Service Manual
Track excavator
Machine model
8 00 3
Edition
1 .0
Language
English
Article number
1 00 0 13 28 26
Documentation Description
Order no.
Operation manual
10 00 13 2 13 6
Service Manual
10 00 1 32 82 6
Spare parts list
1000137282
Legend Edition
I s s ue d
1 .0
0 2 /2 0 0 5
Copyright – 2004 Neuson Baumaschinen GmbH, Linz-Leonding Printed in Austria All rights reserved No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior permission in writing from Neuson Baumaschinen GmbH. The cover features the machine with possible optional equipment.
Neuson Baumaschinen GmbH Haidfeldstrasse 37 A-4060 Linz-Leondin g Document: Order no.: Edition:
SERV-HB 8003 En 1 00 0 13 28 26 1 .0
Inhaltsverzeichnis Operation Important information on this service manual .......................................................... 1-1 Abbreviations/symbols .......................................... ...................... ......................................... ............................................ ......................... 1-1 Identification of warnings and dangers ........................................... ...................... ........................................... ......................... ... 1-2 Designated use and exemption from liability ......................................... ..................... ...................................... .................. 1-3 Type labels and component numbers ...................................................................... 1-4 Serial number .................................................................................................... 1-4 Cab number ....................................................................................................... 1-4 Engine number .................................................................................................. 1-4 Hydraulic pump number ........................... ..... ........................................... ........................................... .................................... .............. 1-5 Main valve block number ................................................................................... 1-5 Travelling drive number ..................................................................................... 1-5 Swivel unit number ............................................................................................ 1-5 Machine: overview ................................................................................................... 1-6 Cab: overview .......................................................................................................... 1-7 Cab: legend .................... ........................................... .................... ............................................ ........................................... ......................... ... 1-8 Instrument panel: overview ...................................................................................... 1-9 Instrument panel: legend ....................................................................................... 1-10 Engine compartment: overview .......................... ... ............................................ ........................................... .............................. ........ 1-11 Chassis: overview .................................................................................................. 1-12 Tilting the cab ............................... .......... ........................................... ........................................... ........................................... .............................. ........ 1-13 Summer/winter operation ....................................................................................... 1-15 Pedal for auxiliary hydraulics/swivelling and rotating the boom ............................. 1-16 Specifications Chassis .................................................................................................................... 2-1 Engine ...................................................................................................................... 2-1 Hydraulic system ....................... ............................................. ....................... ............................................. ................................. .......... 2-2 Undercarriage and swivel unit ......................................... .................... .......................................... ........................................ ................... 2-3 Stabiliser blade ........................................................................................................ 2-3 Electric system ......................................................................................................... 2-4 Noise levels ........................................ ................... ........................................... ........................................... ........................................... ......................... ... 2-5 Coolant compound table .......................................................................................... 2-5 Model-specific tightening torques ................................ ........... ......................................... ........................................... ......................... 2-6 General tightening torques ............................. ...... ........................................... ........................................... ..................................... .............. 2-6 Dimensions model 8003 .......................................................................................... 2-9 Lift capacity table 8003 .......................................................................................... 2-11 Lift capacity table 8003 with extended dipper arm ................................................. 2-12 Lift capacity table 8003 with counterweight ........................................ .................... ....................................... ................... 2-13 2 -13 Lift capacity table 8003 with extended dipper arm and counterweight .................. 2-14 Lift capacity table 8003 Vario (option) ........................................... ...................... .......................................... ........................ ... 2-15 Kinematics ............................................................................................................. 2-16 Maintenance Fluids and lubricants ............................................ ..................... ............................................ ............................................ .............................. ....... 3-1 Maintenance label .................................................................................................... 3-3 Maintenance plan (overview) ................................................................................... 3-5 Service package ...................................................................................................... 3-9 Introduction .............................................................................................................. 3-9 Fuel system ........................... ........................................... ....................... ......................................... ..................................... ................ 3-10 General ............................................................................................................ 3-10 Refuelling from barrels ............................. ....... ........................................... ............................................ .................................. ........... 3-11 Engine lubrication system ...................................................................................... 3-14 Checking the oil level ....................................................................................... 3-14 Cooling system ...................................................................................................... 3-18 ......................................................................................................................... 3-19 SERV-HB 8003 En - Ausgabe 1.0 *8003s11IVZ.fm
I-1
Checking the coolant level ............................................................................... 3-19 Filling up coolant .............................................................................................. 3-20 Air filter .......................................... ..................... ............................................ ............................................ ............................................ ............................. ...... 3-21 3-2 1 V-belt ...................................................................................................................... 3-24 Pressure check ...................................................................................................... 3-27 Test report .............................................................................................................. 3-31 Hydraulic system .................................................................................................... 3-35 Travelling drive ....................................................................................................... 3-40 Chains .................................................................................................................... 3-41 Electric system ....................................................................................................... 3-44 Cab ........................................................................................................................ 3-47 General maintenance work .................................................................................... 3-48 When using washing solvents ......................................... .................... ......................................... ................................ ............ 3-48 When using compressed air ............................................................................ 3-48 When using a high-pressure cleaner or steam jet ....................................... ................... ........................ .... 3-48 When using volatile and easily flammable anticorrosion agents and sprays ... 3-48 Cleaning the seat belt ...................................................................................... 3-49 Engine 4TNV98 engine: overview ........................................................................................ 4-1 Fuel system .............................................................................................................. 4-3 Removing the cylinder-head cover .......................................... ..................... ......................................... ................................ ............ 4-4 Checking and adjusting valve tip clearance ............................................................. 4-4 Tightening order for cylinder head bolts ................................................................... 4-6 Checking the injection nozzles ................................................................................. 4-7 Checking the nozzle jet ............................................................................................ 4-7 Injection time ............................................................................................................ 4-8 Adjusting engine revs ................................... ............ ............................................. ........................................... ...................................... ................. 4-9 Compression ............................................................................................................ 4-9 Checking the coolant thermostat .......................................... ...................... ....................................... ................................. .............. 4-10 Checking the thermal switch .................................................................................. 4-10 Oil pressure switch ................................................................................................. 4-11 Checking the coolant circuit ................................................................................... 4-11 Engine trouble ........................ .... .......................................... .......................................... ........................................ ..................................... ................. 4-12 Hydraulic system Hydraulic pump AP2D36LV3RS6-874-P AP2D36LV3RS6-874 -P .......................... ...... ....................................... ....................................... .................... 5-1 Main valve block ........................ ... ........................................... ........................................... .......................................... ................................... .............. 5-7 Drive counterbalancing system .............................................................................. 5-14 Boom summation – raise ........................... ...... ........................................... ........................................... ...................................... ................. 5-17 Boom check valve (load retaining valve) ....................................... ................... ......................................... ........................ ... 5-18 Dipper arm cylinder summation .......................................... ..................... ......................................... ................................... ............... 5-19 Dipper arm check valve (load retaining valve) ....................................................... 5-20 Secondary pressure limiting valves for the auxiliary hydraulics (option) ................ 5-21 Pilot valves ............................................................................................................. 5-22 Valves .................................................................................................................... 5-27 Drive up to serial number: AC 02956 ..................................................................... 5-34 Auto2Speed drive d rive starting serial no.: AC 02957 0 2957 ........................................ .................... ................................ ............ 5-36 Swivel unit .............................................................................................................. 5-40 Swivel joint ............................................................................................................. 5-46 Breather filter ....................... ........................................... ..................... ........................................... ....................................... .................. 5-47 Troubleshooting in the hydraulic system ................................................................ 5-48 Hydraulics diagram A4 ........................................................................................... 5-49 Hydraulics diagram (legend) .................................................................................. 5-50 Hydraulics diagram ................................................................................................ 5-51 Main valve block diagram ........................................... ..................... ........................................... ........................................... ...................... 5-52 Electric system
I-2
SERV-HB 8003 En - Ausgabe 1.0 * *8003s11IVZ.fm
Ohm's Law (current, voltage, resistance); power ..................................................... 6-1 Measuring equipment, measuring methods ............................................................. 6-1 Cable colour coding ................................................................................................. 6-3 Relays ...................................................................................................................... 6-3 Electric units ....................... ............................................ ....................... ........................................... ......................................... ................... 6-4 Fuse box in instrument panel ................................................................................... 6-4 Main fuse box with relays ......................................... .................... .......................................... ........................................... .......................... .... 6-4 Relays ...................................................................................................................... 6-5 Socket ...................................................................................................................... 6-5 Joystick tip switches ............................ ........ ........................................... ............................................ ........................................... .......................... 6-6 Instrument panel: overview ...................................................................................... 6-7 Switches: overview .................................................................................................. 6-8 Alternator ....................................... .................. ........................................... ........................................... ............................................ ............................... ........ 6-9 Starter ...................................................................................................................... 6-9 Wiring diagram A4: legend .......................................... ..................... .......................................... .......................................... ..................... 6-12 Wiring diagram A4 ........................................ .................. ........................................... .......................................... .................................... ............... 6-13 Wiring harness 1000116497 (legend): engine – chassis A4 ................................. .................. ............... 6-14 6 -14 Wiring harness 1000109697: engine – chassis A4 ................................................ 6-15 Wiring harness 1000125106 (legend): switches A4 ....................................... .................. ............................ ....... 6-16 Wiring harness 1000125106: switches A4 ............................................................. 6-17 Wiring harness 1000109629: cab roof ................................................................... 6-18 Wiring harness 1000109628: armrest .................................................................... 6-19 Wiring harness 1000116138: boom working light .................................................. 6-20 Wiring diagram A3: legend ......................................... .................... .......................................... .......................................... ..................... 6-22 Wiring diagram A3 ........................................... .................... ........................................... ........................................... ................................. .......... 6-23 Wiring harness 1000109624 (legend): engine – chassis A3 ................................. .................. ............... 6-24 6 -24 Wiring harness 1000109624: engine – chassis A3 ................................................ 6-25 Wiring harness 1000125106 (legend): switches A3 ....................................... .................. ............................ ....... 6-26 Wiring harness 1000125106: switches A3 ............................................................. 6-27 Wiring harness 1000109629: cab roof A3 ......................... ...... ...................................... .................................... ................. 6-28 Wiring harness 1000109628: armrest A3 ...................... ... ....................................... ........................................ .................... 6-29 Wiring harness 1000116138: boom working light A3 ........................................ ................... ......................... .... 6-30 Options Air conditioning .......................................... ................... ........................................... ......................................... .......................................... ..................... 7-1 Air-suspension seat ........................................... .................... ........................................... ........................................... .................................. ........... 7-9 Counterweight .......................................................................................................... 7-9 Extended dipper arm .................................. ........... ........................................... ......................................... ......................................... .................... 7-9 Control circuit (pipework) connections for grab ......................................... ................... .................................. ............ 7-10 3rd control circuit connections ............................................................................... 7-10 Auxiliary hydraulics connections connection s ......................... .. ........................................... ........................................... ............................... ........ 7-11 Neuson Vario ......................................................................................................... 7-12 Fuel-filling pump ..................... ........................................... ...................... .......................................... .................................... ............... 7-16 Central lubrication system ........................... .... ........................................... ......................................... ...................................... ................. 7-18 Safe load indicator D (safety valve for boom) ........................................................ 7-22 Safe load indicator F (safety valves for boom and dipper arm) ............................. .................... ......... 7-24 Drive interlock (antitheft protection) ....................................................................... 7-27 Quickhitch facility ................................................................................................... 7-29
SERV-HB 8003 En - Ausgabe 1.0 *8003s11IVZ.fm
I-3
I-4
SERV-HB 8003 En - Ausgabe 1.0 * *8003s11IVZ.fm
Operation
Operation
1 1.1 1.1
Op era t i o n Impo Importa rtant nt inf infor orma matio tion n on on this this serv servic icee manua manuall This service manual contains important information on how to service your machine safely, correctly and economically. Therefore, it aims not only at new staff, but it also serves as a reference for experienced users. It helps 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 operation manual. Prudent and careful work is the best protection against accidents! Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and service of the machine. Insist on using Neuson original spare parts when carrying out maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value. Your Neuson dealer will be pleased to answer any further questions regarding the machine or the service manual. Abbreviations/symbols
This symbol stands for a list • Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞ This symbol requires you to carry out the activity described ➥ Description of the effects or results of an activity
n. s. = not shown “Option” = optional equipment Stated whenever controls or other components of the machine are installed as an option. A combination of digits, d igits, or a combination of digits and letters, e .g. 40/18 or 18 or 40/A 40/A used for identifying the control elements, means: Figure no. 40/control element no. 18 or position A in figure no. 40 Figures carry no numbers if they are placed to the left of the text.
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-1
1.2 1.2
Iden Identi tifi fica cati tion on of warn warnin ings gs and and dan dange gers rs Important indications regarding the safety of the staff and the machine are indicated in this operation manual with the following terms and symbols:
Danger ! Failure to observe the instructions identified by this symbol may result in personal injury or death for the operator or other persons. ☞ Measures for avoiding danger
Caution! Failure to observe the instructions identified by this symbol may result in damage to the machine. ☞ Measures for avoiding danger for the machine
Important! This symbol identifies instructions for a more efficient and economical use of the machine.
Environment! Failure to observe the instructions identified by this symbol may result in damage to the environment. The environment is in danger if environmentally hazardous material (e.g. waste oil) is not subject to proper use or disposal
1-2
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.3 1.3
Desi Designa gnate ted d use use and and exem exempti ption on from from liab liabili ility ty • The machine is intended for: • Moving earth, gravel, coarse gravel or ballast and rubble as well as • Working with the implements mentioned in section Fields of application • Every other application is regarded as not designated for the use of the machine.
Neuson Baumashinen GmbH will not be liable for damage resulting from use other than mentioned above. The user alone will bear the risk. Designated use also includes observing the instructions set forth in the operation manual and observing the maintenance and service conditions.
• The safety of the machine can be negatively affected by carrying out machine modifications without proper authority and by using spare parts, equipment, implements and optional equipment which have not been checked and released by Neuson Baumaschinen GmbH. Neuson Baumaschinen GmbH will not be liable for damage resulting from this • Neuson Baumaschinen GmbH shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the operation manual, and by the negligence of the duty to exercise due care when: • handling • operating • servicing and carrying out maintenance work • repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care, in the safety instructions as well as in the operation and maintenance manuals (machine/engine). • Read and understand the operation manual before starting up, servicing or repairing
the machine. Observe the safety instructions!
• The machine may not be used for transport jobs on public roads
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-3
1.4 1.4
Type ype labe labels ls and and comp compon onen entt num numbe bers rs Serial number The serial number is stamped on the machine chassis under the hydraulic pump. It is also located on the type label. The type label is located at the front right on the machine fame (at cab level) Type label information
Fig. Fig. 1: 1:
Fig. ig. 2: 2:
Type ype labe label:l: locat o catio ionn
Model:
8 0 03
Year:
2 0 04
PIN:
A C 0 00 00 0
Ou t p u t :
4 2. 5 k W
Mass:
7960 kg
Lo ad :
---------------
Max. gross mass:
---------------
Max. axle load:
-----------------------------
Type ype lab label el
Other information – information – see section 2 Specifications on Specifications on page 2-1 Cab number The type label (arrow) is located in the cab, on the upper front left chassis member.
Fig. g . 3:
Cab Cab typ typee label a bel
Engine number The type label (arrow) is located on the cylinder-head cover (engine). Example:
Fig. Fig. 4:
1-4
Yanmar 46557
Dies Diesel el engi engine ne numbe number r
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
Hydraulic pump number The type label (arrow) is located on the hydraulic pump housing
Fig. Fig. 5:
Hydr Hydrau aulilicc pump pump typ typee labe labell
Main valve block number The type label (arrow) is located on the control valve.
Fig. Fig. 6:
Trave Travelli lling n g drive drive type type labe labell
Travelling drive number The type label (arrow) is located on the travelling drive.
Fig. Fig. 7:
Trave Travelli lling n g drive drive type type labe labell
Swivel unit number The type label (arrow) is located on the swivel unit.
Fig. Fig. 8:
Swivel v el unit unit type type labe labell
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-5
1. 5
Mac h i n e : ov o ve r vi ew
1
Boom light
2
Boom
3
Dipper arm
4
2
7
Rubber chains
3
Steel chains (option)
5
Undercarriage
6
Stabiliser blade
7
Ca b
8
Engine cover
1
8
4 5
6
2
3 10
9
Ha n d l e s
10
Tank ffiiller in inlet
11
Devi Device ce for for cou count nter erwe weig ight ht (opt (optio ion) n)
12
Exhaust pipe
12
11
9
Fig. Fig. 9:
1-6
4
Mach Machin inee out outsi side de views views
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.6
C ab : o v er v i e w
27
25
26
28
29
30
1
24
2
23
22
21 3
4 20 19
6
9
10 5
8
7
18
15
14
13
11
12
17
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
16
1-7
1. 7
C a b: le le g e n d
Pos.
1-8
Description
1
Cover for hammer pedal
2
Hammer pedal
3
Control lever (left)
4
Control le lever (r (right)
5
Control lever base (left)
6
Control lever base (right)
7
Armrest (left)
8
Armrest (right)
9
Lever ver – horiz rizonta ntal sea seat adjust justm ment
10
Lever Lever – hor horizo izont ntal al seat seat adjus adjustme tment nt with with con contro troll leve leverr base base
11
Air ve vent (re (reaar win winddow, on on th the le left)
12
Air Air vent vent (rea (rearr win window, dow, on the the righ right) t)
13
Radio (o (option)
14
Seat (b (backrest ad adjustment)
15
Seat belt (lock)
16
Cup holder
17
Br Braacket cket (sto (stora rage ge box box for for docu docume ment nts) s)
18
Switch panel
19
Throttle
20
Fuse box
21
Preheating st start sw switch
22
Cigarette lighter
23
Coolan lant te tempe mperat rature ind indicato cator r
24
Round display element
25
Drive pedal (left)
26
Drive pedal (right)
27
Drive lever (left)
28
Drive lever (right)
29
Stabiliser bl blade pe pedal
30
Stabiliser bl blade le lever
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.8 1.8
Inst Instru rume ment nt pane panel: l: ove overvie rview w
35 34 33
36 37
32
38
39 31
40
42
43
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
44
45
41
46
47
48
49
50
51
1-9
1.9 Pos.
1-10
Instr nstru u me n t pa pa n e l: le legend gend Description
31
Telltale (r(red) – air fifilter
32
Tellta lltalle (ye (yelllow) – cold cold sta starter ter
33
Tell Tellta tale le (red (red)) – hyd hydraul raulic ic oil oil fil filte ter r
34
Tell Tellta tale le (red (red)) – hydr hydrau aulilicc oil oil temp temper erat atur uree
35
Tell Tellta tale le (red (red)) – alte altern rnat ator or char charge ge func functition on
36
Tell Tellta tale le (red (red)) – engi engine ne oil oil pre press ssur uree
37
Tell Tellta tale le (red (red)) – cool coolan antt tem tempe pera ratu ture re
38
Fuel le level in indicator
39
Tell Tellta tale le (re (red) – saf safee load load indi indica cato tor r
40
Hour meter
41
Coolan lant te temperat rature ure in indicat cator
42
High speed
43
Washer system
44
Working light
45
Roof lights
46
Rotating beacon
47
Ventilation
48
Air co conditioning (o (option)
49
Safe loa load ind indicato catorr (op (option ion)
50
Revs switch
51
Not assigned
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.10 1.10 En Engin ginee comp compar artm tmen ent: t: ove overv rvie iew w
52
Pos.
53
Description
54
55
56
57
58 59
60
61
62
For more information see page
52
Main valve block (underneath (underneath the cover)................... cover)................................ ......................... ......................... .......................... ......................... .......................... ........................... .......................... ......................... ........................ ............ 5-7
53
Pressure cut-off valve............................ valve......................................... .......................... .......................... ......................... ......................... ........................... ........................... ......................... ......................... .......................... .......................... ................ ... 5-29
54
Hydraulic pump................... pump............................... ......................... .......................... .......................... ......................... ......................... .......................... ........................... ........................... .......................... .......................... ......................... ........................ ............ 5-1
55
Measurement Measurement ports.................... ports................................. ......................... ......................... .......................... ......................... ......................... ........................... ........................... ......................... ......................... .......................... .......................... ................ ... 3-30
56
Water separator.................... separator................................. .......................... ......................... ......................... .......................... .......................... ......................... .......................... ........................... .......................... ......................... ......................... ..................... ........ 3-12
57
Air filter ......................... ...................................... ......................... ......................... .......................... .......................... ......................... ......................... ........................... ........................... ......................... ......................... .......................... .......................... ................ ... 3-21
58
Oil dipstick............. dipstick ......................... ......................... ......................... ......................... ......................... ......................... ........................ ........................ ............................ ............................ .......................... .......................... ......................... ........................ ............ 3-15
59
Engine ........................ ..................................... ......................... ......................... .......................... ........................ ........................ .......................... ............................ ............................ .......................... ........................ ........................ .......................... ..................... ........ 4-1
60
Coolant tank ........................ .................................... ......................... .......................... ......................... ......................... .......................... ......................... .......................... ........................... .......................... .......................... ......................... ...................... .......... 3-19
61
Fan ........................ ..................................... ......................... ......................... .......................... .......................... ......................... ......................... ........................... ........................... .......................... .......................... .......................... ......................... ........................ ............ 4-1
62
Water/hydraulic Water/hydraulic oil radiator..................... radiator................................. ......................... .......................... ......................... ......................... ........................... ........................... ......................... ......................... .......................... .......................... ................ ... 3-18
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-11
1.1 1.11 Chas Chassi sis: s: over overvi view ew
67 65 64
68
70
63 69 66 71
Pos.
1-12
Description
For more information see page
63 64
Position of main fuse box with relays ........................ ..................................... .......................... .......................... ......................... .......................... ........................... ......................... ......................... .......................... ......................... ............ 2-4 Battery.................................. Battery............................................... .......................... .......................... ......................... ......................... .......................... ........................... ........................... ......................... ......................... .......................... .......................... .................... ....... 3-46
65 66 67
Main valve block.............................. block.......................................... ......................... .......................... ......................... ......................... ......................... ........................... ............................. .......................... ......................... .......................... ......................... ............ 5-7 Gear motor .......................... ....................................... ......................... ......................... .......................... .......................... ......................... .......................... ........................... .......................... ......................... ......................... .......................... ...................... ......... 5-40 Pilot oil supply unit under the cover.......................... cover...................................... ......................... .......................... ........................ .......................... ............................ .......................... ........................ ........................ .......................... ................. 5-5
68
Hydr Hydrau aulilicc oil oil tan tank wit withh leak leak oil oil str strip ip
69
Shuttle valve block ......................... ...................................... .......................... ......................... ......................... ......................... ........................ ........................... ............................ .......................... ........................ ........................ ......................... ............ 5-31
70
Fuel tank
71
Counterbalance Counterbalance valve....................... valve.................................... ......................... ......................... ......................... ......................... ......................... ........................... ............................ ......................... ......................... .......................... ...................... ......... 5-30
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.12 1.12 Tilti ilting ng the the cab
Danger ! Careful when tilting the cab –
Danger of accidents! screws A and C C when driving and working with the ☞ Always tighten lock screws A machine. ☞ Always close the door ☞ Stay clear from underneath the cab as you tilt it
• Swit Switch ch off off the the engi engine ne • Remo Remove ve the the ign ignititio ionn key key • Fold Fold the control control lever lever base base (left (left)) up Slackening the lock screw Unscrew the lock screw as follows: ☞ Switch off the engine ☞ Remove the ignition key ☞ Fold the control lever base (left) up ☞ Raise floor mat B ☞ Unscrew lock screw A screw A with with a suitable tool
A
➥ Lock screw A is located at the front right of the cab
with a suitable tool ☞ Unscrew lock screw C with
B
➥ Lock screw C is located at the rear right of the cab
Danger ! Always close the door. Even if the door is secured in the open position with the door arrester –
Danger of accidents! ☞ Always close the door be fore tilting the cab ☞ Should the door be open as you tilt the cab, do not actuate the door opener
unintentionally
C
Fig. Fig. 10: Cab floo floorr securi securing ng screw screwss
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-13
Tilting the cab Proceed as follows:
E
and pump as far as it will go ☞ Insert tube D onto guide pin E and
F
➥ (jack function) ➥ The cab is raised as far as the pump will go
until the cab is completely tilted beyond the centre of motion ☞ Pull handle G until ➥ The cab is secured with safety cables H and I ☞ Remove the split pin from bracket J
D
➥ Slide tilt rod K into guide L ➥ Secure tilt rod K with the split pin in guide L
Tilting the cab down: ☞ Remove the split pin from guide L ➥ Slide tilt rod K into bracket J
H
➥ Secure tilt rod K with the split pin in bracket J ☞ Use handle G to lower the cab until it is back on the pump ☞ Insert tube D on pin F ☞ Slowly turn tube D counterclockwise (to the left)
G
➥ The cab is lowered by its own weight ➥ The lift pump must be opened when driving with the machine (to prevent the lift
piston from touching the cab)
I
screws A (front) (front) and B (rear) with suitable tools and the specific torque ☞ Mount lock screws A – see Tightening torques for high-resistance screw connections on page 2-8
Caution! Check tilt rod K, the split pin and safety cables H and I and I at regular intervals for cracks and cuts. ☞ Replace defective parts immediately
J K
L
Fig. Fig. 11: 11: Tilting t ing the the cab cab
1-14
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
1.13 1.13 Su Summ mmer er/w /wint inter er op oper erat ation ion Adjust cab temperature tempera ture as follows:
A
Position A
Function Summer operation
Co o ls
B
Winter operation
Heating water circuit open
☞ Open the engine compartment ☞ Turn the ball-type cock as described, to summer or winter operation ☞ Close the engine compartment
Important! Summer and winter operation does not depend on the season, adjust according to your personal requirements. B
Fig. Fig. 12: 12: Heatin Heatingg adjus adjustmen tmentt
Preheated fresh air Selection of “cold” or “preheated” fresh air in winter. A deflector plate on the heater can be set to two diffe rent positions. ➥ Fresh air: heater takes in air from outside the cab fig. cab fig. 12 ➥ Preheated fresh air: heater takes in air from the chassis fig. 13
Fig. Fig. 13: 13: Fres Freshh air air
Change from fresh air to preheated fresh air as follows: ☞ Tilt the cab – cab – see Tilting the cab on page 1-13 ➥ The deflector plate is located on the heater under the cab ☞ Slacken both attachment screws ☞ Reposition and fit the deflector plate back on again ☞ Tilt the cab back down again and secure it
Fig. Fig. 14: Prehea Preheated ted fres freshh air air
SERV-HB 8003 En – Edition 1.0 *8003s110.fm
1-15
1.14 Pedal for auxiliary auxiliary hydraulics/s hydraulics/swivel wivelling ling and rotating rotating the the boom boom The pedal for the auxiliary hydraulics/swivelling the boom can be rotated by 90°. ☞ Slacken 4 screws ☞ Rotate the pedal by 90° ☞ Retighten the 4 screws
The length of the hydraulic hoses is sufficient for easily rotating the pedal by 90°.
Caution! Make sure the hydraulic hoses are not squeezed as you tilt the cab!
