Professional Documents
Culture Documents
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
Pictograms 1.500.50-52
Units 1.800.01
10/2008
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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.
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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.
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques, piston nuts 1.500.01
Führungsbüchse
Gland
Douille
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
Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
General 1.500.50
Symbol Description Symbol Description
023 Working floodlights 039 Speed control
1.500.50/01.2007
Symbol Description Symbol Description
055 Quick movement 071 Danger of crushing
hoisting winch
Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
General 1.500.51
Symbol Description Symbol Description
105 Warning lamp gearbox 151 Universal-mounted
excavator/ loader (AL)
controls
ISO control system right
120 Control 152 Universal-mounted
excavator/ loader (AL)
ISO control system-left
controls
Schaeff control system-
right Schaeff control system left
121 Control 153 Universal-mounted
excavator/ loader (AL)
ISO control system right
controls
Schaeff control system right
122 Control 154 Universal-mounted
excavator/ loader (AL)
Schaeff control system
controls
left
Outrigger right
123 Control 155 Universal-mounted
excavator/ loader (AL)
Intermediate boom
controls
(articulated boom type)
Outrigger left
124 Control 160 Control
telescopic stick in / out Outrigger leg left
1.500.51/01.2007
Symbol Description Symbol Description
167 Outriggers spread 200 Grease gun
181 Switch-over
electric drive
Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
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
Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
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
TL 65 2.22
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
Typ/Model/Type Datum/Edition/Date
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
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
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
Typ/Model/Type Datum/Edition/Date
TL 65 from s/n.: TL00650452 05.2009
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.22.23
DIESEL ENGINE
Manufacturer: Deutz
Type: F4M 2011
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 44 at 2,400 min-1
Construction: 4 cylinders in line
Cooling: external oil cooling
Injection: direct injection
Capacity: cm³ 3,100
High idle: min-1 2,550 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 218
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 / 80 / 720 (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 56 DA with pressure cut-off
Displacement: max. cm³/rev. 56
Travel motor 20/36 km/h version: type/make 51D080 / Danfoss
Displacement 20/36 km/h version: max. cm³/rev. 80
TRAVEL RANGE
Two/ four pre-selectable travel ranges, electro-hydraulically controlled:
TL 80: 20 km/h - version:
tortoise / rabbit km/h 0 to 7.0 / 0 to 20
TL 80 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
Typ/Model/Type Datum/Edition/Date
TL 80 from s/n.: TL00800751 to 1180 01.2008
(SKL 834 / SKL 834 S)
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.24.03
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: bar 230
(see setting instructions, chapter 5, measuring method 2)
Start-up speed: min-1 1,150
Engine stalling (rabbit) - dynamic: min -1
2,200 -100 at 220 bar HP
Brake inching beginning / end: bar 5 - 13
Pressure switch (hydrostatic brake): bar 22
STEERING
Steering unit: type Danfoss OSPC 250 LS dyn.
Steering pump: make Cassappa
Displacement: cm³/rev: 27
Steering pressure (high idle): bar 175
Priority valve: type Danfoss OLS 80 dyn.
WORKING HYDRAULICS
Working pump: make Cassappa
Displacement: l/min. 64
Valve bank: type Parker P 70
Servo-controlled valve: type Brown PRSV
WORKING CYCLES
Lifting frame lift: s 4.7
Lifting frame lower: s 3.2
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 // 4472 004 061
Rear axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 715 // 4472 004 060
Front axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 715 // 4472 004 061
Rear axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 715 // 4472 004 066
2.24.03/01.2008
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 Schaeff 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
CAPACITIES ltr.
Engine oil with oil filter and oil cooler - change: approx. 13.0 engine oil
Hydraulic oil (tank and system) - first filling: approx. 55.0 hydraulic oil
Hydraulic oil tank (change): approx. 46.0 hydraulic oil
Fuel tank: approx. 75.0 diesel
Front axle - central housing: approx. 4.0 transmission oil
Front axle - wheel hub: approx. 0.3 transmission oil, each
Rear axle - central housing and reduction gearbox: approx. 4.5 transmission oil
Rear axle - wheel hub: approx. 0.3 transmission oil, each
Service brake: approx. 0.25 ATF oil
Typ/Model/Type Datum/Edition/Date
TL 80 from s/n.: TL00800751 to 1180 01.2008
(SKL 834 / SKL 834 S)
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.24.04
DIESEL ENGINE Tier 3
Manufacturer: Deutz
Type: D 2011 L04W
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 44 at 2,400 min-1
Construction: 4 cylinders in line
Cooling: water
Injection: direct injection
Capacity: cm³ 3,600
High idle: min-1 2,350 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 225
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
ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 80 / 720 (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 (option)
Two working lights at the rear (option)
TRANSMISSION
Travel pump: type A 4 VG 56 DA with pressure cut-off
Displacement: max. cm³/rev. 56
Travel motor ( 20 km/h ): type/make A 6 VM 80 DA 2
Displacement : max. cm³/rev. 80
Typ/Model/Type Datum/Edition/Date
TL 80 AS ab s/n 147 06.2008
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.25.20
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: min-1 2100-50 at 180 bar HP
(see setting instructions, chapter 5, measuring method 2)
Start-up speed: min-1 1,150
Engine stalling (rabbit) - dynamic: min-1 2,000 -100 at 220 bar HP
Brake inching beginning / end: bar 5 - 13
Pressure switch (hydrostatic brake): bar 22
(see setting instructions,chapter 5,measuring method 2)
STEERING
Steering unit: type Rexroth LAGC100-15/LD240-1
Steering pump: make Cassappa
Displacement: cm³/rev: 29
Steering pressure (high idle): bar 175
Priority valve: type Rexroth LPS80RM/LD7-643/0
WORKING HYDRAULICS
Working pump: make Cassappa
Displacement: l/min. 64
Valve bank: type Walvoil SDM 100/3
WORKING CYCLES
Lifting frame lift: s 6.2
Lifting frame lower: s 4.4
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
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
CAPACITIES ltr.
