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SERVICE MANUAL NEUSON WHEELED EXCAVATOR

6502

Edition: Id.No.:

February 03 9707750

GB

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TABLE OF CONTENT : Chapter O Table of content Product history

Page

A 1 2 3 4 5

Technical Data Primary dimensions Lift capacity charts Hydraulic settings Diesel engine settings Tightening torques

.......................................................... .......................................................... .......................................................... .......................................................... ..........................................................

A2 A7 A12 A14 A16

B 1 2 3 4 5 6 7 8 9 10 11

Maintenance Maintenance schedule ..........................................................

Lubricants ..........................................................

Lubrication chart ..........................................................

Hydraulic system check ..........................................................

Hydraulic pump ..........................................................

Steering unit ..........................................................

Hose burst protection valve ......................................................

Undercarriage ..........................................................

Swivel unit ..........................................................

Diesel engine ..........................................................

Hydraulic oil tank ..........................................................

B2 B6 B8 B9 B18 B19 B19 B20 B25 B26 B37

C 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Hydraulic Hydraulic system diagram ......................................................

Position of components ..........................................................

Hydraulic pump ..........................................................

Pilot oil supply unit ..........................................................

Main valve block ..........................................................

Pilot control valves ..........................................................

Swivel unit ..........................................................

Shuttle valve block ..........................................................

Undercarriage ..........................................................

Driving motor ..........................................................

Floating axle valve ..........................................................

Steering unit ..........................................................

Priority valve .......................................................... C55 Accumulator loading valve ................................................

C2 C4 C7 C11 C17 C31 C36 C44 C45 C47 C52 C54 C56

C 15 16 17 18 D E F G

Hydraulic Directional control valves - way valve ......................................

Swivel joint ..........................................................

Switch valve ..........................................................

Oil tank ..........................................................

Diesel engine Elektric Major components Attachment

Abbreviation: AP ...

MP ...

PPLV ...

SPLV ...

TT ...

Pb1 ...

Adjustment point Measuring point Primary - Pressure limiting valve Secundary - Pressure limiting valve (shock valve) Tightening torque Position of the port shown at the hydraulic diagram

Edition February 2003, Copyright Neuson Baumaschinen GmbH Neuson reserves changes.

C57 C58 C60 C62

PRODUCT HISTORY This overall lists the main technical modifications of the excavator type Neuson 6502 Step

Version

.

Excavator code

Fabr.No.:

Modification / Part group

6502 WD

0000708/1998 AA03159 AA03902 AA04551 AB00473

Fabrication started Swivel joint bracket mod. (SNews 24/00) Drain position DDF (SNews 30/00) Boom cylinder Dm110 (SNews 46/01) Cabin covers Cabin colour (RAL7040grau) Joystick console long(III) Sticker design Elektric wiring version „AB“-long joyst.co Oil supply unit (Wechselventile) Maintenance interval extension poss.

Swivel unit - gear box hydr. oil lubricated Modification solenoid stop bracket (SNews 68/02) Joystick console short (IV) Electric wiring for joystick console IV Position of the instrument panels

6502„AB“

AB00865 (SNews 71/02) AB01533 AB01647 AB01952

SERVICE MANUAL

Technical data

6502

CHAPTER A:

Technical data ( Neuson Service Manual 6502 )

Page A1

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Pict.: Primary dimensions 6502

Page A2

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502 1.

DIMENSIONS

Unit > > Starting with Fabr. No.

6502 0000708/ 98

6502 Triple boom

Option

Dimensions ( H x W x L )

mm

Axle distance

mm

2100 / F

Transport length

mm

5705

degr

80 / 45

80 / 45

Boom swing angle

Left / right

Front boom swing radius

min

Tilt angle uppercarriage Ground clearance

max

Undercarriage width

2740 / 1920 / 3800 2740 / 1920 /3800

2100 / F

mm

1920

1920

degr

N

N

mm

270

270

mm

1920 / 2005 (ZR)

1920 / 2005 (ZR)

Track width

Standard

mm

N

N

Max. Dump height

Standard

mm

4395

5050

Max. Dump height / Option

Dipperstick long

mm

4595

5300

Max. Dig height

Standard

mm

5880

6760

Max. Dig height / Option

Dipperstick long

mm

6080

7000

Max. Dig radius

Standard

mm

6160

6550

Max. Dig radius / Option

Dipperstick long

mm

6460

6850

Max. dig depth

Standard

mm

3560

3645

Max. dig depth / Option

Dipperstick long

mm

3860

3955

Min. tail swing radius

mm

1590

1590

Dozer blade dimensions ( W x H ) Standard

mm

1945 / 400

1945 /400

Dozer blade dimensions ( W x H ) Extension

mm

N

N

Dozer blade max. lift ... Ground

above / below

mm

460 / 285

460 285

Dipperstick length

Standard

mm

1650

1650

Dipperstick "long "

Option

mm

1950

1950

Track rollers / guide rollers

per side

pcs

N

N

Operation weight with

Cab

kg

5970

6180

Operation weight with

Canopy

kg

N

N

Ground pressure

Standard

k g/cm²

Ground pressure

Option

k g/cm²

Explaination: O... Option N... No / Not F... Missing information

Page A3

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Unit > > S tarting with Fab r. No. Gradability

