Mustang Compact Excavator ME8002 Service Manual(918173) - PDF DOWNLOAD

®

ME8002 COMPACT EXCAVATOR

SERVICE MANUAL PART #918173 Revision A - 09/05

®

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

A

Technical data Dimensions .................................................................................................................... A2 Bucket and Geometry...................................................... ......................................... A4 Lift Capacity Chart ........................................................................................................... A6 Hydraulic System ........................................................................................................... A8 Diesel Engine Specifications ......................................................................................... A10

B

Maintenance Maintenance Chart .......................................................................................................... B2 Maintenance General ..................................................................................................... B5 Lubricants ....................................................................................................................... B6 Lubrication Chart (points)................................................................................................ B8 Hydraulic System ........................................................................................................... B9 Hydraulic Pump .............................................................................................................. B18 Hose Burst Protection Valve.......................................................................................... B19 Drive Unit ........................................................................................................................ B19 Swivel Unit ...................................................................................................................... B20 Diesel Engine ................................................................................................................ B21 Undercarriage ................................................................................................................ B31 Hydraulic Oil Tank .......................................................................................................... B32 Fuel Tank ........................................................................................................................ B34

C

Hydraulic Hydraulic System / Diagrams. ....................................................................................... C2 Position of Components ................................................................................................ C5 Hydraulic Pump .............................................................................................................. C8 Pilot Oil Supply Unit ....................................................................................................... C16 Main Valve Block ........................................................................................................... C22 Second Valve Block ...................................................................................................... C48 Pilot Control Valves ....................................................................................................... C51 Swivel Unit ...................................................................................................................... C57 Shuttle Valves (swivel motor brake)........................................ .................................. C64 Drive Unit ........................................................................................................................ C65 Swivel Joint .................................................................................................................... C68 Switch Valve ................................................................................................................... C69 Load Lowering Valve ..................................................................................................... C70 Hydraulic Oil Tank .......................................................................................................... C71

D

Diesel Engine Diesel Engine Specifications ......................................................................................... D2

E

Electrical Electrical Wiring Diagram (up to serial number AB00473) ............................................. E2 Relay Position ................................................................................................................ E6 Solenoid Stop ................................................................................................................ E7 Glow Control Lamp Relay Plug ...................................................................................... E8 Fuse Box ........................................................................................................................ E9 Electrical Wiring Diagram (from serial number AB00473) .............................................. E12 Armrest Connections...................................................................................................... E14

TABLE OF CONTENTS (Continued) Chapter

Page

F

Operating Elements Component Designation ................................................................................................ F2 Joystick Consoles Component Designation...................................................... ...... F5 Joystick Functions ......................................................................................................... F7 Auxiliary Hydraulics / Arm Swing ................................................................................... F9 Lifting the Excavator ....................................................................................................... F10 Torque Specifications

SERVICE MANUAL

Technical data

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Technical data

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Technical data 1.

8002

DIMENSIONS

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DIMENSIONS / Performance

0001105/98

>> Starting with Serial.No.

8' 3" (2570 mm) / 7' 1" (2150 mm) / 13' 6" (3800 mm)

Dimensions ( H x W x L )

21' 7" (6570 mm)

Transport length Boom swing angle

Left / right

Front boom swing radius

min

80º / 50º 5' 6" (1670 mm) N

Tilt angle uppercarriage Ground clearance

max

15" (390 mm) 2' 7" (2150 mm)

Undercarriage width Track width

Standard

18" (450 mm)

Max. Dump height

Standard

17' 0" (5180 mm)

Max. Dump height / Option

Dipper arm long

Max. Dig height

Standard

Max. Dig height / Option

Dipper arm long

Max. Dig radius

Standard

23' 9" (7240 mm)

Max. vertical dig depth

Standard

11' 7" (3520 mm)

Max. vertical digging depth / Opt.

Dipper arm long

Max. dig depth

Standard

Max. dig depth / Option

Dipper arm long

N 23' 8" (7220 mm) N

N 14' 5" (4400 mm) N

Min. tail swing radius

5' 3" (1590 mm)

Dozer blade dimensions ( W x H ) Standard

7' 1" (2150 mm) / 21" (540 mm)

Dozer blade dimensions ( W x H ) Extension Dozer blade max. lift ... Ground

above / below

Dipper arm length

Standard

N 21" (540 mm) / 18" (450 mm) 6' 1" (1850 mm)

Dipper arm "long"

Option

N

Track rollers / guide rollers

per side

5/1

Operation weight with

Cab

Operation weight with

Canopy

N

Ground pressure Ground pressure

Standard Option

0.37 kg/cm 2 Steel Track 600 mm

17417 lbs. (7900 kg)

Gradability

30º / 58%

Noise level

LWA

95 dB (A)

Noise level

LPA

75 dB (A)

Travel speed

Drive

2.4 mph (3,8 km/h) /3.5 mph (5,6 km/h)

Tear out force per

Bucket tooth

719 psi (4960 kp)

Max. dipper arm tear out force

Standard

525 psi (3620 kp)

Slew ( swivel- ) speed

Uppercarriage

9.5 rpm

Tractive effort

Undercarriage

17 lbs. (7.700 kg)

Explaination:

F... Missing information

O... Option

N... No / Not

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Technical data 2.

8002

BUCKET AND GEOMETRY

E

Bolt diameter

55 mm

F

Dipper arm width

7" (170 mm)

L

Bolt distance Bucket carrier

11.8" (300 mm)

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Technical data 3.

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LIFT CAPACITY CHART

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Technical data

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Tab.:

Lift capacity chart - Standard boom

16’ 3" (5.0 m)

19’ 8" (6.0 m)

13’ 0" (4.0 m)

9’ 9" (3.0 m)

A B 13’ 0" (4.0 m) 9’ 9" (3.0 m)

3957 lbs.

(1795 kg)* 3960 lbs.

(1800 kg)*

1742 lbs.

(790 kg) 1477 lbs.

(670 kg)

6’ 6" (2.0 m)

4034 lbs.

(1830 kg)*

1323 lbs.

(600 kg)

4079 lbs.

(1850 kg)*

3’ 3" (1.0 m)

4134 lbs.

(1875 kg)*

1268 lbs.

(575 kg)

0

4255 lbs.

(1930 kg)*

1279 lbs.

(580 kg)

-3’ 3" (-1.0 m) -6’ 6" (-2.0 m) -9’ 9" (-3.0 m)

4365 lbs.

(1980 kg)*

1389 lbs.

(630 kg)

4453 lbs.

(2020 kg)* 4299 lbs.

(1950 kg)*

1709 lbs.

(775 kg) 2480 lbs.

(1125 kg)

Max. A B *

4023lbs.

(1825 kg)*

2623 lbs.

(1190 kg)

5004 lbs.

(2270 kg)*

5004 lbs.

(2270 kg)*

4167 lbs.

(1890 kg)*

1852 lbs.

(840 kg)

4795 lbs.

(2175 kg)*

2701 lbs.

(1225 kg)

6526 lbs.

(2960 kg)*

4905 lbs.

(2225 kg)

1411 lbs.

(640 kg)

4630 lbs.

(2100 kg)*

1874 lbs.

(850 kg)

5787 lbs.

(2625 kg)*

2668 lbs.

(1210 kg)

8212 lbs.

(3725 kg)*

4586 lbs.

(2080 kg)

4288 lbs.

(1945 kg)*

1433 lbs.

(650 kg)

5060 lbs.

(2295 kg)*

2039 lbs.

(925 kg)

6724 lbs.

(3050 kg)*

2601 lbs.

(1180 kg)

9755 lbs.

(4425 kg)*

4354 lbs.

(1975 kg)

4299 lbs.

(1950 kg)*

1433 lbs.

(650 kg)

5360 lbs.

(2445 kg)*

2094 lbs.

(950 kg)

7319 lbs.

(3320 kg)*

2513 lbs.

(1140 kg)

10682 lbs.

(4845 kg)*

3968 lbs.

(1800 kg)

5291 lbs.

(2400 kg)*

1764 lbs.

(800 kg)

7275 lbs.

(3300 kg)*

2480 lbs.

(1125 kg)

10571 lbs.

(4795 kg)*

3649 lbs.

(1655 kg)

1874 lbs.

(2850 kg)*

2491 lbs.

(1130 kg)

9040 lbs.

(4100 kg)*

3472 lbs.

(1575 kg)

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, firm 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% of the hydraulic lifting capacity are exceeded.

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Technical data 5.

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HYDRAULIC SYSTEM Started with Serial No..:

0001105/98

HYDRAULIC PUMP 1

Type

Double variable / gear pump 7008303

2

System

Double variable pump + 1 gear pump

3

Version

A8VO28SR3

5

Oil flow rate

21.3 gpm (80.5 L/min) + 21.3 gpm (80.5 L/min) + 12.9 gpm (48.9 L/min)

PRESSURE ADJUSTMENT 7

8

9

10

11

Main pressure limiting valve

Pump P1, P2 Main pressure limiting valve

Pump P3

(2)

4351 psi (300 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

(2)

3989 psi (275 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar) 508 psi (35 bar) +29 psi (+2 bar) / -29 psi (-2 bar)

Pilot oil pressure Secondary press. limit. valve

Main valve block Secondary press.limit.valve

Dozer blade valve

Swivel motor (SPLV) 12 (Pump - Measuring points)

(3)

5076 psi (350 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

(3)

4351 psi (300 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

(3)

Swivel unit 7008501: 3626 psi (350 bar) +0 / -72.5 psi (-5 bar) Swivel unit 7008490: 3510 psi (242 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

13

Swivel motor (SPLV) (Measured at the motor)

Swivel unit 7008490: 3408 psi (235 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

14

Drive motor Internal press.limit.valve

4351 psi (300 bar) +72.5 psi (+5 bar) / -72.5 psi (-5 bar)

For correct settings : (1)...General - Hydraulic oil temperature: 133 - 122°F (45 - 50°C) (2)...Settings at max. engine rpm (see Maintenance chap.)

(3)...Settings at min. engine rpm (see Maintenance chap.)

QUANTITIES 16

Hydraulic oil tank

32 gals. (122 L)

17

System filling

46 gals. (173 L)

Explanation: N...Not enclosed / not available

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Technical data

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AUXILIARY HYDRAULICS

Pressure controlled oil flow - auxiliary hydraulic Pressure (psi) Pressure (bar)

P2 (gpm)

P2 (L/min)

290.0

20.0

21.1

80

725.0

50.0

20.6

78

1450.0

100.0

20.0

76

2176.0

150.0

19.3

73

2901.0

200.0

17.7

67

3626.0

250.0

14.0

53

4351.0

300.0

11.4

43

Conditions: 1) Pressure = Pressure setting at the attachment 2) Tolerance of the listed oil flow : +0.3 / -0.5 gpm (+1 / -2 L/min) 3) Measuring point for the oil flow = couplers at the dipper arm

S

Clearance - Hose burst protection valves (inside hose versions) Asse m ble d a t the Dozer Blade Cylinder

Scre w size 1/2"

Page A9

Cle a ra nce S 0.134" (3.4 mm)

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SERVICE MANUAL

Technical data 6.

