS / TL100 / 01.2000
TL120
Travel motor 5.300.08
Hydrostatic brake
By releasing the accelerator pedal the travel speed is reduced. The hydrostatic transmission
hereby acts as wear-resistant auxiliary brake.
Additional hydrostatic brake only acts in fast travel range (forward)
By actuating the foot brake pedal, from a special brake pressure both switching solenoids (a)
and (b) at the travel motor are supplied with current via a brake pressure switch (see
Technical Data). This effects that the travel motor is displaced from Q min to Q max.
This effects the following:

Switching solenoid (b) locks the control pressure x1 to the regulator piston.
This one switches the big control spool surface to the tank.
As the high pressure relationship from A to B becomes inverted when the machine is slowed
down (travel motor becomes the pump), the high pressure is transferred from side B to the
ring surface of the control spool via the switching solenoid (a). Now the travel motor is in big
swash plate angle position (Q max.) So the machine is additionally slowed down.
5.300.08/01.2000
SUBGROUP LIST
Functional Description
TL 65 (SKL 824) Location of hydraulic components 6.22
TL 80 AS Walveoil control valve 6.25
TL 70 (SKS 634) Location of hydraulic components 6.37
TL (SKL), general Suction filter function 6.520
05/2010
V
B 2
11 4
8 3
9 12
10 1
7 6
H
T
K
18
16 17
14
13
15
M
Typ Arbeitshydraulik Datum
Model Working hydraulik Edition
Type TL 65 (SKL 824) Hydraulique équipement Date 01.2007
Tipo Hidráulico de trabajo Fecha
Benennung Ventileinbauübersicht Blatt

Description Location of hydraulic components Page
Dénomination Feuille 6.22.11
Position de montage des composants hydrauliques
Posiciones de las válvulas hidráulicas
Pos.
Rep.
No.
V VORDERWAGEN FRONT CHASSIS CHÂSSIS AV
H HINTERWAGEN REAR CHASSIS CHÂSSIS AR

2 Lenkeinheit Steering unit Unite de direction
3 Vorsteuereinheit Y5,Y7,Y8,Y9 Pilot-operated unit Y5,Y7,Y8,Y9 Système pilotage Y5, Y7, Y8, Y9
4 4/2 Wegeventil Y12, Y13 4/2 Solenoid valve Y12,Y13 Electrovanne 4/2 Y12,Y13
(Arbeitshydraulik abschalten) (Stop working hydraulic) (Neutralisation hydr. de travail)
6 Prioritätsventil (Lenken) Priority valve (steering) Valve prioritaire (direction)
7 Verstellmotor Y2,Y6 Variable displacement motor Moteur á cylindrée variable
(Fahren) Y2,Y6 (travel) Y2,Y6 (translation)
8 Speicherblock mit Accumulator bloc with hydr. Bloc d’accumulateurs avec
Hydrospeicher OPTION accumulator OPTION accumulateur hydr. OPTION
(Lastschwingungsdämpfung) (ride control) (anti-tangage)
9 Stabilisieungsmodul OPTION Pilot bloc OPTION Y11, Y15 Bloc de pilotage OPTION
Y11,Y15(Lastschwingungsd.) (ride control) Y11, Y15 (anti-tangage)
10 3/2 Wegeventil OPTION 3/2 Solenoid valve OPTION Electrovanne 3/2 OPTION
Y16 (Lasthalteventil + Y16 (load holding valve + Y16 (clapet anti-chute +
Lastschwingungsdämpfung) ride control) anti-tangage)
11 Steuerventil OPTION Y20,Y21, Valve bank OPTION Distributeur OPTION Y20,Y21,Y22
Y22 (Schaufelrückstellung) Y20,Y21,Y22 (return to dig)) (remise à niveau automatique)
B BODENRAHMEN FLOOR FRAME CADRE DE PLANCHER

12 Vorsteuergerät - Joy-stick Pilot operated valve - Distributeur à commande
joy-stick assistée - manipulateur
M DIESELMOTOR DIESEL ENGINE MOTEUR DIESEL

13 Kombinierter Öl- Wasserkühler Combi radiator cooler Refroidisseur combiné
for oil and water huile et eau
14 Zahnradpumpe Gear pump Pompe à engrenages
(Lenken / Laden) (steering / working) (direction / travail)
15 Verstellpumpe (Fahren) Variable displacement pump Pompe à débit variable
Y3,Y4 (travel) Y3,Y4 (translation) Y3,Y4
T HYDRAULIKÖLTANK HYDRAULIC OIL TANK RÉSERVOIR HYDRAULIQUE

17 Rücklauffilter Return filter Filtre de retour
18 Belüftungsfilter Vent valve Filtre d’aération
K KRAFTSTOFFTANK FUEL TANK RESERVOIR DE CARBURANT


6.22.12
Dénomination Position de montage des composants hydrauliques Feuille
V
B 2
11 4
8 3
9 12
10 1
7 6
H
T
K
18
16 17
14
13
15
M

Pos.
Rep.
No.






6.24.12
Sekundärventil Sekundärventil
Shock valve Shock valve
280 bar 230 bar
Sekundärventil
Shock valve
125 bar
Sekundärventil
Shock valve
Mech. Kreuzbetätigung mit 230 bar
Raste für Schwimmstellung.
Mechanic crosswise operation
with locking for float position. Nachsaugventil
Anti-cavitation valve
Mech. Linearbetätigung mit einseitiger Sekundärventil

Raste für Zusatzsteuerkreis. Shock valve
Mechanic linear operation with one- 280 bar
sided lock for add. circuit.
Lasthalterückschlagventile
Load holding check valves
Y9
Y10
Die Magneten Y9 und Y10 sperren im unbestromten Zustand
die Funktionen Hubrahmen auf-ab und Schaufel ein- auskippen.
Der Arretierungsstift wird dabei durch Federkraft in die Nut im
Schieber eingerastet.
The solenoids Y9 and Y10 are locking the function lift frame
up / down and bucket in / out in not energized condition.
Hauptüberdruckventil, einstellbar. To do this, the spring loaded pin locks the spool by snapping into
Main relief valve, adjustable. the spool groove.
250 bar
Arretierungsstift
Lock pin
Steuerschieber Arretierungsnut
Spool Lock groove
Typ Hydraulik ab Fz.-Id.-Nr. Datum

Model
Type
TL 80 AS Hydraulic from s/n
Hydraulique à partir n du s
0100 Edition
Date
01.2008
Benennung Steuerventil Walvoil SDM 100/3 Blatt

Description Control valve Walvoil SDM 100/3 Page 6.25.01
Distributeur Walvoil SDM 100/3
V
B 5
11 12
8 4
3
9
10 1
7 6
H T
K 18
17
16
13
14
15
M

Pos.
Rep.
No.






6.26.12
V 1
B 3
6
5
12
4
9
14
10 15
11 2
8
13
K T
21
19 20
H
17
16
18
M
Type TL 70 (SKS 634) Hydraulique équipement Date 01.2007

Pos.
Rep.
No.


2 Blocksteuergerät (Schwenken) Valve bank (swing) Bloc distributeur (orientation)
Y31, Y32 Y31, Y32 Y31, Y32
13 4/2 Wegeventil Y34 4/2 Solenoid valve Y34 Electrovanne 4/2 Y34
(Pendelachsverriegelung) (oscillating axle locking) (blocage d’essieu oscillant)
14 3/2 Wegeventil Y33 3/2 Solenoid valve Y33 Electrovanne 3/2 Y33
(Sicherheit Hubrahmen (safety mechanism for (securité bras de
senken) lowering lift frame) levage abaisser)


17 Zahnradpumpe - 2-fach Gear pump - double type Pompe à engrenages - double
(Lenken / Schwenken) (steering / swing) (direction / orientationl)


6.37.12
Pos.
Rep.
No.



6.37.13
Suction filter function:
A 100% filtration of the suction flow guarantees that the boost pump is not contaminated.
Return filter function:

By means of the full flow filtration in the system return, any contamination remaining in the
system after the assembly or repair or getting into the system from outside, is completely
filtered.
Functioning:
The hydraulic oil coming from the system return (A) passes the filter element (1). The volume
the boost pump of the hydrostatic transmission (B) needs is supplied by a pressure valve (2)
pressurised up to 0.5 bar. The surplus oil between the return flow and suction flow is fed into
the tank in filtered condition.
The pressurisation of 0.5 bar in the suction line reduces the cavitation risk in the boost pump
thus allowing excellent cold start characteristics.
An integrated pressure relief valve (3) prevents an inadmissibly high back pressure in the
return line. There is no direct connection between the system return (A) and the suction port
of the boost pump (B) (no bypass) as this valve leads directly to the tank.
The anti-cavitation valve (4) with the sieve (5) of the filter fineness of 125µm guarantees the
supplies of the boost pump in case of a brief oil shortage (drain / cold start).
There is no oil shortage with normal operation.
normal operation anti-cavitation operation
A
A
B
B
3 4
2
TL(SKL), general 01.2007
Suction - return filter 6.520.01
SUBGROUP LIST
Electrical system
Fuse assignment diagrams / wiring diagrams
TL 65 7.22
TL 80 AS 7.25
TL 80 F 7.25
TL 100 7.26
TL 70 7.37
Electrical system, general 7.100
04/2010
Central control module (ZSML)
X60 Signal inputs "engine monitoring"
X5
1 Power supply Terminal 15 output
2 Central mass Terminal 31
3 Charge control generator D+
X91
4 Air filter maintenance switch signal

5 Oil pressure switch signal
6 Hydrostatic brake pressure switch signal
7 Transmission switch signal
8 Engine temperature sensor signal
X20
X90
9 Tank sensor signal

10 Hydraulic oil temperature sensor signal
11 Speed signal generator "W" signal
12 --
13 --
X10
13 --
15 --
X61
16 --
17 --
18 Speedometer signal sensor
X30 Signal inputs "Lighting"
X40

2 --
3 Parking light Terminal 15 input
4 High beam signal
5 Direction indicator control signal
6 Reserve -
X80
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X80 Coordinate lever
X30

3 Travel forward signal
4 Travel reverse signal
5 Float position signal
6 Additional control circuit signal
X31
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.22.05/01.2007
X5
X40 CAN-BUS (Option)
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X90 Programming connection
X61
X91 Immobilizer (Option)

X40
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
TL 65 (SKL 824) 01.2007
Wiring diagram 7.22.06
X31 Module power supply, working
X5
floodlights, rotating beacon, wiper
1 --
2 -
X91
3 Reserve digital output

4 Relay K11:87a N.C. contact output
5 Relay K11:87 N.O. contact output
X20
X90
8 Relay K12 power supply Terminal 15 input

9 Relay K12:87a N.C. contact Output
10 Power supply Terminal 15 input working
floodlight front
11 Relay K11 power supply Terminal 15
input
X10
12 Reserve PWM output

X61
floodlight rear
16 Power supply Terminal 30 input rotating
beacon
X40
17 Reserve Digital output

19 Power supply Terminal 15 input wash/
wipe rear
20 Power supply Terminal 15 input travel
X80
wipe rear
X70 Working floodlights , Wipers
1 Brake light switch Terminal 15 output
X70
2 --
3 Working floodlight front output
4 Working floodlight rear output
5 Rotating beacon output
6 Wiper Terminal 53b 2nd setting output
X30
7 Washer pump front output

8 Wiper Terminal 31b output
9 Interior lamp Terminal 30 output
10 Wiper Terminal 53 output
11 Wiper Terminal 53a output
12 Hand brake switch signal input
13 Washer pump rear output
X31
14 Rear wiper Terminal 53a output

15 --
16 Rear wiper Terminal 31b output
X60
17 Rear wiper Terminal output

L824-ZSML
18 Brake light switch signal input
7.22.06/01.2007
X61 Rear carriage
X5
1 --
2 --
3 Starting Terminal 50a output
X91
4 Pre-heat output
5 Engine shutdown output
6 Brake light output
7 Travel, direction recognition
X20
output
X90
8 Travel, FAST-SLOW output

9 Transmission 1 output
10 Travel motion alarm output
X10
12 Working hydraulics output

13 Fog lamp Output
14 Ride control system 3 output
X61
15 Back-up lamp output

16 Travel reverse output
17 Float position output
18 Additional control circuit output
X40

20 Ride control system 1,2 output
21 Travel forward output
X20 Panel, right
1 Power supply Terminal 15
X80
output
2 --
3 Starting Terminal 50a signal
X70
4 Pre-heat signal
5 Engine shutdown signal
6 Ride control system signal
X30
9 Float position 1 signal

11 4th control circuit signal
13 Rotating beacon signal
14 Working floodlight front signal
X31
15 Working floodlight rear Signal

X5 Power supply
X60
L824-ZSML
TL 65 (SKL 824) 01.2007
FUSE BOX LEFT
heating fan / air conditioner
FL1 15A
wipe / wash front
FL2 15A
wipe / wash rear
FL3 15A
rotating beacon / cab light
FL4 10A
FUSE BOX RIGHT
travel forward / reverse; travel alarm
FL5 10A working light front
ride control FR1 15A
reserve K11
FL6 10A working light rear
air suspended seat FR2 15A
reserve K12
FL7 10A turn signal flasher
FR3 10A
inlet port e-module
FL8 10A hazard
FR4 10A
dash board
FL9 10A socket / radio power supply +
FR5 15A
radio (starter lock)
FL10 10A reserve option ( terminal 30)
FR6 15A
shovel return to dig / refueling pump
FL11 10A signal horn
FR7 10A
high beam light
FR8 10A
low beam light
FR9 10A
STARTER BOX FR10 10A

side marker lamp left
relay
side marker lamp right
K3 flashlightturning K3
K1 signal relay
start-up FR11 10A
relay
K2
pre-glow
relay
K3
engine shut-off
power supply machine
F01 50A
MAXI fast-acting fuse
pre-glow
F02 80A
power supply machine control unit
F03 30A
start-up relay / engine shut-off relay
F04 50A
engine shut-off
F010 10A
ATO fast-acting fuse
reserve
F011 10A
reserve
F012 5A
ATO fast-acting fuse Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n Edition
reserve Type TL65 Circuit électrique à partier du n/s
TL00650329 Date 11.2008
F013 5A Tipo Sistema elèctrico desde el no. Fecha
ATO fast-acting fuse Benennung Sicherungs- und Belegungsplan Blatt
Blatt
reserve Assignment diagramm
F014 5A
Description
Dénomination Schéma de répartition
Page
Feuille 1/1 Page
Feuille
7.22.10
ATO fast-acting fuse Denominación Esquemas de la caja Página Página
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PRE-HEAT STARTER SWITCH START-UP SYSTEM ENGINE SHUT-OFF PRE-HEAT SYSTEM
15 XM15 1
Kl.15
XM30 1 30 XM30 2 Kl.30
sw 6,0Ø
rt 6,0Ø
30
S1
0 I II III 15 54 19 17 50A
pre-heat starter switch
rt
br/ge
2
8
X22 X22
AC compressor
travel forward
travel reverse
10 4
vi/ws
br/ge
rt
5 4 3
control module
Kl.50/2.3
ZSML1.0 ZSML1.0 ZSML1.0
terminal 15 X20 X20 X20
pre-heating start pressure switch engine bloc

hydrostatic engine oil
X61:21 / 4.13
air filter coolant
X61:16 / 4.14
S33:2 / 2.1
starting engine shut-off pre-heating clogging brake temperature pressure
charge control X60 X60 speed X61 X61 X61 X60 X60 X60 X60
terminal 61 ZSML1.0 ZSML1.0 signal ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0
3 11 3 5 4 4 6 8 5
X5
1
br/ge
sw/bl
vi/ws
sw 4,0Ø
sw 6,0Ø
sw 6,0Ø
sw 10Ø
sw 10Ø
30 86 86 30 86 30
1 1 1 1
50A 80A 30A 50A K1 K3 K2
2 2 2 2
starter relay shut-off relay pre-heat relay
F01 F02 F03 F04 87 85 85 87 85 87
input fuses
pressure switch hydrostatic brake 100 bar

sw/vi 2,5Ø
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø
engine coolant temperature transmitter
solenoid clutch compressor air conditioner

rt/ws 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2
solenoid valve travel reverse

5A 2 5A 2 10A2 20A 2
solenoid valve travel forward
engine oil pressure switch

sw 10Ø
bl/sw/ws
switch air filter clogging
rt 6,0Ø
sw/br
sw/bl
bl/ws
sw/vi
vi/ws
rt/ws
rt/ge
rt/bl
gn/rt
bl
gn
17 18 A 13 14 10 8 9 4 B 7 1 2 3 6 11 15
XMOT XMOT XMOTL XMOT XMOT XMOT XMOT XMOT XMOT XMOTL XMOT XMOT XMOT XMOT XMOT XMOT
sw 10Ø
17 18 A 8 B 7 1
2
XMOT 3 6 11 15
rt/bl
bl/sw/ws
bl
rt 50Ø
bl/ws
rt 6,0Ø
sw 10Ø
gn/rt
sw/bl
sw
gn
gr
or
+ W
W16
D+ B+
sw25,0Ø 30 50a
W8 1
W31 1
1 2 1 1
G M
1
S28 S26
1 1
R3 S27
12 V
P P P
G2 /13.14 3~ /13.9 /13.8 Y4 Y3 /13.13
starter R1 2 1 /13.14 2
U 2 /13.8 Y30
br
battery Y1 2 pre-heat unit
/13.8
generatorG1 B- M1
1
2
/13.14 12
2 2
/13.16
XMOT
engine
br 16,0Ø
12
shut-off
valve
br
br
br
br
br
br
br
br
br
4 7 1 15 2 3 6 22 4 3 1
Kl.31
XGNDMASCH
Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Type
Tipo
TL65 Circuit électrique
Sistema elèctrico
à partier du n/s
desde el no.
TL00650511 Date 04.2010
Fecha
Benennung Stromlaufplan Blatt Blatt

