Mustang Compact Excavator ME5002 ME6002 ME6502 Service Manual_918172 - PDF DOWNLOAD

®

ME5002 ME6002 ME6502 COMPACT EXCAVATOR

SERVICE MANUAL Revision A - 09/05

PART #918172 ®

Mustang Manufacturing Company, Inc.

Introduction For your safety and continued proper operation, use only genuine MUSTANG® service parts.

When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number.

The model and serial number decal for this unit is located on the left chassis upright. “Right” and “Left” are determined from a position sitting on the seat and facing forward.

Mustang Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any previously delivered units.

NOTE: Purchase equivalent, quality tires for your loader. Contact your dealer for replacement tire information.

NOTE: Replacement batteries are not provided by the Mustang Company. For battery specifications see “Engine” chapter. ALL REPLACEMENT BATTERIES MUST BE PURCHASED LOCALLY. Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. If a part requires lubrication or a nonstandard torque value, it will be specified behind the part number description in parenthesis.

Items shown in the parts list that do not have part numbers are shown for reference purposes only and are NOT available for purchase.

Dimensions are in inches unless otherwise specified.

NOTE: The following abbreviations and symbols may be used herein: A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ampere AR . . . . . . . . . . . . . . . . . . . . . . . . . . As Required ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly AUX. . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary CCA . . . . . . . . . . . . . . Cold Cranking Amperage CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder FL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flare FOPS . . . . . . Falling Object Protective Structure GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hexagon HF . . . . . . . . . . . . . . . . . . . . . . . . . . . High Flow HYD. . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic JIC . . . . . . . . . . . . . . . . . Joint Industrial Council kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt LBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter MM (mm) . . . . . . . . . . . . . . . . . . . . . Millimeter NA . . . . . . . . . . . . . . . . . . . . Naturally Aspirated N/A . . . . . . . . . . . . . . . . . . . . . . .Not Applicable NEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative N•m . . . . . . . . . . . . . . . . . . . . . . . .Newton meter NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number NPT . . . . . . . . . . . . . . . . . . National Pipe Thread PN . . . . . . . . . . . . . . . . . . . . . . . . . .Part Number POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positive PSI . . . . . . . . . . . . . . . . . Pounds per Square Inch QTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity REF . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference REQ'D.. . . . . . . . . . . . . . . . . . . . . . . . . .Required ROPS . . . . . . . . . .Roll Over Protective Structure RPM. . . . . . . . . . . . . . . . Revolutions Per Minute SAE . . . . . . . . Society of Automotive Engineers SN . . . . . . . . . . . . . . . . . . . . . . . . Serial Number SQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straight TURBO . . . . . . . . . . . . . . . . . . . . . Turbocharger V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt

MUSTANG is a registered trademark of the Mustang Manfacturing Company, Inc.

TABLE OF CONTENTS : Chapter

Page Table of contents

A

Technical data Dimensions.......................................................................................

Bucket and Geometry........................................................................

Lift capacity charts.............................................................................

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

Auxiliary hydraulics............................................................................

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

A2 A4 A6 A12 A13 A14

B

Maintenance Maintenance schedule........................................................................ B2 Maintenance - general....................................................................... B5 Lubricants.......................................................................................... B6 Lubrication chart................................................................................. B8 Hydraulic system................................................................................ B9 Hydraulic pump.................................................................................. B20 Hose burst protection valve................................................................ B21 Drive unit........................................................................................... B22 Swivel unit......................................................................................... B23 Diesel engine.................................................................................... B24 Undercarriage.................................................................................... B35 Hydraulic oil tank................................................................................ B36

C

Hydraulic Hydraulic system / diagrams............................................................... C2 Position of components...................................................................... C6 Hydraulic pump.................................................................................. C9 Pilot oil supply unit............................................................................. C12 Main valve block................................................................................ C17 Pilot control valves............................................................................. C32 Swivel unit......................................................................................... C38 Shuttle valve block............................................................................ C44 Drive unit........................................................................................... C47 Swivel joint........................................................................................ C50 Switch valve...................................................................................... C51 Tank.............................................................................................

C52

D

Diesel Engine Diesel engine specifications...............................................................

Fuel line diagram...............................................................................

Battery..............................................................................................

Radiator............................................................................................

Cylinder head bolt tightening / loosening order...................................

D2 D3 D4 D5 D5

Chapter E

F

Page Electrical Electrical system diagrams ......................................................... E2 Electrical system component positions .............................................. E6 Electrical system diagrams ......................................................... E12 Electrical connections ..................................................................... E21 Fuse box ................................................................................. E27 Operating Elements Machine overview .....................................................................

Component description .....................................................................

Cab equipment and controls .........................................................

Lifting the excavator .....................................................................

Abbreviations: AP MP PPLV SPLV TT Pb1

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

Adjustment point Measuring point Primary - pressure limiting valve Secondary - pressure limiting valve Tightening torque Port code of the hydraulic diagram

F2 F3 F4 F10

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

CHAPTER A:

Technical data

Page A1

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data 1.

5002 - 6002 - 6502

DIMENSIONS

Model 5002 (w/optional long arm)

157.48" (4000 mm)

70.86" (1800 mm)

144.29" (3665 mm)

215.74" (5480 mm) 59.05" (1500 mm)

167.32" (4250 mm)

95.86" (2435 mm)

72.83" (1850 mm) 15.35" (390 mm)

15.74" (400 mm)

15.75" (400 mm)

146" (3710 mm)

45°

98.8" (2510 mm)

72.83" (1850 mm) 80

°

236.6" (6010 mm)

57.87" (1470 mm)

Model 6002 (w/optional long arm)

157.48" (4000 mm)

70.86" (1800 mm)

144.29" (3665 mm)

215.74" (5480 mm) 64.96" (1650 mm)

167.32" (4250 mm)

95.86" (2435 mm)

72.83" (1850 mm) 15.75" (400 mm)

15.74" (400 mm)

98.8" (2510 mm)

45 °

17.12" (435 mm)

151.96" (3710 mm)

72.83" (1850 mm) 8 0°

57.87" (1470 mm)

242.51" (6159 mm)

Page A2

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

Primary dimensions / Performance 5002

6002

0000989/98

0000771/98

8'-0" (2435 m m ) / 6'-1" (1850 m m ) / 12'-0" (3665 m m )

8'-0" (2435 m m ) / 6'-1'' (1850 m m ) / 12'-6" (3800 m m )

Axle distance

6'-7" (2000 mm) / F

6'-7" (2000 mm) / F

T ransport length

18'-7" (5653 mm)

19'-0" (5803 mm)

>> S tartin g with S erial N o .

Dimensions ( H x W x L )

Boom swing angle

Left / right

80° / 45°

80° / 45°

F ront boom swing radius

min

6'-1" (1880 mm)

6'-4" (1920 mm)

N

N

max

1'-1" (340 mm)

1'-1" (340 mm)

6'-1" (1850 mm)

6'-1" (1850 mm)

T ilt angle uppercarriage Ground clearance Undercarriage width T rack width

Standard

1'-4" (400 mm)

1'-4" (400 mm)

Max . D ump height

Standard

13'-1" (4000 mm)

13'-5" (4095 mm)

Max . D ump height / Option

Dipper arm long

13'-9" (4200 mm)

14'-1" (4295 mm)

Max . D ig height

Standard

18'-0" (5480 mm)

18'-4" (5580 mm)

Max . D ig height / Option

Dipper arm long

18'-8" (5680 mm)

19'-0" (5780 mm)

Max . D ig radius

Standard

19'-9" (6010 mm)

20'-7" (6160 mm)

Max . D ig radius / Option

Dipper arm long

20'-6" (6290 mm)

21'-2" (6460 mm)

Max . vertical dig depth

Standard

5'-1" (1549 mm)

Max . vertical digging depth / Opt.

Dipper arm long

Max . dig depth

Standard

12'-2" (3710 mm)

12'-8" (3860 mm)

Max . dig depth / Option

Dipper arm long

13'-2" (4010 mm)

13'-8" (4160 mm) 5'-3" (1590 mm) 6'-1" (1850 mm) / 1'-5" (425 mm) 1'-4" (400 mm) / 1'-5" (435 mm)

Min. tail sw ing radius

6'-7" (2000 mm) 7'-3" (2221 mm)

Dozer blade max . lift ... Ground

above / below

4'-10" (1470 mm) 6'-1" (1850 mm) / 1'-5" (425 mm) 1'-3" (390 mm) / 1'-4" (400 mm)

Dipperstick length

Standard

4'-11" (1500 mm)

5'-5" (1650 mm)

Dipperstick "long "

Option

5'-11" (1800 mm)

6'-5" (1950 mm)

T rack rollers / guide rollers

per side

5/1

5/1

Operation weight w ith

Cab

10,913 lbs. (4960 kg)

12,566 lbs. (5700 kg)

Ground pressure

Standard

3.8 psi (0.27 kg/cm )

2

Ground pressure

Option

400mm T racks

4.3 psi (0.3 kg/cm ) 400mm T racks

Dozer blade dimensions ( W x H ) Standard

Gradability

2

30° / 58%

30° / 58%

Sound level

LWA

98 dB (A)

99 dB (A)

Sound level

LPA

T rav el speed

Drive

75 dB (A) 1.5 mph (2.5 km/h) / 2.8 mph (4.5 km/h)

74 dB (A) 1.9 mph (3.0 km/h) / 3.4 mph (5.5 km/h)

T ear out force per

Bucket tooth

481 psi (3316 kp)

533 psi (3672 kp)

Max . dipper stick tear out force

Standard

349 psi (2405 kp)

360 psi (2482 kp)

Slew ( sw ivel- ) speed

Uppercarriage

8.5 rpm

9 rpm

T ractiv e effort

Undercarriage

12.70 lbs (5.8 kg)

13.4 lbs (6.10 kg)

Explaination: O... Option N... N o / N ot F ... Missing information

Page A3

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data 2.

5002 - 6002 - 6502

BUCKET AND GEOMETRY

Bolt diameter

50 mm

F

Dipper arm width

7.7" (195 mm)

L

Bolt distance Bucket carrier

9.3" (236 mm)

E

Page A4

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

This page intentionally left blank

Page A5

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data 3.

5002 - 6002 - 6502

LIFT CAPACITY CHARTS

Model 5002 lift capacity

9'-10" (3.0 m) 16'-5" (5.0 m)

13'-1" (4.0 m)

16'-5" (5.0 m)

13'-1" (4.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

13'-1" (4.0 m)

9'-10" (3.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

-3'-3" (-1.0 m)

-6'-7" (-2.0 m)

-9'-10" (-3.0 m)

9'-10" (3.0 m)

Page A6

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

5002 LIFT CAPACITY CHART 13’ 1" (4.0 m)

16’ 5" (5.0 m)

9’ 10" (3.0 m)

6’ 7" (2.0 m)

A B 2094 lbs.

(950 kg)* 2161 lbs.

(980 kg)*

1433 lbs.

(650 kg) 1455 lbs.

(660 kg)

2094 lbs.

(950 kg)*

2425 lbs.

(1100 kg)

2381 lbs.

(1080 kg)*

2337 lbs.

(1060 kg)

937 lbs.

(425 kg)

2469 lbs.

(1120 kg)*

1378 lbs.

(625 kg)

3131 lbs.

(1420 kg)*

2161 lbs.

(980 kg)

2315 lbs.

(1050 kg)*

992 lbs.

(450 kg)

2866 lbs.

(1300 kg)*

1268 lbs.

(575 kg)

4090 lbs.

(1855 kg)*

1940 lbs.

(880 kg)

2370 lbs.

(1075 kg)*

838 lbs.

(380 kg)

3142lbs.

(1425 kg)*

1168 lbs.

(530 kg)

4674 lbs.

(2120 kg)*

1986 lbs.

(810 kg)

3064 lbs.

(1390 kg)*

1157 lbs.

(525 kg)

4652 lbs.

(2110 kg)*

1709 lbs.

(775 kg)

7496 lbs.

(3400 kg)*

3417 lbs.

(1550 kg)

4079 lbs.

(1650 kg)*

1764 lbs.

(800 kg)

5842 lbs.

(2650 kg)*

3527 lbs.

(1600 kg)

13’ 1" (4.0 m) 9’ 10" (3.0 m)

2205 lbs.

(1000 kg)* 2161 lbs.

(980 kg)*

1488 lbs.

(675 kg) 1091 lbs.

(495 kg)

6’ 7" (2.0 m)

2293 lbs.

(1000 kg)*

937 lbs.

(425 kg)

2205 lbs.

(1000 kg)*

3’ 3" (1.0 m)

2370 lbs.

(1040 kg)*

838 lbs.

(380 kg)

0

2370 lbs.

(1075 kg)*

860 lbs.

(390 kg)

-3’ 3" (-1.0 m) -6’ 7" (-2.0 m)

2447 lbs.

(1110 kg)*

970 lbs.

(440 kg)

2513 lbs.

(1140 kg)*

1323 lbs.

(600 kg)*

Max. A B *

Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing point Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (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 lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

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

Page A7

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

Model 6002 lift capacity - 3’-9” (100 mm) boom cylinder - Serial Numbers after AA04550

9'-10" (3.0 m) 16'-5" (5.0 m)

13'-1" (4.0 m)

16'-5" (5.0 m)

13'-1" (4.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

13'-1" (4.0 m)

9'-10" (3.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

-3'-3" (-1.0 m)

-6'-7" (-2.0 m)

-9'-10" (-3.0 m)

9'-10" (3.0 m)

Page A8

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

6002 LIFT CAPACITY CHART

13’ 1" (4.0 m)

16’ 5" (5.0 m)

9’ 10" (3.0 m)

6’ 7" (2.0 m)

A B 9’ 10" (3.0 m)

2205 lbs.

(1000 kg)*

1268 lbs.

(575 kg)

6’ 7" (2.0 m)

2260 lbs.

(1025 kg)*

1091 lbs.

(495 kg)

2271 lbs.

(1030 kg)*

3’ 3" (1.0 m)

2326 lbs.

(1055 kg)*

1058 lbs.

(460 kg)

0

2425 lbs.

(1100 kg)*

1025 lbs.

(465 kg)

-3’ 3" (-1.0 m) -6’ 7" (-2.0 m)

2535 lbs.

(1150 kg)*

1257 lbs.

(570 kg)

2623 lbs.

(1190 kg)*

1477 lbs.

(670 kg)*

1 Max. A B *

2161 lbs.

(980 kg)*

1704 lbs.

(800 kg)

1157 lbs.

(525 kg)

2480 lbs.

(1125 kg)*

1687 lbs.

(765 kg)

3131 lbs.

(1420 kg)*

2535 lbs.

(1150 kg)

2425 lbs.

(1100 kg)*

1102 lbs.

(500 kg)

2976 lbs.

(1350 kg)*

1554 lbs.

(705 kg)

4090 lbs.

(1855 kg)*

2425 lbs.

(1100 kg)

2524 lbs.

(1145 kg)*

1058 lbs.

(480 kg)

3306 lbs.

(1500 kg)*

1455 lbs.

(660 kg)

4674 lbs.

(2120 kg)*

2315 lbs.

(1050 kg)

9237 lbs.

(4190 kg)*

4097 lbs.

