DOWNLOAD PDF Wacker Neuson 1403 1503 1903 2203 Compact Excavator Service Manual 1000081432

Service-Manual

Compact Excavator

Machine model

1403-2203

Edition

1.1

Language

English

Item No.

1000081432

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Documentation Description

Order no.

Operation manual

1000147740

Service manual

1000081432

Spare parts list

1000135987 / 1403 1000141528 / 1503 1000141530 / 1903 1000141542 / 2203

Copyright – 2005 Neuson Baumaschinen GmbH, Linz-Leonding Printed in Austria All rights reserved No part of this publication may be reproduced, translated or used in any means - graphic, electranic or mechanical including photocopying, recording, taping or information storage or retrieval systems - without prior permission in writing from Neuson Baumaschinen GmbH. Thecover features the machine with possible optional equipment.

Neuson Baumaschinen GmbH Haidfeldstrasse 37 A-4060 Linz-Leonding Dokument: Order-Nr.: Edition:

SERV-HB 1403 - 2203DE 1000081432 1.1

TABLE OF CONTENT : Chapter O Cover page, table of content Product history A Technical data Primary dimensions ..........................................................

Kinematic ..........................................................

Lift capacity ..........................................................

Hydraulic settings ..........................................................

Diesel engine settings ..........................................................

Maintenance fillings ..........................................................

Tightening torques ..........................................................

Page

A2 A8 A10 A15 A18 A20 A25

B 1 2 3 4 5 6 7 8 9 10

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

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

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

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

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

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

Auxiliary hydraulic system.........................................................

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

Cabin .........................................................

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

B2 B6 B21 B21 B22 B22 B23 B24 B25 B26

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

Hydraulic Hydraulic diagram Hydraulic pump Pilot oil supply unit Main valve block Dozer blade valve Pilot control valves Swivel unit Drive unit Swivel joint Switch valves Collecting tube Pilot hoses panel Oil tank Check valves

C2 C6 C12 C19 C29 C32 C34 C37 C41 C45 C46 C47 C51 C52

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

TABLE OF CONTENT : D E F G

Diesel engine Elektric Major components Attachment

Abbreviations : AP ...

MP ...

PPLV ...

SPLV ...

TT ...

Pb1 ...

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

Edition January 2003, Copyright Neuson Baumaschinen Neuson reserves changes

PRODUCT HISTORY This overall lists the main technical modifications of the excavator types Neuson 1403 Step

Excavator code

Fabr.No.:

Production start Modification

Neuson 1403 Neuson 1403

AB00440 AB00440

Neuson 1403 Neuson 1403

AC01263 AC01800

Neuson 1403 Neuson 1403

AC01876 AC01876

.

Neuson 1503 Step

Excavator code

Fabr.No.:

Production start Modification

Neuson 1503 Neuson 1503

AB00440 AB00440

Neuson 1503 Neuson 1503 Neuson 1503

AC00304 AC00985 AC01800

Neuson 1503 Neuson 1503

AC01876 AC01876

Modification / Part group - Cabin handles (SNews 57) - Joystick console opening angle - Fuel- and air filter position - Dozer blade lever - Hydraulic pump new (SNews 64) - Check valve / boom offset cylinder (SNews 72) - Joystick console (IV) short (News72) - Joystick console (IV) hardening cover (SNews 74/02) .

Modification / Part group - Cabin handles (SNews 57) - Joystick console opening angle - Fuel- and air filter position - Dozer blade lever - Diesel engine 3TNE74 (SNews 58) - New oil tank breather - Check valve / boom offset cylinder (SNews 72) - Joystick console (IV) short (News72) - Joystick console (IV) hardening cover (SNews 74/02)

PRODUKTENTWICKLUNG Neuson 1903 Step

Excavator code

Fabr.No.:

Production start Modification

Neuson 1903 Neuson 1903

AB00440 AB00440

Neuson 1903 Neuson 1903

AC00985 AC01800

Neuson 1903 Neuson 1903

AC01876 AC01876

.

Neuson 2203 Step

Excavator code

Fabr.No.:

Production start Modification

Neuson 2203 Neuson 2203

AB00440 AB00440

Neuson 2203 Neuson 2203 Neuson 2203

AC00304 AC00985 AC01800

Neuson 2203 Neuson 2203

AC01876 AC01876

Neuson 2203

AC02074

Modification / Part group - Cabin handles (SNews 57) - Joystick console opening angle - Fuel- and air filter position - Dozer blade lever - New oil tank breather (SNews 67) - Check valve / boom offset cylinder (SNews 72) - Joystick console (IV) short (News72) - Joystick console (IV) hardening cover (SNews 74/02)

.

Modification / Part group - Cabin handles (SNews 57) - Joystick console opening angle - Fuel- and air filter position - Dozer blade lever - Diesel engine 3TNE74 (SNews 58) - New oil tank breather (SNews 67) - Check valve / boom offset cylinder (SNews 72) - Joystick console (IV) short (News72) - Joystick console (IV) hardening cover (SNews 74/02) - Check valves tilt cylinder

SERVICE MANUAL

Technical Data

1403 - 2203

CHAPTER A:

Technical Data ( Neuson Service Manual 1403 - 2203 )

Page A1

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data 1.

1403 - 2203

PRIMARY DIMENSIONS Pict: Primary dimensions 1403

Page A2

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Pict.: Primary dimensions 1503

Page A3

Id.No.: Edition:

9707747 Jan 03

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SERVICE MANUAL

Technical Data

1403 - 2203

Pict.: Primary dimensions 1903

Page A4

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Pict. : Primary dimensions 2203

Page A5

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data 1.

1403 - 2203

PRIMARY DIMENSIONS

Primary dime nsions Unit

14 03

15 03

15 03

3TN E68EN SR

3TN E74EN SR 2

AB00440

>> Starting with Fabr.No.

