"Service Manual _1000081433 for Wacker Neuson Compact Excavators 2503, 3503, 3003, 3703"

Service-Manual

Compact Excavator

Machine model

2503 - 3703

Edition

1.1

Language

English

Itemn No.

1000081433

Documentation Description

Order no.

Operation manual

1000081417

Service manual

1000081433

Spare parts list

1000015263 / 2503 1000015264 / 3003 1000142100 / 3503 1000142112 / 3703

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

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

SERV-HB 2503 - 3703 1000081433 1.1

TABLE OF CONTENT : Chapter O Table of content / Product history

Page

A 1 2 3 4 5

Technical data Primary dimensions Lift capacities Hydraulic settings Diesel engine settings Tightening torques

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

A2 A9 A15 A19 A22

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

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

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

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

Auxiliary hydraulic ........................................................ ..

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

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

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

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

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

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

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

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

B2 B6 B8 B15 B16 B16 B17 B17 B18 B18 B20 B21

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

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

Component positions ........................................................ ..

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

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

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

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

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

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

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

Switch valves ........................................................ ..

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

Pressure limiting valve (Vario) .................................................

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

C2 C5 C7 C12 C17 C33 C36 C42 C52 C55 C58 C59 C60

D E F G

Diesel engine Elektric Operation elements Attachment

Abbreviations: AP ...

MP ...

PPLV ...

SPLV ...

TT ...

Pb1 ...

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

Edition January 2003, Copyright Neuson Baumaschinen Neuson reserves changes.

Ing. Andreas Huemer ( Neuson Training )

Tel.: ++43 / 732 /90 5 90 - 0 Email.: andreas.huemer@neuson.com

PRODUCT HISTORY This overall lists the main technical modifications of the excavator type Neuson 2503 Step

Excavator code

Fabr.No.:

Production start

2503 RD

AB00001 (SNews 47/01) AB00806 (SNews 50/01) AC00307

Version

.

2503 „AD“

-

AC00351 AC00901 AD00001 (SNews 72/02) (SNews 74/02)

-

AD00029

-

Neuson 3003 Step

Excavator code

Fabr.No.:

Production start

3003 RD

AB00001 (SNews 47/01) AB00806 (SNews 50/01) AC00307

Version

Modification / Part group Rear counterweight opening mechanism Diode ignition lock (SNews53) Relays dozer blade function Lower windscreen seal modification (SNews 61/01) Fuel tank version plastic (SNews 70/02) Swivel unit new (SNews 72/02) Diesel engine Yanmar (SNews 73/02) Joystick console short (IV) Joystick console (IV) hardening cover Sticker design Wiring and instrument panel changed Diesel engine maintenance intervals extension possible (SNews 71/02) Fuel tank ventilation filter (SNews 70) .

3003 „AD“

Modification / Part group -

AC00351 AC00901 AD00001 (SNews 72/02) (SNews 74/02)

-

AD00029

-

Rear counterweight opening mechanism Diode ignition lock (SNews53) Relays dozer blade function Lower windscreen seal modification (SNews 61/01) Fuel tank version plastic (SNews 70/02) Swivel unit new (SNews 72/02) Diesel engine Yanmar (SNews 73/02) Joystick console short (IV) Joystick console (IV) hardening cover Sticker design Wiring and instrument panel changed Diesel engine maintenance intervals extension possible (SNews 71/02) Fuel tank ventilation filter (SNews 70)

PRODUCT HISTORY This overall lists the main technical modifications of the excavator type Neuson 3503 Step

Excavator code

Fabr.No.:

Production start

3503 RD

AB00001 (SNews 47/01) AB00806 (SNews 50/01) AC00307

Version

.

3503 „AD“

AC00413 AC00901 AD00001 (SNews 72/02) (SNews 74/02)

AD00029 Neuson 3703 Step

Excavator code

Fabr.No.:

Production start

3703 RD

AB00001 (SNews 47/01) AB00806 AB01031 (SNews 50/01) AC00307

Version

3703 „AD“

AC00413 AC00901 AD00001 (SNews 72/02) (SNews 74/02)

AD00029

Modification / Part group -

-

Rear counterweight opening mechanism Diode ignition lock (SNews53) Relays dozer blade function Lower windscreen seal modification (SNews 61/01) Fuel tank version plastic (SNews 70/02) Swivel unit new (SNews 72/02) Diesel engine Yanmar (SNews 73/02) Hydraulic pump new Joystick console short (IV) Joystick console (IV) hardening cover Sticker design Wiring and instrument panel changed Diesel engine maintenance intervals extension possible (SNews 71/02) Fuel tank ventilation filter (SNews 70) .

Modification / Part group Rear counterweight opening mechanism Diode ignition lock (SNews53) Release hose tilt cylinder (SNews 59/01) Relays dozer blade function Lower windscreen seal modification (SNews 61/01) Fuel tank version plastic (SNews 70/02) Swivel unit new (SNews 72/02) Diesel engine Yanmar (SNews 73/02) Hydraulic pump new (SNews 73/02) Joystick console short (IV) Joystick console (IV) hardening cover Sticker design Wiring and instrument panel changed Diesel engine maintenance intervals extension possible (SNews 71/02) Fuel tank ventilation filter (SNews 70)

SERVICE MANUAL

Technical data

2503 - 3703

CHAPTER A:

Technical data ( Neuson Service Manual 2503 - 3703 )

Page A1

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

1. DIMENSIONS

Page A2

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Primary dimensions

Page A3

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Primary dimensions Neuson 3503

Page A4

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Primary dimensions Neuson 3703

Page A5

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Primary dimensions

Unit

2503

3003

>> S tarting with Fab r.No.

3503

AB00001

Dimensions ( H x W x L )

mm

Transport length

mm

4410

4695

5170

2370 / 1370 / 3050 2400 / 1480 / 3150 2405 / 1620 / 3360

B oom swing angle

Left / right

degr

80 / 45

80 / 45

80 / 45

Front b oom swing radius

m in

mm

1360

1390

1470

degr

N

N

N

mm

270

275

280

mm

1370

1480

1620

mm

250

300

300

Tilt angle uppercarriage Ground clearance

m ax

Undercarriage width Track width

S tandard

Max. Dump height

S tandard

mm

2925

3150

3620

Max. Dump height / Option

Dipperstick long

mm

3090

3325

3820

Max. Dig height

S tandard

mm

4125

4470

4910

Max. Dig height / Option

Dipperstick long

mm

4260

4635

5110

Max. Dig radius

S tandard

mm

4515

4800

Max. vertical dig depth

S tandard

mm

1810

1990

Max. dig depth

S tandard

mm

2620

2770

3230

mm

1240

1260

1400 1620 / 370

Min. tail s wing radius

2220

Dozer b lade dim ens ions ( W x H )

S tandard

mm

1370 / 340

1480 / 370

Dozer b lade dim ens ions ( W x H )

E xtension

mm

N

N

N

Dozer b lade m ax. lift ... Ground

ab ove / b elow

mm

390 /415

400 / 450

410 / 490

Track rollers / guide rollers

per s ide

pcs

3/ 1

4/ 1

4/ 1

Operation weight with

Cab

kg

2600

3120

3500

Operation weight with

Canopy

kg

2525

3025

3405

Ground pressure

S tandard

k g/cm ²

0,33

0,32

0,33 30 / 58

Gradab ility

degr / %

30 / 58

30 / 58

Noise level

LW A

dB (A )

94

95

95

Noise level

LP A

dB (A )

74

76

74

Travel speed

Drive

k m /h

2,2 / 4,3

2,4 / 4,7

2,5 / 5,0

Tear out force per

B uck et tooth

kp

1970

2700

2980

Max. dipper stic k tear out force S lew ( swivel- ) speed

S tandard Uppercarriage

kp rpm

1270 9

1590 10

2020 10

E xplaination: O... Option N... No / Not F... Missing inform ation

Page A6

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

KINEMATIC

2.

Tab.: Kinematic Unit

2503

3003

3503

E

Bolt diameter

mm

32

40

F

Dipper stick width

mm

118

140

L

Bolt distance Bucket carrier

mm

129,5

180

Page A7

3703

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Kinematic Overall

Kinematic

Unit

1200 - 1501 RD 1302 - 1502 RD

1702 - 2201 RD 1702 - 2202 RD

2100 - 2700 RD

30

E

Bolt diameter

mm

F

Dipper stick width

mm

108

32

L

Bolt distance Buck et carrier

mm

108

268

129,5

Unit

2600 - 2800 RD 2702 - 2902 RD

3000 - 3200 RD 3402 - 3602 RD

3800 WD 3802 WD

118

5000,5001 RD 5501 WD

E

Bolt diameter

mm

40

50

F

Dipper stick width

mm

140

195

L

Bolt distance Buck et carrier

mm

155,5

236

Unit

1403

1503

E

Bolt diameter

mm

32

F

Dipper stick width

mm

118

L

Bolt distance Buck et carrier

mm

129,5

Unit

2503

3003

1903

2203

3503

3703

E

Bolt diameter

mm

32

40

F

Dipper stick width

mm

118

140

L

Bolt distance Buck et carrier

mm

129,5

180

Unit

5002

6002

6502

8002

12002

Bolt diameter

mm

50

50

55

60

F

Dipper stick width

mm

195

195

170

220

L

Bolt distance Buck et carrier

mm

236

236

300

445

E

Page A8

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703 3.

