Service Manual 8003 Eng.

Service Manual
Track excavator
Machine model
8003
Edition
1.0
Language
English
Article number
1000132826
Documentation
Description
Order no.
Operation manual
1000132136
Service Manual
1000132826
Spare parts list
1000137282
Legend
Edition
Issued
1.0
02/2005
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-Leonding
Document:
Order no.:
Edition:
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
Checking the coolant level ............................................................................... 3-19

Filling up coolant .............................................................................................. 3-20
Air filter ................................................................................................................... 3-21
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 ................................................................. 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 starting serial no.: AC 02957 .................................................... 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
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
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 ............................................................................ 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
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
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, or a combination of digits and letters, e.g. 40/18 or 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
Identification of warnings and dangers

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
Designated use and exemption from liability

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
Type labels and component numbers

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. 1:
Fig. 2:
Type label: location
Model:
8003
Year:
2004
PIN:
AC 000000
Output:
42.5 kW
Mass:
7960 kg
Load:
---------------
Max. gross mass:
---------------
Max. axle load:
-----------------------------
Type label
Other information see section 2 Specifications on page 2-1

Cab number
The type label (arrow) is located in the cab, on the upper front left chassis member.
Fig. 3:
Cab type label
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
Example:
Fig. 4:
1-4
Yanmar 46557
Diesel engine number
Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing
Fig. 5:
Hydraulic pump type label
Main valve block number

The type label (arrow) is located on the control valve.
Fig. 6:
Travelling drive type label
Travelling drive number

The type label (arrow) is located on the travelling drive.
Fig. 7:
Travelling drive type label
Swivel unit number

The type label (arrow) is located on the swivel unit.
Fig. 8:
Swivel unit type label
1-5
1.5
Machine: overview
Boom light
Boom
Dipper arm
Rubber chains
Steel chains (option)
Undercarriage
Stabiliser blade
Cab
Engine cover
1
8
4
5
3
10
Handles
10
Tank filler inlet
11
Device for counterweight (option)
12
Exhaust pipe
12
11
Fig. 9:
1-6
Machine outside views
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
Instrument panel: overview
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
Instrument panel: legend
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
1.10 Engine compartment: overview
52
Pos.
52
53
54
55
56
57
58
59
60
61
62
53
54
55
56
57
58 59
60
61
62
Description
For more information see page

Main valve block (underneath the cover).................................................................................................................................................. 5-7
Pressure cut-off valve............................................................................................................................................................................. 5-29
Hydraulic pump......................................................................................................................................................................................... 5-1
Measurement ports................................................................................................................................................................................. 3-30
Water separator...................................................................................................................................................................................... 3-12
Air filter ................................................................................................................................................................................................... 3-21
Oil dipstick .............................................................................................................................................................................................. 3-15
Engine ...................................................................................................................................................................................................... 4-1
Coolant tank ........................................................................................................................................................................................... 3-19
Fan ........................................................................................................................................................................................................... 4-1
Water/hydraulic oil radiator..................................................................................................................................................................... 3-18
1-11
1.11 Chassis: overview
67
65
64
68
70
63
69
66
Pos.
63
64
65
66
67
68
1-12
71
Description
For more information see page

Position of main fuse box with relays ........................................................................................................................................................2-4
Battery .................................................................................................................................................................................................... 3-46
Main valve block........................................................................................................................................................................................5-7
Gear motor ............................................................................................................................................................................................. 5-40
Pilot oil supply unit under the cover...........................................................................................................................................................5-5
Hydraulic oil tank with leak oil strip
69
70
Shuttle valve block ................................................................................................................................................................................. 5-31

Fuel tank
71
Counterbalance valve............................................................................................................................................................................. 5-30
1.12 Tilting the cab
Danger!
Careful when tilting the cab
Danger of accidents!
Always tighten lock screws A and C when driving and working with the
machine.
Always close the door

Stay clear from underneath the cab as you tilt it
Switch off the engine
Remove the ignition key
Fold the control lever base (left) up
Slackening the lock screw
Unscrew the lock screw as follows:

Remove the ignition key
Fold the control lever base (left) up
Raise floor mat B
Unscrew lock screw A with a suitable tool
Lock screw A is located at the front right of the cab
Unscrew lock screw C with a suitable tool
Lock screw C is located at the rear right of the cab
A
B
Danger!
Always close the door. Even if the door is secured in the open position with the
door arrester
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
Tilting the cab

Proceed as follows:
Insert tube D onto guide pin E and pump as far as it will go

(jack function)
The cab is raised as far as the pump will go
Pull handle G until the cab is completely tilted beyond the centre of motion
The cab is secured with safety cables H and I
Remove the split pin from bracket J
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
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)
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)
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.
Replace defective parts immediately
J
K
L
Fig. 11: Tilting the cab
1-14
1.13 Summer/winter operation

Adjust cab temperature as follows:
Position
A
Function
Summer operation
Cools
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. 12: Heating adjustment
Preheated fresh air

Selection of cold or preheated fresh air in winter.
A deflector plate on the heater can be set to two different positions.
Fresh air: heater takes in air from outside the cab fig. 12
Preheated fresh air: heater takes in air from the chassis fig. 13
Fig. 13: Fresh air
Change from fresh air to preheated fresh air as follows:
Tilt the 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. 14: Preheated fresh air
1-15
1.14 Pedal for auxiliary hydraulics/swivelling and rotating the 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
Specifications
Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2
Engine
Engine
Model 8003
Product
Yanmar diesel engine
Model
4TNV98-VNS
Design
Water-cooled 4 stroke diesel engine, EPA2
No. of cylinders
Fuel injection system
Direct injection
Aspiration
Naturally aspirated
Cooling system
Water-cooled/aspirating fan
Lubrication system
Force-feed lubrication with trochoidal pump
Displacement
3318 cm
Nominal bore and stroke
98 x 110 mm
Output
42.5 kW @ 2100 rpm
Max. torque
249 Nm @ 1400 rpm
Max. engine speed without load
2290 +/- 50 rpm
Idling speed
1100 +/- 50 rpm
Valve tip clearance (intake = outlet)
0.15 0.25 mm (cold)
Injection pressure
220 230 bar
Compression
35 +/- 1 bar @ 250 rpm
Engine oil pressure
3 4 bar
Pressure switch for engine oil pump
0.5 +/- 0.1 bar
Opening temperature of thermostat
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
Max. inclined position (engine still

supplied with oil)
Exhaust values according to
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
Engine oil (max./effect.)
10.2 l/4.5 l
Coolant (without radiator)
4.2 l
Radiator
4.9 l
Expansion tank
1.5 l
Tightening torques
Tightening torques
2.3
Cylinder-head bolt
105.0 115.0 Nm (M11x1.25)
Connecting rod bearing screw
55.0 60.0 Nm (M10x1)
Main bearing screw
110.0 120.0 Nm (M11x1.25)
Flywheel screw
190.0 210.0 Nm (M14x1.5)
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)
Max. service pressure
3005 bar
Main pressure limiting valve for

pumps P1, P2
3003 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
2253 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
51.5/+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
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
* Output indications for auxiliary hydraulics with unpressurised reflux line
2.4
Undercarriage and swivel unit

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/cm
Upper carriage swivel speed
2.5
9.2 rpm
Stabiliser blade
Stabiliser blade
Model 8003
Width/height
2300/500 mm
Max. lift over/under subgrade
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
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:
Fuse box
Main fuse box with relays under the

cab
K9
Fig. 2:
2-4
K5
Relais box under the cab
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
Cut-off solenoid timer
V1
Cut-off solenoid recovery diode
V1
K6
Fig. 3:
2.7
K81
Relays
Noise levels
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
Coolant compound table

Outside temperature
Up to C
4
-10
-20
-25
-30
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
Model-specific tightening torques

8003
Live ring
Track roller
Drive pinion
Travelling drive
Gear motor
Angled engine bracket
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 General tightening torques

Tightening torques for hydraulic
screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)

Width across
Tightening
Nominal
Outer
Thread
flats
torque
05
6L
M12X1.5
W/F 14
15 Nm
06
8L
M14X1.5
W/F 17
20 Nm
08
10L
M16X1.5
W/F 19
40 Nm
10
12L
M18X1.5
W/F 22
50 Nm
12
15L
M22X1.5
W/F 27
75 Nm
16
18L
M26X1.5
W/F 32
85 Nm
20
22L
M30X2
W/F 36
100 Nm
25
28L
M36X2
W/F 41
180 Nm
32
35L
M45X2
W/F 55
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
Outer
Thread
flats
torque
05
8S
M16X1.5
W/F 19
40 Nm
06
10S
M18X1.5
W/F 22
50 Nm
08
12S
M20X1.5
W/F 24
60 Nm
10
14S
M22X1.5
W/F 27
75 Nm
12
16S
M24X1.5
W/F 30
90 Nm
16
20S
M30X2
W/F 36
100 Nm
20
25S
M36X2
W/F 41
180 Nm
25
30S
M42X2
W/F 50
270 Nm
32
38S
M52X2
W/F 60
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
20 Nm
35 Nm
45 Nm
55 Nm
65 Nm
90 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
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
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
G1A
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
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
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
10.9
12.9
8.8
10.9
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
45 Nm
65 Nm
80 Nm
40 Nm
59 Nm
87 Nm
110 Nm
147 Nm
69 Nm
100 Nm
135 Nm
180 Nm
230 Nm
110 Nm
160 Nm
210 Nm
275 Nm
350 Nm
170 Nm
250 Nm
280 Nm
410 Nm
480 Nm
245 Nm
345 Nm
410 Nm
570 Nm
690 Nm
340 Nm
490 Nm
550 Nm
780 Nm
930 Nm
460 Nm
660 Nm
710 Nm
1000 Nm
1190 Nm
590 Nm
840 Nm
1040 Nm
1480 Nm
1770 Nm
870 Nm
1250 Nm
1420 Nm
2010 Nm
2400 Nm
1200 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 = 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
10.9
12.9
8.8
10.9
25 Nm
37 Nm
43 Nm
22 Nm
32 Nm
50 Nm
75 Nm
88 Nm
43 Nm
65 Nm
49 Nm
71 Nm
83 Nm
42 Nm
62 Nm
87 Nm
130 Nm
150 Nm
75 Nm
110 Nm
83 Nm
125 Nm
145 Nm
72 Nm
105 Nm
135 Nm
200 Nm
235 Nm
120 Nm
175 Nm
210 Nm
310 Nm
360 Nm
180 Nm
265 Nm
315 Nm
450 Nm
530 Nm
270 Nm
385 Nm
440 Nm
630 Nm
730 Nm
375 Nm
530 Nm
590 Nm
840 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
1300 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 = 0.12 and are to be used as approximate figures.
2-8
2.11 Dimensions model 8003

4110
2710
2710
1570
2810
6420
Fig. 4:
2300
Machine dimensions (model 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)
1850 mm
1850 mm
Dipper arm length (extended version)
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 mm 6290/7420 mm
Max. digging radius (extended dipper arm)
7440 mm 7190/7690 mm
Max. reach at ground level
7020 mm 6770/7270 mm
Max. reach at ground level (extended dipper arm)
7300 mm 7050/7550 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
720
550
67
63
2300
1400
450
3610
450
500
15
50
Vario
3516 mm
2-9
2.12 Lift capacity table 8003
5.0 m
Max
4.0 m
3.0 m
2.0 m
Fig. 5:
Lift capacity table (model 8003)
5.0 m 2000* 1510

4.0 m 1920* 1165 1915* 1330
3.0 m 1895* 985 2020* 1300
2.0 m 1905* 920 2205* 1245
1955* 1950
1.0 m 1930* 890

0.0 m 1960* 910
-1.0 m 1975* 990
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*
-2.0 m 1940* 1180

-3.0 m 1700* 1700*
Max
Admissible load on extended dipper arm
Reach from live ring centre
Load hook height
Lift capacity limited by hydraulics
4830
All table indications in kg and horizontal position on firm ground without bucket.
With the stabiliser blade in driving direction

Without the stabiliser blade, 90 to driving direction
If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket
or implement dead weight.
Calculation basis: according to ISO 10567
The track excavator's lift capacity is restricted by the settings of the pressure relief valves
and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.
2-10
2.13 Lift capacity table 8003 with extended dipper arm
5.0 m
Max
4.0 m
3.0 m
2.0 m
Fig. 6:
Lift capacity table counterweight (model 8003)
5.0 m 1825* 1320

4.0 m 1770* 1050 1760* 1345
3.0 m 1755* 915 1885* 1305
2.0 m 1765* 845 2090* 1245
1730* 1730*
1.0 m 1790* 815

0.0 m 1820* 830
-1.0 m 1840* 895
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
-2.0 m 1830* 1040

-3.0 m 1705* 1415
Max
Load hook height

2-11
2.14 Lift capacity table 8003 with counterweight
Max
5.0 m
4.0 m
3.0 m
2.0 m
Fig. 7:
5.0 m 2000* 1715

4.0 m 1920* 1335 1915* 1515
3.0 m 1895* 1140 2020* 1485
2.0 m 1905* 1070 2205* 1430
1955* 1955*
1.0 m 1930* 1035 2380* 1370

0.0 m 1960* 1060 2455* 1330
-1.0 m 1975* 1150 2345* 1315
-2.0 m 1940* 1370
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*
-3.0 m 1700* 1700*

Max
Load hook height
5560

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:
5.0 m 1825* 1495

4.0 m 1770* 1200 1760* 1520
3.0 m 1755* 1050 1885* 1480
2.0 m 1765* 975 2090* 1420
1730* 1730*
1.0 m 1790* 950 2295* 1355

0.0 m 1820* 965 2415* 1310
-1.0 m 1840* 1040 2375* 1285
-2.0 m 1830* 1205
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
-3.0 m 1705* 1630

Max
Load hook height

2-13
2.16 Lift capacity table 8003 Vario (option)
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
2010* 2010* 1330
3.0 m
1895* 1270
680
2020* 1675
895
2315* 2315* 1275
2925* 2925* 2015
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
5230* 5230* 3380
0.0 m
1960* 1175
-1.0 m 1975* 1275
-2.0 m 1940* 1520
-3.0 m 1700* 1700*
1955* 1955* 1345
815
1175
3335
2385* 2385* 1645
Max
Load hook height
Vario position


Without the stabiliser blade 90 in driving direction
Upper carriage shifted to the rear with Vario option
Rear Vario
Front Vario
Fig. 9:
Lift capacity table Vario (model 8003)
Without the stabiliser blade 90 in driving direction

Upper carriage shifted to the front with Vario option
2-14
2.17 Kinematics
E
Pin diameter
55 mm
Dipper arm width
170 mm
Pin distance to bucket mount
300 mm
Bucket
Dipper arm
Bucket
2-15
2-16
Maintenance
Maintenance
Maintenance
Maintenance
3.1
Fluids and lubricants

Component/
application
Diesel engine
Engine/machine
fluid
Specification
API CD, CE, CF
Engine oil
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
Gearbox oil
Hydraulic oil
Hydraulic oil tank
FINA PONTONIC GLS, SAE85W90

