Escolar Documentos
Profissional Documentos
Cultura Documentos
Track excavator
Machine model
8003
Edition
1.0
Language
English
Article number
1000132826
Documentation
Description
Order no.
Operation manual
1000132136
Service Manual
1000132826
1000137282
Legend
Edition
Issued
1.0
02/2005
SERV-HB 8003 En
1000132826
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
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
I-2
I-3
I-4
Operation
Operation
1
1.1
Operation
Important information on this service manual
This service manual contains important information on how to service your machine safely,
correctly and economically. Therefore, it aims not only at new 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
1-1
1.2
Danger!
Failure to observe the instructions identified by this symbol may result in
personal injury or death for the operator or other persons.
Caution!
Failure to observe the instructions identified by this symbol may result in
damage to 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
1.3
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
Fig. 1:
Fig. 2:
Model:
8003
Year:
2004
PIN:
AC 000000
Output:
42.5 kW
Mass:
7960 kg
Load:
---------------
---------------
-----------------------------
Type label
Fig. 3:
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
Example:
Fig. 4:
1-4
Yanmar 46557
Fig. 5:
Fig. 6:
Fig. 7:
Fig. 8:
1-5
1.5
Machine: overview
Boom light
Boom
Dipper arm
Rubber chains
Undercarriage
Stabiliser blade
Cab
Engine cover
1
8
4
5
3
10
Handles
10
11
12
Exhaust pipe
12
11
Fig. 9:
1-6
1.6
Cab: overview
27
25
26
28
29
30
24
23
22
21
3
4
20
19
10
5
18
15
14
13
11
12
17
16
1-7
1.7
Cab: legend
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1-8
Description
Cover for hammer pedal
Hammer pedal
Control lever (left)
Control lever (right)
Control lever base (left)
Control lever base (right)
Armrest (left)
Armrest (right)
Lever horizontal seat adjustment
Lever horizontal seat adjustment with control lever base
Air vent (rear window, on the left)
Air vent (rear window, on the right)
Radio (option)
Seat (backrest adjustment)
Seat belt (lock)
Cup holder
Bracket (storage box for documents)
Switch panel
Throttle
Fuse box
Preheating start switch
Cigarette lighter
Coolant temperature indicator
Round display element
Drive pedal (left)
Drive pedal (right)
Drive lever (left)
Drive lever (right)
Stabiliser blade pedal
Stabiliser blade lever
1.8
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.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
1-10
Description
Telltale (red) air filter
Telltale (yellow) cold starter
Telltale (red) hydraulic oil filter
Telltale (red) hydraulic oil temperature
Telltale (red) alternator charge function
Telltale (red) engine oil pressure
Telltale (red) coolant temperature
Fuel level indicator
Telltale (red) safe load indicator
Hour meter
Coolant temperature indicator
High speed
Washer system
Working light
Roof lights
Rotating beacon
Ventilation
Air conditioning (option)
Safe load indicator (option)
Revs switch
Not assigned
52
Pos.
52
53
54
55
56
57
58
59
60
61
62
53
54
55
56
57
58 59
60
61
62
Description
1-11
67
65
64
68
70
63
69
66
Pos.
63
64
65
66
67
68
1-12
71
Description
69
70
71
Danger!
Careful when tilting the cab
Danger of accidents!
Always tighten lock screws A and C when driving and working with the
machine.
A
B
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 before tilting the cab
Should the door be open as you tilt the cab, do not actuate the door opener
unintentionally
C
Fig. 10: Cab floor securing screws
1-13
Mount lock screws A (front) and B (rear) with suitable tools and the specific torque
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 at regular intervals for
cracks and cuts.
J
K
L
Fig. 11: Tilting the cab
1-14
Position
A
Function
Summer operation
Cools
Winter operation
Important!
Summer and winter operation does not depend on the season, adjust according to
your personal requirements.
B
Fresh air: heater takes in air from outside the cab fig. 12
Preheated fresh air: heater takes in air from the chassis fig. 13
1-15
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
Specifications
Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2
Engine
Engine
Model 8003
Product
Model
4TNV98-VNS
Design
No. of cylinders
Direct injection
Aspiration
Naturally aspirated
Cooling system
Water-cooled/aspirating fan
Lubrication system
Displacement
3318 cm
98 x 110 mm
Output
Max. torque
Idling speed
Injection pressure
Compression
3 4 bar
69.5 72.5 C
Thermal switch
107 113 C
Firing order
13421
Direction of rotation
Starting aid
Counterclockwise
(as seen from the flywheel)
Intake manifold
(preheating time 10 15 sec)
25/46% in all directions
30/58% 3 minutes.
Observe the machine's hill climbing ability (30/
58%)!
97/68/EC Tier II
EPA Tier II
2-1
Capacities
Capacities
Model 8003
Fuel tank
93 l
10.2 l/4.5 l
4.2 l
Radiator
4.9 l
Expansion tank
1.5 l
Tightening torques
Tightening torques
2.3
Cylinder-head bolt
Flywheel screw
Hydraulic system
Hydraulic system
Pump
Flow rate
Control valve
Model 8003
Twin variable displacement + twin gear pump
2 x 36 + 2 x 16 cm
AP2D36LV3RS6-874-P (variable displacement
pump)
GSP2H-BOF16A16AR-A0-A627-0 (gear pump)
2 x 82.4 + 2 x 36.6 l/min @ 2290 rpm
12 sections/13 sections (3rd control circuit)
3005 bar
3003 bar
245-0/+3 bar
350 bar @ 20 l/min
(stabiliser blade 300 bar)
32.5-0/+4 bar
2253 bar
Standard
2-2
Model 8003
99 l
180 bar
51.5/+1.5 sec @ 50 C oil temperature
12 bar
17.5 bar
21.5 bar
21.5 bar
P2
20 bar
79 l/min
40 bar
78 l/min
60 bar
76.9 l/min
90 bar
76.1 l/min
120 bar
74.4 l/min
150 bar
73.7 l/min
180 bar
72.8 l/min
210 bar
68 l/min
240 bar
61.6 l/min
270 bar
55.9 l/min
300 bar
43.3 l/min
2.4
Model 8003
2 speed ranges
3.2/5.2 kph
Climbing ability
30/58%
Chain width
450 mm
375 mm
Ground pressure
0.36 kg/cm
2.5
9.2 rpm
Stabiliser blade
Stabiliser blade
Model 8003
Width/height
2300/500 mm
450/520 mm
2-3
2.6
Electric system
Electric system
Alternator
12 V 55 A
Starter
12 V 2.3 kW
Battery
12 V 88 Ah
Socket
Fuse no.
Protected circuit
F3
10 A
F4
10 A
Boom light
F5
15 A
Roof lights
F6
10 A
Valves, horn
F7
15 A
F8
10 A
F9
10 A
F10
15 A
Fuse no.
Protected circuit
F1
40 A
F2
50 A
Relay no.
Protected circuit
K9
K5
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 1:
Fuse box
K9
Fig. 2:
2-4
K5
F1
F2
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
V1
V1
K6
Fig. 3:
2.7
K81
Relays
Noise levels
Sound power level
Model 8003
101 dB (A)
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
Water
% by
volume
99
79
65
59
55
Coolant
Anticorrosion agent
cm/l
10
Antifreeze agent
% by volume
% by volume
20
34
40
44
2-5
2.9
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.
Thread
Gap dimension
1/2"
2.4 mm
Stabiliser blade
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
Elastic
seal
O-ring
Non-return
valve with
elastic
seal
18 Nm
25 Nm
45 Nm
55 Nm
70 Nm
125 Nm
180 Nm
310 Nm
450 Nm
540 Nm
18 Nm
35 Nm
70 Nm
90 Nm
180 Nm
310 Nm
450 Nm
540 Nm
15 Nm
25 Nm
35 Nm
40 Nm
45 Nm
60 Nm
100 Nm
160 Nm
210 Nm
260 Nm
15 Nm
30 Nm
45 Nm
55 Nm
100 Nm
160 Nm
210 Nm
260 Nm
18 Nm
25 Nm
35 Nm
50 Nm
70 Nm
125 Nm
145 Nm
210 Nm
360 Nm
540 Nm
18 Nm
35 Nm
50 Nm
65 Nm
140 Nm
190 Nm
360 Nm
540 Nm
Identification
aid outside
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
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
G1A
G1 1/4A
Elastic
seal
O-ring
Non-return
valve with
elastic
seal
35 Nm
55 Nm
70 Nm
90 Nm
125 Nm
135 Nm
180 Nm
310 Nm
450 Nm
540 Nm
55 Nm
80 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
35 Nm
45 Nm
55 Nm
70 Nm
100 Nm
125 Nm
135 Nm
210 Nm
360 Nm
540 Nm
45 Nm
60 Nm
100 Nm
145 Nm
260 Nm
360 Nm
540 Nm
Identification
aid outside
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
2-7
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 = 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
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 = 0.12 and are to be used as approximate figures.
