Mustang Compact Excavators 2803ZT Service Manual(918279) - PDF DOWNLOAD by www.heydownloads.com

2803ZT Compact Excavator SERVICE MANUAL PART #918279 ® Revision A - 05/08 Mustang Manufacturing Company, Inc. ®

Table of Contents PrintedinU.S.A.1-1918279/AP0508 TableofContents Introduction General Information ................................................................................................. 1-1 Serial number locations, type decals and component numbers .............................. 1-2 Designated uses and exemption from liability ......................................................... 1-4 Abbreviations/symbols ............................................................................................. 1-4 Identification of warnings and dangers .................................................................... 1-5 Machine overview .................................................................................................... 1-6 Cab overview ........................................................................................................... 1-7 Cab legend .............................................................................................................. 1-8 Instrument panel overview ....................................................................................... 1-9 Instrument panel legend ........................................................................................ 1-10 Engine compartment overview .............................................................................. 1-11 Chassis overview ................................................................................................... 1-12 Valve compartment ................................................................................................ 1-13 Overview of open engine and valve compartment ................................................. 1-14 Specifications Chassis .................................................................................................................... 2-1 Engine ...................................................................................................................... 2-1 Fuel injection pump ........................................................................................... 2-2 Engine capacities .............................................................................................. 2-2 Engine tightening torques .................................................................................. 2-2 Hydraulic system ..................................................................................................... 2-2 Work hydraulics ................................................................................................. 2-2 Auxiliary hydraulics oil flow ................................................................................ 2-3 Undercarriage and swivel unit ................................................................................. 2-3 Dozer blade ............................................................................................................. 2-3 Electric system ......................................................................................................... 2-3 Fuse box ............................................................................................................ 2-4 Noise levels ............................................................................................................. 2-5 Vibration .................................................................................................................. 2-5 Coolant compound table .......................................................................................... 2-5 Model-specific tightening torques ............................................................................ 2-6 General tightening torques ...................................................................................... 2-6 Tightening torques for hydraulic screw connections (dry assembly) ................. 2-6 Tightening torques for high-resistance screw connections ................................ 2-8 Dimensions .............................................................................................................. 2-9 Lift capacity table ................................................................................................... 2-10 Lift capacity table with optional counterweight ....................................................... 2-11 Bucket geometry .................................................................................................... 2-12

Table of Contents 918279/AP05081-2PrintedinU.S.A Maintenance Fluids and lubricants ................................................................................................ 3-1 Additional oil change and filter replacement (hydraulics) .................................. 3-2 Maintenance label .................................................................................................... 3-3 Explanation of symbols on the maintenance label ............................................. 3-3 Maintenance schedule ............................................................................................. 3-5 Check, clean or inspect ..................................................................................... 3-5 Fluid and filter changes ...................................................................................... 3-6 Functional check ................................................................................................ 3-6 Leakage check ................................................................................................... 3-6 Daily lubrication ................................................................................................. 3-7 Service package ...................................................................................................... 3-8 Introduction .............................................................................................................. 3-8 Fuel system .............................................................................................................. 3-9 Specific safety instructions ................................................................................ 3-9 Refueling ............................................................................................................ 3-9 Stationary fuel pumps ...................................................................................... 3-10 Bleeding the fuel system .................................................................................. 3-10 Emptying the fuel tank ..................................................................................... 3-11 Diesel fuel specification ................................................................................... 3-11 Fuel shut-off valve and water separator .......................................................... 3-11 Replacing the fuel filter .................................................................................... 3-12 Engine lubrication system ...................................................................................... 3-13 Checking the oil level ....................................................................................... 3-13 Adding engine oil ............................................................................................. 3-14 Changing engine oil and filter .......................................................................... 3-15 Cooling system ...................................................................................................... 3-16 Specific safety instructions .............................................................................. 3-16 Checking/adding coolant ................................................................................. 3-17 Draining coolant ............................................................................................... 3-18 Air filter ................................................................................................................... 3-19 Replacing the filter ........................................................................................... 3-20 Functional check of the dust valve once a week ............................................. 3-21 V-belt ...................................................................................................................... 3-22 Checking V-belt tension ................................................................................... 3-22 Tightening the V-belt ........................................................................................ 3-23 Pressure checks .................................................................................................... 3-24 General ............................................................................................................ 3-24 Pilot control pressure check ............................................................................. 3-24 Variable-displacement pump P1 pressure check ............................................ 3-25 Variable-displacement pump P2 pressure check ............................................ 3-26 Gear pump P3 pressure check ........................................................................ 3-27 Gear motor secondary pressure limiting valve pressure check ....................... 3-28 Test ports overview .......................................................................................... 3-28 Primary pressure limiting valves ...................................................................... 3-29 Test report .............................................................................................................. 3-31 Hydraulic system .................................................................................................... 3-33 Specific safety instructions .............................................................................. 3-33 Checking the hydraulic oil level ....................................................................... 3-34 Adding hydraulic oil .......................................................................................... 3-35 Changing hydraulic oil ..................................................................................... 3-35 Monitoring the hydraulic oil return filter ............................................................ 3-36 Checking hydraulic pressure lines ................................................................... 3-37 Travel drive ............................................................................................................ 3-38 Checking the oil level and adding oil ............................................................... 3-38 Draining oil ....................................................................................................... 3-38

Table of Contents PrintedinU.S.A.1-3918279/AP0508 Tracks .................................................................................................................... 3-39 Checking track tension .................................................................................... 3-39 Track tension ................................................................................................... 3-39 Lubrication ............................................................................................................. 3-41 Dozer blade ..................................................................................................... 3-41 Lubrication points on the swivel console ......................................................... 3-41 Boom lubrication points ................................................................................... 3-42 Lubrication points on the dipper arm ............................................................... 3-42 Lubrication strip ............................................................................................... 3-43 Maintenance of attachments ........................................................................... 3-43 Electrical system .................................................................................................... 3-44 Specific safety instructions .............................................................................. 3-44 Regular service/maintenance .......................................................................... 3-45 Specific component instructions ...................................................................... 3-45 Alternator ......................................................................................................... 3-45 Battery ............................................................................................................. 3-46 Jump-starting the engine ................................................................................. 3-47 Cab ........................................................................................................................ 3-48 Replacing the cab filter .................................................................................... 3-48 General maintenance ............................................................................................ 3-49 Cleaning .......................................................................................................... 3-49 General instructions for all areas ..................................................................... 3-49 Inside the cab .................................................................................................. 3-50 Seat belt .......................................................................................................... 3-50 Exterior of the machine .................................................................................... 3-50 Engine compartment ....................................................................................... 3-50 Screw connections and attachments ............................................................... 3-50 Pivots and hinges ............................................................................................ 3-50 Engine 3TNV76-NNS engine overview ................................................................................ 4-1 Fuel system ............................................................................................................. 4-3 Checking and adjusting valve tip clearance ............................................................. 4-4 Tightening order for cylinder head bolts .................................................................. 4-4 Checking the injection nozzles ................................................................................ 4-5 Pressure check .................................................................................................. 4-5 Checking the nozzle jet ............................................................................................ 4-5 Injection time ............................................................................................................ 4-6 Checking and adjusting injection time ............................................................... 4-6 Fuel injection pump replacement ....................................................................... 4-7 Adjusting engine rpm ............................................................................................... 4-8 Compression ............................................................................................................ 4-8 Checking the coolant thermostat ............................................................................. 4-8 Checking the thermal switch .................................................................................... 4-9 Oil pressure switch .................................................................................................. 4-9 Checking the coolant circuit ................................................................................... 4-10 Engine troubleshooting ......................................................................................... 4-10

Table of Contents 918279/AP05081-4PrintedinU.S.A Hydraulicsystem Hydraulic pump PVD-0B-23BP-8G3-5083A ............................................................ 5-1 Pump unit: exploded view .................................................................................. 5-3 Pilot oil supply unit ............................................................................................. 5-4 Main valve block ...................................................................................................... 5-5 Ports .................................................................................................................. 5-5 Legend ............................................................................................................... 5-6 Main valve block diagram .................................................................................. 5-7 Pressure limiting valves ..................................................................................... 5-8 Pump assignment .............................................................................................. 5-9 Drive counterbalancing system .............................................................................. 5-10 Pump assignment for drive counterbalancing .................................................. 5-10 Regeneration – dipper arm section ........................................................................ 5-11 Bucket pre-tension ................................................................................................. 5-11 Flow rate adjustment of auxiliary hydraulics .......................................................... 5-12 Pilot valves ............................................................................................................. 5-13 Joystick ............................................................................................................ 5-13 Pilot valve (driving) .......................................................................................... 5-14 Pilot valve for auxiliary hydraulics .................................................................... 5-16 Changeover valve for SAE/ISO controls (option) ................................................... 5-17 Proportional valve (option) ..................................................................................... 5-17 Travel drive ............................................................................................................ 5-18 Function ........................................................................................................... 5-19 Swivel unit .............................................................................................................. 5-21 Swivel unit brake .............................................................................................. 5-22 Swivel joint ............................................................................................................. 5-25 Sealing ............................................................................................................. 5-25 Breather filter ......................................................................................................... 5-26 Troubleshooting the hydraulic system ................................................................... 5-27 Hydraulics diagram: legend ................................................................................... 5-28 Hydraulics diagram ................................................................................................ 5-29 Hydraulics diagram for options .............................................................................. 5-30 Main valve block diagram ...................................................................................... 5-31 Electricsystem Ohm's Law (current, voltage, resistance); power ..................................................... 6-1 Measuring equipment, measuring methods ............................................................. 6-1 Cable color coding ................................................................................................... 6-3 Relays ...................................................................................................................... 6-3 Use, mode of function ........................................................................................ 6-3 Socket ...................................................................................................................... 6-3 Electric units ............................................................................................................. 6-4 Fuse box .................................................................................................................. 6-4 Switches: overview .................................................................................................. 6-5 Instrument panel legend .................................................................................... 6-5 Alternator ................................................................................................................. 6-6 Starter ...................................................................................................................... 6-6 Wiring diagram legend ............................................................................................. 6-7 Wiring diagram ......................................................................................................... 6-8 Engine wiring harness legend .................................................................................. 6-9 Engine wiring harness diagram .............................................................................. 6-10 Cab wiring harness ................................................................................................ 6-11 Proportional controls (option) ................................................................................. 6-12

Table of Contents PrintedinU.S.A.1-5918279/AP0508 Options Counterweight .......................................................................................................... 7-1 Specifications .................................................................................................... 7-1 Connecting auxiliary hydraulics ............................................................................... 7-1 Attachments ....................................................................................................... 7-2 Auxiliary hydraulics connections .............................................................................. 7-2 Proportional controls ................................................................................................ 7-3 Function ............................................................................................................. 7-3 Ports .................................................................................................................. 7-4 Measures to be taken in case of malfunctions .................................................. 7-4 Joystick .............................................................................................................. 7-4 Boom swivel controls ......................................................................................... 7-5 Auxiliary hydraulics ............................................................................................ 7-5 Hammer operation ............................................................................................. 7-5 Adjusting control response ................................................................................ 7-6 Characteristic curves – status display ............................................................... 7-6 Wiring harness ................................................................................................... 7-7 Control valve plug assignment .......................................................................... 7-8 Safety features .................................................................................................. 7-9 Measures to be taken in case of malfunctions .................................................. 7-9 Diagnostic display .............................................................................................. 7-9

Table of Contents 918279/AP05081-6PrintedinU.S.A

Your decision to purchase the Mustang compact excavator was a good one. We are sure that your decision was carefully considered and that you are looking forward to many years of reliable performance from the machine.

Mustang Manufacturing Co., Inc. has invested much time and effort in developing its lines of equipment. The machine you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.

Modern machinery has become more sophisticated and, with that in mind, Mustang Manufacturing Co., Inc. asks that you read and COMPLETELY understand the contents of this manual and become familiar with the new machine, BEFORE attempting to service it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining and servicing the machine. More importantly, this manual provides a service plan for safe and proper servicing of the machine. Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If the machine was purchased "used," or if the owner's address has changed, please provide your Mustang dealer or Mustang Manufacturing Co., Inc. with the owner's name and current address, along with the machine model and serial number. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

“Right” and “left” are determined from the position of sitting in the operator’s seat, facing forward.

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

Throughout this manual information is provided that is introduced by the word NOTE or IMPORTANT. Be sure to read carefully and comply with the message or directive given. Following this information will improve your maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage and extend the machine's life.

Operational safety and readiness of the machine depends partially on maintenance and service. This is why regular maintenance and service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a qualified technician with appropriate training. Insist on using Mustang original service parts when carrying out maintenance and repair work. This ensures operational safety and readiness of the machine, and maintains its value.

Our wide dealership network stands ready to provide any assistance required, including genuine Mustang service parts. All parts should be obtained from or ordered through your Mustang dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

Purchased from:___________________________________

Date of Purchase: __________________________________

Model No.: _______________________________________

Serial No.:________________________________________

Introduction PrintedinU.S.A.1-1918279/AP0508

1Introduction 1.1GeneralInformation

1.2Serialnumberlocations,typedecalsandcomponentnumbers

Serialnumber

The serial number is stamped on the machine chassis. It is also located on the type label. The type label is located at the front left on the machine frame (at cab level)

Type label information

Model:2803ZT

Serial no.:AG 00000

Model year:2008

Output:15.2 kW

Dead Weight:2670 kg

Max. payload:___________

Gross axle weight rating:___________

Other information – see Specifications on page 2-1

Cabnumber

The type label (arrow) is located on the chassis of the cab, at the upper left beside the door.

Enginenumber

The type label (arrow) is located on the cylinder-head cover (engine).

Example: Yanmar 46557

Introduction 918279/AP05081-2PrintedinU.S.A

Fig. 1-1:Type label: location Fig. 1-2:Type label Fig. 1-3:Cab type label Fig. 1-4:Diesel engine number

Hydraulicpumpnumber

The type label (arrow) is located on the hydraulic pump housing.

Mainvalveblocknumber

The type label (arrow) is located on the lower side of the main valve block.

Traveldrivenumber

The type label (arrow) is located on the travel drive.

Swivelunitnumber

The type label (arrow) is located on top of the swivel unit.

Introduction PrintedinU.S.A.1-3918279/AP0508

Fig. 1-5:Hydraulic pump type label Fig. 1-6:Main valve block type label Fig. 1-7:Travelling drive type label Fig. 1-8:Swivel unit type label

1.3Designated uses and exemption from liability

• The machine is intended for:

- Excavating soil, gravel, coarse gravel, ballast or rubble.

- Working with the attachments mentioned.

• Every other use and attachment is not designated for this machine. Mustang Manufacturing Co., Inc. will not be liable for damage resulting from any other use or attachment. The user alone will bear the risk.

• Follow the instructions in the Operator’s Manual, and also accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Mustang Manufacturing Co., Inc. is not liable for damage resulting from the failure to follow these regulations.

• You can damage the machine by modifying it with parts, equipment, attachments and optional equipment not authorized by Mustang Manufacturing Co., Inc. Mustang Manufacturing Co., Inc. is not liable for damage resulting from unauthorized modifications.

• Mustang Manufacturing Co., Inc. is not liable for personal injury and/or damage to property caused by failure to properly:

- operate,

- transport,

- service and maintain,

- and repair the machine as instructed in this manual and the Operator’s Manual.

• Read and understand the Operator’s Manual before starting, servicing, or repairing the machine. Follow the safety instructions.

• The machine may not be used for transportation on public roads.

• In applications with lifting gear, only use the machine according to its designated use.

1.4Abbreviations/symbols

Abbreviations/symbols

• This symbol stands for a list

- Subdivision within lists or an activity. Follow the steps in the sequence presented.

☞ This symbol requires you to carry out the activity described.

➥ Description of the effects or results of an activity.

n. s. = not shown

“Option” = optional equipment (indicated whenever controls or other components of the machine are installed as an option)

A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/ A, is used for identifying figure elements. For example:

• Figure no. 40/ element no. 18, or position A in figure no. 40.

• Figures carry no numbers if they are placed to the left of the text.

Introduction 918279/AP05081-4PrintedinU.S.A

1.5Identificationofwarningsanddangers

The following signal words are used throughout this manual and on decals on the machine to warn of potentially hazardous conditions.

DANGER!/WARNING!/CAUTION!

Failure to follow the instructions identified by this symbol may result in personal injury or death to the operator or other persons.

☞ Measures for avoiding the hazard.

IMPORTANT!

Failure to follow the instructions identified by this symbol may result in damage to the machine.

☞ Measures for avoiding damage to the machine.

NOTE: Contains instructions to help use the machine more efficiently.

Environment!

Failure to follow the instructions identified by this symbol may result in damage to the environment. The environment can be damaged if hazardous material (e.g., waste oil) is not properly used or disposed.

Introduction PrintedinU.S.A.1-5918279/AP0508

1.6Machineoverview

Introduction 918279/AP05081-6PrintedinU.S.A

1Work light 2Boom 3Auxiliary hydraulics 4Dipper arm 5Handle 6Dozer blade 7 Eye hook for loading/tying down the machine 8Undercarriage 9Exhaust pipe 10Engine cover 11Rotating beacon 12Boom light 13Canopy (standard)/cab (option) 14Fuel filler inlet 15Valve cover 16Counterweight 17Rubber track 18Lubrication point for track tension 3 4 6 10 12 3 17 18 13 15 1 7 8 9 2 5 11 14 78 16 11

Fig.

1-9:Machine outside views

Introduction PrintedinU.S.A.1-7918279/AP0508 1.7Caboverview 15 16 18 14 17 19 236 1457 8 9 10 11 13 12 22 21 20 26 27 25 23 29

1.8Cablegend

Pos.Description

1Boom swivel pedal

2Drive pedal (left)

3Drive lever (left)

4Drive lever (right)

5Drive pedal (right)

6Lever – horizontal seat adjustment

7Auxiliary hydraulics pedal

8Instrument Cluster

9Pre-heating start switch

10Joystick (right)

11Joystick base (right)

12Dozer blade lever

13Console switch panel

14Cab switch panel

15Cigarette lighter

16Radio (option)

17Cup holder

18Air vents

19Cab bearing

20Changeover valve for SAE/ISO controls (option)

21Seat (backrest adjustment)

22Seat belt (lock)

23Armrest (left)

24Armrest on the right (not shown)

25Throttle

26Joystick base

27Joystick

28Document storage (underneath the seat console)

29Seat

Introduction 918279/AP05081-8PrintedinU.S.A

Introduction PrintedinU.S.A.1-9918279/AP0508 1.9Instrumentpaneloverview 34 30 3335 36 39 38 Control element on joystick consoleControl element on cab wall Controlelementsforproportionalcontrolsversion(option): Control element on joystick console Control element on cab wall 40414245464748 404142434445464748 4937

1.10Instrumentpanellegend

Pos.Description

30Indicator (yellow) – cold starter

31Indicator (red) – hydraulic oil filter

32Indicator (red) – alternator charge function

33Indicator (red) – engine oil pressure

34Indicator (red) – coolant temperature

35Indicator (red) – safe load indicator (option)

36Fuel level indicator

37Hour meter

38High speed switch

39Fan switch

40Safe load indicator (option)

41Hydraulic quickhitch switch (option)

42Proportional control status indicator (option)

43Washer switch

44Work light switch

45Roof lights switch (option)

46Rotating beacon switch (option)

47Air filter indicator

Introduction 918279/AP05081-10PrintedinU.S.A

1.11Enginecompartmentoverview

Introduction PrintedinU.S.A.1-11918279/AP0508

5254 48515355 49505960 565758 Pos.DescriptionFormoreinformationseepage 48Water separator 3-11 49Hydraulic pump 5-1 50Fuse box 2-4 51Washer system tank 52Air filter 3-19 53Fuel filter 3-12 54Throttle cable 55Oil dipstick 3-13 56Oil filler opening 3-14 57Radiator 3-17 58Radiator cap 3-17 59Engine cover 60Expansion tank 3-17

Introduction 918279/AP05081-12PrintedinU.S.A

67 6165 6264 6668 63 Pos.DescriptionFormoreinformationseepage 61Heating control 3-48 62Swivel joint 5-21 63Shuttle valve 64Manifold 65Swivel motor 5-21 66Heating 3-48 674/2 way solenoid valve (option) 68Proportional valve (option) 5-17

1.12Chassisoverview

1.13Valvecompartment

Introduction PrintedinU.S.A.1-13918279/AP0508

Pos.DescriptionFormoreinformationseepage 69Fuel filler inlet 5-25 70Changeover valve for SAE/ISO controls 5-17 71Return filter 3-36 72Main valve block 5-5 73Control valve for proportional controls (option) 7-8 74Hydraulic tank cap 5-26 697074 717273

1.14Overviewofopenengineandvalvecompartment

Introduction 918279/AP05081-14PrintedinU.S.A

2Specifications

2.1Chassis

2.2Engine

Sturdy steel sheet chassis, rubber-mounted engine.