LIFT CAPACITY CHARTS

Tab.: Lift capacity - 2503

Page A9

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Lift capacity - 3003

Page A10

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Lift capacity - 3003 Vario

Page A11

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Lift capacity - 3503

Page A12

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Lift capacity - 3503 Vario

Page A13

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Lift capacity - 3703

Page A14

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Legend - Lift capacity charts Max ..................................................................... admissible load with dipper stick straight A .........................................................................................projection from live ring centre B ......................................................................................................... height of lifting hook * ........................................................................... lifting power limited by hydraulic system All values of the table are specified in kg, in horizontal position on solid subsoil and without bucket. .... with dozer blade supported, in travelling direction ... without dozer blade supported, 90° to travelling direction ... without dozer blade supported, 90° to travelling direction superstructure shifted backward by means of option VARIO ... without dozer blade supported, 90° to travelling direction superstructure shifted forward by means of option VARIO If a bucket or other working facilities are installed, the lifting power or tilting load is reduced by the empty weight of such facilities.

Position on solid subsoil and without bucket.

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

WARNING! The Vario system deviates form ISO 10567 in some excavator positions. Other than specified by standard ISO 10567 any exceeding of the tilting load is announced by means of a warning device.

Page A15

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data 4.

2503 - 3703

CYCLE COURSES Neuson 2503

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 3003 Value

allow ed

normal

allow ed

Max. extension of the equipment, w ithout load

Braking angle

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Mark the outer rings of the thrust bearings w ith centering notches. Make the upper frame rotate of 360° and then release the hand grip. Measure the distance betw een the notches after the stop.

degrees

---

---

---

---

---

---

---

---

Max. extension of the equipment, w ithout load

UPPER FRAME ROTATION

Time required to start the rotation

90°

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required for 90° and 180° rotations after the control has been operated.

180°

sec.

Max. extension of the equipment, w ithout load

Time required for the rotation > Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required to perform 5 turns after a first settling turn.

Position for the check

Sw ing gearmotor > Engine off hydraulic drift > Hydraulic oil temperature: 45 - 55 °C > Stop the machine on a 15° plane w ith the boom at 45° w ith respect to the axis of the track frame. > Mark the position betw een the upper and track frame on the thrust bearing. > Measure the shift after 15 minutes. > Max. outreach > Weight in the bucket:

degrees

Hue 1 / 5

Page A16

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 3503 Unit

Check conditions

Neuson 3703

Value normal

Value

allow ed

normal

allow ed

Max. extension of the equipment, w ithout load

Braking angle

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Mark the outer rings of the thrust bearings w ith centering notches. Make the upper frame rotate of 360° and then release the hand grip. Measure the distance betw een the notches after the stop.

degrees

---

---

---

---

---

---

---

---

Max. extension of the equipment, w ithout load

UPPER FRAME ROTATION

Time required to start the rotation

90°

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required for 90° and 180° rotations after the control has been operated.

180°

Max. extension of the equipment, w ithout load

sec.

Time required for the rotation > Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Calculate the time required to perform 5 turns after a first settling turn.

Position for the check

Sw ing gearmotor > Engine off hydraulic drift > Hydraulic oil temperature: 45 - 55 °C > Stop the machine on a 15° plane w ith the boom at 45° w ith respect to the axis of the track frame. > Mark the position betw een the upper and track frame on the thrust bearing. > Measure the shift after 15 minutes. > Max. outreach > Weight in the bucket:

degrees

Hue 1 / 5

Page A17

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model

Upper frame rotation

Classification

Item

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

Neuson 2503

Check conditions

Unit

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

Neuson 3003

Value normal

Value

allow ed

normal

allow ed

cm3/min

> Hydraulic oil temperature: 45 - 55 °C > Bring the pressure to the max. value in the circuit to be checked

---

---

Position for the check

Travel speed > Engine speed: Max. (1) > Hydraulic oil temperature: 45 - 55 °C > Low er the bucket to the ground and raise one track; mark a position; > Make one turn w ith the track and then calculate the time necessary to have the track make 5 turns. > Repeate w ith the second track

sec.

TRAVEL

Position for the check

Travel speed (2) > Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface long at least 10m; calculate the time necessary to cover 20 meters.

Position for the check

Deviation during w ork

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface, long 20m, and measure the deviation. > The surface must be compact and horizontal

mm

> Measure dimension X Hue 2 / 5

Page A18

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model

Upper frame rotation

Classification

Item

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

Neuson 3503

Check conditions

Unit

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

Neuson 3703

Value normal

Value

allow ed

normal

allow ed

cm3/min

> Hydraulic oil temperature: 45 - 55 °C > Bring the pressure to the max. value in the circuit to be checked

---

---

Position for the check

Travel speed > Engine speed: Max. (1) > Hydraulic oil temperature: 45 - 55 °C > Low er the bucket to the ground and raise one track; mark a position; > Make one turn w ith the track and then calculate the time necessary to have the track make 5 turns. > Repeate w ith the second track

sec.

TRAVEL

Position for the check

Travel speed (2) > Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface long at least 10m; calculate the time necessary to cover 20 meters.

Position for the check

Deviation during w ork

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Make the machine travel on a level surface, long 20m, and measure the deviation. > The surface must be compact and horizontal

mm

> Measure dimension X Hue 2 / 5

Page A19

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 2503

Check conditions

Unit

Neuson 3003

Value normal

Value

allow ed

normal

allow ed

Position for the check

TRAVEL

Travel motor hydraulic drift

mm > Engine off > Hydraulic oil temperature: 45 - 55 °C > Machine still on a plane w ith 20° inclination. > Measure the shift after 5 minutes.

Travel motor drainage

WORK EQUIPMENT (Hydraulic drift)

Com plete w ork equipm ent (Low ering of the bucket teeth point)

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Lock the track and measure the delivery.

cm3/min

Position for the check

> In this position it is possible to measure the extension or the retraction of each cylinder and the leaks w ith the load applied to the bucket teeth end. > Plane, level surface. dipper stick > Bucket: rated load cylinder (cylinder > Lever: neutral extension) > Engine off > Hydraulic oil temperature: 45 - 55 °C Bucket > Take the measures as soon as the engine cylinder (cylinder stops. retraction) > Measure the drainage every 5 minutes and check the total drainage after 15 minutes. dozer blade > ( ): bucket w ithout load (check of the § For the blade, raise and after 15 minutes blade edge measure the yields due to leaks. low ering) Boom cylinder (cylinder retraction)

mm

---

---

> Engine off > Hydraulic oil temperature: 45 - 55 °C > In the same position indicated above, stop the machine on a plane w ith 15° inclination Boom and position the upper frame at 90° offset sw ing Measure the extension and retraction of the cylinder after 15 minutes. > ( ): bucket w ithout load Drainage from each cylinder

> Hydraulic oil temperature: 45 - 55 °C > Introduce the max. pressure in the cylinder to be checked

cm3/min

---

---

Hue 3 / 5

Page A20

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model Classification

Item

Neuson 3503 Unit

Check conditions

Neuson 3703 Value

Value normal

allow ed

normal

allow ed

Position for the check

TRAVEL

Travel motor hydraulic drift

mm > Engine off > Hydraulic oil temperature: 45 - 55 °C > Machine still on a plane w ith 20° inclination. > Measure the shift after 5 minutes.

Travel motor drainage

WORK EQUIPMENT (Hydraulic drift )

Com plete w ork equipm ent (Low ering of the bucket teeth point)

> Engine speed: Max. > Hydraulic oil temperature: 45 - 55 °C > Lock the track and measure the delivery.

cm3/min

Position for the check

> In this position it is possible to measure the extension or the retraction of each cylinder and the leaks w ith the load applied to the bucket teeth end. > Plane, level surface. dipper stick > Bucket: rated load cylinder (cylinder > Lever: neutral extension) > Engine off > Hydraulic oil temperature: 45 - 55 °C Bucket > Take the measures as soon as the engine cylinder stops. (cylinder retraction) > Measure the drainage every 5 minutes and check the total drainage after 15 minutes. dozer blade > ( ): bucket w ithout load (check of the § For the blade, raise and after 15 minutes blade edge measure the yields due to leaks. low ering) Boom cylinder (cylinder retraction)

mm

---

---

> Engine off > Hydraulic oil temperature: 45 - 55 °C > In the same position indicated above, stop the machine on a plane w ith 15° inclination Boom and position the upper frame at 90° offset sw ing Measure the extension and retraction of the cylinder after 15 minutes. > ( ): bucket w ithout load Drainage from each cylinder

> Hydraulic oil temperature: 45 - 55 °C > Introduce the max. pressure in the cylinder to be checked

cm3/min

---

---

Hue 3 / 5

Page A21

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model Check conditions

Boom

Position for the check w ithout load

Unit

Value

---

---

LOWERING

---

---

IN

allow ed

---

---

OUT

normal

---

---

LOADING

allow ed

---

---

DUMPING

normal

---

---

RAISING

Bucket teeth onto the ground

Neuson 3003

Value

---

---

LOWERING

RAISING

Item

Neuson 2503

---

---

RIGHT

Classification

---

---

---

---

sec.

