®

Form No.

521
50940187
Revison A
May 2013

Supersedes

Wheel Loader
0490030093

Service Manual

© 2013 Manitou Americas, Inc. • All Rights Reserved. • Printed in USA

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Hydrostatic drive – Tableof contents
22

Table of contents

Description Group

Specifications / controls
Servicing material, sealing kits, lubricants........................................................ 00
Engine.................................................................................................................... 01
Fuel lines ............................................................................................................... 08
Cooling .................................................................................................................. 15
Frame..................................................................................................................... 20
Hydrostatic drive .................................................................................................. 22
Front axle .............................................................................................................. 23
Brakes.................................................................................................................... 24
Rear axle................................................................................................................ 26
Steering system.................................................................................................... 27
Electrical system .................................................................................................. 33
Cab......................................................................................................................... 34
Hydraulic system.................................................................................................. 36
Cab heating ........................................................................................................... 41

SERV-HB 303 58 En - Edition 2.0 * 303sivz.fm

Specifications
Controls
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Specifications 520 / 620

Engine 620 (304 59) ➜❙ 304 59 0328
Frame
Product: Perkins diesel engine
sturdy U-section frame, rubber-mounted operator cab and engine
Model: 1004-4 HR
Engine Cylinder arran- In line
gement:
Engine 520 (303 58) ➜❙ 303 58 0477 Number of 4, water cooled
cylinders:
Product: Perkins diesel engine Capacity: 3990 cm3
Model: 1004-4 LR Nominal bore 100 x 127 mm
Cylinder arran- In line and stroke:
gement: Compression 16.5 : 1
Number of 4, water cooled ratio:
cylinders: Output: 58.5 kW / 79.5 HP, 2.200 rpm (DIN ISO3046)
Capacity: 3990 cm3 Rated engine 243 Nm
Nominal bore 100 x 127 mm torque:
and stroke: Max. engine 279 Nm, 1.400 rpm
Compression 16.5 : 1 torque:
ratio: Fuel consump- 230 g/KWh minimum
Output: 53 kW / 72 HP, 2.200 rpm (DIN ISO 3046) tion

Rated engine 230 Nm Fuel injection Direct fuel injection

torque: system:

Max. engine 270 Nm, 1.200 rpm Injection pres- 250 bar
torque: sure:

Fuel consump- 230 g/KWh minimum Firing order: 1–3–4–2

tion Start of deli- 17.5° before top dead centre
Fuel injection Direct fuel injection very:
system: Starting aid: Flame heater system (preheating time 10 – 15 seconds)
Injection pres- 250 bar Oil lubrication Max. lateral inclination left/right: 67/67 %
sure: of engine is Max. inclination upward/downward: 67/67 %
Firing order: 1–3–4–2 ensured up to
the following Observe tilting limit of the machine!
Start of deli- 17.5° before top dead centre inclined posi-
very: tion:
Starting aid: Flame heater system (preheating time 10 – 15 seconds) Oil pressure: Min. 2.1 bar minimum, 2,200 rpm
Oil lubrication Max. lateral inclination left/right: 67/67 % Valve tip clea- Inlet 0.20 mm
of engine is Max. inclination upward/downward: 67/67 % rance: Outlet 0.45 mm
ensured up to Engine at cold or warm temperature respectively
the following Observe tilting limit of the machine!
inclined posi-
tion:
Oil pressure: Min. 2.1 bar minimum, 2,200 rpm
Valve tip clea- Inlet 0.20 mm
rance: Outlet 0.45 mm
Engine at cold or warm temperature respectively

