DOWNLOAD PDF Wacker Neuson 5002 6002 Compact Excavator Service Manual

SERVICE MANUAL NEUSON COMPACT EXCAVATOR

5002 / 6002

Edition: February 03 Id.No.: 9707749

GB

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TABLE OF CONTENT : Chapter O Table of content Product history A Technical data 1 Primary dimensions 2 Lift capacity charts 3 Hydraulic settings 4 Diesel engine settings 5 Tightening torques

Page

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

A2 A7 A13 A15 A17

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

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

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

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

Hydraulic system ........................................................ ..

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

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

Drive unit ........................................................ ..

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

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

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

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

B2 B6 B8 B9 B20 B21 B22 B23 B24 B35 B36

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

Hydraulic Hydraulic system ........................................................ ..

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

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

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

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

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

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

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

Drive unit ........................................................ ..

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

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

Way valve (Vario) ........................................................ ..

Pressure limiting valve (Vario) ................................................ Öil tank ........................................................ ..

C2 C7 C9 C13 C18 C34 C39 C47 C48 C51 C52 C53 C53 C54

D E F G

Diesel engine Elektric Operating elements Attachment

Abbreviations: AP ...

MP ...

PPLV ...

SPLV ...

TT ...

Pb1 ...

Adjustment point Measuring point Primary - pressure limiting valve Secundary - pressure limiting valve Tightening torque Port code at the hydraulic diagram

Edition February 2003, Copyright Neuson Baumaschinen Neuson reserves changes.

PRODUCT HISTORY This overall lists the main technical modifications of the excavator type Neuson 5002 Step Excavator code

Fabr.No.:

Serial start 5002 RD Version 5002 „AB“

0000989/1998 AB00473

.

AB00865 (SNews 71/02) AB01533 AB01951

Modification / part group -

Fabrikation started Cabin covers Cabin colour (RAL7040gray) Joystick consol long (III) Sticker design Elektric wiring version“AB“ - long joystick co.

Pilot oil supply unit (Shuttle valves) Maintenance interval extension Swivel unit new - gear box hydr. oil lubricated Joystick console short (IV) Electric wiring new (joystick consol IV) Position of the instrument panels

PRODUCT HISTORY This overall lists the main technical modifications of the excavator type Neuson 6002 Step Excavator code Fabr.No.: Modification / part group Serial start 6002 RD Version

6002„AB“

0000771/1998 AA04551 AB00473

AB00865 (SNews 71/02) AB01533

-

AB01647

-

AB01940

-

.

Fabrikation started Boom cylinder Dm110 (SNews 46) Cabin covers Cabin colour (RAL7040gray) Joystick consol long (III) Sticker design Elektric wiring new (joystick consol III) Pilot oil supply unit (Shuttle valves) Maintenance interval extension Swivel unit new - gear box hydr. oil lubricated (SNews 72/02) Solenoid stop bracket - diesel engine mod.

(SNews 68/02) Joystick consol short (IV) - SNews 72/02 Electric wiring changed (joystick cons.IV) Position instrument panel

SERVICE MANUAL

Technical data

5002 - 6002

CHAPTER A:

Technical data ( Neuson Service Manual 5002 - 6002 )

Page A1

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data 1.

5002 - 6002

DIMENSIONS

Pict: Primary dimensions 5002

Page A2

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Pict.: Primary dimensions 6002

Page A3

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Primary dimensions / Performance

Unit > > S tarting with F ab r. No. Dimensions ( H x W x L )

mm

Axle distance

mm

Transport length

5002

6002

0000989/98

0000771/98

6002 Triple boom Option

2435 / 1850 / 3665 2435 / 1850 / 3800 2435 / 1850 / 3800

2000 / F

2000 / F

2000 / F

mm

5653

5803

5378

Boom swing angle

Left / right

degr

80 / 45

80 / 45

80 / 45

Front boom swing radius

min

mm

1880

1920

1920

Tilt angle uppercarriage Ground clearance

max

Undercarriage width

degr

N

N

N

mm

340

340

340

mm

1850

1850

1850

Track width

Standard

mm

400

400

400

Max. Dump height

Standard

mm

4000

4095

4750

Max. Dump height / Option

Dipperstick long

mm

4200

4295

5000

Max. Dig height

Standard

mm

5480

5580

6460

Max. Dig height / Option

Dipperstick long

mm

5680

5780

6705

Max. Dig radius

Standard

mm

6010

6160

6555 6850

Max. Dig radius / Option

Dipperstick long

mm

6290

6460

Max. vertical dig depth

Standard

mm

1549

2000

Max. vertical digging depth / Opt.