8002

DIESEL ENGINE SPECIFICATIONS 1

Diesel engine model

2

Starting with Serial.No.:

3

Type

Yanmar 4TNE98-NSR 0001105/98 Vertical, 4-Cyl. Water-cooled diesel engine

Natural suction Direct injection Preheater Counter-clockwise

Suction system 5 Combustion system 6 Glow system 4

7

Direction of rotation

8

Governor

9

Lubrication system

Mechical Centrifugal Forced lubrication w ith trochoid pump

Electrical Suction fan

10 Starting system 11 Cooling system

DATA: Max. revolution speed ( no load )

2200 rpm +50 / -50

13 Max. rev.speed with load

F

14 Rated revolution speed

2100 rpm +25 / -25

Min. revolution speed (no load)

1100 rpm +50 / -50

12

15

16 Displacement (Bore x Stroke) 17 Output (at rev. Speed 14) 18 Max. engine output 19 No. of cylinders 20 Valve clearance (Intake / exhaust) 21 Compression ratio 22 Fuel injection timing 23 Fuel injection pressure 24 Compression pressure 25 Engine oil pressure (rev. speed level) 26 Pressure switch engine oil pump

Page A10

202.5 cu. in. (3319 cc) ( 98x110 ) 58.7 hp (43.8 kW) 69.1 hp (51.5 kW) 4 0.006 – 0.010 in (0.15 – 0.25 mm) 18.0 11° +/-1° 3191 - 3336 psi (220 - 230 bar) 508 psi (35 bar) ->250 rpm 43.5 - 58 psi (3.0 - 4.0 bar) 5.8 - 8.7 psi (0.4 - 0.6 bar)

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Diesel engine specifications

1

Diesel engine model

2

Starting with Serial No.:

Yanmar 4TNE98-NSR 0001105/98 160 - 185°F (71 - 85°C) 225 - 235°F (107 - 113°C) 1-3-4-2 40 A / 12 V 12 V / 88 Ah 0.5 x 43" (13 x 1090 mm)

27 Thermostat opening temperature 28 Thermo switch On / Out 29 Firing order 30 Alternator (Standard) 31 Battery 32 V-Belt dimensions

TIGHTENING TORQUES: 76 - 83 lb-ft (102.9 - 112.7 Nm) ( M11x1,25 ) 40 - 43 lb-ft (53.9 - 58.8 Nm) ( M10x1,0 ) 80 - 87 lb-ft (107.9 - 117.7 Nm) ( M11x1,25 ) 137 - 152 lb-ft (186.3 - 205.9 Nm) ( M14x1,5 )

33 Cylinder head bolt 35 Connecting rod bolt 36 Metal cap clamping bolt 37 Flywheel clamping bolt 38

N

Glow plug QUANTITIES

23.8 gals. (90 L) 10.8 / 5.3 qts (10.2 / 5 L) 9 qts. (8.7 L)

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

QUALITY 42 Engine oil

BP Vanellus FE API SF-CD + SAE 10W40, API gr.cl. CD

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C HAPTE R B :

Maintenance

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Maintenance 1.

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MAINTENANCE CHART

Servicing activity component

every 10 h

every 50 h

every 250 h every 500 h every 1000 h

(daily)

(w eekly)

(6 months)

(12 months)

(18 months)

annually

ENGINE Oil level

O

Fuel level

O

Leakage

O

Visual check

O

Air filter

O/X

Tightness of mounting bolts Coolant

<>

<>

O O

Engine speed regulation

O

Exhaust system

O

Engine oil

O

Oil filter

<>(1)

<>

<>

<>(1)

<>

<>

V-belt: condition and tension

O

Cooler fins

X

Valve clearance

O

O

Alternator, starter

O

Fuel tank

X

Water pump

O

Fuel filter

O

<>

<>

Cooling system and hoses

O

Electrical connections

O

Pre-glow system

O

Coolant thermostat

O

Battery fluid

O X

O

- Check - Clean

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

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Maintenance

8002

Servicing activity component

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

(w eekly)

(6 months) (12 months)

(18 months)

annually

HYDRAUL IC SYST EM Hydraulic pump fastening bolts

O

Leakage (lines, pumps, cylinders)

O

Hydraulic oil level

O

Oil cooler fins

X

Filter insert

<>(1)

O

Primary and secondary pressure limiting valves

<>

<>

O

Hydraulic oil

O

<>(1)

Breather filter, Filling strainer

<>

<>

O

ELECT RICAL Indicator lamps

O

Function of system

O

Connections

O

T RAVEL GEAR Chain after working

O

Chain tension

O

Bearing play of tread rollers, track carrier rollers, front idlers

O

TRAVEL G E A R U N I T Leakage

O

Gear oil

<>(1)

<>

<>

GEAR RING Bearing system

O

Gearing

O X

<>

- Check - Clean

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

Page B3

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Maintenance

8002

Servicing activity component

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

(w eekly)

(6 months)

(12 months)

(18 months)

annually

HEAT ING Function

O

Leakage (cooling and heating circuit)

O

Seals

O

Fan

O

WORK ING E QUIP M ENT Lubricate lubrication points

O

Bucket teeth (fastening and wear)

O

Pin connections

O

Line connections

O

Piston rods

O

Behaviour of hydraulic cylinder under load

O

O

Bushing bearing play

O

Bearing play

O

GENERAL Operating elements

O

Hydraulic fittings

O

Bolts

O

Lights

O

Windshield washing system Leakage check - visual check

O X

- Check - Clean

O O

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

Page B4

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Maintenance

8002

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 machine 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 a 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 recommendations will void the warranty.

Before starting maintenance or repair, please read all procedures, 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 someplace clearly visible and legible at the compact excavator. Remove the ignition key.

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Maintenance 2.

8002

LUBRICANTS USED AS

NOTES

LUBRICATION TYPE

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

Engine oil

Hydraulic oil

Bio oil

Turn table: Teeth Ball bearings

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

BP Energrease OG (White) BP Energrease L 21 M

Energear Hypo EP 90 API GL 5 FINA Pontonic MP85W90APIGL5 Q8 T55 85W90

Drive gears

RK 15, RK20S

SGXP 220 BP Energrease L 21 M Gleitmo 805 (For initial

Boom, dipper arm, etc.

greasing of the bolts )

BP Energrease L 21 M

Track tension cylinder

Planetary gear Fix and float axles Distribution gear

Wheeled excav.

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

BP Energrease L 21 M

Each Lubr. point Conditions: Engine oil: Grease:

at -13 – 104°F (-25 – 40°C) Outside temperature at -13 – 104°F (-25 – 40°C) Outside temperature

Page B6

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Maintenance

8002

Quantities Engine

Type

Power Output

Engine Oil

Yanmar 4TNE98-NSR

61.2 HP (45.6 kW)

10.8 qts.

(10.2 L)

Coolant

Hydraulic Oil System Fill

9.2 qts.

(8.7 L)

128 qts.

(122 L)

Page B7

Hydraulic Transmission Turning Transmission

Driving Transmission

2.64 qts. 1.32 qts.

(2.5 L) (1.25 L)

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance 3.

8002

LUBRICATION CHART Lubrication points to be lubricated daily - blue plugs.

Lubrication points to be lubricated weekly - green plugs.

Page B8

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

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 machine 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 Features: One Primary-pressure limiting valve for P1 + P2 (Main valve block functions).

One Primary-pressure limiting valve for P3 (Second valve block functions).

Mearsuring ports at the hydraulic pump and at the pilot oil supply unit.

4.1 Pressure test of regulation pump P1 Functions:

boom 1, bucket, drive right.

4.1.1 PPLV 1 setting check : a) Connect pressure gauge to measuring port MP 1. b) With the engine at full throttle, move the boom (cylinders bottom side) up to the stop. c) Check and note the pressure.

4.1.2 Pressure drop check: d) With the engine at full throttle, move the boom (at the bottom side) up to the stop (similar to step 4.2.1.b). e) While holding the boom cylinder at max. pressure, reduce the diesel engine speed quickly from max. to min speed. Check and record the pressure drop.

The pressure drop should not exceed more than 10% of the setting.

(This is an approximate value, and only applies to primary pressure limiting values.)

An excessive pressure drop is an indication of a possible leak. f) Check the setting and pressure drop of function boom cylinder rod side, bucket cylinder bottom and rodside, driving left vorward / reverse in the same manner as described in items 2.2.1 and 2.2.2. g) If any settings deviate from the values in the “Hydraulic System“ section in the “Technical Data“ chapter, please set the correct pressure at the primary pressure limiting valve (PPLV1) or check for and repair the cause for the pressure drop - then repeat steps a - f. h) An excessive pressure drop could be an indication of leakage. (e.g.: def. O-Ring in secondary valve, etc.)

Page B9

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

4.2 Pressure test of regulation pump 2 Functions:

dipper arm 1, drive left, auxiliary hydraulic, boom offset

4.2.1 Check of setting PPLV 1 : i) Connect a pressure gauge to measuring port MP 2. j) At maximum engine speed, move the dipper arm (cylinder bottom side) in to the stop. k) Check and record the pressure.

4.2.2 Check of pressure drop : m) Check and record pressure drop of the individual functions in the same manner as steps d - g. n) Check the settings and pressure drop of the dipper stick (cylinder rodside) and drive right functions in the same manner as steps 4.1.1 - 4.1.2. Record the result. p) If any settings deviate from specifications, set the correct pressure at the primary pressure limiting valve (PPLV1) at the main valve block or check the reason for the pressure drop. Then, repeat steps i - p.

An excessive pressure drop might indicate leakage (e.g.: defective O-ring in secondary valve, etc.).

Pressure test for auxiliary hydraulic system: The auxiliary hydraulics function shows the settings of the primary pressure limiting valve PPLV1 at measuring port MP 2 if no optional secondary pressure limiting valve is installed.

- With ball valve opened - unpressurized return flow (measurement: system building pressure).

- If there are optional secondary valves AH installed, the values in the “Hydraulic System“ section in the “Technical Data“ chapter may be incorrect, because SPLV are set individually.

4.3 Pressure test of gear pump P3 Functions:

dozer blade, swivelling

4.3.1 Check of setting PPLV 2 : r) Connect a pressure gauge to measuring port MP 3 . s) With the engine at maximum speed, move dozer blade (cylinder bottom side) to stop position. t) Check and record the pressure and pressure drop. u) The swiveling function is supplied by pump P3, though the operating pressure is limited by the secondary pressure limiting valves (SPLV) located at the swivel motor - see swivel motor. ( > Check of pressure drop only permissible with primary control values.)

4.4 Pilot Pressure Test: Functions:

hydraulic pilot control

4.4.1 Check of setting PRV: a) Connect the pressure gauge to measuring port MP 4. b) Actuate joystick. c) Check pressure and/or set it at the pressure reducing valve (PRV) at the pilot oil supply unit.

IMPORTANT: Also refer to Test Report - Pressure Test on the following pages.

Page B10

Id.No.: Edition:

918173 Sept. 05

Page B11

FORWARD

IN

OUT

DOWN

UP

Id.No.: Edition:

Drive left

REARWARD

FORWARD

IN

Symbol

Setting: Fall: Primary pressure Setting: Measuring port limiting valve Fall: MP 2 PPLV 1 (Hydraulic pump) Setting: (Main valve block) Fall: Setting: Fall:

Setting: Fall: Setting: Fall: Primary pressure Setting: limiting valve Measuring port Fall: PPLV 1 Setting: (Main valve block) MP 1 Fall: (Hydraulic pump) Setting: Fall: Setting: Fall: Setting Combined press. (not adjustable) Setting

Press. Limit. Valve Measuring port

4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar)

SEETECHNICAL DATA CHAPTER - HYDRAULIC

1160—1450 psi (80—100 bar) +/- 73 psi (5 bar) 4351 psi (300 bar) +/- 73 psi (5 bar)

4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar)

SEETECHNICAL DATA CHAPTER - HYDRAULIC

Settings (1)

> > > > > > > >

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

Checked:

X

X

OK?

8002

Dipper stick OUT

PUMP 2

REARWARD OUT Dipper arm IN

Drive right

Bucket

Boom

PUMP 1

Motion

C HE C K L I S T (2) (3) (4)

Function

Checked:

P RE S S URE PLV PRV (1)

Note: Note:

Serial.No.: Work hrs./Date

SERVICE MANUAL Maintenance

Pressure limiting valve Pressure reducting valve Note: Pressure settings correspond to the excavator serial no.

(Always compare with the pressure setting in the “Technical Data“ chapter.)

Note: Setting is only correct without secondary pressure limiting valves.

Swivel function: see the “Technical Data“ and “Maintenance“ chapters.

See the “Technical Data“ chapter“:

918173 Sept. 05

B

A

Page B12

DOWN

UP

Symbol

Id.No.: Edition:

Joystick

All

Settings (1)

(Pilot oil supply unit)

PRV

Measuring port Setting MP 4 Pilot oil supply unit Fall:

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

SEE TECHNICAL DATA CHAPTER - HYDRAULIC

Setting 3989 psi (275 bar) +/- 73 psi (5 bar) Primary pressure Measuring port limiting valve 435 psi (30 bar) Fall: MP 3 PPLV 2 3989 psi (275 bar) +/- 73 psi (5 bar) (Hydraulic pump) Setting Second valve block 435 psi (30 bar) Fall: / Sett. (4) 3510 psi (242 bar)(1) +/- 73 psi (5 bar) Secondary press.