AC00304

Dimensions ( H x W x L )

mm

2380 / 990 / 2700

2380 / 990 / 2700

2380 / 990 / 2700

Axle distance

mm

1080 / 1454

1223 / 1605

1223 / 1605

Transport length Boom swing angle

Left / right

Front boom swing radius

min

Tilt angle uppercarriage Ground clearance

max

Undercarriage width

mm

3836

3810

3810

degr

80 / 45

80 / 45

80 / 45

mm

1555

1555

1555

degr

N

N

N

mm

200

200

200

mm

990

990 bis 1300

990 bis 1300

Track width

Standard

mm

230

230

230

Max. Dump height

Standard

mm

2495

2545

2545

Max. Dump height / Option

Dipperstick long

mm

N

2665

2665

Max. Dig height

Standard

mm

3450

3500

3500

Max. Dig height / Option

Dipperstick long

mm

N

3620

3620

Max. Dig radius

Standard

mm

3770

3770

3770

Max. vertical dig depth

Standard

mm

2235

1490

1490

Max. dig depth

Standard

mm

2235

2185

2185

Min. tail swing radius

mm

1160

1160

1160

Dozer blade dimensions ( W x H ) Standard

mm

990 / 235

990 / 260

990 / 260

Dozer blade max. lift ... Ground

above / below

mm

230 / 260

260 / 230

260 / 230

Track rollers / guide rollers

per side

pcs

3

3

3

Operation weight with

Cab

kg

1560

1705

1705

Operation weight with

Canopy

kg

1477

1625

1625

Ground pressure

Standard

k g/cm²

0,28

0,27

0,27

Gradability

degr / %

30 / 58

30 / 58

30 / 58

Noise level

LWA

dB (A)

92

93

93

Noise level

LPA

dB (A)

74

77

77

Travel speed

Drive

k m/h

2,3 / 4,5

2,8 / 5,6

2,8 / 5,6

Tear out force per

Buck et tooth

kp

1389

1735

1735

Max. dipper stick tear out force

Standard

kp

852

1038

1038

Slew ( swivel- ) speed

Uppercarriage

rpm

10

10

10

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

Page A6

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

P rim a ry dim e nsions Unit

1903

2203

AB00440

>> Starting with Fab r.No. Dimensions ( H x W x L )

mm

2375 / 990 / 2715

2395 / 990 / 2715

Axle distance

mm

1325 / 1710

1325 / 1710

Transport length Boom swing angle

Left / right

Front b oom swing radius

min

Tilt angle uppercarriage Ground clearance

max

Undercarriage width

mm

3990

3990

degr

80 / 45

80 / 45

mm

1575

1575

degr

N

15

mm

180

180

mm

990 bis 1300

990 bis 1300

Track width

Standard

mm

250

250

Max. Dump height

Standard

mm

2760

2780

Max. Dump height / Option

Dipperstick long

mm

2890

2915

Max. Dig height

Standard

mm

3860

3885

Max. Dig height / Option

Dipperstick long

mm

3990

4275

Max. Dig radius

Standard

mm

4090

4090

Max. vertical dig depth

Standard

mm

1670

1650

Max. dig depth

Standard

mm

2500

2480

Min. tail swing radius

mm

1160

1160

Dozer blade dimensions ( W x H ) Standard

mm

990 / 260

990 /260

Dozer blade max. lift ... Ground

above / below

mm

245 / 238

245 / 238

Track rollers / guide rollers

per side

pcs

4

4

Operation weight with

Cab

kg

1944

2017

Operation weight with

Canopy

kg

1854

1927

Ground pressure

Standard

k g/cm²

0,27

0,28

degr / %

30 / 58

30 / 58

Gradability Noise level

LW A

dB (A)

94

94

Noise level

LPA

dB (A)

75

75

Travel speed

Drive

k m/h

2,0 / 4,0

2,0 / 4,0

Tear out force per

Buck et tooth

kp

1846

1846

Max. dipper stick tear out force

Standard

kp

1198

1198

Slew ( swivel- ) speed

Uppercarriage

rpm

10

10

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

Page A7

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data 2.

1403 - 2203

KINEMATIK Unit

1403

1503

1903

E

Bolt diameter

mm

32

F

Dipper stick width

mm

118

L

Bolt distance Bucket carrier

mm

129,5

Page A8

2203

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab.: Kinematic - Overall

Kinematic

Unit

1200 - 1501 RD 1302 - 1502 RD

1702 - 2201 RD 1702 - 2202 RD

2100 - 2700 RD

30

E

Bolt diameter

mm

32

F

Dipper stick width

mm

108

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 A9

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data 3.

1403 - 2203

LIFT CAPACITY CHARTS

Tab.: Lift capacity - 1403

Page A10

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab.: Lift capacity - 1503

Page A11

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab.: Lift capacity - 1903

Page A12

Id.No.: Edition:

9707747 Jan 03

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SERVICE MANUAL

Technical Data

1403 - 2203

Tab.: Lift capacity - 2203

Page A13

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

LIFT CAPACITY CHART Max..

A......

B...... *.......

allowable load with extended dipper stick overhang from the center of the turntable Height of load fixing pint Lift capacity restricted by the hydraulics

All Chart figures are given in kg rated on level, secured ground without bucket. ... dozer blade support in drive direction ... dozer blade support 90° to drive direction If a bucket or other attachment is mounted the lift capacity, tip load is reduced by their own weight.

Calculation: ISO 10567 The lift force of the compact excavator is restricted by the setting of the pressure valves and the tip over security. Neither the 75 percent of the static tip load or the 87 percent from the hydraulic lift capacity are exceeded.

Page A14

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203 4.