Dipperstick long

mm

Max. dig depth

Standard

mm

3710

3860

3945

Max. dig depth / Option

Dipperstick long

mm

4010

4160

4255

Min. tail swing radius

mm

1470

1590

1590

Dozer blade dimensions ( W x H ) Standard

mm

1850 /425

1850 /425

1850 /425

Dozer blade dimensions ( W x H ) Extension

mm

N

N

N

Dozer blade max. lift ... Ground

above / below

mm

390 / 400

400 / 435

400 / 435

Dipperstick length

Standard

mm

1500

1650

1650

Dipperstick "long "

Option

mm

1800

1950

1950

Track rollers / guide rollers

per side

pcs

5/1

5/1

5/1

Operation weight with

Cab

kg

4960

5700

5900

Operation weight with

Canopy

kg

N

N

N

Ground pressure

Standard

k g/cm²

0,27

0,3

0,3

Ground pressure

Option

k g/cm²

Stahlk ette

Stahlk ette

30 / 58

30 / 58

Gradability

degr / %

2221

30 / 58

Noise level

LWA

dB (A)

98

99

99

Noise level

LPA

dB (A)

75

74

74

Travel speed

Drive

k m/h

2,5 / 4,5

3,0 / 5,5

3,0 / 5,5 3672

Tear out force per

Buck et tooth

kp

3316

3672

Max. dipper stick tear out force

Standard

kp

2405

2482

Slew ( swivel- ) speed

Uppercarriage

rpm

8,5

9

9

Tractive effort

Undercarriage

kg

5.760

6.100

6.100

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

Page A4

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002 2.

KINEMATIC

Kinematic

Unit

5002

6002

6502

8002

12002

E

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

Page A5

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

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:

9707749 Feb 03

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SERVICE MANUAL

Technical data

5002 - 6002 3.

LIFT CAPACITY CHARTS

Tab.: Lift capacity - 5002

Page A7

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Tab. : Lift capacity - 6002 ( Boom cylinder 100 mm) Fabr.No: AA04551 and higher

Page A8

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Tab.: Lift capacity - 6002 ( Boom clinder 110 mm) Fabr.No: AA04551 and higher

Page A9

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Tab.: Lift capacity - 6002 Triple boom (Boom cyl. 110 mm) Fabr.N: AA04551 and higher

Page A10

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Tab.: Lift capacity - 6002 Vario, Standard boom

Page A11

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

LIFT CAPACITY CHART 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 A12

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

CYCLE COURSES

4.

Neuson 5002

Machine model Classification

Item

Check conditions

Unit

Neuson 6002

Value normal

Value

allow ed

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

UPPER FRAME ROTATION

Time required to start the rotation

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 A13

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Cycle courses - excavators

Hueman / 25. April 03

Machine model

Upper frame rotation

Classification

Item

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

Neuson 5002

Check conditions

Unit

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

Neuson 6002

Value normal

Value

allow ed

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 (1)

> Engine speed: Max. > 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 A14

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Check conditions

Unit

Neuson 5002

Neuson 6002

Value

Value

normal

allow ed

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 )

Complete 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 A15

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Cycle courses - excavators

Hueman / 25. April 03

Machine model Check conditions

Boom

Position for the check w ithout load

Unit

Value

---

---

LOWERING

---

---

IN

allow ed

---

---

OUT

normal

---

---

LOADING

allow ed

---

---

DUMPING

normal

---

---

RAISING

Bucket teeth onto the ground

Neuson 6002

Value

---

---

LOWERING

RAISING

Item

Neuson 5002

---

---

RIGHT

Classification

---

---

---

---

sec.