Engine oil with oil filter - change: approx. 9.0 engine oil
Hydraulic oil (tank and system) - first filling: approx. 70.0 hydraulic oil
Hydraulic oil tank (change): approx. 46.0 hydraulic oil
Fuel tank: approx. 70.0 diesel
Front axle - central housing: approx. 4.0 transmission oil
Front axle - wheel hub: approx. 0.3 transmission oil, each
Rear axle - central housing and reduction gearbox: approx. 4.5 transmission oil
Rear axle - wheel hub: approx. 0.3 transmission oil, each
Service brake: approx. 0.25 ATF oil
Coolant fluid approx. 15,0 water with anti-corrosive
and anti-freeze agent
Typ/Model/Type Datum/Edition/Date
TL 80 AS ab s/n 147 06.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.25.21
DIESEL ENGINE
Manufacturer: Deutz
Type: BF4M 2011 Turbo
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 54 at 2,200 min-1
Construction: 4 cylinders in line
Cooling: external oil cooling
Injection: direct injection, turbo charged
Capacity: cm³ 3,100
High idle: min-1 2,350 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 205
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 / 80 / 720 (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 56 DA with pressure cut-off
Displacement: max. cm³/rev. 56
Travel motor 20/36 km/h version: type/make 51D080 / Danfoss
Displacement 20/36 km/h version: max. cm³/rev. 80
TRAVEL RANGE
Two/ four pre-selectable travel ranges, electro-hydraulically controlled:
TL 100: 20 km/h - version:
tortoise / rabbit km/h 0 to 6.0 / 0 to 20
TL 100 S: 36 km/h - version:
Gearbox position 1, tortoise / rabbit: km/h 0 to 6.0 / 0 to 18
Gearbox position 2, tortoise / rabbit: km/h 0 to 12 / 0 to 36
Cardan shaft rev. at 20 km/h - version adjustment at nominal speed
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
Cardan shaft rev. at 36 km/h - version adjustment at nominal speed
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
Typ/Model/Type Datum/Edition/Date
TL 100 from s/n.: TL01000453 to 646 01.2008
(SKL 844 / SKL 844 S)
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.26.03
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: bar 290
Start-up speed: min-1 1,150
Engine stalling (rabbit) - dynamic: min-1 2,000 -100 at 280 bar HP
Brake inching beginning / end: bar 5 - 13
Pressure switch (hydrostatic brake): bar 22
STEERING
Steering unit: type LAGU 400/130-11/LD240-175M01
Steering pump: make WSP 20.14-045
Displacement: cm³/rev: 33
Steering pressure (high idle): bar 175
Priority valve: type LPS 80R11/LD7-643/01
WORKING HYDRAULICS
Working pump: make WSP 20.14-045
Displacement: l/min. 72
Valve bank: type Parker P 70
Servo-controlled valve: type Brown PRSV C01 S053 FO
WORKING CYCLES
Lifting frame lift: s 5.1
Lifting frame lower: s 3.2
Shovel dump in: s ---
Shovel dump out: s ---
AXLES
Front axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 720 // 4472 025 009
Rear axle with self-locking differential - 20 km/h-version: make/type ZF / AP – R – 720 // 4472 025 010
Front axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 720 // 4472 025 009
Rear axle with self-locking differential - 36 km/h-version: make/type ZF / AP – R – 720 // 4472 025 011
2.26.03/01.2008
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 Schaeff 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
CAPACITIES ltr.