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 gear7 (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 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
3-1
Maintenance
Oil grades for the diesel engine, depending on temperature

Engine oil grade
Ambient temperature (C)

C
-20
-15
-10
-5
10
15
20
25
30
35
40
95
104
SAE 10W
SAE 20W
SAE 10W-30
SAE 15W-40
API CD, CF, CF-4,

CI-4
SAE 20
SAE1 E3, E4, E5
SAE 30
SAE 40
F
1.
3-2
-4
14
23
32
41
50
59
68
77
86
Maintenance
3.2
Maintenance label
Explanation of symbols on the maintenance label
Symbol
Assembly
Explanation
General
Visual check
General
Grease instructions
Fuel system
Drain condensation water
Fuel system
Replace the fuel filter, clean the fuel prefilter
Radiator
Check the coolant level
Radiator
Drain and fill in new coolant
Engine
Check valve tip clearance. Adjust if necessary
Engine
Check the engine oil level
Engine
Changing engine oil
Engine
Replace the oil filter
Engine
Check V-belt tension
Travelling drive
Change oil
Travelling drive
Check the oil
Undercarriage
Check chain tension
Hydraulic system
Check oil level
Hydraulic system
Change hydraulic oil
Hydraulic system
Replace the hydraulic oil filter, replace the breather filter
3-3
Maintenance
Symbol
3-4
Assembly
Explanation
Radiator fins
Clean
Heating,
air conditioning
Replace the recirculated air filter
Maintenance plan (overview)
Authorised
workshop
Customer
Every 1500 s/h
Every 1000 s/h

once a year
):
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 (
Every 500 s/h
Fluid and filter changes (
Every 250 s/h
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
Maintenance plan/service hours (s/h)
):
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
3-5
Air filter (damage)
Prefilter with water separator: drain water

Clean
Check V-belt condition and tension
Check the following material. Refill if necessary:

Engine oil
Engine coolant
Hydraulic oil
Gearbox oil6
Check the fuel injection pump
Check the injection pressure
Empty diesel fuel tank
Check alternator, starter and electric connections, bearing play and function
Preheating system, electric connections
Air filter contamination gauge
Pressure test of primary pressure relief valves9
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
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
Insulating mats in engine compartment

Grease supply of central lubrication system
Adhesive labels and operation manual
Authorised
Check battery electrolyte. Fill up with distilled water if necessary
workshop
Customer
Check valve tip clearance, adjust if necessary
Check injection nozzles and valves
Every 1500 s/h
Every 1000 s/h

once a year
Every 500 s/h
Check exhaust system for damage and condition
Every 250 s/h
Every 50 s/h
Work description

Maintenance work
(once a day)
3-6
3.3
Authorised
workshop
Customer
Every 1500 s/h
Every 1000 s/h

once a year
Lubrication service (
Every 500 s/h
Engine cover gas strut
Every 250 s/h
Every 50 s/h
Work description

Maintenance work
(once a day)
3.3
):
Lubricate the following assemblies/components:

Stabiliser blade
Swivelling console
Boom
Dipper arm
Implements
Grease strip on chassis see Lubrication strip on page 3-43
Air conditioning (
):
Carry out the following maintenance and inspection work:

Air conditioning function
Replace cab filter

Check dehumidifier for corrosion, condensation and air bubbles
Compressor oil 10
3-7
Replace dehumidifier
):
Check the function of the following assemblies/components. Rectify if necessary:

Lights, signalling system, acoustic warning system
Heating function
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
Every 1500 s/h
Every 1000 s/h

once a year
Every 500 s/h
Functional check (
Every 250 s/h
Every 50 s/h
Work description

Maintenance work
(once a day)
3-8
3.3
3.4
3.5
Service package
1000127022
1000125571
1000106891
1000106892
1000069998
1000064543
1000012360
1000012847
1000022075
1000022076
1000125682
1000003894
Service package 8003

Engine oil filter
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
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 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 page 3-5).
3-9
3.6
Fuel system
Specific safety instructions
Extreme caution is essential when handling fuel high risk of fire!

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 handle C to climb onto
the chain and as a safe hold during refuelling.
Danger!
All work involving fuel carries an 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. 1:
Fuel filler inlet
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.
Stationary fuel pumps
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
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
right
Fig. 2:
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
Refuelling from a barrel
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 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
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:
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

Unscrew thread A
The water drains
Wait until the indicator ring returns to the bottom of the water separator
Screw thread A back on again
On
Off
B
Interrupt fuel supply as follows:
Turn ball-type cock B to the OFF mark

Fuel supply is interrupted
Turn ball-type cock B to the ON mark
Fuel supply is open again
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
Replacing the fuel filter
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:
Never change the fuel filter if the engine is hot

Fuel filter position
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:
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
Unscrewing the fuel filter
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 thin coat of clean diesel
fuel to it
Screw on the cartridge by hand until the gasket makes contact
Fig. 6:
Cleaning the sealing surface and oiling the gasket
Fig. 7:
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 page 3-11
Make a test run and check for tightness!
Dispose of the old fuel filter cartridge by an ecologically safe method
Tightening the fuel filter
3-13
3.7
Engine lubrication system

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.
Proceed as follows:
max
min
Park the machine on level ground

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
Fig. 8:
3-14
Wipe it with a lint-free cloth

Push it back in as far as possible
Withdraw it and read off the oil level
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:
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
Open filler cap B

Raise oil dipstick A slightly to allow any trapped air to escape
Fill in engine oil

Wait about 3 minutes until all the oil has run into the oil sump
Check the oil level see Checking the oil level on page 3-14
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. 9:
Oil dipstick and oil filler cap
Completely remove all oil spills from the engine
Changing engine oil
Danger!
Caution when draining hot engine oil
Danger of burns!
+ 80 C
Wear protective gloves

Use suitable tools
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!
Change the engine oil as follows:

3-15
Let the engine run until reaching service temperature (oil temperature about 80 C)
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
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
Service valve option

B

Let the engine run until reaching service temperature (oil temperature about 80 C)
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. 11: Drain coupling with hose
B
C
D
Completely drain the oil

Unscrew drain coupling C
Screw on cap A of the oil drain valve
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
Wait a moment until all the oil has run into the oil sump
Fig. 12: Drain coupling with hose
3-16
Replacing the engine oil filter cartridge
Danger!
Caution when draining hot engine oil
A
Danger of burns!
Wear protective gloves
Fig. 13: Engine oil filter position
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:

Place a suitable container under the oil filter to collect the oil
Slowly slacken oil filter cartridge A using a commercially available tool
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 the engine oil filter
Clean the inside of the filter head

Apply a thin coat of 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: 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
Make sure the oil level is correct!

Run the engine for a short time
Check the seal of oil filter cartridge A and retighten by hand
Check the oil level and add engine oil if necessary
Fig. 16: Tightening the filter cartridge
Dispose of the used oil filter in an environmentally friendly manner
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!
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:
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
Once you have filled the expansion tank:

Test run the engine
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 poisonous
Keep away from flames
Avoid eye contact with antifreeze
If antifreeze comes into contact with the eyes
Immediately rinse with clean water and seek medical assistance
Checking the coolant level
Proceed as follows:
Switch off the engine!
Remove the key and carry it with you
Let the engine and the coolant cool down
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
Fig. 17: Expansion tank for 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:
Fig. 18: Radiator filler cap
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
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 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!
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.
Replace outside filter 19/B and inside filter 19/C:

If telltale 31 in the round display element comes on
According to the maintenance plan
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!
General instructions for air filter maintenance:

B
Store filters in their original packaging and in a dry place

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
Check the screws at the induction manifold and the clamps for tightness
Check the function of the dust valve, replace if necessary
Fig. 19: Air filter
3-21
Replacing the filter
Replace outside filter 21/B as follows:

Remove dirt and dust from the air filter and the area around the air filter
Fold both bow clips 21/D on lower housing section 21/E to the outside
Remove lower housing section E
Carefully remove outside filter B with slightly turning movements
Make sure all dirt (dust) inside the upper and lower housing sections, including the dust
Fig. 20: Removing the lower housing section
Fig. 21: Removing the filter element
valve, has been removed
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
Replace inside filter 22/C as follows:

F
Fig. 22: Replacing the inside filter

Remove dirt and dust from the air filter and the area around the air filter
Fold both bow clips D on lower housing section E to the outside
Remove lower housing section E
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:
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
Fig. 23: Air filter dust valve
3-23
3.10 V-belt
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

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

1
Fig. 24: Checking V-belt tension
Check as follows:
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
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 between the
crankshaft disc and the fan wheel position 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:
Tilt the cab upwards
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
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

Screw on cover 5
Connect the battery or the battery master switch
Tilt down the cab
4
Fig. 25: Retightening the V-belt
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.
Always make sure the V-belt has the correct tension

Replace V-belts with damage, cracks, cuts etc.
Avoid contact of oil, grease or similar substances with the V-belt
Check as follows:

Carefully check V-belt 26/1 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
1
About 9 mm
Fig. 26: Checking the V-belt tension of the air conditioning
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
4
Fig. 27: Retightening the V-belt of the air conditioning sys-
Retighten as follows:
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
Check V-belt tension again and adjust it if necessary

Connect the battery or the battery master switch
Close the engine cover
3-26
3.11 Pressure check

General
Run the machine warm before checking the pressure! Hydraulic oil temperature: 50 C
min. (operating temperature)
Pressure drop is checked under constant load

Set the primary pressure limiting valves (PPLV) at maximum engine revs!
See chapter Specifications see Hydraulic 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
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
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 maximum engine revs
Swiftly reduce engine revs from maximum to minimum -> pressure drop
Pressure drop should not exceed the specified value by more than 10 %
Fig. 28: Measuring ports P1 and P2
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
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: Primary pressure limiting valves P1 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

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
Pressure drop should not exceed the specified value by more than 10 %
Fig. 30: Measuring port P3
Adjustment of primary pressure limiting valve 2 (PPLV 2) for pump P3
Adjust the pressure at the primary pressure limiting valve (PPLV 2) 31/B on the main
valve block
Slacken the locknut of the pressure limiting valve

B
pressure gauge

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
Fig. 31: Primary pressure limiting valves P3 and P4
Connect a pressure gauge to measuring port MP 4 30/4

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 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

Move the control lever base (safety switch) to work position
Actuate the joystick
Fig. 32: Pilot control pressure measuring port
Setting the pressure reducing valve 33/C (PRV4)
Adjust the pressure at the pressure reducing valve (PRV 4) 33/C at the pilot oil supply
unit
Check the pilot control pressure again once adjustment is over

C
Fig. 33: Pressure reducing 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

Adjusting the secondary pressure limiting valve of the gear motor
Adjust the pressure at the secondary pressure limiting valve on the gear motor
Slacken the locknut of the pressure limiting valve34/1
pressure gauge
Fig. 34: Secondary pressure limiting valve

Check the secondary pressure limiting valve again once adjustment is over
3-29
Measuring ports: overview
3
1
Fig. 35: Measurement ports
Fig. 36: Measurement ports
Pos.
1
Description
Measuring port for pump 1
MP 1
MP 2
MP 3
Measuring port pump 4
MP 4
Pilot oil supply unit measuring port
MP 5
Primary pressure limiting valves
Pos.
3-30
Description
Primary pressure limiting valves pumps 1 and 2
PPLV 1
Primary pressure limiting valves pumps 3 and 4
PPLV 2
Pressure reducing valve
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
Primary pressure limiting valve PPLV 1

(main valve block)
3.12 Test report
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

(main valve block)
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
3.12 Test report

Pump 3
Movement
Function
Symbol
Stabiliser blade
DOWN
A (2)
B (2)
LEFT
Boom swivel
RIGHT
LEFT
Rotate
RIGHT
Measuring port
Measuring port MP 3
(pump)

(main valve block)
UP
Pressure limiting
valve
Secondary pressure limiting valve

SPLV 4
(gear motor)
Gear motor
Pressure limiting
valve
Measuring port
Specified values
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
Rated value
Drop
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
245-0/+3 bar
25 bar
Rated value
225+3 bar
Rated value
225+3 bar
Measured
Measured
Pilot control
Movement
Function
Joystick
ANY
Symbol
Pressure reducing valve

PRV 5
(pilot oil supply
unit)
Measuring port
Specified values
Rated value
32.5-0/+4 bar
3.13 Hydraulic system

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

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant
otherwise serious infections could set in!
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This may cause damage to the hydraulic pump!
Oil or fuel flowing out of high pressure lines may cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slack nuts or damaged
hoses and lines are detected.
Contact your Neuson dealer immediately
Replace the hose or line if one of the problems mentioned below is detected.
Damaged or leaky hydraulic seals.
Worn or torn shells or uncovered reinforcement branches.
Expanded shells in several positions.
Entangled or crushed movable parts.
Foreign bodies jammed or stuck in protective layers.
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil
Danger of severe damage to the hydraulic system!

Take care to avoid contamination when working!
Always fill in hydraulic oil by means of a strainer or the reflux filter!
Only use authorised oils of the same type
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!
Contact customer service if the hydraulic system filter is contaminated with

metal chippings. Otherwise, follow-on damage may result!
Environment!
Collect hydraulic oil, including biodegradable oil, with a suitable container! Dispose of
drained oil and used filters by an ecologically safe method.
Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil.
3-35
Checking the hydraulic oil level
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
If the implement is not positioned as shown:

Start the engine and let it run at idling speed
Retract the bucket and boom cylinders, lower the boom and the bucket teeth to the
ground
Switch off the engine again.
Fig. 37: Parking the excavator
Checking the hydraulic oil level

A
Proceed as follows:
FULL
LOW

Sight glass A is located on hydraulic oil tank B
Check the oil level on sight glass A

The oil level must be at the FULL level
A gauge element in sight glass A indicates the oil level
If the oil level is lower
Filling up hydraulic oil
Fig. 38: Oil level indicator on the hydraulic oil tank
The oil level varies according to the machine's operating temperature:

Machine condition
Before taking into
service
Normal operation
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:
Retract all hydraulic cylinders
Clean the area around filler opening C with a cloth
Open filler opening C
Check the hydraulic oil level on sight glass B
Close filler opening C
Fig. 39: Hydraulic oil filler inlet
3-37
Changing hydraulic oil
Important!
Only change the hydraulic oil if it is warm (about 50 C).
Retract all hydraulic cylinders before changing the oil.
Open the breather filter to release pressure

Open the drain plug to let the oil drain into a container
Check the hydraulic oil tank for contamination and clean if necessary
Replace the filter according to the maintenance specifications
Screw the drain plug back in correctly
Fill in clean hydraulic oil through the strainer
see Filling up hydraulic oil on page 3-36
Close the hydraulic oil tank correctly

Let the machine run at idling speed without load for some minutes
Monitoring the hydraulic oil reflux filter

33
The red telltale 40/33 on the instrument panel monitors the reflux filter.
The filter element must be replaced by an authorised workshop:
If telltale 33 comes on when the hydraulic oil is at operating temperature

At the latest after 1500 service hours (once every year)
In cold weather telltale 33 may come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
Set engine speed so that telltale 33 goes out
Fig. 40: Telltale for reflux filter
3-38
Checking hydraulic pressure lines

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.

