Wacker Neuson 701s 701sp Compact Loaders Service Manual – PDF DOWNLOAD
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Wacker Neuson 701s 701sp Compact Loaders Service Manual – PDF DOWNLOAD
Language : English
Pages : 301
Downloadable : Yes
File Type : PDF
Size: 13.6 MB
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DESCRIPTION:
Wacker Neuson 701s 701sp Compact Loaders Service Manual – PDF DOWNLOAD
Operation:
1.1 Important information on this service manual:
This service manual contains important information on how to service your machine safely,
correctly and economically. Therefore, it aims not only at new operators, but it also serves
as a reference for experienced ones. Your knowledge and skills will help to avoid
dangerous situations and reduce repair costs and downtimes, Furthermore, the reliability
and the service life of the machine will be increased by following the instructions in the
service manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine.
Insist on using original spare parts when carrying out maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
Your Wacker Neuson After-Sales Service will be pleased to answer any further questions
regarding the machine or the service manual.
TABLE OF CONTENTS:
Wacker Neuson 701s 701sp Compact Loaders Service Manual – PDF DOWNLOAD
A 11
F 11
I 11
M 11
O 11
R 11
S 11
1 Operation 14
1 1 Important information on this service manual 14
1 2 Identification of warnings and dangers 15
1 3 Designated use and exemption from liability 16
1 4 Type labels and component numbers 17
1 5 Machine overview 19
1 6 Cab overview 20
1 7 Cab (legend) 20
1 8 Round indicating instrument overview 21
1 9 Round indicating instrument (legend) 21
1 10 Engine compartment overview 22
701s 22
701sp 23
1 11 Engine cover (open): overview 24
701s 24
701sp 25
1 12 Chassis overview 26
1 13 Tilting the cab 27
2 Specifications 30
2 1 Chassis 30
2 2 Engine 30
Fuel injection pump 32
Capacity 32
Tightening torque 32
2 3 Travelling drive 33
2 4 Brakes 33
2 5 Work hydraulics 33
2 6 Pilot control 34
2 7 Additional control circuit + 3rd control circuit 34
2 8 Electric units 35
Fuse box in instrument panel 35
Main fuse box with relays 35
Relays 35
2 9 Tyres 36
2 10 Noise levels 36
2 11 Vibration 36
2 12 Coolant compound table 36
2 13 Dimensions 37
2 14 Model-specific tightening torques 38
2 15 General tightening torques 38
Tightening torques for hydraulic screw connections (dry assembly) 38
Tightening torques for high-resistance screw connections 40
3 1 Fluids and lubricants 42
Additional oil change and filter replacement (hydraulics) 43
3 2 Maintenance label 44
Explanation of symbols on the maintenance label 44
3 3 Maintenance plan (overview) 46
3 4 Introduction 49
3 5 Fuel system 50
Specific safety instructions 50
Refuelling 50
Stationary fuel pumps 51
Diesel fuel specification 51
Bleeding the fuel system 51
Emptying the fuel tank 52
Fuel prefilter with water separator 52
Replacing the fuel filter 53
3 6 Engine lubrication system 54
Checking the oil level 54
Filling up engine oil 55
Changing engine oil 55
Replacing the engine oil filter cartridge 57
3 7 Cooling system 58
Specific safety instructions 58
Checking/filling up coolant 59
Draining coolant 60
3 8 Air filter 61
Replacing the filter 62
Functional check once a week of the dust valve 63
3 9 V-belt 64
Checking V-belt tension 64
Retightening V-belt 65
3 10 Pressure check 66
General 66
Standard micro ports 66
Variable displacement pump measuring points 67
Preparatory work 69
Main pressure check (P1 & P2) 69