Engine oil with oil filter and oil cooler - change: approx. 13.0 engine oil
Hydraulic oil (tank and system) - first filling: approx. 88.0 hydraulic oil
Hydraulic oil tank (change): approx. 62.0 hydraulic oil
Fuel tank: approx. 102.0 diesel
Front axle - central housing: approx. 4.0 transmission oil
Front axle - wheel hub: approx. 0.3 transmission oil, each
Rear axle - central housing and reduction gearbox: approx. 4.5 transmission oil
Rear axle - wheel hub: approx. 0.3 transmission oil, each
Service brake: approx. 0.25 ATF oil
Typ/Model/Type Datum/Edition/Date
TL 100 from s/n.: TL01000453 to 646 01.2008
(SKL 844 / SKL 844 S)
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.26.04
DIESEL ENGINE Tier 3
Manufacturer: Deutz
Type: D 2011 L04W
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 44 at 2,400 min-1
Construction: 4 cylinders in line
Cooling: water
Injection: direct injection
Capacity: cm³ 3,600
High idle: min-1 2,350 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 225
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 56 DA with pressure cut-off
Displacement: max. cm³/rev. 56
Travel motor 20/36 km/h version: type 51D080 Danfoss
Displacement 20/36 km/h version: max. cm³/rev. 80
TRAVEL RANGE
Two/ four pre-selectable travel ranges, electro-hydraulically controlled:
TL 70: 20 km/h - version:
tortoise / rabbit km/h 0 to 7.0 / 0 to 20
TL 70 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
Typ/Model/Type Datum/Edition/Date
TL 70 from s/n.: TL00700363 05.2009
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.37.22
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 2,300 -50 at 230 bar
(see setting instructions, chapter 5, measuring method 2)
Start-up speed: min-1 1,150
Engine stalling (rabbit) - dynamic: min-1 2,000 -100 at 220 bar HP
Brake inching beginning / end: bar 5 - 13
Pressure switch (hydrostatic brake): bar 22
STEERING
Steering unit: type Rexroth LAGC100-15/LD240-1
Steering pump: make Cassappa
Displacement: cm3/rev. 29
Steering pressure (high idle): bar 175
Priority valve: type Rexroth LPS80RM/LD7-643-0
WORKING HYDRAULICS
Working pump: make Cassappa
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
Servo-controlled valve: type Brown PRSV
WORKING CYCLES
Lifting frame lift: s 4.7
Lifting frame lower: s 3.3
Shovel dump in: s ---
Shovel dump out: s ---
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
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
CAPACITIES ltr.
Engine oil with oil filter - change: approx. 9.0 engine oil
Hydraulic oil (tank and system) - first filling: approx. 55.0 hydraulic oil
Hydraulic oil tank (change): approx. 46.0 hydraulic oil
Fuel tank: approx. 75.0 diesel
Front axle - central housing: approx. 4.0 transmission oil
Front axle - wheel hub: approx. 0.3 transmission oil, each
Rear axle - central housing and reduction gearbox: approx. 4.5 transmission oil
Rear axle - wheel hub: approx. 0.3 transmission oil, each
Service brake: approx. 0.25 ATF oil
Coolant fluid approx. 15,0 water with anti-corrosive
and anti-freeze agent
Typ/Model/Type Datum/Edition/Date
TL 70 from s/n.: TL00700363 05.2009
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.37.23
SUBGROUP LIST
DIESEL ENGINES
TL80AS
10/2008
Specification data 3.250.01
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
Niedrigste Leerlauf- Minimum idle speed: Ralenti extrême: Régimen min. en vacío:
drehzahl: 900/min 900 rpm 900 tr/mn 900 r/min
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
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
3.250.01/01.2007
Deutsch English Français Español
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
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°)
Krümmerseite
Mainfold side
Coté coudes
Lado codo
4-Zylinder
4-cylinder
4-cylindres
4-cilindros
3.250.02/01.2007
Deutsch English Français Español
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.
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
Usinage par
Spanabhebende Mecanizado con
machining process enlèvement de
Bearbeitung arranque de virutas
copeaux
3.250.03/01.2007
31
30
29
11
10
11
12
28 13
27
26 14
15
25
16
17
18
19
24
21
23 22
20
06
07
08
09
05
04 01
03 02
F:\ServHB\Kap03\4-sprachig-deut-eng-fran-span \390004-Deutz-F4M-2011
3.250.04/01.2007
Typ Motor Datum
Model DEUTZ Engine Edition
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
Deutsch English Français Español
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
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.
3.250.05/06.2002
Typ Motor Datum
Model DEUTZ Engine Edition
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
Deutsch English Français Español
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.
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.