Always consult a doctor immediately, even if the wound seems insignificant
otherwise serious infections could set in!
Always observe the following instructions:

Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
Never weld or solder faulty or leaking pressure lines and connections.
Replace damaged parts with new ones!
Never search for leakages with your bare hands, but wear protective
gloves!
Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
Have damaged flexible lines replaced by authorised workshops only!
Leakages and damaged pressure lines must be repaired immediately or replaced by an

authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment
Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20 066, part 5.
1 Q/00
The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication 1 Q/00 means manufactured in the 1st quarter of 2000.
3-39
3.14 Travelling drive

Danger!
Immediately after switching off the engine, the engine's components and the
oil are very hot. This may cause burns.
If the inside of the travelling drive is under pressure, the oil or the plug may be
squeezed out.
Danger of injury and scalding!

Wait until the engine has cooled down before taking up work.
Slowly open the plug to reduce the pressure inside.
Checking the oil level and filling up oil

A
Fig. 41: Checking the oil level
Park the machine on firm and level ground

Place the machine so that filler plug A is at the top
Unscrew screws A and B with a suitable tool
A small quantity of oil must flow out of opening B
If the oil does not flow out of opening B, fill up oil:
Fill in oil at opening A,
until a small quantity of oil flows out of opening B
Screw screws A and B back in again
Move the machine a few metres
If the oil level is not correct:
Repeat the procedure
Draining oil
B
Fig. 42: Draining oil

Place the machine so that filler plug B is at the bottom
Unscrew screws A and B with a suitable tool
The oil now flows out of opening A
Use a suitable container to collect the oil as it drains
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly
manner.
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:
The rubber chain has a mark B as shown in Fig. 43

Place the excavator so that mark B of the rubber chain is between the drive pinion C
and the chain tension roller D
B
C
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)
Fig. 43: Rubber chain mark

Raise the excavator with the boom and the dipper arm
Slowly and carefully actuate the control levers
Use suitable auxiliary means to support the machine
Fig. 44: Raising the excavator
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
Fig. 45: Measuring distance
3-41
Setting the chains
Danger!
The lubricating valve may be squeezed out due to the high grease pressure in
the hydraulic cylinder.

Do not slacken and unscrew the lubricating valve by more than one turn.
Slacken no other component except the lubricating valve.
Keep your face away from the lubricating valve connection.
Contact your Neuson dealer if this does not reduce the tension of the
rubber sliding block.
Caution!
Excessive tension of the chains causes severe damage to the cylinder and the
chain.
Tighten the chains only up to the prescribed measuring distance

Tightening the chains
Inject grease with the pump through lubricating valve A

Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again
Check the tension of the track chains again

If it is not correct:
Adjust again
Should the track chain still be slack after injecting more grease, replace the chain or the
A
seal in the cylinder. Contact a Neuson dealer in this case
Fig. 46: Tightening the chains
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
Fig. 47: Draining grease
Check the tension of the track chains again

If it is not correct:
Adjust again
Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in an environmentally friendly manner.
Apply grease to lubrication points E on the dipper arm

3-42
Lubrication strip
Apply grease to the lubrication strip as follows:
Lubrication point 48/A for the offset cylinder

Lubrication point 48/B for the live ring
Important!
A
Apply grease to lubrication points A and B once a day.
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
3.16 Electric system

The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
Always wear goggles and protective clothing with long sleeves

If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water

Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
During charging in particular, but also during normal battery operation, an oxyhydrogen
mixture is formed in the battery cells danger of explosion!
Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery may rupture or explode!
Replace the battery immediately
Avoid naked flames and sparks and do not smoke in the vicinity of open 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
Dispose of used batteries properly

Service and maintenance work at regular intervals
Before driving the machine
Check every time before driving the machine:

Is the light system OK?
Is the signalling and warning system OK?
Every week
Check once a week:

Electric fuses
see Fuse box in instrument panel on page 2-4
Cable and earth connections
Batter charge condition see Battery on page 3-46
Condition of battery terminals
Instructions concerning specific components

3-44
Cables, bulbs and fuses

Defective components of the electric system must always be replaced by an authorised

expert. Bulbs and fuses may be changed by unqualified persons
When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses
Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse
Only use fuses with the specified load capacity (amperage) see Fuse box in
instrument panel on page 2-4
Alternator
Only test run the engine with the battery connected

When connecting the battery, make sure the poles (+/) are not reversed
Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
Replace defective charge telltales immediately

see Telltale (red) alternator charge function on page 1-10
3-45
Battery
Danger!
Battery acid is highly caustic!
Danger of caustic injury!

Therefore when recharging and/or working near the battery:
Always wear goggles and protective clothing with long sleeves

If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water

Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
During charging in particular, but also during normal battery operation, an
oxyhydrogen mixture is formed in the battery cells
Danger of explosion!
Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
Do not attempt to jump-start the machine if the battery is frozen or if the

acid level is low. The battery may rupture or explode!
Replace the battery immediately
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
Do not disconnect the battery while the engine is running.
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:
Slacken the heater cover

The inside heater filter can be accessed fig. 50
Remove the inside heater filter
Insert a new inside heater filter
Fit the heater cover back on again
Fig. 50: Inside heater filter
3-47
3.18 General maintenance work

Cleaning
Cleaning the machine is divided into 3 separate areas:
Inside the cab

Exterior of the machine
Engine compartment
The wrong choice of cleaning equipment and agents may impair the operating safety of
the machine on the one hand, and on the other undermine the health of the persons in
charge of cleaning the machine. It is therefore essential to observe the following instructions.
General instructions for all areas of
the machine
When using washing solvents
Ensure adequate room ventilation

Wear suitable protective clothing
Do not use flammable liquids, such as petrol or diesel
When using compressed air
Work carefully
Wear goggles and protective clothing
Do not aim the compressed air at the skin or at other people
Do not use compressed air for cleaning your clothing
When using a high-pressure cleaner or steam jet
Electric components and damping material must be covered and not directly exposed
to the jet
Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
Protect the following components from moisture:
Engine
Electric components such as the alternator etc.
Control devices and seals
Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays
Ensure adequate room ventilation

Do not use unprotected lights or naked flames
Do not smoke!
3-48
Inside the cab
Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure may
Penetrate into the electric systems and cause short circuits and
Damage seals and disable the controls!
We recommend using the following aids to clean the cab:
Broom
Vacuum cleaner
Damp cloth
Bristle brush
Water with mild soap solution
Cleaning the seat belt
Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they may destroy the fabric!
Exterior of the machine
The following articles are generally suitable:
High-pressure cleaner
Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only

Switch off the engine before cleaning
Caution!
When cleaning the engine with a water or steam jet
The engine must be cold

Do not point the jet directly at electric sensors such as the oil pressure
switch
The humidity penetrating any such sensors causes them to fail and leads to
engine damage!
3-49
Screw connections and attachments

All screw connections must be checked regularly for tightness, even if they are not listed in
the maintenance schedules.
Engine fastening screws

Fastening screws on the hydraulic system
Line, bucket teeth and pin attachments on the implement
Retighten loose connections immediately. Contact a workshop if necessary.
Lubricate all mechanical pivots on the machine (such as door hinges, joints) and
fittings (such as door arresters) at regular intervals even if
they are not listed in the lubrication plan.
3-50
Engine
Oil drain valve
Oil dipstick
Engine oil filter
Fuel filter
4.1
Fuel injection pump
Oil filler neck
Oil pressure switch
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
Fuel injection pump
4.2
Feed
Reflux
Engine
Fuel system
4-3
Engine
4.3
Removing the cylinder-head cover

Important!
The injection lines on this engine run through the cylinder-head cover.
Therefore, remove the cylinder-head cover with extreme care!
Remove as follows:
Remove all injection lines from the cylinder-head cover

Slightly fold the injection lines away from the engine
Remove the rubber covers from the cylinder-head cover with a screw driver
Unscrew the cylinder-head cover
Fig. 1:
4.4
Removing the cylinder-head cover
Checking and adjusting valve tip clearance

Standard setting of valve tip clearance is possible:
On a cold engine
Remove the cylinder-head cover
Turn the engine until the cylinder reaches top dead centre of the compression cycle.
Check the valve cap for abnormal wear

normal
Fig. 2:
abnormal
Valve cap wear
Check valve tip clearance 3/A with a feeler gauge

Valve tip clearance:0.15 0.25 mm
Fig. 3:
4-4
Valve tip clearance
Engine
B
C
Fig. 4:
Slacken locknut 4/C on the cylinder.

Adjust valve tip clearance by turning set screw 4/B.
Valve tip clearance:0.15 0.25 mm
Tighten locknut 4/C.
Check the setting again with the feeler gauge.
Setting valve tip clearance
Repeat the procedure for each cylinder
4-5
Engine
Place the cylinder-head cover gasket
Mount the cylinder-head cover
Fig. 5:
4.5
Placing the cylinder-head cover gasket
Tightening order for cylinder head bolts

Mount the cylinder-head bolts
Tightening moments:
1st pass
49 58.8 Nm
2nd pass
103.1 112.9 Nm
Caution!
Bear in the mind the order for tightening the cylinder-head bolts!
See figure
Flywheel
Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them!
Order for removing the cylinder-head bolts
Flywheel
4-6
Fan
Engine
4.6
Checking the injection nozzles
Pressure check
Remove the injection line and the injection nozzle

Connect the injection nozzle with the high pressure line of the nozzle tester
Slowly increase pressure until the nozzle ejects fuel and read the pressure off the pressure gauge
If the injection pressure is too low, replace the spacer in the nozzle by a thicker one. If
the pressure is too high, replace the spacer by a thinner one.
Injection pressure: 220 230 bar
Spacer thickness of 0.1 mm corresponds to modification by 19 bar

Fig. 6:
Nozzle tester
Upper nozzle screw

fitting
4.7
Lower nozzle screw fitPressure spring centring Nozzle needle

ting
Compression Compression
Nozzle body
spring
spring seat
Spacers
Checking the nozzle jet

Remove the injection lines and the injection nozzles
Connect the injection nozzle with the high pressure line of the nozzle tester
Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times)
Hold a white sheet of paper about 30 cm away from the nozzle and let the nozzle eject
fuel
Normal atomisation
The nozzle jet must create a circle on the paper

Check the nozzle for drips after it has ejected fuel
Create a pressure of about 20 bar below injection pressure and check whether fuel
escapes from the nozzle
Bad atomisation
Fig. 7:
Nozzle jet
4-7
Engine
4.8
Injection time
Checking injection time
Remove the cylinder-head cover

Turn the engine clockwise with the crankshaft (as seen from the radiator) up to the top
dead centre of the first cylinder and check whether both cams show upwards to the left
and right
Remove the rubber covers from the flywheel housing and check whether the mark on
the belt pulley is aligned with the 0 mark on the scale
Unscrew the injection line of the first cylinder and replace it by the drip tube (fig. 8)
(place a container to collect the fuel)
Rotate the engine 1.5 revolutions until it is 40 before top dead centre in the 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
Rotated towards the engine: earlier injection time

Rotated away from the engine: later injection time
Bend each of the injection lines before you mount them so they are not subject to tension once they are mounted
Engraved scale
Belt pulley
Mark on belt
pulley
Direction of rotation
Mark on pump housing

Flange screws (oblong slots for rotating the pump)
4-8
Engine
4.9
Adjusting engine revs

Important!
Maximum engine revs are sealed in the factory and may not be modified!
Adjust engine revs without load!
Run the diesel engine until it reaches operating temperature

Check idling speed A and maximum revs B with all implement functions in neutral
Idling speed: 1050 +/- 50 rpm
Max. revs: 2575 +/- 50 rpm
Correct the idling speed with set screw 9/A if it is not correct.
Fig. 9:
Adjusting engine revs
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
Warm up the thermostat in a container with water

Check whether the thermostat opens at the prescribed temperature (check with a temperature gauge)
Thermostat opening temperature: 69.5 72.5 C
4.12 Checking the thermal switch

Remove the thermal switch
Warm up the thermal switch in a container with antifreeze or oil
Measure the resistance of the thermal switch as shown by means of an ohmmeter.
The switch must allow the coolant to pass at a temperature of 107 113 C.
Thermometer
Test prods
Fig. 12: Checking the thermal switch
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
Start the engine, check for correct idling speed

Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
Oil pressure switch OK: infinite resistance
The oil pressure switch is defective if the oil can pass
Fig. 13: Oil pressure switch
4.14 Checking the coolant circuit

Leakage check
Fill up the radiator completely

Mount an adapter on the radiator as shown
Increase the pressure in the cooling system by means of a hand pump to about 1 bar
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge
Fig. 14: Checking the radiator for leakage
Checking the radiator cap
Remove the radiator cap and mount it onto the adapter as shown
Increase the pressure to about 1 bar (stamped onto the radiator cap) with the hand
pump
Radiator cap must open

Radiator cap
Fig. 15: Checking the radiator cap
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
Engine does not start or is not easy to start
Defective fuel injector

Defective starting relay
Defective glow plug
Defective solenoid switch
Cut-off solenoid does not attract
Cut-off solenoid without current
High pressure created immediately in the hydraulic system
Engine starts, but does not run smoothly or faultless

Injection line leaks
Oil level too low
Oil level too high
Fouled air filter
Engine overheats. Temperature warning system

responds
Fouled oil cooler fins

Defective fan, torn or loose V-belt
Resistance in cooling system too high, flow capacity too low
Oil level too high
Fouled air filter
Insufficient engine output
Defective air filter maintenance switch or gauge

Engine does not run on all cylinders

Oil level too low
Insufficient or no engine oil pressure
Machine inclination too high (max. 15)

Wrong SAE grade of engine lubrication oil
4-12
Engine
Problem
Possible causes
Oil level too high
Engine oil consumption too high

Oil level too high
Blue

Engine oil combustion (defective cylinder-head gasket)
Engine starting temperature too low
Engine smoke
White

Coolant combustion (defective cylinder-head gasket)
Fouled air filter
Black
Defective air filter maintenance switch or gauge

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
Variable displacement pump unit
Pos.
1
2
3
4
5
6
7
8
9
10
11
Gear pump unit
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
Solenoid valve for safety valve
2nd speed range solenoid valve
Gear motor brake release supply
PV
Drive couterbalancing system supply
Accumulator
Drives/2nd speed range supply
Pressure limiting valve
BV
PR
Pump 1 port
P1
10
Pump 3 port
P3
11
Pump 2 port
P2
12
Tank line
13
Safety valve: protects the pilot oil supply unit if the

pressure relief valve is defective
5-5
Hydraulic system
2
6
7
3
10
12
11
6
13
8
Pos.
5-6
Connection
Description
Port P2
Drive couterbalancing system supply
Accumulator
2nd speed range solenoid valve
Port P1
Safety valve
Tank line
P2
P1
T
10
Port P3
P3
11
Pilot valve supply
BV
12
Drives/2nd speed range supply
PR
13
Gear motor brake release supply
PV
Hydraulic system
5.2
Main valve block
Ports
Rotate
BR3
AR3
Stabiliser blade
BR2
AR2
PR5
T6
T4
T2
Dipper arm
summation
Boom
B8
A8
Bucket
pc2
A7
B7
A6
B6
Right-hand side drive