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

sec.

WORK EQUIPMENT (Speed )

Cylinder completely extended Bucket

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

Cylinder completely retracted

sec.

Cylinder > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dozer blade Position for the check Blade onto the ground

sec.

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

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

LEFT

Cylinder completely extended

sec.

Hue 4 / 5

Page A22

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Machine model Check conditions

Boom

Position for the check w ithout load

Unit

Value

---

---

LOWERING

---

---

IN

allow ed

---

---

OUT

normal

---

---

LOADING

allow ed

---

---

DUMPING

normal

---

---

RAISING

Bucket teeth onto the ground

Neuson 3703

Value

---

---

LOWERING

RAISING

Item

Neuson 3503

---

---

RIGHT

Classification

---

---

---

---

sec.

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

sec.

WORK EQUIPMENT (Speed )

Cylinder completely extended Bucket

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

Cylinder completely retracted

sec.

Cylinder > Engine speed: Max. completely > Hydraulic oil temperature: 45 - 55 °C extended Dozer blade Position for the check Blade onto the ground

sec.

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

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

LEFT

Cylinder completely extended

sec.

Hue 4 / 5

Page A23

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Neuson 2503

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 3003 Value

allow ed

normal

allow ed

Position for the check

Boom

sec.

---

---

sec.

---

---

sec.

---

---

sec.

---

---

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Retract the dipper stick and bucket cylinders completely. > Low er the boom from its maximum height and measure the time from the moment in w hich the bucket touches the ground to the moment in w hich the machine starts lifting.

WORK EQUIPMENT ( Response time )

Position for the check

Dipper stick > Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the dipper stick cylinder completely and then extend it. > Measure the time from the moment in w hich it starts moving again.

Position for the check

Bucket

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the bucket cylinder completely, then extend it . > Measure the time from the moment in w hich the bucket stops at the dead center and the moment in w hich it starts moving again.

Position for the check

Dozer blade

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Raise the blade to the maximum height and then low er it. > Measure the time from the moment in w hich the blade touches the ground and the moment in w hich the machine starts lifting.

Hue 5 / 5

Page A24

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Cycle courses - excavators

Hueman / 25. April 03

Neuson 3503

Machine model Classification

Item

Check conditions

Unit

Value normal

Neuson 3703 Value

allow ed

normal

allow ed

Position for the check

Boom

sec.

---

---

sec.

---

---

sec.

---

---

sec.

---

---

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Retract the dipper stick and bucket cylinders completely. > Low er the boom from its maximum height and measure the time from the moment in w hich the bucket touches the ground to the moment in w hich the machine starts lifting.

Position for the check

WORK EQUIPMENT ( Response time )

Dipper stick

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the dipper stick cylinder completely and then extend it. > Measure the time from the moment in w hich it starts moving again.

Position for the check

Bucket

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Move the boom to the horizontal position > Retract the bucket cylinder completely, then extend it . > Measure the time from the moment in w hich the bucket stops at the dead center and the moment in w hich it starts moving again.

Position for the check

Dozer blade

> Engine speed: Min. Hydraulic oil temperature: 45 - 55 °C > Raise the blade to the maximum height and then low er it. > Measure the time from the moment in w hich the blade touches the ground and the moment in w hich the machine starts lifting.

Hue 5 / 5

Page A25

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data 5.

2503 - 3703

HYDRAULIC SYSTEM

Tab.: Hydraulic settings Excavator type

2503

Unit

S tarted with Fabr. No. . :

AB00001

3003

AD00001

AB00001

AD00001

HY DRAULI C P UMP

1

Variable / gear pump

Variable / gear pump

2528402

3028402

Type

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

System Version A 4 Version B 5 Oil flow rate - version. A 6 Oil flow rate - version. B 2 3

PVD-0B-24P-8G-4900A

PVD-1B-29P-10G-4903F

26,4+26,4+17,6

36,5+36,5+26,3

l/min l/min

DRUCKE I NS TE LLUNG Main pressure limiting valve 7

Pump P 1, P 2 Pump P 3

9

Pilot oil pressure Main valve block

225

225

+3 / -3

+3 / -3

+3 / -3

210

210

210

210

+2 / -3

+2 / -3

+2 / -3

+2 / -3

(2)

bar

35

35

35

35

bar

+4 / -0

+4 / -0

+4 / -0

+4 / -0

275

275

275

275

(3)

bar

+5 / -0

+5 / -0

+5 / -0

+5 / -0

(3)

bar

N 200

N 200

N 200

N 200

+2 / -4

+2 / -4

+2 / -4

+2 / -4

245

245

245

245

+5 / -5

+5 / -5

+5 / -5

+5 / -5

265

265

265

265

+5 / -5

+5 / -5

+5 / -5

+5 / -5

Secondary press. limit. valve 10

240

+3 / -3

bar

Main pressure limiting valve 8

240 (2)

Secondary press.limit.valve

Dozer blade valve Swivel motor (SPLV) 13 (Measured at the motor) 11

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

bar bar

For correct settings : (1)...Generel - Hydraulic oil temperature: 45 - 50°C (2)...Settings at max. engine rpm (see chap. Maintenance) (3)...Settings at min. engine rpm (see chap. Maintenance)

16

QUANTI TI E S Hydraulic oil tank

Liter

27

27

27

27

17

System filling

Liter

42

42

42

42

Explanation: N...Not enclosed / not available

Page A26

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Hydraulic settings Excavator type

3503

Unit

S tarted with Fabr. No. . :

AB00001

3703 AD00001

AB00001

AD00001

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

Type

3528402

4408302

3528402

Variable/gear pump

4408302

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

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

PVD-1B-32P-10G- PVD-2B-44P-12G- PVD-1B-32P-10G- PVD-2B-44P-12G4904F 4713F 4904F 4713F

3

l/min l/min

39,2+39,2+25,7

45,1+45,1+25,5

39,2+39,2+25,7

45,1+45,1+25,5

240

240

240

240

+3 / -3

+3 / -3

+3 / -3

+3 / -3

210

210

210

210

+2 / -3

+2 / -3

+2 / -3

+2 / -3

35

35

35

35

+4 / -0

+4 / -0

+4 / -0

+4 / -0

DRUCKE I NS TE LLUNG Main pressure limiting valve 7

Pump P 1, P 2

(2)

bar

Main pressure limiting valve 8

9

Pump P 3

(2)

Pilot oil pressure

bar bar

275

275

275

275

(3)

bar

+5 / -0

+5 / -0

+5 / -0

+5 / -0

(3)

bar

N 200

N 200

N 200

N 200

+2 / -4

+2 / -4

+2 / -4

+2 / -4

235 - 1. Speed 255 - 2. Speed

235 - 1. Speed 255 - 2. Speed

235 - 1. Speed 255 - 2. Speed

235 - 1. Speed 255 - 2. Speed

Secondary press. limit. valve 10

Main valve block Secondary press.limit.valve

Dozer blade valve Swivel motor (SPLV) 13 (Measured at the motor) 11

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

bar bar

+5 / -5

+5 / -5

+5 / -5

+5 / -5

265

265

265

265

+5 / -5

+5 / -5

+5 / -5

+5 / -5

For correct settings : (1)...Generel - Hydraulic oil temperature: 45 - 50°C (2)...Settings at max. engine rpm (see chap. Maintenance) (3)...Settings at min. engine rpm (see chap. Maintenance)

QUANTI TI E S 16

Hydraulic oil tank

Liter

50

50

50

50

17

System filling

Liter

75

75

75

75

Explanation: N...Not enclosed / not available

Theme: Service News

Fabr.Nr.:

Service News 73/02: New hydraulic pump 35-3703 starting with diesel engine Yanmar type (setting !)