Wiring diagramm
Description
Dénomination circuit électrique
Page
Feuille 1/5 Page
Feuille
7.22.21
Denominación Página Página
Esquemas de los circuitos
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
WASH / WIPE SYSTEM WASH / WIPE SYSTEM WASH / WIPE SYSTEM REAR
HEATING AIR CONDITIONER OPTION AIR- SUSPENDED SEAT
FRONT
15 7
Kl.30/1.16 Kl.15/3.1
30 2
Kl.15/1.16 Kl.30/3.1
Kl50/1.5
1
rt 2,5Ø
1
30A FZ4 30A FL4 /5.8
FZ1
2,5Ø
2 2
br/ge
br/ge
rt
ge 2,5Ø
rt
rt
1 1 1 1
6
FL2 15A FL3 15A FL5 10A FL6 10A
S19:5 /3.11
30 86 30 86
S20:9/3.12
S22:3/3.8
/6.5 2 /6.5 2 /6.5 2 /6.5 2
X20(1)/4.5
K5 K6
CUT-OFF RELAIS CUT-OFF RELAIS
air conditioner switch

87a 87 85
HEATING FAN 87a 87 85 LIGHTS
(WHILE START-UP) (WHILE START-UP)
K5/5.4
1
FL1 15A
ge/sw
/6.5 2
rt/sw
rt/ge
rt/ge
rt/gn
rt/ge
ge/sw
K6/5.3
Kl.30
ge
ge/sw
/11.14 3 4 9 9 3 4 9 3 4 9
blower switch B1 5 6 10 S20 /11.14 S21 /11.14
S22
switch switch switch
S2 0 I II III S31 1 7 2 8 10 wiper front 1 7 2 8 10 wash /wipe 1 7 2 8 10 wiper rear
C1 B3 B4 B5 A3 A4 A5 1 7 2 8 9
/6.1
ws/sw
gn/gr
ge/sw
gn/sw
ge/gn
or/sw
sw/br
rs/sw
ge/br
ge/bl
rt/ge
gn/rt
ge/rt
br/rt
bl/rt
bl/rt
4 17 9 16 2 10 7 9 12
19 21 20 8
ZSML1.0 Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul ZSML1.0 ZSML1.0 ZSML2.0
14 X31 /6.23 K K J K K J K K J X31 X31 /6.23 X31 /6.23

/11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /6.23
wash / wipe system

X170
power supply Back Alarm H16 /

ride control Y16
washer pump front
power supply -
reserve terminal K12

power supply -
14
wash / wipe rear terminal K5,6

washer pump rear
power supply -
power supply +
power supply +
ws/sw
front K1,2,3
thermostat switch
S32 1
terminal 31.b
terminal 53.a
2
/10.8
terminal 53
pump rear
wiper rear
wiper rear
wiper rear
rt/ge
washer
washer wiper wiper wiper wiper
pump terminal 53 term. 31b term. 53a term. 53b
15
X170 X70 X70 X70 X70 X70 X70 X70 X70 X70
/10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1
15
ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0
7 10 8 11 6 13 17 16 14
rt/ge
gn/sw
8
gn/gr
gn/bl
X160
br/ws
bl/sw
ge/vi
br
8
rt/ge
1 2 3
X170 5 6 4
1 2 3
X171
5 6 4
washer pump rear

S33
washer pump front
1
or/ws
br/ws
br/ws
bl/sw
bl/sw
ge/vi
pressure switch dryer
rt/gn
gr/bl
P
bl/rt
bl/sw
bl/gn
/8.15
gr/bl
53 31b 53a 53b

air- suspended seat
31b
bl/ws
2 4 3 1
bl/sw
+ +
bl
gr
or
fan M M M 53
M
53a
wiper rear M
M
M4 M6 wiper front M5 M7 M9
/10.8
M3 - /10.8
/10.16
- /10.8 /9.11 /6.18 2
sw
31
1
compressor/1.16
31
br
br
br
br
br
br
1 2 3 4 5 23
Kl.31/1.16 Kl.31/3.1

Model Electrical system from s/n Edition
Type TL65 Circuit électrique à partir du n/s TL00650511 Date 04.2010
Tipo Sistema elèctrico desde el no. Fecha

Wiring diagramm
Description
Page
Feuille 2/5 Page
Feuille
7.22.22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FUSE E-MODULE
TERMINAL 154 DASH BOARD OPTION OPTION SHOVEL RETURN TO DIG REFUELING PUMP
Kl.15/2.16 Kl.15/4.1
Kl.30/2.16 Kl.30/4.1
rt 2,5Ø
S22:3 /2.12
S17:3/4.15
S17:9/4.15
S19:5/2.7
S20:9 /2.8
FL11 /5.14
FL10 /5.14
rt 2,5Ø
rt 2,5Ø
FL7:1 /5.12
FL7:2 /5.13
power supply +
1 1 1 1
FL7 10A FL8 10A FL9 K FL11 10A
/6.5 2 /6.5 2 2 10A Anzeigemodul /6.5
2
ge
8
sensor lifting frame bottom

14
bl/br
ge
X22
sensor lifting frame top

rt/ws
11 1
sensor shovel adjust

ZSML2.0 ZSML1.0
ge
ge
ge
reserve K11 X31
/6.23
X30
/6.23
power supply power supply all Pin 1
rt/sw
rt/sw
rt/sw
rt/sw
rt/gn
rt/ge
rt/ge
X31:9 & X31:7 from connector of PNP/NC
NPN/NO PNP/NO
central control module 3 5 9 B B B
option switch /11.11 3 4 9 /11.11 5 9
dash board option switch S17 S19 S18 C C C

engine temperature indicator B10 B11 B12
switch return to dig

/11.14 I 0 II A A A
1 7 2 8 10 1 7 10
gn/ws
gn/bl
gn/rt
1 7 10
+
P2 +
P1 fuel gauge
br
br
br
58 58
31 31
t° Q 5 4 3
31 31 GND GND GND

S S
12 13 14
10
X170 X130 X130 X130
12 13 14
10
ws/ge
ws/gn
ws/br
or/ws
br/ws
br/sw
bl/sw
vi/sw
bl/ge
ws/rt
ws/rt
or/bl
bl/rt
sw
gn
br
vi
rt
1 4 2 5 3 10 13 6 1 3 7 12 14 8
6 7 8
Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul ZSML1.0 ZSML1.0 ZSML1.0
W W W W W K K J K K J K K J X30 X30 X30

/6.23 /6.23 /6.23
reversing reversing reversing shovel return reserve shove return lifting frame lifting frame shovel
fan off fan manuelly fan to dig S18 to dig top bottom adjust
option option K12 K12 K11 pressure K11
speed hand reserve reserve reserve break make break V Ref. switch PWM PWM make
4th circuit throttle dig out dig out dig out contact contact contact 2,5V lower out 3 out 4 contact
X60 X60 X60 X60 X60 X10 X10 X30 X30 X31 X31 X31 X31 X31 X31 X30 X30 X31 X31 X31
/8.1 /8.1 /8.1 /8.1 /8.1 /10.2 /10.2 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML2.0 ZSML2.0 ZSML1.0 ZSML1.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML1.0 ZSML1.0 ZSML2.0 ZSML2.0 ZSML2.0
1 7 18 9 10 5 4 10 11 3 6 17 9 7 4 9 12 15 18 5
ge 2,5Ø
gr/ws
or/ws
ge/bl
bl/rt
transmitter
hydraulic oil temperature
gn/ws
or/sw
bl/sw
bl/ws
br/gn
sw/vi
bl/ge
ws/rt
rt/sw
rt/sw
rt/gn
X10 X10
bl/rt
fuel gauge transmitter

vio
sw
18 X130 6 7 9 7
ge
/10.2 /10.2
X130 X130 X130 X160
ZSML2.0 ZSML2.0 15
5 16 X130 17 X130 1 2 3 10 11 8 X130
6 3 18 6 7 9 7
X68 X130 X130 X130 X130 X130 X130
sw
ge
gr/ws
or/ws
ge/bl
bl/rt
bl/rt
5 16
bl/rt
refueling pump
speed sensor
gear switch
5 6 1 2
shovel return to dig raise

2
ge 2,5Ø
shovel return to dig lower
shovel return to dig retract

+UB CAN/L CAN/H
U1
1 dash board
pressure switch lower

pressure switch retract
/10.16
S33 GND
ge
ws/rt
8 7 4 3
C 1 1 1
6 2 +
sw Q 22 1 1
X68
B9 R4 3
P P M M8
6 br
/8.11 R2 /8.15
ge
ge
B bl
A
1
/8.15 1
potentiometer S31 2
S30 2
2
Y21 2
Y22 2
Y20
- /8.15
XR4
br 2,5Ø
1 2
br
br
br
br
br
br
br
br
br
br
br
14
12 11 10 13 13 7 6 8 2 9
Kl.31/2.16 Kl.31/4.1

Type TL65 Circuit électrique à partier du n/s
TL00650511 Date 04.2010

Wiring diagramm
Description
Page
Feuille 3/5 Page
Feuille
7.22.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RIDE
OPTION 4TH HYDRAULIC CIRCUIT WORKING
FLOAT POSITION ADDITIONAL CIRCUIT TRAVEL SPEED CONTROL GEARBOX TRAVEL
HYDRAULIC
Kl.15/3.16 Kl.15/5.1
Kl.30/3.16 Kl.30/5.1
900 /5.8
S17:3 /3.7
X80
X20 K J X80
/6.23 ZSML1.0
S17:9 /3.8
ZSML1.0 Anzeigemodul Anzeigemodul 2 ZSML1.0
1 1
18 11
X20/2.1
rt/gn
rt/gn
rt/ge
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
ws
ge
ge
S21/2 1 3
/2.4
3 3
S10 3 4 10 3 4 10 5 9 10 5 3 4 10 5 9 5 9 5 10
S9 S13 S12 S14 S15 S16
/6.1 /6.1 /6.1 /11.11 /11.14
S21/1
/11.11 /11.14
1 7 2 8 9
S21/3 1 7 2 8 9 1 10 9 1 /6.1 1 7 2 8 9
S21/4 1 10 1 10 7 1 9
2 2 1
S11 2 1 2 1
gr/ws
gr/sw
sw/bl
bl/ws
gr/ge
bl/sw
bl/ge
bl/ge
bl/gn
sw/rt
rt/gn
rt/br
gr/rt
bl/rt
bl/rt
bl/rt
sw
gn
or
gr
bl
vi
rt
5 1 6 2 11 3 5 15 4
5 10 9 6 7 8 7 6 12 11 8 9 3 4
ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 Anzeigemodul Anzeigemodul ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 Anzeigemodul Anzeigemodul Anzeigemodul Anzeigemodul ZSML2.0 ZSML2.0 Anzeigemodul Anzeigemodul Anzeigemodul
X80 X20 X20 X80 X80 X20 X20 J J X20 X20 X20 X80 X80 K J K J X80 X80 K K J
/6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
th
push button float float push button at joystick additional additional travel low speed shut off 4th 4 push button at joystick gearbox working hydraulic rocker switch at joystick travel forward / reverse
at joystick position position additional circuit circuit circuit ride hydraulic hydraulic option travel forward / reverse
impulse preselection off (3rd hydraulic circuit) preselection off control circuit circuit (4th hydraulic circuit)
float position rd
(3 hydraulic circuit) preselection off
PWM PWM travel travel
Out 1 Out 2 forward reverse
X61 X61 X61 X61 X61 X61 X31 X31 X61 X61 X61 X61 X61 X61 X61
/8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /6.23 /6.23 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1
ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0
17 19 18 8 20 14 12 14 9 11 12 21 16 7 10
ws/sw
gn/sw
br/ws
sw/br
br/ge
gn/gr
bl/ws
rs/ge
bl/ge
gn/bl
bl/gn
bl/ge
ge/rt
rt/bl
sw
gr
1
XBACK
4 5 3 4
X130 X130 X68 X68 1
travel direction recognition

4 5 3 4
gn/sw
option solenoid valve
5 10

S34
4th hydraulic circuit

option
working hydraulic
additional circuit 2
1 7 9 travel alarm
travel low speed
/6.5
ride control 1
ride control 2
ride control 3
reverse travel
float position
gn/sw
gearbox 2
gearbox 1
bl/ws shut-off able
sw/bl
rs/ge
rt/bl
2
1 1 1 1 1 1 1 1 1
1 1 1 1 XBACK
Y11 Y15 Y16 Y19 Y18 Y12 Y13 Y5 Y2
/1.13
Y7
Fahren vorwärts /1.13

Y9 Y8 Y6 2
gn/sw
/8.9 /8.9 /8.9 /8.10 /8.10 /8.11 /8.10 /8.9 /8.10
Fahren rückwärts
travel forward
2 2 2 2 2 2 2 1 1 2 2 2 2
travel reverse
1
H16
2
/8.16 travel alarm
reverse travel
br
br
br
br
br
br
br
br
br
br
br
br
br
br
6 16 13 18 19 20 21 7 8 2 3 1 17 9
Kl.31/3.16 Kl.31/5.1

Type TL65 Circuit électrique à partier du n/s TL00650511 Date 04.2010

Wiring diagramm
Description
Page
Feuille 4/5 Page
Feuille
7.22.24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
LIGHTING AND SIGNALING SYSTEM ROTATING WORKING LIGHTS OPTION EXTENSION SOCKET RADIO SOCKET
BEACON
XM15 3
Kl.15/4.16
FL10/3.4
5
FL11/3.14
XM15 /6.15
FL7:1/3.3
FL7:2/3.3
XM30 4 XM30 3
F15/5.1
Kl.30/4.16
/5.16 F15
K6 / 2.5 K5 / 2.2
sw 2,5Ø rt 2,5Ø GND 1
rt 2,5Ø
sw 2,5Ø
sw 2,5Ø
12 13
FR7 10A
sw 2,5Ø
rt 2,5Ø
X170 X170 14
/6.11 2
FL4/2.14
br/ge
12 13
rt
sw
sw
br
rt
rt
2,5Ø
2,5Ø
rt
sw
1 1 1 1 1 1 1
FR4 10A FR3 10A 30
1 10
15 Option Tagfahrlicht
9
49a
2
15 9 FL4 15A FR1 15A FR2 2 15A FL10 10A FR6 15A
/6.11 2 /10.16 X170 /6.11
/6.11 2 /6.5 2 2 2 2 1
/6.11 /6.11
9 FR5 15A
sw
S8 0 11
2 /6.11
56a 56b 58 L R H Horn br/ge
rt/ge
rt/gn
steering 5 6 4 8 7 3
rt/br
1 X22
B5
sw/ws
sw/gn
/6.22
ws/gr
column /10.15
signal horn 16 10 13
br/gn 2
6
/10.2
switch 5 4 X70
X170 X170 /10.1

X31 /6.23 X31 /6.23 X31 /6.23
ZSML2.0
6 /6.22 5 4 1 1
rotating beacon K4 root K7 root K8
sw/ws/gn
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
power supply power supply
ws
ge
ge
ge
rt
li rotating beacon working light working light

900/4.8
front rear
sw/ws
loudspeaker
2 8 3
hazard 11
1 10 5 10 5 ge 10 5 10 5 S26
+ +
8 7
warning S4 X170 X170
S25
1
S23 S3 S5 S6 /6.5
B4
/9.14
B3
/6.1 8 7 11 P
switch 6 1 5 br10 /10.16 2 3 /10.3 /6.1 /9.10
ws/ge
- -
gr/sw
11 2 9 1 9 1 /6.1 9 1 /6.1 9 1
ws
gr/sw
switch
10
1
1
1 1 extension
FR8 FR9 FR10 FR11
socket
2,5Ø
sw/gn 2 2 10A 2 10A
10A 2 10A
sw/ws/gn
ge 2,5Ø
rt 2,5Ø
gr/sw
gr/sw
gr/sw
vi/ws
rt/sw
rt/ws
rt/sw
rt/ge
rt/ge
gr/rt
gr/rt
ws/ge
sw
sw
sw
ge
rt
rt
ws
ws
7 4 3 4 5 6
31 T 4 3 18 12 13 14 15
ZSML2.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML2.0 ZSML2.0 ZSML2.0
XA1 XA2
/6.9 /6.9 /9.1 /9.1 /9.1 /9.1
flashlight K3 X30 /6.23
1 2
X150 X30 /6.23 X70 /10.1 X70 /10.1 X20 /6.23 X20 /6.23 X20
/6.23
turning /6.19
15 53S 1 2
working
high beam parking brake light parking rotating working
signal relay light rear
light brake beacon light front
sw/ws
switch
reversing rotating working working
cab light 5 brake light head light beacon light front light rear 7 4 3 4 5 6
ZSML2.0
X70 X30 X61 X61 X70 X61 X70 X70
/10.1 /8.1 /8.1 /10.1 /8.1 /10.1 /10.1
/6.23
ZSML2.0 ZSML1.0 ZSML1.0 ZSML2.0 ZSML2.0 ZSML2.0 ZSML2.0 B2
9 6 15 5 13 3 3 4 4
flash light 8
radio
2 1 3
check XSDZ
rt/ge
gr/sw
gr/sw
sw/ws sw/ws sw/gn vi/ws
gr/rt
gr/rt
4 sw/gn 5
XSDZ
1
X160
3
X150
5 3
XSDZ
option 2 1 3
X150 X160
1 3 5 3 rear fog lamp
2,5Ø
ge 2,5Ø
rt 2,5Ø
rt/ge
3 gr/sw gr/rt 7 2 1 8 9
2 4 6 4
X171 X160 X150 X150 X160 X171 X171 X171
ge
ge
rt
3 2 4 6 4 7 2 1 8 9
gr/rt
54 58R 58L 1 2 3
1
31
working light
X68
license plate light
rotating beacon
rt/ge
1 4
sw/ws
sw/ws
ws/ge
ws/ge
sw/gn
sw/gn
gr/sw
gr/sw
gr/sw
gr/sw
vi/ws
sw/rt
sw/rt
gr/bl
gr/bl
gr/rt
gr/rt
gr/rt
gr/rt
gr/rt
XAS
ws
ws
XSKS
br 2,5Ø
1
1
front rear extension disconnection 1
E8 socket X22 XSD
/9.14 + 1 1 1 1 6
point for /6.9
XA1
/6.22 /6.19
cab light 4 3 5 2 3 2 5 4 3 2 5 4 4 3 5 2 E4 13 2
2
E1 E2 E4 E5
XSDZ swing loader 8 socket
with switch E3 E3 E6
br 2,5Ø
6
/8.22 1 /7.15 1
/7.15
1
/8.20
1
- E7 2 /9.14
2 2
/9.14
2 2 /6.22
rear light E14 /9.14