1-16
SERV-HB 8003 En – Edition 1.0 * *8003s110.fm
Specifications
Specifications
2 2.1
S pe ci f i cat i on s C h a ss i s Sturdy steel sheet chassis, rubber-mounted engine
2.2
En gin e Engine
Model 8003
Product
Yanmar diesel engine
Model
4TNV98-VNS
Design
Water-cooled 4 stroke diesel engine, EPA2
No. of cylinders
4
Fuel injection system
Direct injection
Aspiration
Naturally aspirated
Cooling system
Water-cooled/aspirating fan
Lubrication system
Force-feed lubrication with trochoidal pump
Displacement
3318 cm³
Nominal bore and stroke
98 x 110 mm
Output
42.5 kW @ 2100 rpm
Max. torque
249 Nm @ 1400 rpm
Max. ax. eng engiine speed withou thoutt lo load
2290 290 +/ +/- 50 50 rpm rpm
Idling speed
1100 +/- 50 rpm
Valve Valve tip tip clearanc clearancee (intak (intakee = outlet) outlet)
0.15 – 0.25 0.25 mm mm ((col cold) d)
Injection pressure
22 0 – 23 0 ba r
Compression
35 +/- 1 bar @ 250 rpm
Engine oil pressure
3 – 4 bar
Pressur Pre ssuree switch switch for engine engine oil oil pump
0.5 +/- 0.1 bar
Openi Opening ng tem temper peratu ature re of of ther thermo mosta statt
69.5 69.5 – 72.5 72.5 °C
Thermal switch
107 – 113 °C
Firing order
1–3–4–2–1 Counterclockwise
Direction of rotation (as seen from the flywheel) Starting aid
Intake manifold (preheating time 10 – 15 sec) 25°/46% in all directions
Max. inclined position (engine still supplied with oil)
30°/58% 3 minutes. Observe the machine's hill climbing ability (30°/ 58%)! 97/68/EC Tier II
Exhaust values according to EPA Tier II
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
2-1
Capacities Capacities
Model 8003
Fuel tank
93 l
Engine oil (max./effect.)
10.2 l/4.5 l
Coolant (without radiator)
4.2 l
R a d i a to r
4.9 l
Expansion tank
1.5 l
Tightening torques Tightening torques
2. 3
Cylinder-head bolt
105.0 – 115.0 Nm (M11x1.25)
Conne onnecctin ting rod bear earing screw crew
55.0 5.0 – 60.0 0.0 Nm (M10x 10x1)
Main bearing screw
110.0 – 120.0 Nm (M11x1.25)
Flywheel screw
190.0 – 210.0 Nm (M14x1.5)
Hydraulic system
Model 8003 Twin variable displacement + twin gear pump 2 x 36 + 2 x 16 cm³ AP2D36LV3RS6-874-P AP2D36LV3RS6-87 4-P (variable displacement pump) GSP2H-BOF16A16AR-A0-A627-0 (gear pump) 2 x 82.4 + 2 x 36.6 l/min @ 2290 rpm
H y d r a u l i c sy st e m
Pump
Flow rate Control valve
12 sections/13 sections (3rd control circuit)
Max. service pressure
300±5 bar
Main pressure limiting valve for pumps P1, P2
300±3 bar
Main pressure limiting valve for pumps P3, P4 Secondary pressure limiting valve for main valve block Main pressure limiting valve for pilot control pressure
245-0/+3 bar 350 bar @ 20 l/min (stabiliser blade 300 bar) 32.5-0/+4 bar
Main pressure limiting valve Swivel unit
225±3 bar
Hydraulic oil cooler
Standard
Hydraulic tank capacity 2nd speed shift pressure Gear motor braking deceleration time
2-2
Model 8003
99 l 180 bar 5 –1.5/+1.5 sec @ 50 °C oil temperature
Circulation pressure P1 (max. revs)
12 bar
Circulation pressure P2 (max. revs)
17.5 bar
Circulation pressure P3 (max. revs)
21.5 bar
Circulation pressure P4 (max. revs)
21.5 bar
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
Auxiliary hydraulics oil flow* Pressure
P2
2 0 b ar
79 l/min
4 0 b ar
78 l/min
6 0 b ar
76.9 l/min
9 0 b ar
76.1 l/min
12 0 ba r
74.4 l/min
15 0 ba r
73.7 l/min
18 0 ba r
72.8 l/min
21 0 ba r
68 l/min
24 0 ba r
61.6 l/min
27 0 ba r
55.9 l/min
30 0 ba r
43.3 l/min
* Output indications for auxiliary hydraulics with unpressurised reflux line
2.4 2.4
Unde Underc rcaarria rriage ge and and swi swivvel un unit it Undercarriage/swivel unit
Model 8003
2 speed ranges
3.2/5.2 kph
Climbing ability
30°/58%
Chain width
450 mm
No. of track rollers on either side Ground clearance
375 mm
Ground pressure
0.36 kg/cm²
Upper carriage swivel speed
2.5
5
9.2 rpm
S t a b i l i s er b l a d e Stabiliser blade
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
Model 8003
Width/height
2300/500 mm
Max. lift over/under subgrade
450/520 mm
2-3
2. 6
E l ec t r i c s ys t em Electric system Alternator
12 V 55 A
Starter
12 V 2.3 kW
Battery
12 V 88 Ah
Socket
E.g. for cigarette lighter; 15 A max.
Fuse box in instrument panel
Fuse no.
Rated current (A)
Protected circuit
F3
10 A
– Indicators, engine relay
F4
10 A
– Boom light
F5
15 A
– Roof lights
F6
10 A
– Valves, horn
F7
15 A
– Heating, air conditioning
F8
10 A
– Wiper, interior light
F9
10 A
– Rotating beacon, radio
F10
15 A
– Socket, cigarette lighter
Fuse no.
Rated current (A)
Protected circuit
F1
40 A
– Start, preheat, cut-off solenoid
F2
50 A
– Fuel-filling pump, main fuse, ignition lock
Relay no.
Protected circuit
K9
– Cut-off solenoid switching relay
K5
– Preheating high current relay
F3 F4 F5 F6 F7 F8 F9 F10 Fig. 1: 1:
Fuse box
Main fuse box with relays under the cab
K9
Fig. Fig. 2: 2:
2-4
K5
F1 F2
Relais a is box box under under the cab cab
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
Relays The relays are located in the relay box under the cab, next to the swivelling console
K7
Switching relay no.
Protected circuit
K6
– Preheating timer
K7
– Starting relay
K8
– Cut-off solenoid timer
V1
– Cut-off solenoid recovery diode
V1
K6
Fig. 3: 3:
2.7
K81
Relays
N o i s e l e ve l s Sound power level
Model 8003
Sound power level (LWA)
101 dB (A)
Sound pressure level (LPA)
78 dB (A)
Important! Measurement of sound power level according to EC Directive 2000/14 EC. Noise level in the cab measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC. Measurements carried out on asphalted surface.
2.8
C oola ola n t c o m p o un und d table ble Outside temperature Up to °C 4 -10 -20 -25 -30
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
W at er % by volume 99 79 65 59 55
Coolant Anticorrosion agent cm³/l
10
Antifreeze agent
% by volume
% by volume
1
– 20 34 40 44
2-5
2.9 2.9
Mode Modell-sp spec ecif ific ic tigh tighte teni ning ng torq torque uess 8003 Live ring Track roller Drive pinion Travelling drive Gear motor Angled engine bracket b racket Engine mounting Pump mounting Pump Swivel joint
M14 10.9 M16 10.9 M14 10.9 M14 10.9 M16 10.9 M10 8.8 M10 8.8 M10 8.8 M12 10.9 M10 10.9
180 Nm * 275 Nm * 180 Nm * 180 Nm * 275 Nm * 45 Nm 45 Nm 50 Nm 79 Nm 64 Nm *
*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.
Screwable hose burst valve Location
Thread
Gap dimension
1 /2 "
2.4 mm
Stabiliser blade
2.10 2.10 Gene Genera rall tigh tighte teni ning ng torque torquess Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL) Width across Tightening Nominal ø Outer ø Thread flats torque 05 6L M12X1.5 W/ F 1 4 1 5 Nm 06 8L M14X1.5 W/ F 1 7 2 0 Nm 08 1 0L M16X1.5 W/ F 1 9 4 0 Nm 10 1 2L M18X1.5 W/ F 2 2 5 0 Nm 12 1 5L M22X1.5 W/ F 2 7 7 5 Nm 16 1 8L M26X1.5 W/ F 3 2 8 5 Nm 20 2 2L M30X2 W/ F 3 6 100 Nm 25 2 8L M36X2 W/ F 4 1 180 Nm 32 3 5L M45X2 W/ F 5 5 220 Nm Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures.
Metric hose fittings for hydraulic applications (heavy execution, DKOL) Width across Tightening Nominal ø Outer ø Thread flats torque 05 8S M16X1.5 W/ F 1 9 4 0 Nm 06 1 0S M18X1.5 W/ F 2 2 5 0 Nm 08 1 2S M20X1.5 W/ F 2 4 6 0 Nm 10 1 4S M22X1.5 W/ F 2 7 7 5 Nm 12 1 6S M24X1.5 W/ F 3 0 9 0 Nm 16 2 0S M30X2 W/ F 3 6 100 Nm 20 2 5S M36X2 W/ F 4 1 180 Nm 25 3 0S M42X2 W/ F 5 0 270 Nm 32 3 8S M52X2 W/ F 6 0 400 Nm Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures.
2-6
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
Screw connections with various seals for hydraulic applications (light execution)
Thread
M10X1.0 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M22X1.5 M27X2.0 M33X2.0 M42X2.0 M48X2.0 G1/8A G1/4A G3/8A G1/2A G3/4A G1A G1 1/4A G1 1/2A
Straight pipe fitting with thread and screwed plug Sealing washer 9 Nm 2 0 Nm 3 5 Nm 4 5 Nm 5 5 Nm 6 5 Nm 9 0 Nm 150 Nm 240 Nm 290 Nm 9 Nm 35 Nm 45 Nm 65 Nm 90 Nm 150 Nm 240 Nm 290 Nm
Elastic seal
O-ring
Non-return valve with elastic seal
18 Nm 25 Nm 45 Nm 55 Nm 70 Nm 1 2 5 Nm 1 8 0 Nm 3 1 0 Nm 4 5 0 Nm 5 4 0 Nm 1 8 Nm 35 Nm 70 Nm 90 Nm 180 Nm 310 Nm 4 5 0 Nm 5 4 0 Nm
15 Nm 25 Nm 35 Nm 40 Nm 45 Nm 60 Nm 100 Nm 1 6 0 Nm 2 1 0 Nm 2 6 0 Nm 1 5 Nm 30 Nm 45 Nm 55 Nm 100 Nm 160 Nm 2 1 0 Nm 2 6 0 Nm
18 Nm 25 Nm 35 Nm 50 Nm 70 Nm 125 Nm 145 Nm 2 1 0 Nm 3 6 0 Nm 5 4 0 Nm 1 8 Nm 35 Nm 50 Nm 65 Nm 1 4 0 Nm 1 9 0 Nm 3 6 0 Nm 5 4 0 Nm
Identification aid outside Ø 10 mm 12 mm 14 mm 16 mm 18 mm 22 mm 27 mm 33 mm 42 mm 48 mm 9.73 mm 13.16 mm 16.66 mm 20.96 mm 26.44 mm 33.25 mm 41.91 mm 47.80 mm
Torque tolerance: – 10 %; countermaterial: steel/aluminium
Screw connections with various seals for hydraulic applications (heavy execution)
Thread
M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M27X2.0 M33X2.0 M42X2.0 M48X2.0 G1/8A G1/4A G3/8A G1/2A G3/4A G 1A G1 1/4A
Straight pipe fitting with thread and screwed plug Sealing washer 20 Nm 35 Nm 45 Nm 55 Nm 55 Nm 65 Nm 90 Nm 150 Nm 240 Nm 290 Nm 35 Nm 45 Nm 65 Nm 90 Nm 150 Nm 240 Nm 290 Nm
Elastic seal
O-ring
Non-return valve with elastic seal
3 5 Nm 5 5 Nm 7 0 Nm 9 0 Nm 125 Nm 135 Nm 180 Nm 310 Nm 450 Nm 540 Nm 5 5 Nm 8 0 Nm 115 Nm 180 Nm 310 Nm 450 Nm 540 Nm
35 Nm 45 Nm 55 Nm 70 Nm 80 Nm 100 Nm 170 Nm 310 Nm 330 Nm 420 Nm 45 Nm 60 Nm 75 Nm 170 Nm 310 Nm 330 Nm 420 Nm
3 5 Nm 4 5 Nm 5 5 Nm 7 0 Nm 1 0 0 Nm 1 2 5 Nm 1 3 5 Nm 2 1 0 Nm 3 6 0 Nm 5 4 0 Nm 4 5 Nm 6 0 Nm 1 0 0 Nm 1 4 5 Nm 2 6 0 Nm 3 6 0 Nm 5 4 0 Nm
Identification aid outside Ø 12 mm 14 mm 16 mm 18 mm 20 mm 22 mm 27 mm 33 mm 42 mm 48 mm 13.16 mm 16.66 mm 20.96 mm 26.44 mm 33.25 mm 41.91 mm 47.80 mm
Torque tolerance: – 10 %; countermaterial: steel/aluminium
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
2-7
Tightening torques for high-resistance screw connections Thread M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
With coarse-pitch thread Screws according to DIN 912, DIN Screws according to 931, DIN 933 etc. DIN 7984 8 .8 1 0 .9 1 2. 9 8. 8 1 0 .9 5 . 5 Nm 8 Nm 10 Nm 5 Nm 7 Nm 10 Nm 14 Nm 17 Nm 8.5 Nm 12 Nm 25 Nm 35 Nm 42 Nm 20 Nm 30 Nm 4 5 Nm 6 5 Nm 8 0 Nm 40 Nm 5 9 Nm 87 Nm 1 1 0 Nm 147 Nm 69 Nm 100 Nm 135 Nm 1 8 0 Nm 230 Nm 1 1 0 Nm 160 Nm 210 Nm 2 7 5 Nm 350 Nm 1 7 0 Nm 250 Nm 280 Nm 4 1 0 Nm 480 Nm 2 4 5 Nm 345 Nm 410 Nm 5 7 0 Nm 690 Nm 3 4 0 Nm 490 Nm 550 Nm 7 8 0 Nm 930 Nm 4 6 0 Nm 660 Nm 710 Nm 1000 Nm 1190 Nm 5 9 0 Nm 840 Nm 1 0 4 0 Nm 1480 Nm 1770 Nm 870 Nm 1250 Nm 1 4 2 0 Nm 2010 Nm 2400 Nm 1 2 0 0 Nm 1700 Nm
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.
Thread M8X1.0 M10X1.0 M10X1.25 M12X1.25 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M24X2.0 M27X2.0 M30X2.0
With fine-pitch thread Screws according to DIN 912, DIN Screws according to 931, DIN 933 etc. DIN 7984 8 .8 1 0 .9 1 2. 9 8. 8 1 0 .9 2 5 Nm 37 Nm 4 3 Nm 22 Nm 3 2 Nm 5 0 Nm 75 Nm 8 8 Nm 43 Nm 6 5 Nm 4 9 Nm 71 Nm 8 3 Nm 42 Nm 6 2 Nm 8 7 Nm 1 3 0 Nm 150 Nm 75 Nm 110 Nm 8 3 Nm 1 2 5 Nm 145 Nm 72 Nm 105 Nm 135 Nm 2 0 0 Nm 235 Nm 120 Nm 175 Nm 210 Nm 3 1 0 Nm 360 Nm 180 Nm 265 Nm 315 Nm 4 5 0 Nm 530 Nm 270 Nm 385 Nm 440 Nm 6 3 0 Nm 730 Nm 375 Nm 530 Nm 590 Nm 8 4 0 Nm 980 Nm 500 Nm 710 Nm 740 Nm 1070 Nm 1250 Nm 630 Nm 900 Nm 1100 Nm 1550 Nm 1800 Nm 920 Nm 1300 Nm 1500 Nm 2150 Nm 2500 Nm 1 3 0 0 Nm 1850 Nm
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.
2-8
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
2.1 2.11 Dime Dimens nsio ions ns mode modell 800 80033
4110 1570
0 1 7 2
0 1 7 2
500 3610
2810
0 5 4
6420 Fig. Fig. 4:
720
6 7 ° 6 3 °
R 1 5 5 0
2300
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
0 5 4
2300
Machin Machinee dimension m ensionss ((mode modell 8003) 8003)
Service weight
Model 8003 7960 kg
8245 kg
Height
2710 mm
2864 mm
Width
2300 mm
2300 mm
Transport length
6420 mm
6570 mm
Max. digging depth
4290 mm
4162 mm
Dipper arm length (standard)
18 1850 mm
1850 mm
Dipper arm length (extended version)
21 2150 mm
2150 mm
Max. digging depth for extended-version dipper arm (+ 300 4580 mm mm) 3670 mm Max. vertical digging depth
4462 mm
Max. vertical digging depth (extended dipper arm)
3970 mm
3814 mm
Max. digging height
6980 mm
7128 mm
Max. digging height (extended dipper arm)
7170 mm
7317 mm
Max. dump height
4840 mm
5000 mm
Max. dump height (extended dipper arm)
5030 mm
5190 mm
Max. digging radius
7170 7170 mm 6290 6290/7 /742 4200 mm
Max. digging radius (extended dipper arm)
7440 7440 mm 7190 7190/7 /769 6900 mm
Max. reach at ground level
7020 7020 mm 6770 6770/7 /727 2700 mm
Max. reach at ground level (extended dipper arm)
7300 7300 mm 7050 7050/7 /755 5500 mm
Max. breakout force at bucket tooth
52.30 kN
52.30 kN
Max. tearout force (standard dipper arm)
38.70 kN
38.70 kN
Max. tearout force (extended dipper arm)
35.10 kN
35.10 kN
Min. tail end slewing radius
1550 mm
1550 mm
Max. tail end lateral projection over chains
400 mm
150/650 mm
Max. boom displacement to bucket centre (right-hand side)
720 mm
970 mm
Max. boom displacement to bucket centre (left-hand side)
550 mm
800 mm
Main data 550
1400
Vario
3516 mm
2-9
2.12 2.12 Lif Liftt capa capaci city ty table table 8003 8003
A
5. 0 m
Max
4.0 m
3. 0 m
2.0 m
B 5.0 m 2000* 1510 4.0 m 1920* 1165
Fig. Fig. 5:
Lift Lift capac capacity ity table table (mod (model el 8003) 8003)
1955*
1 9 50
1 9 15 * 1 33 0
2010*
1 9 30
3.0 m 1895* 985 2.0 m 1905* 920 1.0 m 1930* 890
2 0 20 * 1 30 0
2315*
1 8 45
2925*
2 92 0
2 2 05 * 1 24 5
2750*
1 7 30
4070*
2 62 0
2 3 80 * 1 18 5
3120*
1 6 20
4770*
2 40 0
0.0 m 1960* 910
2 4 55 * 1 14 5
3260*
1 5 50
4750*
2 33 5
-1.0 m 1975* 990 -2.0 m 1940* 1180
2 3 45 * 1 13 0
3135*
1 5 30
4375*
2 33 0
63 0 5
4 830
2690*
1 5 45
3675*
2 36 5
5230*
4 900
2385*
2385*
-3.0 m 1700* 17 1700* Max Max
Admis Admissi sibl blee load load on extend extended ed dippe dipperr arm arm
A
Reach from live ring cen tre
B
Load hook height
*
Lift ca capacity lilimited by by hy hydraulics
All table indications in kg and horizontal p osition on firm ground without witho ut bucket.
With the stabiliser blade in driving direction
Without the stabiliser blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight. Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
2-10
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
2.13 2.13 Lift capaci capacity ty table table 8003 8003 with with extend extended ed dippe dipperr arm
A
5. 0 m
Max
4.0 m
3. 0 m
2.0 m
B 5.0 m 1825* 1320 4.0 m 1770* 1050
Fig. Fig. 6:
Lift Lift capacit capacityy table table counter counterwei weight ght (mode (modell 8003)
17 30 *
1 73 0 *
1 7 60 * 13 4 5
18 05 *
1 80 5 *
3.0 m 1755* 915 2.0 m 1765* 845 1.0 m 1790* 815
1 8 85 * 13 0 5
21 15 *
1 86 5
2550*
2550*
2 0 90 * 12 4 5
25 75 *
1 74 0
3690*
2 68 5
2 2 95 * 11 8 0
29 95 *
1 62 0
4580*
2 42 5
0.0 m 1820* 830
2 4 15 * 11 3 0
32 10 *
1 54 0
4775*
2 32 0
-1.0 m 1840* 895 -2.0 m 1830* 1040
2 3 75 * 11 1 0
31 65 *
1 50 5
4530*
2 29 5
71 50 * 4 7 30
28 35 *
1 51 0
3935*
2 32 0
60 00 * 4 8 00
2855*
2 39 0
-3.0 m 1705* 1415 Max
Admis Admissi sible ble load load on on extend extended ed dipper dipper arm arm
A
Reach from live ring centre
B
Lo a d ho o k h eig h t
*
Lift ca capacity lilimited by by hy hydraulics
All table indications in kg and horizontal position on firm ground without bucket.
With the stabiliser blade in driving direction
Without the stabiliser blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight. Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
2-11
2.14 2.14 Lift capaci capacity ty table table 8003 8003 with counte counterwe rweight ight
A
5.0 m
Max
4.0 m
3.0 m
2.0 m
B 5.0 m 2000* 1715 4.0 m 1920* 1335
Fig. Fig. 7:
Lift Lift capacity capacity table table count counterw erweig eight ht (model (model 8003) 8003)
19 55 *
1955*
1915* 1515
20 10 *
2010*
3.0 m 1895* 1140 2.0 m 1905* 1070 1.0 m 1930* 1035
2020* 1485
23 15 *
2 09 5
29 25 *
29 25 *
2205* 1430
27 50 *
1 97 5
40 70 *
29 85
2380* 1370
31 20 *
1 86 5
47 70 *
27 65
0.0 m 1960* 1060
2455* 1330
32 60 *
1 80 0
47 50 *
27 00
-1.0 m 1975* 1150 -2.0 m 1940* 1370
2345* 1315
31 35 *
1 77 5
43 75 *
27 00
6 3 05
26 90 *
1 75 0
36 75 *
27 35
5230* 5230*
23 85 *
23 85 *
-3.0 m 1700* 17 1 700* Max Max
Admis Admissi sibl blee load load on exten extended ded dippe dipperr arm arm
A
Reach from live ring cent re
B
L o a d h o ok h e i g h t
*
Lift ca capacity lilimited by by hy hydraulics
5 56 0
All table indications in kg and horizontal p osition on firm ground without witho ut bucket.
With the stabiliser blade in driving direction
Without the stabiliser blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight. Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
2-12
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
2.15 Lift capaci capacity ty table table 8003 8003 with extende extended d dipper dipper arm and counterw counterweight eight
A
5. 0 m
Max
4.0 m
3. 0 m
2.0 m
B 5.0 m 1825* 1495 4.0 m 1770* 1200
Fig. Fig. 8:
Lift Lift capacit capacityy table table counter counterwei weight ght (mode (modell 8003)
17 30 *
1 73 0 *
1 7 60 * 15 2 0
18 05 *
1 80 5 *
3.0 m 1755* 1050 2.0 m 1765* 975 1.0 m 1790* 950
1 8 85 * 14 8 0
21 15 *
2 10 0
2550*
2550*
2 0 90 * 14 2 0
25 75 *
1 97 5
3690*
3 03 5
2 2 95 * 13 5 5
29 95 *
1 85 5
4580*
2 77 5
0.0 m 1820* 965
2 4 15 * 13 1 0
32 10 *
1 77 5
4775*
2 67 0
-1.0 m 1840* 1040 -2.0 m 1830* 1205
2 3 75 * 12 8 5
31 65 *
1 74 0
4530*
2 64 5
71 50 * 5 4 25
28 35 *
1 74 5
3935*
2 67 0
60 00 * 5 4 95
2855*
2 74 0
-3.0 m 1705* 1630 Max
Admis Admissi sible ble load load on on extend extended ed dipper dipper arm arm
A
Reach from live ring centre
B
Lo a d ho o k h eig h t
*
Lift ca capacity lilimited by by hy hydraulics
All table indications in kg and horizontal position on firm ground without bucket.
With the stabiliser blade in driving direction
Without the stabiliser blade, 90° to driving direction If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight. Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
2-13
2.16 2.16 Lift capaci capacity ty tabl tablee 8003 8003 Vario ario (optio (option) n)
A
5.0 m
Max
4.0 m
3.0 m
2.0 m
C
B
5.0 m
2 00 0 * 1 95 0
10 40
4.0 m
1 92 0 * 1 50 5
80 5
1915* 1715
9 20
2010* 2010* 1330
3.0 m
1 89 5 * 1 27 0
68 0
2020* 1675
8 95
2315* 2315* 1275
2 92 5 * 29 25 * 20 1 5
2.0 m
1 90 5 * 1 18 5
63 5
2205* 1605
8 60
2750* 2230
1 1 95
4 07 0 * 33 80
18 0 5
1.0 m
1 93 0 * 1 15 0
61 5
2380* 1530
8 20
3120* 2090
1 1 20
4 77 0 * 30 95
16 5 5
0.0 m
1 96 0 * 1 17 5
63 0
2455* 1475
7 90
3260* 2000
1 0 70
4 75 0 * 30 10
16 1 0
68 5
2345* 1460
7 80
3135* 1975
1 0 55
4 37 5 * 30 05
16 0 5
63 05 * 6 23 0
2690* 1995
1 0 65
3 67 5 * 30 50
16 3 0
5230* 5230* 3380
-1.0 m 1975* 1275 -2.0 m 1940* 1520 -3.0 m 1700* 17 1 700*
1955* 1955* 1345
81 5 11 75
3 335
2385* 23 2 385* 16 1 645
Max Max
Admi Admiss ssib ible le load load on on exte extend nded ed dip dippe perr arm arm
A
Reach from live ring centre
B
L o a d h o ok h e i g h t
C
Vario position
*
Lift capacity limited by hydraulics All table indications in kg and horizontal p osition on firm ground without witho ut bucket.