3.250.06/06.2002
Typ Motor Datum
Model DEUTZ Engine Edition
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
Deutsch English Français Español
3.250.07/06.2002
Typ Motor Datum
Model DEUTZ Engine Edition
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
Deutsch English Français Español
3.250.08/06.2002
Typ Motor Datum
Model DEUTZ Engine Edition
Moteur
01.2007
Type F - 4M 2011 Date
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
Deutsch English Français Español
3.250.09/01.2007
Typ Motor Datum
Model DEUTZ Engine Edition
Moteur
01.2007
Type F - 4M 2011 Date
Tipo Motor Fecha
Benennung Einspritzventil – prüfen und einstellen Blatt
Description Injector – checking and adjusting Page
3.250.10
Dénomination Injecteur – contrôle et réglage Feuille
Denominación Inyector – verificatión y ajustes Página
Deutsch English Français Español
3.250.10/01.2007
Typ Motor Datum
Model DEUTZ Engine Edition
Moteur
01.2007
Type F - 4M 2011 Date
Tipo Motor Fecha
Benennung Einspritzventil – prüfen und einstellen Blatt
Description Injector – checking and adjusting Page
3.250.11
Dénomination Injecteur – contrôle et réglage Feuille
Denominación Inyector – verificatión y ajustes Página
Deutsch English Français Español
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.
3.250.11/01.2007
SUBGROUP LIST
Hydraulic system
Diagrams – schemes
TL 65 4.22
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
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
S25 T1 Y4 PS FA FE MB T 4
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
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
27
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
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
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
Work
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
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
04/2010
Anziehdrehmomente Hydromatikpumpen /-motore
Tightening torques Hydromatikpumps /-motors
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 14 x 1,5 VSTI 14 x 1,5 -ED = 30 M 14 x 1,5 VSTI 14 x 1,5 -ED = 22
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 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 40 M 18 x 1,5 VSTI 18 x 1,5 -ED/SA = 29
M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 50 M 20 x 1,5 VSTI 20 x 1,5 -ED/SA = 37
M 22 x 1,5 VSTI 22 x 1,5 -ED = 60 M 22 x 1,5 VSTI 22 x 1,5 -ED = 44
M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 70 M 26 x 1,5 VSTI 16 x 1,5 -ED/SA = 51
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 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
Tipo Hidráulico Fecha
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
Typ/Model/Type Datum/Edition/Date
TL 120 ab Fz.-Id.-Nr.: TL01200100 (SKL 854) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
G 1
2
B
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
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
Messpunkt Hochdruck und Test port HP and Prise de pression
MB Speisedruck charge pressure HP et gavage
Prise de pression
X1 Messpunkt Stelldruck Test port control pressure pression de commande
Prise de pression
X2 Messpunkt Stelldruck Test port control pressure pression de commande
Messpunkt Steuerdruck Test port control pressure
PS nach der PS -Blende after Pp orifice
Après orifice PS
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
Inchfedern Bremsdruck
Inching springs Brake pressure
1 11
G 3
B
Typ/Model/Type Datum/Edition/Date
TL 120 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
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
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
Messpunkt Hochdruck und Test port HP and Prise de pression
MB Speisedruck charge pressure HP et gavage
Prise de pression
X1 Messpunkt Stelldruck Test port control pressure pression de commande
Prise de pression
X2 Messpunkt Stelldruck Test port control pressure pression de commande
Messpunkt Steuerdruck Test port control pressure
PS nach der PS -Blende after Pp orifice
Après orifice PS
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
Typ/Model/Type Datum/Edition/Date
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)
If the values are different, the neutral position can be corrected via the
setscrew (6) at the travel pump.
If the desired value is not reached, turn the setscrew (1) at the regulator
cartridge in or out .
Typ/Model/Type Datum/Edition/Date
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.
− connect 600 bar gauge to high pressure port (MA) forward of the travel pump
− screw in the regulation start setscrew by 1 turn, travel motor must not regulate
− remove brake inching hose from the travel pump and plug
− 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.
Afterwards reconnect the brake hose and de-aerate the brake at the inching block.
Adjust the regulation start as per the instructions, item 7.
− connect 600 bar - gauge to gauge port (MA) or (MB) resp. of the travel pump
− 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.
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
− drive the vehicle against a solid object (wheels must lock up)
− fully accelerate
− 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.
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!
Typ/Model/Type Datum/Edition/Date
Benennung/Description/Dénomination Blatt/Page/Feuille
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
− 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
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
- 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)
Typ/Model/Type Datum/Edition/Date
- 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
TL 80 ab Fz.id.Nr. 0751
M3
20
Y6
Y2
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.
Leckölanschluss M3
L1 Case drain
Typ/Model/Type Datum/Edition/Date
− 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
− fully accelerate
− 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
− 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)
10
Druckschalter S26
Pressure switch S26
5.300.07 / 01.2008
Description A 6 VM DA 5
with switching solenoids
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.
The high pressure side B is pressurized. So the description given under travel range rabbit
(road travel) forward applies.
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).
Typ/Model/Type Datum/Edition/Date
TL65 / TL70s / TL80 / TL80AS / TL100 / 01.2000
TL120
Benennung/Description/Dénomination Blatt/Page/Feuille
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.