/9.14 /9.14
rear light front light front light
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
21 6
left 5
left 15
right 16
right 2 1 7 8 9 10 22 24 12 20
Kl.31/4.16

Type TL65 Circuit électrique à partier du n/s TL00650511 Date 04.2010

Wiring diagramm
Description
Page
Feuille 5/5 Page
Feuille
7.22.25
X5
X91

X20
X90

12 --
13 --
X10
13 --
15 --
X61
16 --
17 --
X40

2 --
4 High beam signal
6 Reserve -
X80
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X30

X31
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.24.05/01.2007
X5
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X61

X40
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
TL 80 (SKL 834) 01.2007
X5
1 --
2 -
X91

X20
X90

floodlight front
input
X10

X61
floodlight rear
beacon
X40

wipe rear
X80
wipe rear
X70
2 --
X30

X31

15 --
X60

L824-ZSML
7.24.06/01.2007
X61 Rear carriage
X5
1 --
2 --
X91
4 Pre-heat output
X20
output
X90

X10
13 Fog lamp Output

X61

X40

X20 Panel, right
X80
output
2 --
X70
4 Pre-heat signal
X30

X31

X5 Power supply
X60
L824-ZSML
TL 80 (SKL 834) 01.2007
FUSE BOX LEFT
FL1 15A
wipe / wash front
FL2 15A
wipe / wash rear
FL3 15A
FL4 10A
FUSE BOX RIGHT
shovel return to dig
reserve
FR3 10A
inlet port e-module
FL8 10A hazard
FR4 10A
dash board
FR5 15A
FR6 15A
FR7 10A
high beam light
FR8 10A
low beam light
FR9 10A

relay
K1 signal relay
start-up FR11 10A
relay
K2
pre-glow
relay
K3
engine shut-off
F01 50A
pre-glow
F02 80A
F03 30A
F04 50A
engine shut-off
F010 10A
exhaust gas recirculating valve
F011 10A
reserve
F012 5A
cold start enhancement Type TL80 Circuit électrique à partier du n/s
TL00801181 Date 11.2008
Blatt
start excess quantity (turbo engine) Assignment diagramm
F014 5A
Description
Page
Feuille 1/1 Page
Feuille
7.24.10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 XM15 1
Kl.15
XM30 1 30 XM30 2 Kl.30
sw 6,0Ø
rt 6,0Ø
30
S1
0 I II III 15 54 19 17 50A
rt
br/ge
2
8
X22 X22
10 vi/ws 4
br/ge
rt
5 4 3
control module
Kl.50/2.3
travel forward
travel reverse
compressor
X61:21 / 4.13
air filter coolant
X61:16 / 4.14
S33:2 / 2.1
3 11 3 5 4 4 6 8 5
X5
1
br/ge
sw/bl
vi/ws
sw 4,0Ø
sw 6,0Ø
sw 6,0Ø
sw 10Ø
sw 10Ø
30 86 86 30 86 30
1 1 1 1
50A 80A 30A 50A K1 K3 K2
2 2 2 2
F01 F02 F03 F04 87 85 85 87 85 87
input fuses

sw/vi 2,5Ø
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø

rt/ws 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2

5A 2 5A 2 10A2 20A 2

start excess quantity valve
cold start enhancement valve
sw 10Ø
bl/sw/ws
rt 6,0Ø
sw/br
sw/bl
bl/ws
sw/vi
vi/ws
rt/ws
rt/ge
rt/bl
gn/rt
bl
gn
17 18 A 13 14 10 8 9 4 B 7 1 2 3 6 11 15
sw 10Ø
17 18 A 13 14 8 9 B 7 1 XMOT 3 6 11 15
turbo engine
2
rt/bl
br/ge
bl/sw/ws
bl
rt 50Ø
bl/ws
rt 6,0Ø
rt
sw 10Ø
gn/rt
sw/br
sw/bl
sw
gn
gr
or
+ W
W16
D+ B+
sw25,0Ø 30 50a
W8 1
W9 1 W31 1
1 2 1 1
G M
1 1 1
S28 S26
1 1
R3 S27
12 V
P P P
G2 /13.14 3~ Y29 /13.9 /13.8 Y4 Y3 /13.13
starter R1 2 1 /13.14 2
U Y10 2 /13.8 Y30
br
battery Y1 Y12 2 pre-heat unit
/13.8
generatorG1 B- M1
1 8
/13.13
10
/13.14
2
/13.14
2
/13.13 12
2 2
/13.16
XMOT
engine exhaust gas
br 16,0Ø
12
shut-off recirculating
valve valve
br
br
br
br
br
br
br
br
br
br
4 7 br 16,0Ø 1 15 2 9 3 6 22 4 3 1
Kl.31
XGNDMASCH
Model Electrical system form s/n TL00802070 und Edition
Type
Tipo
Sistema elèctrico
à partier du n/s
desde el no. 2062,2064,2065 Date 04.2010
Fecha

Wiring diagramm
Description
Page
Feuille 1/5 Page
Feuille
7.24.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FRONT
15 7
Kl.30/1.16 Kl.15/3.1
30 2
Kl.15/1.16 Kl.30/3.1
Kl50/1.5
1
rt 2,5Ø
1
30A FZ4 30A FL4 /5.8
FZ1
2,5Ø
2 2
br/ge
br/ge
rt
ge 2,5Ø
rt
rt
1 1 1 1
6
FL2 15A FL3 15A FL5 10A FL6 10A
S19:5 /3.11
30 86 30 86
S20:9/3.12
S22:3/3.8
/6.5 2 /6.5 2 /6.5 2 /6.5 2
X20(1)/4.5
K5 K6

87a 87 85
K5/5.4
1
FL1 15A
ge/sw
/6.5 2
rt/sw
rt/ge
rt/ge
rt/gn
rt/ge
ge/sw
K6/5.3
Kl.30
ge
ge/sw
/11.14 3 4 9 9 3 4 9 3 4 9
S22
C1 B3 B4 B5 A3 A4 A5 1 7 2 8 9
/6.1
ws/sw
gn/gr
ge/sw
gn/sw
ge/gn
or/sw
sw/br
rs/sw
ge/br
ge/bl
rt/ge
gn/rt
ge/rt
br/rt
bl/rt
bl/rt
4 17 9 16 2 10 7 9 12
19 21 20 8
14 X31 /6.23 K K J K K J K K J X31 X31 /6.23 X31 /6.23

/11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /6.23
wash / wipe system

X170

ride control Y16
washer pump front
power supply -

power supply -
14

washer pump rear
power supply -
power supply +
power supply +
ws/sw
front K1,2,3
thermostat switch
S32 1
terminal 31.b
terminal 53.a
2
/10.8
terminal 53
pump rear
wiper rear
wiper rear
wiper rear
rt/ge
washer
15
X170 X70 X70 X70 X70 X70 X70 X70 X70 X70
/10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1
15
7 10 8 11 6 13 17 16 14
rt/ge
gn/sw
8
gn/gr
gn/bl
X160
br/ws
bl/sw
ge/vi
br
8
rt/ge
1 2 3
X170 5 6 4
1 2 3
X171
5 6 4
washer pump rear

S33
washer pump front
1
or/ws
br/ws
br/ws
bl/sw
bl/sw
ge/vi
rt/gn
gr/bl
P
bl/rt
bl/sw
bl/gn
/8.15
gr/bl
53 31b 53a 53b

air- suspended seat
31b
bl/ws
2 4 3 1
bl/sw
+ +
bl
gr
or
fan M M M 53
M
53a
wiper rear M
M
/10.8
M3 - /10.8
/10.16
- /10.8 /9.11 /6.18 2
sw
31
1
compressor/1.16
31
br
br
br
br
br
br
1 2 3 4 5 23
Kl.31/1.16 Kl.31/3.1

Model Electrical system from s/n TL00802070 und Edition
Type TL80 Circuit électrique à partir du n/s 2062,2064,2065 Date 04.2010

Wiring diagramm
Description
Page
Feuille 2/5 Page
Feuille
7.24.22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FUSE E-MODULE
Kl.15/2.16 Kl.15/4.1
Kl.30/2.16 Kl.30/4.1
rt 2,5Ø
S22:3 /2.12
S17:3/4.15
S17:9/4.15
S19:5/2.7
S20:9 /2.8
FL11 /5.14
FL10 /5.14
rt 2,5Ø
rt 2,5Ø
FL7:1 /5.12
FL7:2 /5.13
power supply +
1 1 1 1
/6.5 2 /6.5 2 2 10A Anzeigemodul /6.5
2
ge
8

14
bl/br
ge
X22

rt/ws
11 1

ZSML2.0 ZSML1.0
ge
ge
ge
reserve K11 X31
/6.23
X30
/6.23
rt/sw
rt/sw
rt/sw
rt/sw
rt/gn
rt/ge
rt/ge
NPN/NO PNP/NO
option switch /11.11 3 4 9 /11.11 5 9


/11.14 I 0 II A A A
1 7 2 8 10 1 7 10
gn/ws
gn/bl
gn/rt
1 7 10
+
P2 +
P1 fuel gauge
br
br
br
58 58
31 31
t° Q 5 4 3
31 31 GND GND GND

S S
12 13 14
10
X170 X130 X130 X130
12 13 14
10
ws/ge
ws/gn
ws/br
or/ws
br/ws
br/sw
bl/sw
vi/sw
bl/ge
ws/rt
ws/rt
or/bl
bl/rt
sw
gn
br
vi
rt
1 4 2 5 3 10 13 6 1 3 7 12 14 8
6 7 8

/6.23 /6.23 /6.23
/8.1 /8.1 /8.1 /8.1 /8.1 /10.2 /10.2 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
1 7 18 9 10 5 4 10 11 3 6 17 9 7 4 9 12 15 18 5
ge 2,5Ø
gr/ws
or/ws
ge/bl
bl/rt
transmitter
gn/ws
or/sw
bl/sw
bl/ws
br/gn
sw/vi
bl/ge
ws/rt
rt/sw
rt/sw
rt/gn
X10 X10
bl/rt

vio
sw
18 X130 6 7 9 7
ge
/10.2 /10.2
X130 X130 X130 X160
ZSML2.0 ZSML2.0 15
5 16 X130 17 X130 1 2 3 10 11 8 X130
6 3 18 6 7 9 7
X68 X130 X130 X130 X130 X130 X130
sw
ge
gr/ws
or/ws
ge/bl
bl/rt
bl/rt
5 16
bl/rt
refueling pump
speed sensor
gear switch
5 6 1 2

2
ge 2,5Ø

+UB CAN/L CAN/H
U1
1 dash board

/10.16
S33 GND
ge
ws/rt
8 7 4 3
C 1 1 1
6 2 +
sw Q 22 1 1
X68
B9 R4 3
P P M M8
6 br
/8.11 R2 /8.15
ge
ge
B bl
A
1
/8.15 1
potentiometer S31 2
S30 2
2
Y21 2
Y22 2
Y20
- /8.15
XR4
br 2,5Ø
1 2
br
br
br
br
br
br
br
br
br
br
br
14
12 11 10 13 13 7 6 8 2 9
Kl.31/2.16 Kl.31/4.1

Model Electrical system form s/n TL00802070+ Edition
Type TL80 Circuit électrique à partier du n/s 2062,2064,2065 Date 04.2010

Wiring diagramm
Description
Page
Feuille 3/5 Page
Feuille
7.24.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RIDE
HYDRAULIC
Kl.15/3.16 Kl.15/5.1
Kl.30/3.16 Kl.30/5.1
900 /5.8
S17:3 /3.7
X80
X20 K J X80
/6.23 ZSML1.0
S17:9 /3.8
1 1
18 11
X20/2.1
rt/gn
rt/gn
rt/ge
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
ws
ge
ge
S21/2 1 3
/2.4
3 3
S10 3 4 10 3 4 10 5 9 10 5 3 4 10 5 9 5 9 5 10
S9 S13 S12 S14 S15 S16
/6.1 /6.1 /6.1 /11.11 /11.14
S21/1
/11.11 /11.14
1 7 2 8 9
S21/3 1 7 2 8 9 1 10 9 1 /6.1 1 7 2 8 9
S21/4 1 10 1 10 7 1 9
2 2 1
S11 2 1 2 1
gr/ws
gr/sw
sw/bl
bl/ws
gr/ge
bl/sw
bl/ge
bl/ge
bl/gn
sw/rt
rt/gn
rt/br
gr/rt
bl/rt
bl/rt
bl/rt
sw
gn
or
gr
bl
vi
rt
5 1 6 2 11 3 5 15 4
5 10 9 6 7 8 7 6 12 11 8 9 3 4
/6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
th
float position rd
/8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /6.23 /6.23 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1
17 19 18 8 20 14 12 14 9 11 12 21 16 7 10
ws/sw
gn/sw
br/ws
sw/br
br/ge
gn/gr
bl/ws
rs/ge
bl/ge
gn/bl
bl/gn
bl/ge
ge/rt
rt/bl
sw
gr
1
XBACK
4 5 3 4
X130 X130 X68 X68 1

4 5 3 4
gn/sw
5 10

S34

option
working hydraulic
1 7 9 travel alarm
travel low speed
/6.5
ride control 1
ride control 2
ride control 3
reverse travel
float position
gn/sw
gearbox 2
gearbox 1
bl/ws shut-off able
sw/bl
rs/ge
rt/bl
2
1 1 1 1 1 1 1 1 1
1 1 1 1 XBACK
Y11 Y15 Y16 Y19 Y18 Y12 Y13 Y5 Y2
/1.13
Y7

Y9 Y8 Y6 2
gn/sw
/8.9 /8.9 /8.9 /8.10 /8.10 /8.11 /8.10 /8.9 /8.10
Fahren rückwärts
travel forward
2 2 2 2 2 2 2 1 1 2 2 2 2
travel reverse
1
H16
2
/8.16 travel alarm
reverse travel
br
br
br
br
br
br
br
br
br
br
br
br
br
br
6 16 13 18 19 20 21 7 8 2 3 1 17 9
Kl.31/3.16 Kl.31/5.1

Model Electrical system form s/n TL00802070 + Edition
2062,2064,2065
Date 04.2010

Wiring diagramm
Description
Page
Feuille 4/5 Page
Feuille
7.24.24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BEACON
XM15 3
Kl.15/4.16
FL10/3.4
5
FL11/3.14
XM15 /6.15
FL7:1/3.3
FL7:2/3.3
XM30 4 XM30 3
F15/5.1
Kl.30/4.16
/5.16 F15
K6 / 2.5 K5 / 2.2
rt 2,5Ø
sw 2,5Ø
12 13
FR7 10A
sw 2,5Ø
sw 2,5Ø
rt 2,5Ø
X170 X170 14
/6.11 2
FL4/2.14
br/ge
12 13
rt
sw
sw
br
rt
rt
2,5Ø
2,5Ø
rt
sw
1 1 1 1 1 1 1
FR4 10A FR3 10A 30
1 10
9
49a
2
/6.11 2 /10.16 X170 /6.11
/6.11 2 /6.5 2 2 2 2 1
/6.11 /6.11
9 FR5 15A
sw
S8 0 11
2 /6.11
rt/ge
rt/gn
rt/br
1 X22
B5
sw/ws
sw/gn
/6.22
ws/gr column
br/gn
/10.15
2 signal horn 16 10 13
6
/10.2
switch 5 4 X70
X170 X170 /10.1

X31 /6.23 X31 /6.23 X31 /6.23
ZSML2.0
6 /6.22 5 4 1 1
sw/ws/gn
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
ws
ge
ge
ge
rt

900/4.8
front rear
sw/ws
loudspeaker
2 8 3
hazard 11
1 10 5 10 5 ge 10 5 10 5 S26
+ +
8 7
S25
1
S23 S3 S5 S6 /6.5
B4
/9.14
B3
/6.1 8 7 11 P
switch 6 1 5 br10 /10.16 2 3 /10.3 /6.1 /9.10
ws/ge
- -
gr/sw
11 2 9 1 9 1 /6.1 9 1 /6.1 9 1
ws
gr/sw
switch
10
1
1
1 1 extension
FR8 FR9 FR10 FR11
socket
2,5Ø
sw/gn 2 10A 10A
10A 2 10A 2 2
sw/ws/gn
ge 2,5Ø
rt 2,5Ø
gr/sw
gr/sw
gr/sw
vi/ws
rt/sw
rt/ws
rt/sw
rt/ge
rt/ge
gr/rt
gr/rt
ws/ge
sw
sw
sw
ge
rt
rt
ws
ws
7 4 3 4 5 6
31 T 4 3 18 12 13 14 15
XA1 XA2
/6.9 /6.9 /9.1 /9.1 /9.1 /9.1
1 2
X150 X30 /6.23 X70 /10.1 X70 /10.1 X20 /6.23 X20 /6.23 X20
/6.23
turning /6.19
15 53S 1 2
working
sw/ws
switch
ZSML2.0
X70 X30 X61 X61 X70 X61 X70 X70
/10.1 /8.1 /8.1 /10.1 /8.1 /10.1 /10.1
/6.23
9 6 15 5 13 3 3 4 4
flash light 8
radio
2 1 3
check XSDZ
rt/ge
gr/sw
gr/sw
vi/ws
sw/ws sw/ws sw/gn
gr/rt
gr/rt
4 sw/gn 5
XSDZ
1
X160
3
X150
5 3
XSDZ
option 2 1 3
X150 X160
2,5Ø
ge 2,5Ø
rt 2,5Ø
rt/ge
3 gr/sw gr/rt 7 2 1 8 9
2 4 6 4
X171 X160 X150 X150 X160 X171 X171 X171
ge
ge
rt
3 2 4 6 4 7 2 1 8 9
gr/rt
54 58R 58L 1 2 3
1
31
working light
X68
license plate light
rotating beacon
rt/ge
1 4
sw/ws
sw/ws
ws/ge
ws/ge
sw/gn
sw/gn
gr/sw
gr/sw
gr/sw
gr/sw
vi/ws
sw/rt
sw/rt
gr/bl
gr/bl
gr/rt
gr/rt
gr/rt
gr/rt
gr/rt
XAS
ws
ws
XSKS
br 2,5Ø
1
1
E8 socket X22 XSD
/9.14 + 1 1 1 1 6
point for /6.9
XA1
/6.22 /6.19
cab light 4 3 5 2 3 2 5 4 3 2 5 4 4 3 5 2 E4 13 2
2
E1 E2 E4 E5
br 2,5Ø
6
/8.22 1 /7.15 1
/7.15
1
/8.20
1
- E7 2 /9.14
2 2
/9.14
2 2 /6.22

