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Documentation
Description
Order no.
Operation manual1000113719
Service manual1000164081
Spare parts list1000142134
Legend
Edition Issued
1.003 / 2006
Copyright – 2006 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:SERV-HB 9001 En Order no.:1000164081
Edition:1.0
Inhaltsverzeichnis
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1Operation
1.1Important 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 operators, but it also serves as a reference for experienced ones. 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.
Careful and prudent working is the best way to avoid 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.
will be pleased to answer any further questions regarding the machine or the service manual.
Your Neuson dealer.
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.
1.2Identification 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.
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1.4Type labels and component numbers
Serial number
The serial number is stamped on the machine chassis next to the right-hand side front tyre. It is also located on the type label. The type label is located on the engine cover.
Type label information
Model:9001
Year:2004
PIN:BB 000000
Output:74.5 kW
Mass:4750 kg
Load:9000 kg
Max. gross mass:---------------
Max. axle load:
Other information –seechapter2 Technische Daten on page2-1
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
Example: Perkins 1104C-44T
Number of torque converter gearbox
The type label (arrow) is located on the changeover (forwards/reverse) valve base, behind the valve.
Fig. 1:Type label: location
Fig. 2:Type label
Fig. 3:Diesel engine number
Fig. 4:Number of torque converter gearbox
Spool number
The type label (arrow) is located on the spool housing
Rollbar number
The type label is located on the rollbar
Axle number
The type label (arrow) is located on the upper side of the axle housing.
Fig. 5:Hydraulic pump type label
Fig. 6:Rollbar type label
Fig. 7:Axle type label
1.5Machine: overview
Assembly designation 9001
8:Machine outside views
Machine overview: legend
1Rear chassis9Tilt ram
2Front chassis10Steering ram
3King link11Rollbar
4Seat
5Control stand
6Mudguard
7Engine cover
8Skip
Fig.
1.6Operating equipment: overview
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Operation
1.7Maintenance prop
1.8Centre pivot prop
Danger!
Fold down the red maintenance prop before you carry out maintenance work with a raised skip.
The maintenance prop shows downwards vertically and is automatically positioned on support C in case the skip should be lowered.
Procedure to follow:
☞ Remove the spring plug from pin B
☞ Fold down maintenance prop A
☞ Lower the skip until pin B fits into the bore of support C and maintenance prop A
☞ Secure by inserting spring plug through pin B
Important!
Fasten the maintenance prop on the skip again (in the reverse order) once maintenance work is over.
Danger!
Secure the steering ram with the red centre pivot prop when crane handling the machine.
The centre pivot prop secures the steering ram to prevent steering movements (via the articulated joint) when crane handling the dumper.
Procedure to follow:
☞ Remove the spring plug from pin B
☞ Rotate centre pivot prop A towards rear chassis C
☞ Secure centre pivot prop A with the spring plug on pin B
Important!