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.
5.300.08/01.2000
SUBGROUP LIST
Functional Description
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
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 80 (SKL 834) Hydraulique équipement Date 01.2007
Tipo Hidráulico de trabajo Fecha
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
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
B 5
11 12
8 4
3
9
10 1
7 6
H T
K 18
17
16
13
14
15
M
Typ Arbeitshydraulik Datum
Model Working hydraulik Edition
Type TL 100 (SKL 844) Hydraulique équipement Date 01.2007
Tipo Hidráulico de trabajo Fecha
B 3
6
5
12
4
9
14
10 15
11 2
8
13
K T
21
19 20
H
17
16
18
M
Typ Arbeitshydraulik Datum
Model Working hydraulik Edition
Type TL 70 (SKS 634) Hydraulique équipement Date 01.2007
Tipo Hidráulico de trabajo Fecha
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.
A
A
B
B
3 4
2
Typ/Model/Type Datum/Edition/Date
TL(SKL), general 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
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
X20
X90
13 --
15 --
X61
16 --
17 --
18 Speedometer signal sensor
X30 Signal inputs "Lighting"
X40
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X80 Coordinate lever
1 Power supply Terminal 15 output
X30
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.22.05/01.2007
X5
X40 CAN-BUS (Option)
1 Power supply Terminal 15 output
2 Central mass Terminal 31
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
2 Central mass Terminal 31
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X90 Programming connection
X61
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 65 (SKL 824) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.22.06
X31 Module power supply, working
X5
floodlights, rotating beacon, wiper
1 --
2 -
X91
X20
X90
floodlight rear
14 Reserve PWM output
15 Reserve PWM output
16 Power supply Terminal 30 input rotating
beacon
X40
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
7.22.06/01.2007
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
output
2 --
3 Starting Terminal 50a signal
X70
4 Pre-heat signal
5 Engine shutdown signal
6 Ride control system signal
7 Additional control circuit signal
8 Additional control circuit signal
X30
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 65 (SKL 824) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.22.07
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
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
MAXI fast-acting fuse
power supply machine control unit
F03 30A
MAXI fast-acting fuse
start-up relay / engine shut-off relay
F04 50A
MAXI fast-acting fuse
engine shut-off
F010 10A
ATO fast-acting fuse
reserve
F011 10A
ATO fast-acting fuse
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
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
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
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2
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
Model Electrical system form s/n Edition
Type
Tipo
TL65 Circuit électrique
Sistema elèctrico
à partier du n/s
desde el no.
TL00650511 Date 04.2010
Fecha
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
/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
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
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
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
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
ge
X22
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
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
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
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
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
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
ge 2,5Ø
shovel return to dig lower
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
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
gn/sw
option solenoid valve
5 10
working hydraulic
additional circuit 2
additional circuit 1
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
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
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
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
ZSML2.0 ZSML2.0 ZSML2.0
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
power supply power supply
ws
ge
ge
ge
rt
- -
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
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
X5
1 Power supply Terminal 15 output
2 Central mass Terminal 31
3 Charge control generator D+
X91
X20
X90
13 --
15 --
X61
16 --
17 --
18 Speedometer signal sensor
X30 Signal inputs "Lighting"
X40
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X80 Coordinate lever
1 Power supply Terminal 15 output
X30
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.24.05/01.2007
X5
X40 CAN-BUS (Option)
1 Power supply Terminal 15 output
2 Central mass Terminal 31
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
2 Central mass Terminal 31
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X90 Programming connection
X61
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 80 (SKL 834) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.24.06
X31 Module power supply, working
X5
floodlights, rotating beacon, wiper
1 --
2 -
X91
X20
X90
floodlight rear
14 Reserve PWM output
15 Reserve PWM output
16 Power supply Terminal 30 input rotating
beacon
X40
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
7.24.06/01.2007
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
output
2 --
3 Starting Terminal 50a signal
X70
4 Pre-heat signal
5 Engine shutdown signal
6 Ride control system signal
7 Additional control circuit signal
8 Additional control circuit signal
X30
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 80 (SKL 834) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.24.07
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
shovel return to dig
FL6 10A working light rear
air suspended seat FR2 15A
reserve
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
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
MAXI fast-acting fuse
power supply machine control unit
F03 30A
MAXI fast-acting fuse
start-up relay / engine shut-off relay
F04 50A
MAXI fast-acting fuse
engine shut-off
F010 10A
ATO fast-acting fuse
exhaust gas recirculating valve
F011 10A
ATO fast-acting fuse
reserve
F012 5A
ATO fast-acting fuse Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n Edition
cold start enhancement Type TL80 Circuit électrique à partier du n/s
TL00801181 Date 11.2008
F013 5A Tipo Sistema elèctrico desde el no. Fecha
ATO fast-acting fuse Benennung Sicherungs- und Belegungsplan Blatt
Blatt
start excess quantity (turbo engine) Assignment diagramm
F014 5A
Description
Dénomination Schéma de répartition
Page
Feuille 1/1 Page
Feuille
7.24.10
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
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
10 vi/ws 4
br/ge
rt
5 4 3
control module
Kl.50/2.3
ZSML1.0 ZSML1.0 ZSML1.0
travel forward
travel reverse
terminal 15 X20 X20 X20
compressor
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
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2
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 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
Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n TL00802070 und Edition
Type
Tipo
TL80 Circuit électrique
Sistema elèctrico
à partier du n/s
desde el no. 2062,2064,2065 Date 04.2010
Fecha
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
/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
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
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
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
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
ge
X22
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
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
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
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
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
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
ge 2,5Ø
shovel return to dig lower
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
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
gn/sw
option solenoid valve
5 10
working hydraulic
additional circuit 2
additional circuit 1
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
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
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
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
br/gn
/10.15
2 signal horn 16 10 13
6
/10.2
switch 5 4 X70
ZSML2.0 ZSML2.0 ZSML2.0
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
power supply power supply
ws
ge
ge
ge
rt
- -
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
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
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
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
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
* These relays are located behind the cab at the battery compartment.