AD00001 and higher

Page A27

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab. Pressure controlled oil flow - auxiliary hydraulic

AUXILIARY HYDRAULIK Excavator

2503

3003

3503 / 3703

Pump 2528402

Pump 3028402

Pump 3528402

Pressure control led oil flow - auxil iary hydraulic ( L / min )

Pressure ( b ar )

P2 + P3

P2

P2 + P3

P2

P2 + P3

P2

12

44,0

25,0

58,0

35,0

62,0

37

25

44,0

25,0

58,0

35,0

62,0

37

60

41,0

24,0

57,0

33,0

60,0

36

90

38,0

23,0

55,0

31,0

55,0

35

120

34,0

22,0

49,0

30,0

49,0

34

150

30,0

21,0

44,0

29,0

42,0

32

180

24,0

19,0

38,0

28,0

36,0

30

Conditi ons: 1) Oil flow list valid for Fabr.No.: AB00001 - AC09999 2) Tolerance of the listed settings : +1 / -2 L/min 3) Pressure = Pressure setting at the tool (bucket) 4) Values measured direct at the couplings at the dipper stick

Tab.: Clearance - Hose burst protection valves (inside hose versions) S

1

Id.No.:* 1108384 1208728 1428449 2208301 2528478 3028434 3528434 3808632 4508563 3408571 5508607 7008563

Excavator 12002 1402-2202 1403-2203 2203 2503 3003 3507, 3703 2702-3602, 3802 WD 5002 6002 6502 8002, 12002

assembled at the Triple boom cyl.

Dozer blade cyl.

Dozer blade cyl.

Tilt cylinder Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Dozer blade cyl.

Screw size 3/4" 3/8" 3/8" 1/4" 3/8" 3/8" 1/2" 3/8" 1/2" 1/2" 3/8" 1/2"

Clearance S 2,2 mm 0,7 mm 1 mm 0,4 mm 0,8 mm 1,8 mm 1,0 mm 1,2 mm 1,2 mm 1,5 mm 1,5 mm 3,4 mm

* Attention: Neuson reserves changes (09.07.02) Please, see the item No. From the actual spare parts books !. Hg/hue

Page A28

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703 6.

DIESEL ENGINE

Version KUBOTA

Tab.: Diesel engine settings - ( Fabr.No.: AB00001 - AC09999 ) Excavator type

Unit

Neuson

Neuson

Neuson

Neuson

2503

3003

3503

3703

S P E CI F I CA T I O N:

1

Diesel engine model

2

Started with Neuson Fabr.No.:

3

Type Suction system Combustion system Glow system

4 5 6 7 8 9 10 11

12

Kubota

Kubota

D 140 3 -B(E)

D 170 3 -B(E) AB 00001

Vertical, 4-cycle water cooled diesel engine Natural suction Special swirl pre-combustion chamber Glow plugs inside the pre.comb. Chamber Counterclock wise (viewed from flywheel) Mechanical centrifugal governor

Direction of rotation Governor

Pressured lubrication Electrical W ater cooled / Suction van

Lub rication system Starting system Cooling system DA T A : Max. revolution speed ( no load )

rpm

232 0 +0 / -50

rpm

F

rpm

220 0 +50 / -50

251 5 +0 / -50

Max. rev.speed with load 13

14

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

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

rpm ccm 1393 ( 80x92,4 ) KW ( PS ) 18,0 ( 24,5 ) KW ( PS ) 21,6 ( 29,4 ) pcs mm deg bar bar bar bar °C °C °C A/V V / Ah mm

Page A29

F

F

F

245 0 +50 / -50 110 0 +50 / -50 1647 ( 87x92,4 ) 23,3 ( 31,7 ) 25,7 ( 35,0 ) 3 0,18 - 0,22 ( k alt ) 23,0 18 +/-1 140 - 150 36 - 38 at 250 rpm (Limit: 26 b ar) 3,0 - 4,0 0,5 - 1,0 69,5 - 72,5 85 118 / ?

1-2-3 30 / 12 12 / 70

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Diesel engine settings - ( Fabr.No.: AB00001 - AC09999 )

Excavator type

Unit

KUBOTA

Neuson

Neuson

Neuson

Neuson

2 50 3

3 00 3

3 50 3

3 70 3

T I G HT E NI NG T O RQ UE S : 34 Cylinder head bolt

Nm

35 Bonnet screw nut

Nm

36 Connection rod bolt

Nm

37 Metal cap clamping bolt

Nm

38 Flywheel clamping bolt

Nm

39

Glow plug Q UANT I T I E S

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

93,1 - 98,0 ( M11x1,25 ) 6,9 - 8,8 ( M8x1,25 ) 44,1 - 49,0 ( M8x1,0 ) 196,1 - 215,8 ( M30x1,5 ) 98,0 - 107,8 ( M12x1,25 ) 19,6 - 24,5 ( M10x1,25 )

Nm 41

Liter Liter Liter

52 7,0 / 5,6 2,7

Q UALI T Y 43 Engine oil

Quality

MIL-L-2104C

Page A30

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703 6.

DIESEL ENGINE

Version YANMAR

Tab.: Diesel engine settings - ( Fabr.No.: AD00001 and higher ) Excavator type

Unit

Neuson

Neuson

Neuson

Neuson

2503

3003

3503

3703

S P E CI F I CAT I O N:

1

Diesel engine model

2

Started with Neuson Fab r.No.:

3

Type Suction system Comb ustion system Glow system

4 5 6

8

Direction of rotation Governor

9

Lub rication system

7

Y anm ar

Y anm ar

Y anm ar

3T NE88-ENSR 1

3T NE88-ENSR 2

4 TN E 8 8 - E N S R

A D0 00 0 1 Vertical, 4-cycle water cooled diesel engine Natural suction Direct injection system Preheater, time relay controlled Counterclock wise (viewed from flywheel) Mechanical centrifugal governor Forced lubrication with trochoid pump Electrical W ater cooled / Suction van

10 Starting system 11 Cooling system

DAT A: Max. revolution speed rpm

2 37 5 +50 / -50

2 65 0 +50 / -50

2 00 0 +50 / -50

13

rpm

1 05 +25 / -25

1 00 +25 / -25

3 00 +25 / -25

14 Revolution speed

rpm

2 20 0 +25 / -25

2 50 0 +25 / -25

1 90 0 +25 / -25

12 ( no load )

Max. rev.speed with load

Min. revolution speed 15 (no load) 16 Displacement (Bore x Strok e) 17 Output ( at rev. Speed 14 ) 18 Max. engine output 19 No. of cylinder 20 Valve clearance (IN=OUT)

rpm ccm KW ( PS ) KW ( PS ) pcs mm

1 10 0 +50 / -50 1642 ( 88x90 ) 19,5 (26,1) 27,1 ( 36,3 ) 3

21 Compression ratio 22 Fuel injection timing 23 Fuel injection pressure 24 Compression pressure 25 Engine oil pressure (rev. speed level) 26 Pressure switch engine oil pump 27 Thermostat opening temperature 28 Thermostat open total 29 Thermo switch On / Out

12 +/-1

deg b ar b ar b ar b ar °C °C °C

30 Firing order 31 Generator power (Standard) 32 Battery 33 V-Belt measurings

1-3-2-1 A/V V / Ah mm

12 / 71 12,5 x 1000

Page A31

2190 ( 88x90 ) 22,1 ( 29,6 ) 36,0 ( 48,0 ) 4 0,15 - 0,25 18,0 14 +/-1 220 - 230 35 +/-1 at 250 rpm 3,0 - 4,0 0,4 - 0,6

107-113 / 100 and more 1-3-4-2 (Nr.1- Zyl.Schwungradseit) 12/88 12,5 x 1000

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Technical data

2503 - 3703

Tab.: Diesel engine settings - ( Fabr.No.: AD00001 and higher ) Excavator type

Unit

YANMAR

Neuson

Neuson

Neuson

Neuson

2503

3003

3503

3703

T I G HT E NI NG T O RQ UE S : 87,0 - 93,0 ( M10x1,25 )

34 Cylinder head b olt

Nm

35 Bonnet screw nut

Nm

36 Connection rod b olt

Nm

37 Metal cap clamping b olt

Nm

38 Flywheel clamping b olt

Nm

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

Nm

N

39

Glow plug Q UANT I T I E S

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

Liter Liter Liter

75 7,5 / 4 6

7,5 / 4 6

7,5 / 4 6

7,5 / 4 6

Q UALI T Y 43 Engine oil

Quality

Theme: Service News

Fabr.Nr.:

API grade CC Klasse or higher

Service News 73/02: New diesel engine type Yanmar for 2503-3703 (settings !)