/9.14 /9.14
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
21 6
left 5
left 15
right 16
right 2 1 7 8 9 10 22 24 12 20
Kl.31/4.16

Type TL80 Circuit électrique à partier du n/s 2062,2064,2065 Date 04.2010

Wiring diagramm
Description
Page
Feuille 5/5 Page
Feuille
7.24.25
3 2 1
1 fuse and relay box ............... at operators compartment, cover right
2 K12 washer/wiper relay ....... underneath cover
3 K1 relay terminal 15 ............ underneath cover
Location Relay Function

E1 K2 Starting safety
E2 K3 Travel direction
E3 K4 Travel - reverse
E4 K5 Travel - forward
E5 K9 Working lights front (Option)
E6 K 10 Working lights rear (Option)
E7 V2 Diodes bloc
E8 V1 Diodes bloc
E9 ----- not assigned
E 10 ----- not assigned
K 11 Flasher transmitter
K01* Starter relay

K02* Glow time control unit
* These relays are located behind the cab at the battery compartment.
TL 80 AS (from serial no. TL80AS0100) 01.2008
Fuse and relay box 7.25.06
Position Ampere Assigned to Position Ampere Assigned to
F1 10 Pre-heat switch, F 15 15 Wiper rear
engine shut off
F2 20 Lighting system F 16 5 Radio, terminal 15
(Option)
F3 10 Socket, F 17 15 Direction indicator,
Radio Wiper / washer, horn
F4 10 Rotating beacon, F 18 15 Working lights front
Cab light
F5 10 Hazard warning light F 19 15 Working lights rear
F6 10 Terminal 30 (Option) F 20 5 Instrument

F7 5 Engine shut-off F 21 15 Refueling pump,
(Option)
F8 10 Exhaust-gas return system F 22 20 Daytime running light
(Option) (Option)
F9 10 Pressure switches brake F 23 20 Rear window defroster
lights, hydrostatic brake
F 10 15 Travel drive, parking brake, F 24 10 Terminal 15 (Option)
backup light
F 11 10 Working hydraulic, F 25 15 Upper beam
travel fast
F 12 10 Additional control circuit F 26 15 Lower beam
F 13 15 Heater fan, air condition F 27 10 Left side marker light
F 14 15 Washer / wiper front F 28 10 Right side marker light
F 01* 50 Main fuse F 02* 60 Pre-heat fuse
F 03* 20 Starter fuse
* These fuses are located behind the cab at the battery compartment.
Cable colours
bg beige dgr dark grey hbr light brown rt red

bl blue ge yellow hgr light grey sw black
br brown gn green hr light red vi violet
dbl dark blue gr grey nt nature ws white
dbr dark brown hbl light blue or orange
7.25.06/01.2008
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
POWER SUPPLY START-UP SYSTEM PRE-HEAT SYSTEM ENGINE SUPERVISION

30 3 5
Kl.30/2.1
8
15 X15 9
Kl.15/2.1
rt 2,5Ø
F20
rt 6,0Ø
sw 2,5Ø
/5.15
sw 2,5Ø
W71 W114
2 1
relay F1 10A F20 2 5A
1
power supply
sw 2,5Ø
!
K1 terminal 15 L20 L21
sw
ge
87 85 30 S1 1/2
60 150
11 14 0 4/4
br
/7.18 /7.17
X22 0 I II III X22
31
17 19 54 15
50A
30 86
S1 S4
sw/bl 2,5Ø
ge S3
/7.23
br/ge
sw 6,0Ø
ge 0,5Ø
00000 00
W9
2 8 L12 L13 L14 L17 L18 L19
15 58 31
X22 X22
L4 L10
4 10
sw/bl 2,5Ø
L1 L2 L3 L5 L6 L7 L8 L9 L11
br/ge
W22
relay
Kl.61/1.11
24 14 6 17 4 18 16 21 2 22 5 19 3 23 1 15 9 20 11 8 10 7 13 12
86 30 86 30
starter reliability relay B1
/7.11
K6
K2 /7.10 engine shut-off display
85 87 87a 85 87
X30
sw/br 2,5Ø
sw/bl 2,5Ø
1 2
br/ge
vi/ws
br/ws 0,5Ø
gn
br
rt
2
XM1 31 5 W112 W113 7 8 9
XM1 XM1 XM1 XM1
2 1
1 1
5 20A 7 8 9
K2 /2.8
F7 5A F8
br/ge
2 2
glow time control unit
sw/ge 0,5Ø
sw/ws 0,5Ø
0,5Ø
bl/ws 0,5Ø
sw/vi 0,5Ø
gr/rt 0,5Ø
bl 0,5Ø
gn 0,5Ø
gr 0,5Ø
sw 0,5Ø
ws 0,5Ø
sw/br
sw/bl
br/ws
vi/ws
rt/gn
W110 W111
rt 6,0Ø
rt
sw 10Ø
sw 6,0Ø
30 86
21 22
XM1 XM1 /6.19 3 6 20 4
W5
pre-heat fuse
starter fuse
2 2 2
/6.18 XM1 XM1 XM1 XM1
21 22
air filter clogging switch

K01 starter relay
F03
5
F01
Kl.56a/4.4
F02
main fuse
50A
60A
20A
3 6 20 4
4
B1:L5/2.8
B1:L6/2.4
B1:L7/2.8
87 85
Kl.58/4.5
Kl.61/1.3
Kl.C /4.2
3
br
rt 6,0Ø
1 1 1
2
2
B+ /5.2
bl/ws
sw/vi
W19
gn
rt/gn
engine oil temperature sensor

K02
8
1
9 X22
11 7
switch engine oil pressure

6
sw 2,5Ø
sw 6,0Ø
sw 6,0Ø
sw 10Ø
XMOT XMOT 13
sw 6,0Ø
rt/bl
11 6
bl
7
sw/br
sw/bl
rt 6,0Ø
bl/ws
rt/ws
rt/ge
sw 35,0Ø
W17 W18
gn
S28
W6 W25
rt/gn
/6.19 W11 W7
17 18 13 14 8 9
A /6.19 1
XMOTL XMOT XMOT XMOT XMOT
B 1 1 1 Q
17 18 A 13 14 8 9 XMOTL P P /6.7
exhaust-gas recirculation
-+
sw/br
B
rt/bl
sw/bl
rt 6,0Ø
S27
2 2 2
R2
R3
bl
2
br/ge
W8 W9
sw 6,0Ø
battery G1
rt
engine shut-off
12 V
sw 25,0Ø W30 W14

/6.21 1
W W20
30
-
D+ G B+
M 50a 1 1 1
3~ Y10 Y29 1
sw 35,0Ø
U 31
excess 2 R1
M1
Y12
cold start 2
Y1
G2
W235
generator B-
starter quantity start 2
flame type glow plug
accumulation
option 1 turbo
br 0,5Ø
10
battery S2 2
br
br
br
br
br
br
br
W123 W23 W24
master switch
br 10Ø
X31
X31 1 33 X31 31X31 1 X31 2 X31 4 X31 5 X31 12 X31 3 X31 4
Kl.31/2.1
battery central ground distributor ground distributor connection board

Type TL80AS Circuit électrique à partier du n/s
TL80AS0147 Date 12.2008

Wiring diagramm
Description
Page
Feuille 1/5 Page
Feuille
7.25.11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PRESSURE SWITCH TRACTION DRIVE WORKING LOW SPEED / HIGH SPEED
Kl.30/1.16 Kl.30/3.1
1
Kl.15/1.16 Kl.15/3.1
/7.17
1 2 3
Kl.58d Kl.58d/3.1
rt 2,5Ø
1 1 1
F9 10A F10 15A F11 10A
2 2 2
gr/bl
gr/bl
gr/bl
ge
ge
ge
W58
10 5 /7.4 10 6 5 10 5
/7.8
/7.6
rt/ge
31
S16 S15 S14
9 1 7 9 8 2 7 1 9 7 1
br
br
B1:L7 /1.14
drive 31
working 31 6
low speed /
/7.8
B1:L5 /1.13
86
87a
/2.15 Low high speed
sw
gr
87
sw
30 85 sw ge ge
86 30 86 30 86 30
V2
diode block /7.11 K3 /7.11 /7.11
K4 K5
relay
85 87 87a 85 87 87a
relay 85 87 87a
relay
driving direction
gn/ge
sw/br
travel
rt/ge
travel
sw
sw
sw
sw
sw
ge
br
br
br
gr
gr
gr
rt
forward
back alarm
31 86 31 reverse 31
87a
R(2) /5.9
87
sw
/7.6
85 30
16 11 12 13 14 15
XM1 XM1 XM1
V1 XM1 XM1 XM1
16 11 12 diode block 13 14 15
gn/ge
br/gn
bl/ge
sw/rt
sw/rt
rt/ge
sw/br
gn
sw
sw
ge
ge
ge
ge
gr
rt
rt
3
R(1) /4.9
K2/1.4
1 3
Low/2.7
1 12 3 2
1 /7.16
XMOT XMOT XMOT XMOT
B1:L6 /1.13
Kl.54 /4.8
staring aid
1 12 /7.17 P 3 2
/7.17 S21
reversing head light

2
S25 2 4
2 1 push button switch
S23
brake lights
brake check lamp
switch travel
gn/ge
sw
ge
(joystick)
gr
W1 W12 brake light W3 W2
switch
parking brake 1 1 1 1
1 1 1
/7.16
/6.4
/7.16 Y6
P
Y2 Y3 Y4 Y9 Y10 /6.7
2
2 solenoid valve 2 solenoid valve 2 solenoid valve 2 2 solenoid valve 2 solenoid valve
S26 solenoid valve low speed /
detection of travel reverse travel forward shut-off
switch shut-off high speed
running direction working hydraulic
hydraulic brake working hydraulic
br
br
br
br
br
br
W28 W29
X31 8 X31 3 X31 4 X31 28 X31 25 X31 14

Kl.31/1.16 Kl.31/3.1

TL80AS0147 Date 12.2008

Wiring diagramm
Description
Page
Feuille 2/5 Page
Feuille
7.25.12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
HEATER FAN WIPERS WIPER REAR RADIO INSTALLATION SOCKET CAB LIGHT ROTATING REAR WINDOW
BEACON HEATING
Kl.30/2.16 Kl.30/4.1
10
3 4 5
Kl.15/2.16 Kl.15/4.1
15 13 10 7 8 14
Kl.58d/2.16 Kl.58d/4.1
rt 2,5Ø
rt 2,5Ø
sw 2,5Ø
rt 2,5Ø
/5.16
F23
1 1 1 1 1 1 1
F13 15A F14 15A F15 15A F16 5A F3 10A F4 10A F23 20A
2 2 2 2 2 2 2
ge
ge
gr/bl
gr/bl
gr/bl
ge
gr/bl
ge
ge
switch
ge 2,5Ø
ge 2,5Ø
switch W13
gr/bl
gr/bl
air conditioner wash pumps ge
rt
S31 5 6 10 S24 3 4 10 10 3 1 2
B1 10 6 5 /7.3 5 10 /7.1 5 6 10
ws/vi
/7.3 /7.1 /7.3
/7.1 S22 /7.1
1 7 2 8 9 1 7 2 8 9 9 5 8
C1 B3 B4 B5 A3 A4 A5
0 I II III S20 9 8 2 7 1 1 9 1 7 2 8 9
switch switch S30
br
br
br
br
br
br
S13 switch S19
br
31 19 31 18 31 11 17 17
wiper wiper rear switch switch
31 13
heater fan 31 12 31 31
front rotating rear window
br/ws
gr/sw
br/ge
br/rt
gn/gr
ge
beacon heating
or
gn/sw
br/ws
gn/gr
bl/sw
ws/vi
vi/ws
gn/bl
ws 2,5Ø
ws 2,5Ø
rt/ge
ge
rt
/7.19
5 15
XM3
I
/7.19 /7.19 /7.19 5
1 2 3 53S
1
XM3 S32 /7.16
1 2 3 2
freezing
rt 2,5Ø
53M
protection 31
6
T
XM3
6
/7.19
K12
or
wiper interval
br/ws
bl/sw
gn/vi
br/rt
12 /7.17
relay
XM2 3 1 2 13 14 11 12
XK1 XK1 XK1 XK1
12
/6.1
3 1 2 13 14 11 12
loudspeaker
or
rt/sw
B1
ws 2,5Ø
ws 2,5Ø
/6.10 1
br/ws
bl/sw
ws/vi
vi/ws
rt/ge
S33 P
2 rt
pressure switch
4 3 1
air conditioner XM7
rt/sw
or
15
B2
4 3 1
XMOT
bl/ws
bl/sw
1 2 3 15 31b rt
bl
31b 1
+ + 53a 53
/8.19
M 53 53a M 1
1
M M
or
M 1 /8.6
M3 /7.22 /7.22
/7.22
M7 15 30 /7.4 R4 rear window
L+ L- R+ R- X1 E10
4 heater fan 1 -
M5 -
M4 M6 31 wiper motor /7.2
2
E9 2 heating
31
rear socket 2 2
rotating beacon
Y30
washer washer wiper motor 31
A1 cab light
4
XM3
pump pump front 2
radio with
solenoid clutch
br 2,5Ø
sw 4,0Ø
4 front rear /8.7
switch
/7.19
air conditioning
br
br
br
br
br
br
br
2
compressor
br
br
X31
26 X31 30 X31 29 X31 23 X31 10 X31 6 X31 1 X31 5 X31 8 X31 9 X31 7
Kl.31/2.16 Kl.31/4.1

TL80AS0147 Date 12.2008

Wiring diagramm
Description
Page
Feuille 3/5 Page
Feuille
7.25.13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
LIGHTING SYSTEM DISCONNECTION POINT FOR OPTIONS WORKING LIGHTS
7 8
Kl.30/3.16 Kl.30/5.1
6 7
Kl.15/3.16 Kl.15/5.1
9 11 12
Kl.58d/3.16 Kl.58d/5.1
F22/5.15
rt 2,5Ø
sw 2,5Ø
rt 2,5Ø
Kl.15 F6/5.10
sw Kl.30
1 1 1 1 1 1
gr/bl
F5 10A F17 15A F2 20A F22 20A F18 15A F19 15A
2 2 2 2 2 2
sw 2,5Ø
ge 2,5Ø
gr/bl
gr/bl
sw
ge
ge
ge
ge
F19
/5.11
Kl.15
gr/rt gr/rt
3
/7.1 2 8 9 5 9 5
/7.22 1 10 9 2
S4
30 15 Option Tagfahrlicht 49a 15
S5 S6
6 10
S8
switch 10 1 10 1
hazard switch 1 5
switch
br
br
0
56a 56b 58 L R H
Horn working
br
5 6 4 8 7 3
steering column lights
31 14
working 31 15
switch front lights

rear
reversing head light

sw/ws/gn
sw/ws/gn
sw/gn
gr/sw
gr/rt
sw
high beam
brake lights
gr 86 30 86 30
F26 low beam
marker light left

/7.11
R(1)/2.10
/7.11
Kl.54/2.4
K10
ws/ge
marker light
relay K9
ws
fuse
fuse
gr
relay
fuse side
fuse side working 85 87 87a 85 87 87a
1 1 1 1 lights working
F28
F27
F25
br
br
15A 15A 10A 10A lights
right
2 2 2 2 front
31 31 rear
high beam check
flasher check
S41:1/5.12
gr/sw
gr/sw
Kl.C/1.13
Kl.56a /1.15
gr/rt
gr/rt
Kl.58 /1.14
8 10 7 9
/7.12 XK1 XK1 XK1 XK1
49 49a C 8 10 7 9
sw/ws
sw/ws
sw/gn
gr/sw
gr/rt
K11
flashing light relay
5 6 7 8 9 10
C2 C3 31
XM2 XM2 XM2 XM2
XM2 XM2
5 6 7 8 9 10
gr/sw
gr/rt
sw/vi
E6 working lights front

E5 working lights front
sw/ws
sw/gn
gr/sw
ge/bl
sw/rt
E7 working light rear

1 2
gr/rt
E8 working light rear

W29
sw
ge
ge
rt
XE12 XE12
1 2
gr/sw
gr/sw
gr/rt
gr/rt
sw/ws
sw/ws
ws/ge
ws/ge
sw/gn
sw/gn
ge/gn
gr/sw
gr/sw
gr/sw
sw/rt
sw/rt
gr/rt
gr/rt
gr/rt
ws
ws
sw
sw
license plate light

3 2 5 4 3 2 5 4 4 3 5 2 4 3 5 2 8 6 5 7 1 9 10 15 14
license plate light
1 1 + + XO1 1 1 1 1
flashing light check lamp H2 /7.11 H1 disconnection point options 1

(trailer operation)
2
signal horn 2
E1 56a 56b L 58 E2 56a 56b R 58 E3 54 55 L 58 E4 54 55 R 58
-
br
- XO1 XO1 XO1 XO1 2 2 2 2
br
E11
E12
head light 1
head light rear light 1 rear light 1 3 11 13 16
3
br/gn
left right left right XE12

br
br
br
br
br
br
br
br
br
br
br
br
br
br
3
br
/6.16
X31 16 X31 8 X31 27 X31 23 X31 24 X31 2 X31 3 X31 8 X31 34 X31 35 X31 36 X31 40 X31 1 X31 2 X31 3 X31 4
Kl.31/3.16 Kl.31/5.1