Engine

Make Yanmar diesel engine

Type

Design

3TNV76-NNS

Water–cooled 4–stroke diesel engine

No. of cylinders 3

Fuel injection system

Indirect injection

Aspiration Natural aspiration

Cooling system

Lubrication

Direction

Water-cooled/aspirating fan

Average engine droop

About 60 rpm; after turning off a warm engine boom, dipper and bucket as far as it will go

Specifications PrintedinU.S.A.2-1918279/AP0508

system Force-feed lubrication with trochoidal pump Displacement 68 cu. in. (1.114 L)

and stroke 3.0 x 3.2

mm)

20.4 hp (15.2 kW)

2500 rpm Max. torque 49 lb.- ft. (66.1 Nm)

1800 rpm

engine speed without load 2675

25 rpm

speed 1300 ± 25 rpm Valve tip clearance (intake = outlet) 0.006 – 0.010 in. (0.15 – 0.25 mm) (cold) Compression 497 ± 14.5 psi (34.3 ± 1 bar) @ 250 rpm Engine oil pressure (at rated speed) 42 – 64 psi (2.9 –4.4 bar) Pressure switch for engine oil pump 7 ± 1.5 psi (0.5 ± 0.1 bar) Thermostat opening temperature 158 – 165° F (70 – 73° C) Thermal switch 225 – 235° F (107 – 113° C) Firing order 1 – 3 – 2

Nominal bore

in. (76 x 82

Output

Max.

Idling

Counterclockwise (as

aid Glow plug (pre-heating

(engine

25° in all directions,

Observe

Specific fuel consumption 279 g/kWh @ rated output

values in compliance 97/68/EC EPA

rotation

seen from the flywheel) Starting

time 4 seconds) Max. inclined position

no longer supplied with oil)

30° briefly

the machine's climbing ability (30°/ 58%).

Exhaust

Specifications

2.3Hydraulicsystem

Specifications 918279/AP05082-2PrintedinU.S.A Fuelinjectionpump Enginecapacities Enginetighteningtorques

Workhydraulics TypeYPES-3ML Design In-line pump Injection pressure 1711 – 1856 psi (118 –128 bar) Speed control Mechanical Lubrication system Engine oil lubrication Capacities Fuel tank 9.5 gal. (36 L) Engine oil 3.5 qt. (3.3 L) (up to max. mark) 1.9 qt. (1.8 L) (up to min. mark) Coolant (without radiator) 0.95 qt. (0.9 L) (engine only) Radiator 4.75 qt. (4.5 L) Expansion tank 0.52 qt. (0.5 L) Tighteningtorques Cylinder-head bolt 40 lb.-ft.– 43 lb.-ft. (53.9 – 57.9 Nm) (M9x1.25) Connecting rod bearing screw 17 lb.-ft. – 20 lb.-ft. (22.6 – 27.5 Nm) (M7x1) Main bearing screw 55 lb.-ft. – 60 lb.-ft. (75.5 – 81.5 Nm) (M10x1.25) Flywheel screw 59 lb.-ft. – 64 lb.-ft. (80.4 – 86.4 Nm) (M10x1.25) Hydraulics Pump Double variable displacement + twin gear pump 0.70 + 0.70 + 0.48 + 0.16 in³ (11.5 + 11.5 + 8 + 2.7 cm³) Flow rate 8.1 + 8.1 + 5.6 + 2.0 gpm (31.0 + 31.0 + 21.2 + 7.6 L/min) at 2500 rpm Service pressure for work and drive hydraulics 3263 psi (300 bar) Swivel unit service pressure 2988 psi (206 bar) Hydraulic oil cooler Standard Hydraulic oil tank capacity 7.0 gal. (26.5 L) Workhydraulics Max. service pressure 3263 ± 43 psi (225 ± 3 bar) Main pressure limiting valve for boom/bucket/dipper 3263 ± 43 psi (225 ± 3 bar) Main pressure limiting valve for dozer blade 2988 -58/+29 psi (206 -4/+2 bar) Pilot control pressure 435 -0/+58 psi (30 -0/+4 bar) Swivel unit engine pressure restriction 2900 -58/+29 psi (200 -4/+2 bar) Filter Return filter

Auxiliaryhydraulicsoilflow

IMPORTANT!

Output indications for auxiliary hydraulics with unpressurized hammer return line.

V, 40 A

V, 1.4 hp (1.1

V; 44 Ah; 680 CCA

Specifications PrintedinU.S.A.2-3918279/AP0508

2.4Undercarriageandswivelunit 2.5Dozerblade

PressureP2+P3P2 217 psi (15 bar)13.7 gpm (52.2 L/min)8.0 gpm (30.5 L/min) 580 psi (40 bar)13.3 gpm (50.6 L/min)7.8 gpm (29.5 L/min) 870 psi (60 bar)12.6 gpm (48 L/min)7.8 gpm (29.5 L/min) 1305 psi (90 bar)11.5 gpm (43.5 L/min)7.5 gpm (28.5 L/min) 1740 psi (120 bar)10.3 gpm (39 L/min)7.1 gpm (27.0 L/min) 2175 psi (150 bar)8.8 gpm (33.5 L/min)6.7 gpm (25.5 L/min) 2610 psi (180 bar)7.1 gpm (27 L/min)5.7 gpm (21.5 L/min) 2900 psi (200 bar)3.1 gpm (12 L/min)5.0 gpm (19.0 L/min) Undercarriage/swivelunit 2 speed ranges 1.3 / 2.3 mph (2.1/3.8 kph) Climbing ability 30° (58%) Rubber track width 11-7/8 in. (300 mm) Top/bottom rollers 1 / 3 per side Ground clearance 10-7/8 in. (277 mm) Ground pressure 3.8 psi (26.2 kPa) Upper carriage swivel speed 10.25 rpm Dozerblade Width/height 5 ft., 2 in. / 11-3/4 in. (1570/299 mm) Max. lift over/under subgrade 15/16-1/2 in. (380/419 mm)

Alternator12

Starter12

kW) Battery12

Sockete.g.,

2.6Electricsystem

Electricsystem

for cigarette lighter; 15 A max.

Fusebox

The fuse box is located in the engine compartment.

Fuseno.Ratedcurrent(A)Protectedcircuit

F310 AIndicators, cutoff solenoid, relays

F410 ABoom working light

F515 ACab working light

F610 AValves, horn

F715 AHeating, air conditioning

F810 AWiper, interior light

F910 ARotating beacon, radio, cigarette lighter

F1015 ASocket

Fuseno.Ratedcurrent(A)Protectedcircuit

F140 AStart, preheat, cutoff solenoid

F250 AIgnition lock

Relayno.Protectedcircuit

K6Pre-heating time lag relay

K7Starting relay

K8Cutoff solenoid time lag relay

K9Pick-up contact cutoff solenoid relay

Specifications 918279/AP05082-4PrintedinU.S.A

Fig. 2-1:Fuse box F3 F4 F8 F9 F10 F5 F6 F7 Fig. 2-2:Relays K7 K6 K8 F1 F2 F1 F2 K9

2.7Noiselevels

Soundpowerlevel

Sound power level (LWA)93 dB (A)

Sound pressure level (LPA) at the operator’s ear ≤77 dB (A)

IMPORTANT!

Measurement of sound power level according to EC Directive 2000/14/EC. Noise level at the operator’s ear measured according to EC Directives 84/532/EEC, 89/ 514/EEC and 95/27/EEC.

Measurements carried out on asphalt surface.

2.8Vibration

Vibration

Effective acceleration value for the upper extremities of the body *

Effective acceleration value for the body *

2.9Coolantcompoundtable

< Trigger value

Outsidetemperature Coolant:HalvolineXLC(basedonethyleneglycol) WaterAnti-corrosion agentAntifreeze agent

Specifications PrintedinU.S.A.2-5918279/AP0508

* Measurements as per 2002/44/EC (excavating, driving and hammering with a Neuson hammer). Machine and attachment operation and maintenance as per Operator's Manual.

Up to °F (°C) % by volume in³/gal (cm³/L)% by volume% by volume 39.2 (4)99 2.6 (10)1 –14 (-10)7920 -4 (-20)6534 -13 (-25)5940 -22 (-30)5544

2.10Model-specifictighteningtorques

Tighteninggradesandtorquesinlb.-ft.(Nm)

*All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.

2.11Generaltighteningtorques

Tighteningtorquesforhydraulicscrewconnections(dryassembly)

Galvanized and dry surface (O-ring slightly oiled). Torque tolerance: -10% Values determined empirically and to be applied as approximate figures.

Metrichosefittingsforhydraulicapplications(heavyexecution,DKOL)

NominaløOuterøThreadWidthacross

Galvanized and dry surface (O-ring slightly oiled). Torque tolerance: -10% Values determined empirically and to be applied as approximate figures.

Specifications 918279/AP05082-6PrintedinU.S.A

Live ring M12 10.9 88 lb.-ft. (120 Nm) * Track rollerM14 10.988 lb.-ft. (120 Nm) * Drive pinionM12 10.988 lb.-ft. (120 Nm) * Travelling driveM12 10.988 lb.-ft. (120 Nm) * Gear motorM12 10.988 lb.-ft. (120 Nm) * Angled engine bracketM10 8.8 33 lb.-ft. (45 Nm) Engine mountingM10 8.833 lb.-ft. (45 Nm) Pump mountingM10 10.933 lb.-ft. (45 Nm) PumpM12 10.981 lb.-ft. (110 Nm) Swivel jointM10 10.974 lb.-ft. (100 Nm) * Counterweight/additional counterweightM20 8.8214 lb.-ft. (290 Nm) * Metrichosefittingsforhydraulicapplications(lightexecution,DKOL) NominaløOuterøThreadWidthacross flats Tighteningtorque lb.-ft.(Nm) 056LM12x1.5W/F 1411 lb.-ft. (15 Nm) 068LM14x1.5W/F 1715 lb.-ft. (20 Nm) 0810LM16x1.5W/F 1930 lb.-ft. (40 Nm) 1012LM18x1.5W/F 2237 lb.-ft. (50 Nm) 1215LM22x1.5W/F 2755 lb.-ft. (75 Nm) 1618LM26x1.5W/F 3263 lb.-ft. (85 Nm) 2022LM30x2W/F 3674 lb.-ft. (100 Nm) 2528LM36x2W/F 41133 lb.-ft. (180 Nm) 3235LM45x2W/F 55162 lb.-ft. (220 Nm)

flats Tighteningtorque lb.-ft.(Nm) 058SM16x1.5W/F 1930 lb.-ft. (40 Nm) 0610SM18x1.5W/F 2237 lb.-ft. (50 Nm) 0812SM20x1.5W/F 2444 lb.-ft. (60 Nm) 1014SM22x1.5W/F 2755 lb.-ft. (75 Nm) 1216SM24x1.5W/F 3066 lb.-ft. (90 Nm) 1620SM30x2W/F 3674 lb.-ft. (100 Nm) 2025SM36x2W/F 41133 lb.-ft. (180 Nm) 2530SM42x2W/F 50199 lb.-ft. (270 Nm) 3238SM52x2W/F 60295 lb.-ft. (400 Nm)

Screwconnectionswithvarioussealsforhydraulicapplications(lightapplication)

Screw connections with various seals for hydraulic applications (heavy application)

Torque tolerance: – 10%; counter material: steel/aluminium

Specifications PrintedinU.S.A.2-7918279/AP0508

Thread

pipe

and

Non-return valve with elastic seal lb.-ft. (Nm) Identification aid outside Ø in. (mm) Sealing washer lb.-ft. (Nm) Elastic seal lb.-ft. (Nm) O-ring lb.-ft. (Nm) M10x1.07 (9)13 (18)11 (15)13 (18)0.4 in. (10) M12x1.515 (20)18 (25)18 (25)18 (25)0.5 in. (12) M14x1.526 (35)33 (45)26 (35)26 (35)0.6 in. (14) M16x1.533 (45)41 (55)30 (40)37 (50)0.6 in. (16) M18x1.541 (55)52 (70)33 (45)52 (70)0.7 in. (18) M22x1.548 (65)92 (125)44 (60)92 (125)0.9 in. (22) M27x2.066 (90)133 (180)74 (100)107 (145)1.0 in. (27) M33x2.0111 (150)229 (310)118 (160)155 (210)1.3 in. (33) M42x2.0177 (240)332 (450)155 (210)266 (360)1.7 in. (42) M48x2.0214 (290)398 (540)192 (260)398 (540)1.9 in. (48) G1/8A7 (9)13 (18)11 (15)13 (18)0.4 in. (9.73) G1/4A26 (35)26 (35)22 (30)26 (35)0.5 in. (13.16) G3/8A33 (45)52 (70)33 (45)37 (50)0.7 in. (16.66) G1/2A48 (65)66 (90)41 (55)48 (65)0.8 in. (20.96) G3/4A66 (90)133 (180)74 (100)103 (140)1.0 in. (26.44) G1A111 (150)229 (310)118 (160)140 (190)1.3 in. (33.25) G1 1/4A177 (240)332 (450)155 (210)266 (360)1.6 in. (41.91) G1 1/2A214 (290)398 (540)266 (360)398 (540)1.9 in. (47.80)

Straight

fitting with thread

screw plug (GE)

Thread Straight pipe fitting with thread and screw plug Non-return valve with elastic seal lb.-ft. (Nm) Identification aid outside Ø in. (mm) Sealing washer lb.-ft. (Nm) Elastic seal lb.-ft. (Nm) O-ring lb.-ft. (Nm) M12X1.515 (20)26 (35)26 (35)26 (35)0.5 in. (12) M14X1.526 (35)41 (55)33 (45)33 (45)0.6 in. (14) M16X1.533 (45)52 (70)41 (55)41 (55)0.6 in. (16) M18X1.541 (55)66 (90)52 (70)52 (70)0.7 in. (18) M20X1.541 (55)92 (125)59 (80)74 (100)0.8 in. (20) M22X1.548 (65)100 (135)74 (100)92 (125)0.9 in. (22) M27X2.066 (90)133 (180)125 (170)100 (135)1.0 in. (27) M33X2.0111 (150)229 (310)229 (310)155 (210)1.3 in. (33) M42X2.0177 (240)332 (450)243 (330)266 (360)1.7 in. (42) M48X2.0214 (290)398 (540)310 (420)398 (540)1.9 in. (48) G1/8A26 (35)41 (55)33 (45)33 (45)0.5 in. (13.16) G1/4A33 (45)59 (80)44 (60)44 (60)0.7 in. (16.66) G3/8A48 (65)85 (115)55 (75)74 (100)0.8 in. (20.96) G1/2A66 (90)133 (180)125 (170)145 (107)1.0 in. (26.44) G3/4A111 (150)229 (310)229 (310)260 (192)1.3 in. (33.25) G1A177 (240)332 (450)243 (330)266 (360)1.6 in. (41.91) G1 1/4A214 (290)398 (540)310 (420)398 (540)1.9 in. (47.80)

Tighteningtorquesforhigh-resistancescrewconnections

Withcoarse-pitchthread,torquesinlb.-ft.(Nm)

Specifications 918279/AP05082-8PrintedinU.S.A

DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head. All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures. DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head. All values subject to a friction coefficient of µ = 0.12 and are to be

used as approximate figures.

Thread

931,DIN933,etc. Screwsaccordingto DIN7984 Grade7 (8.8) Grade8 (10.9) Grade10 (12.9) Grade7 (8.8) Grade8 (10.9) M54.0 (5.5)6 (8)7 (10)4 (5)5 (7) M67 (10)10 (14)13 (17)6.3 (8.5)9 (12) M818 (25)26 (35)31 (42)15 (20)22 (30) M1033 (45)48 (65)59 (80)30 (40)44 (59) M1264 (87)81 (110)108 (147)51 (69)74 (100) M14100 (135)133 (180)170 (230)81 (110)118 (160) M16155 (210)203 (275)258 (350)125 (170)184 (250) M18207 (280)302 (410)354 (480)181 (245)254 (345) M20302 (410)420 (570)509 (690)251 (340)361 (490) M22406 (550)575 (780)686 (930)339 (460)487 (660) M24524 (710)738 (1000)878 (1190)435 (590)620 (840) M27767 (1040)1092 (1480)1305 (1770)642 (870)922 (1250) M301047 (1420)1482 (2010)1770 (2400)885 (1200)1254 (1700)

ScrewsaccordingtoDIN912,DIN

Thread ScrewsaccordingtoDIN912,DIN 931,DIN933,etc. Screwsaccordingto DIN7984 Grade7 (8.8) Grade8 (10.9) Grade10 (12.9) Grade7 (8.8) Grade8 (10.9) M8x1.018 (25)27 (37)32 (43)16 (22)24 (32) M10x1.037 (50)55 (75)65 (88)32 (43)48 (65) M10x1.2536 (49)52 (71)61 (83)31 (42)46 (62) M12x1.2564 (87)96 (130)111 (150)55 (75)81 (110) M12x1.561 (83)92 (125)107 (145)53 (72)77 (105) M14x1.5100 (135)148 (200)173 (235)89 (120)129 (175) M16x1.5155 (210)229 (310)266 (360)133 (180)195 (265) M18x1.5232 (315)332 (450)391 (530)199 (270)284 (385) M20x1.5325 (440)465 (630)538 (730)277 (375)391 (530) M22x1.5435 (590)620 (840)723 (980)369 (500)524 (710) M24x2.0546 (740)789 (1070)922 (1250)465 (630)664 (900) M27x2.0811 (1100)1143 (1550)1328 (1800)679 (920)959 (1300) M30x2.01106 (1500)1586 (2150)1844 (2500)959 (1300)1364 (1850)

Withfine-pitchthread,torquesinlb.-ft.(Nm)

2.12Dimensions

Specifications PrintedinU.S.A.2-9918279/AP0508

7’ 11" (2413 mm) 6 ' 7" (2021 mm) 7' 4 "(2242 mm) 7 ' 11 " (2413 mm) 5 ' 2 " (1575 mm) 3 ' 2 " (970 mm) 13’11-1/2"(4263mm) 9' 3" (2827mm) 2' 6 " (759 mm) (300 mm) 1 ' 0 " (300 mm) 1' 0" 11-3/4 " (299 mm) 5 ' 2 " (1570 mm) (300 mm) 1 ' 0" (533 mm) 1 ' 9" (764 mm) 2 ' 6 " 75° 50° R 2 ' 6" (759 mm) R 5' 5 " (1641 mm) Service weight with cab/canopy 5886/5681 lbs. (2670/2577 kg) Height 7' 11" (2413 mm) Width 5' 2" (1575 mm) Transport length 13’ 11-1/2" (4255 mm) Max. digging depth 9' 0" (2743 mm) Dipper length 4' 1" (1250 mm) Max. digging depth 9' 0" (2744 mm) Max. vertical digging depth 7' 1" (2152 mm) Max. digging height 14' 1" (4299 mm) Max. dump height 9' 9" (2974 mm) Max. digging radius 15' 4" (4681 mm) Max. breakout force at bucket tooth 5057 lbf. (22.5 kN) Max. tearout force 4923 lbf. (21.8 kN) Min. tail end slewing radius 2' 6" (760 mm) Max. tail end lateral projection (90° rotation of upper carriage) 0' 0" (0 mm) Max. boom displacement to bucket center (right side) 1' 9" (533 mm) Max. boom displacement to bucket center (left side) 2' 6" (764 mm)

2.13Liftcapacitytable

Maximum admissible load on extended dipper arm

AReach from live ring center

BLoad hook height

*Lift capacity limited by hydraulics

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

Dozer blade in driving direction

Dozer blade 90° to driving direction

If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment weight.

Calculation basis: According to ISO 10567.

The track excavator's lift capacity is restricted by the settings of the pressure limiting valves and the hydraulic system's stabilizing features. Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.

Specifications 918279/AP05082-10PrintedinU.S.A

11' 6" (3.5 m) 9' 9" (3.0 m) 8' 2" (2.5 m) 9' 9" (3.0 m) *1014 (*460) 893 (405) *937 (*425) *937 (*425) 6' 6" (2.0 m) *992 (*450) 683 (310) *992 (*450) 838 (380) *1036 (*470) *1036 (*470) 3' 3" (1.0 m) *1014 (*460) 628 (285) *1157 (*525) 805 (365) *1367 (*620) 1003 (455) *1764 (*800) 1301 (590) 0' 0" (0.0 m) *1036 (*470) 650 (295) *1279 (*580) 772 (350) *1587 (*720) 948 (430) *2105 (*955) 1223 (555) -3' 3" (-1.0 m) *1058 (*480) 783 (355) *1047 (*475) 772 (350) *1433 (*650) 948 (430) *1885 (*855) 1223 (555)

Fig. 2-3:Lift capacity table

MAX B A

2.14Liftcapacitytablewithoptionalcounterweight

Maximum admissible load on extended dipper arm

AReach from live ring center

BLoad hook height

*Lift capacity limited by hydraulics

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

Dozer blade in driving direction

Dozer blade 90° to driving direction

If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket or attachment weight.

Calculation basis: According to ISO 10567.

Specifications PrintedinU.S.A.2-11918279/AP0508

11' 6" (3.5 m) 9' 9" (3.0 m) 8' 2" (2.5 m) 9' 9" (3.0 m) *1014 (*460) 994 (451) *937 (*425) *937 (*425) 6' 6" (2.0 m) *992 (*450) 767 (348) *992 (*450) 935 (424) *1036 (*470) *1036 (*470) 3' 3" (1.0 m) *1014 (*460) 708 (321) *1157 (*525) 902 (409) *1367 (*620) 1120 (508) *1764 (*800) 1451 (658) 0' 0" (0.0 m) *1036 (*470) 732 (332) *1279 (*580) 869 (394) *1587 (*720) 1065 (483) *2105 (*955) 1373 (623) -3' 3" (-1.0 m) *1058 (*480) 880 (399) *1268 (*575) 869 (394) *1433 (*650) 1065 (483) *1885 (*855) 1373 (623)

Fig. 2-4:Lift capacity table (added counterweight)

MAX B A

2.15Bucketgeometry

EPin diameter1-1/2 in. (40 mm)

FBucket dipper width5-1/2 in. (140 mm)

LPin distance to bucket mount7 in. (180 mm)

Bucket Dipper arm

Bucket

Specifications 918279/AP05082-12PrintedinU.S.A

Maintenance

3Maintenance

3.1Fluidsandlubricants

RadiatorCoolant

96 (EU) ISO 8217 DMX (International) BS 2869 – A1 (GB) Depending on outside temperatures

BS 2869 – A2 (GB)

Soft water + antifreeze ASTM D4985

Distilled water + antifreeze ASTM D4985

Washer systemCleaning agentWater + antifreeze

1.The capacities indicated are approximate values; the oil level check alone is relevant for the correct oil level. Capacities indicated are not system fills.