303s0002.fm
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Engine 520 (303 58) ❙➜ 303 58 0478 Engine 620 (304 59) ❙➜ 304 59 0329
Product: Perkins diesel engine Product: Perkins diesel engine
Model: 1004-4 Model: 1004-4
Cylinder arran- In line Cylinder arran- In line
gement: gement:
Number of 4, water cooled Number of 4, water cooled
cylinders: cylinders:
Capacity: 3990 cm3 Capacity: 3990 cm3
Nominal bore 100 x 127 mm Nominal bore 100 x 127 mm
and stroke: and stroke:
Compression 16.5 : 1 Compression 16.5 : 1
ratio: ratio:
Output: 53 kW / 72 HP, 2.200 rpm (DIN ISO 3046) Output: 58.5 kW / 79.5 HP, 2.200 rpm (DIN ISO3046)
Rated engine 230 Nm Rated engine 243 Nm
torque: torque:
Max. engine 270 Nm, 1.200 rpm Max. engine 279 Nm, 1.400 rpm
torque: torque:
Fuel consump- 230 g/KWh minimum Fuel consump- 230 g/KWh minimum
tion tion
Fuel injection Direct fuel injection Fuel injection Direct fuel injection
system: system:
Injection pres- 250 bar Injection pres- 250 bar
sure: sure:
Firing order: 1–3–4–2 Firing order: 1–3–4–2
Start of deli- 17.5° before top dead centre Start of deli- 17.5° before top dead centre
very: very:
Starting aid: Flame heater system (preheating time 10 – 15 seconds) Starting aid: Flame heater system (preheating time 10 – 15 seconds)
Oil lubrication Max. lateral inclination left/right: 67/67 % Oil lubrication Max. lateral inclination left/right: 67/67 %
of engine is Max. inclination upward/downward: 67/67 % of engine is Max. inclination upward/downward: 67/67 %
ensured up to ensured up to
the following Observe tilting limit of the machine! the following Observe tilting limit of the machine!
inclined posi- inclined posi-
tion: tion:
Oil pressure: Min. 2.1 bar minimum, 2,200 rpm Oil pressure: Min. 2.1 bar minimum, 2,200 rpm
Valve tip clea- Inlet 0.20 mm Valve tip clea- Inlet 0.20 mm
rance: Outlet 0.45 mm rance: Outlet 0.45 mm
Engine at cold or warm temperature respectively Engine at cold or warm temperature respectively

Low-emission engine 520 (option) Low-emission engine 620 (option)

Product: Perkins diesel engine Product: Perkins diesel engine
Model: 1004-42 Model: 1004-42
Rated output: 53 kW / 72 HP, 2200 rpm (DIN ISO 9249) Rated output: 60 kw / 81.5 HP, 2,200 rpm (ISO 9249)

303s0002.fm
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Power train Hydrostatic drive 620 (304 59).

Hydrostatic power train with drive automatic and permanent four wheel Drive pump: Direct flanged to the engine,
drive. High-speed gearbox available as an option. Model: 90R055 DKDB4 H7C6 DXX BXX 404018
Displacement: Max. 55 cm3/rev
Hydrostatic drive 520 (303 58).
Max. service 465 bar
Drive pump: Direct flanged to the engine, pressure (∆p):
Model: 90R055 DKDB4 H7C6 DXX BXX 404018 Starting RPMs: 1,000 – 1,100 +100 rpm, 50 bar HP
Displacement: Max. 55 cm3/rev Droop: 2,050-2,150 +100 rpm, 430+40 bar HP
Max. service 465 bar Boost pump: Displacement: 17 cm3/rev
pressure (∆p): Charging pressure:25 bar
Starting RPMs: 1,000 – 1,100 +100 rpm, 50 bar HP Control: Speed-sensitive hydraulic adjustment of displacement
Droop: 2,050-2,150 +100 rpm, 430+40 bar HP Drive direction: Electrohydraulic control
Boost pump: Displacement: 17 cm3/rev Inching: Hydraulic inching valve, controlled via the master brake
Charging pressure:25 bar cylinder
Control: Speed-sensitive hydraulic adjustment of displacement Hydraulic Attached to the rear axle intermediate gearbox
Drive direction: Electrohydraulic control motor:
Inching: Hydraulic inching valve, controlled via the master brake Variable dis- 51D110 AD3N K1A3 CEB9 NNN 034AA18 1219
cylinder placement
motor model
Hydraulic Attached to the rear axle intermediate gearbox
motor: Capacity: Min. 34 cm3/rev
max. 110 cm3/rev
Variable dis- 51D110 AD3N K1A3 CEB9 NNN 034AA18 1219
placement Control: Speed and pressure-sensitive automotive control
motor model Drive speed: Low speed
Capacity: Min. 34 cm3/rev forward – reverse 0 – 5 kph
max. 110 cm3/rev High speed
forward – reverse0 – 20 kph
Control: Speed and pressure-sensitive automotive control
High speed Low speed
Drive speed: Low speed (option) via forward – reverse0 – 9.5 kph
forward – reverse 0 – 5 kph mechanical High speed
High speed standstill trans- forward – reverse0 – 39 kph
forward – reverse0 – 20 kph fer gearbox
High speed Low speed Traction force: 54.5 kN
(option) via forward – reverse0 – 9.5 kph
mechanical High speed
standstill trans- forward – reverse0 – 39 kph
fer gearbox
Traction force: 52.8 kN

303s0002.fm
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Axles Steering

Front axle Hydraulic four wheel power steering with emergency steering features.