Typ/Model/Type Datum/Edition/Date
TL 80 AS (from serial no. TL80AS0100) 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
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
* These fuses are located behind the cab at the battery compartment.
Cable colours
7.25.06/01.2008
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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
pre-heat starter switch
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
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
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
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
fuel gauge transmitter
sw 6,0Ø
battery G1
rt
engine shut-off
12 V
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
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
switch switch switch
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
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
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
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
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
gr/sw
gr/rt
sw
high beam
brake lights
gr 86 30 86 30
F26 low beam
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
ge/bl
sw/rt
gr/rt
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
E12
head light 1
head light rear light 1 rear light 1 3 11 13 16
3
br/gn
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
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
X5
1 Power supply Terminal 15 output
2 Central mass Terminal 31
3 Charge control generator D+
X91
X20
X90
13 --
15 --
X61
16 --
17 --
18 Speedometer signal sensor
X30 Signal inputs "Lighting"
X40
7 Reserve +
8 Reserve +
9 Reference voltage
X70
10 Reserve - Analog
11 Reserve - Analog
12 Reserve - Analog
X80 Coordinate lever
1 Power supply Terminal 15 output
X30
8 Reserve - Analog
9 Reserve - Analog
X60
L824-ZSML
7.26.05/01.2007
X5
X40 CAN-BUS (Option)
1 Power supply Terminal 15 output
2 Central mass Terminal 31
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
2 Central mass Terminal 31
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X90 Programming connection
X61
3 TXD
4 RXD
5 CTS
6 RTS
X80
X70
X30
X31
X60
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 100 (SKL 844) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.26.06
X31 Module power supply, working
X5
floodlights, rotating beacon, wiper
1 --
2 -
X91
X20
X90
floodlight rear
14 Reserve PWM output
15 Reserve PWM output
16 Power supply Terminal 30 input rotating
beacon
X40
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
7.26.06/01.2007
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
output
2 --
3 Starting Terminal 50a signal
X70
4 Pre-heat signal
5 Engine shutdown signal
6 Ride control system signal
7 Additional control circuit signal
8 Additional control circuit signal
X30
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 100 (SKL 844) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Wiring diagram 7.26.07
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
shovel return to dig
FL6 10A working light rear
air suspended seat FR2 15A
reserve
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
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
MAXI fast-acting fuse
power supply machine control unit
F03 30A
MAXI fast-acting fuse
start-up relay / engine shut-off relay
F04 50A
MAXI fast-acting fuse
engine shut-off
F010 10A
ATO fast-acting fuse
exhaust gas recirculating valve
F011 10A
ATO fast-acting fuse
reserve
F012 5A
ATO fast-acting fuse Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n Edition
cold start enhancement Type TL100 Circuit électrique à partier du n/s
TL01000647 Date 11.2008
F013 5A Tipo Sistema elèctrico desde el no. Fecha
ATO fast-acting fuse Benennung Sicherungs- und Belegungsplan Blatt
Blatt
start excess quantity (turbo engine) Assignment diagramm
F014 5A
Description
Dénomination Schéma de répartition
Page
Feuille 1/1 Page
Feuille
7.26.10
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
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
compressor
10 4
travel forward
travel reverse
vi/ws
br/ge
rt
5 4 3
control module
Kl.50/2.3
ZSML1.0 ZSML1.0 ZSML1.0
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
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2
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 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
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
Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n TL01001091 und Edition
Type
Tipo
TL100 Circuit électrique
Sistema elèctrico
à partier du n/s
desde el no. 1084,1087 Date 04.2010
Fecha
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
/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
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
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
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
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
ge
X22
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
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
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
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
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
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
ge 2,5Ø
shovel return to dig lower
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
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
gn/sw
option solenoid valve
5 10
working hydraulic
additional circuit 2
additional circuit 1
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
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
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
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
ZSML2.0 ZSML2.0 ZSML2.0
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
power supply power supply
ws
ge
ge
ge
rt
- -
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