AD00001 and higher

Page A32

Id.No.: Edition:

9707748 Jan 03

Specifications 3TNV 88 – 4TNV 88 (supplement) Chassis

Sturdy steel sheet chassis, rubber-mounted engine

3 TNV88 engine Engine

Models 2503 – 3003

Product

Yanmar diesel engine

Model

3TNV88-SNS/3TNV88-NNS

Design

Water-cooled 4-stroke diesel engine, EPA2

No. of cylinders

3

Fuel injection system

Direct injection

Aspiration

Natural aspiration

Cooling system

Water-cooled

Lubrication system

Force-feed lubrication with trochoidal pump

Displacement

1642 cm³

Nominal bore and stroke

88 x 90 mm

Net output in kW

19.2 (2503)/21.6 (3003)

Max. torque in Nm

100 (2503)/21.6 (3003)

Max. engine speed without load rpm

2400 (2503)/2700 (3003)

Idling speed

1100 rpm

Valve tip clearance (intake = outlet)

0.15 – 0.25 mm (cold)

1 cylinder

Flywheel side

Compression

19.1 : 1

Compression: specified value

35+/- bar @ 250 rpm

Compression: threshold value

28+/- bar @ 250 rpm

Engine oil pressure

3.5 bar +/- 0.5 bar

Pressure switch for engine oil pump

0.5 +/- 0.1 bar

Thermostat opens at

69.5 – 72.5 °C

Thermal switch

107 – 113 °C

Firing order

1–3–2–1

Direction of rotation

Counterclockwise (as seen from the flywheel)

Starting aid

Intake manifold preheating (preheating time 10 – 15 sec)

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

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

Specific fuel consumption

265 g/kWh (SNS) 273 g/kWh (NNS)

Exhaust values according to

SERV_HB 2503-3703 – Edition 1.0 *2503-3703_EPA2 210.mif

97/68/EC Tier II EPA Tier II

A-33

Fuel injection pump

Model Design

YPD-MP2 Single piston distributor injection pump

Injection pressure

19.6 – 20.6 bar

Revs control

Mechanical

Injection time

12° (SNS) 14.5° (NNS)

Lubrication system

Forced feed lubrication

Capacities

Models 2503 – 3003

Capacity Fuel tank

41 l

Engine oil (max./effect.)

6.7 l/2.8 l

Coolant (engine)

2l

Radiator

2.9 l

Expansion tank

0.5 l

Tightening torque

A-34

Tightening torques

Models 2503 – 3003

Cylinder-head bolt

85.3 – 91.1 Nm (M10x1.25)

Connecting rod bearing screw

44.1 – 49 Nm (M9x1)

Main bearing screw

93.2 – 98.1 Nm (M12x1.5)

Flywheel screw

83.3 – 88.2 Nm (M10x1.25)

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA2 210.mif

Engine 4TNV 88

Engine

Models 3503 – 3703

Product

Yanmar diesel engine

Model

4TNV88-WNS

Design

Water-cooled 4-stroke diesel engine, EPA2

No. of cylinders

4

Fuel injection system

Direct injection

Aspiration

Natural aspiration

Cooling system

Water-cooled/aspirating fan

Lubrication system

Force-feed lubrication with trochoidal pump

Displacement

2189 cm³

Nominal bore and stroke

88 x 90 mm

Output

23.7 kW @ 2000 rpm

Max. torque

131.4 – 143.2 Nm @ 1200 rpm

Max. engine speed without load

2025 +/- 25 min-1 (Neuson setting, initial setting by manufacturer is 2180 rpm)

Idling speed

1100 +/- 25 rpm

Valve tip clearance (intake = outlet)

0.15 – 0.25 mm (cold)

Compression

35 +/- 1 bar @ 250 rpm

Engine oil pressure

3 – 4 bar

Pressure switch for engine oil pump

0.5 +/- 0.1 bar

Thermostat opens at

69.5 – 72.5 °C

Thermal switch

107 – 113 °C

Firing order

1–3–4–2–1

Direction of rotation

Counterclockwise (as seen from the flywheel)

Starting aid

Intake manifold preheating (preheating time 10 – 15 sec)

Max. inclined position (engine still supplied with oil): Specific fuel consumption Exhaust values according to

SERV_HB 2503-3703 – Edition 1.0 *2503-3703_EPA2 210.mif

30 ° in all directions 35°/58 % 3 minutes.

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

250 g/kWh 97/68/EC Tier II EPA Tier II

A-35

Fuel injection pump Model Design

YPD-MP2 Single piston distributor injection pump

Injection pressure

220 – 230 bar

Revs control

Mechanical

Injection time

16°

Lubrication system

Forced feed lubrication

Engine capacities Capacities

Models 3503 – 3703

Fuel tank

52 l

Engine oil (max./effect.)

7.4 l/3.4 l

Coolant (engine)

2.7 l

Radiator

2.9 l

Expansion tank

0.5 l

Tightening torques

Models 3503 – 3703

Engine tightening torques

A-36

Cylinder-head bolt

85.3 – 91.1 Nm (M10x1.25)

Connecting rod bearing screw

44.1 – 49 Nm (M9x1)

Main bearing screw

93.2 – 98.1 Nm (M12x1.5)

Flywheel screw

83.2 – 88.2 Nm (M10x1.25)

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA2 210.mif

Page A37

100 Nm 180 Nm

SW 36

SW 41

M30x2

M36x2

20 22L

25 28L

Id.No.: Edition:

270 Nm SW 50 M42x2

25 30S

400 Nm

180 Nm SW 41 M36x2

20 25S

SW 60

100 Nm SW 36

M30x2

16 20S

M52x2

90 Nm SW 30

12 16S M24x1,5

32 38S

75 Nm

SW 27

10 14S M22x1,5

Surface galvanic coated and dry (O-Ring oiled). Tolerance torque -10 %

220 Nm

85 Nm

SW 32

16 18L M26x1,5

SW 55

75 Nm

SW 27

12 15L M22x1,5

M45x2

50 Nm

SW 22

10 12L M18x1,5

60 Nm

SW 24

08 12S M20x1,5

2503 - 3703

32 35L

40 Nm

50 Nm

SW 22

06 10S M18x1,5

20 Nm

SW 17

M14x1,5

8L

06

SW 19

40 Nm

SW 19

M16x1,5

8S

05

15 Nm

SW 14

M12x1,5

6L

05

08 10L M16x1,5

Torque

Tool

Screw

RA

DN

Torque

Tool

Screw

RA

Heavy type (DKOS)

DN

Light version (DKOL)

Quelle: Fa. Schieffer

Metric hose joints for hydraulic assembling

for hydraulic joints and dry assembling

Quelle: Fa. Schieffer

7.

Tightening torque

SERVICE MANUAL Technical data

TIGHTENING TORQUES

9707748 Jan 03

Metric screw

33 mm 42 mm 48 mm 9,73 mm

70 Nm

125 Nm

180 Nm 100 Nm 145 Nm

M18x1,5 55 Nm

M22x1,5 65 Nm

M27x2,0 90 Nm

M33x2,0 150 Nm 310 Nm 160 Nm 210 Nm

M42x2,0 240 Nm 450 Nm 210 Nm 360 Nm

M48x2,0 290 Nm 540 Nm 260 Nm 540 Nm

9 Nm

35 Nm

G 1/8A

G 1/4A

150 Nm 310 Nm 160 Nm 190 Nm 33,25 mm

G 1A

20,96 mm

Id.No.: Edition:

100 Nm

70 Nm

55 Nm

45 Nm

35 Nm

75 Nm

16,66 mm 100 Nm 20,96 mm

60 Nm

13,16 mm

180 Nm 170 Nm 145 Nm 26,44 mm

115 Nm

60 Nm

45 Nm

150 Nm 310 Nm 310 Nm 260 Nm 33,25 mm

90 Nm

65 Nm

80 Nm

45 Nm

G 1 1/2A 290 Nm 540 Nm 420 Nm 540 Nm 47,80 mm Toleranz der Drehmomente: - 10% ; Gegenwerk stoff: Stahl / Aluminium