ZF planetary steering and drive axle, screwed down to the frame of the Steering Four wheel steering
vehicle; planetary gear reductions in the wheel hubs; hydraulic fixed-calliper modes: Front wheel steering: High speed version: 2nd speed
disc brake in the 40 kph version; 100% differential lock, engaged electrohy- allows for front axle steering only!
draulically and automatically when the service brake is used; integrated
Components: Manual pump; hydraulic pump; 2 steering rams; safety val-
steering ram.
ves; solenoid valve for steering synchronization, priority
Track width: 1518 mm valve.

Camber: 1° Manual pump: Eaton servostat

Displacement 70 ltr./min
King-pin incli- 10° Service pressure 170 bar
nation:
Hydraulic Gear pump (priority valve)
pump: Displacement 33 cm3/rev
Rear axle
Hydraulic rams ZF
ZF planetary steering and drive axle (as front axle), however with axle
casing with oscillation above the centre; service brake: hydraulic fixed-calli- Maximum ±43°
per disc brake in the 20 kph and 40 kph version; parking brake: calliper steering angle
brake acting on service brake disc; 1-speed (20 kph version) or 2-speed (40
kph version) transfer gearbox. Work hydraulics
Oscillation: ± 9° Hydraulic Gear pump
Track width: 1,518 mm pump Displacement 33 cm3/rev
max. 70 ltr/min
Camber: 1°
Service pressure 235 bar
King-pin incli- 10°
Control valve: Nordhydraulik 3-fold pilot control
nation:
Secondary Tilt ram rod side260 bar
Axle load safety: bottom side100 bar

front and rear 4,600 kg max.

Pilot control
Brakes
Pilot control Displacement: 14 cm³/rev (20 ltr./min)
Service Disc brake at rear axle input (high speed version: also on pump = boost Charging pressure25 bar, 1,100 rpm
front axle) pump of
brake:
hydraulic pump
Components: Master brake cylinder, pressure difference valve, brake
Pilot control Four-way lever – control of lift and tilt rams
calliper, differential lock, (inching valve on power train)
unit (joystick):
Brake fluid: See section engine/vehicle fluids and lubricants
Pilot control Control of lock ram and implements
Additional brake force via the hydrostatic drive! unit (simple):
Ball-type stop Lock against unintentional actuation (for long-haul travel
cock: and transport)
Mechanical disc brake mounted on rear axle, acting to both
Parking axles via propshaft
brake:
Outside diame- Ø 270 mm
ter of brake
disc:

303s0002.fm
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Loader unit Movable payload in transport