With the stabiliser blade in driving direction Without the stabiliser blade 90° in driving direction Upper carriage shifted to the rear with Vario option Rear Vario
Front Vario
Fig. Fig. 9:
Lift Lift capaci capacity ty table table Vari Vario (model (model 8003) 8003)
Without the stabiliser blade 90° in driving direction Upper carriage shifted to the front with Vario option If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement dead weight. Calculation basis: according to ISO 10567 The track excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilising features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
2-14
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
2 . 1 7 K i n e ma t i cs E
Pin diameter
55 mm
F
Dipper arm width
170 mm
L
Pin distance to bucket mount
300 mm
Bucket
pper arm
Bucket
SERV-HB 8003 En – Edition 1.0 *8003s210.fm
2-15
2-16
SERV-HB 8003 En – Edition 1.0 * *8003s210.fm
Maintenance
Maintenance
Maintenance
3
Ma i nt ena nce
3.1
Flui luids and lub lubrica ica n ts Component/ application
Diesel engine
Engine/machine fluid
Specification API CD, CE, CF
Engine oil
2
SAE E3, E4, ES (10 W 40)
Season/ temperature
Capacities1
–15 °C +45 °C
10.2 l
Year-round
About 1.3 l each
Year-round
99 l
Q8 T 55, SAE85W-90 Travelling drive
Hydraulic oil tank
3
Gearbox oil
FINA PONTONIC GLS, SAE85W90
Hydraulic oil
HVLP464 PANOLIN HLP Synth 46
Biodegradable oil5
FINA BIOHYDRAN SE 46 BP BIOHYD SE-46
Roller and friction bearings6
Grease
FINA Energrease L21M
Year-round
As required
Open gear 7 (live ring gears)
Grease
BP Energrease MP-MG2
Year-round
As required
Grease nipples
Multipurpose grease8 FINA Energrease L21 M
Year-round
As required
Battery terminals
Acid-proof grease9
FINA Marson L2
Year-round
As required
Fuel tank
Diesel fuel
No. 2-D, DIN 51601 grade
Over 4 °C
No. 1-D, DIN 51601 grade
Below 4 °C
Engine and hydraulic oil cooler
Coolant
Water + antifreeze; SP-C
Year-round
11.8 l
Refrigerating agent
R134a10
Year-round
800 g
Compressor oil
Sanden SP SP10
Year-round
116.5 cm³
Cleaning agent
Water + antifreeze
Year-round
2.0 l
Air conditioning Washer system 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
78 l
The capacities capacities indicate indicatedd are approximativ approximativee values; values; the oil level check check alone alone is relevant relevant for the correct correct oil level level Acco Accord rdin ingg to DIN DIN 515 51511 11 Hypoid gearbox oil based based on basic mineral mineral oil oil (SAE85W-90 (SAE85W-90 accordi according ng to DIN 51502), 51502), (API GL-4, GL-4, GL5) GL5) Acco Accord rdin ingg to DIN DIN 51524 51524 sec sectition on 3 Hydr Hydraul aulic i c est ester er oil oilss (HEE (HEES) S) KF2K-25 KF2K-25 according according to DIN 51502 51502 multipurpo multipurpose se lithium lithium grease grease with with MoS² additiv additivee KP2N-20 KP2N-20 according according to DIN DIN 51502 EP EP multipurpose purpose calcium calcium sulphonate phonate complex complex grease grease KF2K-25 KF2K-25 according according to DIN 51502 51502 multipurpo multipurpose se lithium lithium grease grease with with MoS² additiv additivee Stan Standar dardd acid acid-p -pro roof of gre greas asee Accord According ing to DIN 8960 8960
SERV-HB 8003 En – Edition 1.0 *8003s310.fm
3-1
Maintenance
Oil grades for the diesel engine, depending on temperature Engine oil grade
Ambient temperature (C°) °C
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
95
1 04
SAE 10W SAE 20W SAE 10W-30 SAE 15W-40
API CD, CF, CF-4, CI-4 SAE1 E3, E4, E5
SAE 20 SAE 30 SAE 40 °F
1.
3-2
-4
5
14
23
32
41
50
59
68
77
86
Acco Accord rdin ingg to DIN DIN 515 51511 11
SERV-HB 8003 En – Edition 1.0 * *8003s310.fm
Maintenance 3.2
Mai n te n a n ce la l ab e l
Explanation of symbols on the maintenance label
Symbol
A s s e m b ly
Explanation
General
Visual check
General
Grease instructions
Fuel system
Drain co condensation water
Fuel Fuel syst system em
Repl Replac acee the the fuel fuel filt filter er,, clea cleann the the fuel fuel pref prefililte ter r
Ra d i a t o r
Check the coolant level
Ra d i a t o r
Drain and fill in new coolant
E ng ine
Check valve tip clearance. Adjust if necessary
E ng ine
Check the engine oil level
E ng ine
Changing engine oil
E ng ine
Replace the oil filter
E ng ine
Check V-belt tension
Travelling drive
Cha ng e oil
Travelling drive
Check the oil
Undercarriage
Check chain tension
Hydr Hydrau aulilicc sys syste tem m
Chec Checkk oil oil leve levell
Hydr Hydrau aulilicc sys syste tem m
Chan Change ge hydr hydrau aulilicc oil oil
Hydraul Hydraulic ic syste system m
Replace Replace the the hydrau hydraulic lic oil filt filter, er, repla replace ce the the breathe breatherr filter filter
SERV-HB 8003 En – Edition 1.0 *8003s310.fm
3-3
Maintenance
Symbol
3-4
A s s e m b ly
Explanation
Radiator fins
Clean
Heating, air conditioning
Replace the recirculated air filter
SERV-HB 8003 En – Edition 1.0 * *8003s310.fm
Maintenance plan (overview) S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 1 . f m
Maintenance plan/service hours (s/h)
3.3 3.3
Maint ainten enan ance ce plan plan (over overvi view ew))
Work description For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.
Fluid and filter changes (
( o n c e a d a y )
M a i n t e n a n c e w o r k
●
●
●
●
●
Air filter filter element element as indicated indicated by telltale telltale Cool Coolan antt Hydraulic Hydraulic oil oil filter filter insert 4 Hydr Hydraul aulic ic oil oil Breather – hydraulic hydraulic oil tank Gearb Gearbox ox oil oil5
Inspection work (
E v e r y 2 5 0 s / h
E v e r y 5 0 0 s / h
E v e r y 1 0 0 0 s / h
E v e r y 1 5 0 0 s / h
C u s t o m e r
w o r k s h o p
A u t h o r i s e d
● ● ●
● ● ●
●
●
●
●
●
●
●
●
●
●
●
):
Check the following material. Refill if necessary: • Engi Engine ne oil oil • Engine Engine cool coolant ant • Hydr Hydraul aulic ic oil oil • Gearb Gearbox ox oil oil6
●
●
●
●
●
● ●
●
Clean water ducts7
●
●
Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary
●
●
Check cooling systems, heating and hoses for leakages and pressure (visual check)
●
● ●
Replace cab filter for heating and air conditioning Air filter (damage)
3 - 5
o n c e a y e a r
):
Carry out the following oil and filter changes (check oil levels after test run): • Engin Enginee oil oil 1 • Engine Engine oil oil filter filter 2 • Fuel Fuel fil filte terr 3 • • • • • •
E v e r y 5 0 s / h
●
Prefilter with water separator: drain water • Clean ean
●
Check V-belt condition and tension
●
● ● ●
●
● ●
M a i n t e n a n c e p l a n ( o v e r v i e w )
3 - 6
Maintenance plan/service hours (s/h)
3.3 3.3
Maint ainten enan ance ce plan plan (over overvi view ew))
Work description For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.
Check exhaust system for damage and condition
( o n c e a d a y )
M a i n t e n a n c e w o r k
E v e r y 5 0 s / h
E v e r y 2 5 0 s / h
E v e r y 5 0 0 s / h
o n c e a y e a r
E v e r y 1 0 0 0 s / h
●
A u t h o r i s e d
● ●
●
●
Check the injection pressure 8
● ●
●
●
Empty diesel fuel tank ●
Check battery electrolyte. Fill up with distilled water if necessary
w o r k s h o p
●
Check the fuel injection pump
●
● ●
Check alternator, starter and electric connections, bearing play and function
●
●
Preheating system, electric connections
●
●
●
●
●
●
Air filter contamination contamination gauge gauge Pressure test of primary pressure relief valves
9
●
Check chains for cracks and cuts
●
●
Check chain tension. Retighten if necessary
●
● ●
Bearing play of tread rollers, track carrier rollers, front idlers Check piston rods for damage
●
Pin lock (dipper arm and implement)
●
Line fixtures
●
Check telltales for correct function Cab tilt lock Couplings, dirt pile-up on hydraulic system dust caps Grease supply of central lubrication system Adhesive labels labels and and operation operation manual manual
●
● ● ●
●
●
●
●
●
Insulating mats in engine compartment
● ●
●
Check screws for tightness S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 1 . f m
C u s t o m e r
●
Check valve tip clearance, adjust if necessary
Check injection nozzles and valves
E v e r y 1 5 0 0 s / h
● ● ●
●
●
●
●
●
● ● ●
M a i n t e n a n c e p l a n ( o v e r v i e w )
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 1 . f m
Maintenance plan/service hours (s/h)
3.3 3.3
Maint ainten enan ance ce plan plan (over overvi view ew))
Work description For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.
( o n c e a d a y )
M a i n t e n a n c e w o r k
E v e r y 5 0 s / h
E v e r y 2 5 0 s / h
E v e r y 5 0 0 s / h
o n c e a y e a r
E v e r y 1 0 0 0 s / h
E v e r y 1 5 0 0 s / h
C u s t o m e r
●
●
• Stabi Stabilis liser er blade blade
●
●
• Swivell Swivelling ing console console
●
●
• Boom
●
●
• Dipp Dipper er arm arm
●
●
• Impl Implem emen ents ts
●
●
Grea Grease se str strip ip on cha chass ssis is – see Lubrication strip on page 3-43
●
●
Engine cover gas strut
Lubrication service (
w o r k s h o p
A u t h o r i s e d
):
Lubricate the following assemblies/components:
•
Air conditioning (
):
Carry out the following maintenance and inspection work: • Air condit conditioni ioning ng functio functionn
●
Replace cab filter Check dehumidifier for corrosion, condensation and air bubbles
3 - 7
●
●
●
●
●
●
Replace dehumidifier
●
●
Compressor oil 10
●
●
M a i n t e n a n c e p l a n ( o v e r v i e w )
3 - 8
Maintenance plan/service hours (s/h)
3.3 3.3
Maint ainten enan ance ce plan plan (over overvi view ew))
Work description For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.
Functional check (
( o n c e a d a y )
M a i n t e n a n c e w o r k
E v e r y 5 0 s / h
E v e r y 2 5 0 s / h
E v e r y 5 0 0 s / h
o n c e a y e a r
E v e r y 1 0 0 0 s / h
E v e r y 1 5 0 0 s / h
C u s t o m e r
w o r k s h o p
A u t h o r i s e d
):
Check the function of the following assemblies/components. Rectify if necessary: • Lights, signalling signalling system, acoustic warning warning system
●
• Heati Heating ng functi function on
●
Leakage ch check (
● ●
●
):
Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary: • Visu Visual al chec checkk
●
●
☞ Engine and hydraulic system
●
●
☞ Cooling and heating circuit
●
●
☞ Travelling drive
●
●
1. Drain the engine oil the first time after 50 s/h, then every 250 s/h 2. Replace the engine oil filter the first time after 50 s/h, then every 250 s/h 3. Replace the fuel filter the first time after 50 s/h, then every 500 s/h 4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h 5. Drain the gearbox oil the first time after 50 s/h, then every 1000 s/h 6. Check the gearbox oil every second time 50 s/h servicing is carried out 7. Clean the wate r ducts every second time 1000 s/h servicing is carried out 8. Check the injection nozzles and the valves every second time 1500 s/h servicing is carried out 9. Check the first time at 50 s/h, then every 500 s/h 10. Drain compressor oil every 3000 s/h
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 1 . f m
M a i n t e n a n c e p l a n ( o v e r v i e w )
3.4
3.5
S e r vi ce p a ck ag e 1000127022
1
1000125571
1
Service package 8003 ➥ Engine oil filter
1000106891
1
➥ Fuel filter
1000106892
1
➥ Water separator element
1000069998
1
➥ Seal for diesel fuel filter housing
1000064543
1
➥ O-ring
1000012360
1
➥ O-ring for oil drain plug
1000012847
1
➥ Hydraulic reflux filter insert
1000022075
1
➥ Air filter insert (inside)
1000022076
1
➥ Air filter insert (outside)
1000125682
1
➥ Cylinder-head cover gasket
1000003894
3
➥ O-ring
I n t r o d u ct i o n Operational readiness and the service life of machines are heavily dependent on maintenance. Before carrying out service and maintenance work, always read, understand and follow the instructions given in
• Section 2 “SAFETY INSTRUCTIONS” in the operation manual • The operation manuals of the implements. Daily service and maintenance work, and maintenance according to maintenance plan “A” must “A” must be carried out by a specifically trained driver. All other maintenance work must be carried out by trained and qualified staff only. The maintenance plans indicate when the maintenance work mentioned below must be carried out ( – – see Maintenance plan (overview) on (overview) on page 3-5). 3-5).
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-9
3. 6
F u el sy s t em • Extreme caution is essential when handling fuel – high risk of fire!
Specific safety instructions
• Never carry out work on the fuel system in the vicinity of naked flames or sparks! • Do not smoke when working on the fuel system or when refuelling! • Before refuelling, switch off the engine and remove the ignition key! • Do not refuel in closed rooms! • Wipe away fuel spills immediately! • Keep the machine clean to reduce the risk of fire!
Refuelling
A
Filler inlet A for the fuel tank is located behind the cab, on the left in driving direction. Lock B on the filler inlet can be opened with the key of the machine. Use handleC handle C to climb onto the chain and as a safe hold during refuelling.
B
Danger ! All work involving fuel carries a n increased
Danger of fire and poisoning! ☞ Do not refuel in closed rooms ☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Environment! Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! C
Important!
Fig. g . 1: 1:
Fuel Fuel fil filler l er inle inlett
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system – system – see Bleeding the fuel system on system on page 3-11.
Important! Fill up the tank with the correct fuel type at the end of each working day. This prevents condensation water from forming in the fuel tank over night. Do not fill the tank completely but leave some space for the fuel to expand.
S ta ti on a ry fue l pu mp s
G e ne r a l Only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated. Even the smallest particles of dirt can cause
3-10
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
• Increased engine wear • Malfunctions in the fuel system and • Reduced effectiveness of the fuel filters Refuelling from barrels If refuelling from barrels cannot be avoided, note the following points (see fig. 2): wrong
• Barrels must neither be rolled nor tilted before refuelling • Protect the suction pipe opening of the barrel pump with a fine-mesh strainer • Immerse it down to a max. 15 cm above the floor of the barrel • Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter • Keep all refuelling containers clean at all times
right
Fig. Fig. 2: 2:
Refue Refuellllin ingg from from a bar barre rell
Diesel fuel specification
Use only high-grade fuels Cetane number
Grade
• No. 2-D according to DIN 51 601 • No. 1-D according to DIN 51 601
Use For normal outside temperatures
Min. 45
For outside temperatures below 4 °C or for operation above 1500 m altitude
Bleeding the fuel system
Danger ! If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased
Danger of burns! ☞ Never bleed the fuel system if the engine is hot!
Bleed the fuel system in the following cases:
• After removing and fitt ing the fuel filter, p refilter or the fuel lines ba ck on again • After running the fuel tank empty • After running the engine again, after a fter it has been out ou t of service for a long er period of time ☞ Bleed the fuel system as follows: • Fill the fuel tank • Turn the ignition key to the first position • Wait about 5 minutes while the fuel system bleeds itself automatically • Start the engine
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: • Switch off the engine • Bleed the fuel system again as described above • Have this checked by authorised staff if necessary
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-11
Fuel prefilter with water separator Check the fuel prefilter as follows: ☞ If the red indicator ring rises to position C
On
thread A ☞ Unscrew thread A Off
➥ The water drains ➥ Wait until the indicator ring returns to the bottom of the water separator
thread A back back on again ☞ Screw thread A B Interrupt fuel supply as follows: mark ☞ Turn ball-type cock B to the OFF mark ➥ Fuel supply is interrupted
C
☞ Turn ball-type cock B to the ON mark mark ➥ Fuel supply is open again
A
Fig. Fig. 3:
Fuel Fuel pref prefililter t er
Environment! Thread A is fitted with a hose. Collect the water as it drains with a suitable container and dispose of it in an environmentally friendly manner.
3-12
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Replacing the fuel filter
B
Danger ! If the fuel, as it drains, comes into contact with hot engine parts or the exhaust system, there is an increased
Danger of burns!
A
☞ Never change the fuel filter if the engine is hot
Fig. Fig. 4: 4:
Fuel Fuel filt filter er posit positio ionn
Environment! Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner! ☞ Change fuel filter 4/ A as follows:
• Close the fuel feed line with the stop cock on the fuel prefilter • Thoroughly clean the outside surfaces of fuel filter 4/A 4/A • Place a suitable container under the filter • Slacken and unscrew fuel filter cartridge using a commercially available tool • Collect the fuel as it drains
Fig. Fig. 5:
Unscr Unscrew ewin ingg the the fuel fuel filt filter er
• Clean the sealing surface of the filter carrier if it is fouled • Lightly oil the rubber gasket of the new filter cartridge or apply a th in coat of clean diesel fuel to it • Screw on the cartridge by hand until the gasket makes contact
Fig. 6:
Cleaning Cleaning the the sealing sealing surface surface and oiling the gasket
• Tighten the fuel filter cartridge by turning it a further half revolution • Open the stop cock on the water separator again • Bleed the fuel system – see Bleeding the fuel system on system on page 3-11 • Make a test run – and check for tightness! • Dispose of the old fuel filter cartridge by an ecologically safe method
Fig. Fig. 7:
Tigh Tighte teni ning ng the the fuel fuel fil filte ter r
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-13
3.7
Engi En gine ne lubr lubric icaation tion syste ystem m Caution! If the engine oil level is too low or if an oil change is overdue, this may cause
Engine damage or loss of output! ☞ Have the oil changed by an authorised workshop
– see Maintenance plan (overview) on page 3-5
Checking the oil level
Important! Check the oil level once a day. We recommend checking it before starting the engine. After switching off a warm engine, wait at least 5 minutes before checking.
Checking the oil level ☞ Proceed as follows: • Park the machine on level ground max min
A
• Switch off the engine! • Fold the control lever base up • Let the engine cool down • Open the engine cover • Clean the area around the oil dipstick with a lint-free cloth • Pull out oil dipstick A
☞ Wipe it with a lint-free cloth ☞ Push it back in as far as possible ☞ Withdraw it and read off the oil level Fig. Fig. 8: 8:
3-14
Chec Checki king ng the the oil oil level e vel
☞ However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Filling up engine oil
Caution! Too much or incorrect engine oil may result in engine damage! For this reason: A ☞ Do not add engine oil above the MAX mark of oil dipstick 9/ ☞ Use only the specified engine oil
Environment! Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner! ☞ Proceed as follows: • Clean the area around oil filler cap B with a lint-free cloth
B
OIL
• Open filler cap B • Raise oil dipstick A slightly to allow any trapped air to escape
A
• Fill in engine oil • Wait about 3 minutes until all the oil has run into the oil sump
level – see Checking the oil level on on page 3-14 • Check the oil level – • Fill up if necessary and check the oil level again • Close filler cap B • Push oil dipstick A back in as far as possible Fig. Fig. 9:
Oil dipstic dipstickk and and oil fill filler er cap
• Completely remove all oil spills from the engine
Changing engine oil
Danger ! Caution when draining hot engine oil – + 80 °C
Danger of burns! ☞ Wear protective gloves ☞ Use suitable tools
OIL Fig. 10: Optimum engine oil temperature temperature
Environment! Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!
☞ Change the engine oil as follows: • Park the machine on level ground SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-15
• Let the engine run until reaching service temperature (oil temperature about 80 ° C) • Switch off the engine • Place a container under the opening to collect the oil as it drains • Unscrew the oil drain plug • Completely drain the oil
oil – see section Filling up engine oil on on page 3-15 • Fill in engine oil – • Start the engine and run it at low speed for a short time • Switch off the engine • Wait a moment until all the oil has run into the oil sump • Check the oil level again • Fill up if necessary and check again • Completely remove all oil spills from the engine
Service valve option
• Park the machine on level ground B
C
• Let the engine run until reaching service temperature (oil temperature about 80 ° C) • Switch off the engine • Place a container under the opening to collect the oil as it drains • Unscrew cap A of oil drain valve B • Screw in the drain coupling with a sufficiently long hose D, making sure the end of the hose is in oil drip tray E ➥ Oil drain valve B opens and the engine oil drains
A Fig. Fig. 11: 11:
• Completely drain the oil • Unscrew drain coupling C
Drain Drain coupl coupling ing with with hose hose
• Screw on cap A of the oil drain valve • Fill in engine oil – oil – see section Filling up engine oil on on page 3-15
B
• Start the engine and run it at low speed for a short time • Switch off the engine
C
• Wait a moment until all the oil has run into the oil sump • Check the oil level again
D E
• Fill up if necessary and check again • Completely remove all oil spills from the engine
Fig. Fig. 12: Drain Drain coupl coupling ing with with hose hose
3-16
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Replacing the engine oil filter cartridge
Danger ! Caution when draining hot engine oil – A
Danger of burns! ☞ Wear protective gloves
Fig. Fig. 13: Engine Engine oil filter filter posit position ion
Environment! Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an environmentally friendly manner!! ☞ Change the filter as follows: • Switch off the engine • Place a suitable container under the oil filter to collect the oil • Slowly slacken oil filter cartridge A using a commercially available tool
A
• Let the oil drain into the container • Remove the filter cartridge once the oil is completely drained • Make sure the thread adapter is correctly placed in the filter head
Fig. 14: Unscrewing Unscrewing the engine engine oil filter
• Clean the inside of the filter head • Apply a thin coat o f fresh engine oil to rubber seal B of the new oil filter cartridge • Tighten the new filter cartridge by hand until the gasket makes contact
B
Fig. 15: 15: Cleaning Cleaning the filter lter head head and oiling oiling the the gasket gasket
• Tighten oil filter cartridge A with a commercially available tool by about a further half
revolution A
• Make sure the oil level is correct! • Run the engine for a short time • Switch off the engine • Check the seal of oil filter cartridge A and retighten by hand • Check the oil level and add engine oil if necessary • Completely remove all oil spills from the engine
Fig. 16: Tightening Tightening the filter lter cartridge cartridge
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
• Dispose of the used oil filter in an environmentally friendly manner
3-17
3. 8
C o o l i n g sy st e m The oil and water cooler is located in the engine compartment, on the right side of the engine. The expansion tank for the coolant is also located in the engine compartment, in front of the oil cooler. – see section 1.10 1. 10 Engine Engine compartment: overview on on page 1-11
Specific safety instructions
• Dirt on the cooling ribs reduces the cooler’s heat dissipation capacity! To avoid this: ☞ Clean the outside of the radiator at regular intervals. Use oil-free compressed air (2
bar max.) to clean. Maintain a certain distance to the radiator to avoid damage to the radiator fins. Clean the radiator from the outside to the inside. Refer to the maintenance plans in the appendix for the cleaning intervals ☞ In dusty or dirty work conditions, clean more frequently than indicated in the mainte-
nance plans
• An insufficient coolan t level reduces the heat dissipation capa city as well and can lead to engine damage! Therefore: ☞ Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals ☞ If coolant must be added frequently, check the cooling system for leakages and/or
contact your dealer! ☞ Never fill in cold water/coolant if the engine is warm! ☞ After filling the expansion tank, make a test run with the engine and check the coolant
level again after switching off the engine
• The use of the wrong coolant can destroy the engine and the cooler. Therefore: an tifreeze compound to t o the coolant – but never more than 50 %. If pos☞ Add enough antifreeze sible use brand-name antifreeze compounds with anticorrosion additives ☞ Observe the coolant compound table – table – see section 2.8 2. 8 Coolant Coolant compound table on table on
page 2-5 ☞ Do not use cooler cleaning compounds if an antifreeze compound has been added to
the coolant – otherwise this causes sludge to form, which can damage the engine
• Once you have filled the expansion tank: ☞ Test run the engine ☞ Switch off the engine ☞ Let the engine cool down ☞ Check the coolant level again
Environment! Use a suitable container to collect the coolant as it drains and dispose of it in an environmentally friendly manner!
3-18
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Checking/filling up coolant
Danger ! Never open the coolant tank and never drain coolant if the engine is warm since the cooling system is under high pressure –
Danger of burns! ☞ Wait at least 15 minutes after switching off the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap B to the first notch and allow the pressure to escape ☞ Make sure the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands
Danger ! Antifreeze is flammable and an d poisonous –
Danger of accidents! ☞ Keep away from flames ☞ Avoid eye contact with antifreeze
• If antifr antifreeze eeze comes comes into contact contact with with the the eyes eyes ➥ Immediately rinse with clean water and seek medical assistance
Checking the coolant level ☞ Proceed as follows:
A
• Park the machine on level ground • Switch off the engine! • Fold the control lever base up • Remove the key and carry it with you • Let the engine and the coolant cool down • Open the engine cover
tank A and on the radiator B • Check the coolant level on the transparent coolant tankA ☞ If the coolant level is below the LOW seam LOW seam or if there is no coolant at the radiator's FULL LOW
filler inlet: • Filling up coolant
Fig. Fig. 17: Expans Expansion ion tank tank for cool coolant ant
Important! Check the coolant level once a day. We recommend checking it before starting the engine.
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-19
Filling up coolant After the engine has cooled down: B
☞ Release overpressure in the radiator ☞ Carefully open the cap to the first notch and allow the pressure to fully escape ☞ Open filler cap B ☞ Fill in coolant up to the lower edge of the filler inlet (radiator) ☞ Close filler cap B ☞ Start the engine and let it warm up for about 5 – 10 minutes ☞ Switch off the engine ☞ Remove the key and carry it with you
Fig. Fig. 18: 18: Radiat Radiator or fill filler e r cap cap
☞ Let the engine cool down ☞ Check the coolant level again ➥ The coolant level must be between the LOW and FULL tank seams ☞ If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant
Important! Check the antifreeze every year before the cold season sets in
Draining coolant
Danger ! Never open the coolant tank and never drain coolant if the engine is warm since the cooling system is under high pressure –
Danger of burns! ☞ Wait at least 10 minutes after switching off the engine! ☞ Wear protective gloves and clothing ☞ Open filler cap 18/B to the first notch and allow the pressure to escape
After the engine has cooled down: ☞ Release overpressure in the radiator ☞ Open the cap to the first notch and allow the pressure to fully escape ☞ Open filler cap 18/B ☞ Open the drain plug of the radiator and drain the coolant ☞ Close the drain plug again ☞ Fill up the radiator with suitable coolant
– see Fluids and lubricants on page 3-1 ☞ Check the coolant level
– see Checking the coolant level on page 3-19
3-20
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
3.9
Air f ilter Caution! The filter cartridge will be damaged if it is washed or brushed out! Bear in mind the following to avoid premature engine wear! ☞ Do not clean the filter cartridge ☞ Replace the filter cartridge when the telltale comes on ☞ Never reuse a damaged filter cartridge ☞ Ensure cleanliness when replacing the filter cartridge!
Telltale 19/31 in the round display element monitors the filter cartridge. 19/B and inside filter 19/C : ☞ Replace outside filter 19/B and • If telltale 31 in the round display element comes on • According to the main tenance plan
Important! For applications in especially dusty environment, environment, the air filter is fitted with an extra inside filter C. Do not clean inside filter C.
31
Caution! Filter cartridges degrade prematurely when in service in acidic air for longer periods of time. This risk is present for example in acid production facilities, steel and aluminium mills, chemical plants and other nonferrous-metal plants. at the latest after 50 service ☞ Replace outside filter B and inside filter C at hours!