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

sec.

WORK EQUIPMENT (Speed )

Cylinder completely extended Bucket

> Engine speed: Max. > Hydraulic oil temperatur: 45 - 55 °C Position for the check w ithout load

Cylinder completely retracted

sec.

Cylinder completely extended Dozer blade

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C Position for the check

Blade onto the ground

sec.

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

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

LEFT

Cylinder completely extended

sec.

Hue 4 / 5

Page A16

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Cycle courses - excavators

Hueman / 25. April 03

Neuson 5002

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 6002 Value

allow ed

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.

WORK EQUIPMENT ( Response time )

Position for the check

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 A17

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data 5.

5002 - 6002

HYDRAULIC SYSTEM Excavator type

Unit

S tarted with Fabr. No. . :

5002

6002

0000989/ 98

0000771/ 98

HY DRAULI C P UMP Variable/gear pump Variable/gear pump 1

Type

4408302

5108320

Single variable pump with 2 press. ports + 1 gear pump

System Version A 4 Version B 5 Oil flow rate - version. A 6 Oil flow rate - version. B 2

PVD-2B-44P-12G- PVD-3B-56P4713F 21G-4626F

3

l/min l/min

52,0+52,0+31,0

58,8+58,8+44

230

245

+3 / -3

+3 / -3

DRUCKE I NS TELLUNG Main pressure limiting valve 7

Pump P 1, P 2

(2)

bar

220

220

(2)

bar

+3 / -3

+3 / -3

35

35

bar

+2/ -2

+2/ -2

Main pressure limiting valve 8

Pump P 3

9

Pilot oil pressure

280

280

(3)

bar

+5/ -2

+5/ -2

(3)

bar

N

N

Secondary press. limit. valve 10

Main valve block Secondary press.limit.valve

11

Dozer blade valve

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

Swivel unit 4408400:

190

+0 / -23

(3)

bar

Swivel unit 4408490:

216

+5 / -5

(3)

bar

Swivel unit 4408490:

190

+5 / -5

230

245

bar

+5 / -5

+5 / -5

bar

N

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 ES Hydraulic oil tank

Liter

61

80

17

System filling

Liter

100

120

Explanation: N...Not enclosed / not available

Page A18

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

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) Pressure = Pressure setting at the tool (bucket) 4) Values measured direct 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 A19

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data 6.

5002 - 6002

DIESEL ENGINE

Excavator type

Unit

Neuson

Neuson

Neuson

5002

6002

6502

SP ECI FI CATI ON: Yanmar 4 TN E8 8 -EN SW 4TNE 98-NSR Yanmar

1

Diesel engine model

2

Started with Neuson Fabr.No.:

0000989/ 98

4

8

Direction of rotation Governor

9

Lubrication system

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 Suction system 5 Combustion system 6 Glow system 3

7

0000771/ 98

Yanmar 4TNE 98-NSR

Forced lubrication with trochoid pump Electrical Water cooled / Suction van

10 Starting system 11 Cooling system

DATA: Max. revolution speed 12 ( no load )

rpm

2500 +50 / -50

2300 +50 / -50

2300 +50 / -50

14 Revolution speed

rpm

2400 +25 / -25

2100 +25 / -25

2100 +25 / -25

15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33

Min. revolution speed (no load) Displacement (Bore x Strok e) Output ( at rev. Speed 14 ) Max. engine output No. of cylinder Valve clearance (IN=OUT) Compression ratio Fuel injection timing Fuel injection pressure Compression pressure Engine oil pressure (rev. speed level) Pressure switch engine oil pump Thermostat opening temperature Thermo switch On / Out Firing order Generator power (Standard) Battery V-Belt measurings

1100 rpm +50 / -50 ccm 2189 ( 88x90 ) KW ( PS ) 28,4 ( 38,6 ) KW ( PS ) 36,0 ( 48,3 ) 4 pcs mm deg bar bar bar bar °C °C 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 A20