6502

6502

Triple boom

0000708/ 98

Option

98

98

degr / %

Noise level

LWA

dB (A)

Noise level

LPA

dB (A)

75

75

Travel speed

Drive

k m/h

7 / 20

7 / 20

Tear out force per

Buck et tooth

kp

3672

3672

9

9

Max. dipper stick tear out force

Standard

kp

Slew ( swivel- ) speed

Uppercarriage

rpm

Tractive effort

Undercarriage

kg

Steering system

Hydr.Servo steering

Front floating axle

Steer swinging axle

Rear fixed axle

Fixed

Axle swing angle

degr

Turning angle

degr

8

8

36

36

Tyre size

Single tyres

12 - 16,5

12 - 16,5

Tyre size

Twin tyres

7,50R 15

7,50R 15

Turning radius

mm

5300

5300

Wheel spacing

mm

1600

1600

Explaination: O... Option N... No / Not F... Missing information

Page A4

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

KINEMATIC

2.

Kinematik

Unit

5002

6002

6502

8002

12002

Bolt diameter

mm

50

50

55

60

F

Dipper stick width

mm

195

195

170

220

L

Bolt distance Buck et carrier

mm

236

236

300

445

E

Page A5

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Kinematic - overall

Kinematic

Unit

1200 - 1501 RD 1302 - 1502 RD

1702 - 2201 RD 1702 - 2202 RD

2100 - 2700 RD

30

E

Bolt diameter

mm

F

Dipper stick width

mm

108

32

L

Bolt distance Buck et carrier

mm

108

268

129,5

Unit

2600 - 2800 RD 2702 - 2902 RD

3000 - 3200 RD 3402 - 3602 RD

3800 WD 3802 WD

118

5000,5001 RD 5501 WD

E

Bolt diameter

mm

40

50

F

Dipper stick width

mm

140

195

L

Bolt distance Buck et carrier

mm

155,5

236

Unit

1403

1503

E

Bolt diameter

mm

32

F

Dipper stick width

mm

118

L

Bolt distance Buck et carrier

mm

129,5

Unit

2503

3003

1903

2203

3503

3703

E

Bolt diameter

mm

32

40

F

Dipper stick width

mm

118

140

L

Bolt distance Buck et carrier

mm

129,5

180

Unit

5002

6002

6502

8002

12002

Bolt diameter

mm

50

50

55

60

F

Dipper stick width

mm

195

195

170

220

L

Bolt distance Buck et carrier

mm

236

236

300

445

E

Page A6

Id.No.: Edition:

9707750 Feb 03

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SERVICE MANUAL

Technical data

6502 3.

LIFT CAPACITY CHARTS Max ..................................................................... admissible load with dipper stick straight A .........................................................................................projection from live ring centre B ......................................................................................................... height of lifting hook * ........................................................................... lifting power limited by hydraulic system All values of the table are specified in kg, in horizontal position on solid subsoil and without bucket. .... with dozer blade supported, in travelling direction ... without dozer blade supported, 90° to travelling direction ... without dozer blade supported, 90° to travelling direction superstructure shifted backward by means of option VARIO ... without dozer blade supported, 90° to travelling direction superstructure shifted forward by means of option VARIO If a bucket or other working facilities are installed, the lifting power or tilting load is reduced by the empty weight of such facilities.

Position on solid subsoil and without bucket.

Design fundamentals: acc. to ISO 10567 The lifting power of the compact excavator is limited by the setting of the pressure control valves and the stabilizer system. Neither 75% of the static tilting load nor 87% of the hydraulic lifting power are exceeded.

WARNING! The Vario system deviates form ISO 10567 in some excavator positions. Other than specified by standard ISO 10567 any exceeding of the tilting load is announced by means of a warning device.

Page A7

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity chart - 6502,boom cylinder 5108103 (D=100mm) , single tyres

Page A8

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, boom cylinder 5108203 (D= 110), Single tyres

Page A9

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: LIft capacity chart - 6502,boom cylinder 5108103 (D=100) , twin tyres

Page A10

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, Boom cylinder 5108203 (D= 110mm), Twin tyres

Page A11

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, triple boom, boom cyl. 5108103 (D=100) , single tyres

Page A12

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, Triple boom , boom cylinder 5108203 (D=110), Single tyres

Page A13

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, triple boom, boom cyl. 5108103 (D=100), twin tyres

Page A14

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Tab.: Lift capacity - 6502, Triple boom , boom cylinder 5108203 (D=110mm), Twin tyres

Page A15

Id.No.: Edition:

9707750 Feb 03

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SERVICE MANUAL

Technical data CYCLE COURSES

Neuson 6502

Machine model Classification

Item

Check conditions

Unit

Value normal

allow ed

Max. extension of the equipment, w ithout load

Braking angle

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Mark the outer rings of the thrust bearings w ith centering notches. Make the upper frame rotate of 360° and then release the hand grip. Measure the distance betw een the notches after the stop.

degrees

---

Max. extension of the equipment, w ithout load

Time required to start the rotation UPPER FRAME ROTATION

4.

6502

---

90°

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required for 90° and 180° rotations after the control has been operated.