General instructions for air filter maintenance:
• Store filters in their original packaging and in a dry place B
• Do not knock the filter against other objects as you install it • Check air filter attachments, air intake hoses and air filters for damage, and immediately repair or replace if necessary
C
• Check the screws at the induction manifold and the clamps for tightness • Check the function of the dust valve, replace if necessary
Fig. Fig. 19: Air Air fil filter ter
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-21
Replacing the filter
• Replace outside filter 21/B as follows: D
☞ Switch off the engine ☞ Remove the key and carry it with you ☞ Let the engine cool down ☞ Open the engine cover
E
☞ Remove dirt and dust from the air filter and the area around the air filter ☞ Fold both bow clips 21/D on 21/D on lower housing section 21/E to 21/E to the outside ☞ Remove lower housing section E Fig. 20: Removing ng the lower housing housing section section
☞ Carefully remove outside filter B with slightly turning movements ☞ Make sure all dirt (dust) inside the upper and lower housing sections, including the dust
valve, has been removed B
☞ Clean the parts with a clean lint-free cloth, do not use compressed air ☞ Check the air filter cartridges for damage, only install intact filters ☞ Carefully insert new outside filter B in the upper housing section ☞ Position lower housing section E (make sure it is properly seated) ☞ Close both bow clips D
Fig. Fig. 21: Removin Removingg the filter filter elem element ent
• Replace inside filter 22/C as as follows: F
☞ Switch off the engine ☞ Remove the key and carry it with you ☞ Let the engine cool down ☞ Open the engine cover ☞ Remove dirt and dust from the air filter and the area around the air filter
C
☞ Fold both bow clips D on lower housing section E to the outside ☞ Remove lower housing section E
Fig. Fig. 22: Replac Replacing ing the the inside d e filter filter
☞ Carefully remove outside filter B with slightly turning movements ☞ Carefully remove Innenfilter C ☞ Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
from entering the engine ☞ Make sure all dirt (dust) inside the upper and lower housing sections 22/F , including
dust valve 23/G , has been removed ☞ Clean the parts with a clean lint-free cloth, do not use compressed air ☞ Remove the cloth from the air supply ☞ Check the air filter cartridges for damage, only install intact filters ☞ Carefully insert new inside filter C in the inside housing section F (model 6003 only) ☞ Carefully insert outside filter B in the upper housing section ☞ Position lower housing section E (make sure it is properly seated) ☞ Close both bow clips D
Important! Make sure dust valve G shows downwards once it is installed!
3-22
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Functional check of the dust valve once a week
The air filter is located in the engine compartment, on the right side of the machine ☞ Proceed as follows: • Switch off the engine
handb rake • Apply the handbrake • Squeeze the discharge slot of dust valve 23/G • Remove hardened dust by compressing the upper area of the valve
☞ Clean the discharge slot if necessary
G
Fig. Fig. 23: Air filter filter – dust dust valve valve
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-23
3. 1 0 V-b e l t Danger ! Only check or retighten/replace the V-belt when the engine is switched off –
Danger of personal injury! ☞ Switch off the engine before carrying out inspection work in the engine
compartment! ☞ Disconnect the battery or the battery master switch ☞ Let the engine cool down
Check the V-belt once a day or every 10 service hours, and retighten if necessary! Retighten new V-belts after about 15 minutes of running time.
Checking the V-belt tension
• Check as follows: 1
☞ Switch off the engine ☞ Fold the control lever base up ☞ Remove the key and carry it with you ☞ Disconnect the battery or the battery master switch ☞ Let the engine cool down ☞ Open the engine cover
24/1 for damage, cracks or cuts ☞ Carefully check V-belt 24/1 for ☞ Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley
• If the V-belt is damaged: Fig. Fig. 24: Checki Checking ng V-be V-beltlt tensio tensionn
☞ Have the V-belt replaced by authorised staff ☞ Press with your thumb about 100 N to check the deflection of the V-belt between the
crankshaft disc and the fan wheel position 24/C. 24/C. A new V-belt should have a deflection of 6 to 8 mm, a used V-belt (after about 5 minutes running time) should have a deflection of 7 to 9 mm ☞ Retighten the V-belt if necessary
3-24
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Retightening the V-belt
Caution! Overtightening the V-belt can damage the V-belt, the V-belt guide and the water pump bearing. Avoid contact of oil, grease or similar substances with the V-belt. ☞ Checking V-belt tension – see Checking the V-belt tension on page 3-24
• Retighten as follows: ☞ Switch off the engine ☞ Fold the control lever base up
5
☞ Remove the key and carry it with you ☞ Tilt the cab upwards ☞ Disconnect the battery or the battery master switch ☞ Let the engine cool down ☞ Unscrew cover 25/5
25/3 of alternator 25/4 ☞ Slacken attachment screws 25/3 of ☞ Use a suitable tool to push the alternator in the direction of arrow A until reaching the
correct V-belt tension (fig. 25) ☞ Keep the alternator in this position, and at the same time retighten attachment
screws 3 ☞ Check V-belt tension again and adjust it if necessary
3
☞ Screw on cover 5 ☞ Connect the battery or the battery master switch ☞ Tilt down the cab
A
4 Fig. Fig. 25: Retightenin g hteningg the V-be V-beltlt
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-25
Checking the V-belt of the air conditioning system
Caution! Excessive or insufficient tension of the V-belt may cause damage to the V-belt or to the compressor of the air conditioning system. V-b elt has the correct te nsion ☞ Always make sure the V-belt ☞ Replace V-belts with damage, cracks, cuts etc. ☞ Avoid contact of oil, grease or similar substances substance s with the V-belt
• Check as follows: 2
☞ Switch off the engine
1
☞ Fold the control lever base up ☞ Remove the key and carry it with you
About 9 mm
☞ Disconnect the battery or the battery master switch ☞ Let the engine cool down ☞ Open the engine cover
26/1 for damage, cracks or cuts ☞ Carefully check V-belt 26/1 for ☞ Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley Fig. 26: Checking ng the V-belt V-belt tension tension of of the air conditi conditioning oning
• If the V-belt is damaged: ☞ Have the V-belt replaced by authorised staff ☞ Press with your thumb about 100 N to check the deflection of the V-belt. A new V-belt
should have a deflection of 7 to 9 mm, a used V-belt (after about 5 minutes running time) should have a deflection of 9 to 11 mm ☞ Retighten the V-belt if necessary
Tightening the V-belt of the air conditioning system
• Retighten as follows: 4
3
☞ Switch off the engine ☞ Fold the control lever base up
5
A
☞ Remove the key and carry it with you ☞ Disconnect the battery or the battery master switch ☞ Let the engine cool down ☞ Open the engine cover ☞ Slacken attachment screws 27/3 and 27/3 and 27/4 of 27/4 of alternator 5 ☞ Use a suitable tool to push the compressor in the direction of arrow A until reaching
Fig. 27: Retightening Retightening the the V-belt V-belt of the air air conditioning tioning sys-
the correct V-belt tension (fig. 27) 27) ☞ Keep the compressor in this position, and at the same time retighten attachment
screws 3 and 4 ☞ Check V-belt tension again and adjust it if necessary ☞ Connect the battery or the battery master switch ☞ Close the engine cover
3-26
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
3.1 3.11 Pres Pressu sure re check heck • Run the machine warm before checking the pressure! Hydraulic oil temperature: 50 °C min. (operating temperature)
General
• Pressure drop is checked under constant load • Set the primary pressure limiting valves (PPLV) at maximum engine revs! • See chapter “Specifications” – “Specifications” – see Hydraulic system on system on page 2-2 for the pressure settings
Pressure check of variable displacement pumps P1and P2
Functions: drive to the left, auxiliary hydraulics, swivel, boom 2, dipper arm Function: drive to the right, bucket, boom, dipper arm 2 Checking the primary pressure limiting valve 1 (PPLV 1) for pumps P1 and P2
1
2
28/1 for P1 or MP 2 28/2 for for P2 ☞ Connect the pressure gauge to measuring port MP 1 28/1 for ☞ Retract the dipper arm cylinder (or extend the boom cylinder) as far as it
will go at maximum engine revs ☞ Check and make a note of the pressure value.
Checking pressure drop ☞ Retract the dipper arm cylinder (or extend the boom cylinder) as far as it will go at max-
imum engine revs ☞ Swiftly reduce engine revs from maximum to minimum -> pressure drop
Fig. Fig. 28: Measuri Measuring n g ports ports P1 P1 and P2
☞ Check and make a note of the pressure value. ➥ Pressure drop should not exceed the specified value by more than 10 %
Adjustment of the primary pressure limiting valve 1 (PPLV 1) for pumps P1 and P2 ☞ Adjust the pressure at the primary pressure limiting valve (PPLV 1) 29/A on the main
valve block ☞ Slacken the locknut of the pressure limiting valve ☞ Unscrew the pressure limiting valve until you can read off a pressure drop on the
pressure gauge ➥ The valve seat may be stuck and must be slackened first ☞ Adjust the pressure limiting valve and tighten the locknut
A
☞ Check the primary pressure limiting valve 29/A and the pressure drop once adjustment
is over P1 check also with: rod side boom function, forwards/reverse driving to the left! Fig. 29: 29: Primary Primary pressure pressure limiting ng valves valves P1 and and P2
P2 check also with: base side dipper arm function, base/rod side bucket, forwards/ reverse driving to the right! Checking the auxiliary hydraulics pressure
Important! Factory indications for auxiliary hydraulics secondary valves are possibly invalid since the valves must be adapted to the implement!
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-27
Pressure check of gear pumps P3 and P4
Functions: stabiliser blade, rotation, 3rd control circuit option, triple articulation boom option Checking primary pressure limiting valve 2 (PPLV 2) for pump P3 ☞ Connect a pressure gauge to measuring port MP 3 30/3 ☞Extend the stabiliser blade cylinder as far as it will go at maximum engine revs ☞ Check and make a note of the pressure value.
3
4 Checking pressure drop ☞ Extend the stabiliser blade cylinder as far as it will go at maximum engine revs ☞ Swiftly reduce engine revs from maximum to minimum -> pressure drop ☞ Check and make a note of the pressure value. ➥ Pressure drop should not exceed the specified value by more than 10 %
Fig. Fig. 30: 30: Measur Measuring ing port port P3 P3
Adjustment of primary pressure limiting valve 2 (PPLV 2) for pump P3 ☞ Adjust the pressure a t the primary pressure limiting valve (PPLV 2) 31/B on 31/B on the main
valve block ☞ Slacken the locknut of the pressure limiting valve ☞ Unscrew the pressure limiting valve until you can read off a pressure drop on the
B
pressure gauge ➥ The valve seat may be stuck and must be slackened first ☞ Adjust the pressure limiting valve and tighten the locknut ☞ Check the primary pressure limiting valve 31/B and the pressure drop once adjustment
is over Checking primary pressure limiting valve 2 (PPLV 2) for pump P4 ☞ Connect a pressure gauge to measuring port MP 4 30/4 Fig. 31: 31: Primary Primary pressur pressuree limiting limiting valves ves P3 and and P4
☞ Extend the stabiliser blade cylinder as far as it will go at maximum engine revs ☞ Check and make a note of the pressure value ➥ Pressure is limited to 165 bar by pressure cut-off valve
– see section Pressure cut-off valve on valve on page 5-29 Also check with the retract stabiliser blade, boom swivel and rotate functions!
3-28
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
Checking pilot control pressure Checking pilot control pressure ☞ Connect a pressure gauge to measuring port MP 32/5
5
☞ Move the control lever base (safety switch) to work position ☞ Actuate the joystick joyst ick ☞ Check and make a note of the pressure value.
Fig. 32: 32: Pilot control control pressur pressuree measuring measuring port
Setting the pressure reducing valve 33/C (PRV4) 4) 33/C at the pilot oil supply ☞ Adjust the pressure at the pressure reducing valve (PRV 4) 33/C unit ☞ Check the pilot control pressure again once adjustment is over
C
Fig. Fig. 33: Pressu Pressure re reduci reducing n g valve valve
Secondary pressure limiting valve of the gear motor
Check (idling speed) 1
☞ Connect a pressure gauge to measuring port MP 3 ☞ Place the bucket or the boom against the ground or the stabiliser blade, or rotate
against hydraulic resistance ☞ Check and make a note of the pressure value.
Adjusting the secondary pressure limiting valve of the gear motor p ressure limiting valve on the th e gear motor ☞ Adjust the pressure at the secondary pressure ☞ Slacken the locknut of the pressure limiting valve34/1 valve34/1 ☞ Unscrew the pressure limiting valve until you can read off a pressure drop on the
pressure gauge Fig. 34: Secondary Secondary pressure pressure limiti imiting ng valve valve
➥ The valve seat may be stuck and must be slackened first ☞ Adjust the pressure limiting valve and tighten the locknut ☞ Check the secondary pressure limiting valve again once adjustment is over
SERV-HB 8003 En – Edition 1.0 *8003s312.fm
3-29
Measuring ports: overview
3 1
2
4
5
Fig. Fig. 35: 35: Measure Measurement ment ports ports
Fig. Fig. 36: 36: Measur Measureme ement nt port portss
Pos. 1
Description Measuring port for pump 1
MP 1
2
Measuring port for pump 2
MP 2
3
Measuring port for pump 3
MP 3
4
Measuring port pump 4
MP 4
5
Pilot oil supply unit measuring port
MP 5
Primary pressure limiting valves
C
2
1
Pos.
3-30
1
Description Pr Prim imar aryy pre press ssur uree lim limit itin ingg val valve vess pum pumps ps 1 and and 2
PPLV 1
2
Pr Prim imar aryy pre press ssur uree lilimiti miting ng valv valves es pump pumpss 3 and and 4
PPLV 2
3
Pressure reducing valve
PRV 4
SERV-HB 8003 En – Edition 1.0 * *8003s312.fm
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 3 . f m
3 .12 Tes t r e p or t Pump 1 Movement
Function
Symbol
P r i m a r y p r ( e m s a s u i n r v e a i l l v m e t i n b i l g o v c k a ) l v e P P L V 1
UP Boom DOWN EXTEND Bucket RETRACT
Left-hand side drive
Pressure limiting valve
FORWARDS REVERSE
Measuring port
( p u m p )
M e a s u r i n g p o r t M P 1
Specified values
Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop
Measured
✔
Measured
✔
±3
300 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar
Pump 2 Movement
Function
EXTEND Dipper arm RETRACT
Right-hand side drive
3 - 3 1
Auxiliary hydrauhydraulics
FORWARDS REVERSE A B
Symbol
Pressure limiting valve P r i m a r y p r ( e m s a s i n u r v e a i l l v m e t i n b i l g o c v k a ) l v e P P L V 2
Measuring port
( p u m p )
M e a s u r i n g p o r t M P 2
Specified values
Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop
±3
300 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar 300 ±3 bar 25 bar
3 - 3 2
3 .12 Tes t r e p or t Pump 3 Movement
Function
Symbol
P r i m a r y p r ( e m s s a u i n r v e a l i l v m e t i n b i g l o c v k a ) l v e P P L V 1
UP Stabiliser blade DOWN
Auxiliary hydrauhydraulics
Pressure limiting valve
A (2) B (2) LEFT
Boom swivel RIGHT LEFT Rotate RIGHT
Measuring port
( p u m p )
M e a s u r i n g p o r t M P 3
Secondary pressure limiting valve SPLV 4 (gear motor)
Gear motor
Pressure limiting valve
Measuring port
Specified values
Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop Rated value Drop
245-0/+3 bar 25 bar 245-0/+3 bar 25 bar 245-0/+3 bar 25 bar 245-0/+3 bar 25 bar 245-0/+3 bar 25 bar 245-0/+3 bar 25 bar
Rated value
225+3 bar
Rated value
225+3 bar
Measured
✔
Measured
✔
Pilot control Movement
Function S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 3 1 3 . f m
Joystick
ANY
Symbol
Pressure reducing valve PRV 5 (pilot oil supply unit)
Measuring port
Specified values
Rated value
32.5-0/+4 bar
3.13 3.13 Hydr Hydraaulic ulic sy syste stem Specific safety instructions
• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and repair work. To do this: • Lower all hydraulically controlled implements to the ground • Move all control levers of the hydraulic control valves several times
• Fold the control lever base up • Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately even if the wound seems insignificant – otherwise serious infections could set in! • If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. This may cause damage to the hydraulic pump! • Oil or fuel flowing out of high pressure lines may cause fire or malfunctions, and severe injuries or damage to property. Interrupt work immediately if slack nuts or damaged hoses and lines are detected. ☞ Contact your Neuson dealer immediately
• Replace the hose or line if one of the problems mentioned below is detected. ☞ Damaged or leaky hydraulic seals. ☞ Worn or torn shells or uncovered reinforcement branches. ☞ Expanded shells in several positions. ☞ Entangled or crushed movable parts. ☞ Foreign bodies jammed or stuck in protective layers.
Caution! Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –
Danger of severe damage to the hydraulic system! ☞ Take care to avoid contamination when working! ☞ Always fill in hydraulic oil by means of a strainer or the ref lux filter! ☞ Only use authorised oils of the same type
– see Fluids and lubricants on page 3-1 ☞ Always fill up hydraulic oil bef ore the level gets to o low
– see Filling up hydraulic oil on page 3-36 ☞ If the hydraulic system is filled with biodegradable oil, then only use the
same biodegradable oil for filling up – observe the sticker on the hydraulic oil tank! ☞ Contact customer service if the hydraulic system filter is contaminated with
metal chippings. Otherwise, follow-on damage may result!
Environment! Collect hydraulic oil, including biodegradable oil, with a suitable container! Dispose of drained oil and used filters by an ecologically safe method. Always contact the relevant authorities or co mmercial establishments in charge of oil disposal before disposing of biodegradable oil.
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-35
Checking the hydraulic oil level
Caution! Do not fill up oil if the oil level is above the FULL mark, FULL mark, otherwise the hydraulic system may be damaged and escaping oil may cause serious injuries. ☞ Check the hydraulic oil level each time the machine is taken into service or
once a day
• If the implement is not positioned as shown: ☞ Start the engine and let it run at idling speed ☞ Retract the bucket and boom cylinders, lower the boom and the bucket teeth to the
ground ☞ Switch off the engine again.
Fig. Fig. 37: Parkin Parkingg the exca excavat vator or
Checking the hydraulic oil level A
☞ Proceed as follows: • Park the machine on level ground • Switch off the engine
FULL
• Fold the control lever base up
LOW
• Open the engine cover • Sight glass A is located on hydraulic oil tank B
B
• Check the oil level on sight glass A
FULL level • The oil level must be at the FULL level • A gauge elemen elementt in sight sight glass glass A indicates the oil level If the oil level is lower • Filling up hydraulic oil
Fig. 38: 38: Oil level level indicator cator on the hydraul hydraulic ic oil tank
The oil level varies according to the machine's operating temperature: Machine condition • Before taking into service • Normal operation
Temperature
O il l e v e l
Between 10 and 30 °C
LOW mark LOW mark
Between 50 and 90 °C
FULL mark FULL mark
Important! Measure the oil level of the hydraulic system only after the machine reaches its operating temperature. 1
3-36
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
Filling up hydraulic oil
Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will run out of the filler opening on the hydraulic tank. ☞ Fill up as follows: • Park the machine on level ground • Retract all hydraulic cylinders • Switch off the engine • Fold the control lever base up • Clean the area around filler opening C with a cloth • Open filler opening C • Filling up hydraulic oil • Check the hydraulic oil level on sight glass B • Fill up if necessary and check again • Close filler opening C
Fig. Fig. 39: Hydrau Hydraulic lic oil oil fille fillerr inlet inlet
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-37
Changing hydraulic oil
Important! Only change the hydraulic oil if it is warm (about 50 °C). Retract all hydraulic cylinders before changing the oil. ☞ Open the breather filter to release pressure ☞ Open the drain plug to let the oil drain into a container ☞ Check the hydraulic oil tank for contamination and clean if necessary ☞ Replace the filter according to the maintenance specifications ☞ Screw the drain plug back in correctly ☞ Fill in clean hydraulic oil through the strainer
– see Filling up hydraulic oil on page 3-36 ☞ Close the hydraulic oil tank correctly ☞ Let the machine run at idling speed without load for some minutes
Monitoring the hydraulic oil reflux filter
33
The red telltale 40/33 on the instrument panel monitors the reflux filter. The filter element must be replaced by an authorised workshop:
• If telltale 33 comes on when the hydraulic oil is at operating temperature • At the latest after aft er 1500 service hours (on ce every year) In cold weather telltale 33 may come on immediately when the engine is started. This is caused by increased oil viscosity. In this case: ☞ Set engine speed so that telltale 33 goes out
Fig. 40: Telltale for for reflux reflux filter filter
3-38
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
Checking hydraulic pressure lines Specific safety instructions
Danger ! Caution when checking hydraulic lines, especially when searching for leaks. Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries.
Danger of personal injury! ☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections infectio ns could set in! ☞ Always observe the following instructions:
• Retighten Retighten leaking leaking screwed screwed fittings fittings and hose connections connections only when the system is not under pressure; i.e. release the pressure before working on pressurised lines! • Never weld weld or solder solder faulty faulty or leaking pressure pressure lines and connections. connections. Replace damaged parts with new ones! • Never search for leakages leakages with with your your bare hands, but wear protective protective gloves! • Use paper paper or wood to check for minor minor leaks. leaks. Never Never use use an unprotecte unprotectedd light or naked flame! • Have damaged damaged flexible flexible lines replaced by authorised authorised workshops workshops only!
• Leakages and damaged pressure lines must be repaired immediately or replaced by an authorised workshop or after-sales staff. This not only increases the operating safety of your machine but also helps to protect the environment • Replace hydraulic hoses every 6 years from the date of manufacture, even if they do not seem to be damaged In this respect, we recommend that you observe all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20 066, part 5.
1 Q/00
The date of manufacture (month or quarter and year) is indicated on the flexible line. Example: The indication “1 Q/00” Q/00” means manufactured in the 1st quarter of 2000.
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-39
3.14 .14 Trav ravelli elling ng dri drive ve Danger ! Immediately after switching off the engine, the engine's components and the oil are very hot. This may cause burns. If the inside of the travelling drive is under pressure, the oil or the plug may be squeezed out.
Danger of injury and scalding! ☞ Wait until the engine has cooled down before taking up work. ☞ Slowly open the plug to reduce the pressure inside.
Checking the oil level and filling up oil ☞ Park the machine on firm and level ground
A
plug A is is at the top ☞ Place the machine so that filler plug A ☞ Switch off the engine
B
☞ Let the engine cool down ☞ Fold the control lever base up
screws A and and B with a suitable tool ☞ Unscrew screws A ☞ A small quantity of oil must flow out of openin g B
Fig. Fig. 41: Checki Checking n g the the oil level level
➥ If the oil does not flow out of opening B, fill up oil: ☞ Fill in oil at opening A, ➥ until a small quantity of oil flows out of opening B ☞ Screw screws A screws A and and B back in again ☞ Move the machine a few metres ☞ Check the oil level again ➥ If the oil level is not correct: ☞ Repeat the procedure
Draining oil ☞ Park the machine on firm and level ground
B
☞ Place the machine so that filler plug B is at the bottom ☞ Switch off the engine
A
☞ Let the engine cool down ☞ Fold the control lever base up ☞ Unscrew screws A screws A and and B with a suitable tool
Fig. Fig. 42: 42: Drai Draini ning ng oil oil
➥ The oil now flows out of opening A ☞ Use a suitable container to collect the oil as it drains
Environment! Collect the oil with a suitable container and dispose of it in an environmentally friendly manner.
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SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
3.15 Chain s • Chain wear may vary according to work and ground conditions. ☞ We recommend checking chain wear and tension once a day. ☞ Park the machine on firm and level ground to check and carry out maintenance.
Checking chain tension
Danger ! Working under the machine with the chains off the ground and only supported by the implement is extremely dangerous.
Caution, danger! ☞ Firmly support the machine with chocks or suitable brackets
Check chain tension as follows:
• The rubber chain has a mark B as shown in Fig. 43 ☞ Place the excavator so that mark B of the rubber chain is between the drive pinion C
and the chain tension roller D B
C
D
Important! There is no mark on the steel chains (options). Positioning the steel chains is not possible. • No specific specific position position is required for for the steel chains chains (option)
Fig. Fig. 43: 43: Rubber Rubber chain chain mark mark
☞ Park the machine on firm and level ground ☞ Raise the excavator with the boom and the dipper arm ☞ Slowly and carefully actuate the control levers ☞ Switch off the engine ☞ Remove the key and carry it with you ☞ Fold the control lever base up ☞ Use suitable auxiliary means to support the machine
Fig. Fig. 44: Raisin Raisingg the exca excavat vator or
• Standard play between the sliding block's shoulder and the contact area of the second support roller of the drive pinion is 20 – 25 mm. ☞ Set the tension as follows if it is not in accordance with the rated value.
20 – 25 m
Fig. Fig. 45: 45: Measuri Measuring ng dist distanc ancee
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-41
Setting the chains
Danger ! The lubricating valve may be squeezed out due to the high grease pressure in the hydraulic cylinder.
Danger of personal injury! ☞ Do not slacken and unscrew the lubricating valve by more than one turn. ☞ Slacken no other component except the lubricating valve. ☞ Keep your face away from the lubricating valve connection. ➥ Contact your Neuson dealer if this does not reduce the tension of the
rubber sliding block.
Caution! Excessive tension of the chains causes severe damage to the cylinder and the chain. ☞ Tighten the chains only up to the prescribed measuring distance
Tightening the chains valve A ☞ Inject grease with the pump through lubricating valve A ☞ Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again ☞ Check the tension of the track chains again ➥ If it is not correct: ☞ Adjust again ☞ Should the track chain still be slack after injecting more grease, replace the chain or the
A
seal in the cylinder. Contact a Neuson dealer in this case
Fig. Fig. 46: Tight Tighteni ening ng the the chains chains
Reducing tension
• Draining grease in a way different from the one described below is very dangerous. Also bear in mind the sa fety instructions on this page ☞ Slowly open the lubricating valve A valve A by by 1 turn to allow the grease to flow out. ☞ Place a suitable container underneath to collect the grease ➥ The grease flows out of the groove of the lubricating valve ☞ Retighten the lubricating valve A valve A
A
☞ Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again Fig. Fig. 47: Draini Draining n g grease grease
☞ Check the tension of the track chains again ➥ If it is not correct: ☞ Adjust again
Environment! Use a suitable container to collect the grease as it flows out and dispose of it in an environmentally friendly manner. ☞ Apply grease to lubricat ion points E on on the dipper arm
3-42
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
Lubrication strip Apply grease to the th e lubrication strip as fo llows: 48/A for the offset cylinder ☞ Lubrication point 48/A for 48/B for the live ring ☞ Lubrication point 48/B for C
Important! A
Apply grease to lubrication lu brication points A and B once a day.
B A portable lamp can be connected to t o the lubrication strip's 12 V connectionC connection C. Fig. 48: Lubrication Lubrication strip on the chassis chassis
Maintenance of implements
Important! Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for an increased service life of the implements. Please observe the lubrication and maintenance instructions in the implements' operation manuals
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-43
3.16 .16 Ele Electri ctricc sy syste stem Specific safety instructions
• The battery contains sulphuric acid! This acid must not be allowed to come into contact with the skin, the eyes, clothing or the machine. Therefore when recharging or working near the battery: ☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt: ☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
• During charging in particular, but also during normal battery operation, an oxyhydrogen mixture is formed in the battery cells – danger of explosion! • Do not attempt to jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode! ☞ Replace the battery immediately
• Avoid naked flames and sparks and do not smoke in the vicinity of open b attery cells – otherwise the gas produced during normal battery operation may ignite! • Use only 12 V power sources. Higher voltages will damage the electric components • When connecting the battery leads, make sure the poles +/– are not reversed, otherwise sensitive electric components will be damaged • Do not interrupt voltage-carrying circuits at the battery terminals because of the danger of sparking! • Never place tools or other conductive articles on the battery – danger of short circuit! • Disconnect the negative ( –) –) battery terminal from the battery before starting repair work on the electric system • Dispose of used batteries properly Service and maintenance work at regular intervals Before driving the machine ☞ Check every time before driving the machine: • Is the light system OK? • Is the signalling and warning system OK?