2-8
2710
2710
1570
2810
6420
Fig. 4:
2300
Service weight
Model
8003
7960 kg
8245 kg
Height
2710 mm
2864 mm
Width
2300 mm
2300 mm
Transport length
6420 mm
6570 mm
4290 mm
4162 mm
1850 mm
1850 mm
2150 mm
2150 mm
4462 mm
3970 mm
3814 mm
6980 mm
7128 mm
7170 mm
7317 mm
4840 mm
5000 mm
5030 mm
5190 mm
7170 mm 6290/7420 mm
7440 mm 7190/7690 mm
7020 mm 6770/7270 mm
7300 mm 7050/7550 mm
52.30 kN
52.30 kN
38.70 kN
38.70 kN
35.10 kN
35.10 kN
1550 mm
1550 mm
400 mm
150/650 mm
720 mm
970 mm
550 mm
800 mm
Main data
720
550
67
63
2300
1400
450
3610
450
500
15
50
Vario
3516 mm
2-9
5.0 m
Max
4.0 m
3.0 m
2.0 m
Fig. 5:
1955* 1950
2010* 1930
2315* 1845
2925*
2920
2750* 1730
4070*
2620
2380* 1185
3120* 1620
4770*
2400
2455* 1145
3260* 1550
4750*
2335
2345* 1130
3135* 1530
4375*
2330
6305
2690* 1545
3675*
2365
5230* 4900
2385*
2385*
4830
All table indications in kg and horizontal position on firm ground without bucket.
2-10
5.0 m
Max
4.0 m
3.0 m
2.0 m
Fig. 6:
1730* 1730*
1805* 1805*
2115* 1865
2550*
2550*
2575* 1740
3690*
2685
2295* 1180
2995* 1620
4580*
2425
2415* 1130
3210* 1540
4775*
2320
2375* 1110
3165* 1505
4530*
2295
7150* 4730
2835* 1510
3935*
2320
6000* 4800
2855*
2390
All table indications in kg and horizontal position on firm ground without bucket.
2-11
Max
5.0 m
4.0 m
3.0 m
2.0 m
Fig. 7:
1955* 1955*
2010* 2010*
2315* 2095
2925*
2925*
2750* 1975
4070*
2985
3120* 1865
4770*
2765
3260* 1800
4750*
2700
3135* 1775
4375*
2700
6305
2690* 1750
3675*
2735
5230* 5230*
2385*
2385*
5560
All table indications in kg and horizontal position on firm ground without bucket.
2-12
2.15 Lift capacity table 8003 with extended dipper arm and counterweight
Max
5.0 m
4.0 m
3.0 m
2.0 m
Fig. 8:
1730* 1730*
1805* 1805*
2115* 2100
2550*
2550*
2575* 1975
3690*
3035
2995* 1855
4580*
2775
3210* 1775
4775*
2670
3165* 1740
4530*
2645
7150* 5425
2835* 1745
3935*
2670
6000* 5495
2855*
2740
All table indications in kg and horizontal position on firm ground without bucket.
2-13
5.0 m
Max
4.0 m
3.0 m
2.0 m
5.0 m
2000* 1950
1040
4.0 m
1920* 1505
805
1915* 1715
920
3.0 m
1895* 1270
680
2020* 1675
895
2.0 m
1905* 1185
635
2205* 1605
860
2750* 2230
1195
4070* 3380
1805
1.0 m
1930* 1150
615
2380* 1530
820
3120* 2090
1120
4770* 3095
1655
630
2455* 1475
790
3260* 2000
1070
4750* 3010
1610
685
2345* 1460
780
3135* 1975
1055
4375* 3005
1605
6305* 6230
2690* 1995
1065
3675* 3050
1630
0.0 m
1960* 1175
-1.0 m 1975* 1275
-2.0 m 1940* 1520
-3.0 m 1700* 1700*
815
1175
3335
Max
Vario position
Front Vario
Fig. 9:
2-14
2.17 Kinematics
E
Pin diameter
55 mm
170 mm
300 mm
Bucket
Dipper arm
Bucket
2-15
2-16
Maintenance
Maintenance
Maintenance
Maintenance
3.1
Diesel engine
Engine/machine
fluid
Specification
API CD, CE, CF
Engine oil
Season/
temperature
Capacities1
15 C
+45 C
10.2 l
Year-round
Year-round
99 l
Q8 T 55, SAE85W-90
Travelling drive
Gearbox oil
Hydraulic oil
Hydraulic oil tank
Biodegradable oil5
FINA BIOHYDRAN SE 46
BP BIOHYD SE-46
Roller and
friction bearings6
Grease
Year-round
As required
Grease
BP Energrease MP-MG2
Year-round
As required
Grease nipples
Year-round
As required
Battery terminals
Acid-proof grease9
FINA Marson L2
Year-round
As required
Fuel tank
Diesel fuel
Over 4 C
Below 4 C
Coolant
Year-round
11.8 l
Refrigerating agent
R134a10
Year-round
800 g
Compressor oil
Sanden SP10
Year-round
116.5 cm
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 indicated are approximative values; the oil level check alone is relevant for the correct oil level
According to DIN 51511
Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)
According to DIN 51524 section 3
Hydraulic ester oils (HEES)
KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease
KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
Standard acid-proof grease
According to DIN 8960
3-1
Maintenance
-20
-15
-10
-5
10
15
20
25
30
35
40
95
104
SAE 10W
SAE 20W
SAE 10W-30
SAE 15W-40
SAE 20
SAE 30
SAE 40
F
1.
3-2
-4
14
23
32
41
50
59
68
77
86
Maintenance
3.2
Maintenance label
Symbol
Assembly
Explanation
General
Visual check
General
Grease instructions
Fuel system
Fuel system
Radiator
Radiator
Engine
Engine
Engine
Engine
Engine
Travelling drive
Change oil
Travelling drive
Undercarriage
Hydraulic system
Hydraulic system
Hydraulic system
3-3
Maintenance
Symbol
3-4
Assembly
Explanation
Radiator fins
Clean
Heating,
air conditioning
Authorised
workshop
Customer
):
Carry out the following oil and filter changes (check oil levels after test run):
Engine oil 1
Engine oil filter 2
Fuel filter 3
Air filter element as indicated by telltale
Coolant
Hydraulic oil filter insert 4
Hydraulic oil
Breather hydraulic oil tank
Gearbox oil5
Inspection work (
For service and maintenance work on the implement, please refer to the operation and maintenance manual
of the implement manufacturer as well.
Every 50 s/h
Work description
Maintenance work
(once a day)
3.3
):
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)
3-5
Check alternator, starter and electric connections, bearing play and function
Line fixtures
Authorised
workshop
Customer
For service and maintenance work on the implement, please refer to the operation and maintenance manual
of the implement manufacturer as well.
Every 50 s/h
Work description
3-6
3.3
Authorised
workshop
Customer
Lubrication service (
For service and maintenance work on the implement, please refer to the operation and maintenance manual
of the implement manufacturer as well.
Every 50 s/h
Work description
3.3
):
Air conditioning (
):
Compressor oil 10
3-7
Replace dehumidifier
):
Leakage check (
):
Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
Visual check
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 water 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
Authorised
workshop
Customer
Functional check (
For service and maintenance work on the implement, please refer to the operation and maintenance manual
of the implement manufacturer as well.
Every 50 s/h
Work description
3-8
3.3
3.4
3.5
Service package
1000127022
1000125571
1000106891
1000106892
1000069998
1000064543
1000012360
1000012847
1000022075
1000022076
1000125682
1000003894
Fuel filter
Water separator element
Seal for diesel fuel filter housing
O-ring
O-ring for oil drain plug
Hydraulic reflux filter insert
Air filter insert (inside)
Air filter insert (outside)
Cylinder-head cover gasket
O-ring
Introduction
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
3-9
3.6
Fuel system
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 handle C to climb onto
the chain and as a safe hold during refuelling.
Danger!
All work involving fuel carries an increased
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!
C
Important!
Fig. 1:
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system see Bleeding the fuel 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.
General
Only refuel from stationary fuel pumps. Fuel from barrels or canisters is usually contaminated.
Even the smallest particles of dirt can cause
3-10
right
Fig. 2:
Grade
51 601
No. 1-D according to DIN
51 601
Use
For normal outside temperatures
Min. 45
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 fitting the fuel filter, prefilter or the fuel lines back on again
After running the fuel tank empty
After running the engine again, after it has been out of service for a longer period of
time
3-11
On
Off
B
Interrupt fuel supply as follows:
A
Fig. 3:
Fuel prefilter
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
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!
Fig. 4:
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner!
Fig. 5:
Close the fuel feed line with the stop cock on the fuel prefilter
Thoroughly clean the outside surfaces of fuel filter 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. 6:
Fig. 7:
3-13
3.7
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.
Proceed as follows:
max
min
Fig. 8:
3-14
Caution!
Too much or incorrect engine oil may result in engine damage! For this reason:
Do not add engine oil above the MAX mark of oil dipstick 9/A
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
OIL
Fig. 9:
Danger!
Caution when draining hot engine oil
Danger of burns!
+ 80 C
OIL
Fig. 10: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner!
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
Fill in engine oil see section Filling up engine oil on page 3-15
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
A
Fig. 11: Drain coupling with hose
B
C
D
3-16
Danger!
Caution when draining hot engine oil
A
Danger of burns!
Wear protective gloves
Environment!
Collect the drained engine oil in a suitable container.
Dispose of used oil and filters in an environmentally friendly manner!!
Fig. 15: Cleaning the filter head and oiling the gasket
Tighten oil filter cartridge A with a commercially available tool by about a further half
revolution
A
3-17
3.8
Cooling system
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 Engine compartment: overview on page 1-11
Dirt on the cooling ribs reduces the coolers 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 maintenance plans
An insufficient coolant level reduces the heat dissipation capacity 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!
The use of the wrong coolant can destroy the engine and the cooler. Therefore:
Add enough antifreeze compound to the coolant but never more than 50 %. If possible use brand-name antifreeze compounds with anticorrosion additives
Observe the coolant compound table see section 2.8 Coolant compound 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
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 poisonous
Danger of accidents!