Limiting valves Fall: (Sw ivel motor) SPLV Sett. (4) 3510 psi (242 bar)(1) +/- 73 psi (5 bar) (3) ( Sw ivel motor !)

Fall:

SEE TECHNICAL DATA CHAPTER - HYDRAULIC

0

> > > >

> > > >

>

2901 psi (200 bar) +/- 73 psi (5 bar)

Setting Setting

>

4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar)

Summ. pressure (not adjustable)

> > > > > > > >

SEE TECHNICAL DATA CHAPTER - HYDRAULIC

4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar) 4351 psi (300 bar) +/- 73 psi (5 bar) 435 psi (30 bar)

Measuring port

Setting Fall: Setting Primary pressure Fall: limiting valve PPLV 1 Setting Measuring port (Main valve block) Fall: MP 2 (Hydraulic pump) Setting Fall:

Press. Limit. Valve

PILOT PRESSURE SYSTEM

Swivel motor (uppercarriag LEFT e) RIGHT

DOWN

Dozer blade UP

PUMP 3

Boom

RIGHT

Boom offset LEFT

Auxiliary hydraulics

Motion

CHE CK L I S T Checked

X

X

OK?

(2) (3) (4)

Function

Checked:

PR ES S UR E

PLV PRV (1)

Note: Note:

Serial No.: Work hrs./Date

Maintenance SERVICE MANUAL

8002

Pressure limiting valve Pressure reducting valve Note: Pressure settings correspond to the excavator serial no.

(Always compare with the pressure setting in the “Technical Data“ chapter.)

Note: Setting is only correct without secondary pressure limiting valves.

Swivel function: see the “Technical Data“ and “Maintenance“ chapters.

See the “Technical Data“ chapter“:

918173 Sept. 05

Page B13

Id.No.: Edition:

Drive left

> > > > >

Setting: Fall: Setting: Fall: Setting:

> > >

Fall: Setting Setting

REARWARD

OUT

REARWARD

FORWARD

IN

OUT

IN

(Main valve block)

> >

Fall: Setting:

> > >

Fall: Setting: Fall:

>

>

>

Setting:

Primary pressure Measuring port Fall: limiting valve MP 2 PPLV 1 (Hydraulic pump) Setting:

X

OK?

X SEE TECHNICAL DATA CHAPTER - HYDRAULIC

>

Setting: Summation press. (not adjustable)

> >

>

>

Fall:

FORWARD

Checked:

SEE TECHNICAL DATA CHAPTER - HYDRAULIC

Settings (1)

>

(Hydraulic pump)

Measuring port

Primary pressure limiting valve Measuring port Fall: PPLV 1 Setting: (Main valve block) MP 1 Fall:

Press. Limit. Valve

Setting:

IN

OUT

DOWN

UP

Symbol

8002

Dipper arm

PUMP 2

Dipper arm

Drive right

Bucket

Boom

PUMP 1

Motion

CHECK L I ST

Checked:

(2) (3) (4)

Function

PRESSURE PLV PRV (1)

Note: Note:

Serial No.: Work hrs./Date

SERVICE MANUAL Maintenance

Pressure limiting valve Pressure reducting valve Note: Pressure settings correspond to the excavator serial no.

(Always compare with the pressure setting in the “Technical Data“ chapter.)

Note: Setting is only correct without secondary pressure limiting valves.

Swivel function: see the “Technical Data“ and “Maintenance“ chapters.

See the “Technical Data“ chapter“: version 7008490, 7008501 - different settings

918173 Sept. 05

Page B14

RIGHT

Id.No.: Edition:

Joystick

All

(Pilot oil supply unit)

PRV

( Sw ivel motor !)

SPLV

Secondary press.

Limiting valves

LEFT

Fall:

X

X SEE TECHNICAL DATA SECTION IN THE HYDRAULIC CHAPTE

>

>

>

Fall:

>

>

>

>

>

Sett. (4)

OK?

SEE TECHNICAL DATA SECTION IN THE HYDRAULIC CHAPTE

>

>

Sett. (4)

Fall:

Measuring port Setting MP 4 Pilot oil supply unit Fall:

(Sw ivel motor) (3)

/

Setting

Setting

Primary pressure Measuring port Fall: limiting valve MP 3 PPLV 2 Setting (Hydraulic pump)

>

Fall: Setting

>

>

>

>

Fall: >

>

Setting

Setting Summ. pressure (not adjustable)

Checked

SEE TECHNICAL DATA SECTION IN THE HYDRAULIC CHAPTE

Settings (1)

>

Measuring port

CHECK L I ST

Setting Primary pressure Fall: limiting valve Measuring port PPLV 1 Setting MP 2 (Main valve block) (Hydraulic pump) Fall:

Press. Limit. Valve

Second valve block

Symbol

DOWN

UP

DOWN

UP

RIGHT

LEFT

B

A

Motion

PILOT PRESSURE SYSTEM

Swivel motor (uppercarriage)

Dozer blade

PUMP 3

Boom

Boom offset

Auxiliary hydraulics

Function

Checked:

PRES S URE

(2) (3) (4)

Note:

PLV PRV (1)

Note:

Serial No.: Work hrs./Date

Maintenance SERVICE MANUAL

Pressure limiting valve Pressure reducting valve Note: Pressure settings correspond to the excavator serial no.

(Always compare with the pressure setting in the “Technical Data“ chapter.)

Note: Setting is only correct without secondary pressure limiting valves.

Swivel function: see the “Technical Data“ and “Maintenance“ chapters.

See the “Technical Data“ chapter“:

8002

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Pict.: Position Primary - Pressure limiting valve ( PPLV 1 ) - Main valve block

Primary- Pressure limiting valve PPLV 1 ( AP ) at the main valve block

Pict.: Position Primary-Pressure limiting valve

( PPLV 2 ) - Second valve block

Primary- Pressure limiting valve PPLV 2 ( AP ) at the second valve block

Page B15

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Pict.: Position Secondary - Pressure limiting valves swivel motor ( SPLV )

SecondaryPressure limiting valve Swivel motor

Pict.: Position

SecondaryPressure limiting valve Swivel motor

Pressure Reducting valve ( PRV ) - pilot pressure At the pilot oil supply unit

Pressure reducting valve ( AP )

Page B16

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Pict.: Position Measuring ports ( MP 1 - 3 ) Hydraulic pump

MP 1

MP 3

MP 2

Pict.: Position Measuring ports ( MP4 ) at the pilot oil supply unit

MP 4

Page B17

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance 3.

8002

HYDRAULIC PUMP

Bleeding of hydraulic pump .

- Shut down device - Open the breathing / bleeding filter - Open screw plug air bleed screw - Drain a small amount of hydraulic oil via the air bleed screw MP 3 Threaded plug pump air bleed

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 B18

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

4.

HOSE BURST PROTECTION VALVE Clearance Dimension Check

S

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

If these valves are missing, there may be liability 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 (see the Technical Data chapter).

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

5.

DRIVE UNIT

Gear Box

.

> Check:

- Open the oil level plug ( 2 ).

- The oil level must be at the oil level port.

> Changing:

- Open the oil filler screw ( 1 ) and the drain plug ( 3 ).

- 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 unit the gear oil emerges from the level hole. Refer to the list of lubricants in the Technical Data chapter for proper gearbox oil grade and type.

- Replace and tighten the oil level and filler plugs.

IMPORTANT!: Check for gearbox leakage and for proper gearbox oil level according to the maintenance schedule.

Dispose of waste oil as provided by environmental laws.

1 Gear box oil level

2 3

Page B19

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance 6.

8002

SWIVEL UNIT

Gear Box - Swivel unit 7008501

.

> Check: - Check fluid level at level inspection / refill plug.

- The level should be flush with the inspection plug.

2

> Refilling / changing : - Open drain hose (1) (access from the chassis floor plate - engine).

- Open air bleed screw (2).

- Drain gear oil into an appropriate container.

- Close drain hose (1).

- Fill the gearbox with oil through air bleed screw (2) to maximum level. Refer to the list of lubricants in the Technical Data chapter for proper gearbox oil grade and type.

- Close air bleed screw (2)

1

Dispose of waste oil according to environmental law.

Gear Box - Swivel Unit 7008490 (Serial No.: AB01599 and higher)

.

> Check / refilling / changing : As described in Swivel Unit 7008490 in the Hydraulic System chapter, the gear box is “maintenance-free”. (lubricated with fresh hydraulic oil )

Swivel Motor

.

> Check / settings : Following the pressure test - hydraulic system (Checklist)

Page B20

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

7.

DIESEL ENGINE

Fuel system . > BLEEDING : 1) Check the level in the fuel tank.

2) Turn the fuel valve to the “Open” position (see pict. 2 water separator).

3) Open the air bleed bolts and valves on the filters.

4) Use the fuel priming pump to pump the fuel into the fuel system.

5) Bleed the system until the fuel is free of air bubbles.

Close the air bleeding bolts.

6) Repeate this procedure in the following order: water separator, fuel filter, fuel injection pump.

Picture 1

Picture 2 Preliminary Fuel Filter (Water Separator)

.

> DISMANTLING and INSTALLATION of filter element: Any water 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.

Page B21

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Fuel Filter

.

> DISMANTLING and INSTALLATION of filter cartridge : The main filter cartridge must be replaced at regular intervals according to the maintenance schedule.

1.

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

2.

Dismantle filter cartridge and replace it with a new one.

3.

Vent fuel system.

Air Filter

.

> DISMANTLING and INSTALLATION of filter element: 1.

2.

3.

4.

5.

Remove the filter housing cover.

Remove the wing nut securing the air filter element.

Remove the air filter element and replace it.

Check the safety element and replace it if necessary.

3.

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

Replace the filter housing cover with the “TOP“ marking pointing up.

1.

2.

4.

V- Belt

.

> TENSION CHECK: 1.

2.

3.

Open the engine cover.

Check V-belt tension by pressing the V-belt down between the water pump and the generator pulley (deflection approx. 0.4 – 0.6 in. [10 – 15 mm] – tension o.k.).

For tightening, refer to the figure below.

Page B22

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

.

Fig.: Check of V-belt tension

Fig.: Retightening of V-belt

tube tension bracket alternator water pump crankshaft

alternator

Tappet Clearance

.

> CHECK and ADJUSTMENT : 1.

Checks and adjustments shall be done when the diesel engine is cold.

2.

Remove the valve cover.

3.

Put the relevant cylinder to the top dead center of the compression cycle.

4.

Check valve caps for abnormal wear.

5.

Measure tappet clearance by means of gauge between the rocker arm and the valve head.

Clearance should be 0.006 — 0.010 in. (0.15 — 0.25 mm).

6.

If necessary, adjust tappet clearance using the adjusting screw and lock nut.

7.

Replace the valve cover gasket (replace the gasket with a new one, if necessary).

8.

Replace the valve cover. valve cap

normal

abnormal wear

adjusting screw tappet clearance

lock nut

Page B23

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Compression

.

> Check: 1.

Start the engine and run it until it reaches operating temperature.

2.

Remove the plug for the cut-off solenoid to se the injection pump to zero delivery.

4.

Crank the engine 2 or three revolutions.

Note: Do not attempt to start the engine.

5.

Mount compression gauge on the cylinder you want to measure.

6.

Crank the engine with the starter and read the pressure indicated by the pressure gauge.

• Specified value: 508 +/- 14.5 psi (35 +/- bar) @ 250 rpm.

• Limit value: 406 +/- 14.5 psi (28 +/- 1 bar) @ 250 rpm.

Injection Nozzles

.:

> PRESSURE TEST 1.

2.

3.

4.

Remove the injection line and the injection nozzles.

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

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

If the injection pressure is too low, replace the spacer in the nozzle with the thicker one. If the pressure is too high, replace the spacer with a thinner one.

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

injection nozzle Page B24

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Injection Nozzles

.:

Nozzle setup: Indirect injection

direct injection oil return line upper nozzle union upper nozzle union adjusting washers compression spring

adjusting washers

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

centering pin

compression spring compr. spring seat compression spring centering device injector needle nozzle body

lower nozzle union lower nozzle union

Page B25

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

> CHECKIN G THE NOZZLE JET .