TL80AS0147 Date 12.2008

Wiring diagramm
Description
Page
Feuille 4/5 Page
Feuille
7.25.14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
OPTION FRONT ACCESSORY EQUIPMENT OPTION RIDE CONTROL SYSTEM OPTION TRAVEL MOTION ALARM DISCONNECTION POINT FOR OPTIONS OPTION REFUELING PUMP
4
Kl.30/4.16 Kl.30
2
Kl.15/4.16 Kl.15
4 16 5 6 17
Kl.58d/4.16 Kl.58d
F20/1.11
R(2)/2.9
F22 /4.5
F19/4.16
Kl.30 KL.15
sw 2,5Ø
rt 2,5Ø
F6 /4.12 F23/3.15
Kl.15
1
1 1 1 1
F12 10A
X17:1
F6 10A F21 15A F24 10A
2 2 2 2
1
option
ge 2,5Ø
gr/bl
gr/bl
gr/bl
sw
ge
ge
ge
ge
ge
ge
rt
W119
ge
W122
/7.1 /7.1
10 5 10 5 /7.3 5 6 10 5 10 5 10
/7.1
S40 S12 S10 S41
/7.1 S17
switch switch switch switch switch
2 9
9 1
front accessory 9 1
load holding valve 11 7 8
ride control
1 7 9
travel motion
1 9
options
br
br
br
br
br
equipment W118 W30 W39
alarm
B+/1.1
S41:1 /4.12
21 32 9 7 37 Kl.15
XO3:2
gn/sw
ge/sw
gn/gr
ge/bl
gn/bl
W121
2 1
20A F04 X17:2
1
ge/bl
ge
ge
rt
rt
1
gn/sw
11 13 18 19 17 4 1 2 3 1 2 3
option terminal 30
XM2 XM2 XM1 XM1 XM1 XM2
XO2 XO2 XO2 XO3 XO3
XM2
11 13 18 19 17 3
disconnection disconnection
option 2 option 3
ge 2,5Ø
rt 2,5Ø
XO3
gn/sw
XO2
gn/gr
ge/sw
gn/bl
ge/bl
4 4
W50
86 30
K03
relay 85 87
rt 2,5Ø
front accessory
equipment
1 1 1
1 2 +
XFS /6.7 /6.4 /6.8 /6.15
H3 travel motion alarm M
Y16 Y11
Y15
1 M8
XFS solenoid valve 2 solenoid valve 2 2
/6.12
refueling pump
ride control system 1 solenoid valve -
2
load holding
ride control system 2
br 2,5Ø
br 2,5Ø
br
br
br
br
br
br
br
W51
LSD 1
X31 9 X31 22 X31 10 X31 5 X31 7 X31 6 X31 38 X31 39 X31 21
Kl.31/4.16 Kl.31

TL80AS0147 Date 12.2008

Wiring diagramm
Description
Page
Feuille 5/5 Page
Feuille
7.25.15
X5
X91

X20
X90

12 --
13 --
X10
13 --
15 --
X61
16 --
17 --
X40

2 --
4 High beam signal
6 Reserve -
X80
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X30

X31
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.26.05/01.2007
X5
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X61

X40
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
TL 100 (SKL 844) 01.2007
X5
1 --
2 -
X91

X20
X90

floodlight front
input
X10

X61
floodlight rear
beacon
X40

wipe rear
X80
wipe rear
X70
2 --
X30

X31

15 --
X60

L824-ZSML
7.26.06/01.2007
X61 Rear carriage
X5
1 --
2 --
X91
4 Pre-heat output
X20
output
X90

X10
13 Fog lamp Output

X61

X40

X20 Panel, right
X80
output
2 --
X70
4 Pre-heat signal
X30

X31

X5 Power supply
X60
L824-ZSML
TL 100 (SKL 844) 01.2007
FUSE BOX LEFT
FL1 15A
wipe / wash front
FL2 15A
wipe / wash rear
FL3 15A
FL4 10A
FUSE BOX RIGHT
reserve
FR3 10A
inlet port e-module
FL8 10A hazard
FR4 10A
dash board
FR5 15A
FR6 15A
FR7 10A
high beam light
FR8 10A
low beam light
FR9 10A

relay
K1 signal relay
start-up FR11 10A
relay
K2
pre-glow
relay
K3
engine shut-off
F01 50A
pre-glow
F02 80A
F03 30A
F04 50A
engine shut-off
F010 10A
F011 10A
reserve
F012 5A
cold start enhancement Type TL100 Circuit électrique à partier du n/s
TL01000647 Date 11.2008
Blatt
F014 5A
Description
Page
Feuille 1/1 Page
Feuille
7.26.10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 XM15 1
Kl.15
XM30 1 30 XM30 2 Kl.30
sw 6,0Ø
rt 6,0Ø
30
S1
0 I II III 15 54 19 17 50A
rt
br/ge
2
8
X22 X22
compressor
10 4
travel forward
travel reverse
vi/ws
br/ge
rt
5 4 3
control module
Kl.50/2.3

X61:21 / 4.13
air filter coolant
X61:16 / 4.14
S33:2 / 2.1
3 11 3 5 4 4 6 8 5
X5
1
br/ge
sw/bl
vi/ws
sw 4,0Ø
sw 6,0Ø
sw 6,0Ø
sw 10Ø
sw 10Ø
30 86 86 30 86 30
1 1 1 1
50A 80A 30A 50A K1 K3 K2
2 2 2 2
F01 F02 F03 F04 87 85 85 87 85 87
input fuses

sw/vi 2,5Ø
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø

rt/ws 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2

5A 2 5A 2 10A2 20A 2

sw 10Ø
bl/sw/ws
rt 6,0Ø
sw/br
sw/bl
bl/ws
sw/vi
vi/ws
rt/ws
rt/ge
rt/bl
gn/rt
bl
gn
17 18 A 13 14 10 8 9 4 B 7 1 2 3 6 11 15
sw 10Ø
17 18 A 13 14 8 9 B 7 1 XMOT 3 6 11 15
turbo engine
2
rt/bl
br/ge
bl/sw/ws
bl
rt 50Ø
bl/ws
rt 6,0Ø
rt
sw 10Ø
gn/rt
sw/br
sw/bl
sw
gn
gr
or
+ W
W16
D+ B+
sw25,0Ø 30 50a
W8 1
W9 1 W31 1
1 2 1 1
G M
1 1 1
S28 S26
1 1
R3 S27
12 V
P P P
G2 /13.14 3~ Y29 /13.9 /13.8 Y4 Y3 /13.13
starter R1 2
/13.8
1 /13.14 2
U Y10 2
br
/13.8
generatorG1 B- M1
1 8
/13.13
10
/13.14
2
/13.14
2
/13.13 12
2 2
/13.16
XMOT
engine exhaust gas
br 16,0Ø
12
valve valve
br
br
br
br
br
br
br
br
br
br
4 7 br 16,0Ø 1 15 2 9 3 6 22 4 3 1
Kl.31
XGNDMASCH
Model Electrical system form s/n TL01001091 und Edition
Type
Tipo
Sistema elèctrico
à partier du n/s
desde el no. 1084,1087 Date 04.2010
Fecha

Wiring diagramm
Description
Page
Feuille 1/5 Page
Feuille
7.26.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FRONT
15 7
Kl.30/1.16 Kl.15/3.1
30 2
Kl.15/1.16 Kl.30/3.1
Kl50/1.5
1
rt 2,5Ø
1
30A FZ4 30A FL4 /5.8
FZ1
2,5Ø
2 2
br/ge
br/ge
rt
ge 2,5Ø
rt
rt
1 1 1 1
6
FL2 15A FL3 15A FL5 10A FL6 10A
S19:5 /3.11
30 86 30 86
S20:9/3.12
S22:3/3.8
/6.5 2 /6.5 2 /6.5 2 /6.5 2
X20(1)/4.5
K5 K6

87a 87 85
K5/5.4
1
FL1 15A
ge/sw
/6.5 2
rt/sw
rt/ge
rt/ge
rt/gn
rt/ge
ge/sw
K6/5.3
Kl.30
ge
ge/sw
/11.14 3 4 9 9 3 4 9 3 4 9
S22
C1 B3 B4 B5 A3 A4 A5 1 7 2 8 9
/6.1
ws/sw
gn/gr
ge/sw
gn/sw
ge/gn
or/sw
sw/br
rs/sw
ge/br
ge/bl
rt/ge
gn/rt
ge/rt
br/rt
bl/rt
bl/rt
4 17 9 16 2 10 7 9 12
19 21 20 8
14 X31 /6.23 K K J K K J K K J X31 X31 /6.23 X31 /6.23

/11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /6.23
wash / wipe system

X170

ride control Y16
washer pump front
power supply -

power supply -
14

washer pump rear
power supply -
power supply +
power supply +
ws/sw
front K1,2,3
thermostat switch
S32 1
terminal 31.b
terminal 53.a
2
/10.8
terminal 53
pump rear
wiper rear
wiper rear
wiper rear
rt/ge
washer
15
X170 X70 X70 X70 X70 X70 X70 X70 X70 X70
/10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1
15
7 10 8 11 6 13 17 16 14
rt/ge
gn/sw
8
gn/gr
gn/bl
X160
br/ws
bl/sw
ge/vi
br
8
rt/ge
1 2 3
X170 5 6 4
1 2 3
X171
5 6 4
washer pump rear

S33
washer pump front
1
or/ws
br/ws
br/ws
bl/sw
bl/sw
ge/vi
rt/gn
gr/bl
P
bl/rt
bl/sw
bl/gn
/8.15
gr/bl
53 31b 53a 53b

air- suspended seat
31b
bl/ws
2 4 3 1
bl/sw
+ +
bl
gr
or
fan M M M 53
M
53a
wiper rear M
M
/10.8
M3 - /10.8
/10.16
- /10.8 /9.11 /6.18 2
sw
31
1
compressor/1.16
31
br
br
br
br
br
br
1 2 3 4 5 23
Kl.31/1.16 Kl.31/3.1

Model Electrical system from s/n TL01001091 + Edition
Type TL100 Circuit électrique à partir du n/s 1084,1087 Date 04.2010

Wiring diagramm
Description
Page
Feuille 2/5 Page
Feuille
7.26.22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FUSE E-MODULE
Kl.15/2.16 Kl.15/4.1
Kl.30/2.16 Kl.30/4.1
rt 2,5Ø
S22:3 /2.12
S17:3/4.15
S17:9/4.15
S19:5/2.7
S20:9 /2.8
FL11 /5.14
FL10 /5.14
rt 2,5Ø
rt 2,5Ø
FL7:1 /5.12
FL7:2 /5.13
power supply +
1 1 1 1
/6.5 2 /6.5 2 2 10A Anzeigemodul /6.5
2
ge
8

14
bl/br
ge
X22

rt/ws
11 1

ZSML2.0 ZSML1.0
ge
ge
ge
reserve K11 X31
/6.23
X30
/6.23
rt/sw
rt/sw
rt/sw
rt/sw
rt/gn
rt/ge
rt/ge
NPN/NO PNP/NO
option switch /11.11 3 4 9 /11.11 5 9


/11.14 I 0 II A A A
1 7 2 8 10 1 7 10
gn/ws
gn/bl
gn/rt
1 7 10
+
P2 +
P1 fuel gauge
br
br
br
58 58
31 31
t° Q 5 4 3
31 31 GND GND GND

S S
12 13 14
10
X170 X130 X130 X130
12 13 14
10
ws/ge
ws/gn
ws/br
or/ws
br/ws
br/sw
bl/sw
vi/sw
bl/ge
ws/rt
ws/rt
or/bl
bl/rt
sw
gn
br
vi
rt
1 4 2 5 3 10 13 6 1 3 7 12 14 8
6 7 8

/6.23 /6.23 /6.23
/8.1 /8.1 /8.1 /8.1 /8.1 /10.2 /10.2 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
1 7 18 9 10 5 4 10 11 3 6 17 9 7 4 9 12 15 18 5
ge 2,5Ø
gr/ws
or/ws
ge/bl
bl/rt
transmitter
gn/ws
or/sw
bl/sw
bl/ws
br/gn
sw/vi
bl/ge
ws/rt
rt/sw
rt/sw
rt/gn
X10 X10
bl/rt

vio
sw
18 X130 6 7 9 7
ge
/10.2 /10.2
X130 X130 X130 X160
ZSML2.0 ZSML2.0 15
5 16 X130 17 X130 1 2 3 10 11 8 X130
6 3 18 6 7 9 7
X68 X130 X130 X130 X130 X130 X130
sw
ge
gr/ws
or/ws
ge/bl
bl/rt
bl/rt
5 16
bl/rt
refueling pump
speed sensor
gear switch
5 6 1 2

2
ge 2,5Ø

+UB CAN/L CAN/H
U1
1 dash board

/10.16
S33 GND
ge
ws/rt
8 7 4 3
C 1 1 1
6 2 +
sw Q 22 1 1
X68
B9 R4 3
P P M M8
6 br
/8.11 R2 /8.15
ge
ge
B bl
A
1
/8.15 1
potentiometer S31 2
S30 2
2
Y21 2
Y22 2
Y20
- /8.15
XR4
br 2,5Ø
1 2
br
br
br
br
br
br
br
br
br
br
br
14
12 11 10 13 13 7 6 8 2 9
Kl.31/2.16 Kl.31/4.1

Type TL100 Circuit électrique à partier du n/s 1084,1087 Date 04.2010

Wiring diagramm
Description
Page
Feuille 3/5 Page
Feuille
7.26.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RIDE
HYDRAULIC
Kl.15/3.16 Kl.15/5.1
Kl.30/3.16 Kl.30/5.1
900 /5.8
S17:3 /3.7
X80
X20 K J X80
/6.23 ZSML1.0
S17:9 /3.8
1 1
18 11
X20/2.1
rt/gn
rt/gn
rt/ge
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
ws
ge
ge
S21/2 1 3
/2.4
3 3
S10 3 4 10 3 4 10 5 9 10 5 3 4 10 5 9 5 9 5 10
S9 S13 S12 S14 S15 S16
/6.1 /6.1 /6.1 /11.11 /11.14
S21/1
/11.11 /11.14
1 7 2 8 9
S21/3 1 7 2 8 9 1 10 9 1 /6.1 1 7 2 8 9
S21/4 1 10 1 10 7 1 9
2 2 1
S11 2 1 2 1
gr/ws
gr/sw
sw/bl
bl/ws
gr/ge
bl/sw
bl/ge
bl/ge
bl/gn
sw/rt
rt/gn
rt/br
gr/rt
bl/rt
bl/rt
bl/rt
sw
gn
or
gr
bl
vi
rt
5 1 6 2 11 3 5 15 4
5 10 9 6 7 8 7 6 12 11 8 9 3 4
/6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
th
float position rd
/8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /6.23 /6.23 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1
17 19 18 8 20 14 12 14 9 11 12 21 16 7 10
ws/sw
gn/sw
br/ws
sw/br
br/ge
gn/gr
bl/ws
rs/ge
bl/ge
gn/bl
bl/gn
bl/ge
ge/rt
rt/bl
sw
gr
1
XBACK
4 5 3 4
X130 X130 X68 X68 1

4 5 3 4
gn/sw
5 10

S34

option
working hydraulic
1 7 9 travel alarm
travel low speed
/6.5
ride control 1
ride control 2
ride control 3
reverse travel
float position
gn/sw
gearbox 2
gearbox 1
bl/ws shut-off able
sw/bl
rs/ge
rt/bl
2
1 1 1 1 1 1 1 1 1
1 1 1 1 XBACK
Y11 Y15 Y16 Y19 Y18 Y12 Y13 Y5 Y2
/1.13
Y7

Y9 Y8 Y6 2
gn/sw
/8.9 /8.9 /8.9 /8.10 /8.10 /8.11 /8.10 /8.9 /8.10
Fahren rückwärts
travel forward
2 2 2 2 2 2 2 1 1 2 2 2 2
travel reverse
1
H16
2
/8.16 travel alarm
reverse travel
br
br
br
br
br
br
br
br
br
br
br
br
br
br
6 16 13 18 19 20 21 7 8 2 3 1 17 9
Kl.31/3.16 Kl.31/5.1

Model Electrical system form s/n TL01001091 + Edition
1084,1087
Date 04.2010

Wiring diagramm
Description
Page
Feuille 4/5 Page
Feuille
7.26.24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BEACON
XM15 3
Kl.15/4.16
FL10/3.4
5
FL11/3.14
XM15 /6.15
FL7:1/3.3
FL7:2/3.3
XM30 4 XM30 3
F15/5.1
Kl.30/4.16
/5.16 F15
K6 / 2.5 K5 / 2.2
rt 2,5Ø
sw 2,5Ø
12 13
FR7 10A
sw 2,5Ø
sw 2,5Ø
rt 2,5Ø
X170 X170 14
/6.11 2
FL4/2.14
br/ge
12 13
rt
sw
sw
br
rt
rt
2,5Ø
2,5Ø
rt
sw
1 1 1 1 1 1 1
FR4 10A FR3 10A 30
1 10
9
49a
2
/6.11 2 /10.16 X170 /6.11
/6.11 2 /6.5 2 2 2 2 1
/6.11 /6.11
9 FR5 15A
sw
S8 0 11
2 /6.11
rt/ge
rt/gn
rt/br
1 X22
B5
sw/ws
sw/gn
/6.22
ws/gr
column /10.15
br/gn 2
6
/10.2
switch 5 4 X70
X170 X170 /10.1

X31 /6.23 X31 /6.23 X31 /6.23
ZSML2.0
6 /6.22 5 4 1 1
sw/ws/gn
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
ws
ge
ge
ge
rt