position
Loader unit 520 factor 1.25: 3,300 kg

Bucket capacity heaped as per SAE 0.871 Electrical system

m3
Alternator 12 V, 65 A
Tipping load 3.820 kg
Starter 12 V, 2.8 kW
Payload 1.910 kg (tipping load x 0.5)
Battery 12 V, 100 Ah
Lift load at max. height 2,970 kg
Socket eg for cigarette lighter; 15 A max.
Bucket width 1,950 mm
Dumping height 2.620 mm
Tyres
Dumping reach 760 mm
Scraping depth -66 mm
Tyres 520 (303 58)
Tilt-back angle 50°
Dump-out angle -45° Tyre size Tyre pressure Wheel rims
(bar)*
Breakout force (lift ram) 36.8 kN (hydr. 46.0 kN)
front rear Wheel rim Wheel offset
Breakout force (tilt ram) 43.1 kN
14.5-20 MPT E91-2 10PR 132 2.25* 1.75* 11 x 20 90 mm
Payload on pallet forks
E
Tipping load (DIN 24 094): 3,000 kg
365/80 R20 SPT9 141B 2.75* 2.25* 11 x 20 90 mm
Payload factor 1.25: 2,400 kg
405/70 R20 SPT9 143B** 2.75* 2.00* 11 x 20 90 mm
factor 1.67: 1,800 kg
13 x 20 67 mm
Movable payload in transport position
factor 1.25: 405/70 R20 XM27 136G** 3.50* 2.00* 11 x 20 90 mm
3,000 kg 13 x 20 67 mm
425/75 R20 XM27 148E** 2.25* 1.75* 11 x 20 90 mm
Loader unit 620
* Increase tyre pressure by 0.5 bar during pallet forks operation!
** Requires steering angle limitation on front and rear axles!
Bucket capacity heaped as per SAE 0.922 m3
Tipping load 4,080 kg
Tyres 620 (304 59)
Payload 2,040 kg (tipping load x 0.5)
Lift load at max. height 2,980 kg Tyre size Tyre pressure Wheel rims
(bar)*
Bucket width 2,050 mm
front rear Wheel rim Wheel offset
Dumping height 2,610 mm
16/70-20 EM 10PR NB 38 2.25* 1.75* 13 x 20 67 mm
Dumping reach 767 mm
16/70-20 E91-2 10PR 141B 2.25* 1.75* 13 x 20 67 mm
Scraping depth -74 mm
405/70 R20 SPT9 143B 2.75* 2.25* 11 x 20 90 mm
Tilt-back angle 50°
13 x 20 67 mm
Dump-out angle -45°
455/70 R20 SPT9 150B** 2.25* 1.75* 13 x 20 67 mm
Breakout force (lift ram) 39.1 kN (hydr. 45.9 kN)
425/75 R20 XM27 148E** 2.50* 1.75* 11 x 20 90 mm
Breakout force (tilt ram) 43.0 kN
13 x 20 67 mm
Payload on pallet forks
* Increase tyre pressure by 0.5 bar during pallet forks operation!
Tipping load (DIN 24 094): 3,250 kg
** Requires steering angle limitation on front and rear axles!
Payload factor 1.25 2,600 kg
factor 1.67: 1,950 kg

303s0002.fm
 Specifications wheel loaders 520 / 620 (models 303 58 / 304 59)

Weights Tightening torques

Weights 520 (303 58) Screw Tightening torques in Nm)*

dimensions 8.8 10.9 12.9
Kerb weight: 5,580 kg (daN)* M4 3 5 5
Gross weight rating: 6,500 kg M5 6 9 10
Gross front axle weight rating: 4,600 kg M6 10 15 18
Gross rear axle weight rating: 4,600 kg M8 25 35 45
Max. authorized load for towing device 6,500 kg M10 50 75 83
* Values indicated are valid for machines equipped with standard bucket. M12 88 123 147
M14 137 196 235
Weights 620 (304 59)
M16 211 300 358
Kerb weight: 5,780 kg (daN)* M18 290 412 490
Gross weight rating: 6,500 kg M20 412 578 696
Gross front axle weight rating: 4,600 kg M22 560 785 942
Gross rear axle weight rating: 4,600 kg M24 711 1000 1200
Max. authorized load for towing device 6,500 kg M27 1050 1480 1774
* Values indicated are valid for machines equipped with standard bucket. M30 1420 2010 2400
* These values are valid for screws with untreated, non-lubricated sur-
Noise levels faces.

Measuring method Specific tightening torques

statica dynamicb Wheel nut 420 ±20 Nm
Sound power level 303 58 (520) 97 dB (A) 98 dB(A) Castle nut (steering ram track rod) 150 Nm
Sound power level 304 59 (620) 97 dB (A) 97 dB (A)
Noise level in the cab 72 dB(A) 75 dB(A) Coolant compound table
Noise measurement carried out in accordance with EC guidelines
84/532 EEC, 86/662 EEC, Annex I and II (static and dynamic), Outside Coolant
and 79/113 EEC Annex (idling speed) at rated speed of the diesel temperature Water Anticorrosion agent Antifreeze agent
engine. Measurements carried out on an asphalted surface.
up to °C by volume% cm³/ltr by by volume%
a. valid up to 31.12.97 included
b. valid as of 01.01.98 volume%
4 99 10 1 -
Vibration -10 79 20
-20 65 34
Effective acceleration value for the upper extremi- <2.5 m/s²
ties of the body -25 59 40

Effective acceleration value for the body <0.5 m/s² -30 55 44

303s0002.fm