Keep away from flames
Avoid eye contact with antifreeze
If antifreeze comes into contact with the eyes
Proceed as follows:
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
Check the coolant level on the transparent coolant tank A and on the radiator B
If the coolant level is below the LOW seam or if there is no coolant at the radiator's
FULL
LOW
filler inlet:
Filling up coolant
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:
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:
3-20
3.9
Air filter
Caution!
The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
Important!
For applications in especially dusty 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.
Replace outside filter B and inside filter C at the latest after 50 service
hours!
Check the screws at the induction manifold and the clamps for tightness
Check the function of the dust valve, replace if necessary
3-21
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
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
The air filter is located in the engine compartment, on the right side of the machine
Proceed as follows:
Switch off the engine
Apply the handbrake
Squeeze the discharge slot of dust valve 23/G
Remove hardened dust by compressing the upper area of the valve
3-23
3.10 V-belt
Danger!
Only check or retighten/replace the V-belt when the engine is switched off
Check as follows:
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
Carefully check V-belt 24/1 for damage, cracks or cuts
Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley
3-24
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
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
Slacken attachment screws 25/3 of alternator 25/4
Use a suitable tool to push the alternator in the direction of arrow A until reaching the
Keep the alternator in this position, and at the same time retighten attachment
screws 3
4
Fig. 25: Retightening the V-belt
3-25
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.
Check as follows:
1
About 9 mm
Retighten as follows:
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
Slacken attachment screws 27/3 and 27/4 of alternator 5
Use a suitable tool to push the compressor in the direction of arrow A until reaching
the correct V-belt tension (fig. 27)
Keep the compressor in this position, and at the same time retighten attachment
screws 3 and 4
3-26
Run the machine warm before checking the pressure! Hydraulic oil temperature: 50 C
min. (operating temperature)
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
Connect the pressure gauge to measuring port MP 1 28/1 for P1 or MP 2 28/2 for P2
Retract the dipper arm cylinder (or extend the boom cylinder) as far as it
will go at maximum engine revs
Retract the dipper arm cylinder (or extend the boom 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 %
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
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
Functions: stabiliser blade, rotation, 3rd control circuit option, triple articulation boom
option
Checking primary pressure limiting valve 2 (PPLV 2) for pump P3
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 %
Adjust the pressure at the primary pressure limiting valve (PPLV 2) 31/B on the main
valve block
pressure gauge
3-28
Adjust the pressure at the pressure reducing valve (PRV 4) 33/C at the pilot oil supply
unit
Adjust the pressure at the secondary pressure limiting valve on the gear motor
Slacken the locknut of the pressure limiting valve34/1
Unscrew the pressure limiting valve until you can read off a pressure drop on the
pressure gauge
Fig. 34: Secondary pressure limiting valve
3-29
3
1
Pos.
1
Description
Measuring port for pump 1
MP 1
MP 2
MP 3
MP 4
MP 5
Pos.
3-30
Description
Primary pressure limiting valves pumps 1 and 2
PPLV 1
PPLV 2
PRV 4
Pump 1
Movement
Function
Symbol
Boom
DOWN
EXTEND
Bucket
RETRACT
Left-hand side
drive
FORWARDS
REVERSE
Measuring port
Measuring port MP 1
(pump)
UP
Pressure limiting
valve
Pressure limiting
valve
Measuring port
Specified values
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Measured
Measured
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
Pump 2
Movement
Function
Dipper arm
Right-hand side
drive
3-31
Auxiliary hydraulics
FORWARDS
REVERSE
A
B
Measuring port MP 2
(pump)
RETRACT
EXTEND
Symbol
Specified values
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3003 bar
25 bar
3-32
Function
Symbol
Stabiliser blade
DOWN
Auxiliary hydraulics
A (2)
B (2)
LEFT
Boom swivel
RIGHT
LEFT
Rotate
RIGHT
Measuring port
Measuring port MP 3
(pump)
UP
Pressure limiting
valve
Gear motor
Pressure limiting
valve
Measuring port
Specified values
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
Rated value
225+3 bar
Rated value
225+3 bar
Measured
Measured
Pilot control
Movement
Function
SERV-HB 8003 En Edition 1.0 * *8003s313.fm
Joystick
ANY
Symbol
Measuring port
Specified values
Rated value
32.5-0/+4 bar
Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
Lower all hydraulically controlled implements to the ground
Move all control levers of the hydraulic control valves several times
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This may cause damage to the hydraulic pump!
Oil or fuel flowing out of high pressure lines may cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slack nuts or damaged
hoses and lines are detected.
Replace the hose or line if one of the problems mentioned below is detected.
Damaged or leaky hydraulic seals.
Worn or torn shells or uncovered reinforcement branches.
Expanded shells in several positions.
Entangled or crushed movable parts.
Foreign bodies jammed or stuck in protective layers.
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil
Always fill up hydraulic oil before the level gets too low
see Filling up hydraulic oil on page 3-36
If the hydraulic system is filled with biodegradable oil, then only use the
same biodegradable oil for filling up observe the sticker on the hydraulic
oil tank!
Environment!
Collect hydraulic oil, including biodegradable oil, with a suitable container! Dispose of
drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.
3-35
Caution!
Do not fill up oil if the oil level is above the FULL mark, otherwise the hydraulic
system may be damaged and escaping oil may cause serious injuries.
Check the hydraulic oil level each time the machine is taken into service or
once a day
Proceed as follows:
Park the machine on level ground
Switch off the engine
FULL
LOW
Temperature
Oil level
Between 10 and 30 C
LOW mark
Between 50 and 90 C
FULL mark
Important!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.
1
3-36
Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will
run out of the filler opening on the hydraulic tank.
Fill up as follows:
Park the machine on level ground
Retract all hydraulic cylinders
Switch off the engine
Fold the control lever base up
Clean the area around filler opening C with a cloth
Open filler opening C
Filling up hydraulic oil
Check the hydraulic oil level on sight glass B
Fill up if necessary and check again
Close filler opening C
Fig. 39: Hydraulic oil filler inlet
3-37
Important!
Only change the hydraulic oil if it is warm (about 50 C).
Retract all hydraulic cylinders before changing the oil.
The red telltale 40/33 on the instrument panel monitors the reflux filter.
The filter element must be replaced by an authorised workshop:
3-38
Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20 066, part 5.
1 Q/00
The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication 1 Q/00 means manufactured in the 1st quarter of 2000.
3-39
Draining oil
B
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly
manner.
3-40
3.15 Chains
Chain wear may vary according to work and ground conditions.
We recommend checking chain wear and tension once a day.
Park the machine on firm and level ground to check and carry out maintenance.
Checking chain tension
Danger!
Working under the machine with the chains off the ground and only supported
by the implement is extremely dangerous.
Caution, danger!
Firmly support the machine with chocks or suitable brackets
Check chain tension as follows:
Important!
There is no mark on the steel chains (options). Positioning the steel chains is not
possible.
No specific position is required for the steel chains (option)
Standard play between the sliding block's shoulder and the contact area of the second
support roller of the drive pinion is 20 25 mm.
Set the tension as follows if it is not in accordance with the rated value.
20 25 mm
3-41
Danger!
The lubricating valve may be squeezed out due to the high grease pressure in
the hydraulic cylinder.
Caution!
Excessive tension of the chains causes severe damage to the cylinder and the
chain.
Reducing tension
Draining grease in a way different from the one described below is very dangerous.
Also bear in mind the safety instructions on this page
Slowly open the lubricating valve A by 1 turn to allow the grease to flow out.
Place a suitable container underneath to collect the grease
The grease flows out of the groove of the lubricating valve
Retighten the lubricating valve A
Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again
Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in an environmentally friendly manner.
Lubrication strip
Apply grease to the lubrication strip as follows:
Important!
A
B
A portable lamp can be connected to the lubrication strip's 12 V connection C.
Fig. 48: Lubrication strip on the chassis
Maintenance of implements
Important!
Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for an increased service life of the implements. Please observe
the lubrication and maintenance instructions in the implements' operation manuals
3-43
The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
During charging in particular, but also during normal battery operation, an oxyhydrogen
mixture is formed in the battery cells danger of explosion!
Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery may rupture or explode!
Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells
otherwise the gas produced during normal battery operation may ignite!
Use only 12 V power sources. Higher voltages will damage the electric components
When connecting the battery leads, make sure the poles +/ are not reversed,
otherwise sensitive electric components will be damaged
Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking!
Never place tools or other conductive articles on the battery danger of short circuit!
Disconnect the negative () battery terminal from the battery before starting repair work
on the electric system
When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses
Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse
Only use fuses with the specified load capacity (amperage) see Fuse box in
instrument panel on page 2-4
Alternator
3-45
Battery
Danger!
Battery acid is highly caustic!
Danger of explosion!
Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
Always disconnect the negative terminal () from the battery before starting
repair work on the electric system!
The battery 49/A is located in the chassis underneath the cab behind the gear motor. The
battery is maintenance-free. However, have the battery checked at regular intervals to
make sure the electrolyte level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be carried out by an authorised
workshop.
Always follow the specific battery safety instructions!
A
Important!
Fig. 49: Battery
3-46
3.17 Cab
Replacing the inside heater filter
Tilt the cab to replace the filter see Tilting the cab on page 1-13.
The heater is located at the rear half of the cab.
Replacing the filter:
3-47
Work carefully
Wear goggles and protective clothing
Do not aim the compressed air at the skin or at other people
Do not use compressed air for cleaning your clothing
Electric components and damping material must be covered and not directly exposed
to the jet
Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
Protect the following components from moisture:
Engine
Electric components such as the alternator etc.