Boost pressure check of pump and pilot control pressure check of work hydraulics 70
Work hydraulics pressure check 71
Checking the pilot control pressure of the drive hydraulics 72
Checking the parking brake release pressure 72
Checking the speed-sensitive control pressure 73
Checking the pressure of the 3rd control circuit (Power Flow option 701sp) 73
3 11 Test report 701s 74
3 12 Test report 701sp 76
3 13 Hydraulic system 78
Specific safety instructions 78
Checking the hydraulic oil level 79
Bleeding the hydraulic pump 80
Filling up hydraulic oil 80
After changing the hydraulic oil 81
Changing hydraulic oil 81
Monitoring the hydraulic oil reflux filter 82
Replacing the reflux filter 82
Checking hydraulic pressure lines 83
3 14 Travelling drive 84
Checking the oil level and filling up oil 84
Draining oil 84
3 15 Tyre maintenance 85
Tyre check 85
Wheel change 85
Raising and jacking up the machine 86
Removing the wheels 86
Mounting the wheels 86
3 16 Lubrication work 87
Loader unit 87
Lubrication points on the bucket 87
Maintenance of attachments 87
3 17 Electrical system 88
Specific safety instructions 88
Service and maintenance work at regular intervals 88
Instructions concerning specific components 89
Alternator 89
Battery 90
Jump-starting the engine 90
3 18 General maintenance work 91
Cleaning 91
General instructions for all areas of the machine 91
Inside the cab 92
Exterior of the machine 92
Engine compartment 92
Screw connections and attachments 92
Pivots and hinges 92
4 1 Engine 95
Turbocharged engine 4TNV84T-XNSS Power Flow (up to serial no DB00708) 95
Engine 4TNV88-XNSS (up to serial no DB00708) 97
4 2 Fuel system 99
4 3 Checking and adjusting valve clearance 100
Valve clearance 4TNV88-XNSS (8 valves) 100
Valve clearance 4TNV84T-XNSS (16 valves) 101
4 4 Tightening order for cylinder head bolts 102
4 5 Checking the injection nozzles 103
Pressure check 103
Injection nozzle 4TNV88-XNSS (8 valves) 103
Injection nozzle 4TNV84T-XNSS (16 valves) 103
4 6 Checking the nozzle jet 104
4 7 Injection time 104
Checking injection time 104
Setting injection time 105
Replacement of fuel injection pump 106
4 8 Manual/pedal throttle 107
4 9 Adjusting engine speed 107
4 10 Compression 108
4 11 Checking the coolant thermostat 108
4 12 Checking the thermal switch 109
4 13 Oil pressure switch 109
4 14 Checking the coolant circuit 109
4 15 Turbocharger RHB 31 110
Tolerance values 111
4 1 Engine (tier 3) 112
4TNV88-BKNSS (from serial no DC00713) 112
Turbocharged engine 4TNV84T-ZKNSS (from serial no DC00713) 114
4 2 Fuel system 116
4 3 Removing the valve cover 117
4 4 Checking and adjusting valve clearance 117
Valve clearance 4TNV88-BKNSS (8 valves) 117
Valve clearance 4TNV84T-ZKNSS (16 valves) 118
4 5 Tightening order for cylinder head bolts 119
4 6 Checking the injection nozzles 120
Pressure check 120
Injection nozzle 4TNV88-BKNSS (8 valves) 120
Injection nozzle 4TNV84T-ZKNSS (16 valves) 120
4 7 Checking the nozzle jet 121
4 8 Injection time 121
Checking injection time 121
Setting injection time 123
Replacement of fuel injection pump 124
4 9 Manual/pedal throttle 125
4 10 Adjusting engine speed 125
4 11 Compression 126
4 12 Checking the coolant thermostat 126
4 13 Checking the thermal switch 127
4 14 Oil pressure switch 127
4 15 Checking the coolant circuit 127
4 16 Turbocharger RHB 31 128
Tolerance values 129
4 17 Engine trouble 130
4 18 Electronic engine control unit (E-ECU) 4TNV84T-ZKNSS 132
Turbocharged engine 4TNV84T-ZKNSS (from serial no DC00713) 132
Features 132
4 19 Engine error codes 133
4 20 Error diagnosis 137