(1850 kg)

3306 lbs.

(1500 kg)*

1422 lbs.

(645 kg)

4652 lbs.

(2110 kg)*

2227 lbs.

(1010 kg)

8356 lbs.

(3790 kg)*

4134 lbs.

(1875 kg)

6724 lbs.

(3050 kg)*

4211 lbs.

(1910 kg)

For 3‘ 9“ (100 mm) boom cylinder Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing point Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (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 lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

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

Page A9

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

Model 6002 lift capacity - 4’-1” (110 mm) boom cylinder - Serial Numbers after AA04550

9'-10" (3.0 m) 16'-5" (5.0 m)

13'-1" (4.0 m)

16'-5" (5.0 m)

13'-1" (4.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

13'-1" (4.0 m)

9'-10" (3.0 m)

6'-7" (2.0 m)

3'-3" (1.0 m)

0'-0" (0 m)

-3'-3" (-1.0 m)

-6'-7" (-2.0 m)

-9'-10" (-3.0 m)

9'-10" (3.0 m)

Page A10

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

6002 LIFT CAPACITY CHART

13’ 1" (4.0 m)

16’ 5" (5.0 m)

9’ 10" (3.0 m)

6’ 7" (2.0 m)

A B 9’ 10" (3.0 m)

2778 lbs.

(1260 kg)*

1268 lbs.

(575 kg)

6’ 7" (2.0 m)

2866 lbs.

(1300 kg)*

1091 lbs.

(495 kg)

2866 lbs.

(1300 kg)*

3’ 3" (1.0 m)

2976 lbs.

(1350 kg)*

1058 lbs.

(460 kg)

0

3086 lbs.

(1400 kg)*

1025 lbs.

(465 kg)

-3’ 3" (-1.0 m) -6’ 7" (-2.0 m)

3252 lbs.

(1475 kg)*

1257 lbs.

(570 kg)

3362 lbs.

(1525 kg)*

1477 lbs.

(670 kg)*

1 Max. A B *

2745 lbs.

(1245 kg)*

1704 lbs.

(800 kg)

1157 lbs.

(525 kg)

3142 lbs.

(1425 kg)*

1687 lbs.

(765 kg)

4023 lbs.

(1825 kg)*

2535 lbs.

(1150 kg)

3086 lbs.

(1400 kg)*

1102 lbs.

(500 kg)

3748 lbs.

(1700 kg)*

1554 lbs.

(705 kg)

5456 lbs.

(2475 kg)*

2425 lbs.

(1100 kg)

3197 lbs.

(1450 kg)*

1058 lbs.

(480 kg)

4211 lbs.

(1910 kg)*

1455 lbs.

(660 kg)

6283 lbs.

(2850 kg)*

2315 lbs.

(1050 kg)

11684 lbs.

(5300 kg)*

4079 lbs.

(1850 kg)

4222 lbs.

(1915 kg)*

1422 lbs.

(645 kg)

6272 lbs.

(2845 kg)*

2227 lbs.

(1015 kg)

4800 lbs.

(4800 kg)*

4134 lbs.

(1875 kg)

5093 lbs.

(2845 kg)*

2227 lbs.

(1010 kg)

8543 lbs.

(3875 kg)*

4211 lbs.

(1910 kg)

For 4’ 1” (100 mm) boom cylinder Allowable load with extended dipper arm Overhang from the center of the turntable Height of load fixing point Lift capacity restricted by the hydraulics

All chart figures are given in lbs. (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 lifting capacity, or tilting load is reduced by the empty weight of the attachment.

Position on solid subsoil and without bucket.

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

Page A11

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data 4.

5002 - 6002 - 6502

HYDRAULIC SYSTEM

Excavator Model Starting with Serial No.: HYDRAULIC PUMP 1

Type

System 3 Version A 4 Version B Oil flow rate - version A

6

Oil flow rate - version B

6002

0000989/98

0000771/98

Variable/gear pump

Variable/gear pump

4408302

5108320

Single v ariable pump w ith 2 press. ports + 1 gear pump

2

5

5002

PVD-2B-44P-12G-4713F PVD-3B-56P-21G-4626F 2 x 13.7 gpm (52 L/min) + 8.2 gpm 15.5 gpm (58.8 L/min) + 15.5 gpm (31 L/min) (58.8 L/min) + 11.6 gpm (44 L/min)

PRESSURE SETTING Main pressure limiting valve 7 Pump P1, P2

3336 psi (230 bar)

3553 psi (245 bar)

(2)

+44 psi (3 bar) / -44 psi (3 bar)

+44 psi (3 bar) / -44 psi (3 bar)

3191 psi (220 bar)

3191 psi (220 bar)

(2)

+44 psi (+3 bar) / -44 psi (-3 bar)

+44 psi (+3 bar) / -44 psi (-3 bar)

508 psi (35 bar)

508 psi (35 bar)

+29 psi (+2 bar)/ -29 psi (-2 bar)

+29 psi (+2 bar)/ -29 psi (-2 bar)

Main pressure limiting valve 8

9

Pump P3 Pilot oil pressure Secondary press. limit. valve

10 Main valve block

4061 psi (280 bar)

4061 psi (280 bar)

(3)

+73 psi (+5 bar)/ -29 psi (-2 bar)

+73 psi (+5 bar)/ -29 psi (-2 bar)

(3)

N

N

Secondary press.limit.valve 11

Dozer blade valve Swivel motor (SPLV) (Measuring points pump)

12

13

Swivel motor (SPLV) (Measured at the motor)

14

Drive motor Internal press.limit.valve

15

Check valve Boom offset cylinder

Sw iv el unit 4408400: 2756 psi (190 bar) +0 / -334 psi (-23 bar) (3)

Sw iv el unit 4408490: 2988 psi (206 bar) +73 psi (+5 bar) / -73 psi (-5 bar)

(3)

Sw iv el unit 4408490: 2610 psi (180 bar) +73 psi (+5 bar) / -73 psi (-5 bar)

3336 psi (230 bar)

245

+73 psi (+5 bar) / -73 psi (-5 bar)

+73 psi (-5 bar) / -73 (-5 bar)

N

N

For correct settings : (1)...Generel - Hy draulic oil temperature: 113 - 122°F (45 - 50°C) (2)...Settings at full throttle (see Maintenance chap.)

(3)...Settings at engine idle (see Maintenance chap.)

QUANTITIES 16

Hydraulic oil tank

16.1 gals. (61 L)

21.1 gals. (80

17

System filling

26.4 gals. (100 L)

31.7 gals. (120

Ex planation:

Page A12

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

AUXILIARY HYDRAULICS 1

Excavator

6002 / 6502

5002

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

Pressure

Pressure

P2 + P3

580 psi (40 bar) 21.1 gpm (80 L/min)

653 psi (45 bar)

26.7 gpm (101 L/min)

870 psi (60 bar) 20.6 gpm (78 L/min)

870 psi (60 bar)

26.4 gpm (100 L/min)

1305 psi (90 bar) 19.5 gpm (74 L/min)

1305 psi (90 bar)

25.9 gpm (98 L/min)

1740 psi (120 bar) 18 gpm (70 L/min)

1740 psi (120 bar)

22.5 gpm (85 L/min)

2176 psi (150 bar) 15.9 gpm (60 L/min) 2176 psi (150 bar)

19.8 gpm (75 L/min)

2611 psi (180 bar) 13.2 gpm (50 L/min) 2611 psi (180 bar)

17.7 gpm (67 L/min)

3046 psi (210 bar) 9.2 gpm (35 L/min)

15.9 gpm (60 L/min) 12.2 gpm (46 L/min)

P2 + P3

3046 psi (210 bar) 3480 psi (240 bar)

Conditions 1) Pressure = Pressure setting at the tool (bucket) 2) Tolerance of the listed settings : +0.26 gpm(+1 L/min) / -0.52 gpm(-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)

Excavator 5002 6002 6502

Assembled at the Dozer Blade Cylinder Dozer Blade Cylinder Dozer Blade Cylinder

Page A13

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

Clearance S 0.047" (1.2 mm) 0.059" (1.5 mm) 0.059" (1.5 mm)

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data 5.

5002 - 6002 - 6502

DIESEL ENGINE

E x c avator M odel

5002

6002

6502

S P ECIFICATIO N: Y anm ar

Y anm ar 4TNE98-NS R

1

Dies el engine m odel

2

S tarting with S erial No.:

0000989/98

3

Ty pe Intak e s y s tem Com bus tion s y s tem G low s y s tem

V ertic al, 4-cy c le water-c ooled dies el engine Natural as piration Direct injec tion s y stem P reheater, tim e relay c ontrolled Counterc loc kwise (viewed from flywheel) M ec hanic al c entrifugal governor

4 5 6

8

Direc tion of rotation G overnor

9

Lubric ation sy s tem

7

10 S tarting s y s tem 11 Cooling s y s tem

4 TNE8 8 -ENSW

0000771/98

0000708/98

Forc ed lubric ation with troc hoid pum p E lec tric al W ater-c ooled / Intake fan

DATA: M ax . revolution s peed (full throttle) 12 no load (rpm )

2500 + 50 / -50

2300 + 50 / -50

14 Rated s peed (rpm )

2400 + 25 / -25

2100 + 25 / -25

1100 + 50 / -50

1100 + 50 / -50

16 Dis placem ent (B ore x S trok e)

134 c u. in. (2189 c c ) ( 88x 90 )

202 c u. in. (3319 c c ) ( 98x 110 )

17 O utput ( at rated s peed, 14 )

38 hp (28.4 Kw )

58.7 hp (43.8 Kw )

18 M ax . engine output

48.3 hp (36 Kw )

96 hp (51.5 K)

M in. revolution s peed (idle) - no load 15 (rpm )

19 No. of c y linders 20 V alve c learanc e (IN= O UT) 21 Com pres s ion ratio 22 Fuel injec tion tim ing 23 Fuel injec tion pres s ure 24 Com pres s ion press ure 25 E ngine oil press ure (rev. s peed level) 26 P res s ure s witch engine oil pum p 27 Therm os tat opening tem perature 29 Therm o s witc h On / Out 30 Firing order 31 A lternator power (S tandard) 32 B attery 33 V -B elt m eas urings

4 0.0006 - 0.001" (0.15 - 0.25 m m ) 18.0 11° +/-1° 14° +/-1° 3191 - 3336 ps i (220 - 230 bar) 508 + /- 14.5 ps i (35 + /-1 bar) at 250 rpm 43.5 - 48 ps i (3.0 - 4.0 bar) 5.8 - 8.7 ps i (0.4 - 0.6 bar) 157° - 162.5° F (69.5° 72.5° C) 160° - 185° F (71° - 85° C) 224.6° - 235.4° F (107° - 113° C) / A bove 212° F (100° C) 1-3-4-2 40A / 12V 12V / 88A h 0.5 x 39.3" (12.5 x 1000 mm) 0.5 x 42.9" (13 x 1090 m m )

Page A14

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

Diesel engine 5002

6002 / 6502

64 - 69 lb-ft (87.0 - 93.0 Nm) ( M10x1,25 ) 33 - 40.5 lb-ft (45 - 55 Nm) ( M9x1,0 ) 72.3 - 75.2 lb-ft (98 - 102 Nm) ( M12x1,5 ) 85,0 - 90,0 ( M10x1,25 )

76 -80 lb-ft (102.9 - 112.7 Nm) ( M11x1,25 ) 39.7 43.4 lb-ft (53.9 - 58.8 Nm) ( M10x1,0 ) 79.6 - 86.6 lb-ft (107.9 - 117.7 Nm) ( M11x1,25 ) 186,3 - 205,9 ( M14x1,5 )

Excavator type TIGHTENING TORQUES: 34 Cylinder head bolt 36 Connection rod bolt 37 Metal cap clamping bolt 38 Flywheel clamping bolt

QUANTITIES 40 Fuel tank 41 Engine oil - oil pan (Max./Effect.)

42 Coolant (without radiator)

19.8 gals (75 l) 8.5 / 2.6 qts. (8.0 / 2.5 L) 10.8 / 5.3 qts. (10.2 / 5 L) 7.4 qts. (7 L) 9.2 qts. (8.7 L)

QUALITY 43 Engine oil

Quality

Page A15

BP Vannellus FE, APISH-CD+ SAE 10W 40

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Technical data

5002 - 6002 - 6502

This page intentionally left blank

Page A16

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

C HAPTE R B :

Maintenance

Page B1

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

MAINTENANCE SCHEDULE

1.

O X

- Check - Clean

Gehl 5002 - 6002

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

Page B2

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

O X

- Check - Clean

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

Page B3

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

O X

- Check - Clean

5002 - 6002 - 6502

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

Notice: Use this maintenance schedule as a general overview; more frequent servicing is possible.

The specific maintenance schedule can be found in the operator‘s manual.

Page B4

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Maintenance - General (according to the Operator‘s Manual) The reliability and service-life of machines are to a great extent influenced by care and maintenance.

Cleaning: In the first three months wash the machine only with cold water (do not use high-pressure or steam-jet cleaning). After the first three months the minimum distance between the spraying nozzles and the vehicle must be 12 inches (30 cm), and the water temperature shall not be higher than 140°F (60°C). Do not use aggressive cleaning agents.

Performing specified maintenance is of primary advantage to the owner of a machine.

Perform maintenance as specified by the manufacturer. Failure to perform the specified maintenance will result in exclusions of warranty.

For engine maintenance requirements, refer to the engine operating instructions.

Using lubricants that are not in compliance with the manufacturer’s recommendation will void the warranty.

Before starting machine maintenance or repair, please read all procedures and all warnings and cautions to avoid injury or equipment damage.

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.

If work must be done with the machine lifted, it must be securely supported.

Provide for sufficient ventilation when performing maintenance or repair work in a closed room.

Dispose of oil filters (oil, etc.) as required by environmental law.

When working on and/or below the compact excavator, place a warning sign on the operator’s seat and/or some place clearly visible and legible at the compact excavator. Remove the ignition key.

Page B5

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

2. LUBRICANTS LUBRICANT S - EXCAVAT ORS USED AS

Engine oil

Hydraulic oil

Turn table: Teeth Ball bearings

Drive gears

LUBRICATION TYPE

10W40 (Norm) BP Vanellus FE API SF-CD + SAE 10W40 FINA Kappa SE10W40 Q8 T660-10W40 HVLP 46 (Norm) BP Energol SHF 46 FINA Hydran TSX 46 Q8 Heller 46 Bio oil: BP Biohyd SE S46

BP Energrease OG (White) BP Energrease L 21 M

Energear Hypo EP 90 API GL 5 FINA Pontonic MP85W90 API GL5 Q8 T55 85W90 SGXP 220

Boom, dipper stick,..

BP Energrease L 21 M Gleitmo 805 (For initial greasing of the bolts )

Track tension cylinder

BP Energrease L 21 M

Each Lubr. point

BP Energrease L 21 M

Conditions: Engine oil: Grease:

Page B6

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Quantities Type of Device

5002

6002 6502

Engine

HydrauLic OiL Coolant System Fill

Type

Power Output

Engine Oil

Yanmar 4TNE88-NSW

40.2 HP (30 kW)

9.0 qts. 7.4 qts.