1.

Remove the injection line 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 while sheet of paper about 12 in. (30 cm) away from the nozzle and let the nozzle eject fuel.

5.

The nozzle jet must creat a circle on the paper.

6.

Check the nozzle for drips after it has ejected fuel.

7.

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

8.

If nozzles are replaced/replaired, they must always be checked prior to installation using a nozzle testing device (spraying, leakage, injection pressure).

Indirect injection system

Direct injection system normal atomization

bad atomization

Page B26

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Fuel injection pump

.

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

Remove the spur gear before removing the pump.

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

crankshaft oil pump

Moment of Injection

.

> DIRECT INJECTION: 1.

2.

3.

4.

Remove the injection line for the 1st cylinder.

Note: Cylinder numbering always starts from the flywheel side.

Turn engine clockwise (as seen from the radiator) by rotating the crankshaft, until fuel escapes from the base valve of the injection pump.

Remove rubber cover from the flywheel housing and read injection time by the marks on the flywheel and flywheel housing.

If the markers don’t coincide, adjust injection timing by turning the fuel injection pump.

1st cylinder

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

longitudinal slots for rotating the injection pump Page B27

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

8002

Model: 4TNE98 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!

> Adjustment minimum speed maximum speed limit limit (idle)

Note: The engine must not be under load while performing speed adjustments.

1.

2.

Run the engine up to operating temperature.

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

Idle Speed: 1050 – 1150 rpm Maximum Engine Speed: 2150 – 2250 rpm

3.

Page B28

Set speed by adjusting the screws as shown in the illustration.

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

Oil Pressure Switch

.

> TESTING: 1.

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

2.

Start the engine and check for correct idling speed.

3.

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

test prod

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

Cooling Water Circuit

.

> THERMOSTAT TESTING: 1.

2.

3.

Remove the thermostat.

Heat the thermostat in container filled with water.

Using a thermometer, check whether the thermostat opens at 160 – 185º F (71 – 85º C)

thermostat

thermal switch > THERMAL SWITCH TESTING: 1.

2.

3.

Remove the thermal switch and heat it in a container filled with radiator antifreezer or oil.

Using an ohmmeter, measure the resistance of the thermal swtich.

The swtich must open when the temperature reaches 224 – 236° F (107 – 113° C). switch must go to continuity.

> COOLANT LEVEL CHECK: max.

1.

2.

3.

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 the min. and max. marks.

If necessary, add coolant to the overflow reservoir.

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

Page B29

Id.No.: Edition:

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SERVICE MANUAL

Maintenance

8002

Cooling Water 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 (2.34 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 a pressure tester as shown.

2.

Using a hand pump, increase the pressure to about 34 psi (2.34 bar).

3.

If the radiator cap does not open, it is defective.

radiator cap

Cylinder Head

.

> TIGHTENING ORDER for cylinder head screws :

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.

(1st pass) 36.1 – 43.4 lb-ft (49 – 58.8 Nm) (2nd pass) 76 – 83 lb-ft (103 – 112.7 Nm)

Page B30

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

8.

UNDERCARRIAGE

Track Tension 1.

2.

.

Use the bucket and dozer blade to lift the machine up until the 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 3/4 – 1“ (20 – 25 mm).

> Track Tightening 1.

2.

Remove the 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 the track is too tight, loosen the grease fitting to relieve pressure.

> Track Loosening WARNING! Do not loosen the track tensioner grease fitting more than two turns, or the grease fitting could be ejected under pressure and cause injury.

1.

2.

Remove protective cover.

Loosen valve. Drain grease slowly.

Page B31

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

10. 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 B32

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance

8002

> 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 of 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.

12.

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 B33

Drain Plug

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Maintenance 11.

8002

FUEL TANK

> DRAINING THE FUEL TANK WARNING! Stop and cool the engine before draining the fuel tank. Keep heat, flames and sparks away from fuel. NO SMOKING! Always clean up spilled fuel. Failure to obey warnings can cause an explosion or fire which can result in injury or death.

- Close the fuel valve at the water separator and the fuel filter.

- Turn the uppercarriage 90° to the dozer blade.

- Open the fuel tank drain screw (bottom side of the tank — access form below, inside the right chassis cover).

- Drain fuel into a suitable container. Store fuel properly and always dispose of fuel according to environmental laws.

Page B34

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

C HAPTE R C :

Hydraulics

Page C1

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics 1.

8002

HYDRAULIC SYSTEM

Legend hydraulic diagram ( 7011093, 7011112 ) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30

diesel engine gear pump ( P3 ) variable displacement ( P1+P2 ) pilot oil supply unit main valve block secondary valve block 2 joystick left (pilot control valve) joystick right (pilot control valve) pilot control valves - Function drive pilot control valve - Function auxiliary hydraulic / boom offset cylinder pilot control valve - Function dozer blade switch valve - Function dozer blade / 3rd hydraulics circuit (Option) switch valve - Function auxiliary hydraulics / Boom offset hydraulic oil cooler hydraulic oil return filter swivel unit (uppercarriage) drive unit boom offset cylinder dipper arm cylinder boom cylinder left boom cylinder right bucket cylinder dozer blade cylinder check valve block non return valve switch valve - auxiliary hydraulics (Joystick) electrical (Option) non return valve non return valve distribution block boom cylinders

Page C2

Id.No.: Edition:

918173 Sept. 05

BUCKET

43.5 psi (3 bar)

Page C3

29 psi (2 bar)

BOOM

BUCKET CYLINDER

drive right

bucket

boom1

dipper arm2

725 psi (50 bar)

BOOM CYLINDER

DRIVE RIGHT

508 psi (35 bar)

5076 psi (350 bar)

4351 psi (300 bar)

AUX. HYD.

boom2

bucket

boom

BOOM OFFSET CYLINDER

DRIVE LEFT

3626 psi (250 bar)

3626 psi (250 bar)

LEFT JOYSTICK

BUCKET

ROTATE

DRIVE UNIT LEFT

43.5 psi (3 bar)

P1 ... 4351 psi (300 bar); 22.3 gpm (84.4 L/min) P2 ... 4351 psi (300 bar); 22.3 gpm (84.4 L/min) P3 ... 3989 psi (275 bar); 13.2 gpm (50.0 L/min) n = 3014 min-1

AUX.HYD./ BOOM

AUXILIARY HYDRAULICS

DIPPER ARM CYLINDER

3989 psi (275 bar)

SIGN

SWIVEL UNIT

4351 psi (300 bar)

Sign

AUX. HYD.

BOOM

OPTION: AUXILIARY HYDRAULICS

DOZER BLADE CYLINDER OPTIONAL HYDRAULICS

Pict.:

RIGHT JOYSTICK

DRIVE UNIT RIGHT

SERVICE MANUAL

8002

Hydraulics

Hydraulic diagram (7011093)

Id.No.: Edition:

918173 Sept. 05

Turn

3626 psi (250 bar)

SERVICE MANUAL

Hydraulics

Service News

8002

Issue: (Pilot) System pressure drop Solution: Return line with non-return valve

Possible problem: The pilot system pressure drops during low engine idle.

This is caused by low pressure in the hydraulic system -- minimum 145 – 174 psi (10 – 12 bar).

The hydraulic functions do not react, or react with little control.

Measures to do: An additional non-return valve was added to the return line, increasing hydraulic system pressure.

Page C4

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

POSITION OF COMPONENTS

2.

Pict.: View - right

Service cover Air filter

Service cover hydraulic valves

Fuel tank

Tool box

Hydraulic oil tank

Hydraulic oil return filter Hydraulic tank breather

Air filter

Oil cooler Battery Page C5

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.: View - hydraulic valves (cover) Hydraulic oil tank

Cabin

Main valve block

Hydraulic oil level indicator Pilot oil supply unit

Swivel unit

Page C6

Secondary valve block

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict. : View - rear Relay box

Diesel engine

Hydraulic pump

Page C7

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics 3.

8002

HYDRAULIC PUMP

Type: Features:

7008303 ( A8VO28SR3 ) Double variable-displacement axial piston-pump (Band axis pump system) Common suction hose, Combination power controlled (mech. linked) and single power controller, Three circuit controlled (SR3) + Gear pump (P3) Pict.: Assembling situation hydraulic pump 7008303 Measuring point MP1

Measuring point MP3

Port P1

Suction port

P1 + P2

Double variable pump unit

Type plate

Port P3 Gear pump

Page C8

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.: View from above pump ( 7008303 ) Port X3 ( ->>connected with P3 )

3-circuit power controller

Measuring point MP3 (Gear pump)

1 - Controller screw Q max (M10 x 1,5)

Pump bleed screw P2 P1

Suction port P1 + P2 Measuring point MP2 Port P2

Measuring port MP1 Port P1

>> Pilot oil supply unit <<

Description of hydraulic pump 7008303 controller screws functions: 1.

Controller screw for maximum displacement volume ( Q max ): This screw is adjusted to the maximum displacement volume.

Adjustment of the flow under conditions of pressureless circulation.

2.

Control characteristics adjustment screw: Used to adjust the controller‘s response speed and the rate of pump delivery control.

IMPORTANT! Proper adjustment is a test bench job, so do not change the factory settings.

Page C9

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.: View from below the pump ( 7008303 ) Port P2

Pump bleeding screw (not active)

Positioning press. port (not active)

3- Controller screw Q min (M10x1,5)

4 - Controller screw start of control range ( M6x0,5 )

2 - Control characteristic adjusment screw

Description of hydraulic pump 7008303 controller screws functions (continued) 3.

Controller screw for minimum displacement volume ( Qmin ): To avoid damaging the pump, a certain residual flow must always be maintained (approx. 1.6 gpm — 6 L/min). Adjustment requires a turbine flow meter.

4.

Start of control range controller screw.

Used to set control onset threshold.

X3.

3-circuit power controller port: P3 pushs the variable displacement pumps into the Q min position (system supply).

Page C10

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Description to pict.: functions of the controller screws hydraulic pump 7008303

1 X3

2 4 3

Page C11

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics Pict.:

8002

Part group structure double variable-displacement pump (7008303) Notice: assembling position - 180° turned Start of control range Contr. characterist.

Page C12

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.:

Part group structure, double variable-displacement pump (7008303) Notice: assembling position - 180° turned Start of control range Control characteristic

Page C13

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics Pict.:

8002

Part group structure, double variable-displacement pump (7008303) Notice: assembling position - 180° turned

Page C14

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.:

Part group structure, double variable-displacement pump (7008303) Notice: assembling position - 180° turned

Page C15

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics 4.

8002

PILOT OIL SUPPLY UNIT

Type: Function:

1408610 (blue), 1408615 - Supply of the pressure for the pilot system - Safety function - arm rest switch, - Control pressure for the functions 2nd drive speed and swivel motor park brake - Supply: System accumulator, system drive counter balancing

Pict.: Structure pilot pressure system:

3

4

2

5 1 P3

1 2 3 4 5

P2

P1

5

Pump unit Pilot oil supply unit Joysticks and foot pedals Main valve block Measuring points Page C16

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Fig.: Control oil unit 1408610 / 1408615

(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 counter-balancing system (main valve block) 2nd driving speed (drive unit) valve WK1 - in combination with the push button at the driving lever (formerly port PT - control oil unit 1408610) 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 725 psi (50 bar) - protects the control oil unit in case of a malfunctioning pressure reducing valve.

Shuttle valves - always accept the highest pump pressure for control oil pressure.

Pressure reducing valve (PRV) pilot control pressure - ADJUSTMENT POINT (AP).