180°

Max. extension of the equipment, w ithout load

---

sec.

Time required for the rotation

--> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required to perform 5 turns after a first settling turn.

Position for the check

Sw ing gearmotor > Engine off hydraulic drift > Hydraulic oil temperature: 45 - 55 °C > Stop the machine on a 15° plane w ith the boom at 45° w ith respect to the axis of the track frame. > Mark the position betw een the upper and track frame on the thrust bearing. > Measure the shift after 15 minutes. > Max. outreach > Weight in the bucket:

degrees

Hue 1 / 5

Page A16

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Cycle courses - excavators

Hueman / 25. April 03

Neuson 6502

Machine model

Upper frame rotation

Classification

Item

Sw ing gearmotor drainage Oil drainage from the sw ivel joint (each outlet)

Check conditions

Unit

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Check the oil capacity of the drainage circuit > Max. pressure > Stop rotation

Value normal

allow ed

cm3/min

> Hydraulic oil temperature: 45 - 55 °C > Bring the pressure to the max. value in the circuit to be checked

---

Position for the check

Travel speed > Engine speed: Max. (1) > Hydraulic oil temperature: 45 - 55 °C > Low er the bucket to the ground and raise one track; mark a position; > Make one turn w ith the track and then calculate the time necessary to have the track make 5 turns. > Repeate w ith the second track

sec.

TRAVEL

Position for the check

Travel speed (2) > Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface long at least 10m; calculate the time necessary to cover 20 meters.

Position for the check

Deviation during w ork

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface, long 20m, and measure the deviation. > The surface must be compact and horizontal

mm

> Measure dimension X Hue 2 / 5

Page A17

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 6502

Check conditions

Unit

Value normal

allow ed

Position for the check

TRAVEL

Travel motor hydraulic drift

mm > Engine off > Hydraulic oil temperature: 45 - 55 °C > Machine still on a plane w ith 20° inclination. > Measure the shift after 5 minutes.

Travel motor drainage

WORK EQUIPMENT (Hydraulic drift)

Com plete w ork equipm ent (Low ering of the bucket teeth point)

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Lock the track and measure the delivery.

cm3/min

Position for the check

> In this position it is possible to measure the extension or the retraction of each cylinder and the leaks w ith the load applied to the bucket teeth end. > Plane, level surface. dipper stick > Bucket: rated load cylinder (cylinder > Lever: neutral extension) > Engine off > Hydraulic oil temperature: 45 - 55 °C Bucket > Take the measures as soon as the engine cylinder stops. (cylinder retraction) > Measure the drainage every 5 minutes and check the total drainage after 15 minutes. dozer blade > ( ): bucket w ithout load (check of the § For the blade, raise and after 15 minutes blade edge measure the yields due to leaks. low ering) Boom cylinder (cylinder retraction)

mm

---

> Engine off > Hydraulic oil temperature: 45 - 55 °C > In the same position indicated above, stop the machine on a plane w ith 15° inclination Boom and position the upper frame at 90° offset sw ing Measure the extension and retraction of the cylinder after 15 minutes. > ( ): bucket w ithout load Drainage from each cylinder

> Hydraulic oil temperature: 45 - 55 °C > Introduce the max. pressure in the cylinder to be checked

cm3/min

---

Hue 3 / 5

Page A18

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Cycle courses - excavators

Hueman / 25. April 03

Machine model

Neuson 6502

Item

Check conditions

Unit

Boom

Position for the check w ithout load RAISING

Classification

Bucket teeth onto the ground

Value normal

allow ed

---

Cylinder completely retracted

LOWERING

Cylinder > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dipper stick Position for the check w ithout load

---

IN

sec.

---

OUT

> Engine speed: Max. > Hydraulic oil temperatur: 45 - 55 °C

---

---

Position for the check w ithout load

Cylinder completely retracted

Cylinder > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dozer blade Position for the check Blade onto the ground

DUMPING

sec.

---

RAISING

WORK EQUIPMENT (Speed )

Cylinder completely extended Bucket

LOADING

sec.

---

Cylinder completely retracted

---

---

sec.

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C

LEFT

Cylinder completely extended

LOWERING

Blade raised > Engine speed: Max. at the > Hydraulic oil temperature: 45 - 55 °C max. height Boom offset Position for the check sw ing

RIGHT

sec.

---

Hue 4 / 5

Page A19

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Cycle courses - excavators

Hueman / 25. April 03

Neuson 6502

Machine model Classification

Item

Check conditions

Unit

Value normal

allow ed

Position for the check

Boom

sec.

---

sec.

---

sec.

---

sec.

---

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Retract the dipper stick and bucket cylinders completely. > Low er the boom from its maximum height and measure the time from the moment in w hich the bucket touches the ground to the moment in w hich the machine starts lifting.

Position for the check

WORK EQUIPMENT ( Response time )

Dipper stick

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the dipper stick cylinder completely and then extend it. > Measure the time from the moment in w hich it starts moving again.

Position for the check

Bucket

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the bucket cylinder completely, then extend it . > Measure the time from the moment in w hich the bucket stops at the dead center and the moment in w hich it starts moving again.