2.According to DIN 51502; API CD, CF, CF-4, CI-4; ACEA E3, E4, E5.

3.Hypoid gearbox oil based on basic mineral oil (according to DIN 51502), (API GL-4, GL5).

4.According to DIN 51524 section 3.

Summer or winter diesel fuel

Year-round About 4.75 qts. (4.5 L)

Year-round1.2 qts. (1.2 L)

5.Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10 g/mg, according to DIN 51524, section 3, HVLP, HEES.

6.KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive.

7.KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease.

8.KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive.

9.Standard acid-proof grease.

Maintenance PrintedinU.S.A.3-1918279/AP0508

Component/applicationEngine/machinefluidSpecificationSeason/temperatureCapacities 1 Diesel engine Engine oil2 SAE10W-40 -4° F (-20° C) +104° F (+40° C) About 3.5 qts. (3.4 L) Travelling drive Gearbox oil3 SAE80W-90 Year-round About 20 oz. (0.6 L) each Hydraulic oil tank Hydraulic oil4 HVLP46 Year-round7 gals. (26 L) Biodegradable oil5

FINA

Grease Roller

KF2K-25

Year-roundAs required Open gear7

KP2N-20

Year-roundAs required Grease nipples Multipurpose grease8 KF2K-25

Year-roundAs required Battery terminals Acid-proof grease9 FINA Marson L2 Year-roundAs required Fuel tankDiesel fuel 2-D ASTM D975

(USA) About 9.5 gals. (36 L) 1-D ASTM D975

PANOLIN HLP Synth 46

BIOHYDRAN SE 46

BIOHYD SE-46

and friction bearings6

lithium soap

(live ring gears)

calcium sulfonate complex

lithium soap

– 94

– 94 (USA)

590:

Oil grades for the diesel engine, depending on temperature.

Additionaloilchangeandfilterreplacement(hydraulics)

CAUTION!

An additional oil change and filter replacement may be required depending on how the machine is used. Failure to observe these replacement intervals can cause damage to hydraulic components.

☞ Observe the following intervals

IMPORTANT!

Please refer to the maintenance schedule on page 3-5 for additional maintenance work.

Maintenance 918279/AP05083-2PrintedinU.S.A

EngineoilgradeAmbienttemperature(C°) °C -20-15-10-50510152025303540 SAE10W SAE20W SAE10W-30 API CD, CF, CF-4, CI-4 ACEA E3, E4, E5 SAE10W-40 SAE15W-40 SAE20 SAE30 SAE40 °F -4514233241505968778695104 ApplicationHydraulicoil (servicehours) Hydraulicoilfilterinsert (servicehours) Normal work (excavation work)Every 1000 s/h Replace the first time after 50 s/h, then every 1000 s/h Percentage of hammer work 20%Every 800 s/h 300 s/h 40%Every 400 s/h 60%Every 300 s/h 100 s/h Over 80%Every 200 s/h

3.2Maintenancelabel

Explanationofsymbolsonthemaintenancelabel

SymbolAssemblyExplanation

GeneralVisual check

GeneralGrease instructions

Fuel systemDrain condensation water

Fuel systemReplace the fuel filter, clean the fuel pre–filter

RadiatorCheck the coolant level

RadiatorDrain and fill coolant

EngineCheck valve tip clearance. Adjust if necessary

EngineCheck the engine oil level

EngineChange engine oil

EngineReplace the oil filter

EngineCheck V-belt tension

Travel driveChange oil

Travel driveCheck oil level

UndercarriageCheck track tension

Hydraulic systemCheck oil level

Hydraulic systemChange hydraulic oil

Hydraulic systemReplace the hydraulic oil filter, replace the breather filter

Maintenance PrintedinU.S.A.3-3918279/AP0508

Maintenance 918279/AP05083-4PrintedinU.S.A SymbolAssemblyExplanation Radiator finsClean Heating, air conditioning Replace the air filter 1000h 500h 500h 1000h D D 1000173185 API CF 1000h 10h 50h 3 2 4 D 1 D 1 1 3 50h 10h 1 3 1 -34°C/-29°F ASTMD4985 50h 10h 4/6 10h 500h 250h 1000h 1 SAE 10W-40 ASTMD6210 KF2K-25 Li-soap SAE 80W90 API GL5 ISO6743/4 DIN51524-3 HVLP46 KF2K-25 Li-soap KF2K-25 Li-soap 50h 500h 250h 250h 250h KF2K-20 Ca-sulfonat complex

3.3Maintenanceschedule

1.After emptying the tank, water must be removed and air must be purged from the fuel system before use. See “Fuel shut-off valve and water separator” on page3-11 and “Bleeding the fuel system” on page3-10.

2.Check after first 50 hrs. every 500 hrs. thereafter.

Maintenance PrintedinU.S.A.3-5918279/AP0508

Check,cleanorinspect ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Engine oil levelxx Engine coolant levelxx Hydraulic oil levelxx Gearbox oil levelxx Clean drain holes in cab/canopyxx Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary. xx Check cooling system, heating and hoses for leaks and pressure (visual check) xx Replace cab air filter for heating and air conditioning xx Air filter (damage)xx Inspect water separator prefilter: drain water xx Clean water separatorxx Check V-belt condition and tensionxx Check exhaust system for damagexx Check engine valve clearance, set if necessary xx Fuel injection pump, injection and pressure, injection nozzles and valves xx Check and adjust injection timingxx Empty diesel fuel tank1 xx Clean batteryxx Check alternator, starter and electrical connections, bearing play and function xx Pre–heating system and electrical connections xx Air filter restriction gaugexx Pressure check or primary pressure relief valves2 xxx Check tracks for cracks or cutsxx Check track tension — tighten if necessary xx Cab tilt lock/support components2 xxx Check cylinders piston rods for damagexx Check fasteners for tightness2 xxx Pin lock (dipper arm and attachment)xx Hydraulic line clampsxx Check indicator lights for correct function2 xxx Cab tilt lock/support components2 xxx

Maintenance

Check,cleanorinspect

Fluidandfilterchanges

Maintenance 918279/AP05083-6PrintedinU.S.A

(continued)

Functionalcheck Leakagecheck ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Bearing play on tread rollers, track carrier rollers and front idlers xx Couplings, dirt buildup on hydraulic system dust caps xx Insulating mats in the engine compartmentxx Grease central lubrication system pointxx Warning decals and Operator’s Manual in place xx Engine cover gas strutxx ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Engine oil x1 xxx Engine oil filter x1 xx Fuel filter x2 xx Air filter element when indicator light comes on x Engine coolantxx Hydraulic oil filter insert x2 xx Hydraulic oilxx Breather-hydraulic oil tankxx Gearbox oil x3 xx 1.Change after first 50 hrs; every 250 hrs. thereafter.

after first 50 hrs; every 500 hrs. thereafter. 3.Change after first 50 hrs; every 1000 hrs. thereafter. ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Lights, signaling system, audible warning system xx Heater functionxx ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Visual check for tightness, leaking, chafing of flexible lines and screw connections xx Engine and hydraulic system componentsxx Cooling and heating circuit componentsx x Traveling drive componentsx x Maintenance

2.Change

Maintenance PrintedinU.S.A.3-7918279/AP0508 Dailylubrication ServiceActivityDailyEvery50 Hours Every250 Hours Every500 Hours Every1000HoursCustomerDealer Dozer bladexx Swiveling consolexx Boomxx Dipper armxx Attachmentsxx Chassis (front of undercarriage)xx Maintenance

3.4Servicepackage

3.5Introduction

Operational readiness and the service life of the machines depends heavily upon maintenance.

It is therefore in the interest of the machine owner to carry out the prescribed maintenance. Before performing service and maintenance, always read, understand and follow the instructions given in:

• The “Safety” chapter in the Operator's Manual.

• The Operator's Manuals of the attachments. Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in strong wind.

Dirt may be blown away and cause severe injuries when using compressed air. Always wear protective goggles, masks and clothing.

Daily service and maintenance work, and maintenance according to the maintenance plan must be carried out by a specifically trained person. All other maintenance must be carried out by trained and qualified staff only.

The maintenance plans indicate when maintenance described in this manual must be performed (– see Maintenance schedule on page3-5).

918279/AP05083-8PrintedinU.S.A Maintenance

1Servicepackage(500servicehours) 178677 1 ➥ Engine oil filter 206299 1 ➥ Fuel filter insert 186340 1 ➥ Water separator element 206912 1 ➥ O-ring for fuel filter 165111 1 ➥ Return filter insert 206303 1 ➥ Air filter insert (outside) 206304 1 ➥ Air filter insert (inside) 206249 1 ➥ Sealing ring for oil drain plug 206227 1 ➥ Cylinder head cover gasket 177664 1 ➥ Seal for diesel fuel filter housing 177659 1 ➥ O-ring Maintenance

3.6Fuelsystem

Specificsafetyinstructions

• When handling fuel, there is a high risk of fire.

• Never work on the fuel system in the vicinity of open flames or sparks.

• DO NOT smoke when working on the fuel system or refueling.

• Before refueling, turn off the engine and remove the ignition key.

• Do not refuel in an enclosed area.

• Wipe up fuel spills immediately.

• Keep the machine clean to reduce the risk of fire.

Refueling

Filler inlet A for the fuel tank is located behind the cab, on the left in driving direction.

DANGER!

All work involving fuel carries an increased Riskoffireandpoisoning.

☞ DO NOT refuel in an enclosed room.

☞ Never complete work on the fuel system in the vicinity of open flames or sparks.

Environment!

When draining fuel from the fuel system, collect the fuel as it drains and dispose of it according to environmental laws.

IMPORTANT!

DO NOT run the fuel tank completely empty. Otherwise, air is drawn into the fuel system. This requires bleeding the fuel system. – see Bleeding the fuel system on page3-10.

IMPORTANT!

Fill up the tank with the correct fuel type at the end of each working day. – see Fluids and lubricants on page3-1 for the correct fuel type. A full tank and the correct fuel prevents condensation from forming in the fuel tank overnight. DO NOT fill the tank completely, but leave some space for the fuel to expand.

PrintedinU.S.A.3-9918279/AP0508 Maintenance

Fig. 3-1:Fuel filler inlet

StationaryfuelpumpsGeneral

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated. Even the smallest particles of dirt can cause:

• Increased engine wear.

• Malfunctions in the fuel system.

• Reduced effectiveness of the fuel filters.

Bleedingthefuelsystem

DANGER!

If draining fuel comes into contact with hot engine parts or the exhaust system, there is an increased Riskofburns.

☞ Never bleed the fuel system if the engine is hot.

Bleed the fuel system in the following cases:

• After removing and replacing the fuel filter, water separator or the fuel lines.

• After running the fuel tank empty.

• After running the engine after it has been out of service for a long period of time.

☞ Bleed the fuel system as follows:

• Fill the fuel tank.

• Turn the ignition key to the first position.

• Wait about five minutes while the fuel system bleeds itself automatically.

• Start the engine.

If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:

• Turn off the engine.

• Bleed the fuel system again as described above.

• Have this checked by authorized service technicians.

918279/AP05083-10PrintedinU.S.A Maintenance

Emptyingthefueltank

DANGER!

If draining fuel comes into contact with hot engine parts or the exhaust system, there is an increased

Riskofburns.

☞ Never empty the fuel tank if the engine is hot.

Due to the formation of condensation in the fuel tank, empty the fuel tank every 500 hours as follows:

☞ Place a container with sufficient capacity underneath the drain plug in the chassis.

☞ Open the drain plug to drain the fuel.

☞ Check the fuel tank for contamination and clean if necessary.

☞ Replace the filter according to the maintenance specifications.

☞ Replace the drain plug.

☞ Fill the fuel tank.

☞ Bleed the fuel system – see Bleeding the fuel system on page3-10.

Dieselfuelspecification

Use only high-grade fuels.

GradeUse

• 2-D ASTM D975 – 94 USA

• 1-D ASTM D975 – 94

Fuelshut-offvalveandwaterseparator

If water is seen in the water separator bowl, or the indicator ring rises to position C, the separator needs to be drained.

☞ Twist the fuel shut-off valve B to the Off position as shown.

☞ Unscrew plug A.

➥ Wait until the indicator ring returns to the bottom of the water separator.

☞ Tighten plug A

☞ Twist the fuel shut-off valve B to the On position.

Environment!

Collect the water as it drains into a suitable container and dispose of it according to environmental laws.

PrintedinU.S.A.3-11918279/AP0508 Maintenance

Fig. 3-2:Fuel drain plug

A B C On Off

Fig. 3-3:Water separator

Replacingthefuelfilter

DANGER!

If draining fuel comes into contact with hot engine parts or the exhaust system, there is an increased

Riskofburns.

☞ Never replace the fuel filter if the engine is hot.

Environment!

Use a suitable container to collect the fuel as it drains and dispose of it in an environmentally friendly manner.

☞ Open the engine cover.

☞ Twist the fuel shut-off valve to the Off position.

☞ Unscrew the union nut.

☞ Remove the transparent housing.

☞ Replace the filter insert.

☞ Apply a thin coat of oil or diesel fuel to the housing sealing surface and replace the housing.

☞ Twist the fuel shut-off valve to the On position.

☞ Bleed the fuel system.

– see Bleeding the fuel system on page3-10.

☞ Check the filter for tightness after a short test run.

☞ Dispose of the old filter insert in an environmentally friendly manner.

918279/AP05083-12PrintedinU.S.A Maintenance

B On Off

Fig. 3-4:Fuel filter

3.7Enginelubricationsystem

IMPORTANT!

If the engine oil level is too low or if an oil change is overdue, this may cause Enginedamageorlossofoutput.

☞ Have the oil changed by an authorized workshop

– see Maintenance schedule on page3-5.

Checkingtheoillevel

IMPORTANT!

Check the oil level daily. It is recommended to check it before starting the engine. After turning off a warm engine, wait at least five minutes before checking.

• To check the engine oil, the machine must be on a level surface with the engine turned off.

• Turn off the engine and remove the ignition key.

• Fold the control lever base up.

• Let the engine cool down.

• Open the engine cover.

• Clean the area around the oil dipstick with a lint-free cloth.

• Remove the dipstick from the engine.

☞ Wipe it with a lint-free cloth.

☞ Push it back in as far as possible.

☞ Remove the dipstick and read the oil level.

☞ Add oil if required – see Adding engine oil on page3-14

PrintedinU.S.A.3-13918279/AP0508 Maintenance

A max min MAX min

Fig. 3-5:Checking the oil level

Addingengineoil

IMPORTANT!

Too much or incorrect engine oil may result in engine damage. For this reason:

☞ Do not add engine oil above the MAX mark of oil dipstick 3-6/A

☞ Use only the specified engine oil.

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner.

☞ Proceed as follows:

• Open the engine cover.

• Clean the area around oil filler cap B

• Open filler cap B and raise oil dipstick A slightly to allow any trapped air to escape.

• Add new oil. – see Engine capacities on page2-2. Crankcase capacity is 3.5 qts. (3.3 L). Do Not fill crankcase above the MAX mark on the dipstick.

• Wait about three minutes and Check the oil level – see Checking the oil level on page3-13.

• Add oil if necessary and check the oil level again.

• Replace and tighten the oil filler cap and dipstick.

• Completely remove all oil spills from the engine.

918279/AP05083-14PrintedinU.S.A Maintenance

OIL B A

Fig. 3-6:Oil dipstick and oil filler cap

Changingengineoilandfilter

DANGER!

Caution when draining hot engine oil –Riskofburns.

☞ Wear protective gloves.

OIL

☞ Use suitable tools.

Environment!

Use a suitable container to collect the engine oil as it drains and dispose of it in an environmentally friendly manner.

☞ Position the machine on a level surface. Run the engine until it is at operating temperature (oil temperature about 176 °F [80 °C]), then turn off the engine.

☞ Open the engine cover.

☞ Position a waste oil collection container under engine oil pan.

☞ Remove the drain plug from the oil pan and allow the oil to drain into the waste oil collection container.

☞ Dispose of waste engine oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste engine oil onto the ground or down a drain.

☞ Remove the oil filter A, using a filter wrench as necessary.

☞ Clean the filter housing surface. Put a film of clean oil on the filter gasket. Install the new filter with gasket and hand-tighten.

☞ Reinstall the drain plug.

☞ Clean the area around the oil filler cap.

☞ Remove the oil filler cap and raise the oil dipstick slightly to allow any trapped air to escape.

☞ Add new oil. – see Fluids and lubricants on page3-1 for the correct oil type. Crankcase capacity with filter is 3.5 qts. (3.3 L). DO NOT fill crankcase above the MAX mark on the dipstick.

☞ Replace and tighten the oil filler cap.

☞ Push the oil dipstick back in as far as possible.

☞ Wait about three minutes to allow the oil to run into the oil sump and check the oil level according to – see Checking the oil level on page3-13.

☞ Start the engine and let it run for several minutes. Watch the engine oil light on the control panel. The light should turn off after several seconds. If it does not, shut off the engine, determine the cause and fix the problem before restarting the engine.

☞ Stop the engine and check for leaks at the oil filter and oil drain plug.

PrintedinU.S.A.3-15918279/AP0508

Maintenance

176°F (80°C)

Fig. 3-7:Optimum engine oil temperature

Fig. 3-8:Engine oil filter position

Fig. 3-9:Unscrewing the engine oil filter

Fig. 3-10:Cleaning the filter head and oiling the gasket

Fig. 3-11:Tightening the filter cartridge

3.8Coolingsystem

Specificsafetyinstructions

The radiator is located in the engine compartment in front of the engine. The expansion tank for the coolant is also located in the engine compartment, to the right of the radiator.

• Dirt on the radiator fins reduces the radiator’s heat dissipation capacity. To avoid this:

☞ Clean the outside of the radiator at regular intervals. Use oil-free compressed air (29 psi [2 bar] max.) to clean. Maintain a certain distance to the radiator to avoid damage to the radiator fins. – see Maintenance schedule on page3-5.

☞ In dusty or dirty work conditions, clean more frequently than indicated in the maintenance plan.

• Insufficient coolant level reduces the heat dissipation capacity as well and can lead to engine damage. Because of this:

☞ Check the coolant level at regular intervals. – see Maintenance schedule on page35.

☞ If coolant must be added frequently, check the cooling system for leaks and/or contact your dealer.

☞ Never add cold water/coolant if the engine is warm.

☞ After filling the expansion tank:

• Test run the engine.

• Turn off the engine.

• Let the engine cool down.

• Check the coolant level again.

IMPORTANT!

The use of the wrong coolant can destroy the engine and the cooler. Therefore:

• Use the correct type of coolant – see Fluids and lubricants on page3-1.

• Add enough antifreeze compound to the coolant, but never more than 50%. If possible use brand-name antifreeze compounds with anti–corrosion additives.

• Follow the – see Coolant compound table on page2-5.

• DO NOT use cooler cleaning compounds if an antifreeze compound has been added to the coolant. This causes sludge to form, which can damage the engine.

Environment!

Use a suitable container to collect the coolant as it drains and dispose of it according to environmental laws.

918279/AP05083-16PrintedinU.S.A Maintenance

Checking/addingcoolant

DANGER!

Never open the coolant tank and never drain coolant if the engine is warm because the cooling system is under high pressure –

Riskofburns.

☞ Wait at least 15 minutes after turning off the engine.

☞ Wear protective gloves and clothing.

☞ Open filler cap B to the first notch and allow the pressure to escape.

☞ Make sure the coolant temperature is sufficiently low so you can touch the filler cap with your hands.

DANGER!

Antifreeze is flammable and poisonous.

Riskofaccidents.

☞ Keep away from flames.

☞ Avoid eye contact with antifreeze. If antifreeze comes into contact with the eyes, immediately rinse with clean water and seek medical assistance.

Checkingthecoolantlevel

☞ Proceed as follows:

• Park the machine on level ground.

• Turn off the engine.

• Fold up the control lever base.

• Remove the key and keep it with you.

• Let the engine and the coolant cool down.

• Open the engine cover.

• Check the coolant level on the transparent coolant tank A

☞ If the coolant level is below the LOW seam or if there is no coolant at the radiator's filler inlet:

• Fill the expansion reservoir to the FULL line.

NOTE:

Check the coolant level daily before starting the engine.

PrintedinU.S.A.3-17918279/AP0508 Maintenance

Fig. 3-12:Radiator filler cap

FULL LOW A

Fig. 4:Expansion tank for coolant

Drainingcoolant

Addingcoolant

After the engine has cooled down:

☞ Open the radiator filler cap to the first notch and allow the pressure to fully escape.

☞ Remove the filler cap B

☞ Add coolant up to the lower edge of the filler inlet (radiator).

☞ Close filler cap B

☞ Start the engine and let it warm up for about 5 – 10 minutes.

☞ Turn off the engine.

☞ Remove the key and keep it with you.

☞ Let the engine cool down.

☞ Check the coolant level again.

➥ The coolant level must be between the LOWandFULL expansion tank A seams.