900/4.8
front rear
sw/ws
loudspeaker
2 8 3
hazard 11
1 10 5 10 5 ge 10 5 10 5 S26
+ +
8 7
S25
1
S23 S3 S5 S6 /6.5
B4
/9.14
B3
/6.1 8 7 11 P
switch 6 1 5 br10 /10.16 2 3 /10.3 /6.1 /9.10
ws/ge
- -
gr/sw
11 2 9 1 9 1 /6.1 9 1 /6.1 9 1
ws
gr/sw
switch
10
1
1
1 1 extension
FR8 FR9 FR10 FR11
socket
2,5Ø
sw/gn 2 10A 10A
10A 2 10A 2 2
sw/ws/gn
ge 2,5Ø
rt 2,5Ø
gr/sw
gr/sw
gr/sw
vi/ws
rt/sw
rt/ws
rt/sw
rt/ge
rt/ge
gr/rt
gr/rt
ws/ge
sw
sw
sw
ge
rt
rt
ws
ws
7 4 3 4 5 6
31 T 4 3 18 12 13 14 15
XA1 XA2
/6.9 /6.9 /9.1 /9.1 /9.1 /9.1
1 2
X150 X30 /6.23 X70 /10.1 X70 /10.1 X20 /6.23 X20 /6.23 X20
/6.23
turning /6.19
15 53S 1 2
working
sw/ws
switch
ZSML2.0
X70 X30 X61 X61 X70 X61 X70 X70
/10.1 /8.1 /8.1 /10.1 /8.1 /10.1 /10.1
/6.23
9 6 15 5 13 3 3 4 4
flash light 8
radio
2 1 3
check XSDZ
rt/ge
gr/sw
gr/sw
sw/ws sw/ws sw/gn vi/ws
gr/rt
gr/rt
4 sw/gn 5
XSDZ
1
X160
3
X150
5 3
XSDZ
option 2 1 3
X150 X160
2,5Ø
ge 2,5Ø
rt 2,5Ø
rt/ge
3 gr/sw gr/rt 7 2 1 8 9
2 4 6 4
X171 X160 X150 X150 X160 X171 X171 X171
ge
ge
rt
3 2 4 6 4 7 2 1 8 9
gr/rt
54 58R 58L 1 2 3
1
31
working light
X68
license plate light
rotating beacon
rt/ge
1 4
sw/ws
sw/ws
ws/ge
ws/ge
sw/gn
sw/gn
gr/sw
gr/sw
gr/sw
gr/sw
vi/ws
sw/rt
sw/rt
gr/bl
gr/bl
gr/rt
gr/rt
gr/rt
gr/rt
gr/rt
XAS
ws
ws
XSKS
br 2,5Ø
1
1
E8 socket X22 XSD
/9.14 + 1 1 1 1 6
point for /6.9
XA1
/6.22 /6.19
cab light 4 3 5 2 3 2 5 4 3 2 5 4 4 3 5 2 E4 13 2
2
E1 E2 E4 E5
br 2,5Ø
6
/8.22 1 /7.15 1
/7.15
1
/8.20
1
- E7 2 /9.14
2 2
/9.14
2 2 /6.22

/9.14 /9.14
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
21 6
left 5
left 15
right 16
right 2 1 7 8 9 10 22 24 12 20
Kl.31/4.16

Type TL100 Circuit électrique à partier du n/s 1084,1087 Date 04.2010

Wiring diagramm
Description
Page
Feuille 5/5 Page
Feuille
7.26.25
Central control unit (ZSML)
X5
2 Central ground Terminal 31
X91

X20
X90

12 --
13 --
X10
13 --
15 --
X61
16 --
17 --
X40

2 --
4 High beam signal
6 Lifting frame high
X80
7 Slew left
8 Slew right
9 Reference voltage 2.5V
X70
10 Spare - Analog
11 Option
12 Spare - Analog
X30

X31
8 Slew left signal

9 Slew right signal
X60
L824-ZSML
TL 70 (SKS 634) 01.2007
Connector Assignment 7.37.07
X5
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X61

X40
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
7.37.07/01.2007
X5
X31 Control unit power supply, working
1 --
2 -
X91
3 Spare digital output

5 Cut off lifting frame lower
6 Spare digital output
X20
7 Swing axle lock
X90

floodlight front
X10
12 Option 4th control circuit proportional regulated

output signal 1
X61

floodlight rear
14 Option 4th control circuit proportional regulated
output signal 2
15 Slew left (PWM) output
X40

beacon
17 Spare Digital output
18 Slew right (PWM) output
19 Power supply Terminal 15 input wash/ wipe
rear
X80

21 Power supply Terminal 15 input wash/ wipe
rear
X70

2 --
X30

8 Front wiper Terminal 31b output
10 Front wiper Terminal 53 output
11 Front wiper Terminal 53a output
X31
12 Parking brake switch signal input

13 Rear washer pump output
15 --
X60

L824-ZSML
TL 70 (SKS 634) 01.2007
Connector Assignment 7.37.08
X5
X61 X61 new Rear carriage
from
634/0118
1 1 --
X91
2 2 --
3 3 Starting Terminal 50a output
4 4 Pre-heat output
5 5 Engine shutdown output
X20
6 6 Brake light output
X90
7 7 Travel, direction recognition

output
8 8 Travel, FAST-SLOW output
9 9 Transmission 1 output
10 21 Travel forward output
X10
11 11 Transmission 2 output
12 12 Working hydraulics output
X61
13 16 Travel reverse output

14 15 Back-up lamp output
15 10 Travel motion alarm output
16 14 Ride control system 3 output
X40
17 17 Float position output

18 18 Additional control circuit output
19 19 Additional control circuit output
20 20 Ride control system 1,2 output
21 13 Fog lamp Output
X80
X20 Panel, right

output
X70
2 --
4 Pre-heat signal
X30

11 Option return to dig signal 1
12 Option return to dig signal 2
X31

X60
X5 Power supply
L824-ZSML
7.37.08/01.2007
FUSE BOX LEFT
FL1 15A
wipe / wash front
FL2 15A
wipe / wash rear
FL3 15A
FL4 10A
FUSE BOX RIGHT
reserve
FR3 10A
inlet port e-module
FL8 10A hazard
FR4 10A
dash board
FR5 15A
FR6 15A
FR7 10A
high beam light
FR8 10A
low beam light
FR9 10A

relay
K1 signal relay
start-up FR11 10A
relay
K2
pre-glow
relay
K3
engine shut-off
F01 50A
pre-glow
F02 80A
F03 30A
F04 50A
engine shut-off
F010 10A
F011 10A
reserve
F012 5A
cold start enhancement Type TL70S Circuit électrique à partier du n/s
TL00700250 Date 11.2008
Blatt
F014 5A
Description
Page
Feuille 1/1 Page
Feuille
7.37.10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
15 XM15 1
Kl.15
XM30 1 30 XM30 2 Kl.30
sw 6,0Ø
rt 6,0Ø
30
S1
0 I II III 15 54 19 17 50A
rt
br/ge
2
8
X22 X22
travel reverse
travel forward
compressor
10 vi/ws 4
br/ge
rt
5 4 3
control module
Kl.50/2.3

X61:21 / 4.13
air filter coolant
X61:16 / 4.14
S33:2 / 2.1
3 11 3 5 4 4 6 8 5
X5
1
br/ge
sw/bl
vi/ws
sw 4,0Ø
sw 6,0Ø
sw 6,0Ø
sw 10Ø
sw 10Ø
30 86 86 30 86 30
1 1 1 1
50A 80A 30A 50A K1 K3 K2
2 2 2 2
F01 F02 F03 F04 87 85 85 87 85 87
input fuses

sw/vi 2,5Ø
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø

rt/ws 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2

5A 2 5A 2 10A2 20A 2

sw 10Ø
bl/sw/ws
rt 6,0Ø
sw/br
sw/bl
bl/ws
sw/vi
vi/ws
rt/ws
rt/ge
rt/bl
gn/rt
bl
gn
17 18 A 13 14 10 8 9 4 B 7 1 2 3 6 11 15
sw 10Ø
17 18 A 14 8 9 B 7 1 XMOT 3 6 11 15
turbo engine
2
rt/bl
br/ge
bl/sw/ws
bl
rt 50Ø
bl/ws
rt 6,0Ø
sw 10Ø
gn/rt
sw/br
sw/bl
sw
gn
gr
or
+ W
W16
D+ B+
sw25,0Ø 30 50a
W8 1
W9 1 W31 1
1 2 1 1
G M
1 1
S28 S26
1 1
R3 S27
12 V
P P P
G2 /13.14 3~ Y29 /13.9 /13.8 Y4 Y3 /13.13
starter R1 2 1 /13.14 2
U 2 /13.8 Y30
br
/13.8
generatorG1 B- M1
1 10
/13.14
2
/13.14
2
/13.13 12
2 2
/13.16
XMOT
engine exhaust gas
br 16,0Ø
12
valve valve
br
br
br
br
br
br
br
br
br
br
4 7 16,0Ø 1 15 2 9 3 6 22 4 3 1
Kl.31
XGNDMASCH
Type TL70s Circuit électrique à partier du n/s TL00700402 Date 04.2010

Wiring diagramm
Description
Page
Feuille 1/6 Page
Feuille
7.37.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FRONT
15 7
Kl.30/1.16 Kl.15/3.1
30 2
Kl.15/1.16 Kl.30/3.1
Kl50/1.5
1
rt 2,5Ø
1
30A FZ4 30A FL4 /5.8
FZ1
2,5Ø
2 2
br/ge
br/ge
rt
ge 2,5Ø
rt
rt
1 1 1 1
6
FL2 15A FL3 15A FL5 10A FL6 10A
S19:5 /3.11
30 86 30 86
S20:9/3.12
S22:3/3.8
/6.5 2 /6.5 2 /6.5 2 /6.5 2
X20(1)/4.5
K5 K6

87a 87 85
K5/5.4
1
FL1 15A
ge/sw
/6.5 2
rt/sw
rt/ge
rt/ge
rt/gn
rt/ge
ge/sw
K6/5.3
Kl.30
ge
ge/sw
/11.14 3 4 9 9 3 4 9 3 4 9
S22
C1 B3 B4 B5 A3 A4 A5 1 7 2 8 9
/6.1
ws/sw
gn/gr
ge/sw
gn/sw
ge/gn
or/sw
sw/br
rs/sw
ge/br
ge/bl
rt/ge
gn/rt
ge/rt
br/rt
bl/rt
bl/rt
4 17 9 16 2 10 7 9 12
19 21 20 8
14 X31 /6.23 K K J K K J K K J X31 X31 /6.23 X31 /6.23

/11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /11.1 /6.23
wash / wipe system

X170

ride control Y16
washer pump front
power supply -

power supply -
14

washer pump rear
power supply -
power supply +
power supply +
ws/sw
front K1,2,3
thermostat switch
S32 1
terminal 31.b
terminal 53.a
2
/10.8
terminal 53
pump rear
wiper rear
wiper rear
wiper rear
rt/ge
washer
15
X170 X70 X70 X70 X70 X70 X70 X70 X70 X70
/10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1 /10.1
15
7 10 8 11 6 13 17 16 14
rt/ge
gn/sw
8
gn/gr
gn/bl
X160
br/ws
bl/sw
ge/vi
br
8
rt/ge
1 2 3
X170 5 6 4
1 2 3
X171
5 6 4
washer pump rear

S33
washer pump front
1
or/ws
br/ws
br/ws
bl/sw
bl/sw
ge/vi
rt/gn
gr/bl
P
bl/rt
bl/sw
bl/gn
/8.15
gr/bl
53 31b 53a 53b

air- suspended seat
31b
bl/ws
2 4 3 1
bl/sw
+ +
bl
gr
or
fan M M M 53
M
53a
wiper rear M
M
/10.8
M3 - /10.8
/10.16
- /10.8 /9.11 /6.18 2
sw
31
1
compressor/1.16
31
br
br
br
br
br
br
1 2 3 4 5 23
Kl.31/1.16 Kl.31/3.1

Model Electrical system from s/n Edition
Type TL70s Circuit électrique à partir du n/s TL00700402 Date 04.2010

Wiring diagramm
Description
Page
Feuille 2/6 Page
Feuille
7.37.22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FUSE E-MODULE
Kl.15/2.16 Kl.15/4.1
Kl.30/2.16 Kl.30/4.1
rt 2,5Ø
S22:3 /2.12
S17:3/4.15
S17:9/4.15
S19:5/2.7
S20:9 /2.8
FL11 /5.14
FL10 /5.14
rt 2,5Ø
rt 2,5Ø
FL7:1 /5.12
FL7:2 /5.13
power supply +
1 1 1 1
/6.5 2 /6.5 2 2 10A Anzeigemodul /6.5
2
ge
8

14
bl/br
ge
X22

rt/ws
11 1

ZSML2.0 ZSML1.0
ge
ge
ge
reserve K11 X31
/6.23
X30
/6.23
rt/sw
rt/sw
rt/sw
rt/sw
rt/gn
rt/ge
rt/ge
NPN/NO PNP/NO
option switch /11.11 3 4 9 /11.11 5 9


/11.14 I 0 II A A A
1 7 2 8 10 1 7 10
gn/ws
gn/bl
gn/rt
1 7 10
+
P2 +
P1 fuel gauge
br
br
br
58 58
31 31
t° Q 5 4 3
31 31 GND GND GND

S S
12 13 14
10
X170 X130 X130 X130
12 13 14
10
ws/ge
ws/gn
ws/br
or/ws
br/ws
br/sw
bl/sw
vi/sw
bl/ge
ws/rt
ws/rt
or/bl
bl/rt
sw
gn
br
vi
rt
1 4 2 5 3 10 13 6 1 3 7 12 14 8
6 7 8

/6.23 /6.23 /6.23
/8.1 /8.1 /8.1 /8.1 /8.1 /10.2 /10.2 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
1 7 18 9 10 5 4 10 11 3 6 17 9 7 4 9 12 15 18 5
ge 2,5Ø
gr/ws
or/ws
ge/bl
bl/rt
transmitter
gn/ws
or/sw
bl/sw
bl/ws
br/gn
sw/vi
bl/ge
ws/rt
rt/sw
rt/sw
rt/gn
X10 X10
bl/rt

vio
sw
18 X130 6 7 9 7
ge
/10.2 /10.2
X130 X130 X130 X160
ZSML2.0 ZSML2.0 15
5 16 X130 17 X130 1 2 3 10 11 8 X130
6 3 18 6 7 9 7
X68 X130 X130 X130 X130 X130 X130
sw
ge
gr/ws
or/ws
ge/bl
bl/rt
bl/rt
5 16
bl/rt
refueling pump
speed sensor
gear switch
5 6 1 2

2
ge 2,5Ø

+UB CAN/L CAN/H
U1
1 dash board

/10.16
S33 GND
ge
ws/rt
8 7 4 3
C 1 1 1
6 2 +
sw Q 22 1 1
X68
B9 R4 3
P P M M8
6 br
/8.11 R2 /8.15
ge
ge
B bl
A
1
/8.15 1
potentiometer S31 2
S30 2
2
Y21 2
Y22 2
Y20
- /8.15
XR4
br 2,5Ø
1 2
br
br
br
br
br
br
br
br
br
br
br
14
12 11 10 13 13 7 6 8 2 9
Kl.31/2.16 Kl.31/4.1


Wiring diagramm
Description
Page
Feuille 3/6 Page
Feuille
7.37.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
RIDE
HYDRAULIC
Kl.15/3.16 Kl.15/5.1
Kl.30/3.16 Kl.30/5.1
900 /5.8
S17:3 /3.7
X80
X20 K J X80
/6.23 ZSML1.0
S17:9 /3.8
1 1
18 11
X20/2.1
rt/gn
rt/gn
rt/ge
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
rt/gn
rt/ge
ws
ge
ge
S21/2 1 3
/2.4
3 3
S10 3 4 10 3 4 10 5 9 10 5 3 4 10 5 9 5 9 5 10
S9 S13 S12 S14 S15 S16
/6.1 /6.1 /6.1 /11.11 /11.14
S21/1
/11.11 /11.14
1 7 2 8 9
S21/3 1 7 2 8 9 1 10 9 1 /6.1 1 7 2 8 9
S21/4 1 10 1 10 7 1 9
2 2 1
S11 2 1 2 1
gr/ws
gr/sw
sw/bl
bl/ws
gr/ge
bl/sw
bl/ge
bl/ge
bl/gn
sw/rt
rt/gn
rt/br
gr/rt
bl/rt
bl/rt
bl/rt
sw
gn
or
gr
bl
vi
rt
5 1 6 2 11 3 5 15 4
5 10 9 6 7 8 7 6 12 11 8 9 3 4
/6.23 /6.23 /6.23 /6.23 /6.23 /6.23 /6.23
th th
push button float float push button at joystick additional additional travel low speed shut off 4 4 push button at joystick gearbox working hydraulic rocker switch at joystick travel forward / reverse
float position rd
/8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /6.23 /6.23 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1 /8.1
17 19 18 8 20 14 12 14 9 11 12 21 16 7 10
ws/sw
gn/sw
br/ws
sw/br
br/ge
gn/gr
bl/ws
rs/ge
bl/ge
gn/bl
bl/gn
bl/ge
ge/rt
rt/bl
sw
gr
1
XBACK
4 5 3 4
X130 X130 X68 X68 1

4 5 3 4
gn/sw
5 10

S34

option
working hydraulic
1 7 9 travel alarm
travel low speed
/6.5
ride control 1
ride control 2
ride control 3
reverse travel
float position
gn/sw
gearbox 2
gearbox 1
shut-off able
bl/ws
sw/bl
rs/ge
rt/bl
2
1 1 1 1 1 1 1 1 1
1 1 1 1 XBACK
Y11 Y15 Y16 Y19 Y18 Y12 Y13 Y5 Y2
/1.13
Y7

Y9 Y8 Y6 2
gn/sw
/8.9 /8.9 /8.9 /8.10 /8.10 /8.11 /8.10 /8.9 /8.10
Fahren rückwärts
travel forward
2 2 2 2 2 2 2 1 1 2 2 2 2
travel reverse
1
H16
2
/8.16 travel alarm
reverse travel
br
br
br
br
br
br
br
br
br
br
br
br
br
br
6 16 13 18 19 20 21 7 8 2 3 1 17 9
Kl.31/3.16 Kl.31/5.1

Model
TL70s
Electrical system form s/n Edition
Type Circuit électrique à partier du n/s TL00700402 Date 04.2010