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Technical data

5002 - 6002

Diesel engine Excavator type

Unit

Neuson

Neuson

Neuson

5002

6002

6502

TIGHTENING 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

Nm

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

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

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

Liter Liter Liter

QUALITY 43 Engine oil

Quality

75 8,0 / 2,5 7

75 10,2 / 5 8,7

API grade CC Klasse or higher

Page A21

Id.No.: Edition:

75 10,2 / 5 8,7 API gr.cl. CD

9707749 Feb 03

Page A22

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

Technical data SERVICE MANUAL

5002 - 6002

TIGHTENING TORQUES

9707749 Feb 03

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

Metric screw

outside bore-Ø

Whitworth screw

9707749 Feb 03

Screw

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

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

Technical data

Id.No.: Edition:

Whitworth screw

Page A23

Metric screw

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

SERVICE MANUAL

5002 - 6002

Tightening torques for hydraulic screw joints and dry assembling

Technical data

Tightening torque for high quality screws 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 A24

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.

SERVICE MANUAL

9707749 Feb 03

10.9

5002 - 6002

Id.No.: Edition:

8.8

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 A25 9707749 Feb 03

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

64 Nm*

M10 10.9

64 Nm*

M12 10.9 110 Nm* M16 12.9 358 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*

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

Technical data

Id.No.: Edition:

Track roller

Engine carrier

SERVICE MANUAL

5002 - 6002

Type relativ tightening torques

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SERVICE MANUAL

Technical data

5002 - 6002

Page A26

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

CHAPTER B:

Maintenance ( Neuson Service Manual 5002 - 6002 )

Page B1

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance 1.

5002 - 6002

MAINTENANCE SCHEDULE

Servicing activity com ponent

every 10 h

every 50 h

every 250 h

every 500 h every 1000 h

(daily)

(weekly)

(6 months)

(12 months)

Di esel Oil level

O

Fuel level

O

Leak age

O

Visual check

O

Air filter

O/X

Seating of mounting bolts Coolant

Neuson 5002 - 6002

(18 months)

annual

engi ne

<>

<>

O O

Engine speed regulation

O

Exhaust system

O

Engine oil

O

Oil filter

<>(1)

<>

<>

<>(1)

<>

<>

V-belt: condition and tension

O

Cooler fins

X

Valve clearance

O

O

Generator, starter

O

Fuel tank

X

Water pump

O

Fuel filter

O

<>

<>

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:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

Servicing activity com ponent

every 10 h every 50 h every 250 h every 500 h every 1000 h (daily)

(weekly)

(6 months) (12 months) (18 months)

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

<>

<>

O

valves Hydraulic oil

O

<>(1)

Breather filter Filling strainer

<>

<>

O

ELECTRICAL Indicator lamps

O

Function of system

O

Fastenings

O

TRAVELL GEAR Chain after work ing

O

Chain tension

O

Bearring play of tread rollers, track carrier

O

rollers, front idlers

TRAVEL G E A R U N I T Leak age

O

Gear oil

<>(1)

<>

<>

GEAR RING Bearing system

O

Gearing

<>

O X

- Check - Clean

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

Page B3

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

Servicing activity com ponent

every 10 h every 50 h every 250 h every 500 h (daily)

(weekly)

(6 months) (12 months)

every 1000 h (18 months)

annual

HEATING Function

O

Leak age (cooling and heating circuit)

O

Seals

O

Fan

O

WORKING EQUIPMENT Lubricate lubricating points

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

Bearing play

O

GENERAL Operating elements

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:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

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

Cleaning: In the first 3 months wash the machine only with cold water (no high-pressure or steam-jet cleaning). After the first three months the minimum distance between the spraying nozzles and the vehicle must be 30 cm, and the water temperature shall not be higher than 60°C. Do not use aggressive cleaning agents.

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

Page B5

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

2. LUBRICANTS LUBRICATION FILLINGS - EXCAVATORS USED AS

EX CAVA TOR LUBRI CATI ON TY PE

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:

9707749 Feb 03

Page B7 9707749 Feb 03

Typ

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

6502WD

Yanmar 4TNE98-NSR

47,5

10,2L

8,7L

120L

2L

/

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

Id.No.: Edition:

NEUSON

Mechan. Kraftübertragung

SERVICE MANUAL

Hydraul.