☞ If necessary, add coolant and repeat the procedure until the coolant level remains constant.

IMPORTANT!

Service the coolant/antifreeze annually before the cold season sets in.

DANGER!

Never open the coolant tank or drain coolant if the engine is warm, because the cooling system is under high pressure –Riskofburns.

☞ Wait at least 10 minutes after turning off the engine.

☞ Wear protective gloves and clothing.

☞ Open the radiator filler cap B to the first notch and allow the pressure to escape.

After the engine has cooled down:

☞ Release overpressure in the radiator.

☞ Open the radiator filler cap to the first notch and allow the pressure to fully escape.

☞ Open filler cap B

☞ Open the radiator drain plug at the bottom of the radiator and drain the coolant.

☞ Close the drain plug.

➥ Add coolant to the radiator.

–seesection3.1 Fluids and lubricants on page3-1.

–seesection2.9 Coolant compound table on page2-5.

☞ Check the coolant level according to – see Checking the coolant level on page3-17

☞ Close the filler cap.

918279/AP05083-18PrintedinU.S.A Maintenance

B A B

Fig. 3-1:Filling up coolant Fig. 3-2:Filling up coolant

3.9Airfilter

The air filter is located in the engine compartment, on the right side of the machine.

IMPORTANT!

The filter cartridge will be damaged if it is washed or brushed out. To avoid premature engine wear:

☞ DO NOT clean the filter cartridge.

☞ Replace the filter cartridge when the indicator comes on.

☞ Never reuse a damaged filter cartridge.

☞ Ensure cleanliness when replacing the filter cartridge.

Air filter indicator 49 (see page 1-9) monitors the filter cartridge.

☞ Replace outer filter B and inner filter C:

• If the air filter indicator 49 in the round display comes on.

• According to the maintenance schedule.

Replace the air filter according to the maintenance schedule (see page 3-5) or if the fouling indicator A has dropped to “Service.”

IMPORTANT!

For applicationsinanespeciallydustyenvironment, the air filter is fitted with an extra inner filter C. DO NOT clean inner filter C

IMPORTANT!

Filter cartridges degrade prematurely when you use the machine in acidic air for longer periods of time. Acidic air is present, for example, in acid production facilities, steel and aluminium mills, chemical plants and other non-ferrous metal plants.

☞ Replace outer filter B and inner filter C at the latest after 50 hours.

General instructions for air filter maintenance:

• Store filters in their original packaging and in a dry place.

• DO NOT knock the filter against other objects as you install it.

• Check air filter attachments, air intake hoses and air filters for damage, and immediately repair or replace if necessary.

• Check the screws at the induction manifold and the clamps for tightness.

• Check the function of the dust valve, replace if necessary.

PrintedinU.S.A.3-19918279/AP0508 Maintenance

Fig. 3-3:Indicator

Fig. 3-4:Outer Filter

Fig. 3-5:Inner Filter

Replacingthefilter

• Replace outside filter B as follows:

☞ Turn off the engine.

☞ Remove the key and carry it with you.

☞ Let the engine cool down.

☞ Open the engine cover.

☞ Remove dirt and dust from the air filter and the area around the air filter.

☞ Turn the housing cap A to the left.

☞ Remove the housing cap A

☞ Carefully remove outside filter B with slight turning movements.

☞ Makesure all dirt (dust) inside the upper and lower housing sections (E and A), including dust valve D, has been removed.

☞ Clean the parts with a clean lint-free cloth, DO NOT use compressed air.

☞ Check the air filter cartridges for damage; only install intact filters.

☞ Carefully insert the new outside filter B in the upper housing section E.

☞ Replace the housing cap A and make sure it is properly seated.

☞ Turn the housing cap A to the right to secure it in place.

• Replace inside filter C as follows:

☞ Turn off the engine.

☞ Remove the key and carry it with you.

☞ Let the engine cool down.

☞ Open the engine cover.

☞ Remove dirt and dust from the air filter and the area around the air filter.

☞ Turn the housing cap A to the left.

☞ Remove the housing cap A.

☞ Carefully remove outside filter B with slight turning movements.

☞ Carefully remove inside filter C.

☞ Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust from entering the engine.

☞ Makesure all dirt (dust) inside the upper and lower housing sections (E and A), including dust valve D, has been removed.

☞ Clean the parts with a clean lint-free cloth, do not use compressed air.

☞ Remove the cloth from the air supply.

☞ Check the air filter cartridges for damage, only install intact filters.

☞ Carefully insert the new inside filter C into the lower housing section A.

☞ Carefully insert the outside filter B into the upper housing section E

☞ Replace housing cap A and make sure it is properly seated.

☞ Turn the housing cap A to the right to secure it in place.

IMPORTANT!

Make sure dust valve D points down once it is installed.

918279/AP05083-20PrintedinU.S.A Maintenance

Fig. 3-6:Removing the lower housing section

D A B

Fig. 3-7:Removing the filter element

C E

Fig. 3-8:Replacing the inside filter

Functionalcheckofthedustvalveonceaweek

☞ Proceed as follows:

• Turn off the engine.

• Fold up the control lever base.

• Remove the key and keep it with you.

• Let the engine cool down.

• Open the engine cover.

• Squeeze the discharge slot of dust valve D

• Remove hardened dust by compressing the upper area of the valve.

☞ Clean the discharge slot if necessary.

PrintedinU.S.A.3-21918279/AP0508 Maintenance

Fig. 3-9:Air filter dust valve

3.10V-belt

CheckingV-belttension

DANGER!

Only check, tighten or replace the V-belt when the engine is turned off –Riskofpersonalinjury.

☞ Turn off the engine before carrying out inspection work in the engine compartment.

☞ Disconnect the battery.

☞ Let the engine cool down.

IMPORTANT!

Cracked and stretched V-belts cause engine damage.

☞ Replace the V-belt.

Check the V-belt every 10 hours (or daily if the machine is used for less than 10 hours per day) and tighten if necessary. Tighten new V-belts after approximately 15 minutes of running time.

• Check the V-belt tension as follows:

☞ Turn off the engine.

☞ Fold up the control lever base.

☞ Remove the key and keep it with you.

☞ Allow the engine to cool.

☞ Open the engine cover.

☞ Disconnect the battery using the battery disconnect switch.

☞ Carefully check V-belt 1 for damage, cracks or cuts.

☞ Replace the V-belt if it touches the base of the V-belt groove or pulley disks.

• If the V-belt is damaged:

☞ Replace the V-belt.

☞ Press with your thumb to check the deflection of the V-belt between the crankshaft disc and the fan wheel C. A new V-belt should have a deflection of 1/4 to 5/16 in. (6 to 8 mm); a used V-belt (after about five minutes running time) should have a deflection of 5/16 to 3/8 in. (7 to 9 mm). This deflection equals about 22 lbf (100 N).

☞ Tighten the V-belt if necessary.

☞ Connect the battery.

918279/AP05083-22PrintedinU.S.A Maintenance

1 About8mm 2

Fig. 3-10:Checking V-belt tension

TighteningtheV-belt

IMPORTANT!

V-belt over-tension, or misalignment, can damage the V-belt, the V-belt guide, the water pump bearing and the alternator. Do not allow oil, grease, or similar substances to contact the V-belt.

☞ Check V-belt tension – see Checking V-belt tension on page3-22.

• Tighten the V-belt as follows:

☞ Turn off the engine.

☞ Fold up the control lever base.

☞ Remove the key and keep it with you.

☞ Let the engine cool down.

☞ Open the engine cover.

☞ Disconnect the battery using the battery disconnect switch.

☞ Loosen the alternator adjustment bolt 3

☞ Use a suitable tool to push the alternator in the direction of arrow A until the V-belt is correctly tensioned (Fig. 3-10).

☞ Tighten the alternator adjustment bolt 3

☞ Check V-belt tension again and adjust it if necessary.

☞ Connect the battery.

☞ Close the engine cover.

PrintedinU.S.A.3-23918279/AP0508 Maintenance

A 4

Fig. 3-11:Retightening the V-belt

Maintenance

3.11Pressurechecks

General

Pilotcontrolpressurecheck

• Run the machine until it is warm before performing pressure checks. Hydraulic oil temperature:

122° F (50° C) min. (operating temperature)

• Pressure drop is checked by reducing engine speed from full throttle to idle speed while under constant load.

• Set the primary pressure limiting valves (PPLV) at full throttle.

• See “Specifications”. – see Hydraulic system on page2-2 for the pressure settings.

• Ensurethecleanlinessofallmeasuringpointsandports,micromeasuringlines andpressuregaugesthatareconnect edforcheckingpressure,becauseeven theslightesttracesofdirt,e.g.,agrainofsand,caneffectcircuitintegrityand causeleaks.

Checkingpilotcontrolpressure

☞ Connect a pressure gauge to measuring port MP 4 3-12/A.

☞ Move the control lever base (safety switch) to work position.

☞ Check and make a note of the pressure value.

Adjustingpressurereducingvalve4(PRV4)

☞ Adjust the pressure at the pressure reducing valve 4 (PLV4) 3-13/D at the pilot oil supply unit.

☞ Repeat the pilot control pressure check.

918279/AP05083-24PrintedinU.S.A

Fig. 3-12:Pilot control pressure measuring port

Fig. 3-13:Pressure reducing valve

Variable-displacementpumpP1pressurecheck

Hydraulic supply for boom, bucket and right side drive functions.

Checkingtheprimarypressurelimitingvalve1(PPLV1)

☞ Connect a pressure gauge to measuring port MP 1 3-14/1.

☞ Retract the boom cylinder or the bucket cylinder as far as it will go at full throttle.

☞ Check and make a note of the pressure value.

Checkingpressuredrop

☞ At full throttle, retract the boom cylinder or the bucket cylinder as far as it will go.

☞ Quickly reduce engine speed from full throttle to idle and record the pressure drop.

☞ Check and make a note of the pressure value.

➥ The pressure drop should not exceed the specified value by more than 10%. – see Hydraulic system on page2-2 for the pressure settings.

Settingtheprimarypressurelimitingvalve1(PPLV1)

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 1) 3-15/A on the main valve block.

☞ Loosen the locknut on the pressure limiting valve.

☞ Unscrew the pressure limiting valve until you can observe a pressure drop on the pressure gauge.

➥ It may be necessary to loosen the valve seat first.

☞ Adjust the pressure limiting valve and tighten the locknut.

☞ Repeat primary pressure limiting valve 1 and the pressure drop checks.

Alsocheckboomextension,bucketextension/retractionandthe rightsideforward/reversedrivefunctions.

PrintedinU.S.A.3-25918279/AP0508 Maintenance

Fig. 3-14:Measuring port P1

Fig. 3-15:Primary pressure limiting valve 1

Variable-displacementpumpP2pressurecheck

Hydraulic supply of dipper arm, left side drive and auxiliary hydraulics functions.

Checkingtheprimarypressurelimitingvalve2(PPLV2)

☞ Connect a pressure gauge to measuring port MP 2 3-16/2

☞ With the engine at full throttle, extend the dipper arm cylinder as far as it will go.

☞ Observe and record the pressure value.

Checkingpressuredrop

☞ With the engine at full throttle, extend the dipper arm cylinder as far as it will go.

☞ Quickly reduce engine speed from full throttle to idle and record the pressure drop.

☞ Observe and record the pressure value.

➥ The pressure drop should not exceed the specified value by more than 10%. – see Hydraulic system on page2-2 for the pressure settings.

Settingtheprimarypressurelimitingvalve2(PPLV2)

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 2) 3-17/B on the main valve block.

☞ Loosen the locknut on the pressure limiting valve.

☞ Unscrew the pressure limiting valve until you observe a pressure drop on the pressure gauge.

➥ It may be necessary to loosen the valve seat first.

☞ Adjust the pressure limiting valve and tighten the locknut.

☞ Repeat the primary pressure limiting valve 2 and the pressure drop checks. Alsocheckdipperarmretractionandtheleftsideforward/reversedrivefunctions.

Checkingtheauxiliaryhydraulicspressure.

NOTE:

Factory specifications for auxiliary hydraulics secondary valves may not be valid because the valves must be adapted to the attachment.

918279/AP05083-26PrintedinU.S.A Maintenance

Fig. 3-16:Measuring port P2

Fig. 3-17:Primary pressure limiting valve 2

GearpumpP3pressurecheck

Hydraulic supply for the dozer blade, auxiliary hydraulics, boom swivel, upper carriage rotation, optional 3rd control circuit.

Checkingtheprimarypressurelimitingvalve3(PPLV3)

☞ Connect a pressure gauge to measuring port MP 3 3-18/3

☞ With the engine at full throttle, extend the dozer blade cylinder as far as it will go.

☞ Observe and record the pressure value.

Checkingpressuredrop

☞ With the engine at full throttle, extend the dozer blade cylinder as far as it will go.

☞ Quickly reduce engine speed from full throttle to idle and record the pressure drop.

☞ Observe and record the pressure value.

➥ The pressure drop should not exceed the specified value by more than 10%. – see Hydraulic system on page2-2 for the pressure settings.

Settingtheprimarypressurelimitingvalve3(PPLV3)

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 3) 3-19/C on the main valve block.

☞ Loosen the locknut on the pressure limiting valve.

☞ Unscrew the pressure limiting valve until you observe a pressure drop on the pressure gauge.

➥ It may be necessary to loosen the valve seat first.

☞ Adjust the pressure limiting valve and tighten the locknut.

☞ Repeat the primary pressure limiting valve 3 and the pressure drop checks.

Alsocheckdozerbladeretraction,boomsw ivelanduppercarriagerotationfunctions.

Checkingtheauxiliaryhydraulicspressure

NOTE:

Factory specifications for auxiliary hydraulics secondary valves may not be valid because the valves must be adapted to the attachment.

PrintedinU.S.A.3-27918279/AP0508 Maintenance

Fig. 3-18:Measuring port P3

Fig. 3-19:Primary pressure limiting valve 3

Gearmotorsecondarypressurelimitingvalvepressurecheck

☞ Connect a pressure gauge to measuring port MP 3.

☞ With the engine at idle, place the bucket or the boom against the ground or the dozer blade, or drive against hydraulic resistance.

☞ Observe and record the pressure value.

Adjustingthesecondarypressurelimitingvalveonthegearmotor(atidlingspeed)

☞ With the engine at idle, adjust the pressure at the secondary pressure limiting valve on the gear motor.

☞ Loosen the locknut on the pressure limiting valve.

☞ Unscrew the pressure limiting valve until you observe a pressure drop on the pressure gauge.

➥ It may be necessary to loosen the valve seat first.

☞ Adjust the pressure limiting valve and tighten the locknut.

☞ Repeat the secondary pressure limiting valve check.

918279/AP05083-28PrintedinU.S.A Maintenance

Testportsoverview

4 12

Fig. 3-20:Secondary pressure limiting valve

3 Pos.Description 1Pump 1 test port MP 1 2Pump 2 test port MP 2 3Pump 3 test port MP 3 4Pilot oil supply unit measuring port MP 4

Fig. 3-21:Test ports

Pos.Description

PrintedinU.S.A.3-29918279/AP0508 Maintenance Primarypressurelimitingvalves

1Pump primary pressure limiting valve 1 PPLV 1 2Pump primary pressure limiting valve 2 PPLV 2 3Pump primary pressure limiting valve 3 PPLV 3 4Pressure reducing valve of pilot oil supply unit PRV 4 1 2 3 4

918279/AP05083-30PrintedinU.S.A Maintenance

3.4Testreport

Printed in U.S.A.3-31918279/AP0508 Maintenance ng

Pilotcontrol

Specifiedvalues1stmeasurement 2ndmeasEngineurement speedPressure psi(bar) JoystickANY Measuring port MP 4 (pump) Pressure limiting valve PLV 4 (pilot oil supply unit) Rated value435 -0/+58 (30 -0/+4) Pump1 FunctionMovementSymbolMeasuringportPressurelimitingvalveSpecifiedvalues1stmeasurement 2ndmeasEngineurement speedPressurepsi(bar) Boom UP Measuring port MP 1 (pump) Primary pressure limiting valve PPLV 1 (main valve block) max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) DOWN max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Bucket EXTEND max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) RETRACT max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Left side drive FORWARD max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) REVERSE max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Pump2 FunctionMovementSymbolMeasuringportPressurelimitingvalveSpecifiedvalues1stmeasurement 2ndmeasEngineurement speedPressurepsi(bar) Dipper Arm EXTEND Measuring port MP 2 (pump) Primary pressure limiting valve PPLV 2 (MVB) max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) RETRACT max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Maintenance

FunctionMovementSymbolMeasuringportPressurelimitingvalve

918279/AP05083-32Printed in U.S.A Maintenance Right side drive FORWARD Measuring port MP 2 (pump) Primary pressure limiting valve PPLV 2 (MVB) max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) REVERSE max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Auxiliary hydraulics A max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) B max.3263 ± 43.5 (225 ± 3) min.2930 ± 43.5 (202 ± 3) Pump3

Dozer blade UP Measuring port MP 3 (pump) Primary pressure limiting valve PPLV 3 (main valve block) max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29 (185 -4/+2) DOWN max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29 (185 -4/+2) Auxiliary hydraulics A (2) max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29

-4/+2) B (2) max.2988 -58/+29

-4/+2) min.2683 -58/+29 (185 -4/+2) Swivel boom LEFT max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29 (185 -4/+2) RIGHT max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29 (185 -4/+2)

control circuit (option) LEFT Measuring port MP 3 (pump) Primary

valve PPLV

(main valve block)

-4/+2) min.2683

-4/+2) RIGHT max.2988 -58/+29 (206 -4/+2) min.2683 -58/+29

-4/+2) Upper carriage rotation LEFT Measuring port MP 3 Secondary

valve SPLV (gear motor) max.2901 -58/+29

-4/+2) min.2610 -58/+29

-4/+2) RIGHT max.2901

-4/+2) min.2610 -58/+29

-4/+2)

FunctionMovementSymbolMeasuringportPressurelimitingvalveSpecifiedvalues1stmeasurement 2ndmeasEngineurement speedPressurepsi(bar)

(185

(206

3rd

pressure limiting

max.2988 -58/+29 (206

-58/+29 (185

(185

pressure limiting

(200

(180

-58/+29 (200

(180

3.4Testreport

3.5Hydraulicsystem

Specificsafetyinstructions

• All lines carrying hydraulic oil must be depressurized prior to any maintenance and repair work. To do this:

☞ Lower all hydraulically controlled attachments to the ground.

☞ Move both joysticks several times in all directions.

☞ Shut off the engine and return the ignition key to the "1" position.

• Fold up the control lever base.

WARNING!

Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries. Always consult a doctor immediately, even if the wound appears insignificant, because serious infection could set in.

IMPORTANT!

If the hydraulic oil in the sight glass (Fig. 3-2) is cloudy, this indicates that water or air has entered the hydraulic system. Water or air may cause damage to the hydraulic pumps.

☞ Oil or fuel flowing out of high pressure lines may cause fire or malfunctions, and severe injuries or damage to property. Stop work immediately if loose hydraulic connections or damaged hoses and lines are detected.

☞ Contact your dealer immediately.

• Replace the hose or line if any of the following problems are detected.

☞ Damaged or leaking hydraulic seals.

☞ Worn or torn shells or uncovered reinforcement branches.

☞ Shells expanded in several positions.

☞ Entangled or crushed movable parts.

☞ Debris jammed or stuck in protective layers.

IMPORTANT!

Insufficient, incorrect, or contaminated hydraulic oil presents –Riskofseveredamagetothehydraulicsystem.

☞ Take care to avoid contamination when servicing the machine.

☞ Always add hydraulic oil using a strainer or the return filter.

☞ Only use authorized oils of the same type – see Fluids and lubricants on page 3-1.

☞ Always add hydraulic oil before the level gets too low – see Adding hydraulic oil on page 3-35.

☞ If the hydraulic system is filled with biodegradable oil, then only add biodegradable oil of the same type, and follow the decal on the hydraulic oil tank.

☞ Contact customer service if the hydraulic system filter is contaminated with metal particles. Otherwise, damage may result.

Maintenance PrintedinU.S.A.3-33918279/AP0508

Maintenance

Environment!

Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of drained oil and used filters in an ecologically safe manner. Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil. Checkingthehydraulicoillevel

CAUTION!

Do not add oil if the oil level is above the FULL mark, otherwise the hydraulic system may be damaged and escaping oil may cause serious injuries.

☞ Check the hydraulic oil level each time the machine is put into operation or once a day.

• If the attachment is not positioned as shown:

☞ Start the engine and let it idle.

☞ Retract the bucket and boom cylinders; and lower the boom, the bucket and the dozer blade to the ground.

☞ Turn off the engine.

☞ Proceed as follows:

• Park the machine on level ground.

• Turn off the engine.

• Fold the control lever base up.

• Open the engine cover. Sight glass B is located at the rear right of the excavator below the fuse box.

• Check the oil level on sight glass B.

• The oil level should be at the middle of the sight glass.

•A yellowish color over the entire sight glass indicates overfilling. If the oil level is lower, add hydraulic oil.

The oil level changes according to the machine's operating temperature:

• Normal operation Between 122° and 194° F (50° and 90° C)

IMPORTANT!

In the upper part of the sight glass

Only measure the hydraulic system oil level after the machine reaches operating temperature.

Maintenance 918279/AP05083-34PrintedinU.S.A

Fig. 3-1:Parking the excavator

Fig. 3-2:Oil level indicator on the hydraulic oil tank MIN

B MAX MachineconditionTemperatureOillevel • Before taking into service Between 50° and 86° F (10° and 30° C)

In the lower part of the sight glass

Addinghydraulicoil

Do not add hydraulic oil unless the engine is turned off. Otherwise, hydraulic oil will run out of the filler opening on the hydraulic tank.