Control devices and seals
Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays
3-48
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure may
Penetrate into the electric systems and cause short circuits and
Damage seals and disable the controls!
We recommend using the following aids to clean the cab:
Broom
Vacuum cleaner
Damp cloth
Bristle brush
Water with mild soap solution
Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they may destroy the fabric!
Exterior of the machine
High-pressure cleaner
Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only
Caution!
When cleaning the engine with a water or steam jet
3-49
3-50
Engine
Oil dipstick
Fuel filter
4.1
Fuel injection pump
Exhaust manifold
Air intake
Engine
Engine
Engine
4TNV98 engine: overview
4-1
Fan blade
V-belt
Alternator
Clamping bracket
Starter
Engine
4-2
Fuel pump
Water separator
with stop cock
Fuel filter
with stop cock
4.2
Feed
Reflux
Engine
Fuel system
4-3
Engine
4.3
Fig. 1:
4.4
abnormal
Fig. 3:
4-4
Engine
B
C
Fig. 4:
4-5
Engine
Place the cylinder-head cover gasket
Fig. 5:
4.5
49 58.8 Nm
2nd pass
103.1 112.9 Nm
Caution!
Bear in the mind the order for tightening the cylinder-head bolts!
See figure
Flywheel
Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them!
Flywheel
4-6
Fan
Engine
4.6
Pressure check
If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If
the pressure is too high, replace the spacer by a thinner one.
Nozzle tester
4.7
Spacers
Normal atomisation
Bad atomisation
Fig. 7:
Nozzle jet
4-7
Engine
4.8
Injection time
Checking injection time
Remove the rubber covers from the flywheel housing and check whether the mark on
the belt pulley is aligned with the 0 mark on the scale
Unscrew the injection line of the first cylinder and replace it by the drip tube (fig. 8)
(place a container to collect the fuel)
Rotate the engine 1.5 revolutions until it is 40 before top dead centre in the compression stroke
Slowly keep on turning the engine (degree by degree) until dripping stops
Do not turn back if you have turned too much!
The point at which the dripping stops is the start of delivery (injection time) of the fuel
Fig. 8:
Drip tube
injection pump
You can now read the value (in degrees before top dead centre) off the belt pulley
Setting injection time
If injection time should no longer be correct, you can adjust it by rotating the fuel injection pump
Mark the initial position on the pump housing before setting the fuel injection pump
Remove all injection lines before rotating the injection pump, and slacken the 4 flange
screws by about half a revolution
Rotate the pump in the required direction, and tighten one of the screws before you
check the setting
Engraved scale
Belt pulley
Mark on belt
pulley
Direction of rotation
4-8
Engine
4.9
Fig. 9:
4.10 Compression
Remove the injection lines and the injection nozzles
Set the fuel injection pump to zero delivery (remove the plug for the cut-off solenoid)
Turn the engine
Mount the compression gauge on the cylinder you want to measure
Turn the engine with the starter and read the pressure off the pressure gauge
Specified value: 35 +/- 1 bar @ 250 rpm
Limit value: 28 +/- 1 bar @ 250 rpm
Fig. 10: Compression
4-9
Engine
4.11 Checking the coolant thermostat
Remove the thermostat
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 11: Coolant thermostat
Thermal switch
Thermal switch
Thermometer
Test prods
4-10
Engine
4.13 Oil pressure switch
Remove the cable connection from the oil pressure switch (in the area of the cut-off
solenoid)
Measurement prod
Remove the radiator cap and mount it onto the adapter as shown
Increase the pressure to about 1 bar (stamped onto the radiator cap) with the hand
pump
4-11
Engine
4.15 Engine trouble
Problem
Possible causes
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Defective or flat battery
Loose or oxidised cable connections in starter circuit
Defective starter, or pinion does not engage
Wrong valve tip clearance
4-12
Engine
Problem
Possible causes
Oil level too high
Engine smoke
White
Black
4-13
Engine
4-14
Hydraulic system
Hydraulic system
5
5.1
Hydraulic system
Hydraulic system
Hydraulic pump AP2D36LV3RS6-874-P
Twin variable displacement pump + twin gear pump
1
11
10
Pos.
1
2
3
4
5
6
7
8
9
10
11
Description
Type label
Bleed screw
Leak oil port
Port P1
Control initiation set screw
Control port P3
Control port P4
Control port P4
Control port P3
Port P2
Bleed screw
5-1
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
Description
Port P4
Port P3
Measuring port P2 (not used)
Measuring port P1 (not used)
Plug for shuttle valve1
Plug for nozzle2
Suction port P4
Suction port P3
Suction ports P1 + P2
1. The lubricating oil is taken from the next highest high pressure by means of the shuttle valve behind port 2.
2. The lubricating oil quantity is limited by the nozzle behind plug 5.
5-2
Hydraulic system
Pump unit: exploded view
2
3
4
5
6
8
14
10
11
12
13
15
16
5-3
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5-4
Description
Gear pump
End plate
Pump cover
Piston valve
Spring
Drive unit
Cradle
Plug
Plug
O-ring
Bleeder valve
Plug
Nozzle
Shuttle valve (for lubrication)
Pump housing
Shaft
Hydraulic system
Pilot oil supply unit
2
1
02
"6
13
BAR
11
10
06
06
8
0
0
Pos.
BAR
0
03
12
02
Description
Pilot valve supply
Connection
PV
Accumulator
BV
PR
Pump 1 port
P1
10
Pump 3 port
P3
11
Pump 2 port
P2
12
Tank line
13
5-5
Hydraulic system
2
6
7
3
10
12
11
6
13
8
Pos.
5-6
Connection
Description
Port P2
Accumulator
Port P1
Safety valve
Tank line
P2
P1
T
10
Port P3
P3
11
BV
12
PR
13
PV
SERV-HB 8003 En Edition 1.0 * *8003s510.fm
Hydraulic system
5.2
Ports
Rotate
BR3
AR3
Stabiliser blade
BR2
AR2
PR5
T6
T4
T2
Dipper arm
summation
Boom
B8
A8
Bucket
pc2
A7
B7
A6
B6
P2
P3
5-7
Hydraulic system
Rotate
Stabiliser blade
T1
B5
Dipper arm
A5
pc1
Boom summation
B4
B3
B2
Swivel boom
A3
P4
B1
Auxiliary hydraulics
A2
PT
A1
PP
P1
5-8
PA
Hydraulic system
Legend
Legend
Controlled via
Pa1, Pb1
Pa2, Pb2
Pa3, Pb3
Swivel control
Pa4, Pb4
Boom 2 control
Joystick (right)
Pa5, Pb5
Joystick (left)
Pa6, Pb6
Pa7, Pb7
Bucket control
Joystick (right)
Pa8, Pb8
Boom 1 control
Joystick (right)
Pa9, Pb9
Joystick (left)
Pra2,Prb2
Pra3, Prb3
Rotation control
Joystick (left)
pc1
Joystick (left)
pc2
Joystick (right)
Legend
A1, B1
A2, B2
Auxiliary hydraulics
A3, B3
Offset cylinder
A5, B5
A6, B6
A7, B7
Bucket cylinder
A8, B8
Boom cylinder
AR2, BR2
AR3, BR3
Gear motor
Pump/tank lines
Connection
Legend
P1
Pump 1 port
P2
Pump 2 port
P3
Pump 3 port
P4
Pump 4 port
PR5
PA
PP
PT
T1
T2
T3
T4
T6
DR1
Tank line
dr1, dr2
pcc
Tank line
5-9
Hydraulic system
Main valve block diagcylinder
4
"2
!2
Option
3rd control
circuit
0RB
0RA
!2
"2
Rotate
0RB
0RA
"2
!2
Stabiliser blade
0RB
4
0RA
4
$2
P3+P4 input
02
4
4
DR
PCC
PC
!
Dipper arm
Dipper arm 2
"
0B
0B
0A
0B
0A
DR
0A "
Boom 2
0B
0A
Swivel
0B
0A
"
!
"
!
0A
"
"
!
!
0B
"
!
0A
4
0
Input P1
5-10
Right-hand
side drive
0B
Bucket
0B
Auxiliary hydraulics
0A
PC
!
Boom
"
0B
0A
04
0(
00
0!
Straight-ahead
driving
0 0
Input P2
Hydraulic system
Pressure limiting valves
4
5
7
9
10
11
12
5-11
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
5-12
Description
Stabiliser blade anticavitation valve
Secondary pressure limiting valve (stabiliser blade base side)
P3 + P4 primary pressure limiting valves
Secondary pressure limiting valve (boom rod side)
Secondary pressure limiting valve (boom base side)
Secondary pressure limiting valve (bucket base side)
Bucket rod side secondary pressure limiting valve
P1 + P2 primary pressure limiting valve
Secondary pressure limiting valve (dipper arm rod side)
Secondary pressure limiting valve (dipper arm base side)
Auxiliary hydraulics (optional secondary pressure limiting valve)
Auxiliary hydraulics (optional secondary pressure limiting valve)
Hydraulic system
Pump assignment
Pumps 3 and 4
Pump 2
Pump 1
5-13
Hydraulic system
5.3
Bucket section
Boom section
Boom (2) summation section
Dipper arm section
Dipper arm (2) summation section
Swivel boom section
Auxiliary hydraulics section
Rotate section
Stabiliser blade section
5-14
Hydraulic system
Drive couterbalancing system diagram
4
4
$2 4
DR
PCC
PC
!
Dipper arm 2
"
PB
PB
PA
Dipper arm 1
PB
DR
PC
!
"
PA
PA
PB
PA
"
!
PB
PA
"
!