Kraftübertragung

Motor

5002 - 6002

Gerätetyp

Quantities

Füllmengen

SERVICE MANUAL

Maintenance 3.

5002 - 6002

LUBRICATION CHART

Lubrication points to be lubricated daily - blue screw plugs.

Lubrication points to be lubricated weekly - green screw plugs.

Page B8

Id.No.: Edition:

9707749 Feb 03

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• 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

DOWNLOAD THE COMPLETE MANUAL

SERVICE MANUAL

Maintenance

5002 - 6002

4.

HYDRAULIC SYSTEM

General instructions: -

For maintenance and repair work bleed hydraulic system !

For pressure settings please refer to Chapter - Technical Data!!

Before each pressure test the device must be run up! - Hydraulic oil temperature at least 50°C Primary pressure limiting valves (PPLV) shall be set at max. engine speed (see chapter Techn.Data) The pressure drop ( deltaP between max. and min. diesel engine speed) is tested at unchanged load.

> PRESSURE TEST 4.2 Pressure Test of Gear Pump P1 Functions:

boom, bucket, driving left

4.2.1 Check of setting PPLV 1: a) Apply pressure gauge at measuring port MP 1. b) Move boom cylinder at bottom side to stop at max. diesel engine speed. c) Check and note pressure.

4.2.2 Check of pressure drop: d) Move boom cylinder at bottom side to stop at max. diesel engine speed (item b !). e) Reduce diesel engine speed swiftly from max. to min speed - check and note pressure drop. The pressure drop should not exceed more than 10% of the setting. (Approximate value - only applicable to primary pressure limiting values!) An excessive pressure drop might indicate leakage! f ) Check the setting and pressure drop of function boom rod side, bucket bottom side / rod side, driving left forward / reverse as described in items 2.2.1 and 2.2.2. g ) If any settings deviate from factory settings please set the correct pressure at the primary pressure limiting valve (PPLV 1) at the main valve block and repeat items a - f. h ) An excessive pressure drop might indicate leakage (e.g.: def. O-ring in secondary valve,..)

4.3 Pressure Test of Gear Pump 2 Functions:

dipper stick, driving right, auxiliary hydraulics

4.2.1 Check of setting PPLV 2: i) Apply pressure gauge at measuring port MP 2. j) Move dipper stick at bottom side to stop at max. diesel engine speed. k) Check and note pressure.

Page B9

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

4.3.2 Check of pressure drop : m) Check and note pressure drop of indvidual functions analogous to items d - g. n) Check the settings and pressure drop of functions dipper arm rod side and driving right analogous to items 2.3.1 - 2.3.2 and note the result. p) If any settings deviate from factory settings please set the correct pressure at the primary pressure limiting valve (PPLV 2) at the main valve block and repeat items i - p. q) Note: Pressure test for auxiliary hydraulic system: - With ball valve opened - unpressurized return flow (measurement: system banking-up pressure).

- If there are secondary valves AH installed, the factory specifications may be invalid, as SPLV are set individually (see SNews 36/00) 4.4 Pressure Test of Gear Pump P3 Functions:

dozer blade, auxiliary hydraulics / boom offset, swivelling

4.4.1 Check of setting PPLV 3: r) Apply pressure gauge at measuring port MP 3. s) Move dozer blade at bottom side to stop at max. diesel engine speed. t) Check and note pressure and pressure drop. u) The function auxiliary hydaulics shows the setting of the primary pressure limiting valve PPLC 3 at measuring port MP 3, if there are no secondary valves installed! (see AH - MP2) v) The swivelling function is supplied by pump P3, though the operating pressure is limited by the secondary pressure limiting valves (SPLV 4) at the swivel motor! - See swivel motor. (> Check of pressure drop only admissible with primary pressure control values!)