Accumulator Page C17

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics Fig.:

8002

Oil Control Unit Port Assignment (version 1408615) to variable-displacement pump P2

to variable-displacement pump P1

P2

(1) Safety pressure valve 725 psi (50 bar)

P3

to drive counterbalancing system main valve block

A T

(3) Pressure reducing valve ( AP ) - version 1408615 : Metal cap with ring see next page

port SP >> accumulator

2nd drive speed switch (WK1)

Safety switch armrest (WK2)

port T - Tank

to gear pump P3 port PR (PT) >> drive motors

to pilot control valves P1

BV

(1)

(3)

Safety pressure valve

PR

port SP >> accumulator

PV

function swivel motor parking brake (P)

pressure reducing valve AP safety switch solenoid valve armrest Page C18

2nd drive speed switch (WK1) Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Fig.: Port assignment of control oil unit 1408615

(3) pressure reducing valve AP

Pict.:

(1) safety pressure valve

Position pilot oil supply unit

Pict.:

(3)

pressure reducing valve AP

Page C19

Pilot oil supply unit 1408610

(1)

safety pressure valve -725 psi (-50 bar)

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Fig.:

Control oil unit setup (version 1408610 )

1.

2.

3.

5-6 8-9

pressure reducing valve unit ( AP ) * adjusting washers safety valve (preset to 725 psi / 50 bar) with plastic seal connecting subassembly - accumulator bag shuttle valve subassembly solenoid valves

Tightening torques: 1a.

1e.

2g.

3n.

5r.

5s, 6s 8, 9

111 ft-lbs. (150 Nm) 7.5 ft-lbs. (10 Nm) 74 ft-lbs. (100 Nm) 74 ft-lbs. (100 Nm) 7.5 ft-lbs. (10 Nm) 22 ft-lbs. (30 Nm) 11 - 20 ft-lbs. (15 - 27 Nm)

Page C20

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Service News

Theme: Solution:

Loss of pilot pressure Check valves - pilot oil supply unit

Possible problem: The shuttle valves (check valves) do not close correctly (not sealed) => example gear pump P3 supplied oil disappears into pump P1 port => pressure drop in the pilot pressure system by too less oil supply.

Solution: Replace the malfunctioning shuttle valves to external assembled check valves.

(Different sealing system) Oil supply unit - version 1408615 - equipped with updated shuttle valve seal system.

Page C21

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

MAIN VALVE BLOCK

5.

Type: Features :

7008300 - Combination function of dipper arm cylinder ( both sides ) - Combination function of boom cylinder (bottom side - boom up) - Leakage free valve for spool boom cylinder (bottom side) - Leakage free valve for spool dipper stick cylinder (rod side) - Drive counter-balancing function - Single primary pressure limiting valve for pump P1 + P2

Pict.: Sections Main valve block 7008300

1

2

3

5Pb1

- View A

4

5Pb2 4Pb3

5

6

5Pb4

5Pb5

4Pb2

4Pb1

7

( AP )

View A from above

8

9

10

Page C22

11

12

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Legend pict.: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Sections main valve block 7008300 - View A

Boom offset Dipper arm (cylinder rod side) Leakage free valve - spool dipper arm cylinder (rod side) Boom (2) combination section Auxiliary hydraulics Drive left Primary - pressure limiting valve P1 + P2 ( AP ) Dipper arm (2) combination section Boom Leakage-free valve - spool boom cylinder (bottom side) Bucket Drive right

Pumps / section relation - Main valve block 7008300 12 11 9 8

Function Drive right Function Bucket Function Boom Function Dipper arm (2) summ.

1 2 4 5 6

Function Boom offset Function Dipper arm Function Boom (2) combination Function Auxiliary hydraulics Function Drive left

Page C23

supplied by pump P1

Supplied by pump P2

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics Pict.:

8002

Hydraulic schematic- Main valve block 7008300

XVII

XXXI

XVIII XIX

XXI

XIII

XX

XII 17

XVI XXII

XXIII

XV

13

X

XXX

XI

XXIX IX

VIII

XXVIII

XXVI

XXV MR

Primary pressure limiting valve P1 , P2 (AP)

Page C24

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.: Part groups - view B - Main valve block 7008300

18

1

2

9 3 4 (AP)

10 PLc1 4B3

5

PP 4B2

4B4

4B1

6 11 7

4P

T1 4A3

4A2

View from right

4A1

8

12

13

14

15

16

17

Legend pict.: Part groups - view B - Main valve block 7008300

1. Port leakage oil 18 -> tank (Dr1) 2. Port joystick - boom cylinder (rod side) 3. Secondary pressure limiting valve bucketcylinder (rod side) 4. Primary pressure limiting valve P1, P2 (AP) 5. Port drive counter balancing (A) 6. Port drive right 7. Port bucket cyl. rodside 8. Pump P1 supplied port (4P) 9. Secondary- press. limit. valve boom cylinder (bottom side) 10. Port boom cylinder (bottom side) 11. Load holding valves (check valves) 12. Tank T1 ->to check valve 13. Port boom cylinder (rod side) 14. Sec. press. limiting valve boom cylinder (rod side) 15. Sek. Druckbegr. Löffelzyl. Bodenseite 16. Port bucket cylinder (bottom side) 17. Port drive right 18. Pilot cap - leakage free valve boom cyl.

Page C25

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict.: Part group - view C - Main valve block 7008300

1

2

3

8 4 ( AP ) 9 10

PLc2

11

5B4

5 6

5B2

5B1

5B5

7

12 5A5

13

14

5A4

8

5A2

Left View

5A1

15

16

17

Legend pict.: Part group - view C - Main valve block 7008300

1. Pilot cap - leakage free valve spool dipper stick (rodside) 2. Port leakage oil 1 -> Tank 3. Port joystick dipper arm bottom side function 4. Second. press. limiting valve dipper arm cylinder (rodside) 5. Port dipper arm cyl. (rodside) 6. Port boom offset cylinder (5B1) 7. Load holding valves (check valves) 8. Plugs (Option: secondary PLV auxiliary hydr.)

9. Primary press. limiting valve (AP) 10. Port auxiliary hydraulics 11. Port drive left 12. Load holding valves - sect. drive 13. Port drive right 14. Port auxiliary hydraulics 15. Secondary press. limiting valve dipper stick cylinder (bottom side) 16. Port dipper arm cylinder (bottom side) 17. Port boom offset cylinder Page C26

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Part group - view D - Main valve block 7008300

Pict.:

1 ( AP )

5

Dr 1

Dr 2

2 7

PT

PH

3

6

4

Front View

Legend pict.: Part group - view D - Main valve block 7008300

1.

2.

3.

4.

5.

6.

7.

Primary - pressure limiting valve (AP) Leakage free valve spool dipper stick cylinder (rod side) Plug Type plate 7008300 Leakage free valve spool boom cylinder (bottom side) Plug Valve - drive counter balancing

Page C27

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict. : Part group - view E - (view from behind)

T2

5P

1

2

Legend pict.: Part group - View E - Main valve block 7008300

1.

2.

Pump P2 supplied port ( 5P ) Tank - Check valve

Page C28

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

Pict. : Part group - View F - from bottom side : 1

2

3

4 5Pa2

14

5

6

7

4Pa4

8

9

10

4Pa2

11

5Pa5

5Pa3

12

5Pa4

16

13

15

Legend pict.: Part group - View F - Main valve block 7008300

1. Secondary pressure limiting valve bucket cylinder (rodside) 2. Boom offset right (5Pa1) 3. Dipper arm cylinder (bottom side - 5Pa2) 4. Tank - (5Pa3 - Boom cylinder rodside) 5. Dipper arm cyl. bottom side (4Pa4) to Leakage free valve (PLc2) 6. Pilot press. hoses auxiliary hydraulics 7. Boom cylinder rod side (4Pa3) 8. Secondary pressure limiting valve boom cylinder rod side 9. Bucket cylinder rodside 10. Secondary pressure limit valve bucket cyl. (bottom side) 11. Drive right (4Pa1) 12. Drive left (5Pa5) 14. Plugs auxiliary hydraulics (Option) 15. Leakage free valve- spool dipperstick cylinder (rod side) 16. Auxiliary flow regulator Page C29

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

SINGLE OPERATION 1-1

Spool for TRAVEL LEFT / RIGHT

When the 4Pa1 ( 4Pb1 ) port is pressurized and the “TRAVEL R” spool is switched (Fig. 3), neutral oil passage (a) is shut and the oil which comes from 4P port flows in the cylinder port 4A1 ( 4B1 ) through passage (c). Also, the return oil from the cylinder port returns to the tank through 4A1 ( 4B1 ).

When the 5Pa5 (5Pb5) port is pressurized and the “TRAVEL L” spool is switched (Fig. 3), the oil which comes from 5P flows in the cylinder port 5A5 ( 5B5 ) through parallel passage (B), shuttle spool ( VIII ) passage (14) and passage (C). Moreover, the return oil from the cylinder port returns to the tank through 5B5 ( 5A5 ). Some of the oil which comes from 5P push poppet up through choke ( XXIX ) and flows in the cylinder port 5A5 ( 5B5 ) through passage (C).

1-2

Spool for RESERVE

When the 5Pa4 ( 5Pb4 ) port is pressurized and the “RESERVE” spool is switched (Fig. 4), neutral oil passage (A) is shut and the oil which comes from 5P push poppet ( X ) up and flows in the cylinder port 5A4 ( 5B4 ) through passage (D).

Moreover, the return oil from the cylinder port returns to the tank through 5B4 ( 5A4 ).

This section can install the overload relief valve in the cylinder port 5A4 ( 5B4 ).

1-3

Spool for BUCKET

When the 4Pa2 ( 4Pb2 ) port is pressurized and the “BUCKET” spool is switched (Fig. 4), neutral oil passage (a) is shut and the oil which comes from 4P (through parallel passage (b)) push check valve ( XI ) up and flows in the cylinder port 4A2 ( 4B2 ) through passage (d).

Also, the return oil from the cylinder port returns to the tank through 4B2 ( 4A2 ).

When TRAVEL SPOOL L&R are operated, the bucket can be operated by choke ( XXX ).

Page C30

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

1-2,3 Spool for RESERVE / BUCKET

( FIG. 4 )

Symbol

Symbol

Page C31

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002

1-4 A)

Spool for BOOM NEUTRAL ( Fig. 5 ) The anti-drift valve is installed at the cylinder bottom side of boom 1.

At neutral position, the poppet ( XII ) is shut securely by the pressure supplied by the spring through passage (15), spool ( XIII ) and passage (16) from 4B3.

1-4

Spool for BOOM

B)

BOOM UP ( Fig. 6 ) When the 4Pb3 port is pressurized and the “BOOM 1” spool is switched (Fig. 6), neutral oil passage (a) is shut and the oil coming from 4P (through parallel passage b) pushes check valve ( XII ) up and flows in the cylinder port 4B3 through passage (e) and poppet ( XII ).

If “BOOM 1” is switched, “BOOM 2” is changes by pressure through passage (13).

The oil which came from 5P passes parallel passage (B) and pushes check valve ( XVI ) up. Then it goes to 4B3 port through passage (E) and (5).

The return oil from the cylinder port 4A3 returns to the tank through the spool for “BOOM 1”.

C)

BOOM DOWN ( Fig. 7 ) When the 4Pa3 ( 5Pa3 ) port is pressurized and the “BOOM 1” spool is switched (Fig. 7), the neutral oil passage (a) is shut and the oil which coming from 4P (through parallel passage b) pushes check valve ( XV ) up and flows in the cylinder port 4A3 through passage (e).

At the same time as “BOOM 1” spool is switched, “PLc1” port is pressured and spool ( XIII ) is switched. As a result, the pressure of spring room ( XIV ) is decreased and poppet ( XII ) is opened. The oil which come from 4B3 goes to tank.

Page C32

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002 1-4

Spool for BOOM

( FIG. 6 )

Page C33

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics 1-4

8002

Spool for BOOM

( FIG. 7 )

Page C34

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Hydraulics

8002 1-5

Spool for DIPPER ARM

A)

DUMP (Dipper arm up / - cylinder rod side) ( Fig. 9 ) When the 5Pb2 ( 4Pb4 ) port is pressured and the “ARM1” spool is switched (Fig. 9), neutral oil passage (A) is shut and the oil which comes from 5P pushes check valve ( XIX ) up and flows in the cylinder port 5B2 through passage (G) and poppet ( XXII ).

At the same time, a part of the oil which comes from 5P goes to 5B2 port through passage (B) choke ( XXXI ), check valve ( XVIII) and passage (G).

If “ARM 1” is switched, “ARM2” is changed by pressure through passage (17).