CYCLE COURSES Neuson 1403

Machine model Classification

Item

Check conditions

Unit

Neuson 1503

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 A15

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Neuson 1903

Machine model Classification

Item

Unit

Check conditions

Neuson 2203

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

---

---

---

---

---

---

---

---

UPPER FRAME ROTATION

Max. extension of the equipment, w ithout load

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 A16

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Classification

Item

Upper frame rotation

Machine model

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

Neuson 1403

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 1503

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 > 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:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

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 1903

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 2203

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 > 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 A18

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 1403

Check conditions

Unit

Neuson 1503

Value normal

Value

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 )

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 (cylinder stops. 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 A19

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 1903

Check conditions

Unit

Neuson 2203 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)

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 (cylinder stops. 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 A20

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

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 1503

Value

---

---

LOWERING

RAISING

Item

Neuson 1403

---

---

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 > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dozer blade 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 A21

Id.No.: Edition:

9707747 Jan 03

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DOWNLOAD THE COMPLETE MANUAL

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SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Neuson 1903

Machine model Check conditions

Boom

Position for the check w ithout load

Unit

Value

---

---

LOWERING

---

---

IN

---

---

OUT

allow ed

---

---

LOADING

normal

---

---

DUMPING

allow ed

---

---

RAISING

Bucket teeth onto the ground

normal

---

---

LOWERING

RAISING

Item

Neuson 2203

Value

---

---

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 > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dozer blade 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 A22

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Neuson 1403

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 1503 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 A23

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Cycle courses - excavators

Hueman / 25. April 03

Neuson 1903

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 2203 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 A24

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203 5.

HYDRAULIC SYSTEM

Tab.: Hydraulics 1403 - 1503 Excavator type

Unit

S tarted with Fabr. No. . :

1403

1403

AB00440

AC01263

Gear pump 1208144

Gear pump 1428407

1503

1503

3TNE68ENSR

3TNE74ENSR2

AB00440

AC00304

HY DRAULI C P UMP

1

Type

3 sect. GP

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

Variable / gear pump Variable / gear pump

1528401

1528401

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

W9A3-08-08-08..

3 sect. GP WP09A3B-070070-070-..

3 x 18,5

3 x 16,2

150

175

200

200

+3 / -3

+3 / -3

+3 / -3

+3 / -3

2 3

l/min l/min

PVD-0B-20BP-8GA5-4953(A) PVD-0B-20BP-8G3-4953(B) 23 + 23 + 18,5 + 10 23 + 23 + 18,5 + 6

P RE S S URE S E TTI NG Main pressure limiting valve 7

Pump P 1, P 2

(2)

bar

150

150

175

200

(2)

bar

+3 / -3

+3 / -3

+3 / -3

+3 / -3

35

35

30

30

bar

+2/ -2

+2/ -2

+2/ -1

+2/ -1

Main pressure limiting valve 8

Pump P 3

9

Pilot oil pressure

245

245

245

245

(3)

bar

+5 / -2

+5 / -2

+5 / -2

+5 / -2

N

N

N

Secondary press. limit. valve 10

Main valve block Secondary press.limit.valve

11

Dozer blade valve

(3)

bar

N

Swivel motor (SPLV) (Measuring points pump)

125

125

125

125

12

(3)

bar

-0 / +23

-0 / +23

-0 / +23

-0 / +23

N

N

N

N

bar

( Damping valves )

( Damping valves )

( Damping valves )

( Damping valves )

bar

N

N

N

N

21

21

21

21

Drive motor Internal press.limit.valve Check valve 15 Boom offset cylinder 14

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)

QUANTI TI E S 16

Hydraulic oil tank

Liter

17

System filling

Liter

Explanation: N...Not enclosed / not available

Service News

Theme: Solution: Fabr.Nr.:

Service News 64/02: Higher working pressure for P1,P2 New hydraulic pump (1428407) AC01263 starting Page A25

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab.: Hydraulic 1903 - 2203 Excavator type

Unit

S tarted with Fabr. No. .:

1903

2203

AB00440

AB00440

HYDRAULI C P UMP Variable / gear pump 1

Type

1928401 Single variable pump with 2 press. ports + 2 gear pumps

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

PVD-0B-20BP-8GA5-4952A PVD-0B-20BP-8G3-4952B 23 + 23 + 18,5 + 10 23 + 23 + 18,5 + 6

3

l/min l/min

DRUCKE I NSTE LLUNG Main pressure limiting valve 7

Pump P 1, P 2 Pump P 3

9

Pilot oil pressure Main valve block

+3 / -3

200

200

+3 / -3

+3 / -3

(2)

bar

30

30

bar

+2/ -1

+2/ -1

245

245

(3)

bar

+5 / -2

+5 / -2

N

Secondary press. limit. valve 10

200

+3 / -3

bar

Main pressure limiting valve 8

200 (2)

Secondary press.limit.valve 11

Dozer blade valve

(3)

bar

N

Swivel motor (SPLV) (Measuring points pump)

150

150

12

(3)

bar

-0 / +23

-0 / +23

N

N

bar

( Damping valves )

( Damping valves )

bar

N

N

Drive motor Internal press.limit.valve Check valve 15 Boom offset cylinder 14

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)

QUANTI TI E S 16 Hydraulic oil tank

Liter

System filling

Liter

17

21

Explanation: N...Not enclosed / not available

Page A26

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab. Pressure controlled oil flow - auxiliary hydraulic

A U X IL IA R Y H Y D R A U L IK 1

E xc a va t o r

1403

1503

(Z P 1208144)

3T N E68EN SR

1903

2203

P r e s s u r e c o n tr o l l e d o i l fl o w - a u x i l i a r y h yd r a u l i c ( L / m i n )

D ru c k ( b ar )

P1+P2

P2+P3

P2+P3

15

39,0

42,0

43,0

30

38,5

40,5

42,5

45

38,5

38,5

41,5

60

38,0

37,0

40,0

75

38,0

35,0

38,5

90

37,0

33,5

36,5

105

33,0

31,0

34,5

120

25,0

29,0

33,0

135

13,0

27,0

31,0

150

5,0

21,5

29,5

165

-

9,0

26,0

180

-

-

22,0

C o n d i ti o n s : 1 ) P r e s s u r e = P r e s s u r e s e tti n g a t th e to o l ( b u c k e t) 2 ) T o l e r a n c e o f th e l i s te d s e tti n g s : + 1 / - 2 L /m i n 3 ) O i l fl o w c o n tr o l l e d a t th e r e g u l a r d i p p e r s ti c k c o n n e c ti o n s

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 A27

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data 6.

