Service Manual 8003 eng.

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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


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


17.5 bar


21.5 bar


21.5 bar


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


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


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


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


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


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


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


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


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

*


All table indications in kg and horizontal position on firm ground without bucket.




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

*


5 56 0

All table indications in kg and horizontal p osition on firm ground without witho ut bucket.



2-12


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


B

Lo a d ho o k h eig h t

*


All table indications in kg and horizontal position on firm ground without bucket.




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


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


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


2-15

2-16


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


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


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


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


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

o n c e a y e a r

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

● ● ●

● ● ●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

● ●

●

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) Prefilter with water separator: drain water • Clean ean

●

Check V-belt condition and tension

●

3 - 6

● ● ●

● ●


3.3 3.3



Check exhaust system for damage and condition

( o n c e a d a y )


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

C u s t o m e r

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 injection nozzles and valves

E v e r y 1 5 0 0 s / h

●

Check valve tip clearance, adjust if necessary

●

● ●

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 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

E v e r y 1 5 0 0 s / h

):

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

3 - 5

E v e r y 1 0 0 0 s / h

):

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

●

● ● ●

Check telltales for correct function

●

●

●

Cab tilt lock

●

●

●

●

●

Couplings, dirt pile-up on hydraulic system dust caps

●

Insulating mats in engine compartment Grease supply of central lubrication system Adhesive labels labels and and operation operation manual manual

●

●

● ●

●

●

●

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


3.3 3.3



Check exhaust system for damage and condition

( o n c e a d a y )


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

●

●

8

● ●

●

●

●

Empty diesel fuel tank ●

Check battery electrolyte. Fill up with distilled water if necessary

A u t h o r i s e d

●

●

Check the injection pressure Check injection nozzles and valves

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

● ●

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


E v e r y 1 5 0 0 s / h

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

●

● ● ●

●

●

●

●

● ●

●

Insulating mats in engine compartment

● ●

●

●

●

●

●

Adhesive labels labels and and operation operation manual manual


● ●


3.3 3.3



( o n c e a d a y )


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 Replace dehumidifier Compressor oil

3 - 7

10

●

●

●

●

●

● ●

●

●

●




3.3 3.3



( o n c e a d a y )


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

●

Replace dehumidifier

●

●

Compressor oil 10

●

●

3 - 7

3 - 8


3.3 3.3



Functional check (

( o n c e a d a y )


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




3 - 8


3.3 3.3



Functional check (

( o n c e a d a y )


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


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.


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).


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


• 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


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


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


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


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


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


• 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


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.


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


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


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


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


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


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


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


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!


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


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


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


Service Manual 8003 eng.

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