(8.5 L) (7 L)

63.7 HP 10.8 qts. 9.2 qts.

Yanmar 4TNE98-NSR (47.5 kW) (10.2 L) (8.7 L)

Hydraulic Transmission Turning Transmission

Driving Transmission

26.4 gals.

(100 L)

2.1 qts.

(2 L)

1.1 qts.

(1 L)

31.7 gals.

(120 L)

2.1 qts.

(2 L)

Page B7

Mechanical Transmission Planetary Gear

Live Axle

Steering Transfer Axle Case

1.1 qts.

(1 L) /

1.1 qts.

(1 L)

6.3 qts. 5.3 qts.

(6 L) (5 L)

Id.No.: Edition:

2.6 qts.

(2.5 L)

918172 Sept. 05

SERVICE MANUAL

Maintenance 3.

5002 - 6002 - 6502

LUBRICATION CHART

Lubrication points to be lubricated daily - blue zerk plugs.

Lubrication points to be lubricated weekly - green zerk plugs.

Page B8

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

4.

HYDRAULIC SYSTEM

General instructions: - Always bleed the hydraulic system before performing maintenance and repair work.

- For hydraulic settings, please refer to the Technical Data chapter.

- Before each pressure test the device must be at operating temperature—hydraulic oil temperature at least 122°F (50°C).

- Primary pressure limiting valves (PPLV) must be adjusted at maximum engine speed. (Refer to the Technical Data chapter).

- The pressure drop [(∆ [delta] P) between maximum (full throttle) and minimum (idle) diesel engine speed)] is tested at unloaded condition. > PRESSURE TEST 4.2 Gear Pump P1 Pressure Test Functions:

boom, bucket, driving left

4.2.1 Check setting of PPLV 1: a) Connect pressure gauge to measuring port MP 1. b) With the engine at maximum speed, move boom cylinder at bottom side to stop. c) Check and record the pressure.

4.2.2 Check pressure of drop: d) Move boom cylinder at bottom side to stop at maximum diesel engine speed (item b). e) Reduce diesel engine speed quickly from maximum to minimum speed - check and record the pressure. f) Calculate the pressure drop: maximum speed pressure minus the minimum speed pressure. 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 could 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 4.2.1 and 4.2.2. g) If any values deviate from factory settings, 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 (Example: defective O-ring in secondary valve, etc.)

4.3 Pressure Test of Gear Pump 2 Functions:

dipper stick, driving right, auxiliary hydraulics

4.3.1 Check setting of PPLV 2: i) Connect pressure gauge to measuring port MP 2. j) With the engine at maximum speed, move the dipper arm at bottom side to stop. k) Check and record the pressure and pressure drop.

Page B9

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

4.3.2 Check of pressure drop: l) Check and record pressure drop of indvidual functions similar to items d - g. m) Check the settings and pressure drop of functions dipper arm rod side and driving right similar to items 4.3.1 - 4.3.2 and record the result. n) If any values 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 - n. o) Note: Pressure test for auxiliary hydraulic system: Test with the ball valve opened, so the return flow is unpressurized (this builds pressure in the measurement: system).

If secondary valves AH are installed, the factory specifications may be invalid, because SPLV are set individually.

4.4 Pressure Test of Gear Pump P3 Functions: dozer blade, auxiliary hydraulics / boom offset, swivelling 4.4.1 Check of setting PPLV 3: p) Connect pressure gauge at measuring port MP 3. q) With the engine at maximum speed, move the dozer blade at bottom side to stop. r) Check and record the pressure and pressure drop. (> If there are no secondary valves installed, the auxiliary hydaulics function) shows the setting of the primary pressure limiting valve PPLC 3 at measuring port MP 3. (see AH - MP2) s) 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. (> Check of pressure drop only admissible with primary pressure control valves) 4.5 Pilot Pressure Test Functions: hydraulic pilot control 4.5.1 Check of setting PRV 5 a) Connect pressure gauge at measuring port MP 4 . b) Actuate joystick. c) Check pressure and/or set pressure at the pressure reducing valve (PRV 5) at the control oil unit. (> Also refer to Test Report - Pressure Test on the following pages)

Page B10

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502 Serial No.: Work hrs./Dat.

5002

PRESSURE CHECK LI S T

Checked: Function

Motion

Symbol

Press.Limit.Valve

Setting (1)

Measure point

Checked:

PUMP 1

X

DOWN

Bucket

OUT

Primary press.

Limiting valve PPLV 1 (Main valve block)

Measuring point MP 1 (Main valve block)

IN

Drive left

FORWARD

REARWARD

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

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

PUMP 2

Dipper stick (Arm)

X

OUT

IN

Drive right

FORWARD

Primary press.

Limiting valve PPLV 2 (Main valve block)

Measuring point MP 2 (Main valve block)

REARWARD

Auxiliary hydraulics

Note:

UP

Setting

A

B

Page B11

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

Setting

3336 psi (230 bar) +/- 43.5 psi (3 bar)

Fall

363 psi (25 bar)

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

Id.No.: Edition:

Note:

Boom

OK?

918172 Sept. 05

SERVICE MANUAL

Maintenance Serial No.: Work hrs./Dat. Checked: Motion

Symbol

PRESSURE CHECK L I S T Press.Limit.Valve

Measure point

Setting Dozer blade

Fall

UP

Setting Fall

DOWN

Setting Auxiliary hydraulics

A (2)

Primary press.

Limiting valve PPLV 3 (Main valve block)

B (2)

Arm swing

LEFT

Fall Measuring point MP 3 Setting (Main valve block) Fall / Setting (Swivel motor) Fall (3) Setting Fall

Secondary press.

Limiting valve SPLV 4 ( Swivel motor )

3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

> 3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

> 3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

> 3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

> 3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

> 3191 psi (220 bar) +/45.3 psi (3 bar) > 290 psi (20 bar)

Fall

> 2988 psi (206 bar) +/Sett (4): 72.5 psi (5 bar) > Fall

RIGHT

>

PILOT PRESSURE SYSTEM

Joystick

All

OK? X

> 2988 psi (206 bar) +/Sett (4): 72.5 psi (5 bar) >

RIGHT

Swivel LEFT uppercarriage

Checked:

Setting (1)

Notice:

5002 Function PUMP 3

5002 - 6002 - 6502

X

PRV 5 (Pilot oil supply unit)

Measuring point MP 4 (Pilot oil supply unit)

Setting

507.6 psi (35 bar) +/29 psi (2 bar)

Fall

PRV - Pressure reducting valve PLV - Pressure limiting valve (1) Notice: pressure settings correspond with the Serial No. of the excavator Always compare with the pressure settings in the "Technical Data" chapter (2) Notice: Settings correct only without secondary pressure limiting valves (3) Function swivel: see the "Technical Data" and "Maintenance" chapters (4) Version 4408400, 4408490 have different settings. See the "Technical data" chapter

Page B12

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Serial No.: Work hrs./Dat. Checked:

6002 Function

Motion

Symbol

PRESSURE CHECK LI S T Press.Limit.Valve

Measure point

Checked:

Setting (1)

PUMP 1

X 3353.4 psi (245 bar) 43.5 psi (3 bar) >

Fall

362.5 psi (25 bar)

Setting Fall

DOWN

Setting

Bucket

OUT

Primary press.

Limiting valve PPLV 1 (Main valve block)

Measuring point

Fall

MP 1 Setting (Main valve block) Fall

IN

Setting

Drive left

Fall

FORWARD

Setting Fall

REARWARD

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

>

PUMP 2

X

Setting Dipper stick OUT (Arm)

Fall Setting Fall

IN

Setting Drive right

Notice:

UP

Setting

FORWARD

REARWARD

Primary press.

Limiting valve PPLV 2 (Main valve block)

Measuring point Fall MP 2 (Main valve block) Setting Fall Setting

Auxiliary A hydraulics

Fall Setting

B

Fall

Page B13

3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar) > 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

> 3353.4 psi (245 bar) 43.5 psi (3 bar) > 362.5 psi (25 bar)

>

Id.No.: Edition:

Notice:

Boom

OK?

918172 Sept. 05

SERVICE MANUAL

Maintenance

6002 Serial.No.: Work hours

5002 - 6002 - 6502

PRESSURE CHECK LIST

Date: Checked:

PUMP 3

UP

DOWN

Auxiliary hydraulics

A (2)

Primary press.

Limiting valve PPLV 3 (Main v alv e block)

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

Setting

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

Setting

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

Measuring point Setting MP 3 (Main v alv e block)

B (2)

/ (Sw iv el motor)

Arm swing

Setting

(3)

LEFT

RIGHT

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

Setting

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

Setting

3191 psi (220 bar) +/43.5 psi (3 bar)

Fall

290 psi (20 bar)

3191 psi (220 bar) +/Sett. (4): 43.5 psi (3 bar) Secondary press.

Swivel LEFT uppercarriage

Fall

Limiting v alv e

SPLV 4

Fall

RIGHT

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

3191 psi (220 bar) +/Sett. (4): 43.5 psi (3 bar)

( Sw iv el motor !)

>

> Notice:

Dozer blade

X

>

PILOT PRESSURE SYSTEM

X

PRV 5 Joystick

All

(Pilot oil supply unit)

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

508 psi (35 bar) +/- 29 psi (2 bar)

PRV - Pressure reducting v alv e PLV - Pressure limiting v alv e (1) Notice: pressure settings correspond with the Serial No. of the excavator Alw ay s compare w ith the pressure settings in the "Technical Data" chapter (2) Notice: Settings correct only w ithout secondary pressure limiting v alv es (3) Function sw iv el: see the "Technical Data" and "Maintenance" chapters (4) Versions 4408400, 4408490 use different settings. See the."Technical data" chapter

Page B14

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Serial No.: Work hrs./Dat.

5002 6002

PRESSURE

CHECK LIST

Checked:

Function

Motion

Symbol

Press.Limit.Valve

Measure point

Setting (1)

Checked: OK?

PUMP 1

DOWN

Bucket

OUT IN

Drive left

Primary press.

Limiting valve PPLV 1 (Main v alv e block)

Setting Fall

> >

Setting

>

Fall

>

Measuring point Setting Fall MP 1 Setting

(Main v alv e block)

FORWARD REARWARD

> > >

Fall

>

Setting

>

Fall

>

Setting

>

Fall

>

PUMP 2

X

Dipper stick OUT (Arm) IN

Drive right

Notice:

UP

FORWARD

Primary press.

Limiting valve PPLV 2 (Main v alv e block)

Setting

>

Fall

>

Setting

>

Fall

>

Measuring point Setting Fall MP 2 Setting

(Main v alv e block)

> > >

Fall

>

Setting

>

Auxiliary A hydraulics

Fall

>

Setting

>

B

Fall

>

REARWARD

Page B15

Id.No.: Edition:

Notice:

Boom

X

918172 Sept. 05

SERVICE MANUAL

Maintenance Serial No.:

Date:

Work hours

Checked:

PRESSURE CHECK LIST

PUMP 3

Dozer blade

X

UP DOWN

Auxiliary A (2) hydraulics B (2)

Arm swing

Setting

>

Fall Setting Fall Measuring point Primary press.

Setting MP 3 Limiting valve Fall (Main valve PPLV 3 Setting block) (Main valve block) Fall

> > > > > > >

Setting Fall Setting Fall Sett. (4): Fall

> > > > > >

Sett. (4): Fall

> >

/

LEFT RIGHT

Swivel LEFT uppercarriag e RIGHT

Secondary press.

Limiting valve SPLV 4 ( Swivel motor !)

(Swivel motor) (3)

PILOT PRESSURE SYSTEM

Joystick

All

Notice:

50/6002

5002 - 6002 - 6502

X PRV 5 (Pilot oil supply unit)

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

PRV - Pressure reducting valve PLV - Pressure limiting valve (1) Notice: pressure settings correspond with the Serial No. of the excavator.

Always compare with the pressure setting the "Technical Data" chapter (2) Notice: Settings correct only without secondary pressure limiting valves (3) Function swviel: see the "Technical Data", and "Maintenance" chapters (4) See the "Technical data" chapter for difference settings on versions 4408400, 4408490

Page B16

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502 Fig.:

Position of measuring ports ( MP 1 - 3 ) main valve block

MP 1 Fig.:

MP 2

MP 3

Position of measuring ports ( MP 4 ) control oil unit

MP 4

Page B17

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance Fig.:

5002 - 6002 - 6502

Position of primary pressure limiting valves ( PPLV 1 - 3 ) - main valve block (example 6002 - see the Hydraulic System chapter)

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:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

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:

918172 Sept. 05

SERVICE MANUAL

Maintenance 5.

5002 - 6002 - 6502

HYDRAULIC PUMP

Bleeding of Hydraulic Pump

.

1.

2.

3.

4.

5.

Shut down the excavator.

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 of pump air-bleed screws 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:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

6.

HOSE BURST PROTECTION VALVE

S

CLEARANCE DIMENSION CHECK Safety regulations provide for the installation of hose burst protection facilities in dozer blade cylinders and in tilting cylinders.

If such valves are missing, there will be liability problems in case of an excavator accident.

> SETTING of GAP DIMENSION “S” : 1. Loosen the two nuts.

2. Adjust the gap “S” by means of a gauge for the applicable model of excavator (see Technical Data chapter).

3. Tighten the nuts lightly by hand and fix them cautiously against each other.

Page B21

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SERVICE MANUAL

Maintenance 7.

5002 - 6002 - 6502

DRIVE UNIT

GEAR BOX > CHECK:

- Open the oil level plug.

- The oil level must be at the oil level inspection hole.

> CHANGE:

- Open the oil filler and drain plug.

- Drain oil and collect it in an appropriate container.

- Replace and tighten the drain plug and open oil level plug.

- Fill the gearbox with fresh oil through the filler hole until gear oil emerges from the inspection hole.

- Replace and tighten both the oil level and filler plugs.

Warning:

Frequently check the gear box for leakage and for the proper oil fill level, as specified in the maintenance schedule.

Dispose of waste oil according to environmental laws.

.

For gear oil quality - see List of Lubricants (Technical Data chapter) Fig.: Position A - draining

screw plugs Fig. : Position B - check / change

filler screw gear oil level

oil level plug

Page B22

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

8.

SWIVEL UNIT

Gear Box - Swivel Unit Model 4408400 .

2

CHECK: -

1

-

-

Check filling level at level inspection / refiller screw Level should be flush with the inspection screw REFILL / CHANGE : Open drain hose (1) from under the chassis floor plate.

Position an appropriate container to catch the drain oil.

Open air-bleed screw (2).

Drain gear oil.

Close drain hose (1).

Fill in oil through air-bleed screw (2) to maximum level (for oil quality refer to "Lubrication Fillings", earlier in this chapter).

Close air-bleed screw (2).

Dispose of waste oil according to environmental laws.

Gear Box - Swivel Unit (AB01533 and higher)

Service News

Serial No.:

.

New swivel unit 5002-6002 (“Type 490“) AB01533 and higher Swivel gear box is maintenance free !

> CHECK / REFILL / CHANGE: For machines with serial numbers AB01533 and higher, the swivel unit gear box is "maintenance-free" (the gear box is lubricated with fresh hydraulic oil).

Refer to the Hydraulic System chapter.

Page B23

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance 9.