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
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
X5
1 Power supply Terminal 15 output
2 Central ground Terminal 31
3 Charge control generator D+
X91
X20
X90
13 --
15 --
X61
16 --
17 --
18 Speedometer signal sensor
X30 Signal inputs "Lighting"
X40
7 Slew left
8 Slew right
9 Reference voltage 2.5V
X70
10 Spare - Analog
11 Option
12 Spare - Analog
X80 Coordinate lever
1 Power supply Terminal 15 output
X30
L824-ZSML
Typ/Model/Type Datum/Edition/Date
TL 70 (SKS 634) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Connector Assignment 7.37.07
X5
X40 CAN-BUS (Option)
1 Power supply Terminal 15 output
2 Central ground Terminal 31
X91
3 CAN/HI
4 R1
5 R2
6 CAN/LO
X10 Control panel
X20
X90
1 --
2 Central ground Terminal 31
3 CAN/HI
4 --
5 --
X10
6 CAN/LO
X90 Programming connection
X61
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
floodlights, rotating beacon, wiper
1 --
2 -
X91
X20
7 Swing axle lock
X90
Typ/Model/Type Datum/Edition/Date
TL 70 (SKS 634) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
11 11 Transmission 2 output
12 12 Working hydraulics output
X61
2 --
3 Starting Terminal 50a signal
4 Pre-heat signal
5 Engine shutdown signal
6 Ride control system signal
X30
X5 Power supply
L824-ZSML
7.37.08/01.2007
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
shovel return to dig
FL6 10A working light rear
air suspended seat FR2 15A
reserve
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
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
MAXI fast-acting fuse
power supply machine control unit
F03 30A
MAXI fast-acting fuse
start-up relay / engine shut-off relay
F04 50A
MAXI fast-acting fuse
engine shut-off
F010 10A
ATO fast-acting fuse
exhaust gas recirculating valve
F011 10A
ATO fast-acting fuse
reserve
F012 5A
ATO fast-acting fuse Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n Edition
cold start enhancement Type TL70S Circuit électrique à partier du n/s
TL00700250 Date 11.2008
F013 5A Tipo Sistema elèctrico desde el no. Fecha
ATO fast-acting fuse Benennung Sicherungs- und Belegungsplan Blatt
Blatt
start excess quantity (turbo engine) Assignment diagramm
F014 5A
Description
Dénomination Schéma de répartition
Page
Feuille 1/1 Page
Feuille
7.37.10
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
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
travel reverse
travel forward
compressor
10 vi/ws 4
br/ge
rt
5 4 3
control module
Kl.50/2.3
ZSML1.0 ZSML1.0 ZSML1.0
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
sw/bl 2,5Ø
sw/br 2,5Ø
(starter box)
rt/ge 2,5Ø
1 1 1 1 1
F013 F014 F012 F010 F011
5A 2
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 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
battery Y1 Y12 2 pre-heat unit
/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
shut-off recirculating
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
Typ Elektrisches System ab Fz.-Id.-Nr. Datum
Model Electrical system form s/n Edition
Type TL70s Circuit électrique à partier du n/s TL00700402 Date 04.2010
Tipo Sistema elèctrico desde el no. Fecha
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
/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
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
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
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
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
ge
X22
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
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
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
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
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
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
ge 2,5Ø
shovel return to dig lower
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
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 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
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
gn/sw
option solenoid valve
5 10
working hydraulic
additional circuit 2
additional circuit 1
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
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
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
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
ZSML2.0 ZSML2.0 ZSML2.0
ge 2,5Ø
sw/ws
ws/ge
sw/gn
power supply
gr/sw
power supply power supply
ws
ge
ge
ge
rt
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
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
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
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
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
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
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
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 -
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
Typ/Model/Type Datum/Edition/Date
TL 65 - 70S - 80 - 100 - 120 - 160 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Lubricant Specification 8.01.01
Inspection plan
Typ/Model/Type Datum/Edition/Date
TL 65 (SKL 824) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Inspection plan 8.22.01
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
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
2) Extension of oil change intervals according to oil sample analysis and lab report.
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
Typ/Model/Type Datum/Edition/Date
TL 65 from sn 329 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Test certificate 8.22.03
Inspection plan
Typ/Model/Type Datum/Edition/Date
TL 80 (SKL 834) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Inspection plan 8.24.01
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
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
2) Extension of oil change intervals according to oil sample analysis and lab report.