E-ECU connector assignment 137
Important information on the ECU maintenance wiring harness 138
Flash code 7 – proportional injection pump solenoid (control rack) 139
Related DTC (Diagnostic Trouble Codes) 139
Diagnosis description 141
Flash code 5 – manual throttle 143
Related DTC 143
Work description 145
Flash code 4-1 ECU internal 146
Related DTC 146
Work description 147
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm 148
Related DTC 148
Work description 149
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm 150
Related DTC 150
Work description 152
Flash code 2-4 – sensor 5 V 154
Related DTC 154
Work description 155
Flash code 2-3 – power supply voltage 157
(1) P0562/1: power supply voltage error (voltage too low) 157
DTC detection conditions 157
Troubleshooting 157
Diagnosis description 157
(2) P0563/0: power supply voltage error (voltage too high) 158
DTC detection conditions 158
Troubleshooting 158
Diagnosis description 158
Flash code 6 – engine speed sensor 159
Work description 161
Flash code 1-1 – backup engine speed sensor 162
Related DTC 162
Work description 164
Flash code 9 – overspeed error 165
(1) P0219/0: overspeed error 165
DTC detection conditions 165
Troubleshooting 165
Diagnosis description 165
Flash code 1-7 – proportional solenoid relay of the injection pump (control rack) 166
Related DTC 166
Work description 168
Flash code 1-5 – preheating relay 170
Related DTC 170
Work description 171
Flash code 1-4 – CSD (cold start device) solenoid coil 174
Related DTC 174
Work description 175
Flash code 1-3 – EGR (exhaust gas recirculation) valve 177
Related DTC 177
Work description 179
Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error 181
Related DTC 181
Work description 183
Flash code 8 – proportional injection pump solenoid (control rack) 185
Related DTC 185
Work description 187
Flash code 1-6 – main relay 189
Related DTC 189
Work description 191
Flash code 1-2 – CAN (Controller Area Network) communication 193
Related DTC 193
Work description 194
5 Hydraulic system 197
5 1 Rexroth A20 – VG45 hydraulic pump 197
Pump unit: exploded view 199
Pump distribution 200
5 2 Main valve block 201
Ports 201
Legend 201
Main valve block diagram 202
5 3 Hydraulic control 203
Control lever 203
Joystick (left) 204
Joystick (right) 207
Auxiliary hydraulics control 210
Function 210
Adjustment 210
5 4 Travelling drive 211
Function 211
Drive (exploded view) 211
Front drive gear 213
Rear drive gear (braked) 214
Travelling drive layout 215
5 5 Valves 216
3/3 directional valve (flush valve) 216
5 6 Parallel bucket lift 217
Function 217
Layout 218
5 7 Breather filter 219
5 8 Troubleshooting in the hydraulic system 220
5 9 Hydraulics diagram A4 (701s) 221
5 10 Hydraulics diagram (legend) (701s) 222
5 11 Hydraulics diagram A4 (701sp) 223
5 12 Hydraulics diagram (legend) (701sp) 224
5 13 Hydraulics diagram H-controls A4 (701sp) 225
5 14 Hydraulics diagram H controls (701sp) (legend) 226
5 15 Hydraulics diagram H-controls with lock A4 (701sp) 227
5 16 Hydraulics diagram H controls with lock (701sp) (legend) 228
5 13 Hydraulics diagram 701s A3 up to serial no DB00708 229
5 14 Hydraulics diagram 701sp A3 up to serial no DB00708 230
5 15 Hydraulics diagram 701s A3 from serial no DC00713 231
5 16 Hydraulics diagram 701sp A3 from serial no DC00713 232
5 17 Hydraulics diagram H-controls 701 sp A3 233
5 18 Hydraulics diagram H-controls with lock 701 sp A3 234
6 Electrical system 236
6 1 Ohm’s Law (current, voltage, resistance); power 236
6 2 Measuring equipment, measuring methods 236