☞ Fill up as follows:

• Park the machine on level ground.

• Position the machine as shown in Fig. 3-1

☞ Retract the bucket and boom cylinders; lower the boom, the bucket and the dozer blade to the ground; and set the boom straight (offset cylinder).

• Turn off the engine.

• Fold the control lever base up.

• Clean the area around filler opening with a cloth.

• Open the breather valve.

• Add clean hydraulic oil through the strainer.

• Check the hydraulic oil level on sight glass B

• Add more oil if necessary and check again.

• Close the filler opening.

NOTE:

It is recommended to add oil through the return filter to avoid contaminating the hydraulic oil.

NOTE:

Only change the hydraulic oil when it is warm (about 122° F [50° C]). Retract all hydraulic cylinders before changing the oil.

Changinghydraulicoil

☞ Open the breather filter to release pressure.

☞ Open drain plug 3-5/B and let the oil drain into a container.

☞ Check the hydraulic oil tank for contamination and clean if necessary.

☞ Replace the filter according to the maintenance specifications.

☞ Replace and tighten the drain plug.

☞ Add clean hydraulic oil through the strainer

– see Adding hydraulic oil on page 3-35.

☞ Close the filler opening.

☞ Let the machine run at idle without load for a few minutes.

Maintenance PrintedinU.S.A.3-35918279/AP0508

Fig. 3-3:Hydraulic filler inlet Fig. 3-4:Return filter

Fig. 3-5:Hydraulic oil drain plug

Monitoringthehydraulicoilreturnfilter

Pressure switch A activates the red indicator 31 on the instrument panel which monitors the return filter.

The control pressure is set at 36 psi (2.5 bar) and cannot be modified. Thefilterelementmustbereplacedbyanauthorizeddealer:

• If indicator 31 comes on when the hydraulic oil is at operating temperature.

• After every 1000 service hours (annually).

In cold weather indicator 31 may come on immediately when the engine is started. This is caused by increased oil viscosity. In this case:

☞ Increase engine speed so that indicator 31 goes out.

Maintenance 918279/AP05083-36PrintedinU.S.A

Fig. 3-6:Hydraulic oil filter Indicator

Fig. 3-7:Return filter pressure switch

CheckinghydraulicpressurelinesSpecificsafetyinstructions

DANGER!

Use caution when checking hydraulic lines, especially when searching for leaks. Hydraulic oil escaping under high pressure can penetrate the skin and cause serious injuries

Riskofpersonalinjury.

☞ Always consult a doctor immediately, even if the wound seems insignificant – otherwise serious infections could set in.

☞ Always:

•Tighten leaking threaded fittings and hose connections only when the system is not under pressure.

•Never weld or solder damaged or leaking pressure lines and threaded connections. Replace damaged parts with new ones.

•Never search for leaks with your bare hands. Wear protective gloves and use paper or wood to check for minor leaks.

•Never use an open flame to inspect hydraulic lines or connections.

•Have damaged flexible lines replaced by an authorized dealer only.

• Leaks and damaged pressure lines must be repaired or replaced immediately by an authorized dealer, not only for safety reasons, but also for environmental reasons.

• Replace hydraulic hoses every six years from the date of manufacture, even if they do not appear to be damaged.

The date of manufacture is stamped on the hose at each hose connection. It is recommended that all relevant safety regulations be observed for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety.

Maintenance PrintedinU.S.A.3-37918279/AP0508

3.6Traveldrive

DANGER!

Immediately after turning off the engine:

•Hot engine components and hydraulic oil may cause burns.

•If the the travel drive circuit is under pressure, the oil or the plug may be blown out at high velocity if the plug is loosened.

Riskofinjuryandscalding.

☞ Wait until the engine has cooled before performing hydraulic system maintenance.

☞ Slowly open the breather valve to release hydraulic pressure.

Checkingtheoillevelandaddingoil

☞ Park the machine on firm, level ground.

☞ Place the machine so that filler plug A is at the top.

☞ Turn off the engine.

☞ Let the engine cool.

☞ Fold the control lever base up.

☞ Unscrew screws A and B with a suitable tool.

☞ A small quantity of oil must flow out of opening B

➥ If the oil does not flow out of opening B, add oil:

☞ Add oil through opening A,

➥ until a small quantity of oil flows out of opening B

☞ Replace and tighten screws A and B

☞ Move the machine a few yards (meters).

☞ Check the oil level again.

➥ If the oil level is not correct:

☞ Repeat the procedure.

Drainingoil

☞ Park the machine on firm, level ground.

☞ Position the machine so that filler plug B is at the bottom.

☞ Turn off the engine.

☞ Let the engine cool.

☞ Fold the control lever base up.

☞ Unscrew screws A and B with a suitable tool.

➥ Oil will drain out of opening B.

Environment!

Collect the oil into a suitable container and dispose of it in an environmentally friendly manner.

Maintenance 918279/AP05083-38PrintedinU.S.A

A B

Fig. 3-8:Checking the oil level

B A

Fig. 3-9:Draining oil

3.7Tracks

• Track wear varies according to work and ground conditions.

☞ We recommend checking track wear and tension daily.

☞ Park the machine on firm, level ground when performing maintenance.

Checkingtracktension

DANGER!

Working under the machine with the tracks off the ground and only supported by the attachment is extremely dangerous

Caution,danger.

☞ Firmly support the machine with chocks or suitable brackets.

Check track tension as follows:

☞ Park the machine on firm, level ground.

☞ Raise the excavator on one side with the boom and the dipper arm as shown in fig. 310.

☞ Slowly and carefully actuate the joysticks.

☞ Turn off the engine.

☞ Remove the key and carry it with you.

☞ Fold the control lever base up.

☞ Use suitable auxiliary means to support the machine.

• Standard play between the sliding block's shoulder and the contact area of the second support roller of the drive pinion is 3/4 — 1 in. (20 — 25 mm).

Tracktension

3/4 — 1 in. (20 — 25 mm)

☞ Set the tension if it is not in accordance with the rated value.

DANGER!

The grease fitting may be blown out due to the high grease pressure in the hydraulic cylinder.

Riskofpersonalinjury.

☞ Do not loosen and unscrew the grease fitting by more than one turn.

☞ Loosen no other component except the grease fitting.

☞ Keep your face away from the grease fitting connection.

➥ Contact your dealer if this does not reduce the tension of the rubber sliding block.

Maintenance PrintedinU.S.A.3-39918279/AP0508

Fig. 3-10:Raising the excavator Fig. 3-11:Measuring distance

IMPORTANT!

Excessive track tension causes severe damage to the cylinder and the track.

☞ Only tighten the tracks up to the prescribed distance.

Tighteningthetracks

☞ Inject grease with the grease gun through grease fitting A.

☞ Check that the tension is correct by starting the engine and letting it idle. Slowly move the machine forward and reverse and turn off the engine again.

☞ Check the track tension again.

➥ If it is not correct:

☞ Adjust again.

☞ If the track is still loose after injecting more grease, replace the track or the seal in the cylinder. Contact your dealer in this case.

Looseningthetracks

DANGER!

educingtension

Draining grease in any way different from the one described below is very risky and may cause damage to the machine or personal injury.

Riskofpersonalinjury.

☞ Place a suitable container underneath to collect the grease.

☞ Slowly open the grease fitting A by one turn to allow the grease to flow out.

➥ The grease flows out of the groove of the grease fitting.

☞ Tighten grease fitting A.

☞ Check that the tension is correct by starting the engine and let it idle. Slowly move the machine forward and reverse and turn the engine off again.

☞ Check the track tension again.

➥ If it is not correct:

☞ Adjust again.

Environment!

Dispose of collected grease in an environmentally friendly manner.

Maintenance 918279/AP05083-40PrintedinU.S.A

Fig. 3-12:Tightening the chains

Fig. 3-13:Draining grease

3.8Lubrication

Apply multi-purpose lithium grease with an MoS² additive to all lubrication points indicated. Dozerblade

☞ Apply grease to lubrication points A on the dozer blade cylinder.

☞ Apply grease to lubrication points B (on either side) on the dozer blade.

Lubricationpointsontheswivelconsole

☞ Apply grease to lubrication points C of the swivel console.

Maintenance PrintedinU.S.A.3-41918279/AP0508

A B C

Fig. 3-14:Lubrication points on the dozer blade Fig. 3-1:Lubrication points on the swivel console

Boomlubricationpoints

☞ Apply grease to lubrication points D on the boom.

Lubricationpointsonthedipperarm

☞ Apply grease to lubrication points E on the dipper arm.

Maintenance 918279/AP05083-42PrintedinU.S.A

Fig. 3-15:Boom lubrication points

Fig. 3-16:Lubrication points on the dipper arm

Lubricationstrip

Apply grease to the lubrication strip as follows:

☞ Lubrication point A for live ring ball bearing.

➥ Grease: BP Energrease MP-MG2.

☞ Lubrication point B for the offset cylinder.

IMPORTANT!

Apply grease to lubrication points A and B once a day.

A portable lamp can be connected to the lubrication strip's 12 V connection C

Maintenanceofattachments

IMPORTANT!

Correct maintenance and service is necessary for smooth and continuous operation, and for increased service life of the attachments. Please follow the lubrication and maintenance instructions in the attachment’s Operator's Manual.

Maintenance PrintedinU.S.A.3-43918279/AP0508

B A C

Fig. 3-17:Lubrication strip on the chassis

3.9Electricalsystem

Specificsafetyinstructions

DANGER!

Battery acid is highly caustic: Riskofacidburn.

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves. If acid is spilled:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water.

☞ Thoroughly wash any body part touched by the acid immediately with plenty of water and seek medical attention at once.

During charging in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Riskofexplosion.

☞ Avoid open flame and sparks in the vicinity of the battery, and do not smoke.

☞ Do not jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

☞ Always disconnect the negative cable (–) from the battery before starting repair work on the electrical system.

IMPORTANT!

Always disconnect the negative cable (–) from the battery before starting repair work on the electrical system. Use only 12V power sources. Higher voltages will damage the electrical components.

DO NOT interrupt jump-charging circuits at the battery terminals because of the danger of sparking.

Do not place tools/conductive items on the battery. A short circuit may result. When connecting the battery leads, make sure the poles +/– are not reversed; reversing the poles will damage the electrical components.

• Dispose of used batteries according to environmental regulations.

Maintenance 918279/AP05083-44PrintedinU.S.A

Regularservice/maintenance

Beforeoperatingthemachine

☞ Check:

– Light system.

– Signaling and warning system.

Weekly

☞ Check:

– Electrical fuses – see Fuse box on page 2-4.

– Cable and ground connections.

– Battery charge condition – see Battery on page 3-46.

– Condition of battery terminals.

Specificcomponentinstructions

Cables,bulbsandfuses

Always follow these instructions:

• Defective electrical system components must always be replaced by an authorized technician. The operator or other persons may change bulbs and fuses.

• Ensure good leads and fuses have good electrical contacts.

• Blown fuses indicate overloading or short circuits. Correct the problem before installing new fuses.

• Only use fuses with the specified load capacity (amperage) – see Fuse box on page 24.

IMPORTANT!

When welding on the machine, remove both cables from the battery and ground the welder to machine frame near the repair area.

Alternator

Always observe the following instructions:

• Only test run the engine with the battery connected.

• When connecting the battery, make sure the poles (+/–) are not reversed.

• Always disconnect the battery before completing welding work or if connecting a quick battery charger.

• Replace defective charge indicators immediately – see Instrument panel legend on page 1-10.

Maintenance PrintedinU.S.A.3-45918279/AP0508

DANGER!

Battery acid is highly caustic: Riskofacidburns.

When recharging and/or working near the battery:

☞ Always wear goggles and protective clothing with long sleeves. If acid is spilled:

☞ Thoroughly rinse all affected surfaces immediately with plenty of water.

☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of water and seek medical attention at once.

During charging in particular, but also during normal battery operation, an oxygen-hydrogen mixture is formed in the battery cells –

Riskofexplosion.

☞ Avoid open flames and sparks in the vicinity of the battery and do not smoke.

☞ Do not attempt to jump-start the machine if the battery is frozen or if the acid level is low. The battery may rupture or explode.

•Replace the battery immediately.

☞ Always disconnect the negative terminal (–) from the battery before starting repair work on the electrical system.

Battery A is located in the engine compartment on the right side.

Battery cables must be clean and tightly secured. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery-saver grease.

The battery is maintenance-free and requires no other service.

IMPORTANT!

Do not disconnect the battery while the engine is running.

Maintenance 918279/AP05083-46PrintedinU.S.A Battery

A+

Fig. 3-18:Battery

Jump-startingtheengine

IMPORTANT!

When jump-starting from another machine, be sure the second machine is not running while using the unstarted machine’s glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

Be very careful when jump-starting the machine. The booster battery must be 12-volt.

☞ Turn the ignition key on the machine with the discharged battery to the “P” position.

☞ Open the engine cover.

☞ Stop the engine of the machine with the booster battery.

☞ Connect one end of a jumper cable to the positive (+) terminal on the booster battery.

☞ Connect the other end of the same cable to the positive (+) terminal on the battery of the machine with the discharged battery.

☞ Connect one end of the second jumper cable to the negative (–) terminal on the booster battery.

☞ Connect the other end of the same cable to the frame of the machine with the discharged battery.

☞ Allow this discharge battery to charge for a few minutes.

☞ Start the engine of the machine with the discharged battery. Once the engine is running, remove the cable connected to the frame first. Disconnect the other cable from the positive (+) terminal on the battery disconnect switch. Remove the cables from the booster battery last.

IMPORTANT!

DO NOT allow the booster cable ends to touch when removing them from the batteries. Arcs and direct short circuits can cause severe damage to the electrical system.

Maintenance PrintedinU.S.A.3-47918279/AP0508

3.10Cab

☞ Check cab fastening hardware B for damage.

IMPORTANT!

Check the cab fastening hardware for tightness. Tighten with a suitable tool if necessary

– see General tightening torques on page 2-6.

Replacingthecabfilter

Fresh/recirculatedairfilter

Remove the ventilation grille in the cab to replace the filter. Make sure not to overstretch the cables of the fuse box as you tilt the grille. You can now see the filter mat.

Replacingthefilter:

☞ Remove the hardware securing the ventilation grille in the cab under the seat.

☞ Lift the floor mat and remove the access door in the cab floor.

☞ Remove the ventilation grille.

☞ Remove the existing cab filter from the frame in front of the heating unit.

☞ Insert a new cab filter.

☞ Replace the ventilation grille, the access door and the floor mat.

☞ Replace the ventilation grille hardware and tighten securely.

Maintenance 918279/AP05083-48PrintedinU.S.A

Fig. 3-19:Cab bearing Fig. 3-20:Cab filter

3.11Generalmaintenance Cleaning

Cleaning the machine is divided into three separate areas:

• Inside the cab.

• Machine exterior.

• Engine compartment.

The wrong cleaning equipment and agents can affect the safety of the machine and undermine the health of the persons cleaning the machine.

Generalinstructionsforallareas

Whenusingwashingsolvents

• Ensure adequate room ventilation.

• Wear suitable protective clothing.

• DO NOT use flammable liquids, such as gasoline or diesel fuel.

Whenusingcompressedair

• Work carefully.

• Wear goggles and protective clothing.

• DO NOT aim the compressed air at the skin or at other people.

• DO NOT use compressed air for cleaning your clothing.

Whenusingahigh-pressurecleanerorsteamjet

• Electric components and damping material must be covered and not directly exposed to the jet.

• Cover the vent filter on the hydraulic oil tank, the filler caps for fuel, hydraulic oil, etc.

• Protect the following components from moisture:

• Engine.

• Electric components (alternator, ignition system, etc).

• Control devices and seals.

• Air intake filters, etc.

Whenusingvolatileandeasilyflammableanti–corrosionagentsandsprays:

• Ensure adequate room ventilation.

• DO NOT use unprotected lights or open flames.

• DO NOT smoke.

Maintenance PrintedinU.S.A.3-49918279/AP0508

Insidethecab

Seatbelt

Exteriorofthemachine

Enginecompartment

CAUTION!

Never use high-pressure cleaners, steam jets or high-pressure water to clean inside the cab. Water under high pressure may:

• Penetrate into the electric system and cause short circuits.

• Damage seals and disable controls.

Use any of the following to clean the cab:

• Broom

• Vacuum cleaner

• Damp cloth

• Bristle brush

• Water with mild soap solution

• Only clean the seat belt (DO NOT disconnect the seat belt from the machine) by using a mild soap solution. DO NOT use chemical agents because they may destroy the fabric.

Use any of the following to clean the outside of the cab:

• High-pressure cleaner.

• Steam jet.

WARNING!

Only clean the engine after it is turned off and stopped –Riskofpersonalinjury.

☞ Turn off the engine before cleaning.

IMPORTANT!

When cleaning the engine with a water or steam jet:

☞ The engine must be cold.

☞ DO NOT point the jet directly at electrical sensors such as the oil pressure sender.

Any humidity penetrating these sensors causes them to fail and leads to engine damage.

Screwconnectionsandattachments

All screw connections must be checked regularly for tightness, even if they are not listed in the maintenance schedule.

Tighten loose connections immediately. Contact your dealer if necessary.

Pivotsandhinges

All mechanical pivot points on the machine (e.g., door hinges, joints) and fittings (e.g., door latches) must be lubricated regularly, even if they are not listed in the lubrication schedule.

Maintenance 918279/AP05083-50PrintedinU.S.A

4Engine 4.13TNV76-NNSengineoverview

Airintake

Oilfillerneck Cap

WaterpumpV-belt

Oilpressureswitch

Oildipstick

Fuelinjectionpump

Oilfillerneck

Engine PrintedinU.S.A.4-1918279/AP0508

Fuelfilter Engineoilfilter Fanblade

Engine

Tighteningbracket

Cylinder-headcover

V-belt

Engine 918279/AP05084-2PrintedinU.S.A

Alternator Starter Exhaust manifold

Engine PrintedinU.S.A.4-3918279/AP0508 4.2Fuelsystem B reatherline Fuel

pump Fuel

Re turn Feed Fillerline

Tank Fuel

injection

filter

inlet Water separator with stop cock

pump

4.3Checkingandadjustingvalvetipclearance

☞ Standard setting of valve tip clearance is possible:

➥ On a cold engine.

☞ Remove the cylinder-head cover.

☞ Turn the engine with a screwdriver (as in 4.7) until the cylinder reaches the top dead center of the compression cycle.

➥ Valve overlapping.

☞ Check valve tip clearance 4-2/A with a feeler gauge.

➥ Valve tip clearance:0 0.005 – 0.009 in. (.15 – 0.25 mm).

☞ Loosen locknut 4-2/C

☞ Set the valve tip clearance on the cylinder by turning set screw 4-2/B.

➥ Valve tip clearance:0 0.005 – 0.009 in. (.15 – 0.25 mm).

☞ Tighten locknut 4-2/C – see General tightening torques on page 2-6.

➥ Check the setting again with the feeler gauge.

☞ Repeat the procedure for each cylinder.

4.4Tighteningorderforcylinderheadbolts

Assembly

☞ Mount the cylinder-head bolts.

➥ Tightening torques:

• 1st pass 19.8–21.3lb.-ft.(26.9–28.9Nm)

• 2nd pass 39.7–42.7lb.-ft.(53.9–57.9Nm)

IMPORTANT!

Follow the correct order when tightening the cylinder-head bolts.

☞ See fig. 4-4.

IMPORTANT! Apply a thin coat of oil to the threads and contact surfaces before mounting.

Removing

IMPORTANT!

Follow the correct order when removing the cylinder-head bolts.

☞ See fig. 4-3.

IMPORTANT!

Always work on the cylinder head on a cold engine.

Engine 918279/AP05084-4PrintedinU.S.A

normalabnormal

Fig. 4-1:Valve cap wear

A BC

Fig. 4-2:Valve tip clearance Fig. 4-4:Assembly Fig. 4-3:Removing V-belt side

4.5Checkingtheinjectionnozzles

Pressurecheck

☞ Twist the shut-off valve on the fuel filter to the OFF position.

☞ Clean the area around the injection nozzles.

☞ Remove the injection line and the injection nozzle.

☞ 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 on the pressure gauge.

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

➥ Injection pressure: 1711–1856psi(118–128bar)

• Spacer thickness of 0.004 in. (0.1 mm) corresponds to modification by 100 – 142 psi (6.9 – 9.8 bar).

• Check the pressure again.

• Check the injection nozzle for drips after it has ejected fuel.

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

• Install the nozzle.

• Open the shut-off valve on the fuel filter again.

4.6Checkingthenozzlejet

☞ Remove the injection lines and the injection nozzles.

☞ Connect the injection nozzle with the high pressure line of the nozzle tester.

☞ Quickly create pressure until the nozzle ejects fuel (three or four times).

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

☞ The nozzle jet must create a shape on the paper as shown in fig. 4-6.

Engine PrintedinU.S.A.4-5918279/AP0508

Return oil line Compression spring seat Nozzle needle Pressure spring centering Nozzle body Lower nozzle screw fitting Compression spring Upper nozzle screw fitting Spacers

Fig. 4-5:Nozzle tester

optimal--------------variation--------------

Fig. 4-6:Shape of nozzle jet

4.7Injectiontime

Checkingandadjustinginjectiontime

• Preparation:

☞ Bleed the fuel system if necessary – see Bleeding the fuel system on page 3-10

☞ Clean the engine.