PB
"
Boom 2
Boom 1
Swivel
Bucket
PB
PA
"
!
PB
PA
"
!
Auxiliary hydraulics
PB
0
PA
"
! Left-hand side drive
PB
PA
PA
4
Drive couterbalancing
system
Input P1
Input P2
0
04
00
0(
0
0
5-15
Hydraulic system
5.4
DR
!
"
PB
PA
Boom 1
Boom 2
0
5-16
PB
PA
0
Hydraulic system
5.5
DR
!
"
Line
Boom 2
4
0
PB
PA
Boom base
side
Joystick control
5-17
Hydraulic system
5.6
DR
PCC
PC
!
Dipper arm 2
"
PB
PB
Dipper arm 1
DR
PB
PA
,&&%,34)%,
PA
P!
0
5-18
0
Hydraulic system
5.7
DR
PC
Rod side
dipper arm
!
Line
Dipper arm 2
"
PB
Joystick control
PB
PA
0
4
PA
5-19
Hydraulic system
5.8
Problem:
The secondary circuit is also protected by the primary pressure limiting valve if the spool
valve is enabled. There is no protection if the spool valve is not enabled.
Ensuring protection with the spool valve disabled requires two secondary pressure limiting
valves instead of the plugs.
Adjusting the secondary pressure limiting valves:
The pressure limiting valves must be set at 280 bar.
Short-term pressure peaks can be reduced with this setting.
Please observe the following should the pressure limiting valves be set to less than 280
bar:
Reset the pressure setting to the initial 280 bar when changing implement.
Location:
see Pressure limiting valves on page 5-11
5-20
Hydraulic system
5.9
Pilot valves
Joystick
D
P
E
F
Pos.
Description
Pos.
DescriptionJoystick (left)
DescriptionJoystick (right)
Control lever
Rubber collar
Linkage
Universal joint
Guide plate
Tappet
Tank line
Tank line
5-21
Hydraulic system
Pilot valve (driving)
Pos.
1
2
5-22
Description
Left-hand side drive segment control
Left-hand side drive segment control
Tank line
Hydraulic system
2
3
Pos.
Description
Bellows
Plate (kit)
Tappet
Non-return valves
Damping
5-23
Hydraulic system
Pilot valve for auxiliary hydraulics
0$
1P
1P
C
D
3
Pos.
Description
Pedal
Pedal fixture
Protective caps
Tank line
Mounting plate
Tappet
Spring
5-24
Pos. Description
1
Auxiliary hydraulics control/offset cylinder extension control
Hydraulic system
Pilot valve for stabiliser blade
0$
0
1P
1P
3
4
1
Pos.
Description
Pedal
Pedal fixture
Protective caps
Tank line
Mounting plate
Tappet
Springs
Pos. Description
1
Stabiliser blade cylinder extension control
5-25
Hydraulic system
5.10 Valves
7/2 directional valve (changeover
valve)
Switches from auxiliary hydraulics (valve de-energised) to boom swivel and vice versa
(valve energised).
Electric control via push button on left-hand side joystick.
2
3
8
4
Pos.
1
2
3
4
5
6
7
8
5-26
Description
Solenoid
Main valve block for auxiliary hydraulics segment
Main valve block for auxiliary hydraulics segment
Pilot valve for auxiliary hydraulics
Pilot valve for auxiliary hydraulics
Tank line
Shuttle valve block/main valve block, offset cylinder retraction control
Shuttle valve block/main valve block, offset cylinder extension control
SERV-HB 8003 En Edition 1.0 * *8003s510.fm
Hydraulic system
4/3 directional valve
2
5
Pos.
1
1
1
1
1
1
1
Description
Solenoid 1
Solenoid 2
Main valve block for auxiliary hydraulics segment
Main valve block for auxiliary hydraulics segment
Solenoid 2
Supply from pilot oil supply unit
Tank line
5-27
Hydraulic system
Pressure cut-off valve
The high slewing torque during swivel unit start-up causes pump P4 to be switched direct
to the tank to reduce engine droop.
Further rotation reduces the pressure to under 165 bar and the second P4 pump is automatically switched on for a higher upper carriage rotation speed.
M3
M4
A
P3
P4
T
Location:
In the engine compartment over the hydraulic pump unit
T
BAR
0
0
0
0
Diesel engine
Pump unit
Des.
Pump P3 input
P4
Pump P4 input
Tank line
M3/M4
5-28
Connection
P3
Hydraulic system
Offset cylinder check valve
The function of this valve is to clamp the offset cylinder hydraulically.
The base and rod sides of the offset cylinder are under constant pressure
This prevents the cylinder from slackening.
Applying pressure to one side of the cylinder supports this side with additional pressure
from the other side as the valve opens, in order to override the clamping pressure.
The valve is located direct on the offset cylinder and can only be accessed by tilting the
cab.
V1
V2
3
2
1
C1
C1
C2
C2
V2
V1
Pos.
Counterbalance valve
Offset cylinder
Des.
Description
Connection
C1
C2
V1
V2
5-29
Hydraulic system
Shuttle valve block
Actuating rotation, boom swivel and dipper arm retraction must release the gear motor's
brake.
High forces act on the brake and destroy it if it is not released during these operations.
4
5
&
! ! " " # # $ $ % %
1
6
2
3
4
5
Pos.
1
Description
Port A (-> joystick (left) 4 ->
main valve block, right-hand side rotation control)
5-30
Hydraulic system
Changeover valve for SAE/ISO controls (option)
The directional valve is located on the left in the base plate of the chassis.
I
Fig. 1:
Switching from ISO to SAE controls and vice versa with the directional valve
1
Position
1
2
Function
ISO controls
SAE controls
Danger!
Changing the directional valve over modifies the controls (control levers)
Danger of accidents!
Make sure you know which control mode has been selected before starting
work
J
A
Fig. 2:
Directional valve
5-31
Hydraulic system
Diagram
0A
0A
0B
0B
0A
0B
0A
Joystick (right)
4321
8765
0B
0B
0A
0B
0A
Joystick (left)
0B
0B
02
Pos.
5-32
Description
Hydraulic system
5.11 Drive up to serial number: AC 02956
The travelling drive has two speed ranges.
BAR
3
4
3
7
6
Pos.
Description
Brake cylinder
Drive port (-> swivel joint 4a) forwards hydraulic motor (left)
Drive port (-> swivel joint 6a) reverse hydraulic motor (left)
Drive port (-> swivel joint 7a) forwards hydraulic motor (right)
Drive port (-> swivel joint 5a) reverse hydraulic motor (right)
5-33
Hydraulic system
Function
Driving:
The shuttle valve actuates the brake cylinder and releases the brake if high pressure is
applied to one of the drive ports. The brake piston is slowly actuated at the same time.
Brake piston control causes high pressure to be applied to the motor, which starts turning.
Stopping:
The oil flows from both ports to the tank upon releasing the joystick. The brake piston
slowly returns to home position by means of the throttle orifices. The slow drop of the
brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the
brake piston in neutral position, the ports are no longer connected to the motor, which can
no longer turn. The brake release pressure is reduced via both throttles shortly afterwards.
Speed range 1
5-34
Hydraulic system
5.12 Auto2Speed drive starting serial no.: AC 02957
The travelling drive now has an automatic powershift gearbox. The travelling drive is
basically in 2nd speed if the switch for 2nd speed range is switched on (high speed). 1st
speed is automatically engaged if more power is required.
2'
8
3
9
3
6
4
1
2
Pos.
1
2
1
2
3
4
5
6
7
8
9
Description
Drive port (-> swivel joint 4a) forwards hydraulic motor (left)
Drive port (-> swivel joint 6a) reverse hydraulic motor (left)
Drive port (-> swivel joint 7a) forwards hydraulic motor (right)
Drive port (-> swivel joint 5a) reverse hydraulic motor (right)
2nd speed range port (-> swivel joint 1a)
Leak oil port (-> swivel joint 8a)
5/2 directional valve (2nd speed range)
Brake bleed valve
Brake cylinder
Pressure limiting valve (4a)
Pressure limiting valve (6a)
5-35
Hydraulic system
Function
Driving:
If high pressure is applied to one of the drive ports, the brake release piston is actuated
first and passes high pressure on to the brake cylinder, which releases the brake. The
throttle slowly actuates the brake piston at the same time. Brake piston control causes
high pressure to be applied to the motor, which starts turning.
Stopping:
The oil flows from both ports to the tank upon releasing the joystick. The brake release piston and the brake piston (slowly actuated by the throttle) return to their base positions. The
slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the brake piston in neutral position, the ports are no longer connected to the
motor, which can no longer turn. The brake release pressure is reduced via both throttles
shortly afterwards.
Speed range 1
5-36
Hydraulic system
5-37
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5-38
Description
Circlip
Plug
Thrust washer
Cover with fittings
O-ring
Sun gear
Gear reduction
Circlip
Planetary gears
Gear housing
Circlip
Bearing
Circlip
Lifetime seal
Centering
Hydraulic motor
Hydraulic system
5.13 Swivel unit
Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox
and mechanical motor brake.
2'
3(
10
9
0'
$"
"
5
1
5
6
Pos.
1
2
3
4
5
6
7
8
9
10
Description
Parking brake valve
Brake piston
Leak oil port (-> tank)
Shock anticavitation valves
Left-hand side rotation port (-> main valve block)
Anticavitation line port (-> main valve block/tank)
Right-hand side rotation port (-> main valve block)
ASB valve
Pilot control pressure port (-> pilot oil supply unit)
SH brake release port (-> shuttle valve block)
5-39
Hydraulic system
Parking brake function
Opening the brake
The shuttle valve block directs the pilot control pressure to the SH input if rotation, boom
swivel or dipper arm retraction is carried out. The pilot control pressure at the SH input
causes the piston in the parking brake valve to shift to active state (brake release). This
directs the pilot control pressure at the PG input to the brake cylinder and releases the
brake.