Every week ☞ Check once a week: • Electric fuses
– see Fuse box in instrument panel on on page 2-4 • Cable and earth connections
condition – see Battery on on page 3-46 • Batter charge condition – • Condition of battery terminals
Instructions concerning specific components
3-44
Cables, bulbs and fuses Always observe the following instructions:
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
• Defective components of the electric system must always be replaced by an authorised expert. Bulbs and fuses may be changed by unqualified persons • When carrying out maintenance work on the electric system, pay particular attention to ensuring good contact in leads and fuses • Blown fuses indicate overloading or short circuits. The electric system must therefore be checked before installing the new fuse • Only use fuses with the specified load capacity (amperage) – (amperage) – see Fuse box in instrument panel on on page 2-4 Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected • When connecting the battery, make sure the poles (+/–) are not reversed • Always disconnect the battery before carrying out welding work or conn ecting a quick battery charger • Replace defective charge telltales immediately – see Telltale (red) – alternator charge function on function on page 1-10
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-45
Battery
Danger ! Battery acid is highly caustic!
Danger of caustic injury! Therefore when recharging and/or working near the battery: ☞ Always wear goggles an d protective clothing with long sleeves
If acid is spilt: ☞ Thoroughly rinse all affected surfaces immediately with plenty of water ☞ Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once! During charging in particular, but also during normal battery operation, an oxyhydrogen mixture is formed in the battery cells –
Danger of explosion! ☞ Avoid naked lights a nd sparks in the vicin ity of the battery and an d do not
smoke! ☞ Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery may rupture or explode! • Repla Replace ce the the batter batteryy immedi immediat ately ely ☞ Always disconnect the negative terminal (–) from the battery before starting
repair work on the electric system!
-
The battery 49/A is 49/A is located in the chassis underneath the cab behind the gear motor. The battery is “maintenance-free”. However, have the battery checked at regular intervals to make sure the electrolyte level is between the MIN and MAX marks.
+
Checking the battery requires it to be removed and must be carried out by an authorised workshop. Always follow the specific battery b attery safety instruction s! A
Important! Fig. g . 49: 49: Batt Batter eryy
Do not disconnect the battery while the engine is running.
3-46
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
3 . 17 C a b Replacing the inside heater filter Tilt the cab to replace the filter – filter – see Tilting the cab on cab on page 1-13. 1-13. The heater is located at the rear half of the cab. Replacing the filter: ☞ Slacken the heater cover ☞ The inside heater filter can be accessed fig. 50 ☞ Remove the inside heater filter ☞ Insert a new inside heater filter ☞ Fit the heater cover back on again
Fig. Fig. 50: Inside Inside heat heater er filt filter er
SERV-HB 8003 En – Edition 1.0 *8003s314.fm
3-47
3.18 3.18 Gene Genera rall maint mainten enan ance ce work work Cleaning
Cleaning the machine is divided into 3 separate areas:
• Inside the cab • Exterior of the machine • Engine compartment The wrong choice of cleaning equipment and agents may impair the operating safety of the machine on the one hand, and on the other undermine the health of the persons in charge of cleaning the machine. It is therefore essential to observe the following instructions. General instructions for all areas of the machine
When using washing solvents
• Ensure adequate room ventilation • Wear suitable protective clothing • Do not use flammable liquids, such as petrol or diesel When using compressed air
• Work carefully • Wear goggles and protective clothing • Do not aim the compressed air at the skin or at other people • Do not use compressed air for cleaning your clothing When using a high-pressure cleaner or steam jet
• Electric components and damping material must be covered and not directly exposed to the jet • Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc. • Protect the following components from moisture: • Engine • Electric components such as the alternator etc. • Control devices and seals • Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays
• Ensure adequate room ventilation • Do not use unprotected lights or naked flames • Do not smoke!
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SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
Inside the cab
Caution! Never use high-pressure cleaners, steam jets or high-pressure water to clean inside the cab. Water under high pressure may • Penetrate into the electric systems and cause short circuits and • Damage seals and disable the controls! We recommend using the following aids to clean the cab:
• Broom • Vacuum cleaner • Damp cloth • Bristle brush • Water with mild soap solution Cleaning the seat belt
• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution; do not use chemical agents as they may destroy the fabric! Exterior of the machine
The following articles are generally suitable:
• High-pressure cleaner • Steam jet Engine compartment
Danger ! Clean the engine at engine standstill only –
Danger of personal injury! ☞ Switch off the engine before cleaning
Caution! When cleaning the engine with a water or steam jet ☞ The engine must be cold ☞ Do not point the jet directly at electric sensors such as the oil pressure
switch The humidity penetrating any such sensors causes them to fail and leads to engine damage!
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3-49
Screw connections and attachments All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance schedules. ☞ Engine fastening screws ☞ Fastening screws on the hydraulic system ☞ Line, bucket teeth and pin attachments on the implement
Retighten loose connections immediately. Contact a workshop if necessary. Lubricate all mechanical pivots on the machine (such as door hinges, joints) and fittings (such as door arresters) at regular intervals even if they are not listed in the lubrication plan.
3-50
SERV-HB 8003 En – Edition 1.0 * *8003s314.fm
Engine
Engine
Engine
4
E ng i ne
4.1
4 TN V98 en engin gin e : ov over view iew k c e n r e l l i f l i O
m u p n o i t c e j n i l e u F r e t l i f l e u F
e k a t n i r i A
r e t l i f l i o e n i g n E
k c i t s p i d l i O e v l a v n i a r d l i O
d l o f i n a m t s u a h x E
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
h c t i w s e r u s s e r p l i O
4-1
Engine
r e t r a t S
t e k c a r b g n i p m a l C
r o t a n r e t l A t l e b V
e d a l b n a F
4-2
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine 4.2
F u e l sy st em p m u p n o i t c e j n i l e u F
k c o c r p e o t l i t f s l h e t u i F w
r o k t c a o r a c p p e o s r t s e h t a t i W w
x u l f e R
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
d e e F
p m u p l e u F
4-3
Engine 4.3 4.3
Remo Removi ving ng the the cyli cylind nder er-h -hea ead d cove cover r Important! The injection lines on this engine run through the cylinder-head cover. Therefore, remove the cylinder-head cover with extreme care! Remove as follows: ☞ Remove all injection lines from the cylinder-head cover ☞ Slightly fold the injection lines away from the engine ☞ Remove the rubber covers from the cylinder-head cover with a screw driver ☞ Unscrew the cylinder-head cover
Fig. Fig. 1:
4.4 4.4
Removi Removing ng the the cyli cylinder-he n der-head ad cove cover r
Check Checking ing and and adjus adjusti ting ng valv valvee tip tip clea cleara ranc ncee ☞ Standard setting of valve tip clearance is possible: ➥ On a cold engine ☞ Remove the cylinder-head cover ☞ Turn the engine until the cylinder reaches top dead centre of the compression cycle.
☞ Check the valve cap for abnormal wear
normal Fig. g . 2:
abnormal
Valve alve cap cap wea wear r
A ☞ Check valve tip clearance 3/A with a feeler gauge ➥ Valve tip clearance:0.15 – 0.25 mm
Fig. Fig. 3: 3:
4-4
Valve alve tip tip clea cleara ranc ncee
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine B C
4/C on the cylinder. ☞ Slacken locknut 4/C on 4/B. ☞ Adjust valve tip clea rance by turning set scre w 4/B. ➥ Valve tip clearance:0.15 – 0.25 mm
4/C. ☞ Tighten locknut 4/C. ➥ Check the setting again with the feeler gauge.
Fig. Fig. 4: 4:
Settin Settingg valv valvee tip tip cleara clearance nce
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
☞ Repeat the procedure for each cylinder
4-5
Engine ☞ Place the cylinder-head cover gasket
☞ Mount the cylinder-head cover
Fig. Fig. 5:
4.5 4.5
Placin Placingg the cylin cylinder der-he -head ad cover cover gask gasket et
Tigh Tighte teni ning ng ord order er for for cyl cylin inde derr head head bo bolt ltss ☞ Mount the cylinder-head bolts ➥ Tightening moments: • 1st pass
49 – 58.8 Nm
• 2nd pass
103.1 – 112.9 Nm
Caution! Bear in the mind the order for tightening the cylinder-head bolts! ☞ See figure
Flywheel
Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them! ☞ Order for removing the cylinder-head bolts
Flywheel
4-6
Fan
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine 4.6 4.6
Chec Checki king ng the the inj injec ecti tion on no nozzzles zles
Pressure check ☞ Remove the injection line and the injection nozzle ☞ Connect the injection nozzle with the high pressure line of the nozzle tester ☞ Slowly increase pressure until the nozzle ejects fuel and read the pressure off the pres-
sure gauge ☞ If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If
the pressure is too high, replace the spacer by a thinner one. ➥ Injection pressure: 220 – 230 bar
• Spacer thickness of 0.1 mm corresponds to modification by 19 bar Fig. Fig. 6:
Nozz Nozzle le test tester er
Upper nozzle screw fi t t i n g
4.7
Lower nozzle screw fitPressure spring centring Nozzle needle ting Compression Compression Nozzle body spring spring seat
Spacers
C h e ck ing the n ozzle je t ☞ Remove the injection lines and the injection nozzles ☞ Connect the injection nozzle with the high pressure line of the nozzle tester ☞ Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times) ☞ Hold a white sheet of paper about 30 cm away from the nozzle and let the nozzle eject
fuel ☞ The nozzle jet must create a circle on the paper ☞ Check the nozzle for drips after it has ejected fuel
Normal atomisation
☞ Create a pressure of about 20 bar below injection pressure and check whether fuel
escapes from the nozzle
Bad atomisation Fig. ig. 7:
Nozz Nozzle le jet jet
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
4-7
Engine 4. 8
I n j e c t i o n t i me Checking injection time ☞ Remove the cylinder-head cover ☞ Turn the engine clockwise with the crankshaft (as seen from the radiator) up to the top
dead centre of the first cylinder and check whether both cams show upwards to the left and right ☞ Remove the rubber covers from the flywheel housing and check whether the mark on
the belt pulley is aligned with the 0 mark on the scale ☞ Unscrew the injection line of the first cylinder and replace it by the drip tube (fig. 8)
(place a container to collect the fuel) ☞ Rotate the engine 1.5 revolutions until it is 40° before top dead centre in the compres-
sion stroke ☞ Slowly keep on turning the engine (degree by degree) until dripping stops • Do not turn back if you have turned too much!
☞ The point at which the dripping stops is the start of delivery (injection time) of the fuel Fig. 8: 8:
D ririp tu tube
injection pump ➥ You can now read the value (in degrees before top dead centre) off the belt pulley
Setting injection time ☞ If injection time should no longer be correct, you can adjust it by rotating the fuel injec-
tion pump ☞ Mark the initial position on the pump housing before setting the fuel injection pump ☞ Remove all injection lines before rotating the injection pump, and slacken the 4 flange
screws by about half a revolution ☞ Rotate the pump in the required direction, and tighten one of the screws before you
check the setting ➥ Rotated towards the engine: earlier injection time ➥ Rotated away from the engine: later injection time ☞ Bend each of the injection lines before you mount them so they are not subject to ten-
sion once they are mounted
Engraved scale Belt pulley
Mark on belt pulley
Direction of rotation
Mark on pump housing
Flange screws (oblong slots for rotating the pump)
4-8
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine 4.9
A d j u st i ng en en g i n e re re v s Important! Maximum engine revs are sealed in the factory and may not be modified! Adjust engine revs without load! ☞ Run the diesel engine until it reaches operating temperature
B
☞ Check idling speed A speed A and and maximum revs B with all implement functions in neutral ➥ Idling speed: 1050 +/- 50 rpm ➥ Max. revs: 2575 +/- 50 rpm ☞ Correct the idling speed with set screw 9/A if 9/A if it is not correct.
A
Fig. Fig. 9:
Adjus Adjustiting ng engin enginee rev revss
4 . 1 0 C ompre pres sion ion ☞ Remove the injection lines and the injection nozzles ☞ Set the fuel injection pump to zero delivery (remove the plug for the cut-off solenoid) ☞ Turn the engine ☞ Mount the compression gauge on the cylinder you want to measure ☞ Turn the engine with the starter and read the pressure off the pressure gauge ➥ Specified value: 35 value: 35 +/- 1 bar @ 250 rpm ➥ Limit value: 28 +/- 1 bar @ 250 rpm Fig. Fig. 10: 10: Comp Compre ress ssio ionn
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
4-9
Engine 4.1 4.11 Check Checking ing the the cool coolan antt therm thermos osta tatt ☞ Remove the thermostat
Housing cover
Thermostat Seal
Housing Thermal switch Fig. Fig. 11: 11: Coolan Coolantt therm thermost ostat at
Thermal switch
☞ Warm up the thermostat in a container with water ☞ Check whether the thermostat opens at the prescribed temperature (check with a tem-
Thermal switch
perature gauge) ➥ Thermostat opening temperature: 69.5 – 72.5 °C
4.12 4.12 Check Checking ing the the the therm rmal al switc switch h ☞ Remove the thermal switch
Thermometer
☞ Warm up the thermal switch in a container with antifreeze or oil ☞ Measure the resistance of the thermal switch as shown by means of an ohmmeter. ➥ The switch must allow the coolant to pass at a temperature of 107 – 113 °C.
Test prods
Fig. Fig. 12: Checki Checking n g the therm thermal al switch t ch
4-10
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine 4.13 4.13 Oil Oil pre press ssur uree swit switch ch ☞ Remove the cable connection from the oil pressure switch (in the area of the cut-off
solenoid) ☞ Start the engine, check for correct idling speed
Measurement prod
☞ Measure the resistance of the oil pressure switch as shown by means of an ohmmeter. ➥ Oil pressure switch OK: infinite resistance ➥ The oil pressure switch is defective if the oil can pass
Fig. Fig. 13: Oil pressu pressure re swit switch ch
4.14 4.14 Chec Checki king ng the the coo coola lant nt circ circui uitt Leakage check ☞ Fill up the radiator completely ☞ Mount an adapter on the radiator as shown ☞ Increase the pressure in the cooling system by means of a hand pump to about 1 bar ➥ Check the lines and the connections for leaks if the pressure drops at the pressure
gauge Fig. 14: Checking Checking the the radiator radiator for leakage eakage
Checking the radiator cap ☞ Remove the radiator cap and mount it onto the adapter as shown ☞ Increase the pressure to about 1 bar (stamped onto the radiator cap) with the hand
pump ➥ Radiator cap must open
Radiator cap Fig. Fig. 15: Checkin Checkingg the radi radiator ator cap
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
4-11
Engine 4.15 .15 En Engi gine ne trou troubl blee Problem
Possible causes Wrong SAE grade of engine lubrication oil Fuel grade does not comply with specifications Defective or flat battery Loose or oxidised cable connections in starter circuit Defective starter, or pinion does not engage Wrong valve tip clearance
Engine does not start or is not easy to start
Defective fuel injector Defective starting relay Defective glow plug Defective solenoid switch Cut-off solenoid does not attract Cut-off solenoid without current High pressure created immediately in the hydraulic system Fuel grade does not comply with specifications
Engine starts, but does not run smoothly or faultless
Wrong valve tip clearance Injection line leaks Defective fuel injector Oil level too low Oil level too high Fouled air filter
Engine overheats. Temperature warning system responds
Fouled oil cooler fins Defective fan, torn or loose V-belt Resistance in cooling system too high, flow capacity too low Defective fuel injector Oil level too high Fuel grade does not comply with specifications Fouled air filter
Insufficient engine output
Defective air filter maintenance switch or gauge Wrong valve tip clearance Injection line leaks Defective fuel injector
Engine does not run on all cylinders
Injection line leaks Defective fuel injector Oil level too low
Insufficient or no engine oil pressure
Machine inclination too high (max. 15°) Wrong SAE grade of engine lubrication oil
4-12
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Engine P r obl e m
Possible causes Oil level too high
Engine oil consumption too high
Machine inclination too high (max. 15°) Oil level too high Blue
Machine inclination too high (max. 20°) Engine oil combustion (defective cylinder-head gasket) Engine starting temperature too low Fuel grade does not comply with specifications
Engine smoke
White
Wrong valve tip clearance Defective fuel injector Coolant combustion (defective cylinder-head gasket) Fouled air filter
Black
Defective air filter maintenance switch or gauge Wrong valve tip clearance Defective fuel injector
SERV-HB 8003 En – Edition 1.0 *8003s410.fm
4-13
Engine
4-14
SERV-HB 8003 En – Edition 1.0 * *8003s410.fm
Hydraulic system
Hydraulic system
Hydraulic system
5 5.1 5.1
H yd ra ul ic sys t em Hydr Hydrau auli licc pum pump p AP2D AP2D36 36L LV3 V3RS RS66-87 8744-P P Twin variable displacement pump + twin gear pump
1
2
3
5
4
6
11
10
8
9
Variable displacement pump unit
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
7
Gear pump unit
1 2 3 4 5 6 7 8
Description Type label Bleed screw Leak oil port Port P1 Control initiation set screw Control port P3 Control port P4 Control port P4
9 10 11
Control port P3 Port P2 Bleed screw
5-1
Hydraulic system
2
1
7
8
3
4
5
6
9
Pos. 1 2 3 4 5 6 7 8 9
Description Port P4 Port P3 Measuring port P2 (not used) Measuring port P1 (not used) Plug for shuttle valve1 Plug for nozzle2 Suction port P4 Suction port P3 Suction ports P1 + P2
1. The lubricating oil is taken from th e next highest high pressure by mea ns of the shuttle valve behind port 2. 2. The lubricating oil quantity is limited by the nozzle behind plug 5.
5-2
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Pump unit: exploded view
1
2 3
4
5 6
7
9
8 14
10
11 12 13
15
16
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-3
Hydraulic system
Pos.
5-4
1 2 3 4 5 6 7 8
Description Gear pump End plate Pump cover Piston valve Spring Drive unit Cradle Plug
9 10 11 12 13 14
Plug O-ring Bleeder valve Plug Nozzle Shut Shutttle va valve (f (for lubr ubricatio tion)
15 16
Pump housing S h a ft
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Pilot oil supply unit
2 1
3
13
11 10
5
7
8
9
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
4
6
12
1
Description Pilot valve supply
Connection
2
Solenoid va valve fo for sa safety va valve
3
2nd speed range solenoid valve
4
Gear mo motor br brake re release su supply
PV
5
Drive cou coutterb erbala alanci ncing system suppl pply
A
6
Accumulator
7
Drives/2nd sp speed ra range su supply
8
Pressure limiting valve
9
Pump 1 port
P1
10
Pump 3 port
P3
11
Pump 2 port
P2
12
Tank line
T
13
Safety valve: protects the pilot oil supply unit if the pressure relief valve is defective
BV
PR
5-5
Hydraulic system
1
5
2 6 7 3
8
4
9
10 12
11 6
13 8
4
9
Pos.
5-6
1
Description Port P2
Connection
P2
2
Drive cou coute terrbal balanc ancing syst ystem supp supplly
A
3
Accumulator
4
2nd speed range solenoid valve
5
Port P1
6
Safety valve
7
Tank line
8
Pressure limiting valve
9
Solenoid va valve fo for sa safety va valve
10
Port P3
P3
11
Pilot valve supply
BV
12
Drives ves/2nd 2nd spe speed ed range ange suppl pply
PR
13
Gear ear mot motor or brake re releas ease sup suppl plyy
PV
P1 T
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.2
M ai n v al ve b l o c k
Ports
Rotate
BR3 BR3
AR3
Stabiliser blade
BR2
AR2
PR5 PR5
T6
T4
T2
Dipper arm summation Boom B8
A8
Bucket
pc2
A7
B7
A6
B6
Right-hand side drive Straight-ahead driving
P2
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
P3
5-7
Hydraulic system
Rotate
Stabiliser blade
T1
B5
Dipper arm
A5 pc1 pc1
Boom summation
B4
B3
B2
Swivel boom
A3
P4
B1
Auxiliary hydraulics
A2
Left-hand side drive
PT
A1
PP
P1
5-8
PA
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Legend
Pilot control lines Connection
Legend
Controlled via
Pa1, Pb1
Left-hand side drive control
Drive pedal (left)
Pa2, Pb2
Auxiliary hydraulics control
Auxiliary hydraulics pedal
Pa3, Pb3
Swivel control
Auxiliary hydraulics pedal
Pa4, Pb4
Boom 2 control
Joystick (right)
Pa5, Pb5
Dipper arm 1 control
Joystick (left)
Pa6, Pb6
Right-hand side drive control
Drive pedal (right)
Pa7, Pb7
Bucket control
Joystick (right)
Pa8, Pb8
Boom 1 control
Joystick (right)
Pa9, Pb9
Dipper arm 2 control
Joystick (left)
Pra2,Prb2
Stabiliser blade control
Stabiliser blade pedal
Pra3, Prb3
Rotation control
Joystick (left)
pc1
Dipper arm cylinder load retaining valve
Joystick (left)
pc2
Boom cylinder load retaining valve
Joystick (right)
Main control lines Connection
Legend
A1, B1
Drive unit (left) via swivel joint joint
A2, B2
Auxiliary hydraulics
A3, B3
Offset cylinder
A5, B5
Dipper arm cylinder
A6, B6
Drive unit (right) via swivel swivel joint
A7, B7
Bucket cylinder
A8, B8
Boom cylinder
AR2, BR2
Stabiliser blade cylinder cylinder
AR3, BR3
Gear motor
Pump/tank lines
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Connection
Legend
P1
Pump 1 port
P2
Pump 2 port
P3
Pump 3 port
P4
Pump 4 port
P R5
Pumps P3 and P4 input
PA
Pilot oil supply unit port
PP
“Optional” port for automatic revs control
PT
“Optional” drive alarm port
T1
Tank line via oil cooler and filter in tank
T2
Tank line via non-return valve and filter in tank
T3
Plug (tank line)
T4
Plug (tank line)
T6
Plug (tank line)
DR1
Tank line
dr1, dr2
Tank lines for boom summation
pcc
Tank line
5-9
Hydraulic system Main valve block diagcylinder
Option
3rd control circuit
Rotate
Stabiliser blade
P3+P4 input
Dipper arm
Dipper arm 2
Boom 2
Swivel
Auxiliary hydraulics
Bucket
Right-hand side drive
Left-hand side drive
Input P1
5-10
Boom
Straight-ahead driving
Input P2
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Pressure limiting valves
2
1
3
4 5 7
6
8
9 10
11
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
12
5-11
Hydraulic system Pos.
5-12
1 2 3 4 5
Description Stab Stabiilise liserr blad bladee anti antica cavi vita tati tion on valv valvee Second Secondar aryy pres pressu sure re limi limititing ng valve valve (stabi (stabililiser ser blade blade base base sid side) e) P3 + P4 P4 pri prim mary ary pres pressu sure re lim limitin itingg val valve vess Seco Second ndar aryy pre press ssur uree lim limititin ingg val valve ve (boo (boom m rrod od side side)) Seco Second ndar aryy pre press ssur uree lim limititin ingg val valve ve (boo (boom m bas basee sid side) e)
6 7 8
Seco Second ndar aryy pre press ssur uree lim limititin ingg val valve ve (buc (bucke kett bas basee sid side) e) Buck Bucket et rod rod sid sidee sec secon onda dary ry pres pressu sure re limi limititing ng valv valvee P1 + P2 prim primar aryy pres pressu sure re limi limiti ting ng valv valvee
9 10 11 12
Seco Second ndar aryy pres pressu sure re lim limititin ingg valv valvee (dip (dippe perr arm arm rod rod sid side) e) Second Secondary ary press pressur uree lim limititing ing valve valve (dipp (dipper er arm base base sid side) e) Auxil Auxiliar iaryy hydra hydrauli ulics cs (opt (optio ional nal second secondar aryy press pressur uree limi limititing ng valv valve) e) Auxiliary hydraulics (optional secondary se condary pressure limiting valve) valve )
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system P u mp a s s i gn me nt
Hydraulic supply by pump 1
• Left-hand side drive section • Boom section 2 • Dipper arm section 1 • Auxiliary hydraulics section • Swivel section • Drive couterbalancing system section Hydraulic supply by pump 2
• Right-hand side drive section • Dipper arm section 2 • Boom section 1 • Bucket section Supplied by pumps 3 and 4
• Stabiliser blade section • Swivel unit section • Optional 3rd control circuit section • Option triple articulation boom section
Pumps 3 and 4
Pump 2 Pump 1
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-13
Hydraulic system 5.3
Driv Drivee cou count nteerba rbalanc lancin ing g sys syste tem m Without drive couterbalancing system Actuating the boom b oom as you drive causes the machine to lea ve its track! (P1, P2 each supply a drive, and the boom function is also governed by P1 or P2) Drive couterbalancing system features If the boom is actuated as you drive straight ahead, the machine stays in its track and drive speed stays constant. The drive counterbalancing system is only enabled if both drive valves are enabled. Function ☞ The drive couterbalancing system is enabled by means of an increased banking-up
pressure if both pisto n valves for driving and a boom function. ➥ P2 takes over all boom functions
Pump assignment for drive counterbalancing
Hydraulic supply by pump 1
• Right-hand side drive section • Left-hand side drive section Hydraulic supply by pump 2
• Bucket section • Boom section • Boom (2) summation section • Dipper arm section • Dipper arm (2) summation section • Swivel boom section • Auxiliary hydraulics section Supplied by pumps 3 and 4
• Rotate section • Stabiliser blade section
5-14
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Drive couterbalancing system diagram
Dipper arm 2
Dipper arm 1
Boom 2
Boom 1
Swivel
Bucket
Auxiliary hydraulics
Right-hand side drive
Left-hand side drive
Drive couterbalancing system
Input P1
Input P2
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-15
Hydraulic system 5.4
B oo oom m summ umm ation ion – r aise ise Both P1 & P2 pumps are used to raise the boom at higher speed. Raising the boom
• Moving the joystick also controls a second segment (boom 2) • Pump P2 supplies the boom 2 segment with oil • The summation time (the time the boom 2 segment is switched) is specified by the piston spring in the boom 2 segment Lowering the boom – see Lowering the boom: on boom: on page 5-18
Boom 1
Boom 2
5-16
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.5 5.5
Boom Boom chec checkk val valve ve (loa (load d ret retai aini ning ng val valve ve)) • Boom cylinder base side A pilot-operated loa d retaining valve is us ed to prevent spool spoo l leakage, which allows t he cylinder to retain its home position. Raising the boom: The oil opens the check valve and flows to the base side of the boom cylinder. Lowering the boom: The load on the check valve is reduced by means of the pilot control line and a piston (reflux to tank). This allows the base side oil to flow back via the check valve.