1403 - 2203

DIESEL ENGINE Excavator type

Unit

Neuson

Neuson

Neuson

1403

1503

1503

S P E CIFICATI ON:

1

Diesel engine m odel

2

Started with Neuson Fab r.No.:

3

Type Suction system Comb ustion system Glow system

4 5 6 7 8 9 10 11

Direction of rotation Governor Lub rication system Starting system Cooling sys tem DATA:

rpm

14

Revolution speed

rpm

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

AB00440

AC00304

Yanmar

Forced lub rication with trochoid pump Electric al W ater cooled / Pushing van

Max. revolution speed ( no load )

Min. revolution speed (no load) Displacement (Bore x Strok e) Output ( at rev. Speed 14 ) Max. engine output No. of cylinder Valve c learance (IN=OUT) Compression ratio Fuel injection tim ing Fuel injection pressure Compression pressure Engine oil pressure (rev. speed level) Pressure switch engine oil pump Thermostat opening tem perature Thermostat open total Thermo switch On / Out Firing order Generator power (Standard) Battery V-Belt measurings TI GHT E NING TO RQUE S :

3T N E74- EN SR 2

Vertical, 4-cycle water cooled diesel engine Natural suction Special swirl pre-com b ustion chamb er Glow plugs inside the pre.com b . Cham b er Countercloc k wis e (viewed from flywheel) Mechanical centrifugal governor (All speed type)

12

15

Yanmar 3 T N E 6 8 -E N S R

rpm ccm KW ( PS ) KW ( PS ) pcs mm deg b ar b ar b ar b ar °C °C °C A /V V / Ah mm

2350 +50 / -50

2390 +50 / -50 2200 +25 / -25

1300 +50 / -0 1006 ( 74x78 ) 784 ( 68x72 ) 8,7 ( 11,8 ) 11,8 ( 16,0 ) 14,5 (19,4 ) 17,7 ( 23,7 ) 3 0,15 - 0,25 23,0 14 +/-1 120 0/+10 33 +/-1 at 250 rpm 35 +/-1 at 250 rpm 3,0 - 4,0 0,4 - 0,6 69,5 - 72,5 85 107 - 113 / 100 and more 1-3-2-1 15 / 12 12 / 45 9,5 x 925 9,5 x 855 38 - 42 ( M8x1,25 )

60 - 65 ( M9x1,25)

34

Cylinder head b olt

Nm

35

Bonnet screw nut

Nm

36

Connec tion rod b olt

Nm

37

Metal c ap c lamping b olt

Nm

38

Flywheel clamping b olt

Nm

39

Glow plug QUANTIT IE S

Nm

15 - 20 ( M10x1,25 )

Liter Liter Liter

24 2,4 / 1,0 0,9

Quality

API grade CC classe or higher

Fuel tank Engine oil - oil pan (Max./Effect) 42 Cooling water content (without cooler) Q U A LI T Y 43 Engine oil 40 41

N 23 -28 ( M7x1,0 ) 53 - 57 ( M10x1,25 ) 82 - 88 ( M10x1,25 )

Page A28

80 - 85 ( M10x1,25) 80 - 90 ( M10x1,25 )

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

1403 - 2203

Tab. Diesel engine -Settings Excavator type

Unit

Neuson

Neuson

1903

2203

S P E CI F I C A T I O N :

1

Diesel engine model

2

Started with Neuson Fabr.No.:

3

Type Suction system Comb ustion system Glow system

4 5 6 7 8 9 10 11

Yanmar 3 T N E 7 4 -E N S R 2 A B 00 4 4 0 Vertical, 4-cycle water cooled diesel engine Natural suction Special swirl pre-combustion chamber Glow plugs inside the p.c.Chamb er Counterclock wise (viewed from flywheel) Mechanical centrifugal governor

Direction of rotation Governor Lub rication system Starting system Cooling system D A T A:

Forced lubrication with trochoid pump Electrical W ater cooled / Pushing van

12

Max. revolution speed ( no load )

rpm

2 39 0 +50 / -50

14

Revolution speed

rpm

2 20 0 +25 / -25

15 16 17 18 19 20 21 22 23 24 25 26 27 28 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 Thermostat open total Thermo switch On / Out Firing order Generator power (Standard) Battery V-Belt measurings TIGHTE NING TORQUE S :

A /V V / Ah mm

1 30 0 +50 / -0 1006 ( 74x78 ) 11,8 ( 16,0 ) 17,7 ( 23,7 ) 3 0,15 - 0,25 23,0 14 +/-1 120 0/+10 35 +/-1 at 250 rpm 3,0 - 4,0 0,4 - 0,6 69,5 - 72,5 85 107 - 113 / 100 and more 1-3-2-1 15 / 12 12 / 45 9,5 x 925 60 - 65 ( M9x1,25)

rpm ccm KW ( PS ) KW ( PS ) pcs mm deg b ar b ar b ar b ar °C °C °C

34

Cylinder head b olt

Nm

35

Bonnet screw nut

Nm

36

Connection rod b olt

Nm

37

Metal cap clamping b olt

Nm

38

Flywheel clamping bolt

Nm

39

Glow plug QUANTI TIE S

Nm

N 23 -28 ( M7x1,0 ) 80 - 85 ( M10x1,25) 80 - 90 ( M10x1,25 ) 15 - 20 ( M10x1,25 )

Liter Liter Liter

24 2,4 / 1,0 0,9

Quality

API grade CC Klasse or higher

Fuel tank Engine oil - oil pan (Max./Effect) 42 Cooling water content (without cooler) Q U A LI T Y 43 Engine oil 40 41

Page A29

Id.No.: Edition:

9707747 Jan 03

SERVICE MANUAL

Technical Data

Service News

Theme: Fabr.Nr.:

1403 - 2203 Service News 58/01: New diesel engine 3TNE74 for 1503 !