5-40
Once the rotate function is over, counterpressure is created in the gear motor which
causes the upper carriage to swivel back slightly. The Anti Swing Back valve reduces this
pressure and prevents the upper carriage from swivelling back.
Hydraulic system
5-41
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
5-42
Description
Pinion shaft
Bearing seal ring
Bearing
Gear housing
Plug
Sealing ring
Bearing
Spacer washer
Round nut
Complete drive
O-ring
Gear reduction
Sun gear
Ring gear
Gear reduction
Sun gear
Circlip
Hydraulic motor
Bolt
Hydraulic system
5-43
Hydraulic system
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
5-44
Description
Valve
Spring
O-ring
Plug
O-ring
Plug
O-ring
Plug
Bolt
Spiral ring
O-ring
O-ring
O-ring
Valve set
O-ring
Spiral ring
Spiral ring
O-ring
Pin
Nozzle
Bearing
Control disc
Motor head
Pin
O-ring
Brake piston spring
Spring
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Brake piston
O-ring
O-ring
Spacer washer
O-ring
Plain washer
Steel washer
Circlip
Plate
Spring
Plate
Cylinder block
Pin
Bush
Plate
Piston
Plate
Motor shaft
Bearing
Plug
O-ring
Engine housing
Bolt
Parking brake valve block
O-ring
Nozzle
O-ring
Plug
Hydraulic system
5.14 Swivel joint
8-port swivel joint
Pos.
1
2
3
4
5
6
7
8
Description
High speed
Blade (base side)
Blade (rod side)
Hydraulic motor on left
Hydraulic motor on right
Hydraulic motor on left
Hydraulic motor on right
Leak oil
5-45
Hydraulic system
5.15 Breather filter
The breather filter is in charge of:
Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil
level) prevents the oil tank from inflating.
Pre-tension of the oil tank to the specified overpressure -> supports the variable
displacement pump's suction
The breather filter is located under the tank cover, between the hydraulic filler inlet and the
fuel filler inlet.
Replace the breather filter according to the instructions in the maintenance plan!
see Maintenance plan (overview) on page 3-5
Fig. 3:
Pos.
1
1
Description
Filter fabric
Bleeder valve
1
2
Fig. 4:
5-46
Breather filter
Hydraulic system
5.16 Troubleshooting in the hydraulic system
Problem
Possible causes
Defective safety switch on control lever base
Wrong setting of safety switch on control lever base
Defective solenoid valve on pilot oil supply unit
5-47
!
A
0B
0A
0A
0B
"6
Auxiliary hydrau-
Swivel
Boom 2
Dipper arm 1
!
A
0B
0A
0A
0B
0B
0A
0B
DR
"
!
!
"
"
!
0A "
"
!
PC
Y13
Y3
02
0!
18
03
06
0
19
A
!
A
04
4
0!
4
0(
0
24
0
0
0
4
4
0
0
"2
Blade
0B
0A
0B
Bucket
PC
0A
0B
Boom 1
!
" 0B
0A
DR
Dipper arm 2
0RA
0RB
0RA
0RB
0A
4
23
A
0A
!
4 bar
Joystick
(right)
Rotate
Righthand side
drive
4 Straightahead driving
!
"
"
!
0RB
0RA
!2
"2
PCC
02
!2
"2
!2
22
0B
12
0B
2 bar
13
0A
!
A
20
25
0.4 bar
0B
!
A
0A
0A
!
A
2'
0B
21
Stabiliser
Bucket cylinder
blade cylinder
Boom cylinder
Joystick (left)
11
Y15
Swivel/auxiliary hydraulics
Rotate
0A
0B
0RA
4
'!
10
0RB
!2
$
0
0B
0B
0B
0A
0RB
0RA
2'
Drive fitted with auto2speed hydraulic motors starting serial no. AC02957!
IMPORTANT:
0A
06
'"
3(
0'
Gear motor
16
Blade
00
$2
4
Auxiliary hydraulics
"6
!
BAR
17
06
Bucket
Boom
"6
0
Left-hand side
drive
BAR
Right-hand
side drive
0
Dipper arm
0
5-48
"2
%
$"
14
15
06
$"
X
X
Drive (left) up to
serial no.:
AC02956
Hydraulic system
! ! " " # # $ $ % %
Hydraulic system
5.18 Hydraulics diagram (legend)
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Description
Diesel engine
Variable displacement pump + gear pump
Pilot oil supply unit
Left-hand side joystick pilot valve
Right-hand side joystick pilot valve
Main valve block
Left-hand side drive pilot valve
Pilot valve for drive (right)
Boom swivel pilot valve
Stabiliser blade pilot valve
Changeover valve: boom swivel/auxiliary hydraulics
Oil cooler
Oil filter
Shuttle valve block
Swivel unit
Travelling drive (right)
Travelling drive (left)
Offset cylinder
Dipper arm cylinder
Boom cylinder
Bucket cylinder
Stabiliser blade cylinder
Hose burst valve
Pressure cut-off valve
Vent filter
5-49
Hydraulic system
5-50
AC02956
A
A
!
!
2'
"6
18
!2
19
17
0RB
0RA
!2
"2
20
!
!
"2
4
$2
A
!
!
Blade
0RB
0RA
3(
0'
A
$"
A
!
'"
'!
X
!2
4
21
16
A
06
06
02
4
$"
Swivel unit
23
0RB
A
15
2'
0RA
!
22
4
"2
A
Boom cylBucket
Stabiliser blade inder
cylinder
cylinder
Drive (left) up to
serial no.:
4
DR
PCC
PC
Dipper arm 2
!
Dipper arm
"
DR
PC
Boom
0A "
Auxiliary hydraulics
0A
"
"
!
!
0B
4
0B
"
!
0B
0A
Left-hand Right-hand
side drive side drive
Bucket
0B
04
0
0(
00
0!
0A
Straightahead driving
0B
0A
11
Y15
0A
0B
0
Bucket Boom
0RB
Blade
24
06
0!
"6
14
0RA
0RA
0RB
0A
0B
Joystick
(right)
Joystick
(left)
10
0B
&
Auxiliary
hydraulics/
swivel
! ! " " # # $ $ % %
0
0A
0A
4
0A
0B
0B
0A
0B
"
!
"
!
0B
0A
0A
!
" 0B
0A
0B
0A
Swivel
"2
0A
0B
Boom 2
%
0
!2
0B
0B
0A
$
0B
0
06
02
4
Y13
4 bar
0
2 bar
2
0
0
"6
0
12
Y3
0
03
BAR
BAR
0
13
1
-
25
2 bar
IMPORTANT:
Drive fitted with auto2speed hydraulic motors
starting serial no. AC02957!
5-51
!2
0RB
0RA
!2
"2
0RB
0RA
"2
!2
4
4
$2
Legend
A1, B1
A2, B2
Auxiliary hydraulics
A3, B3
Offset cylinder
A4, B4
A5, B5
A6, B6
Drive (right)
0RB
A7, B7
Bucket cylinder
0RA
A8, B8
Boom cylinder
A9, B9
AR2, BR2
AR3, BR3
Gear motor
AR4, BR4
02
4
Connection
4
DR
PCC
PC
!
"
0B
0B
0A
0B
0A
DR
PC
0A "
!
"
0B
0A
0B
0A
"
!
"
!
0B
0A
"
"
!
!
0B
0A
0B
0A
0B
0A
0B
"
!
4
04
0(
00
0!
Legend
Controlled via
Pa1, Pb1
Pa2, Pb2
Pa3, Pb3
Swivel control
Pa4, Pb4
Joystick (right)
Pa5, Pb5
Joystick (left)
Pa6, Pb6
Pa7, Pb7
Bucket control
Joystick (right)
Pa8, Pb8
Boom control
Joystick (right)
Pa9, Pb9
Joystick (left)
Pra2,Prb2
Pra3, Prb3
Rotation control
Joystick (left)
Pra4, Prb4
Joystick (right)
Pump/tank lines
0A
0
Connection
0 0
5-52
Connection
Legend
P1
Pump 1 port
P2
Pump 2 port
PR5
Pump 3 + 4 port
PA
T1
T2
DR1, DR2
Electric system
Electric system
Electric system
6
6.1
Electric system
Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current I Ampere (A)
Voltage U Volt (V)
Resistance R Ohm (W)
Mnemonic:
U
R
Output
Power "P" Watt (W)
P = U x I = R x I = U/R
6.2
AC = alternating current/voltage;
DC = direct current/voltage
Test device with acoustic and optical signal output
6-1
Electric system
Measuring methods multifunction measuring device
6-2
Electric system
6.3
6.4
Code
blk
brn
red
org
yel
grn
blu
vio
gry
wht
pnk
Relays
Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by microelectronics or
microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be make-contact, break-contact or changeover switches. These undertake the actual switching function.
Zero-centre relay
86
30
86 = Start of coil
(control line)
85 = End of coil
(earth)
30 = Input
(load line)
87 87a
6-3
Electric system
6.5
Electric units
Units
6.6
Alternator
12 V 55 A
Starter
12 V 2.3 kW
Battery
12 V 88 Ah
Socket
Protected circuit
F3
10 A
F4
10 A
F5
15 A
F6
10 A
Valves, horn
F7
15 A
F8
10 A
F9
10 A
F10
15 A
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 2:
6.7
Fuse box
K5
F1
F2
Fuse no.