4.5 Pilot Pressure Test: Functions:

hydraulic pilot control

4.5.1 Check of setting PRV 5: a) Apply pressure gauge at measuring port MP 4 . b) Actuate joystick. c) Check pressure and/or set it at the pressure reducing valve (PRV 5) at the control oil unit. ! Please refer also to Test Report - Pressure Test on the following pages !

Page B10

Id.No.: Edition:

9707749 Feb 03

Function

Motion

Symbol

CHECK LIST Neuson Baumaschinen Press.Limit.Valve Measure point

Check ed:

Setting (1)

PUMP 1

Page B11

Drive left

X Setting Fall

230 bar +/- 3

UP

Setting Fall

230 bar +/- 3

DOWN

Measuring point Setting Fall MP 1 Setting

230 bar +/- 3

OUT

Primary press.

Limiting valve PPLV 1

IN

(Main valve block)

(Main valve block) Fall

25 bar 25 bar 25 bar

230 bar +/- 3 25 bar

Setting Fall

230 bar +/- 3

FORWARD

230 bar +/- 3

BACKWARD

Setting Fall

25 bar 25 bar

> > > > > > > > > > > >

PUMP 2 Dipper stick (Arm)

9707749 Feb 03

Auxiliary hydraulics

X Setting Fall

230 bar +/- 3

OUT

Setting Fall

230 bar +/- 3

IN

Measuring point Setting Fall MP 2 Setting

230 bar +/- 3

FORWARD

Primary press.

Limiting valve PPLV 2

BACKWARD

(Main valve block)

(Main valve block) Fall

25 bar 25 bar 25 bar

230 bar +/- 3 25 bar

Setting Fall

230 bar +/- 3

A

230 bar +/- 3

B

Setting Fall

25 bar 25 bar

> > > > > > > > > > > >

Maintenance

Id.No.: Edition:

Drive right

Notice:

Buck et

OK?

Notice:

Boom

No: Hue0 Stand: Jun

SERVICE MANUAL

NEUSON

Checked:

PRESSURE

5002 - 6002

5002

Fabr.No.: Work hrs./Dat.

NEUSON

Checked:

Function

Motion

Symbol

PRESSURE Neuson Baumaschinen Press.Limit.Valve Measure point

Check ed:

Setting (1)

PUMP 3

Auxiliary hydraulics

X Setting Fall

220 bar

UP

Setting Fall

220 bar

DOWN

Setting Measuring point Fall MP 3 (Main valve block) Setting Fall

220 bar

A (2)

Primary press.

Limiting valve P PLV 3

B (2)

(Main valve block)

/

Page B12

Arm swing

LEFT

(Swivel motor) (3)

RIGHT Secondary press.

Swivel uppercarriage

LEFT

Limiting valve

RIGHT

( Swivel motor !)

S PLV 4

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 5

> >

+/- 5

> >

20 bar 20 bar 20 bar

220 bar 20 bar

Setting Fall

220 bar

Setting Fall

220 bar

Sett (4): Fall

206 bar

Sett (4): Fall

206 bar

20 bar 20 bar bar bar

PILOT PRESSURE SYSTEM

X

PRV... Pressure reducting valve PLV... Pressure limiting valve

9707749 Feb 03

(1)... Not ic e: pres s ure s et tings c orres pond wit h t he Fab r. No. of your exc avat or !

Please, always compare with the pressure setting in chapter "technical data" !

(2)... Notice: Setting only correct without secundary pressure limiting valves !

(3)... Function swviel: see chapt. "Technical Data", see chapt. "Maintenance" (4)... See chapt."Technical data": version 4408400, 4408490 - different settings

bar

SERVICE MANUAL

Id.No.: Edition:

All

35 bar +/- 2

5002 - 6002

Measuring point Setting MP 4 (Pilot oil Fall supply unit) (Pilot oil supply unit) P RV 5

Joystick

OK ?

Notice:

Dozer blade

No: Hue001 Stand: Jun02

CHECK LIST

Maintenance

5002

Fabr.No.: Work hrs./Dat.