Straight-ahead driving
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
A2
Left-hand side drive
PT
A1
PP
P1
5-8
PA
Hydraulic system
Legend
Pilot control lines

Connection
Legend
Controlled via
Pa1, Pb1
Left-hand side drive control
Drive pedal (left)
Pa2, Pb2
Auxiliary hydraulics control
Auxiliary hydraulics pedal
Pa3, Pb3
Swivel control
Pa4, Pb4
Boom 2 control
Joystick (right)
Pa5, Pb5
Dipper arm 1 control
Joystick (left)
Pa6, Pb6
Right-hand side drive control
Drive pedal (right)
Pa7, Pb7
Bucket control
Joystick (right)
Pa8, Pb8
Boom 1 control
Joystick (right)
Pa9, Pb9
Dipper arm 2 control
Joystick (left)
Pra2,Prb2
Stabiliser blade control
Pra3, Prb3
Rotation control
Joystick (left)
pc1
Dipper arm cylinder load retaining valve
Joystick (left)
pc2
Boom cylinder load retaining valve
Joystick (right)
Main control lines

Connection
Legend
A1, B1
Drive unit (left) via swivel joint
A2, B2
A3, B3
Offset cylinder
A5, B5
Dipper arm cylinder
A6, B6
Drive unit (right) via swivel joint
A7, B7
Bucket cylinder
A8, B8
Boom cylinder
AR2, BR2
Stabiliser blade cylinder
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
Pumps P3 and P4 input
PA
Pilot oil supply unit port
PP
Optional port for automatic revs control
PT
Optional drive alarm port
T1
Tank line via oil cooler and filter in tank
T2
Tank line via non-return valve and filter in tank
T3
Plug (tank line)
T4
Plug (tank line)
T6
Plug (tank line)
DR1
Tank line
dr1, dr2
Tank lines for boom summation
pcc
Tank line
5-9
Hydraulic system
Main valve block diagcylinder
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

0B
0A
Bucket
0B
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
Hydraulic supply by pump 1
Left-hand side drive section

Boom section 2
Dipper arm section 1
Auxiliary hydraulics section
Swivel section
Drive couterbalancing system section
Right-hand side drive section

Dipper arm section 2
Boom section 1
Bucket section
Supplied by pumps 3 and 4
Stabiliser blade section

Swivel unit section
Optional 3rd control circuit section
Option triple articulation boom section
Pumps 3 and 4
Pump 2
Pump 1
5-13
Hydraulic system
5.3
Drive counterbalancing system

Without drive couterbalancing system
Actuating the boom as you drive causes the machine to leave its track!
(P1, P2 each supply a drive, and the boom function is also governed by P1 or P2)
Drive couterbalancing system features
If the boom is actuated as you drive straight ahead, the machine stays in its track and drive
speed stays constant.
The drive counterbalancing system is only enabled if both drive valves are enabled.
Function
The drive couterbalancing system is enabled by means of an increased banking-up

pressure if both piston valves for driving and a boom function.
P2 takes over all boom functions

Pump assignment for drive counterbalancing
Right-hand side drive section

Left-hand side drive section
Bucket section
Boom section
Boom (2) summation section
Dipper arm section
Dipper arm (2) summation section
Swivel boom section
Auxiliary hydraulics section
Supplied by pumps 3 and 4
Rotate section
Stabiliser blade section
5-14
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
"
!
PB
Right-hand side drive
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
Boom summation raise

Both P1 & P2 pumps are used to raise the boom at higher speed.
Raising the boom
Moving the joystick also controls a second segment (boom 2)

Pump P2 supplies the boom 2 segment with oil
The summation time (the time the boom 2 segment is switched) is specified by the
piston spring in the boom 2 segment
Lowering the boom
see Lowering the boom: on page 5-18
DR
!
"
PB
PA
Boom 1
Boom 2
0
5-16
PB
PA
0
Hydraulic system
5.5
Boom check valve (load retaining valve)

Boom cylinder base side
A pilot-operated load retaining valve is used to prevent spool leakage, which allows the
cylinder to retain its home position.
Raising the boom:
The oil opens the check valve and flows to the base side of the boom cylinder.
Lowering the boom:
The load on the check valve is reduced by means of the pilot control line and a piston
(reflux to tank). This allows the base side oil to flow back via the check valve.
DR
!
"
Line
Boom 2
4
0
PB
PA
Boom base
side
Joystick control
5-17
Hydraulic system
5.6
Dipper arm cylinder summation

Both P1 & P2 pumps are used to fold the dipper arm at higher speed.
Retracting the dipper arm cylinder
Moving the joystick also controls a second segment (dipper arm 2)

Pump P2 supplies the dipper arm 2 segment with oil
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
Dipper arm check valve (load retaining valve)

Rod side dipper arm cylinder
A pilot-operated load retaining valve is used to prevent spool leakage, which allows the
cylinder to retain its home position.
Rectracting the dipper arm:
The oil opens the check valve and flows to the rod side of the dipper arm cylinder.
Extending the dipper arm:
The load on the check valve is reduced by means of the pilot control line and a piston
(reflux to tank). This allows the base side oil to flow back via the check valve.
DR
PC
Rod side
dipper arm
!
Line
Dipper arm 2
"
PB
Joystick control
PB
PA
0
4
PA
5-19
Hydraulic system
5.8
Secondary pressure limiting valves for the auxiliary hydraulics (option)

Overpressure protection for consumers in secondary circuit
e.g. hydraulic hammer
Important!
The implement manufacturer (e.g. hammer, offset bucket ...) is in charge of overpressure protection for his implements. Neuson Baumaschinen GmbH shall not be
liable for damage to implements.
Problem:
The secondary circuit is also protected by the primary pressure limiting valve if the spool
valve is enabled. There is no protection if the spool valve is not enabled.
Ensuring protection with the spool valve disabled requires two secondary pressure limiting
valves instead of the plugs.
Adjusting the secondary pressure limiting valves:
The pressure limiting valves must be set at 280 bar.
Short-term pressure peaks can be reduced with this setting.
Please observe the following should the pressure limiting valves be set to less than 280
bar:
Have the pressure setting carried out by a specialist

The pump's high flow rate and the fact that the pressure peaks are now reduced by the
secondary pressure limiting valve cartridges at the auxiliary hydraulics section may
cause the hydraulic oil to overheat.
Reset the pressure setting to the initial 280 bar when changing implement.
Location:
see Pressure limiting valves on page 5-11
5-20
Hydraulic system
5.9
Pilot valves
Joystick
Pilot valve for bucket, boom, dipper arm and rotation

Consists of a lever and four pressure reducing valves
2
1 Numbering for right-hand side joystick.
Left-hand side joystick: 3-1-2-4
D
P
E
F
Pos.
Description
Pos.
DescriptionJoystick (left)
DescriptionJoystick (right)
Control lever
Dipper arm extension control
Boom cylinder extension control
Rubber collar
Left-hand side rotation control
Bucket cylinder extension control
Linkage
Dipper arm retraction control
Boom cylinder retraction control
Universal joint
Right-hand side rotation control
Bucket cylinder retraction control
Guide plate
Supply from pilot oil supply unit
Tappet
Tank line
Tank line
5-21
Hydraulic system
Pilot valve (driving)
Pedal with hydraulic damping

Consists of two pedals and four pressure reducing valves
Pos.
1
2
5-22
Description
Left-hand side drive segment control
Left-hand side drive segment control
Right-hand side drive segment control
Right-hand side drive segment control
Pilot control pressure
Tank line
Hydraulic system
2
3
Pos.
Description
Bellows
Shift unit (kit)
Plate (kit)
Tappet
Non-return valves
Damping
5-23
Hydraulic system
Pilot valve for auxiliary hydraulics
Pilot valve with pedals for remote control of directional valves

Consists of a pedal and two pressure reducing valves
0$
1P
1P
C
D
3
Pos.
Description
Pedal
Pedal fixture
Auxiliary hydraulics control/offset cylinder retraction control
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
Pilot valve with pedals for remote control of directional valves

Consists of a pedal and two pressure reducing valves
0$
0
1P
1P
3
4
1
Pos.
Description
Pedal
Pedal fixture
Stabiliser blade cylinder retraction control
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
Tank line
Shuttle valve block/main valve block, offset cylinder retraction control
Shuttle valve block/main valve block, offset cylinder extension control
Hydraulic system
4/3 directional valve
Used for electric auxiliary hydraulics and 3rd control circuit.

Valve is located in pilot control branch and is controlled via tip switches on left-hand side
joystick.
2
5
Pos.
1
1
1
1
1
1
1
Description
Solenoid 1
Solenoid 2
Solenoid 2
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
Pumps P3+P4 output
Tank line
M3/M4
5-28
Connection
P3
Pumps P3/P4 measuring port
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
Pressure setting screw
Des.
Description
Connection
C1
Offset cylinder base side
C2
Offset cylinder rod side
V1
Base side offset cylinder main valve block
V2
Rod side offset cylinder main valve block
5-29
Hydraulic system
Shuttle valve block
Actuating rotation, boom swivel and dipper 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)
Port B (-> joystick (left) 2 ->
main valve block, left-hand side rotation control)

3
Port C (-> pedal, swivel 2 ->
main valve block, offset cylinder extension control)

4
Port D (-> pedal, swivel 1 ->
main valve block, offset cylinder retraction control)

5
Port E (-> joystick (left) 1 ->
main valve block, dipper arm cylinder extension control)

6
5-30
Port F (-> gear motor SH, brake release)
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:
Directional valve position
Switching from ISO to SAE controls and vice versa with the directional valve
1
Position
1
2
Function
ISO controls
SAE controls
Tighten wing nut J after changing control mode.
Danger!
Changing the directional valve over modifies the controls (control levers)
Make sure you know which control mode has been selected before starting
work
Always secure wing nut J on the directional valve's changeover lever
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
Joystick (right) port 1
Main valve block, boom cylinder retraction control
Joystick (right) port 3
Main valve block, boom cylinder extension control
Main valve block, dipper arm cylinder extension control
Joystick (left) port 1
Main valve block, dipper arm cylinder retraction control
Joystick (left) port 3
Hydraulic system
5.11 Drive up to serial number: AC 02956
The travelling drive has two speed ranges.
Hydraulic motor on left

1
2
BAR
3
4
3
7
6
Pos.
Description
Brake cylinder
Leak oil port (-> swivel joint 8a)
2nd speed range port (-> swivel joint 1a)
2nd speed range directional valve
Brake bleed valve
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.
2nd speed range function
Speed range 1
2nd speed range switch: switched off

The directional valve for the 2nd speed range remains in home position (position as shown
in diagram), and the hydraulic motor's swash plate is in maximum capacity position.
The motor runs at low speed.

Speed range 2
2nd speed range switch: switched on

The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash
plate is in minimum capacity position.
The motor runs at high speed.
5-34
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'

7
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.
2nd speed range function
Speed range 1
2nd speed range switch: switched off

The directional valve for the 2nd speed range remains in home position (position as shown
in diagram), and the hydraulic motor's swash plate is in maximum capacity position.
The motor runs at low speed.

Speed range 2
2nd speed range switch: switched on

The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash
plate is in minimum capacity position.
The motor runs at high speed.

If the pressure rises in the travelling drive, the directional valve for the 2nd speed range is
forced back to home position and and hydraulic motor's swash plate returns to maximum
capacity.
The motor now turns at low speed.

The directional valve returns to 2nd speed range as soon as the pressure in the travelling
drive drops again.
The motor runs at high speed again.

Switch operating point of the directional valve: 180 bar
5-36
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)
The shock anticavitation valves are dampened for smooth braking.
5-39
Hydraulic system
Parking brake function
Opening the brake
The shuttle valve block directs the pilot control pressure to the SH input if rotation, boom
swivel or dipper arm retraction is carried out. The pilot control pressure at the SH input
causes the piston in the parking brake valve to shift to active state (brake release). This
directs the pilot control pressure at the PG input to the brake cylinder and releases the
brake.
Movement: rotation, boom swivel or dipper arm retraction

Pilot control pressure is present at the SH input
The piston of the parking brake valve moves to work position
Pilot control pressure is directed to the brake piston
Brake is released
Closing the brake

The shuttle valve block causes the pilot control pressure to drop and the SH input is
unpressurised upon termination of rotation, boom swivel or dipper arm retraction. The piston in the parking brake valve switches to home position (brake) if there is no pressure at
the SH input. The pressure in the brake cylinder escapes via the parking brake valve to the
leak oil system. This enables the brake with some delay (depending on oil viscosity and
brake valve leakage).
End of movement: rotation, boom swivel or dipper arm retraction

The pilot control pressure at the SH input drops
The piston of the parking brake valve moves to home position
No more pilot control pressure on the brake piston
The oil in the brake piston flows to the tank via a throttle orifice
The brake is enabled
Time for releasing the brake: 5 sec +/-1.5 @ 50 C oil temperature
Anti Swing Back (ASB) valve
5-40
Once the rotate function is over, counterpressure is created in the gear motor which
causes the upper carriage to swivel back slightly. The Anti Swing Back valve reduces this
pressure and prevents the upper carriage from swivelling back.
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 right
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
Filtering the intake air
The breather filter is located under the tank cover, between the hydraulic filler inlet and the
fuel filler inlet.
Replace the breather filter according to the instructions in the maintenance plan!
see Maintenance plan (overview) on page 3-5
Fig. 3:
Breather filter position
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
Hydraulic system without function
Contaminated solenoid valve on pilot oil supply unit

Hydraulic oil level too low
Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Quickhitch couplings not connected correctly
Hydraulic hammer does not work correctly
Hydraulic oil quantity too high/too low

Hydraulic oil pressure too high/too low
Defective switch for 2nd speed range
Defective solenoid valve on pilot oil supply unit
Excavator runs in 1st speed only
Contaminated solenoid valve on pilot oil supply unit

Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Counterpressure in travelling drive does not drop below control pressure
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
3rd control circuit

option
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
Travelling drive (right)

Starting serial no.: AC02957
auto2speed
16
Blade
00
$2
4
"6
!
Offset cylin- Dipper arm cylinder

der
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
5.17 Hydraulics diagram A4

&
! ! " " # # $ $ % %
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 (left)
Offset cylinder
Dipper arm cylinder
Boom cylinder
Bucket cylinder
Hose burst valve
Vent filter
5-49
Hydraulic system
5-50
5.19 Hydraulics diagram

Offset cyl- Dipper arm
inder
cylinder
AC02956
A
A
!
!
2'
"6
18
!2
19
17
3rd control circuit option