Line
Boom 2
Boom base side
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Joystick control
5-17
Hydraulic system 5.6
Dipp Dipper er arm arm cyl cylin inde derr sum summ matio ation n Both P1 & P2 pumps are used to fold the dipper arm at higher speed. Retracting the dipper arm cylinder
• Moving the joystick also controls a second segment (dipper arm 2) • Pump P2 supplies the dipper arm 2 segment with oil
Dipper arm 2
Dipper arm 1
5-18
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.7 5.7
Dippe Dipperr arm arm chec checkk val valve ve (loa (load d ret retai aini ning ng valv valve) e) • Rod side dipper arm cylinder A pilot-operated loa d retaining valve is us ed to prevent spool spoo l leakage, which allows t he cylinder to retain its home position. Rectracting the dipper arm: The oil opens the check valve and flows to the rod side of the dipper arm cylinder. Extending the dipper arm: The load on the check valve is reduced by means of the pilot control line and a piston (reflux to tank). This allows the base side oil to flow back via the check valve.
Rod side dipper arm
Line Dipper arm 2
Joystick control
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-19
Hydraulic system 5.8
Seconda Secondary ry pres pressur suree limit limiting ing valves valves for the auxilia auxiliary ry hydr hydraul aulics ics (opt (option) ion) • Overpressure protection for consumers in secondary circuit • e.g. hydraulic hammer
Important! The implement manufacturer (e.g. hammer, offset bucket ...) is in charge of overpressure protection for his implements. Neuson Baumaschinen GmbH shall not be liable for damage to implements.
Problem: The secondary circuit is also protected by the primary pressure limiting valve if the spool valve is enabled. There is no protection if the spool valve is not enabled. Ensuring protection with the spool valve disabled requires two secondary pressure limiting valves instead of the plugs. Adjusting the secondary pressure limiting valves: The pressure limiting valves must be set at 280 bar. Short-term pressure peaks can be reduced with this setting. Please observe the following should the pressure limiting valves be set to less than 280 bar:
• Have the pressure setting carried out by a specialist • The pump's high flow rate and the fact that the pressure peaks are now reduced by the secondary pressure limiting valve cartridges at the auxiliary hydraulics section may cause the hydraulic oil to overheat. • Reset the pressure setting to the initial 280 bar when changing implement. Location: – see Pressure limiting valves on valves on page 5-11
5-20
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.9
Pi l ot va va l ve s • Pilot valve for bucket, boom, dipper arm and rotation
Joystick
• Consists of a lever and four pressure reducing valves
2
4
1 Numbering for right-hand side joystick.
3
Left-hand side joystick: 3-1-2-4
A
B
C
D P
T
E F
Pos.
Description
Pos.
DescriptionJoystick (left)
DescriptionJoystick (right)
A
Control lever
1
Dipper arm extension con trol
Boom cylinder extension control co ntrol
B
Rubber collar
2
Left-hand side rotation control
Bucket cylinder extension control
C
Linkage
3
Dipper arm retraction control
Boom cylinder retraction control
D
Universal joint
4
Right-hand side rotation control
Bucket cylinder retraction control
E
Guide plate
P
Supply from pilot oil supply unit
Supply from pilot oil supply unit
F
Tappet
T
Tank line
Tank line
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-21
Hydraulic system Pilot valve (driving)
• Pedal with hydraulic damping • Consists of two pedals and four pressure reducing valves
1
T
P
Pos.
5-22
3
2
T
1
Description Left Left--hand and si side dr drive se segme gment contr ontrol ol
2
Left-hand side drive segment control
3
Right-hand side drive segment control
4
Right-hand side drive segment control
P
Pilot control pressure
T
Tank line
4
P
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system
2 3 1
5 4
6
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Description
1
Bellows
2
Shift unit (kit)
3
Plate (kit)
4
Tappet
5
Non-return valves
6
Damping
5-23
Hydraulic system Pilot valve for auxiliary hydraulics
• Pilot valve with pedals for remote control of directional valves • Consists of a pedal and two pressure reducing valves
1
2
A
B
C D 3
4
E
F
Pos.
Description
A
Pedal
B
Pedal fixture
1
Auxil Auxilia iary ry hydr hydraul aulic icss cont contro rol/l/off offset set cyli cylinde nderr ret retrac ractition on contr control ol
C
Protective caps
1
Tank line
D
Mounting plate
1
Suppl upplyy from pil pilot oil oil suppl pply unit nit
E
Tappet
F
Spring
5-24
Pos. Description 1 Auxil Auxilia iary ry hydr hydraul aulic icss contr control/ ol/off offset set cyli cylinde nderr extens extensio ionn cont contro roll
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Pilot valve for stabiliser blade
• Pilot valve with pedals for remote control of directional valves Consists of a pedal and two pressure reducing valves
1
2
A
B
C
3
4
D
E
F
3 4
1
2
Pos.
Description
A
Pedal
B
Pedal fixture
1
Stab Stabililiiser ser blad bladee cyli cylind nder er ret retra ract ctio ionn cont contro roll
C
Protective caps
1
Tank line
D
Mounting plate
1
Sup Supply from from pilot oil oil suppl pply uni unit
E
Ta p p e t
F
Springs
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Pos. Description 1 Stab Stabililiiser ser blad bladee cyli cylind nder er exte extens nsio ionn cont contro roll
5-25
Hydraulic system 5. 1 0 Val v es 7/2 directional valve (changeover valve)
Switches from auxiliary hydraulics (valve de-energised) to boom swivel and vice versa (valve energised). Electric control via push button on left-hand side joystick.
2
3 8
7
1
5
4
6
1
2
8
3
7
4
Pos.
5-26
5
6
1 2 3 4 5 6
Description S olen oid Main Main valv valvee blo block ck for for aux auxililia iary ry hydr hydrau aulilics cs segm segmen entt Main Main valv valvee blo block ck for for aux auxililia iary ry hydr hydrau aulilics cs segm segmen entt Pil Pilot valv alve fo for aux auxiiliary ary hy hydrau draullics Pil Pilot valv alve fo for aux auxiiliary ary hy hydrau draullics Tank line
7 8
Shutt Shuttle le val valve ve blo block ck/m /mai ainn valv valvee bloc block, k, offs offset et cyl cylind inder er retr retrac actio tionn contr control ol Shutt Shuttle le val valve ve blo block ck/m /mai ainn valv valvee bloc block, k, offs offset et cyl cylind inder er ext extens ensio ionn contr control ol
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 4/3 directional valve
Used for electric auxiliary hydraulics and 3rd control circuit. Valve is located in pilot control branch and is controlled via tip switches on left-hand side joystick.
1
2
3
6
5
4
1
4
2 5 3
6
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
1
Description Solenoid 1
1 1 1 1 1 1
Solenoid 2 Main Main valv valvee blo block ck for for aux auxililia iary ry hydr hydrau aulilics cs segm segmen entt Main Main valv valvee blo block ck for for aux auxililia iary ry hydr hydrau aulilics cs segm segmen entt Solenoid 2 Suppl pply from pil pilot oil suppl upplyy unit nit Tank line
5-27
Hydraulic system Pressure cut-off valve
The high slewing torque during swivel unit start-up causes pump P4 to be switched direct to the tank to reduce engine droop. Further rotation reduces the pressure to under 165 bar and the second P4 pump is automatically switched on for a higher upper carriage rotation speed. M3
M4 A
P3 P4 T
Location: • In the engine compartment over the hydraulic pump unit
A
Pressure cut-off valve
T
Diesel engine
Pump unit
Des. P3
Pump P3 input
P4
Pump P4 input
A
Pumps P3+P4 output
T
Tank line
M3/M4
5-28
Connection
Pumps P3/P4 measuring port
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Offset cylinder check valve The function of this valve is to clamp the offset cylinder hydraulically. ☞ The base and rod sides of the offset cylinder are under constant pressure ➥ This prevents the cylinder from slackening. ☞ Applying pressure to one side of the cylinder supports this side with additional pressure
from the other side as the valve opens, in order to override the clamping pressure. The valve is located direct on the offset cylinder and can only be accessed by tilting the cab.
V1
V2
2
3
3 2
1
C1
C1
C2
C2
1
V2
V1
Pos. 1
Counterbalance valve
2
Offset cylinder
3
Pressure setting screw
Des.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Description
Connection
C1
Offset cylinder base side
C2
Offset cylinder rod side
V1
Base side offset cylinder main valve block
V2
Rod side offset cylinder main valve block
5-29
Hydraulic system Shuttle valve block Actuating rotation, boom swivel and dipper a rm retraction must release the t he gear motor's brake. High forces act on the brake and destroy it if it is not released during these operations.
1
2 3 4 5
6
1 6
2 3 4 5
Pos. 1
Description Port A ((-> jo joystick (l(left) 4 -> -> main valve block, right-hand side rotation control)
2
Port B (-> joystick (left) 2 ->
main valve block, left-hand side rotation control) 3
Port C (-> pe pedal, sw swivel 2 ->
main valve block, offset cylinder extension control) 4
Port D (-> pe pedal, sw swivel 1 ->
main valve block, offset cylinder retraction control) 5
Port E (-> joystick (left) 1 ->
main valve block, dipper arm cylinder extension control) 6
5-30
Port ort F (-> gear mo motor SH SH, br brake ake re release ase)
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system Changeover valve for SAE/ISO controls (option) The directional valve is located on the left in the base plate of the chassis.
I Fig. Fig. 1:
Direct Direction ional al valve valve positi position on
Switching from ISO to SAE controls and vice versa with the directional valve 1
5
2
6
3
7
4
8
Position • 1 • 2
Function ➥ ISO controls ➥ SAE controls
☞ Tighten wing nut J after after changing control mode.
Danger ! Changing the directional valve over modifies the controls (control levers) –
Danger of accidents! ☞ Make sure you know which control mode has been selected before starting
work on the directional valve's changeover lever ☞ Always secure wing nut J on
J A
Fig. Fig. 2:
B
Dire Direct ctio iona nall valv valvee
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-31
Hydraulic system Diagram
4321
Joystick (right)
8765
Joystick (left)
Pos.
5-32
Description
1
Joystick (right) port 1
2
Main valve block, boom cylinder retraction control
3
Joystick (right) port 3
4
Main valve block, boom cylinder extension control
5
Main valve block, dipper arm cylinder extension control
6
Joystick (left) port 1
7
Main valve block, dipper arm cylinder retraction control
8
Joystick (left) port 3
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.1 5.11 Driv Drivee up to to seri serial al num numbe ber: r: AC AC 0295 029566 The travelling drive has two speed ranges.
Hydraulic motor on left 1
2
8
3 4
9
5
2
6
7
3 7 6
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Description
1
Brake cylinder
2
Leak oil port (-> swivel joint 8a)
3
2nd speed range port (-> swivel joint 1a)
4
2nd speed range directional valve
5
Brake bleed valve
6
Drive port (-> swivel joint 4a) forwards hydraulic motor (left)
7
Drive port (-> swivel joint 6a) reverse hydraulic motor (left)
6
Drive port (-> swivel joint 7a) forwards hydraulic motor (right)
7
Drive port (-> swivel joint 5a) reverse hydraulic motor (right)
8
Pressure limiting valve
9
Pressure limiting valve
5-33
Hydraulic system Fu nc ti o n
Driving: The shuttle valve actuates the brake cylinder and releases the brake if high pressure is applied to one of the drive ports. The brake piston is slowly actuated at the same time. Brake piston control causes high pressure to be applied to the motor, which starts turning. Stopping: The oil flows from both ports to the tank upon releasing the joystick. The brake piston slowly returns to home position by means of the throttle orifices. The slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the brake piston in neutral position, the ports are no longer connected to the motor, which can no longer turn. The brake release pressure is reduced via both throttles shortly afterwards.
2 nd s p e e d r a ng e fun c ti on
Speed range 1
• 2nd speed range switch: switched off The directional valve for the 2nd speed range remains in home position (position as shown in diagram), and the hydraulic motor's swash plate is in maximum capacity position. ➥ The motor runs at low speed.
Speed range 2
• 2nd speed range switch: switched on The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash plate is in minimum capacity position. ➥ The motor runs at high speed.
5-34
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.12 5.12 Auto2S Auto2Spee peed d drive drive star starting ting serial serial no.: no.: AC AC 02957 02957 The travelling drive now has an “automatic powershift” gearbox. The travelling drive is basically in 2nd speed if the switch for 2nd speed range is switched on (high speed). 1st speed is automatically engaged if more power is required. Hydraulic motor on left
7
8
3 9
5
3 6
2
1
4
4 1 2
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
1 2 1 2
Description Driv Drivee port port (-> (-> swi swive vell joi joint nt 4a) forwa forwards rds hydra hydrauli ulicc mot motor or (lef (left) t) Driv Drivee port port (-> (-> swi swivel vel joint joint 6a) rever reverse se hydra hydrauli ulicc moto motorr (lef (left) t) Driv Drivee port port (-> (-> swi swive vell joi joint nt 7a) forwa forwards rds hydra hydrauli ulicc moto motorr (ri (right ght)) Driv Drivee port port (-> (-> swi swive vell joi joint nt 5a) rever reverse se hydra hydrauli ulicc moto motorr (ri (right ght))
3 4 5 6 7 8 9
2nd 2nd spee speedd ran range ge port port (-> (-> swiv swivel el joint oint 1a) 1a) Leak eak oil oil port ort (-> swivel join oint 8a) 5/2 5/2 dir directi ection onal al valv valvee (2nd (2nd spee speedd rang range) e) Brake bleed valve Brake cylinder Pressure limiting valve (4a) Pressure limiting valve (6a)
5-35
Hydraulic system Fu nc ti o n
Driving: If high pressure is applied to one of the drive ports, the brake release piston is actuated first and passes high pressure on to the brake cylinder, which releases the brake. The throttle slowly actuates the brake piston at the same time. Brake piston control causes high pressure to be applied to the motor, which starts turning. Stopping: The oil flows from both ports to the tank upon releasing the joystick. The brake release piston and the brake piston (slowly actuated by the throttle) return to their base positions. The slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the brake piston in neutral position, the ports are no longer connected to the motor, which can no longer turn. The brake release pressure is reduced via both throttles shortly afterwards.
2 nd s p e e d r a ng e fun c ti on
Speed range 1
• 2nd speed range switch: switched off The directional valve for the 2nd speed range remains in home position (position as shown in diagram), and the hydraulic motor's swash plate is in maximum capacity position. ➥ The motor runs at low speed.
Speed range 2
• 2nd speed range switch: switched on The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash plate is in minimum capacity position. ➥ The motor runs at high speed.
If the pressure rises in the travelling drive, the directional valve for the 2nd speed range is forced back to home position and and hydraulic motor's swash plate returns to maximum capacity. ➥ The motor now turns at low speed.
The directional valve returns to 2nd speed range as soon as the pressure in the travelling drive drops again. ➥ The motor runs at high speed again.
Switch operating point of the directional valve: 180 bar
5-36
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-37
Hydraulic system
Pos.
5-38
1 2 3 4 5 6 7 8
Description Circlip Plug Thrust washer Cover with fittings O-ring Sun gear Gear reduction Circlip
9 10 11 12 13 14
Planetary gears Gear housing Circlip Bearing Circlip Lifetime seal
15 16
Centering Hydraulic mo motor
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5 . 1 3 Sw i v el un un i t Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox and mechanical motor brake.
1
2
10 9
3
4
8 7
6
5
1 5 6
7
8
4
Pos. 1 2
Description Parking brake valve Brake piston
3 4 5 6 7 8 9 10
Leak oil port (-> tank) Shock anticavitation valves Left Left-h -han andd sid sidee rot rotat atio ionn por portt (-> (-> main main valv valvee blo block ck)) Anti Antica cavi vita tatition on line line port port (-> (-> mai mainn val valve ve bloc block/ k/ta tank nk)) Righ Rightt-ha hand nd side side rota rotatition on port port (-> (-> mai mainn val valve ve bloc block) k) ASB valve Pilo Pilott con contr trol ol pres pressu sure re port port (-> (-> pil pilot ot oil oil supp supply ly unit unit)) SH brak brakee rel relea ease se port port (-> (-> shu shutt ttle le valv valvee blo block ck))
The shock anticavitation valves are dampened for smooth braking.
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-39
Hydraulic system Parking brake function Opening the brake The shuttle valve block directs the pilot control pressure to the SH input if rotation, boom swivel or dipper arm retraction is carried out. The pilot control pressure at the SH input causes the piston in the parking brake valve to shift to active state (brake release). This directs the pilot control pressure at the PG input to the brake cylinder and releases the brake.
• Movement: rotation, boom swivel or dipper arm retraction • Pilot control pressure is present at the SH input • The piston of the parking brake valve moves to work position • Pilot control pressure is directed to the brake piston • Brake is released Closing the brake The shuttle valve block causes the pilot control pressure to drop and the SH input is unpressurised upon termination of rotation, boom swivel or dipper arm retraction. The piston in the parking brake valve switches to home position (brake) if there is no pressure at the SH input. The pressure in the brake cylinder escapes via the parking brake valve to the leak oil system. This enables the brake with some delay (depending on oil viscosity and brake valve leakage).
• End of movement: rotation, boom swivel or dipper arm retraction • The pilot control pressure at the SH input drops • The piston of the parking brake valve moves to home position • No more pilot control pressure on the brake piston • The oil in the brake piston flows to the tank via a throttle orifice • The brake is enabled Time for releasing the brake: 5 sec +/-1.5 @ 50 °C oil temperature
Anti Swing Back (ASB) valve
5-40
Once the rotate function is over, counterpressure is created in the gear motor which causes the upper carriage to swivel back slightly. The Anti Swing Back valve reduces this pressure and prevents the upper carriage from swivelling back.
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-41
Hydraulic system
Pos.
5-42
1 2 3 4 5 6 7 8
Description Pinion shaft Bearing seal ring Bearing Gear housing Plug Sealing ring Bearing Spacer washer
9 10 11 12 13 14
Round nut Complete drive O-ring Gear reduction Sun gear Ring gear
15 16 17
Gear reduction Sun gear Circlip
18 19
Hydraulic mo motor Bolt
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-43
Hydraulic system
Pos.
5-44
1 2 3 4 5
Description Valve Spring O-ring Plug O-ring
6 7 8 9 10 11 12 13 14
Plug O-ring Plug Bolt Spiral ring O-ring O-ring O-ring Valve set
15 16 17 18 19 20 21 22 23
O-ring Spiral ring Spiral ring O-ring Pin Nozzle Bearing Control disc Motor head
24 25 26 27
Pin O-ring Brake piston spring Spring
28
Brake piston
29 30 31 32 33 34 35 36 37
O-ring O-ring Spacer washer O-ring Plain washer Steel washer Circlip Plate Spring
38 39 40 41 42 43 44 45 46
Plate Cylinder block Pin Bush Plate Piston Plate Motor shaft Bearing
47 48 49 50 51 52 53 54
P lug O-ring Engine housing B ol t Parking brake valve block O-ring Nozzle O-ring
55
P lug
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5 . 1 4 Sw i v el joint oint 8-port swivel joint
Pos. 1 2 3 4 5 6 7 8
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Description High speed Blade (base side) Blade (rod side) Hydraulic motor on left Hydraulic motor on right Hydraulic motor on left Hydraulic motor on right L e ak o i l
5-45
Hydraulic system 5.15 .15 Bre Breathe atherr fil filte ter r The breather filter is in charge of:
• Air intake and outle t for pressure compensat ion in the hydraulic oil ta nk (varying oil level) – prevents the oil tank from inflating. • Pre-tension of the oil tank to the specified overpressure -> supports the variable displacement pump's suction • Filtering the intake air
The breather filter is located under the tank cover, between the hydraulic filler inlet and the fuel filler inlet. Replace the breather filter according to the instructions in the maintenance plan! – see Maintenance plan (overview) on (overview) on page 3-5
Fig. Fig. 3:
Br Breat eathe herr filter t er posit position ion
Pos. 1 1
Description Filter fabric Bleeder valve
1
2 Fig. g . 4: 4:
5-46
Br Brea eath ther er filt filter er
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.16 5.16 Troubles roubleshoot hooting ing in the the hydraul hydraulic ic system system P r obl e m
Possible causes Defective safety switch on control lever base Wrong setting of safety switch on control lever base Defective solenoid valve on pilot oil supply unit
Hydraulic system without function
Contaminated solenoid valve on pilot oil supply unit Hydraulic oil level too low Defective valve fuses Defective/interrupted plug and socket connection towards solenoid valve Quickhitch couplings not connected correctly
Hydraulic hammer does not work correctly
Hydraulic oil quantity too high/too low Hydraulic oil pressure too high/too low Defective switch for 2nd speed range Defective solenoid valve on pilot oil supply unit
Excavator runs in 1st speed only
Contaminated solenoid valve on pilot oil supply unit Defective valve fuses Defective/interrupted plug and socket connection towards solenoid valve Counterpressure in travelling drive does not drop below control pressure
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
5-47
Hydraulic system 5.17 5.17 Hydr Hydrau auli lics cs diag diagra ram m A4 A4
4 1
5 1
r o t o m r a e G
t r a t s s r o t o m c i l u a r d y h d e e p ! s 7 2 5 o t 9 u 2 a 0 C h : t i A T w . N d o n A e l T t t i i a r R f O e e v s P i r g M n I D i
0 1
Blade
) 7 d t h 5 e g 9 e i r 2 p ( 0 s e C 2 o v t i r A . u d : o a g n n i l l l a e i r v e a r s T g n i t r a 6 t S 1
9
5 1
Swivel/auxiliary hydraulics
1 1 Y
4
Rotate
) t f e l ( k c i t s y o J
Dipper arm
7
r e d n i l y c t e k c u r B e d n i l y c m o o B r e d n i r l e y s c i l e i b d a a t l S b
Right-hand side drive
Left-hand side drive
1 2
r a b 4 5 . 2 0
8
5
0 2
t i u c r i c l o r t n o n c i o t d r p 3 o
Bucket
k c ) i t t s h y g o i r J (
e t a t o R
2 m r a r e p p i D
e d a l B
e d i - s t h d e v g n i v i a r i - r R h d t d h g d i a a e g r h t n S a i
t e k c u B
1 m o o B
2 1
3 1
3 2
2 2
r a b 2
Boom
r a b 4
1
6
2
- l y c m r a r e r p e p d i n D i n i l y c t e s r f f e O d
9 1
s c i l u a r d y h y r a i l i x u A
8 1
1 m r a r e p p i D
7 1
5-48
o t p u ) t : . 6 f e o 5 l ( n 9 l 2 e i a v r 0 i r e C D s A
e v l a v f f o t u c e r u s s 4 e r 2 P
2 m o o B
l e v i w S
u a r d y h y r a i l i x u A
e v i r d e d i s d n a h t f e L
3 1 Y
3 3 Y
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
Hydraulic system 5.18 5.18 Hydr Hydrau aulic licss dia diagr gram am (lege (legend) nd) Pos. 1 2 3 4 5 6 7 8
SERV-HB 8003 En – Edition 1.0 *8003s510.fm
Description Diesel engine Variabl able di displa placeme ement pum pump + gea gearr pum pumpp Pilot oil supply unit Left eft-hand and si side joys oystick pi pilot vvaalve Rightght-ha hannd si side jo joysti stick pilot valv alve Main valve block Left eft-hand and side dri drive pil pilot valve
9 10 11 12 13
Pilot valve for drive (right) Boom swivel pilot valve Stab Stabiiliser bla blade pil pilot valve Change Changeove overr valve: valve: boom boom swiv swivel el/au /auxi xililiar aryy hydr hydraul aulic icss Oil cooler Oil filter
14 15 16 17 18 19 20 21
Shuttle valve block Swivel unit Travelling dr drive (r (right) Travelling drive (left) Offset cy cylinder Dipper arm cylinder Boom cylinder Bucket cy cylinder
22 23 24
Stabiliser bl blade cy cylinder Hose burst valve Pressure cut-off valve
25
Vent filter
5-49
Hydraulic system
5-50
SERV-HB 8003 En – Edition 1.0 * *8003s510.fm
5.19 5.19 Hydr Hydrau aulic licss diagr diagram am Drive (left) up to serial no.:
Offset cyl- Dipper arm inder cylinder
AC02956
18
Travelling drive (right)
Boom cylBucket Stabiliserblade inder cylinder cylinder
Starting serial no.: AC02957 auto2speed
22
15
3rd control circuit option Rotate
19
17
20 23
16
Blade
Swivel unit
21
Dipper arm
Left-hand Right-hand side drive side drive
Bucket
6
Straightahead driving
11
Y15 7
Travelling drive (right)
Travelling drive (left)
Boom
Auxiliary hydraulics hydraulics
Swivel
Boom 2
Dipper arm 2
8
Auxiliary hydraulics/ swivel
Bucket Boom
Pressure cut-off valve
14
Blade
9
Joystick (right)
5
4
Joystick (left)
24
10
Y13
4 bar
2 bar
12
2
Y3
3
13 1
25
2 bar
IMPORTANT: Drive fitted with auto2speed hydraulic motors starting serial no. AC02957!
SERV-HB 8003 En – Edition1.0*8003s511.fm
5-51
5.20 5.20 Main Main valv valvee block block diagr diagram am
Main control lines
Conn Connec ecti tion on
Lege Legend nd
A1, B1
Travelling drive (left) (left)
Auxiliary hydraulics hydraulics
A3, B3
Offset cylinder
A4, B4
Boom cylinder summation summation
A5, B5
Dipper arm cylinder cylinder
A6, B6
Drive (right)
A7, B7
Bucket cylinder
A8, B8
Boom cylinder
A9, B9
Dipper arm cylinder cylinder summation
AR2, BR2
Stabiliser blade cylinder
A2, B2
AR3, BR3
Gear motor
AR4, BR4
3rd control circuit (optional) (optional)
Pilot control lines
Bucket control
Joystick (right)
Pa8, Pb8
Boom control
Joystick (right)
Pa9, Pb9
Dipper arm summation control
Joystick (left)
Pra2,Prb2
Stabiliser blade control
Stabiliser blade pedal
Pra3, Prb3
Rotation control
Joystick (left)
Pr Pra4 a4,, Prb Prb44
3rd 3rd con contr trol ol circ circui uit con contr trol ol (ele (elect ctri ric) c)
Joys Joysti tick ck (r (rig ight ht))
Pump/tank lines
Joystick (right)
Pa7, Pb7
Boom summation control
Auxiliary hydraulics pedal
Pa4, Pb4
Joystick (left)
Auxiliary hydraulics pedal
Swivel control
Drive pedal (right)
Auxiliary hydraulics control
Pa3, Pb3
Right-hand side drive control
Pa2, Pb2
Dipper arm control
Drive pedal (left)
Pa6, Pb6
Controlled via
Left-hand side drive control
Pa5, Pb5
Legend
Pa1, Pb1
Connection
Conn Connec ecti tion on
Lege Legend nd
P1
Pump 1 port
P2
Pump 2 port
PR5
Pump 3 + 4 port
PA
Pilot oil supply unit port
T1
Tank liline vi via no non-ret ur urn va valve an and fifilter in in ta tank
T2
Tank line via oi oil co cooler an and fifilter in ta tank
DR1, DR1, DR2 DR2
Tank Tank line liness for for boom boom summ summat atio ionn
5-52
SERV-HB 8003 En – Edition 1.0 *8003s511.fm
Electric system
Electric system
Electric system
6 6.1 6.1
E l ec tr ic sy ste m Ohm' Ohm'ss Law Law (cur (curre rent nt,, volt voltag age, e, resi resist stan ance ce); ); po powe wer r It describes the interrelation between current, voltage and resistance. Current “I “I” – Ampere (A) Voltage “U “U” – Volt (V) Resistance “R “R” – Ohm (ΩW)
Mnemonic:
U R
I
Output Power "P" – Watt (W) P = U x I = R x I² = U²/R
6.2 6.2
Meas Measur urin ing g equi equipm pmen ent, t, mea measu suri ring ng met metho hods ds Multi-function measuring device
• Measurements of values (U, R, I, f) • Continuity test • Diode test Calculate measuring range using known data (P, U, R, I) and set before measuring! Observe AC/DC basic setting. ➥ AC = alternating curren t/voltage; ➥ DC = direct current/voltage
Test device with acoustic and optical signal output
• Continuity test in de-energised machine electric system and of wiring harnesses
SERV-HB 8003 En – Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
6-1
Electric system Measuring methods – multifunction measuring device
• Measuring current (ignition switched on): • Black cable in COM socket (earth), • red cable in A socket or mA socket; connect in series to consumer.