5002 - 6002 - 6502

DIESEL ENGINE Subject: Maintenance intervals - diesel engine Solution: Extension possible (Yanmar)

Service News

Maintenance intervals "500" > Affected parts: Engine oil / -filter > Affected excavators: - only possible if the following points are fullfilled: Maintenance intervals for the excavator diesel engine oil/oil filter have been extended up to 500 work hours The customer can choose between the standard and the extended interval solution.

Standard: NEW - "500 hrs"

Engine oil / filter Engine oil / filter

First Exchange ---> then every 50 hrs.

125 - 250 hrs.

50 hrs.

500 hrs.

Notice the following qualifications for the interval extension: Ov erall : R equir ements to ex tend the engine interv als up to "500hrs" Y an mar Excavato r D iesel en g in e typ e En g in e N o .: 5002

Yanmar 4T N E 88 EN SW

starting 44248

6002 / 6502

Yanmar 4T N E 98 N SR

starting 2956

D etailed ex planation - see page 2 N A ...N ot av ailable

Important!

In case of extreme working conditions (high dust concentration, high temperature, hydraulic hammer ) the exetended service interval cannot be used -- maintenance still has to be done following the standard schedule.

Page B24

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

To extend the maintenance interval of the diesel engine oil / filter up to 500 hours - the following conditions have to be met: A) -

For every excavator: The first engine oil and filter change still has to be done after 50 work hours.

The engine oil and - filter have to be exchanged a minimum of once annually.

C) -

Excavator 5002 The maintenance interval extension up to 500 hrs. is possible for model 5002 with the engine type 4TNE 88 ENSW only (starting with engine No.: 44248) First engine oil and filter change after 50 hrs.

No modifications of the diesel engine or its cooling system are allowed Use only original / approved oil filters Use only engine oil of quality API-CD, API-CE or API-CF

D) -

Excavator 6002 / 6502 The maintenance interval extension up to 500 hrs. is possible for model 6002 units with the engine type 4TNE 98 NSR - 58 HP (43.8kW) (starting with engine No.: 02956) First engine oil and filter change after 50 hrs.

No modifications of the diesel engine or its cooling system are allowed Use only original / approved oil filters Use only engine oil of quality API-CD, API-CE or API-CF

See parts manual for engine oil filter part numbers.

Page B25

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Preliminary Fuel Filter (Water Separator)

.

> Filter element removal and installation: Any water found in the preliminary filter housing (plastic ring in floating position) must be drained.

1.

Turn the shut-off valve counter-clockwise on the preliminary filter housing.

2.

Open and drain preliminary filter housing.

3.

Remove and clean preliminary filter element. Pay close attention to parts order for reassembly.

4.

Reassemble in reverse order from reassembly (plastic ring / spring / filter).

5.

Vent fuel system.

Fuel Filter

.

>Filter cartridge removal and installation: The main filter cartridge must be replaced at regular intervals according to the maintenance schedule.

The main filter is designed as filter cartridge.

1.

Turn the shut-off valve counter-clockwise on the preliminary filter housing.

2.

Remove filter cartridge and replace it with a new one.

3.

Vent the fuel system.

Air Filter 1.

.

>Filter element removal and installation: 2.

1.

2.

3.

4.

3.

4.

5.

Take off cover of filter housing.

Loosen wing nut for air filter element.

Remove air filter element and replace it.

Check safety element, replace it, if necessary.

Pull dust cap out of filter housing cover and empty the housing cover.

Mount cover of filter housing with marking "TOP" facing upward.

Page B26

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

V-Belt Tension Check 1.

2.

Open engine cover.

Check V-belt tension by pressing down on the V-belt between the water pump and the alternator pulley. If the V-belt moves approx. 1/2“ (10 - 15 mm), the V-belt tension is O.K. Refer to the figures on this page for tightening instructions.

3. .

Fig.: Check of V-belt tension

Fig.: V-belt Tightening

tube tension adjustment bracket alternator

water pump crankshaft alternator

Fuel System

. >

VENTING: 1.

Fill main and preliminary fuel filter with fuel and install the filters..

2.

Make sure that shut-off valves are open.

3.

Loosen injection lines at injection nozzles.

4.

Use the vent pump until fuel emerges from the (loosened) injection lines.

5.

Tighten injection lines.

6.

Tighten the vent pump.

vent pump

Page B27

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Valve Tip Clearance . > CHECK and ADJUSTMENT: 1.

Stop the engine and allow it to cool.

2.

Remove the valve cover.

3.

Crank the engine until the piston associated with the valve tip is at top-dead center in the compression cycle.

4.

Check the valve tip for abnormal wear.

5.

Check valve tip clearance using a feeler gauge as indicated in the figure and compare it with the settings specified in the "Technical Data" chapter.

6.

If necessary, correct valve clearance by means of the adjusting screw and lock nut.

7.

Replace the valve cover gasket, if necessary, and replace and secure the valve cover. valve cap

normal

abnormal wear

adjusting screw tappet clearance

lock nut

Compression

.

> CHECK: 1.

2.

3.

5.

6.

7.

Run diesel engine up to operating temperature.

Remove the fuel injection lines and injection nozzles.

Set the fuel injection pump to zero-delivery (remove the plug for the cut-off solenoid).

Mount a compression gauge on the cylinder you want to measure.

Crank the engine and read the pressure on the pressure gauge.

Compare the pressue reading to the values shown in the "Technical Data" chapter.

Page B28

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Injection Nozzles. > PRESSURE TEST .

1.

2.

3.

4.

Remove the fuel injection lines and injection nozzles.

Connect the injection nozzle to the high-pressure line of nozzle tester.

Slowly increase pressure until the nozzle ejects fuel and read the pressure on the pressure gauge. Injection pressure should be 3191 - 3336 psi (220 - 230 bar).

If the injection pressure is too low, replace spacers in the nozzle with thicker ones; if the injection pressure is too high, replace spacers in the nozzle with thinner ones.

Indirect injection system: increase adjusting washer thickness by 0.004” (0.1 mm) = 101.5 - 145 psi (7 - 10 bar) Direct injection system: increase adjusting washer thickness by 0.004” (0.1 mm) = 275.6 psi (19 bar)

nozzle testing device

oil return pipe

Nozzle setup: Indirect injection

oil return pipe upper nozzle screw fitting spacers

Upper nozzle screw fitting

compression spring compression spring seat

spacers

pressure spring centering injector needle nozzle body

nozzle centering pin

compression spring compression spring seat pressure spring centering injector needle nozzle body

lower nozzle screw fitting

lower nozzle screw fitting

Page B29

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

> NOZZLE JET CHECK .

1.

Remove the injection lines and the injection nozzles.

2.

Connect the injection nozzle to the high-pressure line of the nozzle tester.

3.

Quickly create pressure until the nozzle ejects fuel (ejection 3 - 4 times).

4.

Hold a white sheet of paper about 12 in. (30 cm) away from the nozzle and let the nozzle eject fuel onto the paper.

5.

The nozzle jet must create a circle on the paper.

6.

Check the nozzle for drips after it has ejected fuel.

7.

Create a pressure of about 290 psi (20 bar) below injection pressure and check whether fuel escapes from the nozzle.

NOTE: If any repair and/or adjustment is done to the nozzle, it must be checked using a nozzle tester before installation (spraying, leakage, injection pressure, etc.). direct injection system indirect injection system

correct atomization

incorrect atomization

Page B30

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Injection Pump

.

>REMOVAL/ INSTALLATION : The injection pump is driven directly via spur gear from the crankshaft.

Before removing the pump, remove the spur gear.

During assembly, align the relevant markers of the spur gears according to the illustration below. injection pump correct atomization

crankshaft oil pump

Injection Timing

. > Direct injection:

1st cylinder

longitudinal slots for rotating the injection pump

1.

Remove the injection line for the 1st cylinder.

NOTE: Cylinders are numbered in order starting from the flywheel side.

2.

Rotate the engine clockwise (as seen from the radiator ) at the crankshaft, until fuel escapes from the injector pump‘s base valve.

3.

Remove the rubber cover from the flywheel housing and read the injector time from te marks on the flywheel and flywheel housing.

4.

If the markers do not match, adjust injection timing by by rotating the fuel injection pump.

Injection too late: rotate the pump away from the engine Injection too early: rotate the pump towards the engine

Page B31

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Model: 4TNE98 (6002, 6502) moment of injection crankshaft pulley

direction of engine crankshaft rotation crankshaft pulley

direction of engine crankshaft rotation moment of injection marker at pump and gearbox longitudinal slots for rotating the pump

Engine Speed

.

> Warning: Maximum engine speed is set at the factory. Do not exceed specified settings! minimum speed limit (idle)

maximum speed limit > ADJUSTMENT NOTE: The engine must not be under load while performing speed adjustments.

1.

2.

3.

Page B32

Run the engine up to operating temperature.

With all attachment functions in neutral, set engine idle and/or maximum engine speed.

Idle Speed: Both Models: 1050 - 1150 rpm Maximum Engine Speed: Model 5002: 2450 - 2550 rpm Model 6002 / 6502: 2250 - 2350 rpm Set speed by adjusting the screws as shown in the illustration.

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Oil Pressure Switch

.

> TESTING: 1.

test prod

Remove the cable connection from the oil pressure switch (in the area of the cut-off solenoid).

Start the engine and check for correct idling speed.

Using an ohmmeter, measure the resistance of the oil pressure switch:

2.

3.

• Infinite resistance indicates the oil pressure switch is OK. • Continuity indicates the oil pressure switch is defective.

Cooling Water Circuit

.

> TESTING of THERMOSTAT : 1.

2.

3.

Remove the thermostat.

Heat thermostat in a container filled with water.

Using a thermometer, check whether the thermostat opens at the following temperatures:

thermostat

Model 5002: 157 - 162.5° F (69.5 - 72.5° C) Model 6002 / 6502: 160 - 185° F (71 - 85° C)

thermal switch

> TESTING of THERMAL SWITCH : 1.

2.

3.

Remove the thermal switch Heat the thermal switch in a container filled with radiator antifreezer or oil.

Using an ohmmeter, measure the resistance of the thermal switch by means of ohmmeter.

The switch must open when the temperature reaches 224 - 236° F (107 - 113° C). >

max

min Warning:

COOLANT LEVEL CHECK:

1.

2.

Check the coolant level when engine is cold.

The radiator should be completely filled, with the radiator cap closed. The coolant level in the overflow reservoir should be between min. and max. marks.

3.

If necessary, add coolant to the overflow reservoir.

Fill only with water mixed with the proper amount of antifreezer.

Page B33

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

Cooling Circuit

. > LEAKAGE TEST: 1.

Completely fill the radiator.

2.

Mount a hand pump adapter on the radiator as shown.

3.

Using a hand pump, increase pressure in the cooling circuit to about 34 psi (2.3 bar).

4.

Check the coolant circuit lines/connections for leaks if the pressure drops. > CHECK RADIATOR CAP : 1.

Remove the radiator cap and mount it onto the pressure tester as shown.

2.

Using the hand pump, increase the pressure to about 34 psi (2.3 bar ).

3.

The radiator cap is defective if it does not open.

Cylinder Head

.

> TIGHTENING ORDER for cylinder head bolts: 3-cylinder diesel engine:

camshaft side

flywheel side

fan

4-cylinder diesel engine: camshaft side flywheel side

fan

Tighten the cylinder head bolts according to the patterns shown above as follows: Note: Oil the threads and engaging faces of the cylinder head bolts before installation.

Model 5002: Model 6002:

(1st pass) 34 - 39 lb-ft (46 - 53 Nm) (2nd pass) 64 - 69 lb-ft (87 - 93 Nm) (1st pass) 36 - 43 lb-ft (49 - 59 Nm) (2nd pass) 76 - 83 lb-ft (103 - 113 Nm)

> LOOSENING ORDER for cylinder head bolts: Follow the patterns in reverse order.

Page B34

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

10. UNDERCARRIAGE Track Tension

.

1.

2.

Use the bucket and dozer blade to lift the machine up until tracks are just clear of the ground, as shown in the figure. Turn off the engine.

Measure the clearance at the second track roller from the drive gear. Deflection should be between 5/8”-1” (15-25 mm). > Tightening Track

1.

2.

Remove protective cover.

Using a grease gun, pump grease into the fitting until the track is properly tensioned. Adjust both tracks to equal tension.

Note: A grease gun is supplied with machine tool kit.

Important!

Do not over-tension the track. If track is too tight, loosen the grease fitting to relieve pressure. > Release of track tension WARNING! Do not loosen the track tensioner grease fitting more than two turns, or grease fitting could be ejected under pressure and cause injury.

1) 2)

Page B35

Remove protective cover.

Loosen valve. Drain grease slowly.

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

11. HYDRAULIC OIL TANK > CHECKING/FILLING HYDRAULIC OIL LEVEL WARNING! The hydraulic reservoir is under pressure. Avoid contact with leaking hydraulic fluid.

It can penetrate the skin or eyes and cause severe injury.

1.

2.

3.

4.

5.

Position the machine on a level surface.

Fully extend the bucket and boom.

Lower the bucket and dozer blade to the ground. Turn off the machine.

Pull the valve cover latch lever and open the valve cover to expose the hydraulic oil level indicator.

Hydraulic oil level should be between the black and red marks on the indicator. If the oil level is low: a.

Remove the access panel on top of the valve cover to expose the hydraulic oil fill cap. b.

Open the cap slowly to relieve pressure. Remove the cap. c.

Add hydraulic oil as necessary. d.

Replace the hydraulic oil fill cap and tighten securely. e.

Start the engine and let the machine idle for a few minutes to build up pressure. f.

Check hydraulic functions.

Re-check oil level.

Close the valve cover.

Engine

Valve

Valve Cover Latch

Black Mark

Red Mark

Hydraulic Oil Level Indicator

Hydraulic Tank Cap w/Strainer

Hydraulic Oil Cap Access Panel

Page B36

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

> CHANGING HYDRAULIC OIL Note: Change hydraulic oil when it is a operating temperature — approx. 104º F (40º C).

1.

2.

3.

4.

5.

Position the machine on a level surface.

Fully extend the bucket and boom.

Lower the bucket and dozer blade to the ground. Turn off the machine.

Remove the access panel on top of the valve cover to expose the hydraulic oil fill cap.

Open the cap slowly to relieve pressure. Remove the cap and clean any debris out of the strainer.

Open the drain plug and drain oil into a suitable container. Re-install the drain plug and tighten securely.

Filter Gasket

Filter Cover

Cap w/Strainer Filter

IMPORTANT! Always dispose of hydraulic fluids according to environmental law.

DO NOT pour fluids onto the ground or down a drain.

6.

7.

8.

9.

10.

11.

9.

Remove the four bolts securing the filter cover, and remove the cover.

Remove and discard the filter. Put clean hydraulic fluid on the filter gasket and install the gasket and new filter onto the tank.

Re-install and secure the filter cover.

Fill the tank with hydraulic oil until the oil level is between the red and black marks on the hydraulic oil level indicator Replace the hydraulic tank cap and tighten securely.

Start the engine and let it idle for a few minutes to build up pressure.

Check hydraulic functions. Re-check hydraulic oil level.

Replace the access panel.