Rotate
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
!
Starting serial no.:

AC02957
auto2speed
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 "
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!
SERV-HB 8003 En Edition1.0*8003s511.fm
5-51
5.20 Main valve block diagram

4
"2
Main control lines
!2
0RB
0RA
!2
"2
0RB
0RA
"2
!2
4
4
$2
Legend
A1, B1
A2, B2
A3, B3
Offset cylinder
A4, B4
Boom cylinder summation
A5, B5
Dipper arm cylinder
A6, B6
Drive (right)
0RB
A7, B7
Bucket cylinder
0RA
A8, B8
Boom cylinder
A9, B9
Dipper arm cylinder summation
AR2, BR2
AR3, BR3
Gear motor
AR4, BR4
3rd control circuit (optional)
02
4
Connection
4
DR
PCC
PC
Pilot control lines
!
"
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
Left-hand side drive control
Drive pedal (left)
Pa2, Pb2
Auxiliary hydraulics control
Pa3, Pb3
Swivel control
Pa4, Pb4
Boom summation control
Joystick (right)
Pa5, Pb5
Dipper arm control
Joystick (left)
Pa6, Pb6
Right-hand side drive control
Drive pedal (right)
Pa7, Pb7
Bucket control
Joystick (right)
Pa8, Pb8
Boom control
Joystick (right)
Pa9, Pb9
Dipper arm summation control
Joystick (left)
Pra2,Prb2
Stabiliser blade control
Pra3, Prb3
Rotation control
Joystick (left)
Pra4, Prb4
3rd control circuit control (electric)
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
Pilot oil supply unit port
T1
Tank line via non-return valve and filter in tank
T2
Tank line via oil cooler and filter in tank
DR1, DR2
Tank lines for boom summation
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
Measuring equipment, measuring methods

Multi-function measuring device
Measurements of values (U, R, I, f)

Continuity test
Diode test
Calculate measuring range using known data (P, U, R, I)
and set before measuring!
Observe AC/DC basic setting.
AC = alternating current/voltage;
DC = direct current/voltage
Test device with acoustic and optical signal output
Continuity test in de-energised machine electric system and of wiring harnesses
SERV-HB 8003 En Edition 1.0 *8003s610.fm * modified: 02.02.05, 08:34
6-1
Electric system
Measuring methods multifunction measuring device
Measuring current (ignition switched on):

Black cable in COM socket (earth),
red cable in A socket or mA socket; connect in series to consumer.
Measuring voltage (ignition switched on):

red cable in V socket;
connect in parallel to consumer.
Measuring resistance (ignition switched off):
red cable in socket;
connect in parallel to consumer (see measuring voltage).
Test lamp
The test lamp is used to test lines and functions with the ignition switched on.
Line test (testing voltage):

Connect test lamp between test point (live cable) and machine earth or between test point
(earth line) and a live cable.
Functional check (testing current):

Connect test lamp between a connection on the consumer to be tested and the connection
line.
6-2
SERV-HB 8003 En Edition 1.0 * *8003s610.fm * modified: 02.02.05, 08:34
Electric system
6.3
Cable colour coding

Colour
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Grey
White
Pink
6.4
Code
blk
brn
red
org
yel
grn
blu
vio
gry
wht
pnk
Relays
Use, mode of function
Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by microelectronics or
microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be make-contact, break-contact or changeover switches. These undertake the actual switching function.
Zero-centre relay
86
30
86 = Start of coil
(control line)
85 = End of coil
(earth)
30 = Input
(load line)
87 = Make-contact switch output (load line)

87 a= Break-contact switch output (load line)
85
Fig. 1:
87 87a
Terminal description on relay
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
E.g. for cigarette lighter; 15 A max.
Fuse box in instrument panel

Fuse no.
Rated current (A)
Protected circuit
F3
10 A
F4
10 A
Boom working light
F5
15 A
Cab working light
F6
10 A
Valves, horn
F7
15 A
F8
10 A
F9
10 A
Rotating beacon, radio, drive interlock
F10
15 A
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 2:
6.7
Fuse box
Main fuse box with relays

The main fuse box is located under the cab.
K9
K5
F1
F2
Fuse no.
Rated current (A)
Protected circuit
F1
40 A
Start, preheat, cut-off solenoid
F2
50 A
Fuel-filling pump, main fuse, ignition lock
Relay no.
Fig. 3:
6-4
Relais box under the cab
K9
K5
Preheating high current relay
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
Preheating timer (telltale only); black plug
K7
Starting relay
K8
Cut-off solenoid timer; white plug
V1
Cut-off solenoid recovery diode
V1
K6
Fig. 4:
6.9
K81
Relays
Socket
The socket A is located above the lubrication strip B.
Fig. 5:
Lubrication strip on the chassis
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)
Left-hand side joystick (standard and option)
Joystick (right)
2
Pos.
1
2
3
Fig. 7:
6-6
Description
Horn (S55)
Not assigned
Automatic idling speed feature (S48)
Right-hand side joystick (standard and option)
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
Wiring harnesses: overview
6-11
6-12
6.15 Wiring diagram A4: legend

No.
A1
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
2 pole main connection
D0
D/E10
M1
Starter
F2
X4
9 pole connection drive interlock
C/D3
D11/12
B6
Engine oil temperature sensor
E6
M2
Wiper motor
F13
Option
X5
7 pole connection armrest/chassis
B11
Loudspeaker
E15
Option
M4
Fan
C12
Option
X6
5 pole connection armrest switch
C11/12
B12
Loudspeaker
E15
Option
M5
Washer pump
F8
Option
X7
6 pole connection joystick (right)
C11
B14
Warning buzzer
C2
Option
E7
Rear roof light
F14
E9
Front roof light
F13
E10
Front roof light
E11
Boom light
F8/9
E14
Interior light
E/F13
E15
Cigarette lighter
F1
F2
M7
Fuel-filling pump
F1
X8
6 pole connection joystick (left)
D11
Option
M9
Fuel pump
F3
X10
15 pole connection indicator
B/C1
Option
P1
Hour meter
B1
X11
2 pole connection Vario indicator
B6
Option
P2
Fuel level indication
B1
X12
9 pole connection cab
C13/14
P3
Engine oil temperature gauge
A3
X13
5 pole connection engine temperature
A3
R1
Glow plug
F4
X14
2 pole connection automatic revs setting
D3
A14
S1
A1
X15
1 pole connection drive alarm
D1
Main fuse: starter, preheating
E2
S2
Pressure switch engine oil
F5
X16
3 pole connection drive alarm
E2
Main fuse + fuel-filling pump
E1
S3
Engine temperature switch
E5
X19
1 pole connection socket
F7
F3
A4
S4
Air filter pressure switch
F6
XE11
2 pole connection boom working light
E9
F4
Boom working light
A7
S5
Hydraulic oil pressure switch
F7
XS41
2 pole connection safe load indicator
E8
Loc.
F5
Cab working light
A8
S8
Battery master switch
F1
Y1
Cut-off solenoid
F4
F6
Valves, horn
A9
S15
Ventilation switch
A10
Y3
High-speed solenoid valve
F9
F7
Fan, air conditioning
A10
S16
Boom working light switch
A7
Y13
F13
F8
A12
S17
Cab working light switch
A8
Option
Y14
F9
F9
A13
S18
Rotating beacon switch
A13
Option
F10
A14
S20
Wiper/washer switch
A20
Option
Y15
Solenoid valve automatic idling speed setting

Solenoid valve auxiliary hydraulics/swivel
F10
G1
Alternator
F3
S21
High speed switch
A9
Y16
Solenoid valve additional control circuit
F10
Option
G2
Battery
F1
S21.1
High-speed tip switch (prepared)
E9
Y17
Solenoid valve additional control circuit
F11
Option
H2
Preheating telltale
B1
S27
Additional hydraulics/swivel tip switch
D10
Y31
Solenoid valve air conditioning
F12
Option
H3
Engine temperature telltale
B1
S28
Safety switch
C28
H4
Engine oil pressure telltale
B1
S30
Additional control circuit tip switch
D9
Option
H5
Alternator charge function telltale
B1
S31
Additional control circuit tip switch
D9
Option
H6
Air filter telltale
B1
S41
Safe load indicator pressure switch
E8
Option
H7
Hydraulic oil filter telltale
B1
S42
Safe load indicator switch
A7
Option
H9
Safe load indicator telltale
C3
Option
S48
Automatic idling speed tip switch
C9
Option
H28
Rotating beacon
F13
Option
S51
Switch air conditioning
A11
Option
H33
Spare telltale
B1
S52
Air conditioning pressure switch
E12
Option
Option
H30
Spare telltale
C3
S54
Air conditioning thermostat
D12
K5
High current relay preheating
E4
S55
Horn tip switch
C10
K6
Preheating time lag relay
D5
V1
Recovery diode
E4
K7
High current relay start
E2
X1
13 pole connection engine/chassis
D4-6
Option
Option
6.16 Wiring diagram A4
6-13
6-14
6.17 Wiring harness 1000116497 (legend): engine chassis A4
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
K9/87 cut-off solenoid switching relay
M9/1 fuel pump
GND
K8 cut-off solenoid time lag relay
V1 Blocking diode
M9/1 fuel pump
G1/2 alternator
K6 preheating time lag relay
K7/6 start high current relay
GND
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
To
M1 starter
F1 main fuse
F2 main fuse
K9/30 cut-off solenoid relay
K7/A start high current relay
X3/A main connection
M7 fuel-filling pump
M1 starter
R1 glow plug
Y1/1 cut-off solenoid
X1/2 engine/chassis connection
V1 Blocking diode
G1/3 alternator
V1 Blocking diode
GND
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
S5 preheating start switch
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
valve
valve
valve
S52 air conditioning pressure switch
S52 air conditioning pressure switch
Y14/1 changeover valve solenoid valve
Y14/2 changeover valve solenoid valve
GND
X15 drive alarm connection
GND
To
B2 horn
X5/5 armrest/chassis connection
GND
GND
GND
GND
GND
M9/2 fuel pump
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

Y31 air conditioning solenoid valve
GND
X3/B main connection
yel/red
yel/red
yel/red
brn/grn
blk
blk
gry/blk
blk
1
1
1
1
1
1
1
6
6.18 Wiring harness 1000109697: engine chassis A4

Changeover
valve
AH/swivel
changeover
valve
9
9

9

Electr. AH
valve
Electr. AH
valve
9

Drive
alarm

Socket
"
8
High-speed Air conditioning

switch
pressure switch
(prepared)
8
3
3
Preheating
Horn

+
Blocking
diode

Starting
relay
+
Cut-off
solenoid
+

!

6

!
&
&
!
!
"
!

Main fuses

Cut-off
solenoid Preheat
+
+

!

Safe load indicator
83
8

Wiring harness connection
Safety valve
High-speed
valve
9

"
8%

!

Boom working light
9
"
!
"
"

8

3

"

Fuel pump
-
'.$
-
Starter

Alternator

!

!


1000124101
3
"
8
Drive alarm Fuel level indicaHydraulic oil
tor
pressure switch

Fuel-filling
pump
-

8
Water temperature switch

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
6.19 Wiring harness 1000125106 (legend): switches A4
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
S1/1 preheating start switch
X4.1/9 drive interlock connection
X4/7 drive interlock connection
F6 valves and horn fuse
S51/5 air conditioning switch
S15/3 ventilation switch
S21/10 high-speed switch
F8 wiper and interior light fuse
S20/10 wiper/washer switch
X12/4 cab connection
F4 boom working light fuse
S16/10 boom working light switch
To
F10 socket and cigarette lighter fuse
X10/10 indicator connection
X13 engine temperature connection
F3 indicators and engine relay fuse
F9 rotating beacon, radio and drive interlock fuse
S42/5 safe load indicator switch
X6/5 armrest switch connection
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
S18/1 rotating beacon switch
F7 fan and air conditioning fuse
S16/B boom working light switch
F10 socket, cigarette lighter
X11/1 Vario indicator connection
X14/2 automatic revs setting connection
To
B14/3 warning buzzer connection
E15 cigarette lighter
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
Safe load indicator switch
Air conditioning switch
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
1 107 106 106 105 2
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
6.20 Wiring harness 1000125106: switches A4
Automatic revs
setting connection
S1
Cigarette lighter
Engine temperature connection
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
!&
"&
#&
$&
%&
&&
'&
(&
21A 21A 4
15A 15A 5
41
112
Indicators, controls, engine and cut-off solenoid holding contact
114
94
138
95
Boom working light

Cab working light
X
X
58 1
X4.1
X
A
76
44
Valves
87
105
139
89
98

5
43
121
102
7A
120
47

Warning buzzer
122
123
124
Vario X11
indicator
connection
6-17
6-18
6.21 Wiring harness 1000109629: cab roof

Radio
B12
B11
10
11
12
13
Loudspeaker
A1
X
X
7
13
3
X
X
1
X
X
15
8A
E9
Front roof light
E14
Interior light
E7
Rear roof light
H28
Rotating beacon
12
11
5
10
X
X
8 8A
X
3
Cab connection
5
7
9
2
X12
14 15 3
14
GND1
GND2
grn/yel (X12/1)
grn/yel
blu (X12/6)
blu
brn (X12/4)
l 50
blk (GND1)
M2
Wiper
blk
brn
No.
1
2
3
4
5
6
7
8
8A
9
10
11
12
13
14
15
16
Up to
X12 (1) 9 pole plug and socket connector cab
A1.1/4 radio
A1/6 radio
A1/5 radio
A1/4 radio
A1/3 radio
GND1
GND1
GND1
To
M2 wiper motor
H28 rotating beacon
GND1
M2 wiper motor
E9 front roof light
M2 wiper motor
E14 interior light
A1.1/4 radio
A1.1/7 radio
E7 rear roof light
B11 loudspeaker
B11 loudspeaker
B12 loudspeaker
B12 loudspeaker
GND2
A1.1/8 radio
M2 wiper motor
Colour
grn/yel
vio
blk
brn
grn/red
blu
blu
red
red
grn/blu
wht
wht/blk
wht
wht/blk
blk
blk
blk
mm
0.75
1
1
0.75
1
0.75
1
1
1
1
0.5
0.5
0.5
0.5
1.5
1
0.75
6.22 Wiring harness 1000109628: armrest

Heater fan
M4
84
83
74
75
Air conditioning
thermostat
S54
Safety switch
S28
68
82
76
77
58
Armrest switch connection