G 1 1/2A 290 Nm 540 Nm 260 Nm 540 Nm 47,80 mm

G 1 1/4A 240 Nm 450 Nm 330 Nm 360 Nm 41,91 mm

G 1A

G 3/4A

G 1/2A

45 Nm

G 3/8A

55 Nm

48 mm

M48x2,0 290 Nm 540 Nm 420 Nm 540 Nm 35 Nm

42 mm

M42x2,0 240 Nm 450 Nm 330 Nm 360 Nm

G 1/4A

33 mm

M33x2,0 150 Nm 310 Nm 310 Nm 210 Nm

22 mm

20 mm

18 mm

16 mm

14 mm

12 mm

27 mm

90 Nm

M27x2,0

80 Nm

70 Nm

55 Nm

45 Nm

35 Nm

135 Nm 100 Nm 125 Nm

125 Nm

90 Nm

70 Nm

55 Nm

35 Nm

outside bore-Ø

180 Nm 170 Nm 135 Nm

65 Nm

55 Nm

M18x1,5

M22x1,5

45 Nm

M16x1,5

55 Nm

35 Nm

M14x1,5

M20x1,5

20 Nm

M12x1,5

Screw

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

G 1 1/4A 240 Nm 450 Nm 210 Nm 360 Nm 41,91 mm

180 Nm 100 Nm 140 Nm 26,44 mm

65 Nm

90 Nm

55 Nm

G 3/4A

90 Nm

65 Nm

16,66 mm

13,16 mm

22 mm

18 mm

16 mm

G 1/2A

50 Nm

35 Nm

18 Nm

125 Nm

70 Nm

50 Nm

14 mm

45 Nm

45 Nm

30 Nm

15 Nm

60 Nm

45 Nm

40 Nm

35 Nm

G 3/8A

70 Nm

35 Nm

18 Nm

27 mm

55 Nm

M16x1,5 45 Nm

35 Nm

12 mm

45 Nm

25 Nm

M14x1,5 35 Nm

25 Nm

10 mm

25 Nm

18 Nm

M12x1,5 20 Nm

15 Nm

18 Nm

outside bore-Ø

9 Nm

M10x1,0

Screw

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

Light verison

Screws with different seal types for hydraulic use

Tightening torques for hydraulic screw joints and dry assembling

Metric screw Whitworth screw

Page A38

Whitworth screw

Technical data SERVICE MANUAL

2503 - 3703

9707748 Jan 03

M 14x1,5 135 Nm 200 Nm 235 Nm 120 Nm 175 Nm M 16x1,5 210 Nm 310 Nm 360 Nm 180 Nm 265 Nm M 18x1,5 315 Nm 450 Nm 530 Nm 270 Nm 385 Nm M 20x1,5 440 Nm 630 Nm 730 Nm 375 Nm 530 Nm M 22x1,5 590 Nm 840 Nm 980 Nm 500 Nm 710 Nm

65 Nm

110 Nm 147 Nm

87 Nm

135 Nm 180 Nm 230 Nm 110 Nm 160 Nm

210 Nm 275 Nm 350 Nm 170 Nm 250 Nm

280 Nm 410 Nm 480 Nm 245 Nm 345 Nm

410 Nm 570 Nm 690 Nm 340 Nm 490 Nm

550 Nm 780 Nm 930 Nm 460 Nm 660 Nm

M 12

M 14

M 16

M 18

M 20

M 22

Page A39

Id.No.: Edition:

Allen Werten liegt ein Reibungskoeffizient von µ = 0,1 2 zugrunde und si nd al s Ri chtwert e anzuwenden.

DIN 912

M 30x2,0 1500 Nm 2150 Nm 2500 Nm 1300 Nm 1850 Nm

1420 Nm 2010 Nm 2400 Nm 1200 Nm 1700 Nm

105 Nm

110 Nm

M 30

72 Nm

75 Nm

62 Nm

M 27x2,0 1100 Nm 1550 Nm 1800 Nm 920 Nm 1300 Nm

125 Nm 145 Nm

130 Nm 150 Nm

42 Nm

1040 Nm 1480 Nm 1770 Nm 870 Nm 1250 Nm

83 Nm

87 Nm

83 Nm

M 27

M 12x1,5

M12x1, 25

71 Nm

65 Nm

M 24x2,0 740 Nm 1070 Nm 1250 Nm 630 Nm 900 Nm

100 Nm

59 Nm

49 Nm

43 Nm

710 Nm 1000 Nm 1190 Nm 590 Nm 840 Nm

69 Nm

40 Nm

M10x1, 25

88 Nm

2503 - 3703

M 24

80 Nm

30 Nm

75 Nm

32 Nm

45 Nm

20 Nm

50 Nm

22 Nm

M 10

42 Nm

M 10x1,0

43 Nm

35 Nm

12 Nm

37 Nm

25 Nm

8,5 Nm

25 Nm

10.9

M8

17 Nm

M 8x1,0

8.8

14 Nm

7 Nm

12.9

10 Nm

5 Nm

10.9

M6

10 Nm

8.8

Screws DIN 7984

8 Nm

10.9

Screws with DIN 912, DIN 931, DIN 933, usw.

5,5 Nm

8.8

Size

M5

12.9

Screws DIN 7984

10.9

Screw with DIN 912, DIN 931, DIN 933, usw.

with fine screw

8.8

Size

with Standard screw

Tightening torque M A for high quality screw joints

Tightening torque for high quality screws

SERVICE MANUAL Technical data

9707748 Jan 03

120 Nm*

180 Nm* 64 Nm* 123 Nm*

M14 10.9

M10 10.9

M12 10.9

Track roller

Swivel joint

Sprocket

Page A40

Id.No.: Edition:

50 Nm 138 Nm 87 Nm 50 Nm 64 Nm 25,5 Nm 50 Nm

M10 8.8

M14 8.8

M12 8.8

M10 8.8

M10 10.9

M8 8.8

M10 8.8

Engine frame bearings

Pump carrier M12 8.8

M10 8.8

M8 8.8

M10 10.9

M10 8.8

M12 8.8

M14 8.8

M10 8.8

M12 10.9

M12 10.9

M12 10.9

M12 10.9

M10 10.9

79 Nm

50 Nm

25,5 Nm

64 Nm

50 Nm

87 Nm

138 Nm

50 Nm

120 Nm*

120 Nm

123 Nm*

123 Nm*

64 Nm*

180 Nm*

180 Nm

M14 10.9 M14 10.9

299 Nm

M16 10.9

3003 RD

M12 8.8

M10 8.8

M8 8.8

M10 10.9

M10 8.8

M12 8.8

M14 8.8

M10 8.8

M12 10.9

M12 10.9

M12 10.9

M12 10.9

M10 10.9

M14 10.9

M14 10.9

M16 10.9

79 Nm

50 Nm

25,5 Nm

64 Nm

50 Nm

87 Nm

138 Nm

50 Nm

120 Nm*

120 Nm

123 Nm*

123 Nm*

64 Nm*

180 Nm*

180 Nm

299 Nm

3503 RD

M12 8.8

M10 8.8

M8 8.8

M10 10.9

M10 8.8

M12 8.8

M14 8.8

M10 8.8

M12 10.9

M12 10.9

M12 10.9

M12 10.9

M10 10.9

M14 10.9

M14 10.9

M16 10.9

79 Nm

50 Nm

25,5 Nm

64 Nm

50 Nm

87 Nm

138 Nm

50 Nm

120 Nm*

120 Nm

123 Nm*

123 Nm*

64 Nm*

180 Nm*

180 Nm

299 Nm

3703 RD

Attention: Neuson reserves changes - please always check the actual torque from your spare parts book

Pump

Engine carrier

79 Nm

120 Nm*

M12 10.9

M12 8.8

120 Nm

M12 10.9

Swivel unit

Cab screws

123 Nm*

M12 10.9

Drive unit

Turn table

M12 10.9

2503 RD

Tightening torque M A for screw joints at Neuson 2503 - 3703

Type relativ tightening torques for high quality screw joints

Technical data SERVICE MANUAL

2503 - 3703

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

CHAPTER B:

Maintenance ( Neuson Service Manual 2503 - 3703 )

Page B1

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance 1.

2503 - 3703

Maintenance schedule

Servicing activity component

Neuson 2503 - 3703

every 10 h

every 50 h

every 250 h

every 500 h every 1000 h

(daily)

(weekly)

(6 months)

(12 months)

(18 months)

annual

MOTOR Oil level

O

Fuel level

O

Leak age

O

Visual check

O

Air filter

O/X

Seating of mounting bolts Coolant

<>

<>

O O

Engine speed regulation

O

Exhaust system

O

Engine oil

O

Oil filter

<>(1)

<>

<>

<>(1)

<>

<>

V-belt: condition and tension

O

Cooler fins

X

Valve clearance

O

O

Generator, starter

O

Fuel tank

X

Water pump

O

Fuel filter

O

<>

<>

Cooling system and hoses

O

Electrical connections

O

Pre-glow system

O

Coolant thermostat

O

Battery fluid

O

O X

- Check - Clean

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

Page B2

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

Servicing activity component

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

(weekly)

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

annual

HYDRAULIC SYSTEM Fastening bolts Hydraulic pump

O

Leak age (lines, pumps, cylinders)

O

Hydraulic oil level

O

Oil cooler fins

X

Filter insert

<>(1)

O

Primary and secondary pressure limiting

<>

<>

O

valves Hydraulic oil

O

<>(1)

<>

Breather filter Filling strainer

<>

O

ELECTRICAL Indicator lamps

O

Function of system

O

Fastenings

O

TRAVELL GEAR Chain after work ing

O

Chain tension

O

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

O

TRAVEL G E A R U N I T Leak age

O

Gear oil

<>(1)

<>

<>

GEAR RING Bearing system

O

Gearing

<>

O X

- Check - Clean

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

Page B3

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

Servicing activity component

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

(weekly)

(6 months) (12 months)

every 1000 h (18 months)

HEATING Function

O

Leak age (cooling and heating circuit)

O

Seals

O

Fan

O

WORKING EQUIPMENT Lubricate lubricating points

O

Buck et teeth (fastening and wear)

O

Pin fastening

O

Line fastenings

O

Piston rods

O

Behaviour of hydraulic cylinder under load

O

O

Bush bearing play

O

Bearing play

O

GENERAL Operating elements

O

Hydraulic fittings

O

Bolts

O

Lights

O

Windscreen washing system Leak age check - visual check

O X

- Check - Clean

O O

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

Page B4

Id.No.: Edition:

9707748 Jan 03

annual

SERVICE MANUAL

Maintenance

2503 - 3703

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

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

Therefore, compliance with the specified maintenance work is first of all to the advantage of the owner of a machine.