Function

Motion

Symbol

CHECK LIST Neuson Baumaschinen Press.Limit.Valve Measure point

Check ed:

Setting (1)

PUMP 1

Page B13

Drive left

X Setting Fall

245 bar +/- 3

UP

245 bar +/- 3

DOWN

Setting Fall Measuring point Setting Fall MP 1 Setting

245 bar +/- 3

OUT

Primary press.

Limiting valve PPLV 1

IN

(Main valve block)

(Main valve block) Fall

25 bar 25 bar 25 bar

245 bar +/- 3 25 bar

Setting Fall

245 bar +/- 3

FORWARD

Setting Fall

245 bar +/- 3

BACKWARD

25 bar 25 bar

> > > > > > > > > > > >

PUMP 2 Dipper stick (Arm)

9707749 Feb 03

Auxiliary hydraulics

X

245 bar +/- 3

OUT

Setting Fall

245 bar +/- 3

IN

Setting Fall Measuring point Setting Fall MP 2 Setting

245 bar +/- 3

FORWARD

Primary press.

Limiting valve PPLV 2

BACKWARD

(Main valve block)

(Main valve block) Fall

25 bar 25 bar 25 bar

245 bar +/- 3 25 bar

Setting Fall

245 bar +/- 3

A

245 bar +/- 3

B

Setting Fall

25 bar 25 bar

> > > > > > > > > > > >

Maintenance

Id.No.: Edition:

Drive right

Notice:

Buck et

OK?

Notice:

Boom

No: Hue Stand: J

SERVICE MANUAL

NEUSON

Checked:

PRESSURE

5002 - 6002

6002

Fabr.No.: Work hrs./Dat.

PRES SURE CHECK LI ST

Fabr.No.:

Date:

Work hours

Checked:

PUMP 3

Auxiliary hydraulics

Setting Fall

220 bar

UP

Setting Fall

220 bar

DOWN

Setting Measuring point Fall MP 3 (Main valve block) Setting Fall

220 bar

A (2)

Primary press.

Limiting valve PP LV 3

B (2)

(Main valve block)

/

Arm swing

LEFT

(Swivel motor) (3)

Page B14

RIGHT Secondary press.

Swivel uppercarriage

LEFT

Limiting valve

RIGHT

( Swivel motor !)

SP LV 4

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 5

> >

+/- 5

> >

20 bar 20 bar 20 bar

220 bar 20 bar

Setting Fall

220 bar

Setting Fall

220 bar

Sett. (4): Fall

206 bar

Sett. (4): Fall

206 bar

20 bar 20 bar bar bar

PILOT PRESSURE SYSTEM

X

Id.No.: Edition:

PRV... Pressure reducting valve PLV... Pressure limiting valve (1)... N oti c e: pr es s ur e s etti ngs c or r es pond wi th the F ab r . N o. of your ex c avator !

Please, always compare with the pressure setting in chapter "technical data" !

9707749 Feb 03

(2)... Notice: Setting only correct without secundary pressure limiting valves !

(3)... Function swviel: see chapt. "Technical Data", see chapt. "Maintenance" (4)... See chapt."Technical data": version 4408400, 4408490 - different settings

bar

SERVICE MANUAL

All

35 bar +/- 2

5002 - 6002

Measuring point Setting MP 4 (Pilot oil Fall (Pilot oil supply unit) supply unit) PRV 5

Joystick

Notice:

Dozer blade

X

Maintenance

Neus on 6002

PRESSURE

Function

CHECK LIST Neuson Baumaschinen

Checked:

Motion

Symbol

Press.Limit.Valve Measure point

Check ed:

Setting (1)

PUMP 1

Page B15

Drive left

Setting Fall

bar

UP

Setting Fall

bar

DOWN

Measuring point Setting Fall MP 1 Setting

bar

OUT

Primary press.

Limiting valve PPLV 1

IN

(Main valve block)

(Main valve block) Fall

bar bar bar bar bar

Setting Fall

bar

FORWARD

Setting Fall

bar

BACKWARD

bar bar

> > > > > > > > > > > >

PUMP 2 Dipper stick (Arm)

9707749 Feb 03

Auxiliary hydraulics

X Setting Fall

bar

OUT

Setting Fall

bar

IN

Measuring point Setting Fall MP 2 Setting

bar

FORWARD

Primary press.