AC00304 and higher Changed technical data !

Page A30

Id.No.: Edition:

9707747 Jan 03

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Specifications 3TNE 68, 3TNE 74, 3TNV 76 (supplement) Chassis

Sturdy steel sheet chassis, rubber-mounted engine

Engine 3 TNE 68, 3TNE 74 Engine

Models 1403 – 2203

Product

Yanmar diesel engine

Model

3TE68-ENSR/3TNE74-ENSR2

Design

Water-cooled 4-stroke diesel engine, EPA2

No. of cylinders

3

Fuel injection system

Indirect

Aspiration

Natural aspiration

Cooling system

Water-cooled

Lubrication system

Force-feed lubrication with trochoidal pump

Displacement

784 cm3 (3TNE-68) 1006 cm3 (3TNE-74)

Nominal bore and stroke

74 x 78

Output

Depending on engine type

Max. torque in Nm

44 – 49 Nm (3TNE-68) 61 – 64 Nm (3TNE-74)

Max. engine speed without load

Depending on engine type

Idling speed

Depending on engine type

Valve tip clearance (intake = outlet)

0.15 – 0.25 mm (cold)

1 cylinder

Flywheel side

Compression

23.5 : 1 (3TNE-68) 23.1 : 1 (3TNE-74)

Compression: specified value

3TNE 68, 33 bar/3TNE 74, 35 bar @ 250 rpm

Compression: threshold value

3TNE 68, 26 bar/3TNE 74, 28 bar @250 rpm

Engine oil pressure

3.5 +/- 0.5 bar

Pressure switch for engine oil pump

0.5 +/- 0.1 bar

Thermostat opens at

69.5 – 72.5 °C

Thermal switch

107 – 113 °C

Firing order

1–3–2–1

Direction of rotation

Counterclockwise (as seen from the flywheel)

Starting aid

Intake manifold preheating (preheating time 10 – 15 sec)

Max. inclined position (engine still supplied with oil):

25°/46 % in all directions Observe the machine's hill climbing ability (30°/58%)!

Specific fuel consumption

Depending on engine type

Exhaust values according to

SERV-HB 1403 – 2203 DE- Edition 1.1 *1403-2203_EPA2 210.mif

97/68/EC Tier II EPA Tier I

A-31

Fuel injection pump

Model Design

In-line fuel injection pump

Injection pressure

120 +10 bar

Revs control

Mechanical

Injection time

14° +/- 1°

Lubrication system

Forced feed lubrication

Capacity Capacities

Models 1403 – 2203

Fuel tank

24 l

Engine oil (max./effect.)

2.7/1.2 l (3TNE-68) 2.3/1.1 l (3TNE-74)

Coolant (engine)

0.9 l

Radiator

2.0 l

Expansion tank

0.5 l

Tightening torques

Models 1403 – 2203

Tightening torque

Cylinder-head bolt Connecting rod bearing screw

3 TNE 68 (M8x1.25) 38 – 42 Nm 3 TNE 74 (M9x1.25) 60 – 65 Nm 3 TNE 68/74 (M7x1.0) 23 – 28 Nm

Main bearing screw Flywheel screw

A-32

82 – 88.8 Nm (M10x1.25)

SERV-HB 1403 – 2203 DE- Edition 1.1 * *1403-2203_EPA2 210.mif

Engine 3TNV 76

Engine

Models 1403 – 2203

Product

Yanmar diesel engine

Model

3 TNV 76 – SNS

Design

Water-cooled 4-stroke diesel engine, EPA2

No. of cylinders

3

Fuel injection system

Indirect

Aspiration

Natural aspiration

Cooling system

Water-cooled/blowing fan

Lubrication system

Force-feed lubrication with trochoidal pump

Displacement

1116 cm³

Nominal bore and stroke

76 x 82 mm

Output in kW

13.2

Max. torque in Nm

65.8 @ 1600 rpm

Max. engine speed without load

2375 +/- 25 rpm

Idling speed

1300 +/- 25 rpm

Valve tip clearance (intake = outlet)

0.15 – 0.25 mm (cold)

1 cylinder

Flywheel side

Compression

23.5 : 1

Compression: specified value

35 bar @ 250 rpm

Compression: threshold value

28 bar @ 250 rpm

Compression

35 +/- 1 bar @ 250 rpm

Engine oil pressure under full load

0.3 – 0.45 bar

Pressure switch for engine oil pump

0.5 +/- 0.1 bar

Thermostat opens at

69.5 – 72.5 °C

Thermal switch

107 – 113 °C

Firing order

1–3–2–1

Direction of rotation

Counterclockwise (as seen from the flywheel)

Starting aid

Glow plugs (preheating time 4 seconds)

Max. inclined position (engine still supplied with oil):

SERV-HB 1403 – 2203 DE- Edition 1.1 *1403-2203_EPA2 210.mif

25°/46% in all directions 30°/58% 3 minutes.

Observe the machine's hill climbing ability (30°/58%)!

Specific fuel consumption

272 g/kWh

Exhaust values according to

EPA Tier II

A-33

Fuel injection pump Model Design

In-line fuel injection pump

Injection pressure

120+10 bar

Revs control

Mechanical

Injection time

16°

Lubrication system

Forced feed lubrication

Capacities

Models 1403 – 2203

Engine capacities

Fuel tank

24 l

Engine oil (max./effect.)