4) within warranty
8.24.01/01.2007
Desired value Actual value Adjusted Remark
Engine, transmission,
brake, steering, loading
Engine, high idle
running speed min-1 2,350+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
Typ/Model/Type Datum/Edition/Date
TL 80 from sn 1181 and up 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Test certificate 8.24.05
Inspection plan
Typ/Model/Type Datum/Edition/Date
TL 80AS 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Inspection 8.25.01
8.25.01/01.2008
Typ/Model/Type Datum/Edition/Date
TL 80AS 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Inspection 8.25.02
Desired value Actual value Adjusted Remark
Engine, transmission,
brake, steering, loading
Engine, high idle
running speed min-1 2,350+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
Typ/Model/Type Datum/Edition/Date
TL 80 AS from sn 147 till XXX 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Test certificate 8.25.06
Inspection plan To be carried out by trained specialist dealer personnel
2)
30 Check or change hydraulic oil O O X 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
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
Typ/Model/Type Datum/Edition/Date
TL 100 from sn 647 till XXX 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Test certificate 8.26.07
Inspection plan
To be carried out by trained specialist dealer personnel
Typ/Model/Type Datum/Edition/Date
TL 70 (SKS 634) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Inspection plan 8.37.01
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
24 Check function of axle lock and vent cylinders O O
25 Check bearing bushings and bolts of work O O
equipment and replace if necessary
26 Check bushings and bolts of the articulation and the O O
articulated steering and replace if necessary.
27 Check that door catches function perfectly, and O O
replace if necessary
28 Clean or replace the dust filter for cab ventilation O X X
29 Check electrical indicating and warning elements, O O
and lighting system
30 Check smooth running of operator controls and O O
adjust if necessary
31 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.
32 Check or change hydraulic oil O O X 2) X
33 Replace insert of hydraulic oil return suction filter X X X
34 Replace breather X X
35 Check function of brakes and replace brake oil O O X X
36 Bleed brake O O
37 Rear axle differential with transmission / option: X O X 2) X
transmission: oil check or oil change
38 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)
39 X O X X
change
40 Grease machine according to overview of lubricating O O
points
41 Check function, condition and completeness of O O
safety equipment
42 Hydraulic function check with pressure function test O O
43 Test run and test work O O
44 Initial inspection cards and return to Manufacturer O O 4)
8.37.01/01.2007
TL 70 from serial no. TL00700250 till XXX
Typ/Model/Type Datum/Edition/Date
TL 70 from sn 250 till XXX 10.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Test certificate 8.37.05
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
Typ/Model/Type Datum/Edition/Date
TL 65 (SKL 824) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Operation 9.22.01
1 Direction indicator — horn — low/high beam (steering column mounted switch)
3 Accelerator pedal
disabled)
9 Parking brake
10 Socket
11 Fuse carrier
13 Radio
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
Typ/Model/Type Datum/Edition/Date
TL 65 (SKL 824) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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
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
Typ/Model/Type Datum/Edition/Date
TL 80 (SKL 834 / SKL 834 S) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Operation 9.24.01
1 Direction indicator — horn — low/high beam (steering column mounted switch)
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
Typ/Model/Type Datum/Edition/Date
TL 80 (SKL 834 / SKL 834 S) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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 —
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
9.24.02/01.2007
Typ/Model/Type Datum/Edition/Date
TL 80AS 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Operation 9.25.01
9.25.01/01.2008
Typ/Model/Type Datum/Edition/Date
TL 80AS 01.2008
Benennung/Description/Dénomination Blatt/Page/Feuille
Operation 9.25.02
9.25.02/01.2008
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
Typ/Model/Type Datum/Edition/Date
TL 100 (SKL 844 / SKL 844 S) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Operation 9.26.01
1 Direction indicator — horn — low/high beam (steering column mounted switch)
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
Typ/Model/Type Datum/Edition/Date
TL 100 (SKL 844 / SKL 844 S) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
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 —
OFF/Impulse/Continuous mode
26 Operating hour meter
49 not assigned *
27 Fuel gauge
50 Pre-heat/starter switch
28 GREEN — travel direction, reverse
51 Hazard warning switch
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
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
Repair instructions
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
Cylinder function Cylinder number Piston φ / Machine Type Assembly Tool Number
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
Cylinder function Cylinder number Piston φ / Machine Type Assembly Tool Number
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
Cylinder function Cylinder number Piston φ / Machine Type Assembly Tool Number
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
Typ/Model/Type Datum/Edition/Date
Cylinder Assembly General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Overview of Cylinder Assembly Tools 11.001.01
Driver’s cab with cemented window panes
Typ/Model/Type Datum/Edition/Date
TC – TL – TW 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Glue kit - cab window panes 11.300.01
“BETASEAL“ window pane glue kit part no. MCS008042A
11.300.01/01.2007