Page B37

Drain Plug

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SERVICE MANUAL

Maintenance

5002 - 6002 - 6502

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Page B38

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SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

C HAPTE R C :

Hydraulics

Page C1

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 1.

5002 - 6002 - 6502

HYDRAULIC SYSTEM

Legend - hydraulic diagram 5002 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 27 35 36 37

diesel engine variable displacement + gear pump unit pilot oil supply unit joystick (pilot control valve) left joystick (pilot control valve) right main valve block pilot control valves - drive pilot control valve - auxiliary hydraulics pilot control valve - dozer blade switch valve oil cooler ball-type stop valve swivel unit drive unit hydraulic oil return filter boom offset cylinder dipper stick cylinder boom cylinder bucket cylinder dozer blade cylinder hose burst protection valve non-return valve non-return valve shuttle valve block

Page C2

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Model 5002

Page C3

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Legend hydraulic diagram 6002 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 27 35 36 37

diesel engine variable displacement + gear pump unit pilot oil supply unit joystick (pilot control valve) left joystick (pilot control valve) right main valve block pilot control valves - drive pilot control valve - auxiliary hydraulics pilot control valve - dozer blade switch valve oil cooler ball-type stop valve swivel unit drive unit hydraulic oil return filter boom offset cylinder dipper stick cylinder boom cylinder bucket cylinder dozer blade cylinder hose burst protection valve non-return valve non-return valve shuttle valve block

Page C4

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Model 6002

Page C5

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 2.

5002 - 6002 - 6502

POSITION OF COMPONENTS

Fig: View - right main valve block

pilot oil supply unit

hydraulic oil tank oil level inspection glass hydr. oil return filter

air filter / hydraulic oil filter

ball-type stop valve shuttle valve block grease gun

battery Page C6

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.: View - rear side

Exhaust muffler

diesel engine

Relay box Hydraulic oil cooler Radiator Diesel engine

hydraulic pump

Fig.: View left side

swivel unit

switch valve

driving unit Page C7

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 3.

5002 - 6002 - 6502

HYDRAULIC PUMP

Model 5002 Pump: Double variable-displacement axial-piston pump (monohousing design) + 1 gear pump Type: 4408302 (PVD-2B-44P-12G-4713F) - black lacquered Fig.:

Type plate Model 5002 - hydraulic pump

Model 6002 Pump: Double variable-displacement axial-piston pump (monohousing design) + 1 gear pump Type: 5108320 (PVD-3B-56P-21G-4626F) - red lacquered Fig.:

Type plate Model 6002 - hydraulic pump

Features:

-1 axial-piston pump with 2 separate pressure outputs (P1, P2) swash plate type - gear pump, flange-mounted - summation regulation, three-circuit regulation

Tightening torques:

TT

Model 5002

pump / pump bracket M12 10.9 - 64 ft-lbs. (87 Nm) pump bracket / diesel engine M10 10.9 - 47 ft.-lbs. (64 Nm)

Model 6002

pump / pump bracket M16 10.9 - 203 ft-lbs. (275 Nm) pump bracket / diesel engine M10 10.9 - 47 ft-lbs. (64 Nm)

Page C8

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Pump unit 5002 / 6002 ( pressure side view )

variable-displacement pump unit adjusting screw: start of regulation port P1

diesel engine<< P2

P3

P1

TT!

portP3 type plate

Fig.:

gear pump unit

port P2

Pump unit 5002 / 6002 ( suction side view )

adjustings screw: start of regulation

TT pump/pump bracket

port suction line P3

port suction line P1+P2

Page C9

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig.:

5002 - 6002 - 6502

Pump unit ( suction side view / top ) Mounting position adjusting screw flow rate Qmax

pump governor unit

air-bleed screw 6002 adjusting screw flow rate Qmin

P1

P3

P2

TT

port P3

Fig.:

port P1 + P2

Pump unit ( pressure side view / top ) Mounting position! air-bleed screw 5002 adjusting screw flow rate Qmax

air-bleed screw 6002

TT

Page C10

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

regulating springs

Pump unit structure

gear pump

flow rate governor

plate cam

swash plate + bearing

shaft seal

Fig.:

Page C11

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 4.

5002 - 6002 - 6502

PILOT OIL SUPPLY UNIT

Fig.: System diagram of pilot oil circuit

5 3

4

2

5 1 P3

P2

P1

1 pump unit 2 control oil unit 3 hand / foot pilot control valves 4 main valve block 5 measuring ports

Page C12

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Fig.:

Control oil unit (2)

(3) (1)

port P1:>> port P2:>> port P3:>> port T : >> port A : >> port PR: port BV: port PV: (1) (2) (3) (4)

AP (4)

gear pump P3 variable-displacement pump P1 variable-displacement pump P2 tank drive counterbalancing system (main valve block) >> 2nd driving stage (drive unit) valve WK1 - in combination with the push-button on the driving lever (formerly port PT - control oil unit 148610) >> pilot control valves ( joystick, etc.) via the safety solenoid valve in combination with the sensitive micro-switch in the arm rests (WK2). >> supply of of setting chamber to swivel motor - release brake

... safety valve 508 psi (50 bar) - protects the control oil unit in case of pressure reducing valve malfunction ... shuttle valves - always accept the highest pump pressure for control oil pressure ... pressure reducing valve (PRV) pilot control pressure - ADJUSTMENT POINT (AP) ... accumulator

Page C13

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig.:

5002 - 6002 - 6502

Oil control unit port assignment (version 1408610 / 1408615) port P3 << variable displacement pump P2

port P2 << variable displacement pump P1 P2

P3

port A >> drive counterbalancing system main valve block

(1) safety valve

A T

(3) pressure reducing valve ( AP ) - version: 1408615 metal cap with ring see page C15

port SP >> accumulator

WK 1

WK 2

port T - tank

port P1 << gear pump P3 port BV >> pilot control valves

port PR (PT) >> drive unit

P1

BV

(1) safety valve

PR

port SP >> accumulator

PV

port PV (3) pressure reducing valve ( AP ) WK 2

WK 1 Page C14

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Oil control unit 1408615 port assignment (3) pressure reducing valve ( AP )

(1) safety valve

Fig.: Position of control oil unit

Differences between Models 5002 / 6002:

- identical place of installation - identical port assignment - different mounting position

Page C15

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig.:

5002 - 6002 - 6502

Setup of control oil unit (1408610)

1... pressure reducing valve unit ( AP ) * adjusting washers 2... safety valve (preset to 725 psi (50 bar) with plastic seal 3... connecting subassembly - accumulator bag 5 - 6 shuttle valve subassembly 8 - 9 solenoid valves Tightening torques: 1a...

1e...

2g...

3n...

5r...

5s, 6s 8, 9

111 ft-lbs. (150 Nm) 7.3 ft-lbs. (10 Nm) 74 ft-lbs. (100 Nm) 74 ft-lbs. (100 Nm) 7.3 ft-lbs. (10 Nm) 2.2 ft-lbs. (30 Nm) 11 - 14.8 ft-lbs. (15 - 20 Nm)

Page C16

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

5.

MAIN VALVE BLOCK

Model 5002: Type: 4408301 location:

TT = 33 - 35 ft-lbs.

(44 - 48 Nm)

Feature: - regeneration function dipper stick, drive counterbalancing system, standard functions, flow rate adjustment of auxiliary hydraulics 17

view- A

Pa9

pump P3

Pa7

pump P1

Pa6

18

Pa5 Pa4 A9 Pa3

A8 A7

Pa1 A6

B9

19

A5 A4 A3

20 (control oil unit - A)

B5

A2 A1

Pi1

B4

T1 B3 B2 B1

Pb1

1 2 3 4 5 6 7 8 9 10

view- B pump P2

section output - tank 1 section bucket section boom section driving right section input P1,P2 section driving left section dipper stick section flow rate adjustment AH section auxiliary hydraulics (AH) section drive counter-balancing

11 12 13 14 15 16 17 18 19 20

Page C17

section boom offset section dozer blade section swivelling section input P3 secondary pressure limiting valve primary pressure limiting valve ( AP ) suction valves tank 2 port P3 port drive counter-balancing system Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig. :

5002 - 6002 - 6502

Hydraulic diagram main valve block 5002

Page C18

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Pump / section assignment - main valve block 5002 2 3 4 6 8 9 10 11 12 13 14

bucket section boom section right driving section left driving section dipper stick section oil flow adjustment section (AH) auxiliary hydraulics section (AH) counter-balancing section boom offset section dozer blade section swivelling section

Fig.:

Main valve block 5002 - view A

A

B A B C D E F G H I

C

D

E

F

supplied by P1 supplied by P2

supplied by P3

G

H

I

primary pressure limiting valve P3 dozer blade rod side suction valve boom offset cylinder rod side suction valve auxiliary hydraulics plug (option secondary valves) auxiliary hydaulics oil flow adjusting screw dipper stick cylinder valve primary pressure limiting valve P1 boom valve bucket valve

Page C19

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Main valve block 5002 - view B

Fig.:

I D F H I J K

5002 - 6002 - 6502

H

J

F

D

K

auxiliary hydraulics plug (secondary valves option) dipper stick cylinder suction valve boom suction valve bucket suction valve primary pressure limiting valve P2 dozer blade cylinder bottom side valve

Page C20

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Type: Features:

5108300 - regeneration function of dipper stick - summation function lifting of boom - leakage-free shut-off spool valve for boom down - function drive counterbalancing - adjusting screw oil flow adjustment of auxiliary hydraulics 18

Pa9

view- A

pump P3

pump P1

Pa7

20

TT= 33 -35 ft-lbs.

(44 - 48 Nm)

Model 6002 :

Pa6 Pa5 Pa4

A9

Pa3

A8

Pi2

Pa1

A10

A7 A5

B10

22

A6

A4 DR2

A3

A2

B3

A1

21 (control oil unit - A)

B6

Pi1

B4

B2

T1 C B1

Pb1

1 stank 1 output section 2 bucket section 3 boom 1 section 4 right driving section 5 input section P1,P2 6 left driving section 7 boom 2 section 8 dipper arm section 9 oil flow adjustment section (AH) 10 auxiliary hydraulics section (AH) 11 drive counter-balancing section

view - B

pump P2

12 13 14 15 16 17 18 19 20 21 22 Page C21

boom offset section dozer blade section swivelling section input section P3 secondary pressure limiting valve primary pressure limiting valve (AP) suction valves leakage-free shut-off valve tank 2 port drive counter-balancing system port P3 Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Fig.: Hydraulic circuit diagram main valve block 6002

Page C22

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Pump / section assignment - main valve block 6002 2 3 4 6 7 8 10 9 11 12 13 14

bucket section boom 1 section right driving section left driving section boom 2 section dipper stick section auxiliary hydraulics section (AH) oil flow adjustment section AH drive counter-balancing section boom offset section dozer blade section swivelling section

supplied by P1

supplied by P2

supplied by P3

Fig.: Main valve block 6002 - view A

A

B A B C D E F G H I J

C

D

E

F

G

H

I

J

primary pressure limiting valve P3 dozer blade rod side suction valve boom offset cylinder rod side suction valve auxiliary hydraulics plug (secondary valves option) auxiliary hydaulics oil flow adjusting screw dipper stick cylinder valve primary pressure limiting valve P1 boom valve leakage-free shut-off boom valve (bottom side) bucket valve

Page C23

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Fig.: Main valve block 6002 - view B

S

R P Q R S T U

T

Q

P

U

auxiliary hydraulics plug (secondary valves option) dipper stick cylinder valve boom valve bucket valve primary pressure limiting valve P2 dozer blade cylinder bottom side valve

Page C24

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Function: Regeneration - Section Dipper Arm

regeneration

Function

Situation:

Because of heavy loads at the dipper arm, the dipper arm cylinder may become “evacuated“ on the bottom side, which might cause the dipper arm to stall in the vertical position.

Solution:

Regeneration of the rod-side dipper arm cylinder oil to the cylinder bottom side. To enable this, the spool valve is provided with a non-return valve.

Drive Counter-Balancing System

General: Without the drive counter-balancing system, actuating the boom as you drive causes the machine to change direction.

All 5002 - 6002 machines are equipped with drive counter-balancing!

With drive counter-balancing: If the boom is actuated as you drive straight ahead, the machine continues in a straight line and drive speeds stays constant.

The drive counter-balancing system is only enabled if both drive valves are enabled.

Page C25

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Function

5002 - 6002 - 6502

Drive Counter-Balancing System

See circuit diagram drive counter-balancing system: - Both spool valves for driving and one arm function must be actuated.

- The drive counter-balancing system (main valve block) is activated because of an increased banking-up pressure (dotted line).

- P3 - assumes supply of arm functions.

- Section auxiliary hydraulics: Switching pressure drive counter-balancing valve:

145 - 218 psi (10 - 15 bar)

Pump assignment when drive counter-balancing system is active: supplied by P1 section driving left supplied by P2 secion driving right section auxiliary hydrauilcs section bucket section boom supplied by P3 section dipper arm section flow rate AH section dozer blade section swivel unit section drive counter-balancing section drive counter-balancing

Fig.: Port assignment

control oil unit port A >>

Page C26

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Function Drive Counter-Balancing System

Auxiliary Valve

Page C27

Id.No.: Edition:

918172 Sept. 05

Hydraulics

SERVICE MANUAL

Function

Oil Flow Adjusting Screws - Auxiliary Hydraulics ( AH )

Feature:

The set screw on the main valve block allows for changing the auxiliary hydraulics oil flow.

5002 - 6002 - 6502

There are two possible settings: (See the Auxiliary Hydraulics section in the Technical Data chapter) A) Set screw against hydraulic resistance (the valve seat is closed in this position): - P2 + P3 supply the auxiliary hydraulics section with oil.

- Factory setting B) Set screw “open“ (loosen the set screw two revolutions): - P2 supplies the auxiliary hydraulics section with oil.

- The oil supplied by P3 flows to the tank via the opened valve seat.

Warning:

- Use care when loosening the set screw - if the screw is loosened too far it will come out of the valve, and hydraulic oil could exit the system at high pressure!

- Setting the set screw between the A) and B) setting above can cause hydraulic oil overheating! section auxiliary hydraulics adjusting screw oil flow

section oil flow adjustment AH

Page C28

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

5.

MAIN VALVE BLOCK

Option: Valves AH

Feartures:

- Hydraulic component pressure protection in secondary circuit (section AH) - e.g.: hydraulic hammer - If the spool valve AH is open (piloted), the component, the pump and the valves are protected by the primary pressure limiting valves (PPLV).

If the spool valve is closed (no oil flow), the components have no pressue protection !

- Pressure settings without valves - see chapter Technical Data

Assembly:

- Pressure adjustment of the valves (AH) has to be done by person trained in this technology.

- Replace both stoppers by the valves.

Fig.:

Standard version section auxiliary hydraulics - plugs

adjusting screw oil flow auxiliary hydraulics plug

section auxiliary hydraulics

Page C29

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Function Model

5002 - 6002 - 6502

Boom Cylinder Summation (Bottom Side) 6002

Feature: - Both pumps P1 and P2 are used with this feature, speedting the upward motion of the boom.

Boom up : - When the boom lifting funtion is activated - both sections (1+ 2) in the main valve block are engaged.