3.4/1.6 l

Coolant (engine)

0.9 l

Radiator

1.2 l

Expansion tank

0.5

Engine tightening torques

A-34

Tightening torques

Models 1403 – 2203

Cylinder-head bolt

53.9 – 57.9 Nm (M9x1.25)

Connecting rod bearing screw

22.6 – 27.5 Nm (M7x1)

Main bearing screw

75.5 – 81.5 Nm (M10x1.25)

Flywheel screw

80.4 – 86.4 Nm (M10x1.25)

SERV-HB 1403 – 2203 DE- Edition 1.1 * *1403-2203_EPA2 210.mif

Page A35

100 Nm 180 Nm

SW 36

SW 41

M30x2

M36x2

20 22L

25 28L

Id.No.: Edition:

270 Nm SW 50 M42x2

25 30S

400 Nm

180 Nm SW 41 M36x2

20 25S

SW 60

100 Nm SW 36

M30x2

16 20S

M52x2

90 Nm SW 30

12 16S M24x1,5

32 38S

75 Nm SW 27

10 14S M22x1,5

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

60 Nm

SW 24

08 12S M20x1,5

1403 - 2203

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)

Metric hose joints for hydraulic assembling

Quelle: Fa. Schieffer

7.

for hydraulic joints and dry assembling

Tightening torque

SERVICE MANUAL Technical Data

TIGHTENING TORQUES

9707747 Jan 03

Quelle: Fa. Schieffer

Technical Data

Tightening torques for hydraulic screw joints and dry assembling Screws with different seal types for hydraulic use Light verison GE mit E inschraubz apfen S eal E D-Seal O-Ring washer

RHV with E D-seal

outside bore-Ø

S crew

9 Nm

18 Nm

15 Nm

18 Nm

10 mm

M12x1,5 20 Nm

25 Nm

25 Nm

25 Nm

M14x1,5 35 Nm

45 Nm

35 Nm

M16x1,5 45 Nm

55 Nm

M18x1,5 55 Nm

M12x1,5

20 Nm

35 Nm

35 Nm

35 Nm

12 mm

12 mm

M14x1,5

35 Nm

55 Nm

45 Nm

45 Nm

14 mm

35 Nm

14 mm

M16x1,5

45 Nm

70 Nm

55 Nm

55 Nm

16 mm

40 Nm

50 Nm

16 mm

M18x1,5

55 Nm

90 Nm

70 Nm

70 Nm

18 mm

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

Id.No.: Edition:

Whitworth screw

Page A36

Metric screw

M10x1,0

Metric screw

outside bore-Ø

9707747 Jan 03

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

RHV with E D-seal

1403 - 2203

GE mit E inschraubz apfen S eal E D-Seal O-Ring washer

S crew

Whitworth screw

Heavy version

1403 - 2203

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 A37 9707747 Jan 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

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

DIN 912

SERVICE MANUAL

Tightening torque for high quality screws

Technical Data

Type relativ tightening torques for high quality screw joints Tightening torque M A for Neuson 1403 - 2203 1403 RD

1503 RD

1903 RD

2203 RD

Page A38

Turn table

M12 10.9

120 Nm

M12 10.9

120 Nm

M12 10.9

120 Nm

M12 10.9

120 Nm

Track roller

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

Swivel joint

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

Sprocket

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

Drive unit

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M10 10.9

64 Nm*

M12 10.9

120 Nm

M12 10.9

120 Nm

M12 10.9

120 Nm

M12 10.9

120 Nm

M12 12.9

120 Nm

M12 12.9

120 Nm

M12 12.9

120 Nm

M12 12.9

120 Nm

Cab fixing screw

M10 10.9

64 Nm

M10 10.9

64 Nm

M10 10.9

64 Nm

M10 10.9

64 Nm

Engine carrier

M10 8.8

50 Nm

M10 8.8

50 Nm

M10 8.8

50 Nm

M10 8.8

50 Nm

M10 10.9

50 Nm

M10 10.9

50 Nm

M10 10.9

50 Nm

M10 10.9

50 Nm

M8 8.8

25,5 Nm

M8 8.8

25,5 Nm

M8 8.8

25,5 Nm

M8 8.8

25,5 Nm

Pump carrier

M10 8.8

50 Nm

M10 8.8

50 Nm

M10 8.8

50 Nm

M10 8.8

50 Nm

Pump

M12 8.8

79 Nm

M12 8.8

79 Nm

M12 8.8

79 Nm

M12 8.8

79 Nm

Swivel unit

SERVICE MANUAL

9707747 Jan 03

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

1403 - 2203

Id.No.: Edition:

Engine bearings

SERVICE MANUAL

Maintenance

1403 - 2203

CHAPTER

B:

Maintenance ( Neuson Service Manual 1403 - 2203 )

Page - B 1

Id.No.: 9707747 Edition: Jan 03

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

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SERVICE MANUAL

Maintenance

1403 - 2203

1.

MAINTENANCE SCHEDULE

Servicing activity component

Neuson 1403 - 2203

every 10 h

every 50 h

every 250 h

every 500 h every 1000 h

(daily)

(weekly)

(6 months)

(12 months)

(18 months)

annual

MOTOR 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

<>(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

O X

- Check - Clean

<> <> (1)

Page - B 2

- Change/Replace - Change/Replace the first time

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

Servicing activity component

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

<> <> (1)

Page - B 3

- Change/Replace - Change/Replace the first time

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

Servicing activity component

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

(weekly)

(6 months) (12 months)

every 1000 h (18 months)

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

<> <> (1)

Page - B 4

- Change/Replace - Change/Replace the first time

Id.No.: 9707747 Edition: Jan 03

annual

SERVICE MANUAL

Maintenance

1403 - 2203

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 - B 5

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

2.

HYDRAULIC SYSTEM Neuson 1403

Pressure Test

.

> 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 chapt. Technical Data).