6 3 Cable colour coding 238
6 4 Relays 238
Use, mode of function 238
6 5 Electric units 239
Fuse box in instrument panel 239
Main fuse box with relays 239
Relays 239
6 6 Socket 240
6 7 Turn indicators (option) 240
6 8 Round indicating instrument overview 241
6 9 Switches: overview 242
6 10 Alternator 242
6 11 Starter 243
6 12 Wiring diagram up to serial no DB00708 (legend) 245
6 13 Wiring diagram up to serial no DB00708 246
6 14 Wiring diagram from serial no DC00713 (legend) 247
6 15 Wiring diagram from serial no DC00713 248
6 16 701s engine – chassis wiring harness 1000147293 up to serial no DB00708 (legend) 250
6 17 701s engine – chassis wiring harness 1000147293 up to serial no DB00708 251
6 18 701s engine – chassis wiring harness 1000183063 from serial no DC00713 (legend) 252
6 19 701s engine – chassis wiring harness 1000183063 from serial no DC00713 253
6 20 701sp engine – chassis wiring harness 1000185442 from serial no DC00713 (legend) 254
6 21 701sp engine – chassis wiring harness 1000185442 from serial no DC00713 255
6 22 Switches wiring harness 1000139289 up to serial no DB00708 (legend) 256
6 23 Switches wiring harness 1000139289 up to serial no DB00708 257
6 24 701s switches wiring harness 1000183064 from serial no DC00713 (legend) 258
6 25 701s switches wiring harness 1000183064 from serial no DC00713 260
6 26 701sp switches wiring harness 1000185268 from serial no DC00713 (legend) 261
6 27 701sp switches wiring harness 1000185268 from serial no DC00713 263
6 28 Wiring harness 1000147262: rear lights (option) 264
6 29 Wiring diagram up to serial no DB00708 (legend) 266
6 30 Wiring diagram up to serial no DB00708 267
6 31 Wiring diagram from serial no DC00713 (legend) 268
6 32 Wiring diagram from serial no DC00713 269
6 33 701s engine – chassis wiring harness 1000147293 up to serial no DB00708 (legend) 271
6 34 701s engine – chassis wiring harness 1000147293 up to serial no DB00708 272
6 35 701s engine – chassis wiring harness 1000183063 from serial no DC00713 (legend) 273
6 36 701s engine – chassis wiring harness 1000183063 from serial no DC00713 274
6 37 701sp engine – chassis wiring harness 1000185442 from serial no DC00713 (legend) 275
6 38 701sp engine – chassis wiring harness 1000185442 from serial no DC00713 276
6 39 Switches wiring harness 1000139289 up to serial no DB00708 (legend) 277
6 40 Switches wiring harness 1000139289 up to serial no DB00708 278
6 41 701s switches wiring harness 1000183064 from serial no DC00713 (legend) 279
6 42 701s switches wiring harness 1000183064 from serial no DC00713 280
6 43 701sp switches wiring harness 1000185268 from serial no DC00713 (legend) 281
6 44 701sp switches wiring harness 1000185268 from serial no DC00713 282
6 45 Wiring harness 1000147262: rear lights (option) A3 283
7 Options 286
7 1 Rear working light 286
Wiring harness 286
Connections 286
7 2 BP – Biohyd SE 46 287
Properties 287
7 3 Biodegradable oil Panolin 287
Properties 287
7 4 Rearview mirror package 287
7 5 Drive interlock (antitheft protection) 288
Machine 288
Disabling the drive interlock 288
Enabling the drive interlock 288
Programming 288
7 6 Rotating beacon 289
Wiring harness 290
Connections 290
7 7 Crane-handling bracket 291
7 8 FOPS roof level 2 292
7 9 Backup warning system 293
Function 293
Position 293
7 10 Side window 294
Attachment 294
7 11 Full cab glazing (option) 295
7 12 Stabilisers 296
7 13 Road travel certification 297
7 14 Airboss tyres 298
Attachment 298
7 15 Power Flow ports 298
Couplings 299
PLEASE NOTE:
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