Before taking the machine into service again, mount the centre pivot prop back onto the front chassis again by means of pin B
Fig. 9:Maintenance prop
Fig. 10:Centre pivot prop
Fig. 11:Centre pivot prop
Fig. 12:Centre pivot prop
2Specifications
2.1Chassis
2.2Engine
Sturdy steel sheet chassis, rubber-mounted engine
Engine
Model 9001
ProductPerkins diesel engine
Model1104 C-44 T
DesignWater-cooled 4 stroke diesel engine
No. of cylinders4
Fuel injection systemDirect injection
AspirationTurbocharger
Cooling systemWater-cooled
Lubrication systemForce-feed lubrication with trochoidal pump
Displacement4400 cm³
Nominal bore and stroke105 x 127 mm
Output74.5 kW +/- 5% @ 2200 rpm
Max. torque415 Nm @ 1350 rpm
Max. engine speed without load2330 rpm +/- 25 rpm
Idling speed1000 rpm +/- 25 rpm
Valve tip clearance (intake/outlet)0.2/0.45 mm
Injection pressure290 +8/-0 bar
Compression21 – 35 kgf/cm²
Engine oil pressure1
Pressure switch for engine oil pump0.6 +/- 0.15 bar
Thermostat opening temperature79 °C (beginning), 93 °C (fully open)
Thermal switch 110 °C +/- 3 °C
Firing order1 – 3 – 4 – 2 – 1 (1st cylinder on fan side)
Direction of rotation
1.At operating temperature and maximum revs 3.0 kgf/cm²
Counterclockwise (as seen from the flywheel)
Starting aidGlow plugs
Max. inclined position (engine still supplied with oil): 35° in all directions
Exhaust values according to 97/68/EC tier 2
EPA tier 2, ECE R24
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Engine capacities
Capacities
Model 9001
Engine tightening torques
Overview of capacities: –see Betriebs- und Schmierstoffe on page3-1
Tightening torques
Cylinder-head bolt 1st pass 2nd pass
Model 9001
50 Nm
100 Nm+ 225 ° (short screws) or 270° (long screws)
Connecting rod bearing screw70 Nm + 120°
Main bearing screw245 Nm
Flywheel screw115 Nm
2.3Travelling drive
Torque converter gearbox
Model
Design
Model 9001
ITL SS620
2WD torque converter gearbox with electrohydraulic control
Shift Manual
Speeds 4 forwards and reverse
Transmission ratio Up to 6.55:1
Transfer gearbox
Model
Cardan shafts
Flange type
2.4Brakes
Service brake/handbrake
Design
DANA 1480 Yoke
Model 9001
Hydraulic pedal-operated wet dual-circuit brake
Location Brake discs in either axle
Effect
Additional brake effect on rear axle via cardan shaft, handbrake effect on front axle
2.9Electric system
Fuse box
Relays
system
Alternator12 V 40 A Starter12 V 1.4 kW Battery12 V 105 Ah
Fuse number Rated current (A) Protected circuit
110 A– Hazard warning system 30
27.5 A– Clearance lights, numberplate lights
310 A– Low beam
410 A– High beam
5– Not assigned
67.5 A– Drive, handbrake
710 A– Fuel injection pump
8– Not assigned
9– Not assigned
1010.5 A3– Horn
1110 A – Turn indicators, telltale, fuel level indicator + safety relay
The relays are located in the relay box under the the floor panel of the dashboard
Switching
F 1– Main fuse
F 2– Main fuse
K 6– Preheating HC01 19
K 7– Safety relay
K 7.1– Start interlock
K 8– Cutoff solenoid
K 9– Cutoff solenoid, pick-up contact
K 10– Turn indicator relay
K 29– Low-speed telltale D1 – Diode box
Fig. 1:Fuse box
Fig. 2:Relays
2.10Tyres
2.11Noise levels
2.12Coolant compound table
Important!
Measurement of sound power level according to EC Directive 2000/14 EC. Noise level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/EEC and 95/27/EEC.
Measurements carried out on asphalted surface.
2.13General tightening torques
Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)
Nominal ø Outer ø Thread Width across flats Tightening torque
056LM12X1.5W/F 1415 Nm
068LM14X1.5W/F 1720 Nm
0810LM16X1.5W/F 1940 Nm
1012LM18X1.5W/F 2250 Nm
1215LM22X1.5W/F 2775 Nm
1618LM26X1.5W/F 3285 Nm
2022LM30X2W/F 36100 Nm
2528LM36X2W/F 41180 Nm
3235LM45X2W/F 55220 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)
Nominal ø Outer ø Thread Width across flats Tightening torque
058SM16X1.5W/F 1940 Nm
0610SM18X1.5W/F 2250 Nm
0812SM20X1.5W/F 2460 Nm
1014SM22X1.5W/F 2775 Nm
1216SM24X1.5W/F 3090 Nm
1620SM30X2W/F 36100 Nm
2025SM36X2W/F 41180 Nm
2530SM42X2W/F 50270 Nm
3238SM52X2W/F 60400 Nm
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 %
Values determined empirically and to be applied as approximate figures.
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