5 76
X6
4
X5
81
84
68
6 73 74
5
46
83
82
71
58
66
64
62
Joystick (left)
64
66
62
85
77
75
X8
Armrest/chassis connection
Joystick (right) connection
85
71
46
81
73
X7
No.
Up to
46 X5/5 armrest/chassis connection
To
X7/85 joystick (right) connection
Colour
org
mm
No.
75 M4/2 fan
Up to
To
X8/4 joystick (left) connection
Colour
blk
mm
58
S28 safety switch
brn/wht
76
S28 safety switch
gry
62
blu/yel
77
S28 safety switch
gry
64
gry/yel
81
gry
66
gry/grn
82
S54 air conditioning thermostat
yel/red
68
yel/red
83
M4/1 fan
yel/blk
71
brn/grn
84
M4/3 fan
yel/blu
73
blk
85
gry/blk
74
M4/2 fan
blk
6-19
6-20
6.23 Wiring harness 1000116138: boom working light
XE11
53
54
1
53
E1
54
No
Up to
.
53 XE11/1 boom working light
To
E1 boom working light
Colmm
our
grn/yel 1
blk
1
Wiring harnesses: overview
6-21
6.24 Wiring diagram A3: legend

No.
A1
Description
Radio
Section
E14
B1
B2
B6
B11
Fuel indicator
Horn
Engine oil temperature sensor
Loudspeaker
F6
D/E10
E6
E15
B12
Loudspeaker
E15
B14
E7
Warning buzzer
Rear roof light
C2
F14
E9
Front roof light
E10
Front roof light
E11
E14
E15
F1
F2
F3
F4
F5
F6
F7
F8
F9
H6
H7
H9
Boom light
Interior light
Cigarette lighter
Main fuse: starter, preheating
Main fuse + fuel-filling pump
Boom working light
Cab working light
Valves, horn
Fan, air conditioning
Rotating beacon, radio, drive
interlock
Alternator
Battery
Preheating telltale
Engine temperature telltale
Engine oil pressure telltale
Alternator charge function telltale
Air filter telltale
Hydraulic oil filter telltale
Safe load indicator telltale
H28
Rotating beacon
F13
H33
H30
K5
K6
K7
K8
K9
Spare telltale
Spare telltale
High current relay preheating
Preheating time lag relay
High current relay start
Cut-off solenoid time lag relay
B1
C3
E4
D5
E2
D3
E3
F10
G1
G2
H2
H3
H4
H5
F13
F8/9
E/F13
A14
E2
E1
A4
A7
A8
A9
A10
A12
A13
Loc
.
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
.
A14
F3
F1
B1
B1
B1
B1
B1
B1
C3
Opti
on
Opti
on
No.
Description
Section
M1
M2
Starter
Wiper motor
F2
F13
M4
Fan
C12
M5
Washer pump
F8
M7
Fuel-filling pump
F1
M9
P1
P2
P3
R1
S1
S2
S3
S4
S5
S8
S15
S16
S17
Fuel pump
Hour meter
Fuel level indication
Engine oil temperature gauge
Glow plug
Pressure switch engine oil
Engine temperature switch
Air filter pressure switch
Hydraulic oil pressure switch
Battery master switch
Ventilation switch
Boom working light switch
Cab working light switch
F3
B1
B1
A3
F4
A1
F5
E5
F6
F7
F1
A10
A7
A8
S18
Rotating beacon switch
A13
S20
Wiper/washer switch
A20
S21 High speed switch

S21.1 High-speed tip switch (prepared)
S27 Additional hydraulics/swivel tip
switch
S28 Safety switch
S30 Additional control circuit tip
switch
S31 Additional control circuit tip
switch
S41 Safe load indicator pressure
switch
S42 Safe load indicator switch
A9
E9
A7
S48
C9
Loc
.
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
D10
C28
D9
D9
E8
S51
Automatic idling speed tip

switch
Switch air conditioning
S52
Air conditioning pressure switch E12
S54
Air conditioning thermostat
A11
D12
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
Opti
on
No.
S55
V1
X1
Description
Horn tip switch

Recovery diode
13 pole connection engine/
chassis
X2
11 pole connection engine/
chassis
X3
2 pole main connection
X4
9 pole connection drive interlock
X5
7 pole connection armrest/
chassis
X6
5 pole connection armrest
switch
X7
6 pole connection joystick
(right)
X8
6 pole connection joystick
(left)
X10 15 pole connection indicator
X11 2 pole connection Vario indicator
X12 9 pole connection cab
X13 5 pole connection engine temperature
X14 2 pole connection automatic
revs setting
X15 1 pole connection drive alarm
X16 3 pole connection drive alarm
X19 1 pole connection socket
XE11 2 pole connection boom working light
XS41 2 pole connection safe load
indicator
Y1
Cut-off solenoid
Y3
High-speed solenoid valve
Y13 Solenoid valve for safety valve
Y14 Solenoid valve automatic
idling speed setting
Y15 Solenoid valve auxiliary
hydraulics/swivel
Y16 Solenoid valve additional control circuit
Y17 Solenoid valve additional control circuit
Y31 Solenoid valve air conditioning
Section
Loc
.
C10
E4
D4-6
D7-9
D0
C/D3
D11/12
C11/12
C11
D11
B/C1
B6
C13/14
A3
D3
D1
E2
F7
E9
E8
F4
F9
F13
F9
Opti
on
F10
F10
F11
F12
Opti
on
Opti
on
Opti
on
Wiring diagram: legend
6-22
6.25 Wiring diagram A3
6-23
6.26 Wiring harness 1000109624 (legend): engine chassis A3
No
.
1
2
3
4
5
6
7
8
9
10
G1/B alternator
G1/B alternator
M1 starter
F1 main fuse
F1 main fuse
F2 main fuse
F2 main fuse
GND
K7/B start high current relay
M1 starter
F1 main fuse
F2 main fuse
K9/30 cut-off solenoid relay
K7/A start high current relay
M1 starter

M9/1 fuel pump
GND
V1 Blocking diode
R1 glow plug
V1 Blocking diode
Colour
red
red
red
red
red
red
red
red
blk
wht/
red
brn
wht
blu
blk
blu
blu
blu
M9/1 fuel pump

G1/2 alternator
GND
V1 Blocking diode

G1/3 alternator
V1 Blocking diode
blu
blu
brn
brn
wht/blk
wht/blk
gry/red
blu/blk
pnk/blk
blk/blu
blk
blk
blk
blk
blk
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
G1/1 alternator
S2 engine oil pressure switch

1
1
33 S3 engine temperature switch

34 S3 engine temperature switch

35 S4 air filter pressure switch

36 S4 air filter pressure switch
37 B1 fuel level indicator

GND
pnk
wht/
grn
blk/grn
grn/
wht
gry/blu
blk
vio/blk
11
12
13
14
15
16
16
A
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30
A
31
32
Up to
To
mm
10
6
6
4
4
4
6
4
4
4
6
4
1
2.5
1
1
1
No
.
38
38
A
39
40
Up to
To
GND



41 X16/1 drive alarm connection

44 S21.1 high-speed tip switch (prepared)
45 S21.1 high-speed tip switch (prepared)
46 B2 horn
47 X19 socket
48 X19 socket
49 M5 washer pump
50 M5 washer pump
51 XS41/1 safe load indicator
52 XS41/2 safe load indicator
55 S21.1/1 high-speed tip switch (prepared)
56 Y3 high-speed solenoid valve
57 Y3 high-speed solenoid valve
58 Y13 solenoid valve for safety valve
60 GND
61 GND
62 Y15/1 auxiliary hydraulics/swivel
solenoid valve
63 Y15/2 auxiliary hydraulics/swivel
solenoid valve
64 Y16/1 electr. auxiliary hydraulics
solenoid valve
solenoid valve
Colmm
our
blk
1
blk
1
1
1

blk
org/
wht
blu
gry
B2 horn
gry

GND
GND
GND
GND
org
red/blk
blk
blk/wht
blk
vio/blu
blk
grn/yel
blk
brn/blk
1
1.5
1.5
1
1
1
1
1
1
1

GND
1
1
1

M9/2 fuel pump
brn/blk
blk
brn/
wht
blk
blk
blu/yel
1
1
1
GND
blk
gry/yel 1
GND
blk
1
1
No
Up to
.
solenoid valve
solenoid valve
68 S52 air conditioning pressure switch
69 S52 air conditioning pressure switch
70 X2/11 engine/chassis connection
71 Y14/1 changeover valve solenoid
valve
72 Y14/2 changeover valve solenoid
valve
73 GND
79 X15 drive alarm connection
80 GND
Colmm
our
gry/grn 1
GND
blk

Y31 air conditioning solenoid valve
yel/red
yel/red
yel/red
brn/grn
1
1
1
1
GND
blk

blk
1
gry/blk 1
blk
6
To
1
1
1
1
1
Wiring harness 1000109624 (legend): engine chassis
6-24
6.27 Wiring harness 1000109624: engine chassis A3

Electr. AH
valve
Electr. AH
Changeover valve AH/swivel
changeover valve valve
9

9

9

9

8

High-speed
switch
(prepared)
Drive
alarm

3
Horn
Air conditioning pressure

switch
Socket
"
+
8

3
Preheating Cut-off Starting

solenoid relay

Blocking
diode

+
+
+
!

!
&
!

"
!

&
!
+
6

Main fuses

Cut-off
solenoid Preheat

!

Safe load indicator

83
8

Safety valve
High-speed
valve

1000125106
9

Boom working light
9

!
"
8%

"
!

"
"

8

3

"

-
-
-
Starter

Alternator

!

!

3
8
"
Pressure switch Drive alarm Fuel level indicator

hydraulic oil

3


1000124101
Fuel-filling
pump
Fuel pump
'.$

8
Water temperature switch

8

Washer pump
-

9
2

9
3
Cut-off solenoid
Air filter presPreheating sysEngine oil pressure switch Air condi-tem
tioning valve
sure
6-25
6.28 Wiring harness 1000125106 (legend): switches A3
No.
7
7A
15
15 A
19
19A
21
21A
23
31
32
33
34
35
37
40
41
42
42A
43
Up to
44
47
49
51
53
55
58A
59
71
76
78
82
83
84
86
87
88
89
90
91
92
93
94

To
F9 rotating beacon, radio and drive
interlock fuse
Colour
red
6
red
4
blu
1
blu
1
brn
1
brn
1
wht/blk 1
wht/blk 1
gry/red 1
pnk
1
wht/grn 1
blk/grn 1
grn/wht 1
gry/blu 1
vio/blk 1
org/wht 1
blu
1
blu
1
blu
1
red
1
gry
1
red/blk 1.5
blk/wht 1
vio/blu 1
grn/yel 1
brn/blk 1
brn/wht 1
gry
1
brn/grn 1
gry
1
blk
1
yel/red 1
yel/blk 1
yel/blu 1
wht/blk 1
gry
1
gry
1
blu
1
blu
1
blu/wht 1
blu/wht 1
blu/red 1
grn
1
No.
94A
95
96
97
98
98A
99
101
102
103
105
106
107
108
109
110
111
112
113
114
Up to
F5 cab working light fuse
interlock fuse
115 S18/10 rotating beacon switch

116
117
118
119
120
121
122
123
124
125
126
127
128
129

S16/B boom working light switch
F10 socket, cigarette lighter
interlock fuse
To
Colour
grn
1
grn
1
grn
1
grn
1
blu
1
blu
1
grn/red 1
grn/blu 1
red
1

vio
yel
yel
yel
yel
yel/blk
vio/blu
vio/blu
blu
blu
blu
1
1
1
1
1
1
1
1
1
1
1
blu
vio/blu
grn/yel
grn/yel
grn/yel
red/blk
red
1
1
1
1
1.5
1

brn/blu
blk
blk
blk
blk
1
1
1
1
1
blk

blk
blk
1
1
No.
130
131
132
133
134
135
136
137
138
139
Up to
To
Colour
blk
1
blk
1
blk
1
blk
1
blk
1
blk
1
blk
1.5
blk
1.5
blu
2.5
blu
2.5
Wiring harness 1000109630

(legend): switches
6-26
6.29 Wiring harness 1000125106: switches A3
135
134
116
10
109
X
82
X
X
X
X
X
1 107 106 106 105 2
133
134
108
10
84
X
X
109 6
107 10
108
83
133
132
1 95
115 10
116
103
X
102
X
X
X
X
X
131
132
96 96 97 2
101 X
X 99
X X
131
130
97
1 53 117
S20
2
X
X
X
X
129
130
94A
10
5 94 94A
10
S21
X 89 90
49 X
93 91 92
92 X
129
128
90
X
X
5 87 88
X
7 X
X
10
55
X
127
128
88
2
4
6
8
10
S1
Automatic revs setting connection
X14
Indicator connection
Cigarette lighter
19A
Engine temperature connection
138
139
S16
9.
86
E15
X13
19A
S17
X
X
X
X
S18
110
X
51
X
S15
7A
1
3
S51
114
115
126
19
S42
High speed switch
10
127
Ventilation
switch
Safe load indicator

switch
Boom working light

switch
Wiper/washer
Cab working light
switch
switch
SWF: 593.757
Rotating beacon
switch
Air conditioning switch
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
122
71 9
21
47
49
X 10
51
X 11
10
35
19
34
15
33
41
X1
42 1
4 84
135
136
137
82 2
5 59
X3
Main connection
X2
Engine/chassis Engine/chassis
connection
connection
71 1
98A
7 98
98A
103 2
137
78 3
83 3
X6
93 1
X4
91 4
121
101 99 5
78
86
76 6
43 42A 7
5 42 42A
X12
Cab connection
59
58
21 8
15 9
!&
"&
#&
$&
%&
&&
'&
(&
21A 21A 4
15A 15A 5
41
112
114
94
138
95
X
X
58 1
X4.1
Drive interlock
connection
76
44
87
105
139
89
98
43
121
102
7A
120
47
6-27
Indicators, controls, engine and cut-off solenoid holding contact
Warning buzzer
122
123
124
X11
Vario indicator
connection
Boom working light

Cab working light
Valves
6.30 Wiring harness 1000109629: cab roof A3

10
Radio
B12
B11
11
12
A1
13
Loudspeaker
X
X
7
X
X
15
8A
E9
Front roof light
E14
Interior light
E7
Rear roof light
H28
X
X
12
11
5
10
13
3
X
X
8 8A
X
3
Cab connection
5
7
9
2
Rotating beacon
X12
14 15 3
14
GND1
GND2
grn/yel (X12/1)
grn/yel
blu (X12/6)
blu
brn (X12/4)
l 50
M2
Wiper
blk
brn
blk (GND1)
No
Up to
.
1 X12 (1) 9 pole plug and socket
connector cab
connector cab
connector cab
connector cab
connector cab
connector cab
connector cab
connector cab
8A A1.1/4 radio
connector cab
10 A1/6 radio
11 A1/5 radio
12 A1/4 radio
13 A1/3 radio
14 GND1
15 GND1
16 GND1
M2 wiper motor
Colmm
our
grn/yel 0.75
H28 rotating beacon
vio
GND1
blk
M2 wiper motor
brn
0.75
E9 front roof light
M2 wiper motor
grn/
red
blu
0.75
E14 interior light
blu
A1.1/4 radio
red
A1.1/7 radio
E7 rear roof light
red
1
grn/blu 1
B11 loudspeaker
B11 loudspeaker
B12 loudspeaker
B12 loudspeaker
GND2
A1.1/8 radio
M2 wiper motor
wht
wht/blk
wht
wht/blk
blk
blk
blk
To
0.5
0.5
0.5
0.5
1.5
1
0.75
6-28
6.31 Wiring harness 1000109628: armrest A3
Heater fan
M4
84
83
74
75
Air conditioning
thermostat
S54
Safety switch
S28
68
82
76
77
58