Protected circuit
F1
40 A
F2
50 A
Relay no.
Fig. 3:
6-4
K9
K5
Electric system
6.8
Relays
The relays are located in the relay box under the cab, next to the swivelling console
K7
Switching relay
no.
Protected circuit
K6
K7
Starting relay
K8
V1
V1
K6
Fig. 4:
6.9
K81
Relays
Socket
The socket A is located above the lubrication strip B.
Fig. 5:
6-5
Electric system
6.10 Joystick tip switches
Joystick (left)
2
Pos.
1
2
3
Fig. 6:
Description
Changeover or boom swivel and auxiliary hydraulics (S27)
Tip switch for additional control circuit (S30)
Tip switch for additional control circuit (S31)
Joystick (right)
2
Pos.
1
2
3
Fig. 7:
6-6
Description
Horn (S55)
Not assigned
Automatic idling speed feature (S48)
Electric system
6.11 Instrument panel: overview
Pos.
1
2
3
4
5
6
7
Description
Indicator (X10)
Temperature indicator diesel engine (X13)
Cigarette lighter (E15)
Preheating start switch (S1)
Fuse box ( see Fuse box in instrument panel on
page 6-4)
Switch panel
Radio option (A1)
6-7
Electric system
6.12 Switches: overview
10
12
11
Pos.
8
9
10
11
12
13
14
15
16
17
6-8
13
14
15
16
17
Description
Switch high speed (S21)
Switch wiper/washer (S20)
Switch boom working light (S16)
Switch cab working light (S17)
Switch rotating beacon (S18)
Switch ventilation (S15)
Switch air conditioning system option (S51)
Switch safe load indicator option (S42)
Not assigned
Not assigned
Electric system
6.13 Alternator
The alternator charges the battery and supplies rectified 3 phase alternating current to
electric consumers.
Pos.
1
2
1
Fig. 8:
Description
Connection B (battery)
Connection P starting relay
Connection IG telltale (12V)
Connection L telltale (earth)
Alternator
6.14 Starter
2
Pos.
1
Fig. 9:
Description
Connection S starting relay
Connection B battery
Alternator
6-9
Electric system
6-10
6-11
6-12
Radio
Description
Section
E14
B1
Fuel indicator
B2
Horn
Loc.
Option
No.
K8
Description
Cut-off solenoid time lag relay
Section
D3
Loc.
No.
X2
Description
11 pole connection engine/chassis
Section
D7-9
F6
K9
E3
X3
D0
D/E10
M1
Starter
F2
X4
C/D3
D11/12
B6
E6
M2
Wiper motor
F13
Option
X5
B11
Loudspeaker
E15
Option
M4
Fan
C12
Option
X6
C11/12
B12
Loudspeaker
E15
Option
M5
Washer pump
F8
Option
X7
C11
B14
Warning buzzer
C2
Option
E7
F14
E9
F13
E10
E11
Boom light
F8/9
E14
Interior light
E/F13
E15
Cigarette lighter
F1
F2
M7
Fuel-filling pump
F1
X8
D11
Option
M9
Fuel pump
F3
X10
B/C1
Option
P1
Hour meter
B1
X11
B6
Option
P2
B1
X12
C13/14
P3
A3
X13
A3
R1
Glow plug
F4
X14
D3
A14
S1
A1
X15
D1
E2
S2
F5
X16
E2
E1
S3
E5
X19
F7
F3
A4
S4
F6
XE11
E9
F4
A7
S5
F7
XS41
E8
Loc.
F5
A8
S8
F1
Y1
Cut-off solenoid
F4
F6
Valves, horn
A9
S15
Ventilation switch
A10
Y3
F9
F7
A10
S16
A7
Y13
F13
F8
A12
S17
A8
Option
Y14
F9
F9
A13
S18
A13
Option
F10
A14
S20
Wiper/washer switch
A20
Option
Y15
F10
G1
Alternator
F3
S21
A9
Y16
F10
Option
G2
Battery
F1
S21.1
E9
Y17
F11
Option
H2
Preheating telltale
B1
S27
D10
Y31
F12
Option
H3
B1
S28
Safety switch
C28
H4
B1
S30
D9
Option
H5
B1
S31
D9
Option
H6
B1
S41
E8
Option
H7
B1
S42
A7
Option
H9
C3
Option
S48
C9
Option
H28
Rotating beacon
F13
Option
S51
A11
Option
H33
Spare telltale
B1
S52
E12
Option
Option
H30
Spare telltale
C3
S54
D12
K5
E4
S55
C10
K6
D5
V1
Recovery diode
E4
K7
E2
X1
D4-6
Option
Option
6-13
6-14
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30A
31
32
33
34
35
36
37
38
38A
Up to
G1/B alternator
G1/B alternator
M1 starter
F1 main fuse
K5/30 preheating relay
F1 main fuse
F2 main fuse
F2 main fuse
GND
K7/B start high current relay
K5/87 preheating relay
K9/87 cut-off solenoid switching relay
M9/1 fuel pump
GND
K8 cut-off solenoid time lag relay
K8 cut-off solenoid time lag relay
V1 Blocking diode
M9/1 fuel pump
G1/2 alternator
K6 preheating time lag relay
K6 preheating time lag relay
K6 preheating time lag relay
K6 preheating time lag relay
K6 preheating time lag relay
K8 cut-off solenoid time lag relay
K8 cut-off solenoid time lag relay
K7/6 start high current relay
GND
K5/85 preheating relay
K6 preheating time lag relay
K8 cut-off solenoid time lag relay
V1 Blocking diode
G1/1 alternator
S2 engine oil pressure switch
S3 engine temperature switch
S3 engine temperature switch
S4 air filter pressure switch
S4 air filter pressure switch
B1 fuel level indicator
GND
B1 fuel level indicator
To
M1 starter
F1 main fuse
F2 main fuse
K5/30 preheating relay
K9/30 cut-off solenoid relay
K7/A start high current relay
X3/A main connection
M7 fuel-filling pump
M7 fuel-filling pump
M1 starter
R1 glow plug
Y1/1 cut-off solenoid
Y1/2 cut-off solenoid
Y1/3 cut-off solenoid
X1/2 engine/chassis connection
V1 Blocking diode
K7/1 start high current relay
X1/2 engine/chassis connection
X1/1 engine/chassis connection
X1/3 engine/chassis connection
K5/86 preheating relay
X1/4 engine/chassis connection
K7/3 start high current relay
X1/5 engine/chassis connection
K9/86 cut-off solenoid switching relay
K9/85 cut-off solenoid switching relay
G1/3 alternator
K5/85 preheating relay
K6 preheating time lag relay
K8 cut-off solenoid time lag relay
V1 Blocking diode
K7/5 start high current relay
X1/6 engine/chassis connection
X1/7 engine/chassis connection
X1/8 engine/chassis connection
X1/9 engine/chassis connection
X1/10 engine/chassis connection
GND
X1/11 engine/chassis connection
X16/2 drive alarm connection
X16/2 drive alarm connection
Colour
red
red
red
red
red
red
red
red
blk
wht/red
brn
wht
blu
blk
blu
blu
blu
blu
blu
brn
brn
wht/blk
wht/blk
gry/red
blu/blk
pnk/blk
blk/blu
blk
blk
blk
blk
blk
pnk
wht/grn
blk/grn
grn/wht
gry/blu
blk
vio/blk
blk
blk
mm
10
6
6
4
4
4
6
4
4
4
6
4
1
2.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
No.
39
40
41
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
60
61
62
63
64
65
66
67
68
69
70
71
72
73
79
80
Up to
B1 fuel level indicator
S5 preheating start switch
X16/1 drive alarm connection
S21.1 high-speed tip switch (prepared)
S21.1 high-speed tip switch (prepared)
B2 horn
X19 socket
X19 socket
M5 washer pump
M5 washer pump
XS41/1 safe load indicator
XS41/2 safe load indicator
XE11/1 boom working light
XE11/2 boom working light
S21.1/1 high-speed tip switch (prepared)
Y3 high-speed solenoid valve
Y3 high-speed solenoid valve
Y13 solenoid valve for safety valve
GND
GND
Y15/1 auxiliary hydraulics/swivel solenoid
valve
Y15/2 auxiliary hydraulics/swivel solenoid
valve
Y16/1 electr. auxiliary hydraulics solenoid
valve
Y16/2 electr. auxiliary hydraulics solenoid
valve
Y17/1 electr. auxiliary hydraulics solenoid
valve
Y17/2 electr. auxiliary hydraulics solenoid
valve
S52 air conditioning pressure switch
S52 air conditioning pressure switch
X2/11 engine/chassis connection
Y14/1 changeover valve solenoid valve
Y14/2 changeover valve solenoid valve
GND
X15 drive alarm connection
GND
To
S5 preheating start switch
X2/1 engine/chassis connection
X1/1 engine/chassis connection
X2/2 engine/chassis connection
B2 horn
X5/5 armrest/chassis connection
X2/4 engine/chassis connection
GND
X2/5 engine/chassis connection
GND
X2/6 engine/chassis connection
GND
X2/7 engine/chassis connection
GND
X2/8 engine/chassis connection
X2/8 engine/chassis connection
GND
X5/4 armrest/chassis connection
Y13 solenoid valve for safety valve
M9/2 fuel pump
X5/1 armrest/chassis connection
Colour
blk
org/wht
blu
gry
gry
org
red/blk
blk
blk/wht
blk
vio/blu
blk
grn/yel
blk
brn/blk
brn/blk
blk
brn/wht
blk
blk
blu/yel
mm
1
1
1
1
1
1
1.5
1.5
1
1
1
1
1
1
1
1
1
1
1
1
1
GND
blk
gry/yel
GND
blk
gry/grn
GND
blk
yel/red
yel/red
yel/red
brn/grn
blk
blk
gry/blk
blk
1
1
1
1
1
1
1
6
AH/swivel
changeover
valve
9
9
9
Electr. AH
valve
Electr. AH
valve
9
Drive
alarm
Socket
"
8
Preheating
Horn
+
Blocking
diode
Starting
relay
+
Cut-off
solenoid
+
!