☞ Mark the position of the fuel injection pump on the engine block.

• Trace the mark with a touch-up applicator.

☞ Move the throttle to work position, and apply current to the cutoff solenoid.

☞ Unscrew only the injection line of the 1st cylinder and bend it a little to the side so that you can see the opening to the fuel injection pump.

NOTE:

To be able to see better, use a section of an injection line (cut at an angle, as shown on the left in fig. 4-7) or a transparent tube (as shown on the right in fig. 4-7) instead of the injection line.

• Measurement:

☞ Remove the cap – see 3TNV76-NNS engine overview on page 4-1.

☞ Rotate the pump in the required direction and stop when fuel starts coming out.

☞ As you do so, carefully watch the opening where the injection line was.

☞ Wipe away the fuel and turn back to about 30° before top dead center of the 1st cylinder.

☞ Repeat the measurement.

☞ Read the mark on the crankshaft (18°). Injection time is set correctly if it corresponds to this value.

☞ If it does not correspond to this value, loosen the fuel injection pump (do not unscrew it completely) and rotate it a little.

➥ Rotated toward the engine: later injection time.

➥ Rotated away from the engine: earlier injection time.

☞ Tighten the fuel injection pump firmly and check injection time again.

☞ Repeat the procedure as required.

IMPORTANT!

Bend the injection lines as you mount them so they are not subject to tension after they are mounted. Bleed the injection lines after they are installed.

Engine 918279/AP05084-6PrintedinU.S.A

Fig. 4-7:Measuring equipment Fig. 4-8:Mark on housing Fig. 4-9:Opening on fuel pump

Fuelinjectionpumpreplacement

☞ Clean the engine.

☞ Twist the fuel shut-off valves on the fuel filter and the water separator to the OFF position.

☞ Unscrew the injection lines.

☞ Mark the initial position on the pump and wheel case housing before removing the fuel injection pump.

☞ Remove gear casing cover 4-10/1 of the fuel injection pump.

☞ Turn the engine until the marks on the gears coincide, see Fig. 4-11

☞ Completely loosen locknut 4-11/2 of the drive pinion.

☞ Loosen bolts S

☞ Remove the fuel injection pump.

☞ Turn the gears until the marks coincide.

☞ Install the new fuel injection pump.

☞ Check the marked position of the drive pinion on the fuel injection pump (fig. 4-11).

☞ Loosen and tighten nut 4-11/2, tighten screws S

☞ Check injection time

– see Injection time on page 4-6.

☞ Replace the gear casing cover 4-10/1 on the fuel injection pump.

☞ Replace the injection lines.

☞ Twist the fuel shut-off valves on the fuel filter and the water separator to the ON position.

☞ Bleed the fuel system – see Bleeding the fuel system on page 3-10

IMPORTANT!

Do not loosen bolts 4-12/3 on the drive pinion of the fuel injection pump. These bolts determine the precise setting of the fuel injection pump and are set by the manufacturer.

Engine PrintedinU.S.A.4-7918279/AP0508

S S

Fig. 4-10:Gear casing

B A 2 B A

Fig. 4-11:Gear casing

Fig. 4-12:Gear casing

4.8Adjustingenginerpm

IMPORTANT!

Maximum engine rpm is set at the factory and must not be modified. Adjust engine rpm without load.

☞ Run the engine until it reaches operating temperature.

☞ Check idling speed A and maximum rpm B with all attachment functions in neutral.

➥ Idling speed: 1300 +/- 50 rpm.

➥ Max. speeds: 2375 +/- 10 rpm.

4.9Compression

☞ Remove the injection lines and nozzles.

☞ Remove the plug for the cut-off solenoid to set the fuel injection pump to zero delivery.

☞ Crank the engine 2-3 revolutions (do not attempt to start the engine).

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

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

➥ Specified value: 508 +/- 15 psi (35 +/- 1 bar) @ 250 rpm.

➥ Limit value: 406 +/- 15 psi (28 +/- 1 bar) @ 250 rpm.

4.10Checkingthecoolantthermostat

☞ Remove the thermostat.

➥ The thermostat is located on the water pump – see 3TNV76-NNS engine overview on page 4-1.

Engine 918279/AP05084-8PrintedinU.S.A

A B

Fig. 5:Adjusting engine speeds Fig. 6:Compression Thermal switch Housing Seal Thermostat Housing cover Fig. 7:Coolant thermostat

Thermometer

Thermostat

☞ Heat the thermostat in a container with water.

☞ Using a thermometer, check whether the thermostat opens at 157.1° – 162.5° F (69.5° – 72.5° C)

4.11Checkingthethermalswitch

Thermometer

☞ Remove the thermal switch.

☞ Heat the thermal switch in a container with antifreeze or oil.

☞ Using an ohmmeter, measure the resistance of the thermal switch.

➥ The switch must allow the coolant to pass at a temperature of 225° – 235° F (107° – 113° C).

Thermal Switch

Test probes

4.12Oilpressureswitch

Measurement probe

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

☞ Start the engine; check for correct idling speed (1300 +/- 50 rpm).

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

➥ Infinite resistance indicates the oil pressure switch is OK.

➥ The oil pressure switch is defective if the oil can pass out of the connection.

Engine PrintedinU.S.A.4-9918279/AP0508

Fig. 8:Checking the thermal switch Fig. 9:Oil pressure switch

4.13Checkingthecoolantcircuit

Coolantsystemleakagecheck

☞ Completely fill the radiator.

☞ Mount a hand pump adapter onto the radiator as shown.

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

➥ Check the coolant lines/connections for leaks if the pressure drops at the pressure gauge.

Radiatorcapcheck

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

☞ Increase the pressure to about 34 psi (2.3 bar) (stamped onto the radiator cap) with the pressure tester.

➥ The radiator cap must open.

Radiator cap

4.14Enginetroubleshooting

ProblemPossiblecauses

Engine oil wrong SAE grade

Incorrect fuel grade

Defective or dead battery

Loose or oxidized cable connections in starter circuit

Starter defective, or pinion does not engage

Incorrect valve tip clearance

Fuel injector defective

Engine does not start or is not easy to start

Starting relay defective

Glow plug defective

Fuse defective

Fuel filter dirty

Air filter very dirty

Cutoff solenoid does not engage starter

High pressure in hydraulic system preventing engine start

Air in fuel system

Engine 918279/AP05084-10PrintedinU.S.A

Fig. 10:Checking the radiator for leaks Fig. 11:Checking the radiator cap

ProblemPossiblecauses

Incorrect fuel grade

Incorrect valve tip clearance

Injection line leaks

Engine starts, but does not run smoothly or faultless

Defective fuel injector

Fuel filter dirty

Air in fuel system

Oil level too low

Oil level too high

Air filter dirty

Cooler fins dirty

Defective fan, torn or loose V-belt

Engine overheats; temperature warning system responds

Resistance in cooling system too high, flow capacity too low

Fuel injector defective

Low coolant level

Water pump defective

Cooling system leaks

Oil level too high

Incorrect fuel grade

Fuel filter dirty

Air filter dirty

Insufficient engine output

Incorrect valve tip clearance

Injection line leaks

Fuel injector defective

Air in fuel system

Injection line leaks

Engine does not run on all cylinders

Defective fuel injector/injection pump

Oil level too low

Insufficient or no engine oil pressure

Machine inclination too high

Engine oil wrong SAE grade

Oil level too high

Machine inclination too high

Engine oil consumption too high

Engine oil wrong SAE grade

Worn piston rings

Engine PrintedinU.S.A.4-11918279/AP0508

Engine smoke

ProblemPossiblecauses

Oil level too high

Machine inclination too high

Blue

Engine oil combustion (defective cylinder-head gasket)

Engine oil wrong SAE grade

Worn piston rings

Engine starting temperature too low

Incorrect fuel grade

White

Fuel injector defective

Extreme misalignment of injection time

Coolant combustion (defective cylinder-head gasket)

Air filter dirty

Defective fuel injector (drips)

Black

Incorrect fuel injection pump setting

Incorrect valve tip clearance

Dirty injection nozzle

Engine 918279/AP05084-12PrintedinU.S.A

5Hydraulicsystem

The hydraulic system is governed by the throttle.

Twin variable-displacement pump and two gear pumps.

Pos.Description

1Port P4

2Pressure limiting valve

3Bleed screw

5Port P1

Hydraulic system PrintedinU.S.A.5-1918279/AP0508 Hydraulic system

5.1HydraulicpumpPVD-0B-23BP-8G3-5083A

4 3 2 1 65

GearpumpunitVariable-displacementpumpunit Pilotoilsupplyunit 4Port P2 6Port P3

Hydraulic system 918279/AP05085-2PrintedinU.S.A 8 910

Variable-displacementpumpunitGearpumpunit Pos.Description

7Suction

line port

8Port

PB1 (gear motor supply)

9Port

PA (2nd speed range)

10Port

PB2 (pilot valve supply)

Hydraulic system PrintedinU.S.A.5-3918279/AP0508 Pumpunit:explodedview 18 7 6 16 14 15 17 12 13 11 1 10 8 6 5 4 2 3 9

Pos.DescriptionPos.Description

1Drive unit11O-ring 2Swash plate12O-ring 3Ball13O-ring 4Stop stud14Pilot oil supply unit 5Stop pin15Solenoid switch 6Spring16Solenoid switch 7Stop pin17Fastening screw 8Grooved ball bearing18Variable-displacement pump sealing kit 9Rotary shaft lip seal 10Gear pump

918279/AP05085-4PrintedinU.S.A Pilotoilsupplyunit 124 9 6 8 35 7 5 7

Hydraulic system

Both valves can be interchanged.

30bar Pos.DescriptionPort

1Gear motor supply PB1 2Pilot valve supply PB2 3Solenoid valve for safety valve 4Drives/2nd speed range supply PA 52nd speed range solenoid valve 6Pump 4 supply Internal to P4 7Pressure limiting valve 8Tank line 9Accumulator

5.2Mainvalveblock

3rdcontrolcircuit(option)

Hydraulic system PrintedinU.S.A.5-5918279/AP0508

Ports Bucket Leftsidedrive Dipperarm Auxiliaryhydraulics Dozerblade Uppercarriagerotation Straight-ahead/drive counterbalancingsystem Boom Rightsidedrive InputP1P2 B1A1 B3A3 A T2 1 P1P2 A B4 4 A B5 5 A B6 6 A B7 7 A B8 8 P T3 2 B2 B9A9

Swivelboom B10A10 Auxiliaryhydraulicsflowrate adjustmentsegment

Hydraulic system

Maincontrollines

PortLegend

A1, B1Bucket cylinder

A2, B2Boom cylinder

A3, B3Drive (right) via swivel joint

A4, B4Drive (left) via swivel joint

A5, B5Dipper arm cylinder

A6, B6Auxiliary hydraulics

A7, B73rd control circuit (option)

A8, B8Swivel boom

A9, B9Dozer blade

A10, B10Upper carriage rotation

T2, P3Straight-ahead/drive counterbalancing system

Pump/tanklines

PortLegend

P1Pump 1 port

P2Pump 2 port

P3Pump 3 port

T1Tank line via non-return valve and filter in tank

T2Tank line via oil cooler and filter in tank

S:bucketpre-tension

– see Bucket pre-tension on page 5-11.

918279/AP05085-6PrintedinU.S.A Legend

Mainvalveblockdiagram

InputP1

InputP2

Bucket Boom Rightsidedrive Leftsidedrive

Dipperarm

Auxiliaryhydraulics

3rdcontrolcircuit

Boomswivel

Dozerblade

Uppercarriagerotation

Drivecounterbalancing systemP3

system PrintedinU.S.A.5-7918279/AP0508

Hydraulic

Hydraulic system

Pos.Description

1Secondary pressure limiting valve (bucket base side)

2Primary pressure limiting valve P1

3Secondary pressure limiting valve (dipper rod side)

4Secondary pressure limiting valve (bucket rod side)

5Secondary pressure limiting valve (boom rod side)

6Secondary pressure limiting valve (boom base side)

7Primary pressure limiting valve P2

8Secondary pressure limiting valve (dipper arm base side)

9Secondary pressure limiting valve (dozer blade base side)

10Primary pressure limiting valve P3

11Anti-cavitation valve

918279/AP05085-8PrintedinU.S.A Pressurelimitingvalves 4 5 7 9 8 6 10 3 2 1 11

Pumpassignment

Hydraulicsupplybypump1

• Bucket section

• Boom section

• Right side drive section

Hydraulicsupplybypump2

• Left side drive section

• Dipper arm section

• Auxiliary hydraulics section

Hydraulicsupplybypump3

• Auxiliary hydraulics section

• Auxiliary hydraulics flow rate adjustment segment

• 3rd control circuit (option)

• Boom swivel

• Dozer blade section

• Upper carriage rotation section

• Drive counterbalancing system section

Bucket

Boom

Rightsidedrive InputP1P2

Leftsidedrive Dipperarm

Auxiliaryhydraulics

Auxiliaryhydraulicsflow rateadjustmentsegment

Boomswivel

Dozerblade

Uppercarriagerotation

InputP3 outputT2

3rdcontrolcircuit(option) Drivecounterbalancingsystem

PrintedinU.S.A.5-9918279/AP0508

Hydraulic system

Pump3 Pump2 Pump1

5.3Drivecounterbalancingsystem

Withoutdrivecounterbalancingsystem

Actuating the boom as you drive causes the machine to change direction. (The boom function is governed by P1 or P2; P1 and P2 each supply a drive.)

Withdrivecounterbalancingsystem

If the boom is actuated as you drive straight ahead, the machine continues in a straight line and drive speed stays constant. The drive counter-balancing system is only enabled if both drive valves are enabled.

Function

☞ The drive counterbalancing system functions by increasing pressure at both boom and driving piston valves so function is not lost in either function when both are used simultaneously.

➥ P3 takes over all boom functions.

Pumpassignmentfordrivecounterbalancing

Hydraulicsupplybypump1

• Right side drive section

Hydraulicsupplybypump2

• Left side drive section

Hydraulicsupplybypump3

• Bucket section

• Boom section

• Dipper arm section

• Auxiliary hydraulics section

• Auxiliary hydraulics flow rate adjustment segment

• 3rd control circuit section (option)

• Boom swivel

• Dozer blade section

• Swivel unit section

• Drive counterbalancing system section

Hydraulic system 918279/AP05085-10PrintedinU.S.A

5.4Regeneration–dipperarmsection

Problem

High loads on the dipper arm can cause the dipper arm cylinder to be “emptied” on the base side, which can cause the dipper arm to stop in vertical position.

Solution

A non-return valve is integrated in the dipper arm segment so the rod-side oil can flow to the base side.

Location

The regeneration valve is located in the dipper arm segment on the lower side.

5.5Bucketpre-tension

A nozzle is integrated in the pressure line of the bucket segment. If the bucket and the boom (both supplied with oil by the same pump) are actuated at the same time, both move simultaneously, and not the bucket (with its smaller mass) first, and then the boom with its larger mass – see Main valve block diagram on page 5-7.

Nozzlelocation:

Hydraulic system PrintedinU.S.A.5-11918279/AP0508

5.6Flowrateadjustmentofauxiliaryhydraulics

The available oil quantity at the auxiliary hydraulics ports can be modified via set screws A or B on the main valve block.

For more information about the set screw – see Pressure limiting valves on page 5-8.

IMPORTANT!

The "open" and "against hydraulic resistance" effects described below are achieved by opening one of the set screws.

There are two possible positions

– see Auxiliary hydraulics oil flow on page 2-3.

Setscrew“againsthydraulicresistance”

The valve seat is closed in this position.

• P2 and P3 supply the auxiliary hydraulics section with oil

• Factory setting

Setscrew“open”

Unscrew the valve seat by at least two revolutions, but no more than three, to open the valve seat completely.

• P2 supplies the auxiliary hydraulics section with oil

• P3 supplies the oil that flows to the tank via the open valve seat.

IMPORTANT!

Intermediate positions of the set screws cause the hydraulic oil to warm up –Riskofoverheating.

Hydraulic system 918279/AP05085-12PrintedinU.S.A

5.7Pilotvalves

Joystick

• Pilot valve for bucket, boom, dipper arm and upper carriage rotation

• Consists of a lever and four pressure limiting valves

Numbering for right joystick. Left side joystick 3 – 1 – 4 – 2

Set of tappets = sealing kit See the Parts Manual for parts ordering information.

Pressure (bar)

Joystickcharacteristiccurve

Joystick position (degrees)

Pos.DescriptionPos.Description(leftsidejoystick)Description(rightsidejoystick)

AJoystick1Dipper arm extension controlBoom cylinder extension control

BRubber collar2Left side rotation controlBucket cylinder extension control

CLinkage3Dipper arm retraction controlBoom cylinder retraction control

DUniversal joint4Right side rotation controlBucket cylinder retraction control

EGuide platePSupply from pilot oil supply unitSupply from pilot oil supply unit

FTappetTTank lineTank line

system PrintedinU.S.A.5-13918279/AP0508

Hydraulic

E F B T P 23

A C D

Hydraulic system

Pilotvalve(driving)

• Pedal with hydraulic damping

• Consists of two pedals and four pressure limiting valves

Characteristiccurvefor drivepilotvalve Pressure psi (bar)

381 ± 18 (26.25 ± 1.25)

82 ± 5 (5.65 ± 0.35)

Pilot valve piston stroke (mm)

Joystick position (degrees)

Pos.Description

1Right side drive segment control

2Right side drive segment control

3Left side drive segment control

4Left side drive segment control

P Pilot control pressure

T Tank line

918279/AP05085-14PrintedinU.S.A

1234

P TT

Pos.Description

1Bellows

3Plate (kit)

4Tappet

5Non-return

6Damping

Hydraulic system PrintedinU.S.A.5-15918279/AP0508 1 2 3 5 4 6

Set of tappets = sealing kit See the Parts Manual for parts ordering information. 2Shift unit (kit) valve (also used for bleeding pedal damping)

Hydraulic system

Pilotvalveforauxiliaryhydraulics

• Pilot control unit with pedals for remote control of directional valves

• Consists of a pedal and two pressure reducing valves

BPedal fixture

CProtective

DMounting plate

ETappet

FSpring

918279/AP05085-16PrintedinU.S.A

M = (5 0Nm) A M= (10Nm) A 37 lb.-ft. 7 lb.-ft. (28±2.5) 2°30' 0 0 0 0 (6±0.5) 1°30' à 0.95 11° 12° 30' 11°30' à 4.95 9°35' à 5.8 406±36 87±7 34 1 A B E C D 2 Characteristiccurvefordrivepilotvalve Pressure psi (bar)

Joystick position (degrees)

stroke (mm) F

Pilot valve piston

sealing kit

Parts Manual

ordering information.

Set of tappets =

See the

for parts

1Auxiliary hydraulics

Pos.DescriptionPos.Description APedal

control/offset cylinder extension control

2Auxiliary

hydraulics control/offset cylinder retraction control

caps 3Tank line

4Supply

from pilot oil supply unit

5.8ChangeovervalveforSAE/ISOcontrols(option)

The SAE/ISO valve is located through an access panel in the back wall of the cab, at the left behind the seat.

DANGER!

Switching the SAE/ISO valve modifies the controls (control levers) –Riskofaccidents.

☞ Make sure you know which control mode has been selected before starting work.

☞ Always secure wing nut J on the changeover lever

Switch-over carried out via ISO and SAE controls, and vice versa, with the directional valve.

☞ Tighten wing nut J after changing control mode.

Directionalvalveports

1Joystick (right) port 1

2Boom cylinder retraction control

3Joystick (right) port 3

4Main valve block, boom cylinder extension control

5Main valve block, dipper arm cylinder extension control

6Joystick (left) port 1

7Main valve block, dipper arm cylinder retraction control

8Joystick (left) port 3

5.9Proportionalvalve(option)

A proportionalvalve ensures a modifiable control signal (an electric signal as a rule) is steplessly transformed into a proportional output signal.

Refer to the Operator's Manual for proportional valve operation information.

Hydraulic system PrintedinU.S.A.5-17918279/AP0508

Fig. 5-1:Directional valve position

J AB 1 2 3 48 7 6

A ➥ ISO controls

B ➥ SAE controls

Fig. 5-2:Directional valve

5PositionFunction •

•

27 T P AB

Joystick (left)

Hydraulic system

5.10Traveldrive

• Swash-plate piston motor

• The drive has two speed ranges switched via two capacity positions

Pos.Description

1Drive port (-> swivel joint right 4/left 3)

2Drive port (-> swivel joint right 2/left 5)

32nd speed range port (-> swivel joint 8)

4Directional valve forward/reverse = brake piston

5Return oil port (-> swivel joint 1)

6Solenoid valve 2nd speed range

7Pressure limiting valves

8Shuttle valve

918279/AP05085-18PrintedinU.S.A

12 3 5 6 1 2 3 5 4 7 8

Function

Driving:

If high pressure is applied to one of the drives, the brake release piston is actuated first and passes high pressure on to the brake cylinder, which releases the brake. The throttle slowly actuates the brake piston at the same time. Brake piston control causes high pressure to be applied to the motor, which starts turning.

Stopping:

The oil flows from both ports to the tank upon releasing the joystick. The brake release piston and the brake piston (slowly actuated by the throttle) return to their base positions. The slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the brake piston in neutral position, the ports are no longer connected to the motor, which can no longer turn. The brake release pressure is reduced via both throttles shortly afterward.