5 76
X6
4
X5
81
84
68
6 73 74
5
46
83
82
71
58
66
64
62
Joystick (left)
64
66
62
85
77
75
X8
Armrest/chassis connection
Joystick (right) connection

85
71
46
81
73
X7
No
.
46
58
62
64
66
68
71
73
74
Up to
To
S28 safety switch
M4/2 fan
6-29
Colour mm
org
brn/wht
blu/yel
gry/yel
gry/grn
yel/red
brn/grn
blk
blk
1
1
1
1
1
1
1
1
1
No
.
75
76
77
81
82
83
84
85
Up to
M4/2 fan
S28 safety switch
To
Colour mm

S28 safety switch
M4/1 fan
M4/3 fan
blk
gry
gry
gry
yel/red
yel/blk
yel/blu
gry/blk
1
1
1
1
1
1
1
1
6.32 Wiring harness 1000116138: boom working light A3
XE11
53
54
1
53
54
No
Up to
.
E1
To
Colmm
our
grn/yel 1
blk
1
6-30
Options
Options
7
7.1
Options
Air conditioning
Danger!
Avoid contact with the heat exchanger or the condenser
and the supply lines. Lines and hoses carrying refrigerating agents or coolants can be pressurised and hot.
Danger of burns!
Always empty the system before carrying out maintenance work on the
cooling circuit.
Avoid contact with parts carrying coolant.
Carry out maintenance work with the fan at a standstill only.
Have maintenance and repair work carried out by specialised staff only.
Important!
Make sure the cooling system does not come into contact with chlorine, choric
substances, oil, grease or humidity. Use drain and fill systems for R134a only.
Important!
The air conditioning system runs best by taking in outside air.
see Summer/winter operation on page 1-15
7-1
Options
Diesel engine
Air conditioning unit
Compressor
Dehumidifier
Condenser
Installation: overview
7-2
Options
Components
Heater/air conditioning unit

The air conditioning unit consists of:
Evaporator: This is where the liquid refrigerating agent evaporates, and the air taken in
by the fan is cooled
Expansion valve: Installed in the evaporator and controls the quantity of liquid refrigerating agent injected.
Ice guard: A fixed-setting thermostat with sensors placed between the evaporator fins
prevents them from icing up due to freezing condensation water. The thermostat
switches the evaporator's refrigerating agent supply off at 1.1 C +/-0.8 C and on
again at +2.2 C +/-0.8 C as required.
Heat exchanger
Twin radial fan: Can be controlled in steps and is overload-protected by means of a
temperature microfuse.
Pos.
1
2
3
4
5
Description
Thermostat cable
Fan cable
Expansion valve
Service cover
Intake/outlet direction
7-3
Options
Compressor
The compressor takes in the gaseous refrigerating agent from the evaporator, compresses
it and presses the refrigerating agent into the condenser. The diesel engine drives the
compressor via a V-belt and an electro-magnetic clutch.
Condenser
The condenser condenses the compressed refrigerating agent, i.e. it is delivered to the
condenser in gaseous state and emerges at the lowest position of the condenser in liquid
form.
Fig. 1:
Compressor
Dehumidifier with pressure switch

The dehumidifier consists of a collector with integrated dryer, a sight glass and a pressure
switch.
The dehumidifier serves as an expansion receptacle and tank for the refrigerating agent. It
can bind a small quantity of water chemically, thereby withdrawing it from the circuit.
A sight glass on the dehumidifier enables to check the level of the circuit.
Important!
The cooling system is not working properly if gas bubbles appear in the sight
glass.
Replace the dehumidifier if the sight glass is cloudy or shows traces of corrosion.
Caution!
Fig. 2:
7-4
Dehumidifier with pressure switch
Always keep the dehumidifier closed otherwise the dryer is saturated by the
humidity in the air and is no longer serviceable.
Options
Filling up the air conditioning system
Important!
Always have the air conditioning system filled up by an authorised workshop with
specialised staff.
Only use refrigerating agent R134a according to DIN 8960!
Fill up the system in accordance with the operation manual of the manufacturer
of the fill station.
Fill up the system with enough refrigerating agent. Make sure no bubbles appear
in the sight glass.
Start evacuation
20 minutes min. < 20 mbar
Interrupt evacuation
Check connections
Check for stabile vacuum Pressure gauge
Wait 5 minutes min. rises
or rectify
System is tight
Evacuate for a further 25

minutes min.
Fill in gaseous refrigerating agent to a pressure of

3 bar
Pressure gauge
rises
Check for leakage

System is tight
Fill in required quantity of

refrigerating agent
Caution!
Do not overfill the system.
Overfilling reduces the system's cooling capacity and can cause damage to
the system.
7-5
Options
Maintenance
Important!
Important information for maintenance and repair work:
There may be residual pressure in the system even if it is empty. Release this
pressure with extreme care as you remove the connections.
When working on the cooling circuit, close all openings tightly to prevent
humidity from penetrating into the system.
Do not open the cooling circuit outdoors in humid weather or rain.
Checking the compressor oil

Check the oil level if:
a system component has been replaced

the system leaks oil
the maintenance interval is due see Maintenance plan (overview) on page 3-5
Proceed as follows:
Let the compressor run at idling speed with the diesel engine for 10 minutes.
Open the oil filler opening
Push the oil dipstick into the oil filler opening
Withdraw the oil dipstick from the compressor and read off the oil level at the grooves
Fig. 3:
Oil filler inlet for the air conditioning compressor
on the oil dipstick.
The oil level must reach 5 7 grooves

Fill in oil of the same grade if the oil level is lower
Fresh/recirculated air filter
Tilt the cab to replace the filter see section 1.12 Tilting the cab on page 1-13.
The air conditioning system is located at the rear half of the cab.
Replacing the filter:
Remove the cover between the air conditioning unit and the front air duct
You can now access the inside filter
Remove the inside filter
Insert a new inside heater filter
Fit the cover between the air conditioning unit and the front air duct back on again
7-6
Options
Troubleshooting
Problem
Defective or loose fuse
Check the fuse's seat, insert correctly if necessary. Replace a defective fuse. Trouble
occurring again within short time indicates
there is a short circuit or obstruction in the
system. Check the fan for obstruction or a
defect and rectify the cause.
Line interruption
Check the line for loose contacts or ruptures
Defective fan motor
Replace the fan
Defective fan switch
Check or replace the switch
Short circuit in cable or fan switch
Eliminate the short circuit. Install a new

cable and/or switch if necessary
Contaminated contacts
Clean the pins. Proceed with extreme care

to avoid short circuits.
Heat exchanger heavily contaminated
Clean carefully and avoid damage that could

cause leaks.
Flow temperature too low
Wait for the engine to warm up
Defective thermostat
Replace the thermostat
Heat exchanger fins contaminated
Check and/or clean the heat exchanger
Folded or pinched line
Eliminate the cause for the error and reroute

the hoses
Loose hose connection
Check the seat of the flexible lines and

tighten the clamps
Damaged hose
Mount and connect a new hose
Damaged heat exchanger
Replace the heat exchanger
Loose or torn V-belt
Adjust V-belt tension, replace the V-belt
Interruption in the compressor's solenoid

coil
Check the current to the clutch
V-belt pulley does not turn even though

electro-magnetic clutch is applied
Check and/or replace the compressor
Compressor clutch slips
Repair the clutch or replace the compressor
Fan does not work
Fan cannot be switched off
Reduced fan output
No or insufficient heating output
Coolant leaks from the unit
Compressor does not work
Condenser overflow
Iced condenser
Loss of refrigerating agent
Remedy
Possible causes
Expansion valve is blocked or stuck in open

Replace the expansion valve
position
Thermostat sensor in wrong position
Place the sensor in new position
Defective expansion valve or thermostat
Replace the expansion valve or thermostat
Interruption of refrigerating agent line
Check all lines for external damage or chafing
System leak
Evacuate, fill up, check for leaks and repair
7-7
Options
Problem
Insufficient cooling output
System cools with interruptions
System runs very loudly
Remedy
Possible causes
Fan duct obstructed
Check air intake and outlet for obstruction.

Eliminate the cause for trouble
Refrigerating agent level too low
Fill up refrigerating agent
Humidity in system
Empty the air conditioning system, replace

the dehumidifier, evacuate and fill up
Dehumidifier saturated or clogged
Replace the dehumidifier
Condenser fins contaminated
Clean the fins

Important: No use of high-pressure cleaner
Line interruption
Check, repair and/or replace the lines
Defective fan motor
Replace the fan
Loose or excessively worn V-belt
Retighten or replace the V-belt
Loose compressor bracket or worn inside

parts of the compressor
Repair the bracket, replace the compressor
Excessive wear of fan motor
Replace the fan
System too full
Suck off refrigerating agent
Not enough refrigerating agent in the system
Check for leaks

Fill up the system
7-8
Options
7.2
Air-suspension seat
Ports
The air compressor of the air-suspension seat requires a 12 Volt power supply.
Tension is picked off the plug on the right-hand side joystick X7:
No.
Up to
81 X7/1 joystick (right) connection
Seat +12 V
73 X7/1 joystick (right) connection
Seat earth
7.3
To
Counterweight
Specifications
Counterweight
Model 8003
Weight
400 kg
Additional tail end lateral projection over chains
65 mm
Important!
Bear in mind the lift capacity table when using a counterweight!
7.4
Extended dipper arm
Specifications
Extended dipper arm
Model 8003
Length
2150 mm
Important!
Bear in mind the lift capacity table when using a counterweight!
7-9
Options
7.5
Control circuit (pipework) connections for grab

Connect and disconnect the grab couplings as follows:
Removing the coupling:

Extend bucket cylinder 4/A to the middle
Release the pressure on the bucket cylinder by moving the right-hand side control lever
to the left and right

Turn lock sleeve 4/C towards lock ball 4/B
Pull lock sleeve C upwards
The coupling opens
Connecting the coupling:
B
C
Connect the coupling onto the bucket cylinder connection making sure it is straight
Wait until you hear a hissing sound of the connection
Fully connect the coupling on the connection
Turn back the lock again (away from lock ball B)
Flat-seal couplings (can be coupled under residual pressure)
Fig. 4:
Grab couplings
Plug
ISO designation
12.5
Thread
1/2 BSP
Sleeve
12.5
1/2 BSP
Couplings according to ISO 16028
7.6
3rd control circuit connections
Important!
Follow the operation manual of the implement manufacturer for connecting the 3rd
control circuit to the implement.
Standard connections:
Connection
Standard
Quick coupler option
7-10
Bush
Bulkhead coupling 1/2"
Quick coupler 12.5 1/2"
Options
7.7
Auxiliary hydraulics connections
Important!
Follow the operation manual of the implement manufacturer for connecting the
auxiliary hydraulics to the implement.
Standard connections:
T
U
Fig. 5:
Connections for auxiliary hydraulics
Connection
T
Dipper arm (left)

Pressure line
bulkhead coupling 1/2"
Dipper arm (right)
Pressure line
Unpressurised reflux line (hammer)
U
V
Quick coupler options:

Connection
T
Dipper arm (left)

Pressure line
quick coupler 12.5 1/2"
U
V
Dipper arm (right)
Pressure line
quick coupler 12.5 1/2"
Unpressurised reflux line (hammer)
quick coupler 17 3/4"
Couplings according to ISO 16028
Couplings cannot be coupled under pressure!

Electric auxiliary hydraulics option:
As an option, the auxiliary hydraulics can be controlled electrically via 2 buttons on the joystick on the left
Important!
Follow the operation manual of the implement manufacturer for connecting the
auxiliary hydraulics to the implement.
7-11
Options
7.8
Neuson Vario
Danger!
Lower the excavator arm to the ground when using the Neuson Vario feature,
otherwise
Danger of accidents
Support the machine with the excavator arm when using the Vario feature
Using the Neuson Vario feature
The following steps must be followed under all circumstances when changing the eccentric
position
Brace excavator arm 6/A on the ground with the boom cylinder.
To unlock the Neuson Vario feature, press and hold both front switches on the left-hand
side 6/B and right-hand side 6/C joystick.
A
Press and hold both buttons B and C about 5 seconds without moving the joysticks to
unlock.
The Neuson Vario feature has four lock positions at offset positions of 90 each (0/360,
90, 180, 270).
Press the left-hand side joystick D to the left or right for a 90 rotation, press and hold
B
Fig. 6:
buttons B and C as you do so.

C
Using the Neuson Vario feature
Both buttons B and C can be released once the excavator has moved.
The Neuson Vario feature automatically engages after a 90 rotation.
If repositioning beyond 90 is required with the Neuson Vario feature, press buttons B
and C beyond the 90 lock position.
As soon as buttons B and C are released, the Neuson Vario feature engages in the
next possible lock position.
Important!
Always check whether the lock position is engaged!
For improved driving features on slopes, reposition the centre of gravity towards the slope
with the Neuson Vario feature.
7-12
Options
Vario diagram
G
B8
"
PR
"

Fig. 7:
PBAR
02
Neuson Vario valve
Description
B8
B
A
T
PR
E
F
G
Function
Description
Boom rod side port
Lock cylinder rod side port
Lock cylinder base side port
Tank line port
Pilot control pressure port
Solenoid valve
Solenoid valve
Lock cylinder
Opening the lock
Brace the excavator arm on the ground with the boom ->
Pressure is applied to boom cylinder rod side port B8
Press buttons B and C on the joysticks on either side

Solenoid valves E and F are enabled -> pressure from B8 to B
Pressure is applied to lock cylinder rod side port
Lock cylinder base side port is switched to tank
The lock opens
Locking
Release buttons B and C

Solenoid valves return to initial position -> pressure is interrupted
Pilot control pressure is applied to lock cylinder base side port A
Lock cylinder rod side port B is switched to tank
Keep on rotating the upper carriage

Lock cylinder engages in the next possible lock position
7-13
Options
Neuson Vario warning device
Danger!
Do not bypass the warning device or make it inoperative. Working with the
excavator is only allowed with a fully functional warning light.
Caution, danger!
This safety feature must be checked by an authorised workshop every time
maintenance is carried out.
The warning light features a functional check. The warning light comes on
briefly every time the machine is started. Always make sure the warning
light is fully functional
Depending on the position of the Vario feature, stability is higher or lower with respect to a
standard excavator. Observe the lift capacity table and the warning ranges in Fig. 8.
Warning ranges:
A
Lengthwise excavation
Reduced stability
Upper carriage not in proper range with

respect to Vario feature, no modification of
stability (hydraulically limited)
Warning range A
danger of tilting!
Fig. 8:
7-14
Crosswise excavation
Warning range B
Warning range A
danger of tilting!
Warning range
Options
Danger!
The machine can tilt if the boom is not lowered and swivelled out of the area of
danger as soon as the alarm is given (warning sound, warning light A), or if the
alarm is ignored
Brake the upper carriage and rotate it in the other direction.
Fig. 9:
The warning device is set to 73 % of the static tilt load in an unfavourable position of the
upper carriage. As soon as the load is exceeded and work is carried in an unfavourable
position of the upper carriage (warning range), or if the upper carriage is rotated into the
warning range, the warning sounds briefly and warning light A comes on.
Warning light
Ports
"

WH
BN
BL
BK
!
!
+
8

!