Position for the check

Dozer blade

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Raise the blade to the maximum height and then low er it. > Measure the time from the moment in w hich the blade touches the ground and the moment in w hich the machine starts lifting.

Hue 5 / 5

Page A20

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502 5.

HYDRAULIC SYSTEM Excavator type

6502

Unit

S tarted with Fabr. No. . :

0000708/ 98

HYDRAULI C P UMP Variable / gear pump 1

2

Type

5108320

System

Vari. pump with 2 press. ports + 1 gear pump

Version

PVD-3B-56P-21G-4626F

3 4 5 6

Oil flow rate

58,8+58,8+44

l/min

DRUCKEI NS TE LLUNG

220

Main pressure limiting valve 7

Pump P 1, P2

(2)

bar

+3 / -3

(2)

bar

+3 / -3

bar

+2/ -2

220

Main pressure limiting valve 8

Pump P 3

9

Pilot oil pressure

35 280

Secondary press. limit. valve 10

Main valve block

(3)

bar

+5/ -2

(3)

bar

N

Secondary press.limit.valve 11

Dozer blade valve

Swivel unit 4408400: 190 +0 /-23

Swivel motor (SPLV) 12 (Measuring points pump) Swivel motor (SPLV) 13 (Measured at the motor) Drive motor Internal press.limit.valve Check valve 15 Boom offset cylinder 14

(3)

bar

Swivel unit 4408490: 216 +5/-5 Swivel unit 4408490: 190 +5/-5

220 bar

+5 / -5

bar

N

For correct settings : (1)...Generel - Hydraulic oil temperature: 45 - 50°C (2)...Settings at max. engine rpm (see chap. Maintenance) (3)...Settings at min. engine rpm (see chap. Maintenance)

16

QUANTI TI E S Hydraulic oil tank

Liter

80

17

System filling

Liter

120

Explanation: N...Not enclosed / not available

Page A21

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

AUXILIARY HYDRAULIK 1

Excavator

5002

6002 / 6502

Pressure controlled oil flow - auxiliary hydraulic ( L / min )

Druck ( bar )

P2 + P3

Druck ( bar )

P2 + P3

40

80,0

45,0

101,0

60

78,0

60,0

100,0

90

74,0

90,0

98,0

120

70,0

120,0

85,0

150

60,0

150,0

75,0

180

50,0

180,0

67,0

210

35,0

210,0 240

60,0 46

Conditions 1) Pressure = Pressure setting at the tool (bucket) 2) Tolerance of the listed settings : +1 / -2 L/min 3) Oil flow rate was measured at the couplings at the dipper stick

S

Clearance - Hose burst protection valves (inside hose versions)

Id.No.:* 1108384 1208728 1428449 2208301 2528478 3028434 3528434 3808632 4508563 3408571 5508607 7008563

Excavator 12002 1402-2202 1403-2203 2203 2503 3003 3507, 3703 2702-3602, 3802 WD 5002 6002 6502 8002, 12002

assembled at the Triple boom cyl.

Dozer blade cyl.

Dozer blade cyl.

Tilt cylinder Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Screw size 3/4" 3/8" 3/8" 1/4" 3/8" 3/8" 1/2" 3/8" 1/2" 1/2" 3/8" 1/2"

Clearance S 2,2 mm 0,7 mm 1 mm 0,4 mm 0,8 mm 1,8 mm 1,0 mm 1,2 mm 1,2 mm 1,5 mm 1,5 mm 3,4 mm

* Attention: Neuson reserves changes (09.07.02) Please, see the item No. From the actual spare parts books !. Hg/hue

Page A22

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502 6.

DIESEL ENGINE

Excavator type

Unit

Neuson

Neuson

Neuson

5002

6002

6502

Yanmar

Yanmar

Yanmar 4TNE 98-NSR

SP ECI FI CATI ON:

1

Diesel engine model

2

Started with Neuson Fabr.No.:

4 TN E8 8 -EN SW 4TNE 98-NSR

0000989/ 98

8

0000708/ 98

Vertical, 4-cycle water cooled diesel engine Natural suction Direct injection system Preheater, time relay controlled Counterclock wise (viewed from flywheel) Mechanical centrifugal governor

Type 4 Suction system 5 Combustion system 6 Glow system 3

7

0000771/ 98

Direction of rotation Governor

Forced lubrication with trochoid pump Electrical Water cooled / Suction van

Lubrication system 10 Starting system 11 Cooling system 9

DATA: Max. revolution speed 12 ( no load )

14 Revolution speed

Min. revolution speed 15 (no load) 16 Displacement (Bore x Strok e) 17 Output ( at rev. Speed 14 ) 18 Max. engine output 19 No. of cylinder 20 Valve clearance (IN=OUT)

rpm

2500 +50 / -50

2300 +50 / -50

2300 +50 / -50

rpm

2400 +25 / -25

2100 +25 / -25

2100 +25 / -25

1100 rpm +50 / -50 ccm 2189 ( 88x90 ) KW ( PS ) 28,4 ( 38,6 ) KW ( PS ) 36,0 ( 48,3 ) 4 pcs mm