Description Wiring diagramm Page Page
Dénomination circuit électrique Feuille Feuille
7.37.24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BEACON
XM15 3
Kl.15/4.16
FL10/3.4
5
FL11/3.14
XM15 /6.15
FL7:1/3.3
FL7:2/3.3
XM30 4 XM30 3
F15/5.1
Kl.30/4.16
/5.16 F15
K6 / 2.5 K5 / 2.2
rt 2,5Ø
sw 2,5Ø
12 13
FR7 10A
sw 2,5Ø
sw 2,5Ø
rt 2,5Ø
X170 X170 14
/6.11 2
FL4/2.14
br/ge
12 13
rt
sw
sw
br
rt
rt
2,5Ø
2,5Ø
rt
sw
1 1 1 1 1 1 1
FR4 10A FR3 10A 30
1 10
9
49a
2
/6.11 2 /10.16 X170 /6.11
/6.11 2 /6.5 2 2 2 2 1
/6.11 /6.11
9 FR5 15A
sw
S8 0 11
2 /6.11
rt/ge
rt/gn
rt/br
1 X22
B5
sw/ws
sw/gn
/6.22
ws/gr
column /10.15
br/gn 2
6
/10.2
switch 5 4 X70
X170 X170 /10.1

X31 /6.23 X31 /6.23 X31 /6.23
ZSML2.0
6 /6.22 5 4 1 1
sw/ws/gn
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
ws
ge
ge
ge
rt

900/4.8
front rear
sw/ws
loudspeaker
2 8 3
hazard 11
1 10 5 10 5 ge 10 5 10 5 S26
+ +
8 7
S25
1
S23 S3 S5 S6 /6.5
B4
/9.14
B3
/6.1 8 7 11 P
switch 6 1 5 br10 /10.16 2 3 /10.3 /6.1 /9.10
ws/ge
- -
gr/sw
11 2 9 1 9 1 /6.1 9 1 /6.1 9 1
ws
gr/sw
switch
10
1
1
1 1 extension
FR8 FR9 FR10 FR11
socket
2,5Ø
sw/gn 2 2 10A 2 10A
10A 2 10A
sw/ws/gn
ge 2,5Ø
rt 2,5Ø
gr/sw
gr/sw
gr/sw
vi/ws
rt/sw
rt/ws
rt/sw
rt/ge
rt/ge
gr/rt
gr/rt
ws/ge
sw
sw
sw
ge
rt
rt
ws
ws
7 4 3 4 5 6
31 T 4 3 18 12 13 14 15
XA1 XA2
/6.9 /6.9 /9.1 /9.1 /9.1 /9.1
1 2
X150 X30 /6.23 X70 /10.1 X70 /10.1 X20 /6.23 X20 /6.23 X20
/6.23
turning /6.19
15 53S 1 2
working
sw/ws
switch
ZSML2.0
X70 X30 X61 X61 X70 X61 X70 X70
/10.1 /8.1 /8.1 /10.1 /8.1 /10.1 /10.1
/6.23
9 6 15 5 13 3 3 4 4
flash light 8
radio
2 1 3
check XSDZ
rt/ge
gr/sw
gr/sw
vi/ws
sw/ws sw/ws sw/gn
gr/rt
gr/rt
4 sw/gn 5
XSDZ
1
X160
3
X150
5 3
XSDZ
option 2 1 3
X150 X160
2,5Ø
ge 2,5Ø
rt 2,5Ø
rt/ge
3 gr/sw gr/rt 7 2 1 8 9
2 4 6 4
X171 X160 X150 X150 X160 X171 X171 X171
ge
ge
rt
3 2 4 6 4 7 2 1 8 9
gr/rt
54 58R 58L 1 2 3
1
31
working light
X68
license plate light
rotating beacon
rt/ge
1 4
sw/ws
sw/ws
ws/ge
ws/ge
sw/gn
sw/gn
gr/sw
gr/sw
gr/sw
gr/sw
vi/ws
sw/rt
sw/rt
gr/bl
gr/bl
gr/rt
gr/rt
gr/rt
gr/rt
gr/rt
XAS
ws
ws
XSKS
br 2,5Ø
1
1
E8 socket X22 XSD
/9.14 + 1 1 1 1 6
point for /6.9
XA1
/6.22 /6.19
cab light 4 3 5 2 3 2 5 4 3 2 5 4 4 3 5 2 E4 13 2
2
E1 E2 E4 E5
br 2,5Ø
6
/8.22 1 /7.15 1
/7.15
1
/8.20
1
- E7 2 /9.14
2 2
/9.14
2 2 /6.22

/9.14 /9.14
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
br
21 6
left 5
left 15
right 16
right 2 1 7 8 9 10 22 24 12 20
Kl.31/4.16


Wiring diagramm
Description
Page
Feuille 5/6 Page
Feuille
7.37.25
1 2 3 4 5 6 7 8 9 10 11 12
F11
FL11
1
10A
Swingloader
X80 X80
2
ZSML1.0 ZSML1.0
2 1 2
XSKS
ws
ge
2 /2.1 JOYSTICK
ge
ge
ge
proximity switch
proximity switch
proximity switch
3 3 3
1
B B B
NPN/NO PNP/NC PNP/NC
C C C
B10 A B11 A B12 A S21/1 S21/2 S21/3 S21/4
push push push push
br
br
br
gn/ws
gn/br
gn/rt
17 18 19
button 2 1
button 2
button 2 1 button 2 1
GND GND GND switch switch switch switch
12 13 14
X130 X130 X130

12 13 14
sw/br
sw/bl
sw/vi
sw
gn
gr
or
bl
vi
rt
6 7 8 3 4 5 6 7 8 9
ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0
X30 X30 X30 X80 X80 X80 X80 X80 X80 X80
reserve L-Input reserve H-Input reserve H-Input travel travel impulse additional additional swing left swing right
lifting frame swing left swing right forward reverse float position th
3 hydraulic
th
3 hydraulic
top circuit circuit
K11 K12 K11 K12 PWM Out 3 PWM Out 4

make contact make contact break contact break contact
X31 X31
X31 X31 X31 X31
ZSML1.0 ZSML1.0
ZSML1.0 ZSML1.0 ZSML1.0 ZSML1.0 15 18
5 5 7 7 4 4 9 9
X150
4 3 5 6
gr/ws
or/ws
1 2
or/sw
rs/sw
br/gn
gr/bl
6 7
9 11 8 10 X130 X130
X130 X130 X130 X130
6 7
sw/ws
ws/ge
ws/ge
sw/gn
gr/sw
9 11
gr/rt
ws
ws
gn/gr
gn/rt
gn/sw
gn/vi
4 5 2 3 3 2 5 4
1 1 lighting E1 E2 1 1
/2.10
Y34 solenoid valve left /2.10 solenoid Y32 solenoid
solenoid Y33 1
lighting 1
Y31 /3.8
/3.6
axle locking valve /3.8 valve
valve /3.6 right
swing swing
shut-off 2 2 2 2
left right
lifting frame
br
br
br
br
br
br
bottom
5 6 1 2 3 4


Wiring diagramm
Description
Page
Feuille 6/6 Page
Feuille
7.37.26
Gewinde nicht bündig Gewinde bündig
Nennschaltabstand max. = 8 mm Nennschaltabstand max. = 5 mm
Thread not even Thread even

nominal switching distance max. = 8 mm nominal switching distance max. = 5 mm
Filetage pas à fleur Filetage à fleur

distance de commutation nominale max. = 8 mm distance de commutation nom. max. = 5 mm
8 5
2
Anschlusskabel: 3 x 0,5 mm
Connecting cable
Câble de raccordement
br - braun/ brown/ brun = Plus/ positive/ positif
bl - blau/ blue/ bleu = Masse/ ground/ masse
sw - schwarz/ black/ noir = Signal/ signal/ signal
br
+ 1 + Consumer / consommateur
sw Last
# 5 350 639 017 A 4
NO-switch (normaly open)
-
NPN
bl contacteur
3 Schließer
br
+ 1 PNP
Schließer NO-switch (normaly open)
sw contacteur
# 5 350 639 018 A 4 Last
bl
- 3 -
br
+ 1 PNP
Öffner NC-switch (normaly closed)
sw A 2 contact repos
# 5 350 639 019 Last
bl
- 3 -
Typ Elektrisches System Datum

Model Electrical system Edition
Type Circuit électrique Date 01.2007
Tipo Sistema elèctrico Fecha
Benennung
Näherungsschalter Blatt
Description Page
Proximity switch Feuille 7.100.07
Dénomination
Denominación
Interrupteur de proximité Página
SUBGROUP LIST
Maintenance
Inspection plans and test certificates
Lubricant Specification 8.01
TL 65 8.22
TL 80 8.24
TL 80AS 8.25
TL 100 8.26
TL 70 8.37
01/2009
Fuel, lubricant and coolant specifications
Prescribed fuels, lubricants and coolants
for Central Europe
Application Code designation Designation Specification, Remarks
according to Bi 1) Standards, Quality
Engine -- Diesel fuel DIN 51601
ASTM D975 1-D / 2-D Before using RME-fuels
(rape oil methyl ester), it is essential
to consult your responsible
dealer for further details.
Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer’s
API CF4 instructions
ACEA E3 or E4
Hydraulic system HYD 1040 Hydraulic oil or HVLP D 68 The following viscosity limit values
multi-grade or must be kept (according to
engine oil SAE 10W-40 ASTM 445)
at 100 °C min. 10 mm 2/s (cSt)
at –10 °C approx. 1,500 mm 2/s (cSt)
BIO-E-HYD-HEES Biodegradable Filling according to The same viscosity specifications
hydraulic oil on customer specifications. apply as for mineral hydraulic oils.
synthetic ester Brand label on machine.
base When changing from mineral
to biodegradable hydraulic oils, the
Do not mix tank and hydraulic system must be
biodegradable oils of completely drained, cleaned and
different suppliers. flushed.
For further details before changing
oils, please consult your responsible
dealer.
Axles GO 90 LS Transmission oil SAE 85W-90LS Alternative recommendations
API-GL 5 SAE 90LS
SAE 80W-90LS
Lubricating points MPG-A Multi-purpose, K2K-30
lithium-soap DIN 51825
based grease
Brake ATF Brake oil ATF
Type A Suffix A
Dexron-IID
1)
In conformity with the regulation lubricants of the Main Association of the German Building
Industry e.V.
Alternative recommendation for other temperature ranges
Engine oil Hydraulic oil
according to API CG 4 or CF 4 and according to DIN 51524.T3 HVLP
according to ACEA E3 or E2
0W-30
0W-40
5W-30
5W-40
10W-30
10W-40
15W-40
Viskode 20W-50
-30 -20 -10 0 10 20 30 °C
-22 -4 14 32 50 68 88 °F
Umgebungstemperatur/Ambient temperature/Température ambiante
TL 65 - 70S - 80 - 100 - 120 - 160 10.2008
Lubricant Specification 8.01.01
Inspection plan
To be carried out by trained specialist dealer personnel.
O = Checking, Maintenance Operating hours 2x 1x

min. min.
X = Replace
Perform work with machine at operating temperature after every every every yearly yearly
100 500 1,000 2,000
1 Check whether machine-specific instruction book is O O
in the machine
2 Change engine oil X 2) X
3 Change engine oil filter X X
4 Drain water from fuel tank O O O
5 Change fuel filter X X
6 Clean fuel pump and screen filter O
7 Check air intake O O
8 Change air filter - main cartridge to service indicator X
Change air filter - safety cartridge 1)
9 as required
10 Clean cooling fins of hydraulic oil radiator. O O O
In case of high exposure to dust,
shorten the cleaning intervals.
11 Clean cooling fins of engine oil radiator O O O
12 Check V-belt tension O O
13 Check engine mounts and pump attachments O O
14 Check engine speed adjustment, top-end and low O O
idle speed
15 Check valve lash of engine and adjust if necessary O
16 Check injection valves O
17 Check fuel leak oil pipe and replace if necessary O X1)
3)
18 Replace toothed belt
19 Check crankcase breather in valve cover O
20 Check acid level and battery connections O O
21 Check condition of tires, tire pressure and tightness O O
of wheel nuts
22 Check secure fastening of axles and propeller shaft O O
23 Check bearing bushings and bolts of work O O
equipment and replace if necessary
24 Check bushings and bolts of the articulation and the O O
articulated steering and replace if necessary.
TL 65 (SKL 824) 01.2007
Inspection plan 8.22.01
min. min.
X = Replace
100 500 1,000 2,000
25 Check that door catches function perfectly, and O O
replace if necessary
26 Clean or replace the dust filter for cab ventilation O X X
27 Check electrical indicating and warning elements, O O
and lighting system
28 Check smooth running of operator controls and O O
adjust if necessary
29 Check tightness of all pipes, hoses, control valve, O O
hydraulic pumps, cylinders, etc.
When tightening hose and pipe
connections, screw-in couplings must be
locked to prevent rotation.
30 Check or change hydraulic oil O O X 2) X
31 Replace insert of hydraulic oil return suction filter X X X
32 Replace breather X X
33 Check function of brakes and replace brake oil O O X X
34 Bleed brake O O
35 Rear axle differential with transmission / option: X O X 2) X
transmission: oil check or oil change
36 Front axle differential - oil check or oil change X O X 2) X
Wheel hubs of front and rear axles: oil check or oil 2)
37 X O X X
change
38 Grease machine according to overview of lubricating O O
points
39 Check function, condition and completeness of O O
safety equipment
40 Hydraulic function check with pressure function test O O
41 Test run and test work O O
42 Initial inspection cards and return to O O 4)
MANUFACTURER
1) at least every 2 years
2) Extension of oil change intervals according to oil sample analysis and lab report.
3) Every 5 years or 5,000 operating hours respectively
4) within warranty
8.22.01/01.2007
Desired value Actual value Adjusted Remark
Engine, transmission,
brake, steering, loading
Engine, high idle
running speed min-1 2,450+50
Engine, low idle
running speed min-1 850+50
Charge pressure, high idle
pilot pressure bar 30+5 running speed
Start-up speed min-1 1,150
Engine stalling min-1 2,100 full throttle,

260 bar HP,
rabbit, dyn.
Pressure cut-off bar 450
High pressure (SV) bar 480
Regulation start dynamic at

DA-motor bar 240 2200 min-1
Cardan shaft rev. min-1 see Techn. Data Chapter 2
Beginning / end of
inching bar 5 - 13
Pressure switch,
hydrostatic brake bar 22
Main pressure relief full throttle,
valve bar 250 50° - 60° C
Line relief pressures out in out in out in

hydraulic cylinders
Lifting frame bar 280 ---
Tilting bar 130 280
Add. control circuit bar 230 230
Steering bar 175 175
TL 65 from sn 329 10.2008
Test certificate 8.22.03
Inspection plan
To be carried out by trained specialist dealer personnel.

min. min.
X = Replace
100 500 1,000 2,000
in the machine
2 Change engine oil X 2) X
Change air filter - safety cartridge 1)
9 as required
10 Clean cooling fins of hydraulic oil radiator. O O O
11 Clean cooling fins of engine oil radiator O O O
idle speed
3)
of wheel nuts
TL 80 (SKL 834) 01.2007
min. min.
X = Replace
100 500 1,000 2,000
and lighting system
adjust if necessary
34 Bleed brake O O
37 X O X X
change
points
safety equipment
42 Initial inspection cards and return to O O 4)
MANUFACTURER
4) within warranty
8.24.01/01.2007
Engine, high idle
Engine, low idle
Engine stalling min-1 2,000-100 full throttle,

220 bar HP,
rabbit, dyn.
Regulation start See Chap. 5

DA-motor bar 230
Beginning / end of
inching bar 5 - 13
Pressure switch,
valve bar 250 50° - 60° C

hydraulic cylinders
Tilting bar 130 280
TL 80 from sn 1181 and up 10.2008
Inspection plan
TL 80AS 01.2008
Inspection 8.25.01
8.25.01/01.2008
TL 80AS 01.2008
Inspection 8.25.02
Engine, high idle
Engine, low idle
Engine stalling min-1 2,000-100 full throttle,

220 bar HP,
rabbit, dyn.