2speedrangefunctions

Speedrange1

• “High speed” switch 38 (see page 1-9): switched off The solenoid valve on the pilot oil supply unit is de-energized, and the oil flows through the control line to the tank. The swash plate of the hydraulic motor is fully swivelled in this position, i.e., the motor is at maximum capacity.

➥ The engine runs at slow speed but at maximum tractive power.

Speedrange2

• “High speed” switch 38 (see page 1-9): switched on The solenoid valve is energized, and the swash plate of the hydraulic motor returns to base position, i.e., the motor is at minimum capacity.

➥ The engine runs at high speed but at low tractive power.

Hydraulic system PrintedinU.S.A.5-19918279/AP0508

918279/AP05085-20PrintedinU.S.A Pos.Description 1Travel drive 2Screw connection 3Screw connection 4Screw connection 5Hydraulic motor 6Hydraulic motor sealing kit 7Seal 8Bearing 9Cover 10O-ring 11Snap ring 12Valve set 13Piston valve for speed range 14Brake valve 15Travel drive brake 9 11 10 8 7 6 1 5 4 3 2 2 12 13 13 14 15 14

Hydraulic system

5.11Swivelunit

Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox and mechanical motor brake.

Pos.Description

1SH brake release port (-> shuttle valve)

2Pilot control pressure port (-> pilot oil supply unit)

3Brake release valve

4Right side rotation port (-> main valve block)

5Anti-cavitation line port (-> main valve block/tank)

6Left side rotation port (-> main valve block)

7Shock anti-cavitation valves

8Return oil port (-> tank)

9Brake piston

The shock anti-cavitation valves are dampened for smooth braking.

Hydraulic system PrintedinU.S.A.5-21918279/AP0508

x x x R/G 12 8 1 2 9 7 3 456 7 5 1 2 64 7 8

Hydraulic system

Swivelunitbrake

Hydraulicswivelunitbrake:

The upper carriage's rotation is sufficiently braked by moving the right joystick back to the neutral position. Moving the joystic in the opposite direction (counter-action) brakes the upper carriage with maximum hydraulic output.

Mechanicalstopbrake:

A multi-disc brake integrated in the rotation drive has an additional mechanical brake effect with time delay. This negative-effect brake is used as a stop brake and parking brake for the swivel unit. The upper carriage can be stopped in any position.

IMPORTANT!

Do not use the brake as a service brake, but only as a stop brake and parking brake for the swivel unit.

918279/AP05085-22PrintedinU.S.A

Hydraulic system PrintedinU.S.A.5-23918279/AP0508 Ref.No. Description Ref.No. Description 1Pinion shaft11O-ring 2Spacer washer12Ring gear 3Bearing seal ring13Gear reduction 4Bearing14Gear reduction 5Gear housing15Sun gear 6Sealing ring16Motor flange 7Bearing17Hydraulic motor 8Round nut18Screw 9Complete drive19Screw 10Spacer washer20Plug

system 918279/AP05085-24PrintedinU.S.A 4 3 2 1 2

Hydraulic

Pos.Description 1Shock valve 2Gear motor valve set 3Engine brake set 4Timer valve

1aPilot

☞

Hydraulic system PrintedinU.S.A.5-25918279/AP0508

5.12Swiveljoint

8-port swivel joint Sealing Loosen the circlip on the lower side. Pull the swivel joint apart. Replace the sealing rings. Push together again.

13 12

Insert the circlip again.

Pos.PortPos.Description

control pressure (PV) pilot oil supply unit1-8Sealing rings and 4aRight side drive9PU prop ring and 5aLeft side drive10V sealing ring and 7aDozer blade11Circlip Traveling drive tank line12Inside part 13Outside part

5.13Breatherfilter

The breather filter controls:

• Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil level) prevents the oil tank from inflating.

• Pressurization of the oil tank to the specified amount supports the variable–displacement pump's suction.

• Filtering the intake air.

• Opens at 5.8 psi (0.4 bar).

The breather filter is located at the rear right of the machine. Replace the filter as indicated in the maintenance schedule

– see Maintenance schedule on page 3-5.

IMPORTANT!

The breather filter must be replaced at 1000 hours under all circumstances.

Pos.Description

1Filter fabric

2Bleeder valve

918279/AP05085-26PrintedinU.S.A

Hydraulic system

1 2

Fig. 5-4:Breather filter

5.14Troubleshootingthehydraulicsystem

ProblemPossiblecauses

Defective safety switch on joystick base

Wrong setting of safety switch on control lever base

Defective solenoid valve on pilot oil supply unit

Hydraulic system does not function

Contaminated solenoid valve on pilot oil supply unit

Hydraulic oil level too low

Defective valve fuses

Defective/interrupted solenoid valve plug and socket connection

Quick-hitch couplings not correctly connected

Hydraulic oil level too high/too low

Hydraulic hammer does not work correctly

Hydraulic oil pressure too high/too low

Incorrect nitrogen fill

Defective 2nd speed range switch

Defective solenoid valve on pilot oil supply unit

Contaminated solenoid valve on pilot oil supply unit

Excavator runs in 1st speed only

Defective valve fuses

Defective/interrupted solenoid valve plug and socket connection

Counter-pressure in travel drive does not drop below control pressure

Hydraulic system PrintedinU.S.A.5-27918279/AP0508

Hydraulic system

5.15Hydraulicsdiagram:legend

Pos.Description

1Diesel engine

2Variable-displacement pump + gear pump

3Pilot oil supply unit

4Pressure accumulator

5Joystick (right)

6Joystick (left)

7Accelerator pedal

8Pilot control filter

9Shuttle valve

10Throttle non-return valve

11Main valve block

12Swivel joint

13Bucket cylinder

14Boom cylinder

15Travel drive

16Dipper arm cylinder

17Offset cylinder

18Dozer blade cylinder

19Swivel unit

20Hose burst valve

21Non-return valve

22Oil cooler

23Return filter

24Breather filter

25Hydraulic oil tank

26Micro ports

27Proportional valve

28Quick-connect option

29Hose burst valve DE

30Hose burst valve FR

313rd control circuit shock cartridge

32Auxiliary hydraulics shock cartridge

33SAE valve

918279/AP05085-28PrintedinU.S.A

Pressure limiting valve Fixed–displacement motor Throttle orifice Spring-loaded solenoid valve Double-acting cylinder Non-return valve Fixed–displacement pump Double variable–displacement pump Measuring port Tank lineOil cooler Pressure accumulator Variable–displacemeent motor Shut-off valveFilter

5.16Hydraulicsdiagram

Gearmotor

Dozerbladecylinder

Offsetcylinder

Auxiliaryhydraulics

Dipperarmcylinder

P1....3263psi(225bar)/11.5ccm/UQ=30.5L/min

P2....3263psi(225bar)/11.5ccm/UQ=30.5L/min

P3....2988psi(206bar)/8ccm/U/Q=21.2L/min

P4....435psi(30bar)/2.7ccm/UQ=7.2L/min

Highidle....2675U/min

PrintedinU.S.A5-29918279/AP0508 Hydraulic System

Traveldrive (right) Traveldrive (left) Boomcylinder Bucketcylinder Boom Left-hand side drive Right-hand side drive Joystick (right) Joystick (left) 3rdcontrolcircuit (option) Diesel engine

Hydraulic System

Bucket

5.17Hydraulicsdiagramforoptions

3rd control circuit

Proportional controls (auxiliary hydraulics) + 3rd control circuit (proportional)

Auxiliary hydraulics

Auxiliary hydraulics shock cartridge

3rd control circuit shock cartridge

Safe load indicator DE

3rd control circuit (proportional)

Auxiliary hydraulics

Safe load indicator FR

Proportional controls (auxiliary hydraulics)

918279/AP05085-30PrintedinU.S.A

Joystick (left) Joystick (right) Joystick (left) Joystick (right) Grab Bucket Boom Boom Dipper Joystick (left) Joystick (right) SAE valve

Pilotcontrollines

PortLegendControlledvia

Pa1, Pb1Bucket controlJoystick (right)

Pa2, Pb2Boom controlJoystick (right)

Pa3, Pb3Right side drive controlDrive pedal (right)

Pa4, Pb4Left side drive controlDrive pedal (left)

Pa5, Pb5Dipper arm controlJoystick (left)

Pa6, Pb6Auxiliary hydraulics controlSwitch on joystick

Pa7, Pb73rd control circuit (option) controlSwitch on joystick

Pa8, Pb8Boom swivel controlHammer pedal

Pa9, Pb9Dozer blade controlDozer blade lever

Pa10, Pb10Upper carriage rotation controlJoystick (left)

Maincontrollines

PortLegend

A1, B1Bucket cylinder

A2, B2Boom cylinder

A3, B3Drive unit (right) via swivel joint

A4, B4Drive unit (left) via swivel joint

A5, B5Dipper arm cylinder

A6, B6Auxiliary hydraulics

A7, B73rd control circuit

A8, B8Offset cylinder

A9, B9Dozer blade cylinder

A10, B10Swivel unit

Pump/tanklines

PortLegend

P1Pump 1 port

P2Pump 2 port

P3Pump 3 port

P4Pump 4 port

T1Tank line via non-return valve and filter in tank

T2Tank line via oil cooler and filter in tank

S: bucket pre-tension "Bucket pre-tension" on page5-11

PrintedinU.S.A5-31918279/AP0508

5.18Mainvalveblockdiagram

918279/AP05085-32PrintedinU.S.A

6Electricsystem

6.1Ohm'sLaw(current,voltage,resistance);power

It describes the interrelation between current, voltage and resistance.

Current “ I” – Ampere (A)

Voltage “ E” – Volt (V)

Resistance “ R” – Ohm (Ω)

Mnemonic: Output

Power “P” – Watt (W)

P = E x I = R x I² = E²/R

6.2Measuringequipment,measuringmethods

Multifunctionmeasuringdevice

• Measurements of values (E, R, I, P)

• Continuity test

• Diode test

Calculate measuring range using known data (P, E, R, I) and set before measuring.

Observe AC/DC basic setting.

➥ AC = alternating current/voltage;

➥ DC = direct current/voltage

Testdevicewithacousticandopticalsignaloutput

• Continuity test in de-energized machine electrical system and wiring harnesses.

Electric system PrintedinU.S.A.6-1918279/AP0508

E RI Electric system

Measuringmethods–multi–functionmeasuringdevice

• Measuring current (ignition turned on):

• Black cable in COM socket (ground),

• Red cable in A socket or mA socket; connect in series load.

• Measuring voltage (ignition turned on):

• Black cable in COM socket (ground),

• Red cable in V socket;

• Connect in parallel to load.

• Measuring resistance (ignition turned off):

• Black cable in COM socket (ground),

• Red cable in Ω socket;

• Connect in parallel to load (see measuring voltage).

Testlamp

The test lamp is used to test lines and functions with the ignition turned on.

• Line test (testing voltage): Connect test lamp between test point (live cable) and machine ground or between test point (ground line) and a live cable.

• Functional check (testing current): Connect test lamp between a connection on the load to be tested and the connection line.

Electric system 918279/AP05086-2PrintedinU.S.A

6.3Cablecolorcoding

6.4Relays

Use,modeoffunction

Relays are used for switching electric loads (high currents) whereby the control power of the relay coil is relatively low. Relays can therefore be controlled by microelectronics or microswitches (e.g., touchpad keyboards, sensors).

The switch contacts can be make-contact, break-contact or changeover switches. The switch contacts perform the actual switching function.

Zero-centerrelay

86=Start of coil (control line)

85=End of coil (ground)

30=Input(load line)

87=Make-contact switch output (load line)

87 a=Break-contact switch output (load line)

6.5Socket

Electric system PrintedinU.S.A.6-3918279/AP0508

ColorCode Blackblk Brownbrn Redred Orangeorg Yellowyel Greengrn Blueblu Violetvio Graygry Whitewht Pinkpnk 8630 858787a

Socket A is located at the front of the machine next to the type label above lubrication strip B. Fig. 6-1:Terminal description on relay

Fig. 6-2:Lubrication strip on the chassis A

Electric system

6.6Electricunits

Units

Alternator12 V 40 A

Starter12 V 1.1 kW

Battery12 V 44 Ah; 630 CCA

Sockete.g., for cigarette lighter; 15 A max.

6.7Fusebox

The fuse box is located in the engine compartment, on the left.

Fuseno.Ratedcurrent(A)Protectedcircuit

F310 AIndicators, cutoff solenoid, relays

F410 ABoom working light

F515 ACab working light

F610 AValves, horn

F715 AHeating, air conditioning

F810 AWiper, interior light

F910 ARotating beacon, radio, cigarette lighter

F1015 ASocket

Fuseno.Ratedcurrent(A)Protectedcircuit

F140 AStart, preheat, cutoff solenoid

F250 AIgnition lock

Relayno.Protectedcircuit

K6Pre-heating time lag relay

K7Starting relay

K8Cutoff solenoid time lag relay

K9Pick-up contact cutoff solenoid relay

918279/AP05086-4PrintedinU.S.A

Fig. 6-3:Fuse box F3 F4 F8 F9 F10 F5 F6 F7 Fig. 6-4:Relays K7 K6

F1 F2 F1 F2 K9

6.8Switches:overview

Control element on right side joystick consoleControl element on cab wall

1236789

Controlelementsforproportionalcontrolsversion(option)

Control element on right side joystick console Control element on cab wall

123456789

Instrumentpanellegend

Pos.Description

1High speed switch

2Fan switch

3Safe load indicator (option)

4Hydraulic quickhitch switch (option)

5Proportional control status indicator (option)

6Washer switch

7Work light switch

8Roof light switch (option)

9Rotating beacon switch (option)

Electric system PrintedinU.S.A.6-5918279/AP0508

Electric system

6.9Alternator

The alternator charges the battery and supplies direct current to electrical components.

Pos.Description

1 Connection B (battery)

2 Connection P starting relay

Connection IG indicator (12 V)

Port L indicator (during service 12 V, otherwise ground)

12 6.10Starter

Pos.Description

1 Connection S starting relay

2 Connection B battery

918279/AP05086-6PrintedinU.S.A

Fig. 6-5:Alternator

1 2

Fig. 6-6:Starter

6.11Wiringdiagramlegend

No.DescriptionSection

A1RadioC14/15Option

B1Fuel level indicatorF6

B2HornC9

B11LoudspeakerE15Option

B12LoudspeakerE15Option

B14Warning buzzerC2

B19Quick-hitch warning buzzer (quickhitch system) B8

E7Rear roof lightE13/14Option

E9Front roof lightE13Option

E11Boom lightE11

E14Interior lightE14

E15Cigarette lighterE11

F1Main fuse: start, pre-heating, cutoff solenoid E1

F2Main fuse: ignition lockE1

F3Fuse: displays, cutoff solenoid, relaysA4

F4Boom working light, heatingA10

F5Valves, hornA9

F6Cab working lightA14

F7Wiper, interior lightA13

F8Wiper, interior lightA11

F9Rotating beacon, radioA14

F10Socket, cigarette lighterA11

G1AlternatorF2

G2BatteryF1

H2Pre-heating indicatorC1

H3Engine temperature indicatorC1

H4Engine oil pressure indicatorB1

H5Alternator charge function indicatorB1

H6Air filter clogging indicatorB1

H7Hydraulic oil filter clogging indicatorB1

H9Safe load indicatorC1Option

H28Rotating beaconE13Option

K6Pre-heating time lag relayE4

K7Starting relayE2

K8Cutoff solenoid time lag relayE3

No.DescriptionSection

K9Pick-up contact cutoff solenoid relayE3

M1StarterF2

M2WiperE12Option

M4Heater fanM10Option

M5Washer pumpF12Option

M9Fuel pumpF3

P1Hour meterB1

P2Fuel gaugeB1/2

R1Pre-heating systemF4

S1Ignition lockA1

S2Engine oil pressure switchE/F5

S3Engine temperature switchF5

S5Hydraulic oil pressure switchE/F6

S16Boom work light switchB11

S17Cab work light switchB14Option

S18Rotating beacon switchB13Option

S15Heating switchB10

S20Wiper/washer switchB12Option

S21High speed switchB9

S21.1High speed tip switchD9Option

S28Safety switchD7

S40Quick-hitch switch (quick-hitch system) B8Option

S41Safe load indicator pressure switchF8Option

S42Safe load indicator switchB7Option

S55Horn tip switchB9

V1Recovery diodeE1

X4Drive interlockC3

X8Left side joystick connector

X10Instrument panel connectorB/C1/2

X12Cab connectorF12/13

X14Proportional controls portB11

X19Socket portF11

Y1Cutoff solenoidF3/4

No.DescriptionSection

Y3High-speed valveE9

Y13Safety valveE7

Y25Quick-hitch valve (quick-hitch system)E8Option

PrintedinU.S.A6-7918279/AP0508

D12

918279/AP05086-8PrintedinU.S.A 6.12Wiringdiagram

6.13Enginewiringharnesslegend

No.UptoToColourmm²

1G1 + 12 V/30M1red10

2G1 + 12 V/30F1red6

3M1 + 12 V/30F2red 6

4F1 + 12 V/30K9/30red4

5F1 + 12 V/30K7/Ared4

6F2 + 12 V/30 ignition lockS1/1red6

7F2 + 12 V/30F9/Gred4

8S1/5 12 V/15 ignition lockF4/Bblu4

9S1/6 12 V/15 ignition lockF7/Eblu4

10K7/B starter 50M1wht-red2.5

11K9/87 pick-up contact cutoff solenoidY1/1wht2.5

12S1/3 pre–heatingS1/9brn4

13S1/4 pre–heatingR1brn4

14S1/8 pre–heatingK6brn1

15S1/7 starter 50aX4/4wht-blk

16X4.1/8 starter 50aX4.1/4wht-blk1

17X4/8 starter 50aK6wht-blk1

18K7/3 starter 50aK6wht-blk1

19G1/1 alternator charge indicatorB18/5pnk1

20X10/8 alternator charge indicatorB18/5pnk1

21S3 engine temperature switchB18/9blk-grn1

22X10/14 engine temperature switchB18/4blk-grn1

23S2 engine oil pressureB18/6wht-grn1

24X10/10 engine oil pressureB18/1wht-grn1

25B1/1 fuel tank sensorX10/4vio-blk1

26K6 pre–heating indicatorX10/12gry-red1

27K8 cutoff solenoid relayK9/86blu-blk1

28K8 cutoff solenoid relayK9/85pnk-blk1

29G1/3 rpm signalK7/6blk-blu1

30F3/1 12 V/15 indicating instrument, relayG1/2blu1

31F3/1 12 V/15 indicating instrument, relayK7/1blu1

32F3/1 12 V/15 indicating instrument, relayV1blu1

33F3/1 12 V/15 indicating instrument, relayX4/5blu1

34X4/7 12 V/15 indicating instrument, relayX4/5blu1

35X4/7 12 V/15 indicating instrument, relayX10/1blu1

36X4.1/5 12 V/15 indicating instrument, relayX4.1/9blu1

37X4/9 12 V/15 cutoff solenoidK8blu-blk1

38X4/9 12 V/15 cutoff solenoidM9blu-blk1

39Y1/2 12 V/15 cutoff solenoidM9blu-blk1

40F4/2 12 V lights, fanS16/1yel1

41S16/10 12 V lights, fanS16/1yel1

42F4/2 12 V lights, fanS15/1yel1

43S15/2 12 V lights, fanS15/1yel1

44S15/2 12 V lights, fanS15/10yel1

45S16/5 boom work lightE11/1yel-grn1

46S16/5 instrument panel lightsE15yel-grn1

47X10/2 instrument panel lightsE15yel-grn1

48S15/6 heating IM4/1yel-blk1

49S15/3 heating IIM4/3yel-blu1

50F5/3 + 12 V valves/hornX4/1gry1

51S21/1 + 12 V valves/hornX4/1gry1

52S21/1 + 12 V valves/hornS21/10gry1

53S40/1 + 12 V valves/hornS21/10gry1

54S40/1 + 12 V valves/hornS40/10gry1

55S42/10 + 12 V valves/hornS40/10gry1

56F5/3 + 12 V valves/hornS21.1/1gry1

57B2 + 12 V valves/hornS21.1/1gry1

59X4.1/1 + 12 V valves/hornX4.1/6gry1

60X4/6 + 12 V valves/hornS28gry1

61S28 safety valveY13brn-wht1

62S21.1/2 high speedS21/5brn-blk1

63Y3 high speedS21/5brn-blk1

64S40/5 quickhitch (quickhitch system)Y25/1gry-yel1

65S40/5 quickhitchB19gry-yel1

66S41/1 overloadS42/1vio-blu1

67B18/8 overloadS42/5vio-blu1

68B18/2 overloadX10/13vio-blu1

69S55/1 hornB2org1

70F6/4 12 V roof lightsS17/1grn1

71S17/2 12 V roof lightsS17/1grn1 72S17/2 12 V roof lightsS17/10grn1 73S18710 12 V roof lightsS17/10grn1