21 Compression ratio 22 Fuel injection timing 23 Fuel injection pressure 24 Compression pressure 25 Engine oil pressure (rev. speed level) 26 Pressure switch engine oil pump 27 Thermostat opening temperature 29 Thermo switch On / Out

deg bar bar bar bar °C °C

30 Firing order 31 Generator power (Standard) 32 Battery 33 V-Belt measurings

A/V V / Ah mm

1100 1100 +50 / -50 +50 / -50 3319 ( 98x110 ) 43,8 ( 59,5 ) 51,5 (68,5 ) 4 0,15 - 0,25 18,0 11 +/-1 14 +/-1 220 - 230 35 +/-1 at 250 rpm 3,0 - 4,0 0,4 - 0,6 69,5 - 72,5 71 - 85 107-113 / 100 and more 1-3-4-2 (Nr.1- Zyl. auf Schwungradseit) 40 / 12 12 / 88 12,5 x 1000 13 x 1090 LI

Page A23

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Technical data

6502

Diesel engine Excavator type

Unit

Neuson

Neuson

Neuson

5002

6002

6502

TI GHTE NI NG TORQUES : 34 Cylinder head bolt

Nm

35 Bonnet screw nut

Nm

36 Connection rod bolt

Nm

37 Metal cap clamping bolt

Nm

38 Flywheel clamping bolt

Nm

39

Glow plug

87,0 - 93,0 ( M10x1,25 ) N 45 - 55 ( M9x1,0 ) 98,0 - 102,0 ( M12x1,5 ) 85,0 - 90,0 ( M10x1,25 )

Nm

102,9 - 112,7 ( M11x1,25 ) N

N 53,9 - 58,8 ( M10x1,0 ) 107,9 - 117,7 ( M11x1,25 ) 186,3 - 205,9 ( M14x1,5 )

N

QUANTI TI ES 40 Fuel tank 41 Engine oil - oil pan (Max./Effect) 42 Cooling water content (without cooler)

Liter Liter Liter

75 8,0 / 2,5 7

75 10,2 / 5 8,7

75 10,2 / 5 8,7

QUALI TY 43 Engine oil

Quality

API grade CC Klasse or higher

Page A24

Id.No.: Edition:

API gr.cl. CD

9707750 Feb 03

Page A25

100 Nm 180 Nm

SW 36 SW 41

M30x2

M36x2

20 22L

25 28L

Id.No.: Edition:

180 Nm 270 Nm

SW 41 SW 50

M36x2 M42x2

20 25S 25 30S

400 Nm

100 Nm SW 36 M30x2

16 20S

SW 60

90 Nm SW 30

12 16S M24x1,5

M52x2

75 Nm SW 27

10 14S M22x1,5

32 38S

60 Nm SW 24

08 12S M20x1,5

Surface galvanic coated and dry (O-Ring oiled). Tolerance torque -10 %

220 Nm

85 Nm

SW 32

16 18L M26x1,5

SW 55

75 Nm

SW 27

12 15L M22x1,5

M45x2

50 Nm

SW 22

10 12L M18x1,5

32 35L

40 Nm

50 Nm

SW 22

06 10S M18x1,5

20 Nm

SW 17

M14x1,5

8L

06 SW 19

40 Nm

SW 19

M16x1,5

8S

05

15 Nm

SW 14

M12x1,5

6L

05

08 10L M16x1,5

Torque

Tool

Screw

RA

DN

Torque

Tool

Screw

RA

Heavy type (DKOS)

DN

Light version (DKOL)

Quelle: Fa. Schieffer

Metric hose joints for hydraulic assembling

for hydraulic joints and dry assembling

Quelle: Fa. Schieffer

7.

Tightening torque

6502

SERVICE MANUAL Technical data

TIGHTENING TORQUE

9707750 Feb 03

Technical data

Tightening torques for hydraulic screw joints and dry assembling Screws with different seal types for hydraulic use Heavy version