Doing the specified maintenance work is made mandatory by the manufacturer. Any default will lead to restrictions of warranty.

For maintenance work at the engine please cf. the operating instructions for the engine.

If lubricants are used that are not in compliance with the manufacturer’s recommendation any guarantee becomes extinct.

Before starting maintenance and repair at your vehicle, please get informed about any damage that occurred.

Before starting maintenance or repair work lower the working equipment to the ground. Apply locking and safety levers.

Bleed residual pressure off the hydraulic system.

Let the engine cool down (hot cooling water).

If work must be done with the machine lifted, it must be appropriately secured (supported).

During maintenance or repair work in a closed room provide for sufficient ventilation.

Dispose of oil filters,oil, etc. as provided by the environmental law.

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

Page B5

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

2. LUBRICANTS LUBRICATION FILLINGS - EXCAVATORS USED AS

EX CAVA TOR LUBRI CATI ON TY PE

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

Engine oil

Syntetic Hydraulic oil

Bio oil

Turn table : Teeth Ball bearings

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

BP Energrease OG (Farbe weiss) BP Energrease L 21 M

Drive gears

Energear Hypo EP 90 API GL 5 FINA Pontonic MP85W90APIGL5 Q8 T55 85W90 RK 15, RK20S

Boom , dipper stick,..

SGXP 220 BP Energrease L 21 M Gleitmo 805 (For the first greasing of the bolts )

Track tension cylinder

Planetary gear Fix and float axles Distribution gear

Each Lubr. point

BP Energrease L 21 M

Wheeled excav.

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

BP Energrease L 21 M

Conditions: Engine oil: Grease:

von -25°C bis + 40°C Aussentemperatur von -25°C bis +40°C Aussentemperatur

Page B6

Id.No.: Edition:

9707748 Jan 03

Page B7

Id.No.: Edition:

45,6

Yanmar 4TNE98-NSR

Deutz 1012EC

8002RD

11002HV Forst

75

47,5

47,5

Yanmar 4TNE98-NSR

6002RD

Yanmar 4TNE98-NSR

30

Yanmar 4TNE88-NSW

5002RD

10L

10,2L

10,2L

10,2L

8,5L

8,5L

7,5L

6,9L

2,4L

2,4L

10L

8,7L

8,7L

8,7L

7L

7L

6L

4L

3,2L

3,2L

135L

122L

120L

120L

100L

79L

79L

68L

31L

31L

2,5L

2,5L

2L

2L

2L

1

1L

1L

/

/

2L

1,25L

/

1L

1L

/

0,75L

0,75L

0,5L

0,5L

Motor- Kühlflüs- Hydrauliköl Drehge- Fahrgeöl sigkeit Systemfüllung triebe triebe

Hydraul.

Kraftübertragung

1L

1L

Planetengetriebe

6L

6L

5L

5L

2,5L

2,5L

Starr- Lenk- Verteilerachse achse getriebe

Mechan. Kraftübertragung

2503 - 3703

6502WD

30

Yanmar 4TNE88-NSW

20

3802WD

Yanmar 3TNE88-NSR

2702RD u.2902RD

13,5

23

Yanmar 3TNE74-NSR

1902RD u.2202RD

10

Yanmar 4TNE88-NSR

Yanmar 3TNE68-NSR

1402Primus 1402RD u.1502RD

KW

3402RD u.3602RD

Typ

Motor

NEUSON

Gerätetyp

Füllmengen

SERVICE MANUAL Maintenance

QUANTITIES

9707748 Jan 03

SERVICE MANUAL

Maintenance 3.

2503 - 3703

HYDRAULIC SYSTEM

3.1 General Prerequisites: -

Before each pressure test the device must be run up! - Hydraulic oil temperature at least 40°C. For hydraulic settings please refer to chapter Technical Data.

Primary pressure limiting valves must be adjusted at max. engine speed (see chapter Technical Data).

3.2 Pressure Test of Variable Displacement Pump P1 Functions: bucket, boom, driving left a) b) c) d)

Apply manometer at measuring port MP 1.

Move bucket cylinder to stop (bottom and rod side).

Check pressure and/or adjust it at pressure reducing valve PRV 1 at the main valve block.

Check the functions boom, driving left by following items a - c.

3.3 Pressure Test of Variable Displacement Pump 2 Functions: dipper stick, driving right, auxiliary hydraulics a) b) c) d)

Apply manometer at measuring port MP 2.

Move dipper stick to stop (bottom and rod side).

Check pressure and/or adjust it at pressure reducing valve PRV 2 at the main valve block.

Check the functions driving right and auxiliary hydraulics by following items a - c.

3.4 Pressure Test of Gear Pump P3 Functions: swivelling, dozer blade, auxiliary hydraulics / boom offset a) b) c) d)

Apply manometer at measuring port MP 3.

Move dozer blade to stop (bottom and rod side).

Check pressure and/or adjust it at pressure reducing valve PRV 3 at the main valve block.

Check the function auxiliary hydraulics by following items a - c.

e)

The swivelling function is supplied by pump 3, though the operating pressure is limited by the secondary pressure limiting valve at the swivel motor! - See secondary pressures of swivel motor.

3.5 Pilot Pressure Test: Functions: hydraulic pilot control a) b) c)

Apply manometer at measuring port MP 4.

Actuate joystick.

Check pressure and/or adjust it at the pressure reducing valve at the control oil unit.

Page B8

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

Fig.: Measuring ports at the control oil unit

MP 1

MP 3

MP 2

MP 4

Fig.: Control oil unit left

Fig.: Control oil unit right

MP 4 MP 1 MP 3 MP 2

Page B9

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

Pict.: Primary - Pressure limiting valves ( AP ) -

Primary pressure limiting valve

P3

BUCKET

P1

BOOM

DRIVE

DRIVE

Primary pressure limiting valve

DIPPER STICK

AUXILIARY HYD

DOZER BLADE

SWIVEL

Position: Main valve block

Primary pressure limiting valve

P2

Pict.: Pilot oil supply unit 1408615

(1 ) Pressure reduction valve( AP ) - version 1408615

(2 ) Safty valve

Page B10

Id.No.: Edition:

9707748 Jan 03

Page B11

Meas uring point

IN

Id.No.: Edition:

Sett.(2): Fall (2): Sett.(2): Fall (2):

A

B

BACKWARD

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

Setting Fall

IN

FORWARD

Setting Fall

Setting Fall

Setting (Main valve block) Fall Setting Fall MP 1

Setting Fall

OUT

BACKWARD

FOREWARD

(Main valve block)

OUT

Setting Fall

DOWN Primary pressure limiting valve P P LV 1

Setting Fall:

9707748 Jan 03

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

24 bar

240 bar

Settings (1)

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

+/- 3

> >

> >

> >

> >

> >

> >

> >

> >

> >

> >

> >

> >

Check ed

Neuson Excavators

PRESSURE CHECKLIST

X

X

OK ?

No Sta

2503 - 3703

Auxiliary hydraulics

Drive right

Dipper stick

PUMP 2

Drive left

Buck et

Boom

Press.limit.valve Measuring point

A B 00502 50 Huemer Andreas

UP

Symbol

Function

PUMP 1

Checked by:

NEUSON

Motion

Fabr.No: Work hrs/Dat.

Notice Notice

2503

SERVICE MANUAL Maintenance

PLV PRV PLV... Pressure limiting valve PRV... Pressure reducting valve (1)... Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

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

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

(3)... FunctionSwivel: see chapter „Technical data“ and „Maintenance“ (4)... See chapt. „Technical data“: different settings

Pict.: Pressure checklist - example 2503 Fabr.No.: AB00502 (settings not binding)

Page B12

DOWN

RIGHT

LEFT

RIGHT

LEFT

B (2)

Id.No.: Edition:

All Pilot oil supply unit

Setting

Sett.(4): Fall

Sett.(4): Fall

Setting Fall

Setting Fall

Pilot oil supply unit Fall

MP 4

PRV 5

PLV PRV PLV... Pressure limiting valve PRV... Pressure reducting valve (1)... Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

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

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

(3)... FunctionSwivel: see chapter „Technical data“ and „Maintenance“ (4)... See chapt. „Technical data“: different settings

Joystick

Measuring point

Press.Reduc.valve

( Swivel motor !)