74S17/6 front roof lightX12/1grn-red1

75S17/3 rear roof lightX12/2grn-blu1

76F7/5 12 V wiperS20/2lblu1

77S20/10 12 V wiperS20/2lblu1

78S20/6 wiperX12/3blu-wht1

79S20/6 wiperS20/7blu-wht1

80S20/5 wiper resetX12/4blu-red1

81S20/3 washer pumpM5blk-wht1

82F7/5 12 V wiperX12/8lblu1

83X12/9 12 V wiperX12/8lblu1

84F8/6 proportional controlsX14/1gry-grn1

12 V drive interlock, rotating beaconX4/2red1

No.UptoToColourmm²

PrintedinU.S.A6-9918279/AP0508

86S18/1

87S18/1 12

radioA1/7red1 88S20/10 12 V/15 radioA1/4lblu1 90F10/8 socketX19red/blk1.5 91F10/8 cigarette lighterE15red/blk1.5 92S18/5 rotating beaconX12/11vio1 93S5 oil filterX10/6org-wht1 94A1.1/6 right- side loudspeakerX12/6grn-blk1 95A1.1/5 right- side loudspeakerX12/7grn1 96A1.1/4 left- side loudspeakerX12/12gry1 97A1.1/3 left- side loudspeakerX12/13gry-blk1 100Y1/3 groundGNDblk1 101Y13 groundGNDblk1 102Y3 groundGNDblk1 103M9 groundGNDblk1 104M5 groundGNDblk1 105M5 groundK7/5blk1 106K6 groundGNDblk1 107K6 groundK8blk1 108V1 groundK8blk1 109X14/2 groundGNDblk1 110X14/2 groundS5blk1 111M4/2 groundGNDblk1 112M4/2 groundB1/2blk1 113X19 groundGNDblk1 114X19 groundE11/2blk1 115Y25/2 groundGNDblk1 116S41/2 groundGNDblk1 117E15 groundGNDblk1 118X12/5 groundGNDblk2.5 119X4/3 groundGNDblk1 120X4/3 groundS42/9blk1 121S40/9 groundS42/9blk1 122S40/9 groundB19/2blk1

123S15/9 groundB19/2blk1 124S15/9 groundS21/9blk1 125S55/2 groundS21/9blk1 126S55/2 groundX10/5blk1 127S20/9 groundGNDblk1 128S20/9 groundS16/9blk1 129S17/9 groundS16/9blk1 130S17/9 groundS18/9blk1 131A1/8 groundS18/9blk1 132X12/10 groundGNDblk1.5

85F9/7

V/30

No.UptoToColourmm²

Wiringharness1000168673engine–chassis:legend

6.14Enginewiringharnessdiagram

Radio

Cigarette lighter

Heating

TankQuick-hitchOverload2nd speed

Cutoff solenoid

Boom light

Socket Horn

Rotating beacon

Cab light

Boom light

Wiper

Overload

Quick-hitch

Fan

2nd speed

Horn

Safety switch

Cutoff solenoid

Pre–heating

Oil pressure

Alternator

Engine temperature

Oil filter

Cutoff solenoid timer

Pre-heating timer

Starter

Indication

Ignition lock

Proportional controls

Washer pump

Starting relay

Safety valve 2nd speed Fuel pump

918279/AP05086-10PrintedinU.S.A

6.15Cabwiringharness

Front roof light

Interior light

Rear roof light

Rotating beacon

PrintedinU.S.A6-11918279/AP0508

Connect strand to ground rail Wiper No.UptoToColorNo.UptoToColor 5X12/1E9grn/red111X12/12B11wht1 6X12/11H28vio112X12/7B12wht/blk0.5 7X12/9E14blu113X12/6B12wht0.5 8X12/10GNDblk2.514blk1 9X12/2E7grn/blu115blk1 10X12/13B11wht/blk116blk1

918279/AP05086-12PrintedinU.S.A 6.16Proportionalcontrols(option) No.UptoToColorNo.UptoToColor 1X14/1 12 VX11/12blu114X11/8 valve 3Y18/1gry/red1 2X14/1 12 VX12/3blu115X11/7 valve 4Y19/1gry/blu1 3X13/3 12 VX12/3blu116X11/5 indicatorH10/2yel/red1 4H10/1 12 VX14/3blu117X11/6 indicatorH11/2yel/blk1 5H10/1 12 VH11/1blu118X10/6 5 V joystickX12/1red1 6X11/2 valve groundGND V1brn119X13/1 5 V joystickX12/1red1 7Y16/2 valve groundGND V1brn120X10/7 joystick groundX12/4blk/wht1 8Y17/2 valve groundGND V1brn121X13/4 joystick groundX12/4blk/wht1 9X11/4 valve 1Y16/1gry/blk122X10/5 joystick signalX12/2wht1 10X11/9 valve 2Y17/1gry/blk123X10/4 joystick signalX13/2wht/blk1 11X11/3 valve groundGND V2brn/blk124X10/2 hammer tip switchX12/5grn/red1 12Y18/2 valve groundGND V2brn/blk125X11/1 groundX14/2blk1 13Y19/2 valve groundGND V2brn/blk1

7Options

NOTE:

Use Loctite S2420 or VaryBond 12-43 on the securing hardware.

7.1Counterweight Specifications

CounterweightModel

Weight247 lbs. (112 kg)

Tightening torque for screws214 lb.-ft. (290 Nm)

Max. tail end lateral projection over tracks1.338 in. (34 mm)

NOTE:

When using a counterweight – see Lift capacity table on page 2-10.

7.2Connectingauxiliaryhydraulics

Connect and disconnect the quick-connect couplings as follows:

☞ Park the machine on firm, level ground.

☞ Extend dipper arm cylinder A halfway.

☞ Turn off the engine.

☞ Turn the ignition key to position “1”.

☞ Release the pressure on bucket cylinder A by moving the joystick left and right.

☞ Fold the control lever base up.

☞ Twist and pull lock sleeve C upward.

☞ The coupling opens.

Connectingthecoupling:

☞ Connect the coupling onto the dipper arm cylinder connection making sure it is straight.

☞ Wait until you hear a hissing sound from the connection.

☞ Fully connect the coupling on the connection.

☞ Twist the lock away from lock ball B.

PrintedinU.S.A.7-1918279/AP0508

Options

B A C Options

Fig. 7-1:Quick-connect couplings

Options

Switchingtheshut-offvalves:

Bucket operation:

☞ Set the shut-off valve to position A.

Auxiliary hydraulics operation:

☞ Set the shut-off valve to position B

Attachments

NOTE:

Please refer to the operator's and maintenance manual from the attachment manufacturer for using and performing maintenance on attachments such as hammers, thumbs, etc.

7.3Auxiliaryhydraulicsconnections

IMPORTANT!

Follow the instructions in the Operator's Manual from the attachment manufacturer for connecting the auxiliary hydraulics to attachments.

Standardconnections:

918279/AP05087-2PrintedinU.S.A

B B A

Fig. 7-2:Shut-off valve

TV U PortDipper(left)Dipper(right) T ☞ Pressure line V ☞ Pressure line U ☞ Large return line

Fig. 7-3:Connections for auxiliary hydraulics

7.4Proportionalcontrols

NOTE:

Fast actuation of the joystick moves the attachment fast. Slow actuation of the joystick moves the attachment slowly.

Function

This control mode offers proportional operation of the auxiliary hydraulics circuit depending on the position of switch B on the joystick (Fig. 7-4 ).

You can also modify proportional control properties. Precision work, for instance, does not require the full throughput of the auxiliary hydraulics. Heavy work, such as hammer operation, requires full throughput however. – see Adjusting control response on page 7-6, and refer to the following table.

NOTE:

Always use button X (see Fig. 7-4) on the joystick for hammer operation. Pressing button X ensures full throughput irrespective of the characteristic curve that has been selected.

Options PrintedinU.S.A.7-3918279/AP0508

Joystick

PortsHosedesignation

JAuxiliary hydraulics (left)

KAuxiliary hydraulics (right)

WARNING!

The system still works correctly if only one component breaks down. However, if more than one component breaks down, the pressure regulating valves may malfunction. Due to the potential pressures involved, serious injury could result.

System breakdowns can never be excluded, therefore:

☞ Disconnect the electric controls from the power supply before performing repairs or maintenance on the hydraulic system.

☞ Stay clear of areas that present a risk of crushing.

☞ Stay clear of areas between moving hydraulic components and fixed obstacles which present a risk of crushing.

☞ The operator of the machine or hydraulic system must be aware of possible machine or system errors.

DANGER!

Unintentional operation of the joystick when driving on public roads presents a Riskofaccidents.

NOTE:

Always perform smooth control movements.

Options 918279/AP05087-4PrintedinU.S.A Ports Measurestobetakenincaseofmalfunctions

HT line IP line

D C A B 27 X PositionLeverFunction • A ☞ Forward ➥ Dipper arm extended • B ☞ To the right ➥ Upper carriage rotates to the right • C ☞ Backward ➥ Dipper arm is retracted • D ☞ To the left ➥ Upper carriage rotates to the left

Fig. 7-4:Left joystick

Boomswivelcontrols

Swivelboomtotheleft:

☞ Move the pedal 1 to the left.

Swivelboomtotheright:

☞ Move the pedal to the right.

Auxiliaryhydraulics

Actuatingtheauxiliaryhydraulics:

Oilflowin1stdirection:

☞ Move the hammer pedal 8 to the left.

Oilflowin2nddirection:

☞ Move the hammer pedal to the right.

Hammeroperation

Switchingonhammeroperation:

☞ Press and hold button C on the joystick.

Switchingoffhammeroperation:

☞ Release button C on the control lever.

Options PrintedinU.S.A.7-5918279/AP0508

Fig. 7-5:Swivel controls

Fig. 7-6:Auxiliary hydraulics

Fig. 7-7:Hammer operation

Adjustingcontrolresponse

Forslow,precisemovements:

☞ Turn off the ignition.

☞ Move slide switch B to the left D

☞ Hold slide switch B to the left D and start the engine at the same time.

☞ Release slide switch B

Status display 42 acknowledges by flashing once.

Forfastmovements–maximumthroughput:

☞ Turn off the ignition.

☞ Move slide switch B to the right C

☞ Hold slide switch B to the right C and start the engine at the same time.

☞ Release slide switch B.

➥ The status display acknowledges by flashing twice.

Characteristiccurves–statusdisplay

Displays the characteristic curve that has been selected for the control valve.

Forslow,precisemovements:

Indicator 1 in status display 42 flashes once after starting the engine.

Forfastmovements–maximumthroughput:

☞ Indicator 1 in status display 42 flashes twice after starting the engine.

NOTE:

The characteristic curve that has been set last is active if the machine is started again.

918279/AP05087-6PrintedinU.S.A

Options

B DC

Fig. 7-8:Adjusting control response

1 42

Fig. 7-9:Characteristic curves – status display

Wiringharness

PortsHosedesignation

X10Connector 1 control unit

X11Connector 2 control unit

X12Joystick

X13Joystick

X14Proportional controls port

H10Proportional circuit 1 indicator

H11Proportional circuit 1 indicator

Y16Auxiliary hydraulics solenoid valve

Y17Auxiliary hydraulics solenoid valve

Y18Connector 1 proportional circuit 2

Y19Connector 2 proportional circuit 2

PrintedinU.S.A.7-7918279/AP0508

Options

Controlvalveplugassignment

X10 digital/analog inputs

PINDescriptionPorts

1TXSerial interface

2SW2Hammer operation

3SW4Power

4A_POT2Joystick signal channel 2

5A_POT1Joystick signal channel 1

Control valve

6U-analogAnalogous supply +5 V

7R_POT1GND joystick

8R_POT2GND potentiometer

9A_POT3Potentiometer signal

10SW3Auto

11SW1Pressure switch

12RXSerial interface

X11 supply outputs

PINDescriptionPorts

1M_ECUGround

2MVH1+ channel 1

3MVH2+ channel 2

4MVL1APulse modulation channel 1/magnet 1

5LSW2Indicator

6LSW3Indicator

7MVL2APulse modulation channel 2/magnet 1

8MVL2BPulse modulation channel 2/magnet 2

9MVL1BPulse modulation M channel 1/magnet 2

10MOT2Engine

11MOT1Engine

12U_ECU+12 V supply

918279/AP05087-8PrintedinU.S.A

Safetyfeatures

☞ Microcontroller: Diagnoses error reports by the output stage.

☞ Monitor: Disables the output stage if the microcontroller malfunctions.

☞ Output stage: Controls the status of the supply lines from the pressure regulating valves.

☞ Watchdog: Disables the microcontroller if the microcontroller malfunctions.

☞ Switch for valve supply: Disables the power supply to the valves if a critical error is detected.

Measurestobetakenincaseofmalfunctions

CAUTION!

System breakdowns can never be excluded, therefore:

• Disconnect the electronic controls from the power supply before performing hydraulic system maintenance or repair.

• Keep clear of hydraulic system components or hydraulically actuated components (risk of crushing).

• Do Not get in between moving hydraulic components and fixed obstacles (risk of crushing).

• The operator of the machine or hydraulic system must be aware of possible machine or system errors.

Diagnosticdisplay

The control valve status displays using a flashing code. The following errors are identified by the number of flash pulses:

The system turns off automatically if a critical error is detected. Activating the control unit is only possible by repeatedly turning on the supply voltage.

Options PrintedinU.S.A.7-9918279/AP0508

No.Pinno.DescriptionErrorTroubleshootingCritical error 0--No error-1B 5Channel 1 input (left)Defective input voltage Check voltage, home position: 2.5 V deflected: 0.7 V –4.3 V2A4, A9Channel 1 output; Y16/Y17Overload or overheating

magnet on valve3A4, A9Channel 1 output; Y16/Y17 Short circuit on

voltage Check wiringx 4B4Channel 2 input (right)Defective input voltage Check voltage, home position: 2.5 V, deflected: 0.7 V – 4.3 V5A7, A8Channel 2 output; Y18/Y19Overload or overheating (output stage)Check magnet on valve6A7, A8Channel 2 output; Y18/Y19 Short circuit on ground or operating voltage Check wiringx 7-System start-x 8A10, A11Motor outputOverheating (output stage)Check motorx 9--EEProm data error-x 10B6+5V joystickDefective 5V supply-x

(output stage)Check

ground or operating

Only the error occurring last is issued if several errors occur at the same time. Troubleshoot one error at a time until the status no longer flashes.

To obtain a detailed status of the output stage for channels No. 1 and 2, the hammer operation input must be activated during system start. The system flashes only briefly if there are no errors.

In case of an error, the error code is issued in the following order of the pulse modulation outputs:

☞ Channel 1/Magnet 1 > Pause > Channel 1/Magnet 2 > Pause > Channel 2/Magnet 1 > Pause > Channel 2/Magnet 2.

An error code (number of flash pulses) is assigned to each of the pulse modulation outputs:

ErrorcodeError

1No error

2Overload, overtemp

3Open load

4Short circuit on ground

The error code ends at the last output stage by displaying an error.

Examples:

➥ A: channel 2/magnet 1 has an “open load” interruption. The following flash sequence is then issued:

1 > Pause > 1 > Pause > 3

Cause of error: interruption of coil from solenoid valve (Y19), wiring interrupted, contact error on plug (Y16; X11).

➥ B: channel 1/magnet 1 has an “Overtemp” error and channel 2 has a “Short circuit to ground” error, the following flash sequence is issued:

2 > Pause > 1 > Pause > 1 > Pause > 4

Cause of error:

• Channel 1: output stage overload; short circuit of coil from solenoid valve, short circuit of valve wiring (not to ground or operating voltage).

• Channel 2: wiring, ground contact in valve.

918279/AP05087-10PrintedinU.S.A

Options

TORQUE SPECIFICATIONS

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

Hydraulicfittingswithvariousseals(lightapplication).Alltorquevaluesareinlb.-ft.(Nm)unlessmarkedotherwise. ThreadStraightpipefittingwiththreadandscrewedplug(GE)Non-returnvalve withelasticseal Identificationaid SealingoutsideØ washerElasticsealO-ring

Hydraulicfittingswithvariousseals(heavyapplication).Alltorquevaluesareinlb.-ft.(Nm)unlessmarkedotherwise.

ThreadStraightpipefittingwiththreadandscrewedplug(GE)Non-returnvalve withelasticseal Identificationaid SealingoutsideØ washerElasticsealO-ring

M10X1.07 (9)13 (18)11 (15)13 (18)0.4 in. (10 mm) M12X1.515 (20)18 (25)18 (25)18 (25)0.5 in. (12 mm) M14X1.526 (35)33 (45)26 (35)26 (35)0.6 in. (14 mm) M16X1.533 (45)41 (55) 30 (40)37 (50)0.6 in. (16 mm) M18X1.541 (55)52 (70)33 (45)52 (70)0.7 in. (18 mm) M22X1.548 (65)92 (125)44 (60)92 (125)0.9 in. (22 mm) M27X2.066 (90)133 (180)74 (100)107 (145)1.0 in. (27 mm) M33X2.0111 (150) 229 (310)118 (160)155 (210)1.3 in. (33 mm) M42X2.0177 (240)332 (450)155 (210)266 (360)1.7 in. (42 mm) M48X2.0214 (290)398 (540)192 (260)398 (540)1.9 in. (48 mm) G1/8A7 (9)13 (18)11 (15)13 (18)0.4 in. (9.73 mm) G1/4A26 (35)26 (35)22 (30)26 (35)0.5 in. (13.16 mm) G3/8A33 (45)52 (70)33 (45)37 (50)0.7 in. (16.66 mm) G1/2A48 (65)66 (90)41 (55)48 (65)0.8 in. (20.96 mm) G3/4A66 (90)133 (180)74 (100)103 (140)1.0 in. (26.44 mm) G1A111 (150)229 (310)118 (160)140 (190)1.3 in. (33.25 mm) G1 1/4A177 (240)332 (450)155 (210)266 (360)1.7 in. (41.91 mm) G1 1/2A214 (290)398 (540)192 (260)398 (540)1.9 in. (47.80 mm)

M12X1.515 (20)26 (35)26 (35) 26 (35)0.5 in. (12 mm) M14X1.526 (35)41 (55)33 (45) 33 (45)0.6 in. (14 mm) M16X1.533 (45)52 (70)41 (55) 41 (55)0.6 in. (16 mm) M18X1.541 (55)66 (90)52 (70)52 (70)0.7 in. (18 mm) M20X1.541 (55)92 (125)59 (80)74 (100)0.8 in. (20 mm) M22X1.548 (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) M33X2.0111 (150)229 (310)229 (310)155 (210)1.3 in. (33 mm) M42X2.0177 (240)332 (450)243 (330)266 (360)1.7 in. (42 mm) M48X2.0214 (290)398 (540)310 (420)398 (540)1.9 in. (48 mm) G1/8A26 (35)41 (55)33 (45)33 (45)0.5 in. (13.16 mm) G1/4A33 (45)59 (80)44 (60)44 (60)0.7 in. (16.66 mm) G3/8A48 (65)85 (115)55 (75)74 (100)0.8 in. (20.96 mm) G1/2A66 (90)133 (180)125 (170)107 (145)1.0 in. (26.44 mm) G3/4A111 (150)229 (310)229 (310)192 (260)1.3 in. (33.25 mm) G1A177 (240)332 (450)243 (330)266 (360)1.7 in. (41.91 mm) G1 1/4A214 (290)398 (540)310 (420)398 (540)1.9 in. (47.80 mm)

Withcoarse-pitchthread.Alltorquevaluesareinlb.-ft.(Nm)unlessmarkedotherwise.

ThreadThreadsaccordingtoDIN912,DIN931,DIN933,etc.ThreadsaccordingtoDIN7984

Withfine-pitchthread.Alltorquevaluesareinlb.-ft.(Nm)unlessmarkedotherwise.

8.810.912.98.810.9 M54.1 (5.5)6 (8)7 (10)4 (5)5 (7) M67 (10)10 (14)13 (17)6.3 (8.5)9 (12) M818 (25)26 (35)31 (42)15 (20)22 (30) M1033 (45)48 (65)59 (80)30 (40)44 (59) M1264 (87)81 (110)108 (147)51 (69)74 (100) M14100 (135)133 (180)170 (230)81 (110)118 (160) M16155 (210)203 (275)258 (350)125 (170)184 (250) M18207 (280)302 (410)354 (480)181 (245)254 (345) M20302 (410)420 (570)509 (690)251 (340)361 (490) M22406 (550)575 (780)686 (930)339 (460)487 (660) M24524 (710)738 (1000)878 (1190)435 (590)620 (840) M27767 (1040)1092 (1480) 1305 (1770)642 (870)922 (1250) M301047 (1420)1482 (2010)1770 (2400)885 (1200)1254 (1700)

ThreadThreadsaccordingtoDIN912,DIN931,DIN933,etc.ThreadsaccordingtoDIN7984 8.810.912.98.810.9 M8X1.018 (25)27 (37)32 (43)16 (22)24 (32) M10X1.037 (50)55 (75)65 (88)32 (43)48 (65) M10X1.2536 (49)52 (71)61 (83)31 (42)46 (62) M12X1.2564 (87)96 (130)111 (150)55 (75)81 (110) M12X1.561 (83)92 (125)107 (145)53 (72)77 (105) M14X1.5100 (135)148 (200)173 (235)89 (120)129 (175) M16X1.5155 (210)229 (310)266 (360)133 (180)195 (265) M18X1.5232 (315)332 (450)391 (530)199 (270)284 (385) M20X1.5325 (440)465 (630)538 (730)277 (375)391 (530) M22X1.5435 (590)620 (840)723 (980)369 (500)524 (710) M24X2.0546 (740)789 (1070)922 (1250)465 (630)664 (900) M27X2.0811 (1100)1143 (1550)1328 (1800)679 (920)959 (1300) M30X2.01106 (1500) 1586 (2150)1844 (2500)959 (1300)1364 (1850)

918196/AP0508©2006GEHLCompany.Allrightsreserved.PrintedinU.S.A. ® Mustang Manufacturing Co., Inc. 1880 Austin Road, P.O. Box 547, Owatonna, Minnesota, 55060-0547 USA www.mustangmfg.com 918279/AP0508 © 2008 MUSTANG MANUFACTURING COMPANY, INC. PRINTED IN USA All Rights Reserved.