Screw

outside bore-Ø

M10x1,0

9 Nm

18 Nm

15 Nm

18 Nm

M12x1,5 20 Nm

25 Nm

25 Nm

M14x1,5 35 Nm

45 Nm

M16x1,5 45 Nm

10 mm

M12x1,5

20 Nm

35 Nm

35 Nm

35 Nm

12 mm

25 Nm

12 mm

M14x1,5

35 Nm

55 Nm

45 Nm

45 Nm

14 mm

35 Nm

35 Nm

14 mm

M16x1,5

45 Nm

70 Nm

55 Nm

55 Nm

16 mm

55 Nm

40 Nm

50 Nm

16 mm

M18x1,5

55 Nm

90 Nm

70 Nm

70 Nm

18 mm

M18x1,5 55 Nm

70 Nm

45 Nm

70 Nm

18 mm

M20x1,5

55 Nm

125 Nm

80 Nm

100 Nm

20 mm

M22x1,5 65 Nm

125 Nm

60 Nm

125 Nm

22 mm

M22x1,5

65 Nm

135 Nm 100 Nm 125 Nm

22 mm

M27x2,0 90 Nm

180 Nm 100 Nm 145 Nm

27 mm

M27x2,0

90 Nm

180 Nm 170 Nm 135 Nm

27 mm

M33x2,0 150 Nm 310 Nm 160 Nm 210 Nm

33 mm

M33x2,0 150 Nm 310 Nm 310 Nm 210 Nm

33 mm

M42x2,0 240 Nm 450 Nm 210 Nm 360 Nm

42 mm

M42x2,0 240 Nm 450 Nm 330 Nm 360 Nm

42 mm

M48x2,0 290 Nm 540 Nm 260 Nm 540 Nm

48 mm

M48x2,0 290 Nm 540 Nm 420 Nm 540 Nm

48 mm

G 1/8A

9 Nm

18 Nm

15 Nm

18 Nm

9,73 mm

G 1/4A

35 Nm

55 Nm

45 Nm

45 Nm

13,16 mm

G 1/4A

35 Nm

35 Nm

30 Nm

35 Nm

13,16 mm

G 3/8A

45 Nm

80 Nm

60 Nm

60 Nm

16,66 mm

G 3/8A

45 Nm

70 Nm

45 Nm

50 Nm

16,66 mm

G 1/2A

65 Nm

115 Nm

75 Nm

100 Nm 20,96 mm

G 1/2A

65 Nm

90 Nm

55 Nm

65 Nm

20,96 mm

G 3/4A

90 Nm

180 Nm 170 Nm 145 Nm 26,44 mm

G 3/4A

90 Nm

180 Nm 100 Nm 140 Nm 26,44 mm

G 1A

150 Nm 310 Nm 310 Nm 260 Nm 33,25 mm

G 1A

150 Nm 310 Nm 160 Nm 190 Nm 33,25 mm

Whitworth screw

Metric screw

outside bore-Ø

G 1 1/4A 240 Nm 450 Nm 330 Nm 360 Nm 41,91 mm

G 1 1/4A 240 Nm 450 Nm 210 Nm 360 Nm 41,91 mm

G 1 1/2A 290 Nm 540 Nm 420 Nm 540 Nm 47,80 mm

G 1 1/2A 290 Nm 540 Nm 260 Nm 540 Nm 47,80 mm

Toleranz der Drehmomente: - 10% ; Gegenwerk stoff: Stahl / Aluminium

SERVICE MANUAL

9707750 Feb 03

Screw

GE mit Einschraubz apfen RHV with Seal ED-Seal O-Ring ED-seal washer

6502

Id.No.: Edition:

Whitworth screw

Page A26

Metric screw

Light verison GE mit Einschraubz apfen RHV with Seal ED-Seal O-Ring ED-seal washer

Tightening torque M A for high quality screw joints with Standard screw Size

Screw with DIN 912, DIN 931, DIN 933, usw.

with fine screw

Screws DIN 7984

Size

Screws with DIN 912, DIN 931, DIN 933, usw.

Screws DIN 7984

Page A27 9707750 Feb 03

10.9

12.9

8.8

10.9

8.8

10.9

12.9

8.8

10.9

M5

5,5 Nm

8 Nm

10 Nm

5 Nm

7 Nm

M 8x1,0

25 Nm

37 Nm

43 Nm

22 Nm

32 Nm

M6

10 Nm

14 Nm

17 Nm

8,5 Nm

12 Nm

M 10x1,0

50 Nm

75 Nm

88 Nm

43 Nm

65 Nm

M8

25 Nm

35 Nm

42 Nm

20 Nm

30 Nm

M10x1, 25

49 Nm

71 Nm

83 Nm

42 Nm

62 Nm

M 10

45 Nm

65 Nm

80 Nm

40 Nm

59 Nm

M12x1, 25

87 Nm

130 Nm 150 Nm

75 Nm

110 Nm

M 12

87 Nm

110 Nm 147 Nm

69 Nm

100 Nm

M 12x1,5

83 Nm

125 Nm 145 Nm

72 Nm

105 Nm

M 14

135 Nm 180 Nm 230 Nm 110 Nm 160 Nm

M 14x1,5 135 Nm 200 Nm 235 Nm 120 Nm 175 Nm

M 16

210 Nm 275 Nm 350 Nm 170 Nm 250 Nm

M 16x1,5 210 Nm 310 Nm 360 Nm 180 Nm 265 Nm

M 18

280 Nm 410 Nm 480 Nm 245 Nm 345 Nm

M 18x1,5 315 Nm 450 Nm 530 Nm 270 Nm 385 Nm

M 20

410 Nm 570 Nm 690 Nm 340 Nm 490 Nm

M 20x1,5 440 Nm 630 Nm 730 Nm 375 Nm 530 Nm

M 22

550 Nm 780 Nm 930 Nm 460 Nm 660 Nm

M 22x1,5 590 Nm 840 Nm 980 Nm 500 Nm 710 Nm

M 24

710 Nm 1000 Nm 1190 Nm 590 Nm 840 Nm

M 24x2,0 740 Nm 1070 Nm 1250 Nm 630 Nm 900 Nm

M 27

1040 Nm 1480 Nm 1770 Nm 870 Nm 1250 Nm

M 27x2,0 1100 Nm 1550 Nm 1800 Nm 920 Nm 1300 Nm

M 30

1420 Nm 2010 Nm 2400 Nm 1200 Nm 1700 Nm

M 30x2,0 1500 Nm 2150 Nm 2500 Nm 1300 Nm 1850 Nm

DIN 912 Allen Werten liegt ein Reibungskoeffizient von µ = 0,1 2 zugrunde und si nd al s Ri chtwert e anzuwenden.