- Boom section 2 is controlled along with section 1 via the pilot hose of the joystick.

- The oil of P2 is routed to the main hose of the boom via an external pipe.

- The speed of summation is controlled by the finemetering grooves in the spool valve of boom 2.

- The special design of the spool valve engages only pump 1 for finely-controlled upward boom movement, .

Boom down: - The leak-free spool valve controlling the boom down function (boom cylinder bottom side) is piloted along with setion 1 via the pilot hose of the joystick.

When the valve opens, the oil of the boom cylinder bottom side can return to the tank. section boom 1

section boom 2

boom up Pa5

Pa2

port boom cylinder A2

C

A5

B2

port boom cylinder external summation hose Page C30

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Diagram - summation section boom 6002

Page C31

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Function Model

5002 - 6002 - 6502

Leakage-Free Spool Valve - Boom Down 6002 (load holding valve, pilot-controlled)

Features:

- Functions to hold the boom cylinder in position (bottom side).

- Pilot-controlled load holding valve blocks any movement of the boom caused by boom spool valve leakage.

Boom up:

(see also function - boom cylinder summation) - The valve is opened by the oil flow, oil is delivered to the bottom side of the cylinder.

Boom down: - The valve is opened by the pilot hose (boom down).

- The oil from the boom cylinder (bottom side) can pass the valve.

pilot hose boom up

shut-off valve - leakage-free spool valve boom down Pa2

port tank

Pi2

DR2

Pb2

<< external pilot hose function boom down

Page C32

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

6.

PILOT CONTROL VALVES

Type: Features :

Joysticks - progressive hydraulic pilot control unit - directly controlled pressure reducing valve

Fig.: Manual control valve (joystick)

1 3 4 6 7 10

control lever rod assembly rubber collar joint guide plate tappet Page C33

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 6.

PILOT CONTROL VALVES - Assignment

Function:

Switch Valve

Via selector lever at the directional control valve the assignment of the joysticks may be reversed. joystick right - boom joystick left - dipper arm joystick right - dipper arm joystick left - boom

Pos. 1: Pos. 2:

Fig.:

5002 - 6002 - 6502

Port assignment / mounting position - directional control valve

D < HU3 (joystick)

dir. control valve 1408450 Pos 2 / Pos 1

(main v. bl.) LST3 > H (joystick) LST3 > C (main v. bl.) LST1 > F (main v. bl.) LST1 > A

G < HU3 (main v. bl.)

B < HU1 (joystick) E < HU1 (main v. bl.) selector lever

position 1

position 2 Fig.: Joystick positions left / right

Joystick left LST 3 LST 1 DL 2 DR 4

dipper arm out dipper arm in swivelling left swivelling right

-> -> -> ->

joystick pos. 3 joystick pos. 1 joystick pos. 2 joystick pos. 4 2

Joystick right HU 3 boom up -> HU 1 boom down -> LO 4 bucket out -> LÖ 2 bucket in ->

joystick pos. 3 joystick pos. 1 joystick pos. 4 joystick pos. 2

Page C34

1

3 P

4

T Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Changed assignment of joystick function - switch valve LEVER

joystick left

position 1 1 dipper arm out 2 dipper arm in 3 swivelling left 4 swivelling right 5 boom down 6 boom up 7 bucket in 8 bucket out

Fig.:

position 2

joystick right

boom down boom up swivelling left swivelling right dipper arm out dipper arm in bucket in bucket out

Location of switch valve

switch valve: - access via floor plate chassis right

Page C35

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Type:

Pilot control valve driving Pilot control valve blade

Features:

- foot valve, hydraulically piloted

2 3 4 7 11 16

Page C36

pedal pedal base protection cap fixing plate tappet subassembly springs

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Type:

Pilot control valve auxiliary hydraulics

Features:

foot valve, hydraulically piloted

2 3 4 7 11 16

Page C37

pedal pedal base protection cap fixing plate tappet subassembly springs

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

SWIVEL UNIT

7.

Types:

4408400, 4408490

Fig:

Version - swivel unit 4408400 (Serial No: AB01532 and below)

Features:

- swash plate axial-piston motor with hydr. brake piston - mech. parking brake (brake disks) - hydr. piloted - parking brake is opened by function: swivelling, boom offset.

- gear box requires maintenance (see Maintenance chap.)

1

5

6

2

2 3 7

4

8

1 swivel unit 2 3 port suction hose - main valve block 4 5 motor oil return port 6 7 port A/B (> main valve block) 8 9 port S (>shuttle valve block) 10 11 gear oil - inspection and filler screw

Page C38

valves (SPLV) port A/B (>main valve block) parking brake - valve block oil bleed hose - gear box port PV (>pilot oil supply unit)

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

swivel unit 4408400

Fig.:

6 2

9 10

11 TT

Page C39

= 110 Nm

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig.. :

5002 - 6002 - 6502

Hydraulic diagram swivel unit

E

D C

F

F

A C E MU PG SH

port (>main valve block) B port (>main valve block) piston parking brake D parking brake valve hydraulic brake valve F valves suction hose (>main valve block / non-return valve) port - parking brake valve (>pilot oil supply unit) port - parking brake valve (> shuttle valve block /joystick)

Page C40

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Version - swivel unit 4408490 - Serial No.: AB01533 and higher

Fig.:

Feature:

- swash plate axial-piston motor with hydraulic brake piston - mech. parking brake (brake disks) - hydr. piloted - parking brake is opened by function: swivelling, boom offset.

- gear box lubricated by hydraulic oil periodic replacement required (see Maintenance chapt.).

1

1 4 2

5 3

6 7

1 2 3 4 5 6 7

TT

= 81 ft-lbs.

(110 Nm)

Id.No.: Edition:

918172 Sept. 05

shock valves port PG (> pilot oil supply unit) port SH (>shuttle valve block) port MU - suction hose (> main valve block/tank) port B (> main valve block) port A (> main valve block) port return oil (>tank) Page C41

®®

Hydraulics

SERVICE MANUAL 5002 - 6002 - 6502

Fig.: Hydraulic diagram - swivel unit - Serial No.: AB01533 and higher

B

A

D

C A B C D

parking brake piston swivel motor parking brake valve suction valves suction hose MU (>main valve block)

Note: Swivel unit - periodic oil replacement required - see the Maintenance chapter.

Service News

Theme: New swivel unit (“Type 490“) Serial No.: AB01533 and higher Swivel gear box requires no maintenance

Page C42

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Fig.: Gear Box

Swivel unit 4408490 Swivel unit 4408490 Pos. Dimension 15 M60 x 20 29 M8 x 20 31 M8 x 35 32 M10 x 50

Page C43

TIGHTENING TORQUES Part Loctite® 243 Nut 8.8 Screw 8.8 Screw 12.9 Screw

Tightening torque 700 - 774 lb.-ft. (950 - 1050 Nm) 18 lb.-ft. (25 Nm) 18 lb.-ft. (25 Nm) 63 lb.-ft. (85 Nm)

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.: Swivel motor

Swivel unit

Legend of fig.: Swivel motor (swivel unit) 4 18 20 25 27 30 41

plug 6 distribtion plate 19 brake disks 22 parking brake piston 26 bearing 29 suction valve (check valve) 35 parking brake (control) valve block

bearing steel disk - parking brake spacers springs - brake piston motor head valve (relief valve)

Page C44

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

Function

Release of Parking Brake (Opening)

Feature:

The swivel motor and boom offset functions control the parking brake control valve (the signal is switched via the shuttle valve block).

Parking brake opening:

The parking brake control valve (and also the parking brake piston) are opened by pilot pressure (joystick -> shuttle valve block).

Parking brake locking:

As soon as the pilot pressure drops (joystick centered in the neutral position), the parking brake control valve is switched to neutral position by spring force. In neutral position, oil from the brake piston runs off via brake valve leakage (throttle symbol). Depending on the viscosity of the oil and the brake valve leakage, the brake is applied after a certain time delay.

- For less aggressive braking and to minimize swing motion, the swivel motor (serial numbers before AB01532) is provided with a hydraulic brake valve.

On units with serial numbers AB01533 and above, the suction valves are damped.

- The non-return valve in the suction hose line provides vaccum for the suction valves.

Page C45

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 8.

5002 - 6002 - 6502

SHUTTLE VALVE BLOCK

Type: Feature:

2708316 transfers pilot pressure from the piloted joystick to the parking brake control valve main valve block

swivel motor

Fig.: Ports - shuttle valve block / main valve block

section boom offset D

C

B

A

E

swivelling section

<<< port SH - swivel motor

Page C46

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

DRIVING MOTOR

9.

Type: Features:

5108350 - swash plate axial-piston motor, 2 driving speeds - mechanical motor parking bake (brake disks) - hydraulically opened; mechanically closed - hydraulic braking unit is used to prevent motor overspeeding - double planetary gear requires maintenance (see the Maintenance chapter).

1 2

3

4

5

TT

Fig.: Drive unit

1 3 5

prake pistons / suction valves port for oil return (>swivel joint) port for 2nd driving stage BV (>DDF)

Page C47

2 4

= (M14 10.9) 132.7 ft-lbs.

(180 Nm)

valves ports A/B (>swivel joint)

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics Fig.:

5002 - 6002 - 6502

Hydraulic diagram - drive unit 5108350 1

3 2

4 drive unit 2 BV (control oil unit )

A B Fig.: Drive unit b

1 3 A/B

parking brake piston valves (damped) ports for driving

2 4 BV

Page C48

dir. control valve 2nd driving speed hydraulic braking unit port for 2nd driving speed

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502 Fig.:

Hydraulic diagram - driving motor 5108350

valves

piston motor

directional control valve 2nd driving speed

brake piston suction valve

double planetary gear

Page C49

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

10. SWIVEL JOINT Types: Features:

Fig.:

44508500, 4508546 - 8-port swivel joint - Note: When ordering seal sets, please specify the excavator serial number.

Hydraulic diagram - driving motor 5103350

driving fast blade rod side blade bottom side driving left top driving right top driving left bottom driving right bottom oil return

Page C50

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics

5002 - 6002 - 6502

11. SWITCH VALVE Function: Type:

Switching of Functions Auxiliary Hydraulics / Boom Offset 2708315

Feature:

- electrically piloted via left joystick (6/2-way valve) - non-supplied ports -> tank

Fig.: Port assignment of switch valve

solenoid valve

D

C

B

F

switch valve offset/AH: - access via floor plate chassis bottom left

A

E tank Fig.: Port assignment

A / B - pilot control valve auxiliary hydraulics C / D - main valve block sect. auxiliary hydraulics E / F - main valve block sect. boom offset

Page C51

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Hydraulics 14.

5002 - 6002 - 6502

OIL TANK - Hydraulic System

A) Breather filter

>> see also Maintenance chapt.

The breather provides the following functions: - Pressure compensation in the hydaulic tank (varying oil level) by venting the tank - protection of oil tank against swelling - Pressurizing the oil tank to the defined pressure -> to support intake of the variable displacement pump - Filtering of intake air Initial pressure: 6 psi (0.4 bar) return filter hydraulic tank

breather ( hydraulic tank)

Fig.: Hydraulic oil tank

filter cloth

breather valve

Fig.: Breather Page C52

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502

CHAPTER D:

Diesel engine

Page D1

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502

Diesel Engine Specifications Refer to the diesel engine section in the technical data chapter in this manual for diesel engine specification information.

Important Diesel Engine Service Items - Model 6002

Service News

Theme: Gasket - cylinder head engine 4TNE98 Solution: Cylinder gasket made thicker

Possible problem: Affected: Yanmar 4TNE98 until engine 06850 Damage to the cylinder head gasket can be caused by extreme operating temperatures which could be caused by an unsealed cooling system or a low coolant level in the cooling system subtank.

Solution: Starting with engine Serial No.: 06851 the cylinder head gasket is thicker - mandatory modification of the gasket is no longer required.

Service News

Theme: Bracket solenoid stop -engine 4TNE98 Solution: Modification (-kit) with new bracket Serial No.: AB01647 and higher

Possible problem: Malfunction of the solenoid stop can be caused by: - Bad power transformation from the solenoid to the injection pump lever, possibly caused by dirt, heat, damage, etc.

- Malfunction of the relay solenoid stop possibly caused by heat, faulty wiring, etc.

When changing the solenoid, It is recommended that the bracket and the relays also be modified.

Page D2

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502

Fuel Line Diagram

1

2

3

4 5 6

7 8

1 2 3 4 5

Fuel inject valves Fuel inject pump Non-return valve Throttle Main fuel filter

6 7 8

Page D3

Fuel pump with mech. pump Water separator Fuel tank

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502

A) BATTERY

Battery capacity:

. see the Diesel Engine section in the “Technical data“ chapter

> Structure Pole

Housing

Screw for fluid fill level control Cover Cathode plates Insulation Glass mats Anode plates

B) COOLING WATER LINE

.

Thermo switch

Cylinder head Sub tank Bypass Water cooler Engine block

Page D4

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502 C) RADIATOR

.

Position diesel engine fan shroud cover as follows: Charge fan -> Discharge fan ->

D)

1/3 of the fan width inside the fan shroud 2/3 of the fan width inside the fan shroud

CYLINDER HEAD BOLT TIGHTENING ORDER

4-cylinder diesel engine: Tighten the cylinder head bolts in the following order: Camshaft side Fly wheel side

Cooling Side

Cylinder Head Bolt Tightening Torques: Model 5002: first pass: 32.5 - 34.6 fit-lbs. (44 - 47 Nm) second pass: 64 - 69 ft-lbs. (87 - 93 Nm) Model 6002: first pass: 38.4 - 42 ft-lbs. (52 - 57 Nm) second pass: 76 - 83 ft-lbs. (102.9 - 112.7 Nm) Important: Oil the bolt threads and the contact surfaces of the cylinder head bolts before inserting them.

E)

CYLINDER HEAD BOLT LOOSENING ORDER

Loosen the cylinder head bolts in reverse order from shown in the diagram.

Page D5

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Diesel engine

5002 - 6002 - 6502

This page intentionally left blank

Page D6

Id.No.: Edition:

918172 Sept. 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

C HAPT E R E :

Electrical

Page E1

Id.No.: Edition:

918172 June 05

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Page E2

.

Electrical SERVICE MANUAL

5002 - 6002 - 6502

Electrical diagram (up to Serial No.: AB00472 )

Id.No.: Edition:

918172 June 05

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Page E3

.

5002 - 6002 - 6502

SERVICE MANUAL Electrical

Electrical diagram (up to Serial No.: AB00472 )

Id.No.: Edition:

918172 June 05

. . .

- "

- .

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Legend Wiring Diagram 5002 - 6002 FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FUG1 FUK1

Instruments and indicator lights 7.5A Switch relay initial contact and glow plug 30A Windshield wiper motor 7.5A 2nd gear (button) 7.5A Cab lighting 10A Free (turning lights 10A) Horn and fan motor Light switch 15A Change over and safety solenoid valve 7.5A Work lights 15A Alternator 10A, Switch for 2nd gear Main fuse 50A Blinker

G1 G3 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16 HA1 HA2 K0 K1 K2 K3

Battery Alternator Glow plug indicator Charge indicator Water temperature warning signal Oil pressure indicator Clogged air filter Check return filter Minimum fuel warning light Light indicator (lights on/off) Right work light Left work light Left side work light Right side work light Roof light Rear light Rear light Work light Buzzer Horn Starter relay Relay work light Blinker relay Time relay 1.5 sec. stop solenoid Page E4

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

K4 K5

Switch relay initial contact Time relay glow plug indicator 15 sec.