• Measuring voltage (ignition switched on): • Black cable in COM socket (earth), • red cable in V socket; • connect in parallel to consumer. • Measuring resistance (ignition switched off): • Black cable in COM socket (earth), • red cable in Ω socket; • connect in parallel to consumer (see measuring voltage).
Test lamp The test lamp is used to test lines and functions with the ignition switched on.
• Line test (testing voltage): Connect test lamp between test point (live cable) and machine earth or between test point (earth line) and a live cable.
• Functional check (testing current): Connect test lamp between a connection on the consumer to be tested and the connection line.
6-2
SERV-HB 8003 En – Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
Electric system 6.3
6.4
C ab l e co l o u r c o d i n g Colour Black Brown Re d
Code b lk brn red
Orange Yellow Green Blue V iole t Grey W h i te Pink
org yel grn b lu vio gry wh t p nk
R el ay s
Use, mode of function
Relays are used for switching electric loads (high currents) whereby the control power of the relay coil is relatively low. Relays can therefore be controlled by microelectronics or microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be make-contact, break-contact or changeover switches. These undertake the actual switching function. Zero-centre relay
86
30
86 = Star Startt of coil coil
(con (contr trol ol line line))
85 = End End of coil oil
(eart arth)
3 0 = I np u t
(load line)
87 = MakeMake-co conta ntact ct swit switch ch output output (load (load line) line) 87 a= Break-c Break-conta ontact ct switch switch outpu outputt (load (load line) line) 85 Fig. Fig. 1:
87 87a
Termina erminall descr descript iption ion on relay relay
SERV-HB 8003 En – Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
6-3
Electric system 6. 5
E l e ct r i c u n i t s Units
6.6
Alternator
12 V 55 A
Starter
12 V 2.3 kW
Battery
12 V 88 Ah
Socket
E.g. for cigarette lighter; 15 A max.
Fusse bo Fu boxx in ins instrum trumen entt pane panell Fuse no.
Rated current (A)
Protected circuit
F3
10 A
– Indicators, engine relay
F4
10 A
– Boom working light
F5
15 A
– Cab working light
F6
10 A
– Valves, horn
F7
15 A
– Heating, air conditioning
F8
10 A
– Wiper, interior light
F9
10 A
– Rotating beacon, radio, drive interlock
F10
15 A
– Socket, cigarette lighter
F3 F4 F5 F6 F7 F8 F9 F10 Fig. 2: 2:
6.7
Fuse box
Main fus fuse box box with ith re relay lay s The main fuse box is located under the cab. K9
K5
F1 F2
Fuse no.
Rated current (A)
Protected circuit
F1
40 A
– Start, preheat, cut-off solenoid
F2
50 A
– Fuel-filling pump, main fuse, ignition lock
Relay no.
Fig. Fig. 3: 3:
6-4
Relais a is box box unde underr the the cab cab
K9
– Cut-off solenoid switching relay
K5
– Preheating high current relay
SERV-HB 8003 En – Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
Electric system 6.8
R el ay s The relays are located in the relay box under the cab, next to the swivelling console
K7
Switching relay no.
Protected circuit
K6
– Preheating timer (telltale only); black plug
K7
– Starting relay
K8
– Cut-off solenoid timer; white plug
V1
– Cut-off solenoid recovery diode
V1
K6
Fig. 4: 4:
6.9
K81
Relays
S o ck et The socket A is located above the lubrication strip B.
A
B
Fig. Fig. 5:
Lubrica Lubricatio tionn strip strip on the the chas chassis sis
SERV-HB 8003 En – Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
6-5
Electric system 6.10 6.10 Joys Joysti tick ck tip tip swi switc tche hess Joystick (left) 2
1
Fig. Fig. 6:
3 Pos.
Description
1
Changeover or boom swivel and auxiliary hydraulics (S27)
2
Tip switch for additional control circuit (S30)
3
Tip switch for additional control circuit (S31)
Pos.
Description
1
Horn (S55)
2
Not assigned
3
Automatic idling speed feature (S48)
1
Left-h Left-hand and side d e joysti joystick c k (s (stand tandard ard and and option) option)
Joystick (right) 2
1
Fig. Fig. 7:
6-6
3
1
RightRight-han handd side joyst joystick ick (stand (standard ard and and option) option)
SERV-HB 8003 En – Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
Electric system 6.1 6.11 Instr Instrum umen entt pan panel el:: ove overv rvie iew w
1
2
7
3
5
6
4
3
Pos.
Description
1
Indicator (X10)
2
Temperature indicator – diesel engine (X13)
3
Cigarette lighter (E15)
4
Preheating start switch (S1)
5
Fuse box ( – – see Fuse box in instrument panel on on page 6-4) 6-4)
6
Switch panel
7
Radio option (A1)
SERV-HB 8003 En – Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
7
6
5
4
2
1
6-7
Electric system 6.12 6.12 Swit Switch ches es:: over overvi view ew
8
6-8
9
10
12
11
13
14
15
Pos.
Description
8
Switch – high speed (S21)
9
Switch – wiper/washer (S20)
10
Switch – boom working light (S16)
11
Switch – cab working light (S17)
12
Switch – rotating beacon (S18)
13
Switch – ventilation (S15)
14
Switch – air conditioning system option (S51)
15
Switch – safe load indicator option (S42)
16
Not assigned
17
Not assigned
16
17
SERV-HB 8003 En – Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
Electric system 6 . 1 3 A l ter n a to r The alternator charges the battery and supplies rectified 3 phase alternating current to electric consumers.
Pos.
Description
1
Connection B (battery) Connection P starting relay
2
Connection IG telltale (12V) Connection L telltale (earth)
1 Fig. ig. 8: 8:
2
Alt er ernato nat orr
6.14 Starter
2
1
Fig. ig. 9: 9:
Pos.
Description
1
Connection S starting relay
2
Connection B battery
Alt er ernato nat orr
SERV-HB 8003 En – Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
6-9
Electric system
6-10
SERV-HB 8003 En – Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
Wiring harnesses: overview
6 - 1 1
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
6 - 1 3
6.16 6.16 Wiri Wiring ng dia diagra gram A4 A4
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
6.18 6.18 Wiring Wiring harne harness ss 1000 1000109 109697 697:: engine engine – chas chassis sis A4 A4 AH/swivel changeover valve
Changeover valve
Main fuses
Electr. AH valve
Electr. AH valve
Horn
Drive alarm
Blocking diode
Cut-off solenoid Preheat
High-speed Air conditioning switch pressure switch (prepared)
Preheating
Socket
Starting relay
Cut-off solenoid
Safe load indicator
Wiring harness connection
Safety valve
High-speed valve
Boom working light
1000125106
Water temperature switch
Washer pump
Fuel-filling pump
Fuel pump
Starter
Alternator
Wiring harness connection 1000124101
Drive alarm Fuel level indicaHydraulic oil tor pressure switch
Air filter presPreheating Engine oil sure switch Air condi- system tioning pressure valve 6 - 1 5
Cut-off solenoid
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
6.20 6.20 Wiring Wiring harn harness ess 100012 100012510 5106: 6: swit switche chess A4 Rotating beacon switch
Air conditioning switch Ventilation switch
Safe load indicator switch S42
S51
S15
S18
1
110
X
2
1 109
X
2
1 107 106 106 105 2
3
X
X
4
3
X
X
4
3
51
X
6
5
82
X
6
5
X
X
X
8
7
X
X
8
7
X
135 134
116
10
9
133 134
108
10
9
133 132
5 7
9
Boom working light switch Cab working light switch S17 95
96
S16 1 53 117
1
103
X
2
1
4
3
X
X
4
3
101
X
4
3
6
5
102
X
6
5
X
99
6
5 94 94A
8
7
X
X
8
7
X
X
8
7
X
107 10 108
9
131 132
115 10 116
9
131 130
97
10
9
129 130
84
X 83
109
X
96
High speed switch Wiper/washer switch
97 2
X
S20
X
2
1
X
X
4
3
49
X
6
5
93
X
8
7
92
94A
10
9
129 128
89
S21
90 2
X
1
55
X
2
X
X
4
88
X
6
X
X
8
88
10
4
3
6
5
X
8
7
90
10
9
127 128
91
92
87
Preheating start switch 7 5 7 . 3 9 5 : F W S
S1
Automatic revs setting connection
Cigare Cigarette tte lighte lighterr
Engine Engine temper temperatu ature re connect connection ion
Indicator connection
3 4
X14 X14
19A 19A 5
X A 7 7 2
1
114 115
X
126
6
8 9 3 3 1 1
86
9.
A 1 9
1 9
10
127
E15 E15
7
X13 X13
8
120
136
117
126
125
118
125
124
34
112
119
113
118
13
X
32
7
1
40
53
7
12
X
31
6
2
44
55
8
11
37
23
5
71
9
21
4
10
35
19
3
9
34
15
2
8
33
4 A
41
42
1
3
122
4
47
5
49
X
6
51
X
84
71
1
6
98A
93
1
1
59
82
2
7
98A 98
103 2
2
43
83
3
3
78
8
1 21 21
91 4
4
86
9
101
99
5 42 42A
76
5
59
137 78
3
X4
5
X12 X12
Cab connection
6
58
X4.1
B
C
D
E
F
G
H
X
112 114
X
94
138
X
2
X
95
X
X
21
8
15
9
58
Drive interlock connection
76 44
21A
21A 4
9
15A
15A 5
Valves
87
X
105
139
X
X
89
X
98
Heating, air conditioning 5
6
X
3 8
Boom working light Cab working light
4
X
1
Indicators, controls, engine and cut-off solenoid holding contact
3
42A 7
2
7
1
X 6
B
135 136 137
X3 Main connec10 X6 tion 11 Armrest switch connection
X2 X1 Engine/chasEngine/chassis connection sis connection
6 - 1 7
7
41
43
121
X
102
7A
120
X
47
Wiper, interior light Rotating beacon, radio, drive interlock
7
8
Socket, cigarette lighter
X A
122
Warning buzzer
123 124
X1 1 Vario X11 indicator connection
6 - 1 8
6.21 6.21 Wiring Wiring harnes harnesss 1000 1000109 109629 629:: cab cab roof roof B11 10
Radio
B12
11
12
A1
13
Loudspeaker
8
6
7
5
8
Front roof light E14
Interior light E7
Rear roof light H28
2
3
6
5
X X 1
4
X X
15 8A 7
E9
4
X 10 12 X 11 13
2
8 8A
X X
X 3
1
Cab connection
5 7 9
1
1
6
6
2
2
7
7
3
3
4
4
8
8
5
5
9
9
2
X12
Rotating beacon
14 15 3
14
GND1
GND2
grn/yel (X12/1)
grn/yel
blu (X12/6)
blu
brn (X12/4) l 50
blk (GND1)
M2 Wiper blk
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
brn
N o. Up to 1 X12 (1) 9 pole plug and socket connector – cab
M2 wiper motor
To
Colour grn/yel
mm² 0 .7 5
2
X12 (2) 9 pole plug and socket connector – cab
H28 rotating beacon
vio
1
3
X12 (3) 9 pole plug and socket connector – cab
GND1
blk
1
4
X12 (4) 9 pole plug and socket connector – cab
M2 wiper motor
brn
0 .7 5
5
X12 (5) 9 pole plug and socket connector – cab
E9 front roof light
grn/red
1
6
X12 (6) 9 pole plug and socket connector – cab
M2 wiper motor
blu
0 .7 5
7
X12 (7) 9 pole plug and socket connector – cab
E14 interior light
blu
1
8
X12 (8) 9 pole plug and socket connector – cab
A1.1/4 radio
red
1
8A
A1.1/4 radio
A1.1/7 radio
red
1
9 10
X12 (9) 9 pole plug and socket connector – cab A1/6 radio
E7 rear roof light B11 loudspeaker
grn/blu wht
1 0 .5
11
A1/5 radio
B11 loudspeaker
wht/blk
0 .5
12
A1/4 radio
B12 loudspeaker
wht
0 .5
13
A1/3 radio
B12 loudspeaker
wht/blk
0 .5
14 15
GND1 GND1
GND2 A1.1/8 radio
b lk bl k
1 .5 1
16
GND1
M2 wiper motor
b lk
0.75
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
6.22 6.22 Wiring Wiring harnes harnesss 100010 100010962 9628: 8: armres armrestt Heater fan M4
84
X
83
74 75
Air conditioning thermostat S54
Safety switch 68
S28
82 76 77
58
Armrest switch connection 5 76
81
X6 4
7
84
68
X5 6 5
73
74
46
83
3
82
2
71
1
58
4
66
3
64
2
62
1
Joystick (left) 64
3
66
6
62
2
85
5
77
1
75
4
X8
Armrest/chassis connection
Joystick (right) connection 85
3
X
6
71
2
46
5
81
1
73
4
X7
6 - 1 9
No. Up to 46 X5/5 armrest/chassis connection
To X7/85 joystick (right) connection
Colour org
1
mm ²
N o. 75 M4/2 fan
58
X5/4 armrest/chassis connection
S28 safety switch
62
X5/1 armrest/chassis connection
X8/2 joystick (left) connection
64
X5/2 armrest/chassis connection
X8/3 joystick (left) connection
66
X5/3 ar armrest/chassis co connection
X8/6 joystick ((lleft) co connection
68
X5/7 armrest/chassis connection
S54 air conditioning thermostat
71
X6/1 armrest switch connection
X7/2 joystick (right) connection
73
X5/6 armrest/chassis connection
X7/4 joystick (right) connection
74
X5/6 armrest/chassis connection
M4/2 fan
bl k
1
Up to
To X8/4 joystick (left) connection
Colour bl k
mm²
brn/wht
1
76
X6/5 armrest switch connection
S28 safety switch
gry
1
blu/yel
1
77
S28 safety switch
X8/1 joystick (left) connection
gry
1
gry/yel
1
81
X6/5 armrest switch connection
X7/1 joystick (right) connection
gry
1
gry/grn
1
82
X6/2 armrest switch connection
S54 air conditioning thermostat
yel/red
1
yel/red
1
83
X6/3 armrest switch connection
M4/1 fan
yel/blk
1
brn/grn
1
84
X6/4 armrest switch connection
M4/3 fan
yel/blu
1
blk
1
85
X8/5 joystick (left) connection
X7/3 joystick (right) connection
gry/blk
1
1
6 - 2 0
6.23 6.23 Wiring Wiring harne harness ss 1000 10001116138: 16138: boom working working light light
XE11 53 54
1
53
2
54
No Up to . 53 XE11/1 boom working light 54 XE11/2 boom working light
S E R V - H B 8 0 0 3 E n – E d i t i o n 1 . 0 * * 8 0 0 3 s 6 1 1 . f m
E1
To E1 boom working light E1 boom working light
Colmm² our grn/yel 1 b lk 1
Wiring harnesses: overview
6-21
SERV-HB 8003 En – Edition 1.0 *8003s612.fm
6.25 6.25 Wirin Wiring g diagr diagram am A3
6-23
SERV-HB 8003 En – Edition 1.0 *8003s612.fm
6.27 Wiring Wiring harnes harnesss 100010962 1000109624: 4: engine engine – chassis chassis A3
Main fuses
Electr. AH valve
Electr. AH Changeover valve AH/swivel changeover valve valve
High-speed switch (prepared)
Drive alarm
Socket
Blocking diode
Horn
Air conditioning pressure switch
Cut-off solenoid Preheat
Preheating Cut-off Starting solenoid relay
Safe load indicator
Safety valve
High-speed valve
Wiring harness connection 1000125106
Boom working light
Water temperature switch
Washer pump
Fuel-filling pump
Fuel pump
Starter
Alternator
Wiring harness connection 1000124101
alarm Fuel level level indicaindicaPressure switch Drive alarm tor – hydraulic oil
Cut-off solenoid Air filter presPreheating sysAir condi-tem Engine oil pressure switch tioning valve sure
6-25
SERV-HB 8003 En – Edition 1.0 *8003s612.fm
6.29 Wiring Wiring harn harness ess 100012 1000125106 5106:: switch switches es A3
Ventilation switch
Safe load indicator switch
S42
S51
S15
S18
110
X
2
1 109
X
2
1 107 106 106 105 2
3
X
X
4
3
X
X
4
3
84
5
51
X
6
5
82
X
6
5
X
7
X
X
8
7
X
X
8
7
X
9
135 134
116
10
9
133 134
108 10
9
133 132
1
Boom working light switch Wiper/washer Cab working light switch switch
Rotating beacon switch
Air conditioning switch
S17 95
96
S16 1 53 117
103
X
2
1
4
3
X
X
4
3
101
X
4
3
6
5
102
X
6
5
X
99
6
5 94 94A
8
7
X
X
8
7
X
X
8
7
107 10 108
9
131 132
115 10 116
9
131 130
97
10
9
X 83
109
X
1
96
97 2
S20
X
2
1
X
X
4
3
49
X
6
5
93
X
X
8
7
92
129 130
94A
10
9
129 128
X
High speed switch
89
S21
90 2
X
1
4
3
6
5
X
8
7
90
10
9
91
92
55
X
2
X
X
4
X
6
X
X
8
127 128
88
10
87
88
Preheating start switch 7 5 7 . 3 9
5 : F W S
S1
Automatic revs setting connection 4
X14
Indicator connection Cigarette lighter
3
19A 5
X 2
1
X
126 127
6
8 9 3 3 1 1
A 7 7
114 115
Engine temperature connection
86
9.
A 1 9
E15 E15
7
10
8
X13
1 9
120
136
117
126
125
118
125
124
34
112
119
113
118
X
13
X
32
7
1
40
53
7
12
X
31
6
2
44
55
8
37
23
5
3
122
71
9
4
47
5
49
X
10
6
51
X
11
11
21
4
35
19
3
9
34
15
2
8
33 41 42
10
1
4 A
B
7
135 136 137
5
X3 Main connection
X2 X1 Engine/chassis Engine/chassis connection connection
84
59
71
1
6
98A
93
1
1
59
82
2
7
98A 98
103 2
2
43
3
78
91 4
4
86
99
5 42 42A
83
137 78
3 8
X6 Armrest switch connection
9
1 21 21 101
3
X4
5
X12 X12
6 7
Cab connection
X4.1
58
76
A
B
C
D
E
1
X
94
138
X
X
95
X
X
2
X
X 8
15
9
58
Drive interlock connection
F
G
1 2
8
21A 21A 4
9
15A 15A 5
Valves
5
X 89
X
98
6
X
3
4
105
X
43
121
X
102
7A
120
X
47
H
7
8
6-27
Warning buzzer
123 124
X11 Vario indicator connection
Boom working light Cab working light
87
139
Indicators, controls, engine and cut-off solenoid holding contact
3
76 44
42A 7
21
114
X
X 6
41 112
122
Heating, air conditioning Wiper, interior light Rotating beacon, radio, drive interlock Socket, cigarette lighter
SERV-HB 8003 En – Edition 1.0 *8003s612.fm
6.30 Wiring Wiring harn harness ess 100010 1000109629 9629:: cab roof roof A3 A3 B11 10
Radio
B12
11
12
A1
13
Loudspeaker
8
6
4
2
X 10 12 X X 11 13 X 7
5
3
1
8
6
4
2
X X
15 8A 7
5
8 8A
X X
X 3
1
Cab connection E9
Front roof light E14
Interior light E7
Rear roof light H28
5 7 9
1
1
6
6
2
2
7
7
3
3
4
4
8
8
5
5
9
9
2
X12
Rotating beacon
14 15 3
14
GND1
GND2
grn/yel (X12/1) grn/yel
blu (X12/6)
blu
brn (X12/4) l 50
blk (GND1)
M2 Wiper blk
SERV-HB 8003 En – Edition1.0*8003s612.fm
brn
No Up to . 1 X12 (1) 9 pole pole plug plug and socket socket connector – cab 2 X12 (2) 9 pole pole plug plug and socket socket connector – cab 3 X12 (3) 9 pole pole plug plug and socket socket connector – cab 4 X12 (4) 9 pole pole plug plug and socket socket connector – cab 5 X12 (5) 9 pole pole plug plug and socket socket connector – cab 6 X12 (6) 9 pole pole plug plug and socket socket connector – cab 7 X12 (7) 9 pole pole plug plug and socket socket connector – cab 8 X12 (8) 9 pole pole plug plug and socket socket connector – cab 8A A A11.1/4 radio 9 X12 (9) 9 pole pole plug plug and socket socket connector – cab 10 A1/6 radio 11 A1/5 radio 12 A1/4 radio 13 A1/3 radio 14 GND1 15 GND1 16 GN GND1
M2 wiper motor
Colmm² our grn/yel 0.75
H28 rotating beacon
vio
1
GND1
blk
1
M2 wiper motor
brn
0.75
E9 front roof light
1
M2 wiper motor
grn/ red blu
0.75
E14 interior light
blu
1
A1.1/4 radio
red
1
A1.1/7 radio E7 rear roof light
red 1 grn/blu 1
B11 loudspeaker B11 loudspeaker B12 loudspeaker B12 loudspeaker GND2 A1.1/8 radio M2 wiper motor
wht wht/blk wht wht/blk blk blk blk
To
0.5 0.5 0.5 0 .5 1 .5 1 0.75 6-28
6.31 Wiring Wiring harn harness ess 1000109 1000109628: 628: armrest armrest A3 A3
Heater fan M4
84
X
83 74 75
Air conditioning thermostat S54
Safety switch 68
S28
82 76 77
58
Armrest switch connection 5
76
81
X6 4
7
84
68
X5 6 5
73
74
46
83
3
82
2
71
1
58
Joystick (left)
66
3
64
2
1
3
66
6
62
2
85
5
77
1
75
4
X8
4
62
64
Armrest/chassis connection
Joystick (right) connection 85
3
X
6
71
2
46
5
81
1
73
4
X7
No . 46 58 62 64 66 68 71 73 74
Up to X5/ 5 armres t/t/chassis co connection X5/4 armrest/chassis connection X5/1 armr armreest/c st/chhassi assis con connect nectio ionn X5/2 armr armreest/c st/chhassi assis con connect nectio ionn X5/3 armr armreest/c st/chhassi assis con connect nectio ionn X5/7 armr armreest/c st/chhassi assis co connect nectio ionn X6/1 armr armreest swit switch ch con connecti ection X5/6 armr armreest/c st/chhassi assis con connect nectio ionn X5/6 armrest/chassis connection
To X7/85 jo joystick ((rright) ccoonnection S28 safety switch X8/2 8/2 joyst oystic ickk (left left)) conn conneectio ctionn X8/3 8/3 joyst oystic ickk (left left)) con connect nectio ionn X8/6 8/6 joyst oystic ickk (left left)) con connect nectio ionn S54 S54 air air con conditi itionin oningg the therm rmoosta stat X7/2 X7/2 joyst oystic ickk (rig (right ht)) con connect nectiion X7/4 7/4 joyst oystic ickk (rig (right ht)) conn connec ecti tioon M4/2 fan
6-29
Colour mm² org brn/wht blu/y lu/yel el gry/ gry/yyel gry/g ry/grn rn yel/re / red brn/g rn/grn rn blk blk
1 1 1 1 1 1 1 1 1
No . 75 76 77 81 82 83 84 85
U p to M4/2 fan X6/5 armrest switch connection S28 safety switch X6/5 armrest sw switch connection X6/2 X6/2 armre rmrest st swit switch ch conn conneecti ction X6/3 armrest switch connection X6/4 armrest switch connection X8/5 joystick (l(left) co connect ion
To
Colour mm²
X8/4 joystick (left) connection S28 safety switch X8/1 joystick (left) connection X7/1 joystick (r(right) connection S54 air cond condit itio ioni ning ther thermo most staat M4/1 fan M4/3 fan X7/ 3 joyst ick (r(right ) connection
blk gry gry gry yel/ yel/re redd yel/blk yel/blu gry/ bl blk
1 1 1 1 1 1 1 1
SERV-HB 8003 En – Edition 1.0 *8003s612.fm
6.32 Wiring harness 1000116138: 1000116138: boom working working light light A3 A3
XE11 53 54
1
53
2
54
No Up to . 53 XE11/1 boom working light 54 XE11/2 boom working light
SERV-HB 8003 En – Edition1.0*8003s612.fm
E1
To E1 boom working light E1 boom working light
Colmm² our grn/yel 1 blk 1
6-30
Options
Options
7 7.1
Opt i on s A i r co n d i t i o n i n g
Specific safety instructions
Danger ! Avoid contact contact with the heat heat exchanger or the condenser condenser and the supply lines. Lines and hoses carrying refrigerating agents or coolants can be pressurised and hot.
Danger of burns! ☞ Always observe the following instructions:
• Always empty the system system before before carrying carrying out maintenance maintenance work on the cooling circuit. • Avoid Avoid contac contactt with with parts parts carr carryin yingg coolant coolant.. • Carry out maintenance maintenance work with with the fan at a standstill standstill only. • Have maintenanc maintenancee and repair repair work work carried carried out by specialised specialised staff staff only. only.
Important! Make sure the cooling system does not come into contact with chlorine, choric substances, oil, grease or humidity. Use drain and fill systems for R134a only.
Important! The air conditioning system runs best by taking in “outside” air. – see Summer/winter operation on operation on page 1-15
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-1
Options Installation: overview
r e s n e d n o C
r e i f i d i m u h e D
r o s s e r p m o C
t i n u g n i n o i t i d n o c r i A
e n i g n e l e s e i D
7-2
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options C om po ne n ts
Heater/air conditioning unit The air conditioning unit consists of:
• Evaporator: This Evaporator: This is where the liquid refrigerating agent eva porates, and the air taken in by the fan is cooled • Expansion valve: Installed valve: Installed in the evaporator and controls the quantity of liquid refrigerating agent injected. • Ice guard: A guard: A fixed-setting thermostat with sensors placed between the evaporator fins prevents them from icing up due to freezing condensation water. The thermostat switches the evaporator's refrigerating agent supply off at –1.1 °C +/-0.8 °C and on again at +2.2 °C +/-0.8 °C as required. • Heat exchanger • Twin radial fan: Can fan: Can be controlled in steps and is overload-protected by means of a temperature microfuse.
5
1
Pos.
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
2
1 2
Description Thermostat cable Fan cable
3 4 5
Expansion valve Service cover Intake/outlet direction
3
4
7-3
Options Compressor The compressor takes in the gaseous refrigerating agent from the evaporator, compresses it and presses the refrigerating agent into the condenser. The diesel engine drives the compressor via a V-belt and an electro-magnetic clutch.