Technical data

Id.No.: Edition:

8.8

SERVICE MANUAL

6502

Tightening torque for high quality screws

Technical data

Type relativ tightening torques for high quality screw joints Tightening torque M A for Screw joints at Neuson 5002 - 12002 5002 RD Turn table

6002 RD

6502 WD

8002 RD

12002 R D

M14 10.9 180 Nm* M16 10.9 275 Nm* M16 10.9 275 Nm* M16 10.9 275 Nm* M18 10.9 395 Nm* M16 10.9 275 Nm*

Page A28

Track roller

M16 10.9 275 Nm* M16 10.9 275 Nm*

Swivel joint

M10 10.9

Sprocket

M14 10.9 180 Nm* M14 10.9 180 Nm*

Drive unit

M14 10.9 180 Nm* M14 10.9 180 Nm*

Swivel unit

M12 10.9 110 Nm* M12 10.9 110 Nm* M12 10.9 110 Nm* M12 10.9 110 Nm* M14 12.9 220 Nm*

Cab fixing screws

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M12 8.8

87 Nm

M12 8.8

87 Nm

M12 8.8

87 Nm

M12 8.8

87 Nm

M12 8.8

87 Nm

Engine carrier

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 10.9

64 Nm

M12 10.9

110 Nm

M12 10.9

110 Nm

M12 10.9

110 Nm

M12 10.9

110 Nm

M8 8.8

25,5 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

M10 8.8

45 Nm

Pump carrier

M10 10.9

64 Nm

M10 10.9

64 Nm

M10 10.9

64 Nm

M10 10.9

64 Nm

M10 10.9

64 Nm

Pump

M12 10.9

87 Nm

M16 10.9

275 Nm

M16 10.9

275 Nm

M10 10.9

64 Nm

M16 10.9

275 Nm

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M14 10.9 180 Nm* M16 10.9 275 Nm* M8 10.9

35,3 Nm* M16 10.9 275 Nm* M16 10.9 275 Nm*

9707750 Feb 03

SERVICE MANUAL

Id.No.: Edition:

*) Alle mit * gekennzeichneten Verbindungen, müssen mit Loctite S2420 oder VaryBond 12-43 eingeklebt werden.

6502

Engine carrier

64 Nm*

M12 10.9 110 Nm* M16 12.9 358 Nm*

SERVICE MANUAL

Maintenance

6502

CHAPTER B:

Maintenance ( Neuson Service Manual 6502 )

Page B1

Id.No.: Edition:

9707750 Feb 03

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SERVICE MANUAL

Maintenance

6502

MAINTENANCE SCHEDULE

1.

Servicing activity Component

Neuson 6502

daily

every 50 h

every

every

every

every 10 h

weekly

250 h

500 h

1000 h

annual

ENGINE Oil level

O

Fuel level

O

Leak age

O

Visual check

O

Air filter

O/X

Seating of mounting bolts Coolant

<>

<>

O O

Engine speed regulation

O

Exhaust system

O

Engine oil

O

Oil filter V-belt: condition and tension Cooler fins

<>(1)

<>

<>

<>(1)

<>

<>

O O

X

Valve clearance

O

Generator, starter

O

Fuel tank

X

Water pump

O

Fuel filter

<>(1)

<>

<>

Cooling system and hoses

O

Electrical connections

O

Pre-glow system

O

Coolant thermostat

O

Battery fluid

O X

O

- Check - Clean

<> - Change/Replace <> (1) - Change/Replace the first time

Page B2

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Maintenance

6502

Servicing activity Component

every 10 h every 50 h daily

weekly

every

every

every

250 h

500 h

1000 h

annual

HYDRAULIC SYSTEM Fastening bolts Hydraulic pump

O

Leak age (lines, pumps, cylinders)

O

Hydraulic oil level

O

Oil cooler fins

X

Filter insert

<>(1)

O

Primary and secondary pressure limiting valves Hydraulic oil

<>

<>

O O

<>(1)

Breather filter Filling strainer

<>

O

ELECTRICAL Indicator lamps

O

Function of system

O

Fastenings

O

TRAVELL UNIT Tyres after work ing

O

Wheel nuts

O

Bearing play of wheels and axle bolts Brak e unit

O O

Brak elinings

O

TRAVEL GEAR UNIT Leak age

O

Gear oil

<>(1)

<>

<>

GEAR RING Gearing

<>

Bearing system

O X

O

- Check - Clean

<> - Change/Replace <> (1) - Change/Replace the first time

Page B3

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Maintenance

6502

Servicing activity Component

every 10 h

every 50 h

every

every

every

daily

weekly

250 h

500 h

1000 h

annual

HEATING Function

O

Leak age (cooling and heating circuit)

O

Seals

O

Fan

O

WORKING EQUIPMENT Lubricate lubricating points (acc. to lubricating plan)

O

Buck et teeth (fastening and wear)

O

Pin fastening

O

Line fastenings

O

Piston rods

O

Behaviour of hydraulic cylinder under load

O

O

Bush bearing play

O

O

GENERAL Operating elements (precise motion)

O

Hydraulic fittings

O

Bolts

O

Lights

O

Windscreen washing system Leak age check + Visual check

O X

- Check - Clean

O O

<> - Change/Replace <> (1) - Change/Replace the first time

Notice: This maintenance schedule is an an generell overview, modifications possible.