The oil supplied from 4P push the check valve up after neutral oil passage (a) and passage (3) passing and flows in the 5B2 port.

A part of oil from 4P port pushes up the tandem check valve ( XXI ), passes passage (4) (G) and arm1 spool, and flows into port 5B2. The return oil from the cylinder port returns to the tank through 5A2 and arm 1 spool.

B)

CROWD ( Dipper arm down / - cylinder bottom side ) ( Fig. 10 ) When the 5Pa2 port is pressured and the “ARM 1” spool is switched (Fig. 10), neutral oil passage (A) is shut and the oil coming from 5P pushes check valve ( XIX ) up and flows into the cylinder port 4A2 through passage and spool (G).

Some of the oil from the 5P port flows into the port 5A2 through passage (B), choke ( XXXI ), check valve ( XVIII ) and passage (G).

This choke is equipped to decide the priority of the operation simultaneously. At the same time as switching the arm 1 spool, PLc2 port is pressured and spool ( XXII ) is operated. As a result, the spring room ( XXIV ) is decompressed and poppet ( XXII ) is opened. The oil from the cylinder port returns to the tank through arm 5B2.

At the same time as switching the arm 1 spool, 4Pa4 port is pressured and arm 2 spool is switched. The oil supplied from 4P pushes the check valve ( XX ) up after neutral oil passage (a) and passage (3) is complete and flows into the 5A2 port through passage (G) and arm 1 spool. Some of oil from 4P port flows into port 5A2 through check valve ( XXI ) and passage (4).

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Hydraulics 1-5

8002

Spool for DIPPER STICK ( ARM )

( FIG. 9 )

Page C36

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Hydraulics

8002 1-5

Spool for DIPPER STICK ( ARM )

( FIG. 10 )

Page C37

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8002

Spool for BOOM OFFSET CYLINDER ( SWING ) When the 5Pb1 ( 5Pa1 ) port is pressurized and the “SWING” spool is switched (Fig. 8) neutral oil passage (A) is shut and the oil which comes from 5P port flows into the cylinder port 5B1 ( 5A1 ) through passage (B), poppet ( XVII ).

The oil from the cylinder port returns to the tank through 5A1 ( 5B1 ).

Page C38

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Hydraulics

8002 1-7

RELIEF VALVE

A)

MAIN PRESSURE LIMITING VALVE ( Fig. 11 ) The oil which comes from 5P passes parallel passage (B) and pushes the poppet ( XXVI ) up, then it goes into passage (19) through passage (18).

The oil which comes from 4P passes neutral passage (a) and pushes the poppet ( XXV ) up, then it goes in passage (19) through passage (18).

The main pressure limiting valve limits the pressure of 4P (pump 1) and 5P (pump 2) to the setting pressure.

B)

SEC. PRESSURE LIMITING VALVE (Overload relief valve) The secondary pressure limiting valve installed at the cylinder port of the boom, the arm and bucket prevents the pressure of actuators from rising abnormally.

When set pressure of this valve is higher than main pressure limiting valve, the highest pressure is restricted by this valve. This valve has the function to prevent the cavitation when the pressure of the cylinder port becomes negative pressure.

Main pressure limiting valve

Page C39

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SERVICE MANUAL

Hydraulics Function

8002

Drive Counter-Balancing System

General: Without drive balancing:

If an arm function is activated during straight travel, travel direction is not maintained (P1, P2 supply one drive unit, each).

All units are equipped with drive counter-balancing function.

With drive balancing: The unit maintains straight travel if an arm function is activated.

Both drive motors are supplied by pump P1 - P2, supplying the arm functions.

The drive counter-balancing system is activated only if both driving valves are active.

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

- The drive counter-balancing system (main valve block) is activated because of a pressure build-up (port PP / A).

- P2 supplies the remaining sections.

Switching pressure drive counter-balancing valve: Pump / main valve block sections - relation - with active drive counter -balancing: 12 6

Function Drive right Function Drive left

Supplied by pump P1

11 9 8 1 2 4 5

Function Bucket Function Boom Function Dipper arm (2) combination Function Boom offset Function Dipper arm Function Boom (2) combination Function Auxiliary hydraulics

Page C40

Supplied by pump P2

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Pict. : Ports - drive counter-balancing system

Pilot oil supply unit port A- >>

Valve drive counter-balancing

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Hydraulics Pict.:

8002

Function Drive counte- balancing system

Page C42

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8002

Function Feature:

Summation Boom / Dipper arm cylinder Both pumps (P1 and P2) are used for the function to achieve a faster motion.

For the boom lifting and dipper stick out (cylinder rodside) motion.

Boom UP (cyl. bottom side) : If function boom lifting up is active - both sections (1+ 2) in the main valve blcok are piloted parallel.

The oil from pump P2 is transfered internal to the main pipe of the boom section and passes the leakage free valve spool boom.

The timing of summation is controlled by the spring tension of the summation spool.

(Fine metering - only realized by the spool boom 1) A fixed quantiy of oil can always pass the combination spool - which gives a fixed maximum summation pressure. (see pressure setting) Boom DOWN (cyl. rod side): The leakage free valve for the spool boom is piloted parallel by the joystick hose and opened.

Due to this, the oil from the bottom side of the cylinder can pass the leakage free valve - to tank.

The summation function for boom down (5Pa3) is not active.

Dipper arm OUT (cyl. rod side): If function dipper arm out is active - both sections (1+2) in the main valve block are piloted parallel.

A part of the oil from pump P1 is transfered internal (passing a check valve) to the main section dipper arm.

The timing of summation is controlled by the spring tension of the summation spool.

(Fine metering - only realized by the main spool) A fixed quantity of oil can always pass the summation spool - which gives a fixed maximum summation pressure.

Dipper arm IN (cyl. bottom side): The leakage free valve for the spool dipper stick is piloted and opened parallel by the joystick hose Due to this, the oil from the rod side of the cylinder can pass the leakage free valve - to tank.

The summation function for dipper arm in (4Pa4) is not active.

Page C43

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Hydraulics Pict.:

8002

Schematic- Combination section boom / dipper arm cylinder

Page C44

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Hydraulics

8002

Leakage free valve - section spools

Function -

Boom down - cylinder bottom side Dipper am out - cylinder rod side

Features: Pilot controlled load holding valves to block any spool leakage and movement of a cylinder.

Boom Up: (boom cylinder bottom side) - Leakage free valve is floated and passed by the high pressure oil to the bottom side of the boom cylinder.

Boom Down: - The leakage free valve is opened to tank by the joystick hose - boom down.

- Due to this, the oil from the bottom side of the cylinder can pass the leakage free valve.

Dipper arm In (dipper arm cylinder bottom side): - Leakage free valve is opened to tank by the joystick hose - dipper arm cyl. bottom side - Due to this, the oil from the rod side of the cylinder can pass the leakage free valve.

Dipper arm Out : - Leakage free valve is floated and passed by high pressure oil to the rod side of the dipper stick cylinder.

Dr -> Tank Pilot hoses joystick

PLc1

Primary-pressure limiting valve P1 / P2 ( AP ) Page C45

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Hydraulics 5.

8002

MAIN VALVE BLOCK

Option: Shock valves AH

Features: Pressure shock limiting of auxiliary hydraulic system components (Section AH) - e.g.: Hydraulic breaker The components, the pump and the valve block is protected by the primary pressure limiting valve if the spool auxiliary hydraulics is “open” .

If the spool is not piloted - the system between the valve and the consumer is not protected in case of shocks.

For information about setting without secondary pressure limiting valves (shock valves) see the Technical Data chapter.

Assembling: The pressure setting and assembling has to be done by authorized trained persons only. Always replace both plugs at the same time.

Pict.: Standard version section auxiliary hydraulics - plugs (view C)

Primary press. limiting valve ( AP )

Plugs / Secondary pressure limiting valves

Page C46

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Service News

Issue: Shock valves for auxiliary hydraulics Solution: Terms of assembling and setting

Possible problems: To prevent damage in the hydraulic system by overheating (high quantity of oil flow in this system), the pressure difference from the shock valves to the primary pressure limiting valves should be low.

Solution: Setting and adjustment must be done by a trained perso.

If the attachment (or setting) is changed - check the setting of the shock valves !

Page C47

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Hydraulics 6.

8002

SECONDARY VALVE BLOCK ( Valve block 2 )

Type: 7008305 ( 2 SM 12 ) Pict. : Sections secondary valve block 7008305

1

2

3 Pb2

4 ( AP )

Pb1

T TT1

B2

B1 T

P

Legend:

A2

A1

Pa2

Pa1

P

Hydraulic diagram 7008305

Part group valve block 7008305

1. - Section dozer blade 2. - Secondary-pressure limiting valve dozer blade cylinder (bottom side) - TT = 52 ft.-lbs.

(70 Nm) 3. - Section swivel motor 4. - Primary-pressure limiting valve pump P3 ( AP ) - TT = 52 ft.-lbs. (70 Nm) T. - Tank P. - Supply port form pump P3 A1, A2, B1, B2. - Supply port for dozer blade cyl./ swivel motor (see hydr. diagram) Pa1, Pa2, Pb1. - Pilot hoses from the joysticks and foot pedals TT1. - Tightening torque = 13 ft.-lbs. (18 Nm) Page C48

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Hydraulics

8002

6.

SECONDARY VALVE BLOCK

Option: 3. Hydr. circuit

Type: 7008702 ( 3 SM 12 ) Pict.: Sections valve block 7008702 5

6

Pb3

2

Pb2

1

3

Pb1

4 ( AP )

T B3

B2

B1 T

P A3

A2

A1

P

Pa3

Pa2

Pa1

6

Part group valve block 7008702 1. - Section dozer blade 2. - Secondary-pressure limiting valve dozer blade cylinder (bottom side) - TT = 52 ft.-lbs (70 Nm) 3. - Section swivel motor 4. - Primary-pressure limiting valve pump P3 ( AP ) - TT = 52 ft.-lbs. (70 Nm) 5. - Section 3rd hyraulic circuit 6. - Secondary-pressure limiting valve 3rd hydr. circuit T. - Tank P. - Supply from pump P3 A1, A2, B1, B2. - Supply port to dozer blade cyl./ swivel motor (see hydr. diagram) Pa1, Pa2, Pb1. - Pilot hoses from the joysticks and foot pedals TT1. - Tightening torque = 13ft.-lbs. (18 Nm) Legend:

Page C49

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Hydraulics 6.

8002

SECONDARY VALVE BLOCK

Option: Triple boom

Type: 7008712 ( 3 SM 12 ) Pict. : Sections valve block 7008712 5

2 Pb2

B3

1 Pb2

B2

3

4 ( AP )

Pb1

T

B1 T

P

A3

Pa3

A2

A1

Pa2

Pa1

P

Legend: Part group valve block 7008712

1. - Section dozer blade 2. - Secondary-pressure limiting valve dozer blade cyl. (bottom side) - TT = 52 ft.-lbs.

(70 Nm) 3. - Section swivel motor 4. - Primary-pressure limiting valve pump P3 ( AP ) - TT = 52 ft.-lbs. (70 Nm) 5. - Section triple boom T. -Tank P. - Supply port from pump P3 A1, A2, B1, B2. - Supply port to dozer blade cyl. / swivel motor (see hydr. diagram) Pa1, Pa2, Pb1. - Pilot hoses from the joysticks and foot pedals Page C50

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Hydraulics

8002

7.

PILOT CONTROL VALVES

Type: Features :

Joysticks - 7008550, 7008540 ( 4TH6E ) - 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 C51

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Hydraulics

8002

Type:

Pilot control valve driving Pilot control valve blade -

Features:

foot valve, hydraulically piloted

2708312 ( 2TH6RP ) 4508310 ( 2TH6RP )

2 3 4 7 11 16 Page C52

pedal pedal base protection cap fixing plate tappet subassembly springs Id.No.: Edition:

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8002

Type:

Pilot control valve auxiliary hydraulics - 008307 ( 2TH6RG )

Features:

foot valve, hydraulically piloted

2 3 4 7 11 16 Page C53

pedal pedal base protection cap fixing plate tappet subassembly springs Id.No.: Edition:

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Hydraulics

Service News

8002

Issue: Uncontrolled motions by blocked joystick throttle Solution: Additional filters for the joysticks

Possible problem: Updates to the joystick provided additional throttling at the joystick (pos. 3) for finer metering. If the throttle would become blocked, the boom could not be controlled.