The pressure drop (delta P between max. and min. diesel engine speed) is tested at unchanged load.

2.2 Pressure Test of Gear Pump P1 Functions: boom, bucket, driving right, auxiliary hydraulics 2.2.1 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.

2.2.2 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 valves!) 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 right forward / reverse as described in items 2.2.1 and 2.2.2. (Note: auxiliary hydraulic function see item q) 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,..)

2.3 Pressure Test of Gear Pump 2 Functions: dipper stick, driving left, auxiliary hydraulics 2.2.1 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 - B 6

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

2.3.2 Check of pressure drop : m) Check and note the pressure drop of the indvidual functions analogous to items d - g. n) Check the settings and pressure drop of functions dipper stick 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) The function auxiliary hydaulics shows the setting of the primary pressure limiting valve PPLC 1, 2 at measuring ports MP 1, MP 2, if there are no secondary valves installed!

2.4 Pressure Test of Gear Pump P3 Functions: dozer blade, boom offset, swivelling 2.4.1 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. v)

The swivelling function is supplied by pump P3, though the operating pressue 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 valves!)

2.5 Pilot Pressure Test: Functions: hydraulic pilot control 2.5.1 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 - B 7

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

Pict.: Measuring points at the MP panel ( MP - Measuring point)

Position

MP 3 MP 2 MP 1 Pict.: Measuring point at the distribution block,

MP 4

Pict.: Primary- pressure limiting valve at the main valve block ( PPLV 1+ 2)

PPLV 1

EP

Page - B 8

PPLV 2

Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

PPLV 3 (MP 3)

Pict.: Primary- pressure limiting valve at the

dozer blade valve ( PPLV - 3)

Position

Pict.: Pressure reducing valve at the

pilot oil supply unit ( PRV ) (1 ) Pressure reducing valve (AP) - Version 1408615

(2 ) Pilot pressure safty valve

Page - B 9

Id.No.: 9707747 Edition: Jan 03

Function

Motion

Symbol

Press.limit.valve Measuring point

Check ed

Settings (1)

PUMP 1

Page - B 10

Setting Fall

175 bar

OUT

175 bar

FOREWARD

Primary pressure Measuring point Setting Limiting valve Fall PP LV 1 MP 1 Setting (Main valve block) (Main valve block) Fall Setting Fall

175 bar

BACKWARD

Sett. (2): Fall:

175 bar

A

175 bar

B

Sett. (2): Fall

IN Drive right

Auxiliary hydraulics / Boom offset

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

18 bar 18 bar 18 bar

175 bar 18 bar 18 bar bar bar

PUMP 2 Id.No.: 9707747 Edition: Jan 03

Dipper stick

X Setting Fall

175 bar 175 bar

FOREWARD

Primary pressure Measuring point Setting limiting valve Fall PP LV 2 MP 2 Setting (Main valve block) (Main valve block) Fall

175 bar

BACKWARD

Setting Fall

OUT IN

Drive left

+/- 3

> >

+/- 3

> >

+/- 3

> >

+/- 3

> >

18 bar 18 bar

175 bar 18 bar 18 bar

SERVICE MANUAL

Setting Fall

175 bar

DOWN

+/- 3

18 bar

1403 - 2203

Setting Fall

175 bar

UP

Notice:

Buck et

X

Notice:

Boom

OK?

Maintenance

Neuson Excavators

Checked by:

(1)...

PRESSURE CHECKLIST

PLV... Pressure limiting valve PRV... Pressure reducting valve Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

Always compare with the pressure setting in chapter „Technical data“ !

Notice: Setting only correct without secondary pressure limiting valves !

FunctionSwivel: see chapter „Technical data“ and „Maintenance“ See chapt. „Technical data“: different settings

NEUSON

No: H Stand:

(2)...

(3)...

(4)...

1403

Fabr.No: AC 01264 Work hrs/Dat. 50 hrs / 20. Dec 2002

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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

Motion

Symbol

Press.limit.valve Measuring point

Check ed

Settings (1)

PUMP 2

X Primary pressure

A B

Measuring point

limiting valve

P P LV 2

MP 2

(Main valve block)

Main valve block

Sett.(2): Fall

175 bar

Sett. (2): Fall:

175 bar

+/- 3

> >

+/- 3

> >

N bar N bar

PUMP 3

X

150 bar

+/- 3

> >

+/- 3

15 bar

> >

Sett.(4): Fall

125 bar

+23/- 0 >

N bar

>

Sett.(4): Fall:

125 bar

+23/- 0 >

N bar

>

Setting Measuring point Fall MP 3 P P LV 3 (Main valve block) Setting (Dozer blade valve) Fall Primary pressure

Page - B 11

Dozer blade

UP DOWN

Secundary press.

Swivel unit

LEFT

Limiting valve

S P LV 4 RIGHT

15 bar

limiting valve

(Swivel motor!)

/ (Swivel motor) (3)

150 bar

PILOT PRESSURE

Joystick

All

Notice:

Auxiliary hydraulics / Boom offset

OK?

SERVICE MANUAL

Function

Neuson Excavators

1403 - 2203

PRESSURE CHECKLIST

Check by:

(1)...

NEUSON

No: Hue001 Stand: Dez02

PLV... Pressure limiting valve PRV... Pressure reducting valve Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

Always compare with the pressure setting in chapter „Technical data“ !

Notice: Setting only correct without secondary pressure limiting valves !

FunctionSwivel: see chapter „Technical data“ and „Maintenance“ See chapt. „Technical data“: different settings

Fabr.No: A C 01264 Work hrs/Dat. 50 hrs / 20. Dez 2002

(2)...

(3)...

(4)...

1403

X Press. redu.valve

Measuring point

P RV

MP 4

(Pilot oil supply unit) (pilot oil supply u.) Fall:

(1)... Notice: pressure settings correspond with the Fabr.No. of the excavators !

Always compare with the settings in chapter "Technical data" !