M1 M2 M3 M4 M5

Starter Fan motor Wiper motor Windshield washer pump Additional filler pump for filling fuel tank (optional)

P1 R1 R2

Operating hours counter and fuel gauge Warm up glow plug Fuel gauge sender

S1 S2 S3 S4 S5 S6 S7 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19

Switch for 2nd gear Switch for fan motor Switch wiper motor Light switch Switch for rear work lighting Switch for work lights Feeler for minimum fuel warning light Feeler for water temperature Feeler for oil pressure switch Feeler for clogged air filter Feeler for return filter Ignition Switch roof light Button for 2nd gear Horn button Change over valve button Switch safety solenoid valve

Y0 Y1 Y2 Y3 X1 X6 X2 X7

Stop solenoid Change over valve Solenoid valve 2nd gear Safety solenoid valve Plug in engine area 21 pole Plug for addtional filler pump 2 pole Plug in engine area 6 pole Cab plug 7 pole

Page E5

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Relay position 5002 Glow relay (for glow contol lamp only; ca 15 sec.)

Timer relay solenoid pull wiring; 1.5 sec

Relay solenoid hold wiring Main fuse (50 A) Starter relay

Pict.:

Plug Glow timer relay (black plug) 1

5

2

6

3

7

4

8

1 2 3 4

2xblack / white red/gray 2xblack brown 1 mm²

5 6 7 8

red / white yellow black red

1 mm² 1 mm² 1 mm²

Ignition lock 50a and Starter relay Glow control Ground and diode Glow control

Page E6

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Plug timer relay for pull wiring (white plug)

1 2 3 4

black / pink black / blue 2xblack 2xblue

5 6 7 8

red / white yellow black red

1

5

2

6

3

7

4

8

1 mm² 1 mm² 1 mm² 1.5 mm²

Relay pull wiring solenoid stop Relay pull wiring solenoid stop Timer glow control relay Timer relay pull wiring 30A-fuse (conn. 54 ignition lock)

Starter relay 1 2 4

1 2 3 4

black / white 1 mm² black 1 mm² green 4 mm² red / white 4 mm²

3

Diode and glow relay Ignition lock 50a and diode Ignition lock 30 Starter 50

Page E7

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Timer relay solenoid stop pull wiring 5002

1 3 2

1 2 3

white 1.5 mm², 30A Fuse (clamp 54 Ignition lock) and timer relay solenoid red 1.5 mm², 2xblue 1 mm², red 1 mm² solenoid stop black / blue and black / pink from timer relay pull wiring

Plug solenoid stop Black : Ground Red: Hold wiring White: Pull wiring

Page E8

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Relay 6002

Relay solenoid stop Timer relay pull wiring (1.5 sec.)

Glow lamp control relay (ca. 15 sec.)

Starter relay Main fuse 50A Starter relay plug

1 2 3 4

1

5

2

6

3

7

4

8

white black/white yellow black

5 6 7 8

blue 1 mm² timer relay glow+ timer pull wiring black/white 1 mm² timer relay-pull. +Ignition lock. Kl.50a black/orange 1 mm² alternator connection W black 1 mm² ground green 2.5 mm² starter connector 30 white/red 2.5 mm² starter connector 50 Page E9

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Solenoid stop plug Black (ground) White (Timer pull wiring 1.5 sec.)

Red (Hold wiring , clamp 15) Adjustment: 1) Thread the magnetic core all the way in.

2) Push the control rack of the injection pump to its stop.

3) use screw D to adjust the leverage of the magnetic engine brake cylinder. screw D Solenoid stop relay plug

Plug 1 white: 2.5 mm² red: 2.5 mm² red: 1 mm² blue: 2x1.5 mm²

Solenoid stop (Pull wiring 1.5 sec.)

Solenoid stop (Holding wiring) Not wired (Option ) Fuse 30 A

Plug 2 black / blue and black / pink:Timer relay pull contact

Page E10

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Plug glow control lamp relay (black plug)

1 2 3 4 5 6 7 8

1

5

2

6

3

7

4

8

2xblack/white 1 mm² red/gray 1 mm² 2xblack 1 mm² braun 1 mm² red/white yellow black red

Starting lock connector 50a reset glow control Glow control Ground Glow control + Ignition lock

Plug timer relay for pull wiring (white plug)

1 2 3 4 5 6 7 8

1

5

2

6

3

7

4

8

black/pink 1 mm² black/blue 1 mm² 2xblack 1 mm² 1xblue 1.5 mm² red/white yellow black red

Relay solenoid stop Relay solenoid stop Glow timer relay Starter relay

Page E11

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Electrical wiring 5002 ( Serial No.: AB00473 and higher )

Page E12

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Electrical wiring 5002 ( Serial No.: AB00473 and higher )

Page E13

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Legend - Model 5002 electrical wiring S e ria l No.: AB00473 a nd highe r A B 1 s top s olenoid B1 water tem p. s ens or B2 horn B3 fuel level s ens or G1 alternator H2 right front light H3 arm light H12 c ontrol lam p preheating H13 c ontrol lam p load c ontrol H14 c ontrol lam p engine tem perature H15 c ontrol lam p engine oil pres s ure H16 c ontrol lam p air filter c logged H17 c ontrol lam p hy draulic oil filter c logged H18 c ontrol lam p overload warning H20 c abin roof light front H21 c abin roof light bac k H22 rotating lam p K 1.1 relay off engine tem p.

K 1.2 relay air c onditioning on K 1.3 c lim ac om pres s or K2 tim er preheating 10 s ec .

K4 s tarting relay K5 s olenoid engine s top tim er K6 s olenoid engine s top M 1 heating van M 2 refuelling pum p M 5 s tarter M 6 winds c reen wiper M 7 winds c reen was her S1 alternator s peed pic k up S2 water tem perature s witc h S4 air filter is c logged S5 engine oil pres s ure S6 3rd hy draulic c irc uit button S7 boom s wing / ex tend hy draulic button S8 3rd hy draulic c irc uit button S 10 s afety s witc h right S 11 fas t s peed s witc h S 12 pres s ure s witc h overload warn devic e S 14 hy draulic oil filter is c logged S 15 winds hield wiper / was her S 16 heating van s witc h S 17 fas t s peed s witc h S 18 arm light s witc h S 19 front / s ide light s witc h S 20 s tarting s witc h S 21 rotation light s witc h S 22 s witc h overload warn devic e S 23 s witc h roof light S 35 tem perature air c onditioning

Page E14

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Legend - Model 5002 electrical wiring S 36 S 37 S38 S39 R1 X0 X1 X4 X5 X6 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X24 X26 X27 X28 X29 X30 X31 Y2 Y3 Y4 Y5 Y6 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 Q1 Q2 X40 X41 X42 X43

Se ria l No.: AB00473 a nd highe r air conditioning switch air conditioning switch air conditioning pressure switch air conditioning pressure switch preheating accessory socket (cigarette lighter) main connector engine cable tree engine relays alternator load control alternator main plus starter m ain plus starter solenoid heating / air conditioning switches left instrum ent panel connector heating / air conditioning ventilator connector right to left arm rest connector right to left arm rest connector right to left arm rest main connector arm rest cable tree ground socket connector engine speed / pum p reg. connector to horn button anti-theft device connector cabin connector instrument panel connector motor oil control buzzer boom swing / extend hydraulic valve 3rd hydraulic circuit 3rd hydraulic circuit safety valve fast speed valve switch lights, control lam ps anti-theft device, engine relay lights chassis, arm heating van, air conditioning horn arm rest left, engine speed, pum p regulation windshield wiper, cabin stop solenoid, alternator valves option cabin socket, refuelling pum p rotating light, cabin, anti-theft device main fuse main fuse main connector back lights lights front left lights front right boom lights

Page E15

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

L e g e nd - M o d e l 5 0 0 2 e le ctrica l wiring Y2 Y3 Y4 Y5 Y6 Y8 Y9 F1 F2 F3 F4 F5 F6 F7 F8 F9 F 10 F 11 Q1 Q2

S e ria l N o .: AB 00473 a n d h ig h e r boom s wing / ex tended hy draulic valve 3 rd hy draulic c irc uit 3 rd hy draulic c irc uit s afety valve fas t s peed valve full floating ax le valve s hield up / dow n s witc h lights , c ontrol lam ps anti-theft devic e, engine relay c has s is lights , arm heating van, air c onditioning horn arm res t left, engine s peed, pum p regulation w inds hield w iper, c abin s top s olenoid, alternator valves c abin option s oc k et, refuelling pum p rotating light, c abin, anti-theft devic e m ain fus e m ain fus e

Page E16

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Electrical diagram 6002 (starting with Serial No.: AB00473)

Page E17

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Electrical diagram 6002 (starting with Serial No.: AB00473)

Page E18

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

L e g e n d - M o d e l 6 0 2 e le c tr i c a l w i r i n g S e ria l N o .: A B 0 0 4 7 3 a n d h ig h e r A B 1 s t o p s o le n o id B1 w ater tem p. s en s or B2 h o rn B3 fu e l l e ve l s e n s o r G1 a lt e rn a t o r H2 r i g h t fr o n t l i g h t H3 a rm lig h t H 1 2 c o n t ro l la m p p re -h e a t in g H 1 3 c o n t ro l la m p lo a d c o n t ro l H 1 4 c o n t ro l la m p e n g in e t e m p e ra t u re H 1 5 c o n t ro l la m p e n g in e o il p re s s u re H 1 6 c o n t r o l l a m p a i r fi l t e r c l o g g e d H 1 7 c o n t r o l l a m p h y d r a u l i c o i l fi l t e r c l o g g e d H 1 8 c o n t r o l l a m p o ve r l o a d w a r n i n g H 2 0 c a b i n r o o f l i g h t fr o n t H 2 1 c a b in ro o f lig h t b a c k H 2 2 ro t a t in g la m p K 1 . 1 r e l a y o ff e n g i n e t e m p .

K 1 . 2 re la y a ir c o n d it io n in g o n K 1 . 3 a ir c o n d it io n in g c o m p re s s o r K2 t im e r p re h e a t in g 1 0 s e c .

K4 s t a rt in g re la y K5 s o le n o id e n g in e s t o p t im e r K6 s o le n o id e n g in e s t o p M 1 h e a t i n g va n M 2 r e fu e l l i n g p u m p M 5 s t a rt e r M 6 w in d s c re e n w ip e r M 7 w in d s c re e n w a s h e r S1 a lt e rn a t o r s p e e d p ic k u p S2 w a t e r t e m p e ra t u re s w it c h S4 a i r fi l t e r i s c l o g g e d S5 e n g in e o il p re s s u re S6 3 rd h y d ra u lic c irc u it b u t t o n S7 b o o m s w in g / e x t e n d h y d ra u lic b u t t o n S8 3 rd h y d ra u lic c irc u it b u t t o n S 1 0 s a fe t y s w i t c h r i g h t S 1 1 fa s t s p e e d s w i t c h S 1 2 p r e s s u r e s w i t c h o ve r l o a d w a r n i n g d e vi c e S 1 4 h y d r a u l i c o i l fi l t e r i s c l o g g e d S 1 5 w in d s h ie ld w ip e r / w a s h e r S 1 6 h e a t i n g va n s w i t c h S 1 7 fa s t s p e e d s w i t c h S 1 8 a rm lig h t s w it c h S 1 9 fr o n t / s i d e l i g h t s w i t c h S 2 0 s t a rt in g s w it c h S 2 1 ro t a t io n lig h t s w it c h S 2 2 s w i t c h o ve r l o a d w a r n d e vi c e S 2 3 s w it c h ro o f lig h t S 3 5 a ir c o n d it io n in g t e m p e ra t u re S 3 6 a ir c o n d it io n in g s w it c h S 3 7 a i r c o n d i t i o n i n g va n s w i t c h S 3 8 a ir c o n d it io n in g p re s s u re s w it c h S 3 9 a ir c o n d it io n in g p re s s u re s w it c h

Page E19

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

L e g e n d - M o d e l 6 0 0 2 e le c t r i c a l w i r i n g R1 X0 X1 X4 X5 X6 X9 X1 0 X1 1 X1 2 X1 3 X1 4 X1 5 X1 6 X1 7 X1 8 X1 9 X2 4 X2 6 X2 7 X2 8 X2 9 X3 0 X3 1 Y2 Y3 Y4 Y5 Y6 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 Q1 Q2 X4 0 X4 1 X4 2 X4 3 Y2 Y3 Y4 Y5 Y6 Y8 Y9

S e ria l N o .: A B 0 0 4 7 3 a n d h ig h e r p re h e a t in g a c c e s s o ry s o c k e t (c ig a re t t e lig h t e r) m a in c o n n e c t o r e n g in e c a b le t re e e n g in e re la y s a lt e rn a t o r lo a d c o n t ro l a lt e rn a t o r m a in p lu s s t a rt e r m a in p lu s s t a rt e r s o le n o id h e a t in g / a ir c o n d it io n in g s w it c h e s c o n n e c t o r i n s t r u m e n e n p a n e l l e ft h e a t i n g / a i r c o n d i t i o n i n g ve n t i l a t o r c o n n e c t o r r i g h t t o l e ft a r m r e s t c o n n e c t o r r i g h t t o l e ft a r m r e s t c o n n e c t o r r i g h t t o l e ft a r m r e s t m a in c o n n e c t o r a rm re s t c a b le t re e g ro u n d socket c o n n e c t o r e n g in e s p e e d / p u m p re g u la t io n h o rn b u t t o n c o n n e c t io n c o n n e c t o r a n t i - t h e ft d e vi c e c a b in c o n n e c t o r in s t ru m e n t p a n e l c o n n e c t o r m o t o r o il c o n t ro l buzzer b o o m s w i n g / e x t e n d h y d r a u l i c va l ve 3 rd h y d ra u lic c irc u it 3 rd h y d ra u lic c irc u it s a fe t y va l ve fa s t s p e e d va l ve s w it c h lig h t s , c o n t ro l la m p s a n t i - t h e ft d e vi c e , e n g i n e r e l a y lig h t s c h a s s is , a rm h e a t i n g va n , a i r c o n d i t i o n i n g h o r n a r m r e s t l e ft , e n g i n e s p e e d , p u m p r e g u l a t i o n w in d s h ie ld w ip e r, c a b in s t o p s o le n o id , a lt e rn a t o r va l ve s o p t io n c a b in s o c k e t , r e fu e l l i n g p u m p r o t a t i n g l i g h t , c a b i n , a n t i - t h e ft d e vi c e m a i n fu s e m a i n fu s e m a in c o n n e c t o r b a c k lig h t s l i g h t s fr o n t l e ft l i g h t s fr o n t r i g h t lig h t s o n b o o m b o o m s w i n g / e x t e n d h y d r a u l i c va l ve 3 rd h y d ra u lic c irc u it 3 rd h y d ra u lic c irc u it s a fe t y va l ve fa s t s p e e d va l ve fu l l fl o a t i n g a x l e va l ve s h ie ld u p / d o w n

Page E20

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

L e g e n d - M o d e l 6 0 2 e le c tr i c a l w i r i n g F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 Q1 Q2

S e ria l N o .: A B 0 0 4 7 3 a n d h ig h e r s w it c h lig h t s , c o n t ro ll la m p s a n t i - t h e ft d e vi c e , e n g i n e r e l a y lig h t s c h a s s is , a rm h e a t i n g va n , c l i m a , h o r n a r m r e s t l e ft , e n g i n e s p e e d , p u m p r e g u l a t i o n w in d s c re e n w ip e r, c a b in s t o p s o le n o id , a lt e rn a t o r va l ve s o p t io n c a b in s o c k e t , r e fu e l l i n g p u m p r o t a t i n g l i g h t , c a b i n , a n t i t h i e f d e vi c e m a i n fu s e m a i n fu s e

5002 Connection beween engine wiring and armrest X1 B D E G

21 pol.