Solution: To prevent blocking of the throttle caused by dirt, a prefilter was added at the joystick.

Start of modification: Serial No. AA02305 (only necessary in combination with the throttle).

Page C54

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Hydraulics

8002

7.

PILOT CONTROL VALVES - Assignment

Switch Valve

Function: The joysitck may be reversed via a selector lever at the directional control valve.

Pos. 1: Pos. 2:

Fig.:

joystick right - boom joystick right - dipper arm

joystick left - dipper arm joystick left - boom

Port assignment / mounting position - directional control valve >> top <<

D < HA3 (joystick)

dir. control valve 1408450 Pos 2 / Pos 1

(main v. bl) LST1 > H (joystick) LST1 > C (main v. bl.) LST3 > F (main v. bl.) LST3 > A position 1

G < HA3 (main valve bl.)

B < HA1 (joystick) E < HA1 (main valve. bl.) selector lever

position 2 Fig.:

Joystick positions left / right

Joystick left LST 3 dipper arm out -> LST 1 dipper arm in -> DL 2 swivelling left -> DR 4 swivelling right ->

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

Joystick right HA 3 HA 1 LÖ 4 LÖ 2

boom up boom down bucket out bucket in

-> -> -> ->

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

Page C55

1

3 P

4

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Fig..: Changed assignment of joystick function - option switch valve

LEVER position 1 position 2

joystick left 1 2 3 4 5 6 7 8

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

joystick right

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

Pict.: Position switch valve

Switch valve: - Open chassis cover right under the door

Page C56

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Hydraulics

8002

SWIVEL UNIT

8.

Type: 7008501 (until Serial No.: AB01598)

7008490 (started with Serial No.: AB01599) Version - Swivel unit 7008501 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 periodic maintenance. Refer to the Maintenance chapter.

Pict.:

1

2

3

1

4 5 S

6

P

7

1. - Secondary-pressure limiting valve (Shock suction valves) swivel motor 2. - Leakage oil drain 3. - Suction port 4. - Park brake valve block 5. - Supply port from the sec. valve block (A1, B1) 6. - Oil fill and controll screw 7. - Oildrain hose S. - Pilot hose - park brake valve P. - Pressure supply hose park brake valve

Page C57

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Pict.: Hydraulic diagram swivel motor 7008501 Park brake valve block

Shock suction valves

Pict.: Hydraulic diagram - swivel motor 7008490

Parking Brake Valve Block

Page C58

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8002

Fig.: Feature:

Version - swivel unit 7008490 - Serial No.: AB01599 and higher - swash plate axial piston motor with hydraulic brake piston - mech. parking brake (brake disks) - hydraulically activated.

- parking brake is opened by function: swivelling, boom offset.

- gear box lubricated by hydraulic oil (periodic replacement required, see the Maintenance chapter).

MU

1

1

SH A,B

PG SH DR

PG

1.

SH. PG. MU. A,B. DR.

Secondary pressure limiting valves (shock suction valves) Port SH at the park valve block (to> secondary valve block) Port PG at the park valve block (to> pilot oil supply unit) Port suction hose (> Main valve block / tank) Supply port to A1, B1 (> secondary valve block) Leakage oil drain (>Tank)

Page C59

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Hydraulics

8002 Pict.: Gear box - swivel unit

Swivel unit 7008490

Page C60

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8002

Pict. : Swivel motor

Swivel unit 7008490

Page C61

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8002

Leg. pict.: Swivel motor (swivel unit 7008490) 1.

19.

33.

Suction valve Part group - park brake Park brake valve block

14.

21.

Secondary pressure limiting valves (AP) Bearing

TIGHTENING TORQUES Swivel unit 7008490 Pos. 8 10 19

Dimension M60x2,00 M18x1.5 M10x110

GEAR BOX

Loctite 243 12.9

Part Round nut Plug Screw

Tightening torques 701 - 774 ft-lbs (950 - 1050 Nm) 15 - 22 ft-lbs (20 30 Nm) 63 ft - lbs (85 Nm)

Function Release of Parking Brake (Opening)

Feature: the

The functions swivel motor and dipper arm cylinder (bottom side) control parking brake control valve by passing the shuttle valves.

Parking brake opening:

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

Parking brake locking:

As soon as the pilot pressure drops (joystick without function) the parking brake control valve is switched to its neutral position by spring force. In neutral position, the oil of the brake piston runs off via brake valve return (throttle symbol).

Because of this, the brake is applied after a certain time delay (depending on the viscosity of the oil and the speed of the brake valve return).

- To realize a softer braking motion and minimize swing motions the swivel motor (version 7008501) is provided with a hydraulic brake valve.

For version 7008490 the shock suction valves are damped - The check valve in the suction hose line supports suction of the shock suction valves.

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Pict. : Function - swivel motor - Release the park brake

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Hydraulics 9.

8002

SHUTTLE VALVES

( swivel motor park brake function )

Function: Transfer the pilot pressure of the moved joystick function to the swivel motor park brake valve block.

Pict.:

Position shuttle valves - function park brake swivel motor

shuttle valves (inside hoses)

Port 1,2 Port 3 Port 4 Port 5

From the joystick - function swivelling left / right From the joystick - function dipper arm cylinder (bottom side) Hydraulic oil cooler Control hose to swivel motor - park brake valve block (S)

Page C64

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Hydraulics

8002

10. DRIVING UNIT Type: Features:

> 7008302 - swash plate axial piston motor, 2 driving speeds - mech. motor parking bake (brake disks) - hydr. opened, mech. closed - hydr. braking unit to avoid motor overspeeding - double planetary gear requires periodic maintenance (see the Maintenance chapter) 1 2

3

4

5 Pict.: Drive motor

1 3 5

Hydr. brake piston / suction valves 2 Port leakage oil (->swivel unit) 4 Port 2nd driving speed BV (->swivel joint)

Page C65

Second. press. limiting valves Port A/B (->swivel joint)

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Hydraulics Bild:

8002

Hydraulic diagram - Driving unit 7008302 1

2

3 3

BV (pilot oil supply unit)

Hydr. brake piston

A

B

Pict.: Driving unit

1.

3.

A/B.

Park brake piston Shock valves (damped) Ports drive

2.

4.

BV.

Directional valve 2nd drive speed Hydr. brake piston Port 2nd drive speed (->> swivel joint / pilot oil suppl unit)

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Pict.: Hydraulic diagram - driving unit 7008302

Shock valves

Piston motor

Directional valve 2nd drive speed

Hydr. brake piston Suction valve

Double planetary gear box

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11. SWIVEL JOINT Types: Features:

> 7008500, > 7008517 (Note: seal kits are different for each type) - 8 canal swivel joint - Notice: For seal kits orders - always note the Serial No. of the excavator.

Pict.: Drain position swivel joint :

Dozer blade rod side Drive left / top Drive left / bottom

2nd drive speed

Leakage oil

Dozer blade bottom s.

Drive right / top Drive right / bottom

Page C68

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Hydraulics

8002

12. SWITCH VALVE A) Type: Function:

Switch valve 2708315 Switching of Functions Auxiliary Hydraulics / Boom Offset

Feature:

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

Fig.: Port assignment of switch valve

Chassis

Solenoid

D

C

B

A

F

E

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

Tank Ad 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 C69

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13. LOAD LOWERING VALVE Type: Function:

7008315 The counter-balance valve, prevents that pulling forces from moving the boom offset cylinder out of its fixed position.

Features:

Setting of the pressure limiting valves is higher than the system pressure.

The valves are opened by the pressure of the opposite valve.

Pict.: Assembling position load lowering valve - (view from above) C1

Pressure limit. valve

Pressure limit. valve

C2

V2

V1

Pict.: Load lowering valve 7008315

V1. - Port from main valve block ( 5A1 ) V2. - Port from main valve block ( 5B1 ) C1. - Port to the boom offset cylinder (rod side) C2. - Port to the boom offset cylinder (bottom side) Position load lowering valve (open the left chassis cover) Page C70

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Hydraulics

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16.

OIL TANK - Hydraulic System

A) Breathing filter

>> also see Maintenance chap

The breather provides the following functions: -

Pressure compensation in the hydraulic tank (due to varying oil level) by intake and release of air in and out of the tank - protection of oil tank against over-pressure Pressurizing the oil tank to the defined overpressure -> to support intake of the variable-displacement pump Filtering of intake air Initial pressure: 5.8 psi (0.4 bar) Breather filter ( Hydraulic tank )

Filter cloth

Breather valve

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Diesel engine

8002

C HAPT E R D :

Diesel engine

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Diesel engine

8002

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

Service News

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

Possible problem: Affected: Yanmar 4TNE98 until engine serial number 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 overflow tank.

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

Service News

Issue: 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: - Inadequate power transfer 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.

(Modification kit: 7005582V)

A) RADIATOR

.

Position diesel engine fan / fan shroud: Pressing fan Sucking fan

->

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

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Electrical

8002

C HAPT E R E :

Electrical

Page E1

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Electrical

8002

Electrical wiring diagram legend (up to serial. no.: AB00473) FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FUG1 FUK1 G1 G3 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16 HA1 HA2 K0 K1 K2 K3

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 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

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Electrical

8002

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 Feeler for fuel gauge

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 X2 X3 X4 X5

Stop solenoid Change over valve Solenoid valve 2nd gear Safety solenoid valve Plug in engine area 21 pole Plug in engine area 6 pole Plug for work lights 2 pole Plug for solenoid valve 24 pole Plug 2 pole

X6 X7 X8 X9 X10 Page E3

Plug for addtional filler pump 2 pole Cab plug 7 pole Plug for buzzer 2 pole Plug 1 pole Horn plug 2 pole Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical Pict.:

8002

Electrical wiring diagram (from Serial No.: 0001105/98 to AB00473)

Page E4

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Pict.:

Electrical wiring diagram (from Serial No.: 0001105/98 to AB00473)

Page E5

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Pict.: Relay position

Relay solenoid stop Timer relay solenoid stop (1,5 sec.)

Glow light control relay (ca. 15 sec.)

Starter relay

Main fuse 50A

Starter relay plug

Pict:

1 2 3 4

1

5

2

6

3

7

4

8

white black/white yellow black

5 blue 1mm² timer relay glow + timer pull wiring 6 black/white 1 mm² timer relay-pull. + Ignition lock. Kl.50a 7 black/orange 1 mm² alternator connection W 8 black 1 mm² ground green 2.5 mm² Starter Connector 30 white/red 2.5 mm² Starter Connector 50

Page E6

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Pict.: Solenoid stop plug

Black (ground) White (Timer pull wiring 1.5 sec.)

Red (Hold wiring, Connector 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 Pict.: Solenoid stop relay plug

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

solenoid stop (Pull wiring1,5 sec.) solenoid stop (Holding wiring) not wired (Option ) fuse 30 A

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

Page E7

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical Pict.:

8002

Glow control lamp relay plug (black plug) 1

5

2

6

3

7

4

8

1 2 3 4

2xblack/white red/gray 2xblack braun

1 mm² 1 mm² 1 mm² 1 mm²

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

5 6 7 8

red/white yellow black red

Pict.:

Plug timer relay for pull wiring (white plug) 1

5

2

6

3

7

4

8

1 2 3 4

black/pink black/blue 2xblack 1xblue

5 6 7 8

red/white yellow black red

1 mm² 1 mm² 1 mm² 1.5 mm²

Relay solenoid stop Relay solenoid stop Glow timer relais Starter relais

Page E8

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Fuse box These fuses are integrated in the right joystick armrest console.

Pict.:

Positions of the fuses inside the fuse box

No. Capacity (A) F1 20 F2 25 F3 10 F4 7,5 F5 15 F6 F7 F8

30 15 10

F9 F10 F11

20 15 10

Used for Heater, Horn (Air conditioning fan, Compressor - Option) Arm lights: side front arm lights Starter relais, Glow relay, (Opt. anti-theft system) Joystick consol arm rest right (e.g.: lights,..)