DA-motor bar 180
Beginning / end of
inching bar 5 - 13
Pressure switch,
valve bar 250 50° - 60° C

hydraulic cylinders
Tilting bar 130 280
TL 80 AS from sn 147 till XXX 10.2008
Inspection plan To be carried out by trained specialist dealer personnel
O = Checking, Maintenance Operating hours

2x 1x
X = Replace
after every every every min. min.
Perform work with machine at operating temperature 100 500 1000 2000 jearly jearly
in the machine
2)
2 Change engine oil X X
9 Change air filter - safety cartridge as required 1)
10 Clean cooling fins of hydraulic oil cooler (combined cooler). O O O
11 Clean cooling fins of engine oil cooling system (comb. cooler). O O O


14 Check engine speed adjustment, top-end and O O
low idle speed
1)
17 Check fuel leak oil pipe and replace if necessary O X
3)
of wheel nuts
23 Check bearing bushings and bolts of work equipment O O
and replace if necessary
27 Check electrical indicating and warning elements, and O O
lighting system
28 Check smooth running of operator controls and adjust O O
if necessary
Typ Wartung und Pflege Datum

Model Maintenance Edition
Type TL 100 Entretien
Entretenimiento
Date 01.2007
Tipo Fecha
Benennung Inspektionsplan Blatt

Description Inspection plan Page
Dénomination Plan de révisions Feuille 8.26.01
Denominación Tabla de inspección Página
Inspection plan To be carried out by trained specialist dealer personnel
O = Checking, Maintenance Operating hours

2x 1x
X = Replace
after every every every min. min.
Perform work with machine at operating temperature 100 500 1000 2000 jearly jearly
29 Check tightness of all pipes, hoses, control valve, hydraulic O O

pumps, cylinders, etc.
When tightening hose and pipe connections,

screw-in couplings must be locked to prevent
rotation.
2)
30 Check or change hydraulic oil O O X X
34 Bleed brake O O
2)
35 Rear axle differential with transmission / option: transmission: X O X X
oil check or oil change
2)
36 Front axle differential - oil check or oil change X O X X
2)
37 Wheel hubs of front and rear axles: oil check or oil change X O X X
38 Grease machine according to overview of lubricating points O O

39 Check function, condition and completeness of safety O O
equipment

4)
42 Initial inspection cards and return to manufacture O O

4) within warranty
Typ Wartung und Pflege Datum

Model Maintenance Edition
Type TL 100 Entretien
Entretenimiento
Date 01.2007
Tipo Fecha
Benennung Inspektionsplan Blatt

Description Inspection plan Page
Dénomination Plan de révisions Feuille 8.26.02
Denominación Tabla de inspección Página
TL 100 from serial no. TL01000647 till XXX

Engine, high idle
running speed min-1 2,350 +50
Engine, low idle
running speed min-1 850 +50
pilot pressure bar 30 ±1 running speed
Engine stalling min-1 2,000 -100 full throttle,

280 bar HP,
rabbit, dyn.
Regulation start See Chap.5

DA-motor bar 290
Beginning / end of
inching bar 5 - 13
Pressure switch,
valve bar 250 50° - 60° C

hydraulic cylinders
Tilting bar 130 280
TL 100 from sn 647 till XXX 10.2008
Inspection plan
To be carried out by trained specialist dealer personnel

min. min.
X = Replace
100 500 1,000 2,000
in the machine
2 Change engine oil X X
9 Change air filter - safety cartridge as required 1)
10 Clean cooling fins of hydraulic oil cooler O O O
In case of high exposure to dust, shorten the

cleaning intervals.
11 Clean cooling fins of engine oil cooling system O O O
idle speed
18 Replace toothed belt 3)
of wheel nuts
23 Check that ring gear attachment screws are O O
securely fastened

TL 70 (SKS 634) 01.2007
min. min.
X = Replace
100 500 1,000 2,000
24 Check function of axle lock and vent cylinders O O
and lighting system
adjust if necessary
36 Bleed brake O O
39 X O X X
change
points
safety equipment
44 Initial inspection cards and return to Manufacturer O O 4)

4) within warranty
8.37.01/01.2007
TL 70 from serial no. TL00700250 till XXX
Desired Actual Adjusted Remarks

value value
Engine, high idle
running speed min-1 2,350 +50
Engine, low idle
running speed min-1 850 +50
pilot pressure bar 30 +5 running speed
Start-up speed min-1 1,150 ±50
Engine stalling min-1 2,200 -100 full throttle,

220 bar HP,
rabbit, dyn.

DA-motor bar 230
Beginning / end of
inching bar 5 - 13
Pressure switch,
Main pressure full throttle,
relief valve bar 250 50° - 60° C

hydraulic cylinders
Tilting bar 130 280
Slewing bar 230 230
Steering bar 175 175 full throttle
TL 70 from sn 250 till XXX 10.2008
SUBGROUP LIST
Operation
TL 65 9.22
TL 80 9.24
TL 80AS 9.25
TL 100 9.26
TL 70 9.37
01/2008
Operator controls and display elements
The following list includes non-standard equipment !
14 1 2 3 4
5
6
7
8
10
11
12
13
L824-010
15
TL 65 (SKL 824) 01.2007
Operation 9.22.01
1 Direction indicator — horn — low/high beam (steering column mounted switch)
2 Brake inching pedal
3 Accelerator pedal
4 Tilt adjustment of steering wheel (option: height adjustment)
5 Actuation of additional control circuit
6 Control lever — loader installation
7 Direction-of-travel pre-selection (without function if working hydraulics are
disabled)
8 Impulse mode — float position
9 Parking brake
10 Socket
11 Fuse carrier
12 Fan: fresh air/ re-circulating air
13 Radio
14 Control rod for mechanical quick-attach system
15 Washer tank
9.22.01/01.2007
24 25 26 27 28
23 29
22 30
21 31
20 32
33 34 35 36 37 38 39 40 41 42
43 51
50
44 0
45
I
46 52
47 53
48 54
49 55
56
L824-010-1
57
TL 65 (SKL 824) 01.2007
Operation 9.22.02
20 not assigned * 40 Windshield wash function front/rear
21 YELLOW — pre-heating monitor 41 Windshield wiper, front
22 RED — battery charge indicator 42 Windshield wiper, rear
23 RED — parking brake 43 Switch for air conditioning and
24 GREEN — travel direction, forward temperature control
25 Coolant temperature 44 Fan switch – heater
26 Operating hour meter 45 not assigned *
27 Fuel gauge 46 not assigned *
28 GREEN — travel direction, reverse 47 Pre-selection switch for actuation of
29 GREEN — direction indicator additional control circuit (Pos. 5)
30 BLUE — high beam 48 Pre-selection switch for float position —
OFF/Impulse/Continuous mode
31 RED — engine oil pressure
49 not assigned *
32 YELLOW — air filter indicator
50 Pre-heat/starter switch
33 Travel speed — fast/slow
51 Hazard warning switch
34 Change-over switch for high gear
52 Working floodlight, front
Only press when machine
53 Working floodlight, rear
is at standstill!
35 Multi-function switch with lock for 54 not assigned *
work equipment cut-off and change- 55 not assigned *
over of the direction-of-travel pre- 56 not assigned *
selection switches from pos. 07 to 57 Heater control
pos. 36
58 Monitor — transmission indicator range I
Only press when machine 59 Monitor — transmission indicator range II
is at standstill! 60 Monitor — transmission indicator range —
36 Pre-selection of travel direction — disabled
Function only active if working
hydraulics are disabled If this symbol comes up, the
37 not assigned *
transmission is in an
intermediate position. The
38 not assigned *
machine is not ready to
39 not assigned *
start! This can be remedied by
performing brief steering
movements until the
transmission engages.
61 Speed indicator
9.22.02/01.2007
14 1 2 3 4
5
6
7
8
10
11
12
13
L824-010
15
TL 80 (SKL 834 / SKL 834 S) 01.2007
Operation 9.24.01
3 Accelerator pedal
disabled)
9 Parking brake
10 Socket
11 Fuse carrier
13 Radio
15 Washer tank
9.24.01/01.2007
24 25 26 27 28
23 29
22 30
21 31
20 32
33 34 35 36 37 38 39 40 41 42
43 51
50
44
0
45
46 I
52
47 53
48 54
49 55
56
L824-010-1
57
TL 80 (SKL 834 / SKL 834 S) 01.2007
Operation 9.24.02
20 not assigned * 40 Windshield wash function front/rear
21 YELLOW — pre-heating monitor 41 Windshield wiper, front
22 RED — battery charge indicator 42 Windshield wiper, rear
23 RED — parking brake 43 Switch for air conditioning and
24 GREEN — travel direction, forward temperature control
25 Coolant temperature 44 Fan switch – heater
26 Operating hour meter 45 not assigned *
27 Fuel gauge 46 not assigned *
28 GREEN — travel direction, reverse 47 Pre-selection switch for actuation of
29 GREEN — direction indicator additional control circuit (Pos. 5)
30 BLUE — high beam 48 Pre-selection switch for float position —
31 RED — engine oil pressure
49 not assigned *
32 YELLOW — air filter indicator
33 Travel speed — fast/slow
34 Change-over switch for high gear
52 Working floodlight, front
Only press when machine
53 Working floodlight, rear
is at standstill!
35 Multi-function switch with lock for 54 not assigned *
work equipment cut-off and change- 55 not assigned *
over of the direction-of-travel pre- 56 not assigned *
selection switches from pos. 07 to 57 Heater control
pos. 36
58 Monitor — transmission indicator range I
Only press when machine 59 Monitor — transmission indicator range II
is at standstill! 60 Monitor — transmission indicator range —
36 Pre-selection of travel direction — disabled
Function only active if working
hydraulics are disabled If this symbol comes up, the
37 not assigned *
transmission is in an
intermediate position. The
38 not assigned *
machine is not ready to
39 not assigned *
start! This can be remedied by
performing brief steering
movements until the
transmission engages.
61 Speed indicator
9.24.02/01.2007
TL 80AS 01.2008
Operation 9.25.01
9.25.01/01.2008
TL 80AS 01.2008
Operation 9.25.02
9.25.02/01.2008
14 1 2 3 4
5
6
7
8
10
11
12
13
L824-010
15
TL 100 (SKL 844 / SKL 844 S) 01.2007
Operation 9.26.01
3 Accelerator pedal
disabled)
9 Parking brake
10 Socket
11 Fuse carrier
13 Radio
15 Washer tank
9.26.01/01.2007
24 25 26 27 28
23 29
22 30
P
21 31
20 32
II
33 34 35 36 37 38 39 40 41 42
Option
“S”-Version 43 51
61 50
58 I
44
0
45
I
59 II
47 0 3
6 52
62
9
48
60 N 53
46
54
49
55
56
L844-010-1
57
Instrument panel
TL 100 (SKL 844 / SKL 844 S) 01.2007
Operation 9.26.02
20 not assigned * 45 not assigned *
21 YELLOW — pre-heating monitor 46 not assigned *
22 RED — battery charge indicator 47 Pre-selection switch for actuation of
23 RED — parking brake additional control circuit (Pos. 5)
24 GREEN — travel direction, forward 48 Pre-selection switch for float
25 Coolant temperature position —
26 Operating hour meter
49 not assigned *
27 Fuel gauge
28 GREEN — travel direction, reverse
29 GREEN — direction indicator
30 BLUE — high beam 52 Working floodlight, front
31 RED — engine oil pressure 53 Working floodlight, rear
32 YELLOW — air filter indicator 54 not assigned *
33 Travel speed — fast/slow 55 not assigned *
34 Change-over switch for high gear 56 Option — 4th control circuit
Only press when machine is 57 Heater control
at standstill! 58 Monitor — transmission indicator
35 Multi-function switch with lock for range I
work equipment cut-off and change- 59 Monitor — transmission indicator
over of the direction-of-travel pre- range II
selection switches from pos. 07 to 60 Monitor — transmission indicator
pos. 36 range — disabled
Only press when machine is If this symbol comes up, the
at standstill! transmission is in an
36 Pre-selection of travel direction — intermediate position. The
Function only active if working machine is not ready to
hydraulics are disabled start! This can be remedied
37 not assigned * by performing brief steering
38 not assigned * movements until the
39 not assigned * transmission engages.
61 Speed indicator
40 Windshield wash function front/rear
62 Option — Flow setting for 4th control
41 Windshield wiper, front
circuit, e.g. sweeper rotating speed
42 Windshield wiper, rear
* for non-standard equipment
43 Switch for air conditioning and
temperature control
44 Fan switch – heater
9.26.02/01.2007
SUBGROUP LIST
Options
General Immobilizer KAT 10.050
General Air Condition filling quantities 10.400
01.2010
Programming of new Keys
Typ Datum
Model All machines with KAT imobilizer Edition 09.2009
Benennung
Imobilizer Blatt
Description
Page 10.050.01
Deletion of trained keys
Prüf- Schaltdruck Schaltdruck
Maschinentyp Füllmenge Füllmedium Füllanschluß- Magnetkupplung Magnetkupplung
type ein aus
Machine Filling Cooling Test Port Pressure Pressure

Type Quantities agent Type Solenoid Solenoid
Coupling on Coupling off
TL65 (SKL824) 800g R134a R134a genormt 2bar 25 bar

1.764 lb R134a R134a standard 29 PSI 363 PSI
TL70s (SKS634) 800g R134a R134a genormt 2bar 25 bar


SKL873-200 1100g R134a R134a genormt 2bar 25 bar
TL210 900g R134a R134a genormt 2bar 25 bar



TW70 (HML23) 1200g R134a R134a genormt 2 bar 27 bar



TC60 (HR20) 1100g R134a R134a genormt 2 bar 27 bar



TC48 (HR18) 1250g R134a R134a genormt
2.756 lb R134a R134a standard
TC50 1250g R134a R134a genormt
2.756 lb R134a R134a standard
Typ Allgemein Datum

Model General Edition 01.2008
Benennung Klimaanlagen Füllmengen Blatt

Description Page 10.400.01
Air conditioning filling quantities
SUBGROUP LIST
Repair instructions
TC / TL (HR / SKL) Overview Assembly Tool 11.001.01
TC 15-50 (HR) Glue kit, cabin window panes 11.300.01
01/2007
Overview of assembly tools for pistons with piston rings TC 15 / TC 16 / TC 20 / TC 29 / TC 35 / TC 48 (HR)
Cylinder function Cylinder number Piston φ / Machine Type Assembly Tool Number
Rod φ
Boom / Dipperstick 6 5005 400 00 70/35 TC 15/16/20 6 9500 300 02
6 5005 405 00
6 5005 410 00
Dipperstick 6 5004 265 00 63/35 TC 15/16 6 9500 300 01
Bucket 6 5004 811 00 63/40 TC 15/16/20 6 9500 300 01
Dozer blade 6 5004 065 00 63/30 TC 15/16/20 none
Rod φ
Boom 6 5006 375 00 80/40 TC 29 6 9500 300 03
Dipperstick 6 5005 695 00 70/40 TC 29 6 9500 300 02
Bucket 6 5005 835 00 70/35 TC 29 6 9500 300 02
Articulation 6 5006 430 00 80/40 TC 29/TC 35 6 9500 300 03
Dozer blade 6 5007 297 00 90/40 TC 29/TC 35 none
Rod φ
Boom 6 5007 545 00 90/45 TC 35 6 9500 300 04
Dipperstick 6 5005 845 00 70/45 TC 35 6 9500 300 02
Bucket 6 5005 855 00 70/35 TC 35 6 9500 300 02
Rod φ
Boom 6 5009 200 00 100/50 TC 48 6 9500 300 05
Dipperstick 6 5007 870 00 90/55 TC 48 6 9500 300 04
Bucket 6 5005 860 00 70/45 TC 48 6 9500 300 02
Articulation 6 5007 870 00 90/55 TC 48 6 9500 300 04
Dozer blade new 6 5011 470 00 110/50 TC 48 none
Dozer blade old 6 5009 100 00 100/45 TC 48 none
Cylinder Assembly General 01.2007
Overview of Cylinder Assembly Tools 11.001.01
Driver’s cab with cemented window panes
If need be, the repair kit part no. MCS008042A is available.

It also contains the repair instructions.
TC – TL – TW 01.2007
Glue kit - cab window panes 11.300.01
“BETASEAL“ window pane glue kit part no. MCS008042A
1. Remove the broken glass pane by

means of the cutting wire enclosed. 6. Tear off the rear steel cap of the glue
cartridge and remove the enclosed
2. Trim the remaining PUR material back “Silicagel“ bag.
to a thickness of 1 - 2 mm by using a
well-sharpened knife. 7. Evenly apply the glue “BETASEAL“ or
“BETAMATE“ on the glue surfaces of
3. Clean / activate the cut surfaces with the cabin by means of the enclosed
“BETAWIPE 4001“ (blue cap) and let nozzle.
dry for 2 - 3 minutes.
8. Position the pane immediately with an
4. Apply “BETAWIPE VP 04604“ (yellow appropriate glass transport handle and
cap) on the glue surfaces of the glass press into place with an appropriate
pane by means of a (clean) cloth and webbing.
rub dry.
5. Shake “BETAPRIME 5100“ (green cap)

well before use for approx. 1 minute. Drying times and safety regulations:
Then rapidly apply “BETAPRIME 5100“ Please respect the instructions of the
on the glue surface of the pane by glue manufacturer.
means of the applicator and let dry for
15 minutes.
11.300.01/01.2007

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SERVICE - MANUAL

TL 65 - 80 - 80AS - 100 - 70S

Foreword / Information for the User 1.100.01

Safety and Accident Prevention 1.200.01-05

Tightening torques, piston nuts 1.500.01

Test ports 1.600.01

Foreword / Information for the User 1.100.01

If special attachments, such as Uni-shovel,

2 Correct use The manufacturer’s operating instructions

Safety and Accident Prevention 1.200.01

Safety and Accident Prevention 1.200.02

Safety and Accident Prevention 1.200.03

Safety and Accident Prevention 1.200.04

20 Fire protection 22 Other dangers

Failure of the hydraulics

Safety and Accident Prevention 1.200.05

Hydraulikzylinder ∅ Gewinde - Führungsbüchse Anziehdrehmomente Nm

35/45 M50x2 200 - 230

Symbol Description Symbol Description

002 Pre-heat 013 Hydraulic oil temperature

003 Engine oil pressure 014 Hydraulic oil filter

005 Engine oil level 016 Operational status,

006 Coolant temperature 017 Parking brake

007 Coolant level 018 Brake accumulator

008 Air filter 019 Excavator brake

009 Fuel, fuel level 020 Service brake

010 Fan, 021 Hazard warning system

011 Windscreen wash/ 022 Direction indicator,

024 Upper beam indicator 040 Oscillating axle lock

025 Direction of travel 041 Steering inversion

026 Rotating beacon 042 All-wheel steering

027 Light, lower beam 043 Rocker pedal for travel

028 Central grease system 044 Only shift when machine

029 Lashing points 045 High gear

030 Overload warning 046 Cabin lift / lower

032 Travel speed, fast 048 First aid kit

033 Travel speed, slow 049 Fire extinguisher

034 Working hydraulics 050 Switch-over monitor for

036 Locked 052 Switch for all-wheel

037 Float position 053 Interior lighting

038 Dozer blade 054 Reset hydraulic pulley

056 Cable uncoil limit switch 072 Danger of injury

057 Auxiliary winch 073 Observe notes in

058 Magnet system 074

059 Hydraulic rock breaker 075 Linde - no load

060 Electric boom height 076 Remote control

061 Undercarriage- 077 Warning - general

062 Switch-over swing 078 Temperature - General

064 Grab rotation 080

065 Bucket return 100 Control by Joystick

066 Ride control system 101

067 Bucket return 102 Quick mount-hitch lock

068 Hydraulic oil level 103

070 Safety distance, 104 Water pump for sweeper

125 Control 161 Control

126 Switch-over rock 162 Control

127 Control 163 Control

128 Switch-over (HR 12) 164 Steering

140 Shifting of slide bearing 165 Wheel lock (HS 41)

150 Universal-mounted 166 Free wheel (HS 41 M)

168 Outriggers lift / lower 201 Danger

169 Steering mode switch 202 On the machine:

170 Outrigger left 203 Note