6
!
&
&
!
!
"
!
Main fuses
Cut-off
solenoid Preheat
+
+
!
83
8
Safety valve
High-speed
valve
9
"
8%
!
9
"
!
"
"
8
3
"
Fuel pump
-
'.$
-
Starter
Alternator
!
!
3
"
8
Drive alarm Fuel level indicaHydraulic oil
tor
pressure switch
Fuel-filling
pump
-
8
8
Washer pump
-
1000125106
3
2
9
3
Air filter presPreheating
Engine oil
sure switch Air condi- system
tioning
pressure
valve
9
Cut-off solenoid
6-15
6-16
No.
7
7A
15
15 A
19
19A
21
21A
23
31
32
33
34
35
37
40
41
42
42A
43
44
47
49
51
53
55
58A
59
71
76
78
82
83
84
86
87
88
89
90
91
92
93
94
94A
Up to
X3/A main connection
S1/1 preheating start switch
X1/2 engine/chassis connection
X4.1/9 drive interlock connection
X1/3 engine/chassis connection
S1/3 preheating start switch
X1/4 engine/chassis connection
X4.1/4 drive interlock connection
X1/5 engine/chassis connection
X1/6 engine/chassis connection
X1/7 engine/chassis connection
X1/8 engine/chassis connection
X1/9 engine/chassis connection
X1/10 engine/chassis connection
X1/11 engine/chassis connection
X2/1 engine/chassis connection
X1/1 engine/chassis connection
X1/1 engine/chassis connection
X4/7 drive interlock connection
X4/5 drive interlock connection
X2/2 engine/chassis connection
X2/4 engine/chassis connection
X2/5 engine/chassis connection
X2/6 engine/chassis connection
X2/7 engine/chassis connection
X2/8 engine/chassis connection
X4.1/1 drive interlock connection
X4/1 drive interlock connection
X2/9 engine/chassis connection
F6 valves and horn fuse
X4/3 drive interlock connection
S51/5 air conditioning switch
S15/3 ventilation switch
S15/6 ventilation switch
X4/4 drive interlock connection
F6 valves and horn fuse
S21/10 high-speed switch
F8 wiper and interior light fuse
S20/10 wiper/washer switch
X12/4 cab connection
S20/7 wiper/washer switch
S20/5 wiper/washer switch
F4 boom working light fuse
S16/10 boom working light switch
To
S1/1 preheating start switch
F10 socket and cigarette lighter fuse
X4/9 drive interlock connection
X4.1/5 drive interlock connection
S1/8 preheating start switch
S1/6 preheating start switch
X4/8 drive interlock connection
X4.1/8 drive interlock connection
X10/10 indicator connection
X10/8 indicator connection
X10/8 indicator connection
X10/9 indicator connection
X13 engine temperature connection
X10/3 indicator connection
X10/4 indicator connection
X10/6 indicator connection
F3 indicators and engine relay fuse
X4/5 drive interlock connection
X4/5 drive interlock connection
F9 rotating beacon, radio and drive interlock fuse
F6 valves and horn fuse
F10 socket and cigarette lighter fuse
S20/3 wiper/washer switch
S42/5 safe load indicator switch
S16/1 boom working light switch
S21/1 high-speed switch
X4.1/6 drive interlock connection
X6/5 armrest switch connection
X6/1 armrest switch connection
X4/6 drive interlock connection
X12/3 cab connection
X6/2 armrest switch connection
X6/3 armrest switch connection
X6/4 armrest switch connection
S1/7 preheating start switch
S21/5 high-speed switch
S21/5 high-speed switch
S20/2 wiper/washer switch
S20/2 wiper/washer switch
S20/6 wiper/washer switch
S20/6 wiper/washer switch
X12/1 cab connection
S16/5 boom working light switch
S16/5 boom working light switch
Colour
red
red
blu
blu
brn
brn
wht/blk
wht/blk
gry/red
pnk
wht/grn
blk/grn
grn/wht
gry/blu
vio/blk
org/wht
blu
blu
blu
red
gry
red/blk
blk/wht
vio/blu
grn/yel
brn/blk
brn/wht
gry
brn/grn
gry
blk
yel/red
yel/blk
yel/blu
wht/blk
gry
gry
blu
blu
blu/wht
blu/wht
blu/red
grn
grn
6
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
No.
95
96
97
98
98A
99
101
102
103
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
Up to
F5 cab working light fuse
S17/1 cab working light switch
S17/1 cab working light switch
F8 wiper and interior light fuse
X12/7 cab connection
S17/1 cab working light switch
S17/3 cab working light switch
F9 rotating beacon, radio and drive interlock fuse
S18/1 rotating beacon switch
F7 fan and air conditioning fuse
S15/1 ventilation switch
S15/1 ventilation switch
S51/10 air conditioning switch
S15/3 ventilation switch
S42/1 safe load indicator switch
X10/13 indicator connection
F3 indicators and engine relay fuse
X10/1 indicator connection
F3 indicators and engine relay fuse
S18/10 rotating beacon switch
S18/10 rotating beacon switch
S16/B boom working light switch
X13 engine temperature connection
X13 engine temperature connection
F10 socket, cigarette lighter
F9 rotating beacon, radio and drive interlock fuse
X11/1 Vario indicator connection
X10/5 indicator connection
X13 engine temperature connection
X13 engine temperature connection
X14/2 automatic revs setting connection
X14/2 automatic revs setting connection
S20/9 wiper/washer switch
S20/9 wiper/washer switch
S17/9 cab working light switch
S17/9 cab working light switch
S15/9 ventilation switch
S15/9 ventilation switch
S42/9 safe load indicator switch
S42/9 safe load indicator switch
To
S17/1 cab working light switch
S17/2 cab working light switch
S17/10 cab working light switch
X12/7 cab connection
X12/8 cab connection
X12/5 cab connection
X12/9 cab connection
S18/5 rotating beacon switch
X12/2 cab connection
S15/2 ventilation switch
S15/2 ventilation switch
S15/10 ventilation switch
S15/10 ventilation switch
S51/1 air conditioning switch
B14/3 warning buzzer connection
B14/3 warning buzzer connection
X13 engine temperature connection
X13 engine temperature connection
X14/1 automatic revs setting connection
X14/1 automatic revs setting connection
S42/10 safe load indicator switch
E15 cigarette lighter
E15 cigarette lighter
X10/2 indicator connection
E15 cigarette lighter
X12/8 cab connection
X2/3 engine/chassis connection
X11/2 Vario indicator connection
X11/2 Vario indicator connection
X13 engine temperature connection
X13 engine temperature connection
S21/9 high-speed switch
S21/9 high-speed switch
S16/9 boom working light switch
S16/9 boom working light switch
S18/9 rotating beacon switch
S18/9 rotating beacon switch
S51/9 air conditioning switch
S51/9 air conditioning switch
X3/B main connection
Colour
grn
grn
grn
blu
blu
grn/red
grn/blu
red
vio
yel
yel
yel
yel
yel/blk
vio/blu
vio/blu
blu
blu
blu
blu
vio/blu
grn/yel
grn/yel
grn/yel
red/blk
red
brn/blu
blk
blk
blk
blk
blk
blk
blk
blk
blk
blk
blk
blk
blk
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
S42
1
3
5
7
Rotating beacon
switch
Ventilation
switch
S51
110
X
51
X
X
X
X
X
135
134
116
10
S15
S18
109
X
82
X
X
X
X
X
133
134
108
10
84
X
X
133
132
109 6
107 10
108
83
Boom working
light switch
Cab working light
switch
S17
2
1 95
115 10
116
103
X
102
X
X
X
X
X
131
132
S16
96 96 97 2
101 X
X 99
X X
131
130
97
Wiper/washer
switch
1 53 117
5 94 94A
X
X
X
X
10
129
130
94A
High speed
switch
S20
2
10
S21
X 89 90
49 X
93 91 92
92 X
129
128
X
X
5 87 88
X
7 X
X
10
2
4
6
90
55
X
127
128
88
4
6
8
10
SWF: 593.757
Automatic revs
setting connection
S1
Cigarette lighter
Indicator connection
3
4
19A
138
139
9.
86
E15
X13
115
126
10
127
114
19
19A
7A
X14
120
136
117
118
126
125
125
124
112
113
34
8
119
118
!
8
8
8
!
!
!
!
!
8
"
13
32
40
53 7
12
31
44
55 8
11
37
23
71 9
21
19
15
10
35
34
33
41
42
122
47
49
51
5 59
X3
Main connec10
tion
X 11
X2
4 84
135
136
137
X1
Engine/chasEngine/chassis connection sis connection
98A
93 1
59
98A
103 2
43 42A 7
71 1
82 2
7 98
137
78 3
83 3
X6
Armrest switch
connection
X4
91 4
121
101 99 5
78
86
5 42 42A
X12
Cab connection
3
4
58
76 6
21 8
15 9Drive
interlock
connection
! &
"