(2)... Notice: Setting only "correct" without secondary press. limiting valves installed !

(3)... Function swivel: see chapter "Techncal data", see chapt. Maintenance (4)... See chapter "Technical data": different settings possible

N

bar

Maintenance

Id.No.: 9707747 Edition: Jan 03

PLV... Pressure limiting valve PRV... Pressure reducing valve

35 bar +/- 2

Setting

Symbol

Press.limit.valve Measuring point

Check ed

Settings (1)

PUMP 1

Page - B 12

Setting Fall

bar

OUT

bar

FOREWARD

Primary pressure Measuring point Setting Limiting valve Fall PP LV 1 MP 1 Setting (Main valve block) (Main valve block) Fall Setting Fall

bar

BACKWARD

Sett. (2): Fall:

bar

A

bar

B

Sett. (2): Fall

IN Drive right

Auxiliary hydraulics / Boom offset

bar bar bar bar bar bar bar bar

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

PUMP 2 Id.No.: 9707747 Edition: Jan 03

Dipper stick

X Setting Fall

bar bar

FOREWARD

Primary pressure Measuring point Setting limiting valve Fall PP LV 2 MP 2 Setting (Main valve block) (Main valve block) Fall

bar

BACKWARD

Setting Fall

OUT IN

Drive left

bar bar bar bar bar

> > > > > > > >

SERVICE MANUAL

Setting Fall

bar

DOWN

bar

1403 - 2203

Setting Fall

bar

UP

Notice:

Buck et

X

Notice:

Boom

OK?

Maintenance

Neuson Excavators

(1)...

Motion

Checked by:

PLV... Pressure limiting valve PRV... Pressure reducting valve Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

Always compare with the pressure setting in chapter „Technical data“ !

Notice: Setting only correct without secondary pressure limiting valves !

FunctionSwivel: see chapter „Technical data“ and „Maintenance“ See chapt. „Technical data“: different settings

Function

PRESSURE CHECKLIST

No: H Stand:

(2)...

(3)...

(4)...

NEUSON 1403

Fabr.No: Work hrs/Dat.

Symbol

Press.limit.valve Measuring point

Check ed

Settings (1)

PUMP 2

X Primary pressure

A B

Measuring point

limiting valve

P P LV 2

MP 2

(Main valve block)

Main valve block

Sett.(2): Fall

bar

Sett. (2): Fall:

bar

bar bar

> > > >

PUMP 3

Page - B 13

Dozer blade

X

UP DOWN

Setting Measuring point Fall MP 3 P P LV 3 (Main valve block) Setting (Dozer blade valve) Fall Primary pressure

bar

limiting valve

bar

Secundary press.

Swivel unit

LEFT

Limiting valve

S P LV 4 RIGHT

(Swivel motor!)

/ (Swivel motor) (3)

bar bar

Sett.(4): Fall

bar

Sett.(4): Fall:

bar

bar bar

PILOT PRESSURE

Joystick

All

> > > > > > Notice:

Auxiliary hydraulics / Boom offset

OK?

> >

SERVICE MANUAL

Motion

1403 - 2203

Function

Neuson Excavators

(1)...

PRESSURE CHECKLIST

Check by:

PLV... Pressure limiting valve PRV... Pressure reducting valve Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

Always compare with the pressure setting in chapter „Technical data“ !

Notice: Setting only correct without secondary pressure limiting valves !

FunctionSwivel: see chapter „Technical data“ and „Maintenance“ See chapt. „Technical data“: different settings

NEUSON 1403

No: Hue001 Stand: Dez02

(2)...

(3)...

(4)...

Fabr.No: Work hrs/Dat.

X Press. redu.valve

Measuring point

P RV

MP 4

Setting

(Pilot oil supply unit) (pilot oil supply u.) Fall:

(1)... Notice: pressure settings correspond with the Fabr.No. of the excavators !

Always compare with the settings in chapter "Technical data" !

(2)... Notice: Setting only "correct" without secondary press. limiting valves installed !

(3)... Function swivel: see chapter "Techncal data", see chapt. Maintenance (4)... See chapter "Technical data": different settings possible

bar

Maintenance

Id.No.: 9707747 Edition: Jan 03

PLV... Pressure limiting valve PRV... Pressure reducing valve

bar

SERVICE MANUAL

Maintenance

1403 - 2203

2.

HYDRAULIC SYSTEM Neuson 1503 / 1903 / 2203 .

Pressure Test 2.6 Pressure Test of Variable Displacement Pump P1 Functions: boom, bucket, driving right

2.6.1 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.

2.6.2 Check 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 valves!) 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 right 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,..)

2.7 Pressure Test of Variable Displacement Pump 2 Functions: dipper stick, driving left, auxiliary hydraulics 2.7.1 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.

2.7.2 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 stick rod side and driving right analogous to items 2.3.1 - 2.3.2 and note the result.

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Id.No.: 9707747 Edition: Jan 03

SERVICE MANUAL

Maintenance

1403 - 2203

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 additional 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) The funktion auxiliary hydaulics shows the setting of the primary pressure limiting valve PPLV 2, 3 at measuring ports MP 2, MP 3, if there are no secondary valves installed!

2.8 Pressure Test of Gear Pump P3 Functions (1503, 1903): Functions (2203):

dozer blade, offset, swivelling, undercarriage telesc., aux. hydr. dozer blade, offset, swveilling, undercarriage telesc., AH, tilt.cyl.

2.8.1 Check of setting PPLV 3: r) Apply pressure gauge at measuring port MP 3. t) Move dozer blade at bottom side to stop at max. diesel engine speed. s) Check and note pressure and pressure drop. v)

The swivelling function is supplied by pump P3, though the operating pressue 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 valves!)

2.9 Pilot Pressure Test: Functions: hydraulic pilot control 2.9.1 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 !

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Id.No.: 9707747 Edition: Jan 03

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