!
+
"
"

BL

BK

BN

!

!

!
!

"
"
9

"
6
!
!
(

9
!
!
8
8
No.
1
2
2A
2b3
3
3A
4
4A
4b
6
6A
7
7A
8
From
X14 supply port
X14 supply port
Y19 Vario solenoid valve
X14 supply port
B13 proximity switch
K14 Vario time lag relay
B13 Vario proximity switch
K15 Vario switching relay
X6/1 armrest connection
H32 Vario telltale
S1 start switch
Via
B13 proximity switch
Up to
Y19.1 Vario solenoid valve
H32 Vario telltale
X2/6 pressure switch port
B16 Vario buzzer
Y19.1 Vario solenoid valve
B16 Vario buzzer
Colour
blu
blk
blk
blk
yel
yel
vio
vio
vio
brn
brn
gry
gry
7-15
Options
7.9
Fuel-filling pump
Refuel with the fuel-filling pump 10/A as follows:
Place the machine on level ground

Insert the hose of fuel-filling pump A into the container with the fuel see Stationary
B
A
fuel pumps on page 3-10
Press button B to switch on fuel-filling pump 10/A

The fuel tank is full as soon as telltale 10/C comes on
Press button B to switch off fuel-filling pump A
Important!
Fig. 10: Fuel-filling pump
Switch off the fuel-filling pump as soon as telltale C comes on, otherwise the fuel
tank may overflow and can be damaged.
C
Bear in mind the fuel tank's maximum capacity
Fig. 11: Fuel-filling pump telltale
The float switch screwed into the fuel tank triggers the telltale.
Fig. 12: Float switch
7-16
Options
Connections
The electric connection for the fuel-filling pump is already installed.

The telltale has its own wiring harness, connected to the engine/chassis wiring harness by
means of plug X16.
;

;

6
No.
Up to
38 XE16/2 drive alarm connection

41 XE16/1 drive alarm connection
100 X17 float switch
To
X17 float switch
S60/1 telltale
S60/2 telltale
Colmm
our
blk
1
blu
1
vio
1
7-17
Options
7.10 Central lubrication system
Grease-based central lubrication system with 12 lubrication points
Position
The electric pump for the central lubrication system is installed over the hydraulic pump.
The electric pump presses the grease through the lubrication line towards the distributing
block on the boom.
From the distributing block, the grease passes on to the lubrication points.
Fig. 13: Central lubrication system pump
Connections
1
2
3
4
5

Pos.
1
2
3
4
5
7-18
Description
Earth (brown)
+ Intermediate lubrication tip switch connection (orange)
+ Ignition (black)
Error telltale (red)
+ Lubrication telltale (green)
Options
Function
Pos.
Description
1
2
3
4
Push button on motor housing

Red LED
Green LED
Break time potentiometer
Cycle time potentiometer
The green LED comes on for about 1.5 sec once ignition is switched on to indicate
readiness.
Pressing the push button on the pump's motor housing switches on the pump and starts
the lubrication cycle. The pump drive motor is switched off and cycle time begins once
lubrication time is over.
All further lubrications start automatically according to the cycle time set.
Lubrication time is stopped and saved if ignition or lubrication is switched off during cycle
time. The data is read from the memory upon switching ignition on again, and lubrication is
resumed where it was interrupted.
Pressing the push button on the motor housing or on the instrument panel starts intermediate lubrication at any give time if ignition is switched on.
Fig. 14: Central lubrication system push button
Status LEDs
Indication
Meaning
Green LED 1.5 sec
Ignition on (operational readiness)
Steady green light
Comes on during lubrication
Steady red light
Grease level error

Remains lit until grease tank is refilled
Blinking red light
Overpressure error
7-19
Options
Adjusting breaks and lubrication
times
Adjust breaks and lubrication times with potentiometers.

Lubrication time
1min to 16 min
1
Break
0.5 h to 8 h
0.5
16
Repair in case of clogging

Clogging indication
Overpressure beyond service pressure means the system is clogged and is indicated as
follows:
Grease escapes by the pressure relief valve

Blinking red LED on the pump housing
Causes for clogging in the system
Crushed or clogged lubrication line

Bearing overfilled or clogged with lubricant
Inadequate lubricant for central lubrication systems
Clogged distributor output
Clogged distributor
Detecting clogging
Unscrew the main line off the main distributor

Actuate the pump with the push button and check whether the lubricant is delivered
correctly
Screw the main line onto the main distributor

Unscrew the lines one after an other and actuate the pump every time
Repairing a clogged distributor
Remove the distributor from the system

Unscrew the screw plugs of the piston bore
Move the piston back and forth (do not remove)
Screw the screw plugs back in again
You can remove the piston of the defective distributor and check it for scratches or damage.
If there are traces of hardened grease on the piston or the bores,
remove the grease with compressed air or by washing the piston.
7-20
Options
Important!
Traces of hardened grease are a sign that the grease is not suitable for central
lubrication systems
Problem
Pump does not work
Pump works but does not supply grease
No grease rims on all lubrication points
Defective integrated electronic controls
Replace the controls and the cap
Electric line interrupted
Replace the electric line
Defective pump
Replace the pump
Air inclusions in piston
Vent the pump
Level too low
Fill up the tank
Defective pump element
Replace the pump element
Pump does not work
See Pump does not work
Breaks too long or lubrication time too short Shorten breaks or increase lubrication time
System clogged
No grease rims on some lubrication points
No grease rim on one lubrication point
Reduced pump revs
Grease escapes by the pressure relief valve
Remedy
Possible causes
See Grease escapes by the pressure relief

valve
Burst or leaky supply lines to secondary disReplace the lines

tributor
Leaky screw connections
Retighten or replace the screw connections
Burst or leaky lubrication line to lubrication

point
Replace the line
Leaky screw connections
Retighten or replace the screw connections
High system pressure
Check system bearings
Low ambient temperatures
No damage (intermediate lubrication once

or twice if necessary)
System pressure too high
Detect and eliminate clogging
System pressure too high
Detect and eliminate clogging
Clogged distributor
Replace the distributor
Clogged system
Repair clogged/stuck bearings
Defective valve spring
Replace the pressure relief valve
7-21
Options
7.11 Safe load indicator D (safety valve for boom)
Position
6
5
3
4
Pos.
1
2
3
4
5
6
Function
Description
Boom segment pilot control port
Joystick connection
Boom pressure line port
Hose burst valve
Pressure switch
Leak oil strip port
The valve is mounted direct on the base-side port of the boom cylinder.
Extend cylinder function:
Cylinder can be extended as usual (always free flow towards the cylinder)
The built-in non-return valve safely holds the load in rest position.
Retract cylinder function:
7-22
Options
Pilot control pressure moves valve (CT2) to work position (free oil reflux from the base
side)
The valve moves back to home position if the pilot control pressure drops
In addition, a safety valve (CT1) protects the hydraulic cylinder from overload.
Important!
The valve settings are sealed
Diagram
"
!
%
&7
&7
&7
4
0B
&7
!
7-23
Options
7.12 Safe load indicator F (safety valves for boom and dipper arm)
Position
3
4
9
7
Pos.
1
2
3
4
5
6
7
8
9
7-24
Description
Boom segment pilot control port
Dipper arm segment pilot control connection
Joystick connection
Joystick connection
Dipper arm pressure line port
Leak oil strip port
Pressure switch
Hose burst valve
Boom pressure line port
Options
Function
One valve is mounted direct on the base-side port of the boom cylinder, the other valve is
mounted on the rod-side port of the dipper arm cylinder.
Extend boom cylinder function:
Cylinder can be extended as usual (always free flow towards the cylinder)
Retract boom cylinder function:
Pilot control pressure moves valve (CT2) to work position (free oil reflux from the base
side)
Retract dipper arm cylinder function:
Cylinder can be retracted as usual (always free flow from the cylinder)
Extend dipper arm cylinder function:
Pilot control pressure moves valve (CT2) to work position (free oil flow to the base side)
In addition, a safety valve (CT1) protects the hydraulic cylinder from overload.
Important!
The valve settings are sealed
7-25
Options
Diagram
"
"
!
!
%
&7
&7
&7
&7
&7
0B
&7
&7
4
0B
&7
!
7-26
Options
7.13 Drive interlock (antitheft protection)
Position
2
Pos.
1
1
2
Description
Transponder receiver surface
Red LED
Fig. 15: Drive interlock
Disabling the drive interlock
Approach the transponder to 2 cm to the transponder receiver surface

The red LED goes out
Insert the ignition key into the ignition lock within 30 seconds and turn it at least to position 1
The drive interlock remains disabled

Enabling the drive interlock
Remove or turn the ignition key to position 0

The drive interlock is enabled after 30 seconds
The blinking red LED indicates the drive interlock is enabled
Programming
Coding transponder keys

The so-called main or master key is required for coding a new or uncoded key, or a key
with different coding, for the drive interlock.
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45
see Disabling the drive interlock on page 7-27
The LED changes to steady green light

The system is in programming mode now (coding mode)!
Remove the master key from the transponder receiver surface
The LED changes to rapidly blinking green light
Hold the key to be programmed against the transponder receiver surface
The key is coded once the LED comes on slowly three times
Hold further keys next to the transponder receiver surface to code them as mentioned
above
The drive interlock is enabled as soon as there is no key contact for 30 seconds.
Blinking red light
7-27
Options
Deleting programming/coding
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45
see Disabling the drive interlock on page 7-27
The LED changes to steady green light

The system is in programming mode now (coding mode)!
Hold the master key against the transponder receiver surface for a further 30 seconds
The LED changes to steady red light
The system is in delete mode now (coding mode)!
Remove the master key
The LED changes to rapidly blinking red light
You have 30 seconds to hold the master key again to the transponder receiver surface
to confirm deletion.
The system is deleted once the LED comes on slowly three times
Caution!
Deletion deletes all normal transponders and the master!
Reason: Once a key is lost, you can no longer delete it!
Therefore, the entire system is deleted for safety reasons and can be
completely recoded with the remaining (or newly ordered) keys.
Configuration of the deleted system

Once deletion is over, the system recognises any TREBE transponder key, i.e. the system
can be disabled with any key.
The first transponder key to be recoded for the system is automatically the new master and
can be used for coding the normal transponder keys. see Programming on page 7-27
Important!
The following applies both to the coding and programming mode: The system
leaves the coding and programming modes and is disabled as soon as the ignition
key is inserted in the ignition lock and turned to the first position.
7-28
Options
7.14 Quickhitch facility
M
Danger!
The implement must always be safely locked onto the quickhitch facility
Before starting work, make sure the implement is securely locked onto the
quickhitch facility by means of the lock mechanism. You must be able to

see the lock on either side of the mounting bore of the implement.
Re-equip as follows:
Approach the machine to the implement
Hitch coupling bar M onto coupling claws L of the quickhitch to pick up the bucket
Engage lock mechanism N in mounting bores O
Place the bucket on level ground
N
P
O
Fig. 16: Bucket with quickhitch facility
Lock as follows:
S

Insert tube P (included in scope of delivery) in clamping sleeve Q
Press the tube downwards
The lock pins must be in position R
Insert the spring plug in fixture T to lock the quickhitch facility
Caution!
Always make sure the spring plug is inserted correctly
R
Unlock as follows:
Remove the spring plug from fixture T
Insert tube P (included in scope of delivery) in clamping sleeve Q
Press the tube upwards
The lock pins must be in position S
T
Fig. 17: Bucket with quickhitch facility
7-29
Options
7-30
NK Lifton Limited
Station Road Ind Park
Brompton-on-Swale
Richmond, North Yorkshire, DL 107 SN
United Kingdom
Phone (+44) 1748 81 06 66
Fax (+44) 1748 81 07 77
e-Mail enquiries@kramer.uk.com
www.nklifton.com
NeusonKramerFrance SA
43, rue du Landy - 93211 Saint Denis
Laplaine cedex
tl +33 (0) 141624162
fax +33 (0) 141624165
e-mail info@neusonkramerfrance.fr
www.neusonkramerfrance.fr
Neuson Baumaschinen GmbH

Haidfeldstrasse 37
A-4060 Linz / Leonding
Telefon +43 (0) 732 / 90590-0
Fax +43 (0) 732 / 90590-0
e-Mail office@neuson.com
www.neusonkramer.com

Service Manual 8003 Eng.

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Service Manual

Spare parts list

Copyright 2004 Neuson Baumaschinen GmbH, Linz-Leonding

Neuson Baumaschinen GmbH

Checking the coolant level ............................................................................... 3-19

SERV-HB 8003 En - Ausgabe 1.0 * *8003s11IVZ.fm

Ohm's Law (current, voltage, resistance); power ..................................................... 6-1

SERV-HB 8003 En - Ausgabe 1.0 *8003s11IVZ.fm

SERV-HB 8003 En - Ausgabe 1.0 * *8003s11IVZ.fm

This symbol stands for a list

This symbol requires you to carry out the activity described

SERV-HB 8003 En Edition 1.0 *8003s110.fm

Identification of warnings and dangers

Measures for avoiding danger

Measures for avoiding danger for the machine

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

Designated use and exemption from liability

SERV-HB 8003 En Edition 1.0 *8003s110.fm

Type labels and component numbers

Type label: location

Max. gross mass:

Max. axle load:

Other information see section 2 Specifications on page 2-1

Cab type label

Diesel engine number

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

Hydraulic pump number

Hydraulic pump type label

Main valve block number

Travelling drive type label

Travelling drive number

Travelling drive type label

Swivel unit number

Swivel unit type label

SERV-HB 8003 En Edition 1.0 *8003s110.fm

Steel chains (option)

Tank filler inlet

Device for counterweight (option)

Machine outside views

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

SERV-HB 8003 En Edition 1.0 *8003s110.fm

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

Instrument panel: overview

SERV-HB 8003 En Edition 1.0 *8003s110.fm

Instrument panel: legend

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

1.10 Engine compartment: overview

For more information see page

SERV-HB 8003 En Edition 1.0 *8003s110.fm

1.11 Chassis: overview

For more information see page

Shuttle valve block ................................................................................................................................................................................. 5-31

Counterbalance valve............................................................................................................................................................................. 5-30

SERV-HB 8003 En Edition 1.0 * *8003s110.fm

1.12 Tilting the cab

Always close the door

Switch off the engine

SERV-HB 8003 En Edition 1.0 *8003s110.fm

Tilting the cab

Insert tube D onto guide pin E and pump as far as it will go

Tilting the cab down:

Remove the split pin from guide L

Replace defective parts immediately