Description main positive ground main positive preheating

A C F H J K L M N P R S T U V W X

load control lamp plus 12V/15 relay: preheating, start (+15) plus 15: stop solenoid plus 15: stop solenoid air conditioning pressure air conditioning compressor start relay preheating lamp alternator (+15) water temperature switch water temperature sensor engine speed engine oil pressure res clogged air filter air conditioning temperature

pink blue blue blue blue yellow / red yellow / blue white / black grey / red blue / red green / black green / white blue / black white

Page E21

Id.No.: Edition:

red black red brown

grey / blue yellow

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

6002 connection beween motor and armrest X1 B D E G

21 pol.

Description main positive ground main positive preheating

A C F H J K L M N P R S T U V W X

load control lamp plus 12V/15 relay: preheating, start (+15) plus 15: stop solenoid plus 15: stop solenoid air conditioning pressure air conditioning compressor start relay preheating lamp alternator (+15) water temperature switch water temperature sensor engine speed engine oil pressure res clogged air filter air conditioning temperature

red black red brown pink blue blue blue blue yellow / red yellow / blue white / black grey / red blue / red green / black green / white blue / black white grey / blue yellow

5002 connection beween chassis and armrest X17

24 pol.

1 2 3 4 5 6 7 11 12 13 14 15 16 17 18 20 21 24

24 poles Description safety valve boom swing / extend hydraulic valve fast speed valve heating van II heating van I 12V fast speed switch fuel level front lights socket / refuelling pump hydraulic oil level ground horn ground arm light 3rd hydraulic circuit clogged hydraulic oil filter overload warning device switch 3rd hydraulic circuit

Page E22

brown / white light blue / yellow brown / black yellow red grey violet green / blue red / black orange / blue black orange / black black green / yellow red / black / red orange / white blue / black / blue pink

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

6002 connection beween chassis and armrest X17

24 pol.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

24 poles safety valve boom swing / extend hydraulic valve fast speed valve heating van II heating van I 12V fast speed switch fuel level

brown / white light blue / yellow brown / black yellow red grey violet

front lights socket / refuelling pump hydraulic oil level ground horn ground arm light 3rd hydraulic circuit

green / blue red / black orange / blue black orange / black black green / yellow red / black / red

clogged hydraulic oil filter overload warning device switch

orange / white blue / black / blue

3rd hydraulic circuit

pink

Connection to RIGHT armrest X1 B D E G A C F H J K L M N P R S T U V W X

21 pol. 21 pol. Description main plus ground main plus preheating

red black red brown

load control lamp plus 12V/15 relay: preheating, start (+15) plus 15: stop solenoid plus 15: stop solenoid air conditioning pressure switch air conditioning compressor start relay preheating lamp alternator (+15) water temperature switch water temperature sensor engine speed eingine oil pressure res. clogged air filter air conditioning temperature

Page E23

pink blue blue blue blue yellow / red yellow / blue white / black grey / red blue / red green / black green / white blue / black white grey / blue yellow

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

C onne ction to R IG H T armre st X 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 X 14, fe m a le 3 4 5 11 X 15, m a le 1 2 3 4 5 6 7 8 9 10 11 12 13 X 16,m a le 1 2 3 4

24 pol. 24 pole s de scription s afety valve boom s wing / ex tend hy draulic valve fas t s peed valve heating van II heating van I fas t s peed s witc h fuel level res . res . s ide lights front lights s oc k et / refuelling pum p hy draulic oil level ground horn ground arm light 3rd hy draulic c irc uit pum p regulation valve c logged hy draulic oil filter overload warning devic e s witc h res . res .

3rd hy draulic c irc uit 13 pole s AM P : dis play bac k light ground water tem perature s peed pic k up s ignal 13 pole s AM P : res . res . res . res .

3rd. hy draulic c irc uit 3rd. hy draulic c irc uit s afety s witc h arm res t boom s wing / ex tend hy draulic air c onditioning tem perature res . air c onditioning c om pres s or air c onditioning pres s ure water tem perature s witc h 4 pol. AM P : valves s upply + 15 ground plus 12 V plus 12 V

Page E24

brown / white light blue / y ellow brown / blac k y ellow red grey violet

green green / blue red / blac k orange / blue blac k orange blac k green / y ellow red / blac k / red blue / y ellow orange / white blue / blac k / blue

pink green blac k green / white blue / blac k

red / blac k / red pink brown / white lightblue / y ellow y ellow blue / y ellow y ellow / red green / blac k grey blac k red red

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Connection to RIGHT armrest X24

6 pol. AMP X15, P1 X15, P1 X15, P1 GND Supply +12 V res

dark blue green / black light blue black red

1 2 3 4 5 6 7 8 9 10 11

starter valves stop solenoid starter valves stop solenoid

white / black brown / white blue white / black brown / white blue

ground

black

supply +30 supply +15

red blue

1 2 3 4 5 6 7 8 9

windscreen wiper back rotating lamp ground windscreen wiper cabin roof light front windscreen washer supply +15 supply +30 cabin roof light back

blue / red violet black white green white/black/white blue red black yellow / black

1 2 3 4 5 6 X27

X28

Connection between right and left armrest X14, male 1 2 3 4 5 6 7 8 9 10 11 12 13

13 poles AMP: res. Lamp res. lamp display back light ground water temperature brake lamp (6502) accumulator load lamp (6502) res. lamp res. lamp nc. speeed pickup signal indicator lamp (6502) light lamp (6502)

Page E25

brown brown green black green / white red / yellow green / white brown brown blue / black blue / red yellow / black

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

Connection between right and left armrest X15, female 1 2 3 4 5 6 7 8 9 11 12 13 X16,female 1 2 3 4 X11, female 1 2 3 4 5 6 7 8 9 10 11 X13, female 1 2 3 4 5 6

13 poles AMP: res. res. res. res.

3rd. hydraulic circuit 3rd. hydraulic circuit safety swich armrest boom swing / extend hydraulic clima temperature clima compressor clima pressure water temperature switch 4 pol. AMP: valves supply +15 ground plus 12 V plus 12 V 11 pol. AMP: ventilator speed III ventilator speed II ventilator speed I res water temperature ( switch) pump regulation valve clima compressor to thermostate in clima clima pressure switch ground plus 12 V 6 pol. AMP thermostat to switch on thermostet to clima compressor ground ventilator speed II ventilator speed I ventilator speed III

Page E26

red / black / red pink brown / white lightblue / yellow yellow yellow / blue yellow / red green / black grey black red red orange orange red green / black lightblue / yellow yellow / blue yellow yellow / red black red yellow yellow black orange orange red

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502 Fuse box

These fuses are integrated in the right joystick armrest consol Positions of the fuses inside the fuse box No. Capacity (A) F1 7,5 F2 10 F3 25 F4 20 F5 10 F6 15 F7 30 F8 15 F9 F10 F11

10 15 15

Used for Joystick consol arm rest right (z.B.: lights, etc.)

Starter relay, Glow relay, (opt. anti-theft system) Arm lights: side front arm lights Heater, Horn, (Air conditioning van, compressor - Option) Joystick consol left, Cabin (+15), Windshield wiper/washer Solenoid stop, Generator (+15) Safty solenoid switch arm rest, 2nd drive speed, Arm swing/auxiliary hydraulics elec. piloted (Opt.) Opt. roof lights Plug engine room, Fuel pump (Opt.) Option roof turn light, Cabin (+30), anti-theft system Accessory socket (cigarette lighter)

The main fuse F0 (50A) is located in the relay box - engine area

Page E27

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Electrical

5002 - 6002 - 6502

This page intentionally left blank

Page E28

Id.No.: Edition:

918172 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

C HAPTE R F :

Operating elements

Page F1

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

Machine Overview

2

3,4 5,6

7

17

18

8

9

1 10 11

12 13

14

15 1 2 3 4 5 6 7 8 9 10

16

11 12 13 14 15 16 17 18 19 20

Bucket arm cylinder Boom Left drive lever Right drive lever Left control lever Right control lever Cab Driver's seat Engine cover Bucket arm

Page F2

19

20

Bucket cylinder Backhoe bucket Boom cylinder Steering control console Traveling drive Undercarriage Protective cover for track tensioner Chassis Lifting eyes Dozer blade

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

Component Description

6 1

2 3 9 4

5 10 11 8

7 1 2 3 4 5 6

Oil tank Main hydraulic valve and pilot unit Opening for filling hydraulic oil Hydraulic oil level indicator Return filter Tank support

7 8 9 10 11

Page F3

Engine cover Battery Diesel tank Drain plug oil tank Drain plug diesel tank

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

Cab Equipment and Controls 1

2

4

5

6

7

15 8 8

3 25

10

24

14

22 23

11

12,13

19

11

16

20

21 9

18

17 18

Page F4

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Auxiliary hydraulics pedal Drive pedal left Seat spring tension adjustment Drive pedal right Seat back adjustment Drive brake Dozer blade lever Heating and air vents Cab lighting Accelerator Arm rest Side cover latch Engine cover latch Right control lever for boom and bucket, horn Ashtray Instrument panel Radio Speaker Ignition lock Storage Fuse box Heating Left control lever for bucket arm and swiveling; swing arm Left steering control console fold-back lever Seat position adjustment

Page F5

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

Pict.: Component designation joystick consoles 1 2 3 4 5 6 7 8

Fuel gauge Charge indicator Oil pressure Coolant temperature warning signal Clogged air filter Glow plug indicator Clogged hydraulic filter (optional) Overload warning indicator

9 10 11 12 13 14 15 16 17 18

Light indicator (lights on/off) Operating hours counter Heater switch Windshield wiper/ washer switch Overdrive Switch for work lights Switch for chassis lights Fuse box Ignition key Cold/ warm adjustment

Left joystick console

Right joystick console

2 3 4 5

10

1 6 7 8 9

17 13

11 18

14 12

15

16 Page F6

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502 Pict.:

Joystick functions (Standard)

The excavating equipment is operated using the left and right control levers on the driver's seat console.

To operate the bucket stick and swivel the superstructure use the left control lever. The boom and bucket are operated using the right control lever.

Left joystick

Button for boom control

Horn

Right joystick

Pict.:

Left joystick console ( Joystick )

1

3

1 2 3 4

forward rearward left right

Dipper arm up (away from the excav.)

Dipper arm down (to the excavator) Uppercarriage turns left Uppercarriage turns right

Page F7

4

2

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements Pict.:

5002 - 6002 - 6502

Right joystick console ( Joystick )

5

7

8

6 5 6 7 8

Function:

forward rearward left right

Boom down Boom up Bucket inward (toward the excavator) Bucket out (away from the excavator)

Dozer blade

Dozer blade up and down motion is controlled by the lever / right pedal.

Dozer blade down

Dozer blade up

Dozer blade lever

Page F8

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502 Function:

Auxiliary hydraulics / Arm swing (Boom/Dipper stick)

> Auxiliary hydraulics

=

Pedal auxiliary hydr. Left / Right

> Arm swing

=

Pedal auxiliary hydr. Left / Right + Bottom on the left joystick

The arm swing direction and the side of the pressurized hose of the auxiliary hydraulic system is controlled by the pedal side.

Notice: If a hydraulic hammer (breaker) is used - block ball valve - position open “hammer“ (Area of the main valve block) - overheating of the hydraulic system is possible.

Without hammer - block ball valve - position closed (double side pressure) Pedal Auxiliary hydraulics

Function Block ball valve - Tank return for hammer function > CLOSE:

A

B

Standard Return of the auxiliary oil passes the main valve block

> OPEN: “Hammer function“ Return to the tank (e.g., “depressurized return“)

Page F9

Id.No.: Edition:

918157 June 05

SERVICE MANUAL

Operating elements

5002 - 6002 - 6502

Lifting the excavator Raise arm and dozer blade.

Fasten rope, chains, etc., to the boom and to the dozer blade on the left and the right (3-point suspension).

To prevent damage, ensure there is enough distance between the ropes/chains and the excavator.

The fastening points are indicated with stickers.

Ensure the ropes/chains etc., cannot come undone. Ensure the ropes/chains etc., are rated strong enough to support the weight of the excavator.

Minimum force required per lift: 9 tonf (80 kN) L1 = about 9’ 0”. (2.75 m) P1 ...

P2 ...

L2 (2X)= about 15’ 7” (4.75 m)

Fastening point boom Fastening points left and right side of dozer blade

P1

L1 L2

P2

Page F10

Id.No.: Edition:

918157 June 05

TORQUE SPECIFICATIONS Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M10X1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12X1.5

15 (20)

18 (25)

18 (25)

18 (25)

0.5 in. (12 mm)

M14X1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (14 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18X1.5

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

Thread

M22X1.5

48 (65)

92 (125)

44 (60)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

74 (100)

107 (145)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

G1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20.96 mm)

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14X1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (14 mm)

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

M18X1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20X1.5

41 (55)

92 (125)

59 (80)

74 (100)

0.8 in. (20 mm)

M22X1.5

48 (65)

100 (135)

74 (100)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

Thread

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5

4.1 (5.5)

6 (8)

7 (10)

4 (5)

5 (7)

M6

7 (10)

10 (14)

13 (17)

6.3 (8.5)

9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12

64 (87)

81 (110)

108 (147)

51 (69)

74 (100)

M14

100 (135)

133 (180)

170 (230)

81 (110)

118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20

302 (410)

420 (570)

509 (690)

251 (340)

361 (490)

M22

406 (550)

575 (780)

686 (930)

339 (460)

487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8X1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10X1.0

37 (50)

55 (75)

65 (88)

32 (43)

48 (65)

M10X1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12X1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12X1.5

61 (83)

92 (125)

107 (145)

53 (72)

77 (105)

M14X1.5

100 (135)

148 (200)

173 (235)

89 (120)

129 (175)

M16X1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18X1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20X1.5

325 (440)

465 (630)

538 (730)

277 (375)

391 (530)

M22X1.5

435 (590)

620 (840)

723 (980)

369 (500)

524 (710)

M24X2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27X2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30X2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

®

Mustang Manufacturing Co., Inc. 1880 Austin Road, P.O. Box 547, Owatonna, Minnesota, 55060-0547 USA www.mustangmfg.com

918172/AP0905

© 2005 MUSTANG MANUFACTURING COMPANY, INC. All Rights Reserved.

PRINTED IN USA