Safety solenoid switch arm rest, 2nd drive speed, Arm swing/auxiliary hydraulics electrically piloted (Opt.) 3rd-hydr. circuit (Option) Solenoid stop, alternator (+15) Cabin (+15), Windshield wiper, washer Joystick console left, (electr. diesel engine idler control, pump regulator) Option roof rotating beacon, Cabin (+30), anti-theft device Plug engine room, Fuel pump (Opt.) Option roof lights

Not all functions available — common wiring for all models.

The main fuse (50A) is located in the relay box - engine area The main fuse protect the ignition lock and the glow system

Page E9

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Starting with Serial No.: AB0473 AB1 stop solenoid S21 B1 water temp. Sensor S22 B2 horn S23 B3 fuel level sensor S35 G1 alternator S36 H1 right side lamp S37 H2 right front light S38 H3 arm light S39 H4 left front light R1 H5 left side light X0 H12 control lamp preheating X1 H13 control lamp load control X4 H14 control lamp engine temperature X5 H15 control lamp engine oil pressure X6 H16 control lamp air filter clogged X9 H17 control lamp hydraulic oil filter clogged X10 H18 control lamp overload warning X11 H20 cabin roof light front X12 H21 cabin roof light back X13 H22 rotating lamp X14 K1.1 relay a/c off engine temp.

X15 K1.2 relay a/c on X16 K1.3 a/c compressor X17 K2 timer preheating 10 sec.

X18 K4 starting relay X19 K5 solenoid engine stop timer X24 K6 solenoid engine stop X26 M1 heating van X27 M2 refuelling pump X28 M5 starter X29 M6 windscreen wiper X30 M7 windscreen washer X31 S1 alternator speed pick up Y2 S2 water temperature switch Y3 S4 air filter is clogged Y4 S5 engine oil pressure Y5 S6 3rd hydraulic circuit button Y6 S7 boom swing / extended hydraulic button F1 S8 3rd hydraulic circuit button F2 S10 safety switch right F3 S11 fast speed switch F4 S12 pressure switch overload warn device F5 S14 hydraulic oil filter is clogged F6 S15 windscreenwiper / washer F7 S16 heating van switch F8 S17 fast speed switch F9 S18 arm light switch F10 S19 front / side light switch F11 S20 starting switch

rotation light switch switch overload warn device switch roof light temperature a/c a/c switch a/c van switch a/c pressure switch a/c pressure switch preheating cigarette lighter main connector engine cable tree some engine relays alternator load control alternator main plus starter main plus starter solenoid heating / a/c switches connector instrumenenpanel left heating / a/c ventilator connector right to left armrest connector right to left armrest connector right to left armrest main connector armrest cable tree ground socket connector engine speed / pump reg. connector to horn button connector anti-theft device cabin connector connector instrumenten panel motoroil control buzzer boom swing / extended hydraulic valve 3rd hydraulic circuit 3rd hydraulic circuit safety valve fast speed valve switch lights, control lamps anti-theft device, engine relais lights chassis, arm heating van, clima, horn armrest left, engine speed, pumpregulation windscreenwiper, cabin stop solenoid, alternator valves option cabin socket, refuelling pump rotating light, cabin, anti thief device

Page E10

Id.No.: Edition:

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SERVICE MANUAL

Electrical

8002

Starts with Serial No.: AB00473 Q1 main fuse Q2 main fuse X40 main connector back lights X41 lights front left X42 lights front right X43 lights on boom Y2 boom swing / extended hydraulik valve Y3 3rd hydraulic circuit Y4 3rd hydraulic circuit Y5 safety valve Y6 fast speed valve Y8 full floating axle valve Y9 shiel up / down Fuse box : F1 switch lights, controll lamps F2 anti-theft device, engine relay F3 lights chassis, arm F4 heating van, a/c horn F5 armrest left, engine speed, pump/regulator F6 windscreenwiper, cabin F7 stop solenoid, alternator F8 valves F9 option cabin F10 socket, refuelling pump F11 rotating light, cabin, anti-theft device

Fuse box The fuse box is integrated into the armrest.

The main fuse, 50 Ampere, is situated in the relay box .

An additional main fuse, 40 Ampere, is situated in the right armrest Additionally, the timer relay for rear lights (option) and lights is in the right armrest.

Page E11

Id.No.: Edition:

918173 Sept. 05

shiel

Electrical Pict.:

SERVICE MANUAL 8002

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

Page E12

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Pict.:

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

Page E13

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Right armrest connections X1

21 pol.

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

21 pol. main plus red earth black main plus red preheating brown load control lamp pink plus 12V/15 blue relay: glow plugs, start, etc. (+15) blue plus 15: stop solenoid blue plus 15: stop solenoid blue a/c pressure switch yellow / red a/c compressor yellow / blue start relay white / black preheating lamp grey / red alternator (+15) blue / red water temperature switch green / black water temperature sensor green / white engine speed blue / black eingine oil pressure white res. air filter is clogged grey / blue a/c temperature yellow 24 poles safety valve brown / white boom swing / extended hyd. Valve lightblue / yellow fast speed valve brown / black heating van II yellow heating van I red fast speed switch grey fuel level violett res. res. side lights green front lights green / blue socket / refuelling pump red / black hydraulic oil level orange / blue earth black horn orange earth black arm light green / yellow 3rd hydraulic circuit red / black / red pump regulation valve blue / yellow hydraulic oil filter is clogged orange / white overload warning device switch blue / black / blue res. res.

3rd hydraulic circuit pink

Page E14

Id.No.: Edition:

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SERVICE MANUAL

Electrical

8002

Right armrest connections (continued) X14, female 3 4 5 11 X15, male 1 2 3 4 5 6 7 8 9 11 12 13 X16,male 1 2 3 4 X24 1 2 3 4 5 6 X27 1 2 3 4 5 6 8 10 11 X28 1 2 3 4 5 6 7 8 9

13 poles AMP: display back light earth water temperature speeed pickup signal 13 poles AMP: pump regulation valve (12002) poti (12002) poti (12002) poti (12002) 3 rd. Hydraulic circuit 3 rd. Hydraulic circuit safety swich armrest boom swing / extended hydraulic a/c temperature a/c compressor a/c pressure water temperature switch 4 pol. AMP: valves supply +15 earth plus 12 V plus 12 V 6 pol. AMP X15, P1 X15, P1 X15, P1 GND Supply +12 V res

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

starter valves stop solenoid starter valves stop solenoid ground supply +30 supply +15

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

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

blue / red violett black white green white/black/white blue red black yellow / black

Page E15

Id.No.: Edition:

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SERVICE MANUAL

Electrical

8002

Connections between right and left armrests X14, male 13 poles AMP: 1 res. Lamp 2 res. lamp 3 display back light 4 earth 5 water temperature 6 brake lamp (6502) 7 accumulator load lamp (6502) 8 res. lamp 9 res. lamp 10 nc.

11 speeed pickup signal 12 indicator lamp (6502) 13 light lamp (6502) X15, female 13 poles AMP: 1 pump regulation valve (12002) 2 poti (12002) 3 poti (12002) 4 poti (12002) 5 3 rd. Hydraulic circuit 6 3 rd. Hydraulic circuit 7 safety swich armrest 8 boom swing / extended hydraulic 9 a/c temperature 10 11 a/c compressor 12 clima pressure 13 water temperature switch X16,female 4 pol. AMP: 1 valves supply +15 2 earth 3 plus 12 V 4 plus 12 V X11, female 11 pol. AMP: 1 ventilator speed III 2 ventilator speed II 3 ventilator speed I 4 res 5 water temperature ( switch) 6 pump regulation valve 7 a/c compressor 8 to thermostate in clima 9 a/c pressure switch 10 earth 11 plus 12 V X13, female 6 pol. AMP 1 thermostat to switch on 2 thermostet to a/c compressor 3 earth 4 ventilator speed II 5 ventilator speed I 6 ventilator speed III

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

Page E16

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

Connections between the engine wire harness and armrest X1

21 pol.

B D E G

main plus earth main plus preheating

red black red brown

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 a/c pressure a/c compressor start relay preheating lamp alternator (+15) water temperature switch water temperature sensor engine speed eingine oil pressure res air filter is clogged a/c temperature

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

Connection beween the chassis and armrest X17

24 pol.

1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 20 21 24

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

Page E17

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

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Electrical

8002

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Page E18

Id.No.: Edition:

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SERVICE MANUAL

Operating Elements

8002

C HAPTE R F :

Operating Elements

Page F1

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Pict.: Component designation

2

1

3

16,17

8,9

7

4

5

20

13

6

10 11 12

20

18 1 2 3 4 5 6 7 8 9 10

14

19

15 11 12 13 14 15 16 17 18 19 20

Dipper arm Dipper arm cylinder Boom Cabin Drivers seat Engine cover Bucket cylinder Joystick left Joystick right Bucket

Page F2

Boom cylinder Joystick consol Dozer blade Undercarriage Chassis Drive lever / pedal left Drive lever / pedal right Driving unit Track tensioner cylinder Eyes for lifting and tying down the excavator Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Pict.: Component designations - cabin 1

2

4

5

6

7

15 8 8

3 25

10

24

14

22 23 12,13

11 19

11 20

16 21 9

18

17 18

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

Hammer + cover Drive pedal left and switch for overdrive Seat spring tension adjustment Drive pedal right and foot pedal Seat back adjustment Foorest Lever for dozer plade with foot pedal Heating and air vents Cab lighting Accelerator Armrest Cable to open side cover

13 14 15 16 17 18 19 20 21 22 23 24 25

Page F3

Cable to open engine cover Right control lever for boom and bucket Ashtray Instrument panel Radio Speaker Ignition lock Storage Fuse box Heating Left control lever for bucket stick and swiveling swing arm Lever to fold back left steering control console Seat adjustment

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Pict.: Component designation

1

2

4 5 6 7 8 9 10 11

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

Control block Hydraulic oil level indicator Drain plug oil tank Drain plug diesel tank Opening for filling hydraulic oil Tank support Diesel tank Return filter Diesel pump Battery Oil tank Engine cover

13

Page F4

12

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Pict.:

Joystick consoles component designation

1 2 3 4

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

5 6 7 8

9 10 11 12 13 14 15 16 17 18

Left joystick console

Light indicator (lights on/off) Hour meter Heater switch Windshield wiper/ washer switch Overdrive Switch for work lights Switch for chassis lights Fuse box Ignition key Temperature adjustment

Right joystick console

2 3 4 5

10

1 6 7 8 9

17 13

11 18

14 12

15

16 Page F5

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements Pict.:

8002

Joystick functions (Standard)

The excavating equipment is operated using the left and right control levers on the operator'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.

Bottom or Switch valve

Left joystick

Horn

Right joystick

Pict.: Left joystick consol ( Joystick )

1

3

1 2 3 4

forward rearward left right

Dipper arm up (away from the excav.)

Dipper arm down (to the excavator) Swing left Swing right

Page F6

4

2

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Pict.: Right joystick consol ( Joystick )

5

7

8

6 5 6 7 8

Function:

forward rearward left right

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

Dozer blade

Up and down motion of the dozer blade is piloted by the right lever / pedal.

Dozer blade lower

Dozer blade control lever

Dozer blade lift

Page F7

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements Function:

8002

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 hydra. is controlled by the side pedal.

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

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

A

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

Standard Return of the auxiliary oil passes the main valve block

> OPEN:

“ breaker function” Return into the tank (depressurized return)

B

Ball block valve “breaker function”

Page F8

Id.No.: Edition:

918173 Sept. 05

SERVICE MANUAL

Operating Elements

8002

Lifting the excavator Raise arm and dozer blade.

Fasten cable, 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 cable/chains and the excavator.

The fastening points are indicated with stickers.

Ensure that the cable/chains etc. cannot come undone.

Minimum force required per lift 8.9 ton force (80 kN).

L1 = about 11‘ 6“ (3.5 m) L2 (2X) = about 13‘ 2“ (4 m) P1 ... Boom fastening point P2 ... Dozer blade fastening points (left and right)

Page F9

Id.No.: Edition:

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SERVICE MANUAL

Operating Elements

8002

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Page F10

Id.No.: Edition:

918173 Sept. 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 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 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

918173/AP0905

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

PRINTED IN USA