Condenser The condenser condenses the compressed refrigerating agent, i.e. it is delivered to the condenser in gaseous state and emerges at the lowest position of the condenser in liquid form.
Fig. ig. 1: 1:
Comp Comprr es essor sor
Dehumidifier with pressure switch The dehumidifier consists of a collector with integrated dryer, a sight glass and a pressure switch. The dehumidifier serves as an expansion receptacle and tank for the refrigerating agent. It can bind a small quantity of water chemically, thereby withdrawing it from the circuit. A sight glass on the dehumidifier enables to check the level of the circuit.
Important! The cooling system is not working properly if gas bubbles appear in the sight glass. Replace the dehumidifier if the sight glass is cloudy or shows traces of corrosion.
Caution! Fig. Fig. 2:
7-4
Dehumid Dehumidifi ifier e r with with pressu pressure re swit switch ch
Always keep the dehumidifier de humidifier closed otherwise the th e dryer is saturated by t he humidity in the air and is no longer serviceable.
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Filling up the air conditioning system
Important! Always have the air co nditioning system filled u p by an authorised workshop with specialised staff. • Only use refrigeratin refrigeratingg agent R134a according according to DIN 8960! – see Fluids and lubricants on lubricants on page 3-1 • Fill up the system in accordance accordance with the operation operation manual of the manufacturer manufacturer of the fill station. • Fill up the system with with enough refrigerating refrigerating agent. Make sure sure no bubbles appear in the sight glass.
Start evacuation 20 minutes min. < 20 mbar
Interrupt evacuation Check connections Check for stabile vacuum Pressure gauge Wait 5 minutes min. rises
or rectify
System is tight
Evacuate for a further 25 minutes min.
Fill in gaseous refrigerating agent to a pressure of 3 bar
Check for leakage
Pressure gauge rises
System is tight
Fill in required quantity of refrigerating agent
Caution! Do not overfill the system. ☞ Overfilling reduces the system's cooling capacity and can cause damage to
the system.
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-5
Options Maintenance
Important! Important information for maintenance and repair work: • There may be residual residual pressure in the system system even if it is empty. Release this this pressure with extreme care as you remove the connections. • When working on the cooling cooling circuit, close close all openings tightly tightly to prevent humidity from penetrating into the system. • Do not open the cooling cooling circuit circuit outdoors in humid humid weather or rain. rain.
Checking the compressor oil Check the oil level if:
• a system component has been replaced • the system leaks oil • the maintenance interval is due – due – see Maintenance plan (overview) on (overview) on page 3-5 Proceed as follows: ☞ Let the compressor run at idling speed with the diesel engine for 10 minutes. ☞ Open the oil filler opening ☞ Push the oil dipstick into the oil filler opening ☞ Withdraw the oil dipstick from the compressor and read off the oil level at the grooves Fig. 3:
Oil filler filler inlet inlet for for the the air conditioning conditioning compressor compressor
on the oil dipstick. ➥ The oil level must reach 5 – 7 grooves ☞ Fill in oil of the same grade if the oil level is lower
– see Fluids and lubricants on page 3-1 Fresh/recirculated air filter Tilt the cab to replace the filter – filter – see section 1.12 1. 12 Tilting Tilting the cab on cab on page 1-13. The air conditioning system is located at the rear half of the cab. Replacing the filter: ☞ Remove the cover between the air conditioning unit and the front air duct ☞ You can now access the inside filter ☞ Remove the inside filter ☞ Insert a new inside heater filter ☞ Fit the cover between the air conditioning unit and the front air duct back on again
7-6
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Troubleshooting Problem
Defective or loose fuse
Check the fuse's seat, insert correctly if necessary. Replace a defective fuse. Trouble occurring again within short time indicates there is a short circuit or obstruction in the system. Check the fan for obstruction or a defect and rectify the cause.
Line interruption
Check the line for loose contacts or ruptures
Defective fan motor
Replace the fan
Defective fan switch
Check or replace the switch
Short circuit in cable or fan switch
Eliminate the short circuit. Install a new cable and/or switch if necessary
Contaminated contacts
Clean the pins. Proceed with extreme care to avoid short circuits.
Heat exchanger heavily contaminated
Clean carefully and avoid damage that could cause leaks.
Flow temperature too low
Wait for the engine to warm up
Defective thermostat
Replace the thermostat
Heat exchanger fins contaminated
Check and/or clean the heat exchanger
Folded or pinched line
Eliminate the cause for the error and reroute the hoses
Loose hose connection
Check the seat of the flexible lines and tighten the clamps
Damaged hose
Mount and connect a new hose
Damaged heat exchanger
Replace the heat exchanger
Loose or torn V-belt
Adjust V-belt tension, replace the V-belt
Interruption in the compressor's solenoid coil
Check the current to the clutch
V-belt pulley does not turn even though electro-magnetic clutch is applied
Check and/or replace the compressor
Compressor clutch slips
Repair the clutch or replace the compressor
Fan does not work
Fan cannot be switched off
Reduced fan output
No or insufficient heating output
Coolant leaks from the unit
Compressor does not work
Condenser overflow Iced condenser
Loss of refrigerating agent
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
Remedy
Possible causes
Expansion valve is blocked or stuck in open Replace the expansion valve position Thermostat sensor in wrong position
Place the sensor in new position
Defective expansion valve or thermostat
Replace the expansion valve or thermostat
Interruption of refrigerating agent line
Check all lines for external damage or chafing
System leak
Evacuate, fill up, check for leaks and repair
7-7
Options Problem
Insufficient cooling output
System cools with interruptions
System runs very loudly
Remedy
Possible causes Fan duct obstructed
Check air intake and outlet for obstruction. Eliminate the cause for trouble
Refrigerating agent level too low
Fill up refrigerating agent
Humidity in system
Empty the air conditioning system, replace the dehumidifier, evacuate and fill up
Dehumidifier saturated or clogged
Replace the dehumidifier
Condenser fins contaminated
Clean the fins Important: No use of high-pressure cleaner
Line interruption
Check, repair and/or replace the lines
Defective fan motor
Replace the fan
Loose or excessively worn V-belt
Retighten or replace the V-belt
Loose compressor bracket or worn inside parts of the compressor
Repair the bracket, replace the compressor
Excessive wear of fan motor
Replace the fan
System too full
Suck off refrigerating agent
Not enough refrigerating agent in the system
Check for leaks Fill up the system
7-8
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options 7.2
A ir - su sp e n s i o n se sea t The air compressor of the air-suspension seat requires a 12 Volt power supply.
Ports
Tension is picked off the plug on the right-hand side joystick X7: No. Up to 81 X7/1 joystick (right) connection 73 X7/1 joystick (right) connection
7.3
To Seat +12 V Seat earth
C o u n t er w e i g h t
Specifications Counterweight
Model 8003
We i g h t
400 kg
Additional tail end lat eral projection over chain s
65 mm
Important! Bear in mind the lift capacity table when using a counterweight!
7.4
E x t e n d e d d i p p er ar m
Specifications Extended dipper arm
Model 8003
L e n g th
2150 mm
Important! Bear in mind the lift capacity table when using a counterweight!
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-9
Options 7.5 7.5
Contr Control ol circ circuit uit (pipe (pipewo work rk)) conn connec ectio tions ns for grab grab Connect and disconnect the grab couplings as follows: Removing the coupling: ☞ Park the machine on firm and level ground ☞ Extend bucket cylinder 4/A to 4/A to the middle ☞ Switch off the engine ☞ Release the pressure on the bucket cylinder by moving the right-hand side control lever
A
to the left and right ☞ Fold the control lever base up ☞ Turn lock sleeve 4/C towards towards lock ball 4/B
upwards ☞ Pull lock sleeve C upwards ☞ The coupling opens
Connecting the coupling: ☞ Connect the coupling onto the bucket cylinder connection making sure it is straight
B
☞ Wait until you hear a hissing sound of the connection ☞ Fully connect the coupling on the connection ☞ Turn back the lock again (away from lock ball B )
C
Flat-seal couplings (can be coupled under residual pressure) Fig. g . 4:
Plug
ISO designation 1 2 .5
Thread 1/2 BSP
Sleeve
1 2 .5
1/2 BSP
Grab Grab coup coupliling ngss
Couplings according to ISO 16028
7.6
3rd 3rd con conttrol rol cir circu cuit it con onne necction tionss
Important! Follow the operation manual of the implement manufacturer for connecting the 3rd control circuit to the implement.
Standard connections: Connection Standard Quick coupler option
7-10
Bush Bulkhead coupling 1/2" Quick coupler 12.5 1/2"
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options 7.7 7.7
Auxi Auxili liar aryy hydr hydrau auli lics cs conn connec ecti tion onss
Important! Follow the operation manual of the implement manufacturer for connecting the auxiliary hydraulics to the implement.
Standard connections: T U Fig. Fig. 5:
Connect Connection ionss for auxi auxiliary l iary hydra hydrauli ulics cs
V
Connection T
Dipper arm (left) Pressure line bulkhead coupling 1/2"
Dipper arm (right)
Pressure line bulkhead coupling 3/4" Unpressurised reflux line (hammer) bulkhead coupling 1/2"
U V
Quick coupler options: Connection T
Dipper arm (left) Pressure line quick coupler 12.5 1/2"
U V
Dipper arm (right)
Pressure line quick coupler 12.5 1/2" Unpressurised reflux line (hammer) quick coupler 17 3/4"
Couplings according to ISO 16028
Couplings cannot be coupled under pressure! Electric auxiliary hydraulics option: As an option, the auxiliary hydrau lics can be controlled electrically via 2 buttons on the joystick on the left
Important! Follow the operation manual of the implement manufacturer for connecting the auxiliary hydraulics to the implement.
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-11
Options 7. 8
N e u s on Var i o Danger ! Lower the excavator arm to the ground when using the Neuson Vario feature, otherwise –
Danger of accidents ☞ Support the machine with the excavator arm when using the Vario feature
Using the Neuson Vario feature
The following steps must be followed under all circumstances when changing the eccentric position 6/A on the ground with the boom cylinder. ☞ Brace excavator arm 6/A on ☞ To unlock the Neuson Vario feature, press and hold both front switches on the left-hand
side 6/B and 6/B and right-hand side 6/C joystick. 6/C joystick. A
☞ Press and hold both buttons B and C about 5 seconds without moving the joysticks to
unlock. The Neuson Vario feature has four lock positions at offset positions of 90° each (0°/360°, 90°, 180°, 270°). ☞ Press the left-hand side joystick D to the left or right for a 90° rotation, press and hold
D
buttons B and C as as you do so. ☞ Both buttons B and C can be released once the excavator has moved.
B Fig. Fig. 6:
C Using n g the the Neus Neuson on Vari Vario featu feature re
➥ The Neuson Vario feature automatically engages after a 90° rotation. ☞ If repositioning beyond 90° is required with the Neuson Vario feature, press buttonsB buttonsB
and C beyond beyond the 90° lock position. ➥ As soon as buttons B and C are released, the Neuson Vario feature engages in the
next possible lock position.
Important! Always check whether the lock position is enga ged! For improved driving features on slopes, reposition the centre of gravity towards the slope with the Neuson Vario feature.
7-12
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Vario diagram G B8
B
E
F
PR
A
Fig. Fig. 7:
T
Neus Neuson on Vario ario valv valvee
Description B8 B A T PR E F G
Fu nc ti on
Description Boom rod side port Lock cylinder rod side port Lock cylinder base side port Tank line port Pilot control pressure port Solenoid valve Solenoid valve Lock cylinder
Opening the lock ☞ Brace the excavator arm on the ground with the boom -> • Pressure is applied to boom cylinder rod side port B8
☞ Press buttons B and C on on the joysticks on either side
B8 to B • Solenoid valves E and F are enabled -> pressure from B8 to • Pressure is applied to lock cylinder rod side port • Lock cylinder base side port is switched to tank • The lock opens
Locking ☞ Release buttons B and C • Solenoid valves return to initial position -> pressure is interrupted • Pilot control pressure is applied to lock cylinder base side port A • Lock cylinder rod side port B is switched to tank
☞ Keep on rotating the upper carriage • Lock cylinder engages in the next possible lock position
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-13
Options Neuson Vario warning device
Danger ! Do not bypass the warning device or make it inoperative. Working with the excavator is only allowed with a fully functional warning light.
Caution, danger! ☞ This safety feature must be checked by an authorised workshop every time
maintenance is carried out. ☞ The warning light features a functional check. The warning light comes on
briefly every time the machine is started. Always make sure the warning light is fully functional Depending on the position of the Vario feature, stability is higher or lower with respect to a standard excavator. Observe the lift capacity table and the warning ranges inFig. in Fig. 8 . Warning ranges: A ☞ Crosswise excavation
B ☞ Lengthwise excavation
Reduced stability
Upper carriage not in proper range with respect to Vario feature, no modification of stability (hydraulically limited)
Warning range A danger of tilting! Fig. g . 8:
7-14
Warning range B
Warning range A danger of tilting!
Warn Warnin ingg ran range ge
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options
A
Danger ! The machine can tilt if the boom is not lowered and swivelled out of the area of danger as soon as the alarm is given (warning sound, warning light A), or if the alarm is ignored
Danger of accidents! ☞ Brake the upper carriage and rotate it in the other direction.
Fig. Fig. 9:
The warning device is set to 73 % of the static tilt load in an unfavourable position of the upper carriage. As soon as the load is exceeded and work is carried in an unfavourable position of the upper carriage (warning range), or if the upper carriage is rotated into the warning range, the warning sounds briefly and warning light A comes on.
Warni arning ng light g ht
Ports
N o. 1 2 2A 2 b3 3 3A 4 4A 4b 6 6A 7 7A 8
From X14 supply port X14 supply port Y19 Vario solenoid valve X14 supply port B13 proximity switch K14 Vario time lag relay B13 Vario proximity switch K15 Vario switching relay K14 Vario time lag relay X6/1 armrest connection Y19 Vario solenoid valve H32 Vario telltale S1 start switch K14 Vario time lag relay
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
Via B13 proximity switch
K14 Vario time lag relay
Up to K15 Vario switching relay Y19 Vario solenoid valve Y19.1 Vario solenoid valve H32 Vario telltale K14 Vario time lag relay K15 Vario switching relay K15 Vario switching relay X2/6 pressure switch port B16 Vario buzzer Y19 Vario solenoid valve Y19.1 Vario solenoid valve K15 Vario switching relay K15 Vario switching relay B16 Vario buzzer
Colour blu b lk b lk b lk yel yel vio vio vio brn brn gry gry
7-15
Options 7. 9
F u el -fi l l i ng pu pu mp Refuel with the fuel-filling pump 10/A as 10/A as follows: ☞ Place the machine on level ground
B
☞ Switch off the engine ☞ Open the engine cover
A
pump A into into the container with the fuel – fuel – see Stationary ☞ Insert the hose of fuel-filling pump A fuel pumps on page 3-10 ☞ Press button B to switch on fuel-filling pump 10/A ➥ The fuel tank is full as soon as telltale 10/C comes 10/C comes on
pump A ☞ Press button B to switch off fuel-filling pump A
Important!
Fig. Fig. 10: 10: Fuel-f Fuel-fill illing i ng pump pump
Switch off the fuel-filling pump as soon as telltale C comes on, otherwise the fuel tank may overflow and can be damaged. C
• Bear in mind mind the fuel tank's tank's maximum maximum capacity capacity
Fig. Fig. 11: Fuel-f Fuel-fill illing i ng pump pump telltale telltale
The float switch screwed into the fuel tank triggers the telltale.
Fig. Fig. 12: 12: Floa Floatt swit switch ch
7-16
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Connections
The electric connection for the fuel-filling pump is already installed. The telltale has its own wiring harness, connected to the engine/chassis wiring harness by means of plug X16.
N o.
Up to
38 XE16/2 drive alarm connection 41 XE16/1 drive alarm connection 100 X17 float switch
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
To X17 float switch S60/1 telltale S60/2 telltale
Colmm² our b lk 1 b lu 1 vio 1
7-17
Options 7.10 7.10 Cent Centra rall lub lubric ricat ation ion syst system em Grease-based central lubrication system with 12 lubrication points Position The electric pump for the central lubrication system is installed over the hydraulic pump. The electric pump presses the grease through the lubrication line towards the distributing block on the boom. From the distributing block, the grease passes on to the lubrication points.
Fig. 13: Central Central lubrication ubrication system system pump pump
Connections 1 2 3 4 5
Pos. 1 2 3 4 5
7-18
Description – Earth (brown) + Inte Interm rmed edia iate te lub lubri rica catition on tip tip swi switc tchh conn connec ectition on (or (oran ange ge)) + Ignition (black) – Error telltale (red) + Lu Lubrication te telltale (g (green)
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Function
1
Pos. 1
4
5
3
2
Description Push button on motor housing Red LED Green LED
2 3 4
Cycle time potentiometer
5
Break time potentiometer
The green LED comes on for about 1.5 sec once ignition is switched on to indicate readiness. Pressing the push button on the pump's motor housing switches on the pump and starts the lubrication cycle. The pump drive motor is switched off and cycle time begins once lubrication time is over. All further lubrications start sta rt automatically according to t o the cycle time set. Lubrication time is stopped and saved if ignition or lubrication is switched off during cycle time. The data is read from the memory upon switching ignition on again, and lubrication is resumed where it was interrupted. Pressing the push button on the motor housing or on the instrument panel starts intermediate lubrication at any give time if ignition is switched on.
Fig. 14: 14: Central Central lubricati lubrication on system system push push button button
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
Status LEDs
Indication
Meaning
Gree Greenn LED LED 1.5 1.5 sec sec
Igni Igniti tion on on (ope (opera rati tion onal al readi eadine ness ss))
Steady green light
Comes on during lubrication
Steady red light
Grease level error Remains lit until grease tank is refilled
Blinking red light
Overpressure error
7-19
Options Adjusting breaks and lubrication times
Adjust breaks and lu brication times with poten tiometers. Lubrication time 1min to 16 min 1
Break 0.5 h to 8 h 0.5
16
8
Repair in case of clogging Clogging indication Overpressure beyond service pressure means the system is clogged and is indicated as follows:
• Grease escapes by the pressure relief valve • Blinking red LED on the pump housing Causes for clogging in the system
• Crushed or clogged lubrication line • Bearing overfilled or clogged with lubricant • Inadequate lubricant for central lubrication systems • Clogged distributor output • Clogged distributor Detecting clogging ☞ Unscrew the main line off the main distributor
bu tton and check whether whe ther the lubricant is d elivered ☞ Actuate the pump with the push button correctly ☞ Screw the main line onto the main distributor ☞ Unscrew the lines one after an other and actuate the pump every time
Repairing a clogged distributor
• Remove the distributor from the system • Unscrew the screw plugs of the piston bore • Move the piston back and forth (do not remove) • Screw the screw plugs back in again You can remove the piston of the defective distributor and check it for scratches or damage. If there are traces of hardened grease on the piston or the bores, remove the grease with compressed air or by washing the piston.
7-20
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options
Important! Traces of hardened grease are a sign that the grease is not suitable for central lubrication systems
Problem
Pump does not work
Pump works but does not supply grease
No grease rims on all lubrication points
Defective integrated electronic controls
Replace the controls and the cap
Electric line interrupted
Replace the electric line
Defective pump
Replace the pump
Air inclusions in piston
Vent the pump
Level too low
Fill up the tank
Defective pump element
Replace the pump element
Pump does not work
See “Pump does not work”
Breaks too long or lubrication time too short Shorten breaks or increase lubrication time System clogged
No grease rims on some lubrication some lubrication points
No grease rim on one lubrication point
Reduced pump revs
Grease escapes by the pressure relief valve
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
Remedy
Possible causes
See “Grease escapes by the pressure relief valve”
Burst or leaky supply lines to secondary disReplace the lines tributor Leaky screw connections
Retighten or replace the screw connections
Burst or leaky lubrication line to lubrication point
Replace the line
Leaky screw connections
Retighten or replace the screw connections
High system pressure
Check system bearings
Low ambient temperatures
No damage (intermediate lubrication once or twice if necessary)
System pressure too high
Detect and eliminate clogging
System pressure too high
Detect and eliminate clogging
Clogged distributor
Replace the distributor
Clogged system
Repair clogged/stuck bearings
Defective valve spring
Replace the pressure relief valve
7-21
Options 7.11 7.11 Saf Safee load load indica indicator tor D (safet (safetyy valve valve for boom) boom) Position
1
2
6 5 3 4
Pos.
Function
1 2 3
Description Boom se segment pi pilot ccoontrol po port Joystick connection Boom pressure line port
4 5 6
Hose burst valve Pressure switch Leak oil strip port
The valve is mounted direct on the base-side port of the boom cylinder. “Extend cylinder” function:
• Cylinder can be extended as usual (always “free flow” towards the cylinder) The built-in non-return valve safely holds the load in rest position. “Retract cylinder” function:
7-22
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options • Pilot control pressure moves valve (CT2) to work position (free oil reflux from the base side) • The valve moves back to home position if the pilot control pressure drops In addition, a safety valve (CT1) protects the hydraulic cylinder from overload.
Important! The valve settings are sealed
Diagram
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-23
Options 7.12 7.12 Saf Safee load load indicat indicator or F (safet (safetyy valves valves for for boom boom and dipper dipper arm) arm) Position
8
1
5
2
3 4
6
5
9 7
Pos. 1 2
7-24
Description Boom se segment pi pilot ccoontrol po port
3 4
Dipper arm segment pilot control connection Joystick connection Joystick connection
5 6 7 8 9
Dipper arm pressure line port Leak oil strip port Pressure switch Hose burst valve Boom pressure line port
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options Function
One valve is mounted direct on the base-side port of the boom cylinder, the other valve is mounted on the rod-side port of the dipper arm cylinder. “Extend boom cylinder” function:
• Cylinder can be extended as usual (always “free flow” towards the cylinder) The built-in non-return valve safely holds the load in rest position. “Retract boom cylinder” function:
• Pilot control pressure moves valve (CT2) to work position (free oil reflux from the base side) • The valve moves back to home position if the pilot control pressure drops “Retract dipper arm cylinder” function:
• Cylinder can be retracted as usual (always “free flow” from the cylinder) The built-in non-return valve safely holds the load in rest position. “Extend dipper arm cylinder” function:
• Pilot control pressure moves valve (CT2) to work position (free oil flow to the base side) • The valve moves back to home position if the pilot control pressure drops In addition, a safety valve (CT1) protects the hydraulic cylinder from overload.
Important! The valve settings are sealed
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-25
Options Diagram
7-26
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options 7.13 7.13 Drive Drive int interl erlock ock (antith (antitheft eft protec protectio tion) n) Position
2 Pos. 1
1 2
Description Transponder re receiver su surface Red LED
Fig. Fig. 15: 15: Drive Drive interl interlock o ck
Disabling the drive interlock ☞ Approach the transponder t ransponder to 2 cm to the transponder receiver surface ➥ The red LED goes out ☞ Insert the ignition key into the ignition lock within 30 seconds and turn it at least to posi-
tion 1 ➥ The drive interlock remains disabled
Enabling the drive interlock ☞ Remove or turn the ignition key to position 0 ➥ The drive interlock is enabled after 30 seconds ➥ The blinking red LED indicates the drive interlock is enabled
P r og r a mm i ng
Coding transponder keys The so-called main or master key is required for coding a new or uncoded key, or a key with different coding, for the drive interlock. ☞ Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 – 45 – see Disabling the drive interlock on page 7-27 ➥ The LED changes to steady green light ➥ The system is in programming mode now (coding mode)! ☞ Remove the master key from the transponder receiver surface ➥ The LED changes to rapidly blinking green light ☞ Hold the key to be programmed against the transponder receiver surface ➥ The key is coded once the LED comes on slowly three times ☞ Hold further keys next to the transponder receiver surface to code them as mentioned
above The drive interlock is enabled as soon as there is no key contact for 30 seconds. ➥ Blinking red light
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-27
Options Deleting programming/coding ☞ Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 – 45 – see Disabling the drive interlock on page 7-27 ➥ The LED changes to steady green light ➥ The system is in programming mode now (coding mode)! ☞ Hold the master key against the transponder receiver surface for a further 30 seconds ➥ The LED changes to steady red light ➥ The system is in delete mode now (coding mode)! ☞ Remove the master key ➥ The LED changes to rapidly blinking red light
the transponder receiver surface ☞ You have 30 seconds to hold the master key again to thetransponder to confirm deletion. ➥ The system is deleted once the LED comes on slowly three times
Caution! Deletion deletes all “normal“ transponders and the master! • Reason: Once a key is is lost, you can no longer longer delete it! • Therefore, Therefore, the entire system is deleted deleted for safety reasons and can be completely recoded with the remaining (or newly ordered) keys.
Configuration of the deleted system Once deletion is over, the system recognises any TREBE transponder key, i.e. the system can be disabled with any key. The first transponder key to be reco ded for the system is automatically the ne w master and can be used for coding the “normal” transponder keys. – keys. – see Programming on on page 7-27
Important! The following applies both to the coding and programming mode: The system leaves the coding and programming modes and is disabled as soon as the ignition key is inserted in the ignition lock and turned to the first position.
7-28
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
Options 7.14 7.14 Quic Quickh khit itch ch faci facili lity ty M
Danger ! The implement must always be safely locked onto the quickhitch facility –
Danger of accidents! ☞ Before starting work, make sure the implement is securely locked onto the
L
quickhitch facility by means of the lock mechanism. You must be able to see the lock on either side of the mounting bore of the implement. ☞ Re-equip as follows:
machin e to the implement • Approach the machine • Hitch coupling bar M onto coupling claws L of the quickhitch to pick up the bucket • Engage lock mechanism N in mounting bores O • Place the bucket on level ground
N P
O
Fig. 16: Bucket Bucket with with quickhi quickhitch tch facility ity
☞ Lock as follows:
S
• Switch off the engine • Insert tube P (included in scope of delivery) in clamping sleeve Q • Press the tube downwards • The lock pins must be in position R • Insert the spring plug in fixture T to lock the quickhitch facility
Q
Caution! Always make sure the spring plug is inserted correctly R
☞ Unlock as follows: • Switch off the engine • Remove the spring plug from fixture T • Insert tube P (included in scope of delivery) in clamping sleeve Q • Press the tube upwards • The lock pins must be in position S
T Fig. 17: Bucket with quickhitch quickhitch facility ty
SERV-HB 8003 En – Edition 1.0 *8003s710.fm
7-29
Options
7-30
SERV-HB 8003 En – Edition 1.0 * *8003s710.fm
NK Lifton Limited Station Road Ind Park Brompton-on-Swale Richmond, North Yorkshire, DL 107 SN United Kingdom Phone (+44) 1748 81 06 66 Fax (+44) 1748 81 07 77 e-Mail
[email protected] www.nklifton.com
NeusonKramerFrance SA 43, rue du Landy - 93211 Saint Denis Laplaine cedex tél +33 (0) 141624162 fax +33 (0) 141624165 e-mail
[email protected] www.neusonkramerfrance.fr
Neuson Baumaschinen GmbH Haidfeldstrasse 37 A-4060 Linz Linz / Leonding Leonding Telefon +43 (0) 732 / 90590-0 Fax +43 (0) 732 / 90590-0 e-Mail
[email protected] www.neusonkramer.com