The specific maintenance schedule can be found in the machine enclosed user manual !

Page B4

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Maintenance

6502

Maintenance - General (according to Operating Instructions) The reliability and service-life of machines are to a great extent influenced by care and maintenance.

Therefore, compliance with the specified maintenance work is first of all to the advantage of the owner of a machine.

Doing the specified maintenance work is made mandatory by the manufacturer. Any default will lead to restrictions of warranty.

For maintenance work at the engine please cf. the operating instructions for the engine.

If lubricants are used that are not in compliance with the manufacturer’s recommendation any guarantee becomes extinct.

Before starting maintenance and repair at your vehicle, please get informed about any damage that occurred.

Before starting maintenance or repair work lower the working equipment to the ground. Apply locking and safety levers.

Bleed residual pressure off the hydraulic system.

Let the engine cool down (hot cooling water) If work must be done with the machine lifted, it must be appropriately secured (supported).

During maintenance or repair work in a closed room provide for sufficient ventilation.

Dispose of oil filters,oil, etc. as provided by the environmental law.

When working at and/or below the excavator place a warning sign on the driver’s seat and/or clearly visible and legible at the crawler excavator. Withdraw the ignition key.

Never work at the electrical equipment in a damp environment or with wet hands (gloves).

Remove the negative pole from the battery when working at the electrical equipment.

Page B5

Id.No.: Edition:

9707750 Feb 03

SERVICE MANUAL

Maintenance 2.

6502

LUBRICANTS LUBRICATION FILLINGS - EXCAVATORS USED A S

EXCAVATOR LUBRI CATI ON TYP E

10W40 (Norm) BP Vanellus FE APISF-CD + SAE 10W 40 FINA Kappa SE10W40 Q8 T660-10W40

Engine oil

Hydraulic oil

Bio oil

Turn table : Teeth Ball bearings

HVLP 46 (Norm) BP Energol SHF 46 FINA Hydran TSX 46 Q8 Heller 46 BP Biohyd SE S46

BP Energrease OG (Farbe weiss) BP Energrease L 21 M

Drive gears

Energear Hypo EP 90 API GL 5 FINA Pontonic MP85W90APIGL5 Q8 T55 85W90 RK 15, RK20S

Boom , dipper stick,..

SGXP 220 BP Energrease L 21 M Gleitmo 805 (For the first greasing of the bolts )

Track tension cylinder

Planetary gear Fix and float axles Distribution gear

Each Lubr. point

BP Energrease L 21 M

Wheeled excav.

SAE 90 Hypoidöl (GL 5) FINA Pontonic MP85W90APIGL5 Q8 T55 85W90

BP Energrease L 21 M

Conditions: Engine oil: Grease:

von -25°C bis + 40°C Aussentemperatur von -25°C bis +40°C Aussentemperatur

Page B6

Id.No.: Edition:

9707750 Feb 03

KW

Motor- Kühlflüs- Hydrauliköl Drehge- Fahrgeöl sigkeit Systemfüllung triebe triebe

1402Primus 1402RD u.1502RD

Yanmar 3TNE68-NSR

10

2,4L

3,2L

31L

/

0,5L

1902RD u.2202RD

Yanmar 3TNE74-NSR

13,5

2,4L

3,2L

31L

/

0,5L

2702RD u.2902RD

Yanmar 3TNE88-NSR

20

6,9L

4L

68L

1L

0,75L

3402RD u.3602RD

Yanmar 4TNE88-NSR

23

7,5L

6L

79L

1L

0,75L

3802WD

Yanmar 4TNE88-NSW

30

8,5L

7L

79L

1

/

5002RD

Yanmar 4TNE88-NSW

30

8,5L

7L

100L

2L

1L

6002RD

Yanmar 4TNE98-NSR

47,5

10,2L

8,7L

120L

2L

1L

Id.No.: Edition:

6502WD

Yanmar 4TNE98-NSR

47,5

10,2L

8,7L

120L

2L

/

9707750 Feb 03

8002RD

Yanmar 4TNE98-NSR

45,6

10,2L

8,7L

122L

2,5L

1,25L

11002HV Forst

Deutz 1012EC

75

10L

10L

135L

2,5L

2L

Planetengetriebe

Starr- Lenk- Verteilerachse achse getriebe

1L

6L

5L

2,5L

1L

6L

5L

2,5L

Maintenance

Typ

Page B7

NEUSON

Mechan. Kraftübertragung

SERVICE MANUAL

Hydraul.

Kraftübertragung

Motor

Quantities

Gerätetyp

6502

Füllmengen

SERVICE MANUAL

Maintenance 3.

6502

LUBRICATION CHART

Lubrication points to be lubricated daily - blue screw plugs.

W = Lubrication points to be lubricated weekly - green screw plugs.

W

lubrication block

W

W

at the steering axle

bearing track syst. of uppercarriage

W

offset cylinder

live ring

W

Page B8

W

W

W

W

Id.No.: Edition:

9707750 Feb 03

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

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