Limiting valve PPLV 2

BACKWARD

(Main valve block)

(Main valve block) Fall

bar bar bar bar bar

Setting Fall

bar

A

Setting Fall

bar

B

bar bar

> > > > > > > > > > > >

Maintenance

Id.No.: Edition:

Drive right

Notice:

Buck et

X

Notice:

Boom

OK?

SERVICE MANUAL

NEUSON 5002-6002

No: Hue Stand: J

5002 - 6002

Fabr.No.: Work hrs./Dat.

Work hours

PRESSURE CHECK LI ST

Date: Checked:

PUMP 3

Auxiliary hydraulics

Setting Fall

bar

UP

Setting Fall

bar

DOWN

Setting Measuring point Fall MP 3 (Main valve block) Setting Fall

bar

A (2)

Primary press.

Limiting valve PPLV 3

B (2)

(Main valve block)

/

Arm swing

LEFT

(Swivel motor) (3)

RIGHT

Page B16

Secondary press.

Swivel uppercarriage

LEFT

Limiting valve

RIGHT

( Swivel motor !)

SPLV 4

bar bar bar bar bar

Setting Fall

bar

Setting Fall

bar

Sett. (4): Fall

bar

Sett. (4): Fall

bar

bar bar bar bar

PILOT PRESSURE SYSTEM

> > > > > > > > > > > >

PRV... Pressure reducting valve

Id.No.: Edition:

PLV... Pressure limiting valve (1)... Noti c e: pr es s ur e s etti ngs c or r es pond wi th the F ab r . No. of your ex c avator !

Please, always compare with the pressure setting in chapter "technical data" !

(2)... Notice: Setting only correct without secundary pressure limiting valves !

9707749 Feb 03

(3)... Function swviel: see chapt. "Technical Data", see chapt. "Maintenance" (4)... See chapt."Technical data": version 4408400, 4408490 - different settings

bar bar

SERVICE MANUAL

Measuring point Setting MP 4 (Pilot oil Fall (Pilot oil supply unit) supply unit)

5002 - 6002

All

> >

X

PRV 5

Joystick

> >

Notice:

Dozer blade

X

Maintenance

Neus on 50/6002Fabr.No.:

SERVICE MANUAL

Maintenance

5002 - 6002

Fig.: Position of measuring ports ( MP 1 - 3 ) main valve block 5002 / 6002

MP 1

MP 2

MP 3

Fig.: Position of measuring ports ( MP 4 ) control oil unit 5002 / 6002

MP 4

Page B17

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

Fig.: Position of primary pressure limiting valves ( PPLV 1 - 3 ) - main valve block

(example Neuson 6002 - see chapter Hydraulic System)

PPLV 3

PPLV 1

PPLV 2 Fig.: Position of secondary pressure limiting valves ( SPLV ) - swivel unit

SPLV 4

SPLV 4

Page B18

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance

5002 - 6002

Fig.: Position of pressure reducing valve ( PRV 5 ) - control oil unit 1408610

(3) pressure reducing valve ( AP )

Fig.: Position of pressure reducing valve ( PRV 5 ) - control oil unit 1408615

(3) pressure reducing valve ( AP )

Page B19

Id.No.: Edition:

9707749 Feb 03

SERVICE MANUAL

Maintenance 5.

5002 - 6002

HYDRAULIC PUMP

Bleeding of Hydraulic Pump

.

- Shut down device.

- Open breathing/bleeding filter.

- Open screw plug air-bleed screw.

- Drain a small amount of hydaulic oil via the air-bleed screw.

- Bleed suction line via measuring port.

Fig.: Position 9of pump air-bleed screws 5002 / 6002 air-bleed screw 5002

air-bleed screw 6002

Bleeding of Suction Line

.

The measuring port mounted on the pump suction line (in the engine compartment) is provided for venting the pump suction line.

Page B20

Id.No.: Edition:

9707749 Feb 03

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