SPLV 4

limiting valve

Secondary pressure

(Swivel motor) (3)

/

Fall (2):

Sett.(2): Primary pressure Measuring point limiting valve Fall (2): MP 3 PPLV 3 (Main valve block) Sett.(2):

Setting Fall

UP

A (2)

Setting Fall

(Main valve block)

Checked by: Andreas Huemer

Work hrs.: 50

PILOT PRESSURE SYSTEM

Swivel motor

Boom offset

Auxiliary hydraulics

Dozer blade

PUMP 3

Date: 02.January 2003

Fabr.No.: AB 00502

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

210 bar +/- 3 210 bar +/- 3 210 bar +/- 3 210 bar +/- 3 210 bar +/- 3 200 bar +/- 5 200 bar +/- 5

N bar

35 bar +/- 2

N bar

N bar

20 bar

20 bar

20 bar

20 bar

20 bar

20 bar

> >

210 bar +/- 3

X

X

PRESSURE CHECKLIS

Notice

Neuson 2503

Maintenance SERVICE MANUAL

2503 - 3703

Bild: Druckprüfprotokoll - Beispiel 2503 Fabr.Nr.: AB00502 (Einstellwerte unverbindlich)

9707748 Jan 03

Page B13

(Main valve block)

OUT

IN

Id.No.: Edition:

Sett(2) Fall (2): Sett(2) Fall (2):

A

B

BACKWARD

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

Setting Fall

IN

FORWARD

Setting Fall

Setting Fall

Setting (Main valve block) Fall Setting Fall MP 1

Setting Fall

OUT

BACKWARD

FOREWARD

Primary pressure limiting valve P P LV 1

Setting Fall

DOWN Meas uring point

Press.limit.valve Measuring point

Setting Fall:

Symbol

UP

Motion

Checked by:

9707748 Jan 03

bar

bar

bar

bar

bar

> >

> >

> > bar

bar

> >

> >

> >

bar

bar

bar

bar

bar

bar

bar

bar

> >

> >

bar

bar

> >

> >

> >

> >

bar

bar

bar

bar

bar

bar

bar

Settings (1)

Check ed

Neuson Excavators

X

X

OK ?

No: H Stand

2503 - 3703

Auxiliary hydraulics

Drive right

Dipper stick

PUMP 2

Drive left

Buck et

Boom

PUMP 1

Function

NEUSON 2503-3703

PRESSURE CHECKLIST

Notice Notice

Fabr.No: Work hrs/Dat.

SERVICE MANUAL Maintenance

PLV PRV PLV... Pressure limiting valve PRV... Pressure reducting valve (1)... Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

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

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

(3)... FunctionSwivel: see chapter „Technical data“ and „Maintenance“ (4)... See chapt. „Technical data“: different settings

Page B14

RIGHT

LEFT

RIGHT

LEFT

B (2)

Id.No.: Edition:

All Pilot oil supply unit

Setting

Sett.(4) Fall

Sett.(4) Fall

Setting Fall

Setting Fall

Pilot oil supply unit Fall

MP 4

PRV 5

PLV PRV PLV... Pressure limiting valve PRV... Pressure reducting valve (1)... Notice: pressure settings correspond with the Fabr.Nr. of your excavator !

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

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

(3)... FunctionSwivel: see chapter „Technical data“ and „Maintenance“ (4)... See chapt. „Technical data“: different settings

Joystick

Measuring point

Press.Reduc.valve

( Swivel motor !)

SPLV 4

limiting valve

Secondary pressure

(Swivel motor) (3)

/

Fall (2):

Primary pressure Sett.(2): Measuring point limiting valve Fall (2): MP 3 PPLV 3 (Main valve block) Sett.(2):

DOWN

A (2)

Setting Fall

UP

(Main valve block)

Checked by:

Date:

Setting Fall

PILOT PRESSURE SYSTEM

Swivel motor

Boom offset

Auxiliary hydraulics

Dozer blade

PUMP 3

Work hrs:

bar

bar

bar

bar

bar

bar

bar

bar

bar

bar

bar

> >

> >

> >

> >

> >

bar

bar

> >

> >

> >

bar

bar

bar

bar

bar

X

X

PRESSURE CHECKLIS

Notice

Type:

Maintenance SERVICE MANUAL

2503 - 3703

9707748 Jan 03

SERVICE MANUAL

Maintenance

2503 - 3703

4.

AUXILIARY HYDRAULICS

> PILOT PEDAL

.

Fig.: Pedal auxiliary hydraulic system

> CHECK of activation of auxiliary hydraulic system : It must be ensured that the piston of the auxiliary hydraulic system (operated mechanically via cable pull) can be operated fully in both directions.

Otherwise the hydraulic system may be overheated!.

adjusting screw AH pedal > ADJUST

.

a) Adjustment of cable pull in both operating directions: 1)

Actuate pedal by hand and drive cylinder fully in the main valve block.

If pedal stop is limited by the adjusting screws - turn out adjusting screws.

Warning: 2) 3) 4) 5)

Actuate pedal only by hand! - Maladjustment of the pedal might lead to kinking of the cable because of excessive pedal forces (thrust) !

Screw in adjusting screw to stop while the pedal is actuated.

Subsequently the adjusting screw must be turned out again half a turn (stop clearance).

Fix adjusting screw by means of lock nut.

Check activation.

This adjustment must be done for both adjusting screws.

Warning:

Check of activation - subject to maintenance (see maintenance schedule).

b) The pedal must not rest on the floor carpet!

Page B15

Id.No.: Edition:

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SERVICE MANUAL

Maintenance 5.

2503 - 3703

HYDRAULIC PUMP

> BLEED - Shut down device.

- Open breathing/bleeding filter.

- Open stopper of bleeding hose.

- Drain a small amount of hydraulic oil via the bleeding hose (hose down).

- Lift the bleeding hose a little above the level of the hydraulic pump, drain a small amount of hydraulic oil and reseal the bleeding hose.

- Fix bleeding hose again at the rear wall of the engine compartment.

Fig.: Position of bleeding hose of hydraulic pump

tool kit

6.

silencer

HOSE BURST PROTECTION VALVES

S

> GAP DIMENSION CHECK The European Safety Regulations provide for the installation of hose burst protection facilities in dozer blade cylinders and in tilting cylinders.

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

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

2. Adjust the gap S by means of a gauge for the relevant type of excavator (see Chapt. Technical Data).

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

Page B16

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SERVICE MANUAL

Maintenance

2503 - 3703

7.

DRIVE UNIT

GEAR BOX_______________________________________________________. > CHECK:

- Open the oil level plug.

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

> CHANGE:

- Open the oil filler and drain plug.

- Drain oil and collect it in an appropriate vessel.

- Close drain plug and open oil level plug.

- Fill in fresh oil via the filler orifice until gear oil emerges from the inspection orifice.

- Close oil level plug and filler orifice.

.

Warning:

It is recommended, as specified in the maintenance schedule, to check leakage and thus the filling level in the drive unit continually.

Dispose of waste oil as provided by environmental laws.

For gear oil quality - see List of Lubricants (Chapt. Technical Data)

filler screw oil level plug gear oil level

drain plug

8.

SWIVEL UNIT

As described in chapter Hydraulic System - Swivel Unit the gear box is „maintenance-free“ (as lubricated with hydraulic oil).

Page B17

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Maintenance 9.

2503 - 3703

HYDRAULIC OIL TANK

> HYDRAULIC OIL CHANGE The hydraulic oil shall be changed only when warm (approx. 40°C) Before changing the oil withdraw all hydraulic cylinders.

Turn uppercarriage by 90°.

Fig.: Oil drain hose 1) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Open breather filter (width across 36) to unpressurize tank (tank pressurized).

Open drain hose of oil tank carefully (access from below - chassis floor).

Drain oil into collecting vessel.

Check hydraulic oil tank for contamination and clean it, if necessary.

Replace filter according to maintenance instructions.

Close screw plug of drain hose properly again.

Fill in clean hydraulic oil via filter station (filtering 10 mµ).

Vent hydraulic pump (see chapt. Hydraulic Pump).

Close hydraulic oil tank properly.

Let machine run idle for several minutes.

Dispose of old oil as provided by environmental laws.

10. DIESEL ENGINE

Service News

Theme: Solution:

Service News 71 / 02: Maintenance intervals - diesel engine!

Extension possible (Yanmar)

Maintenance intervals „ 500 „ > Affected parts: > Affected excavators:

Type: Yanmar

( Extension as described in SNews T 71 /02 )

Engine oil / -filter 2503 - 12002 - only possible if the following points are fullfilled:

To save costs - Neuson can offer an extension for the maintenance interals of the excavator diesel engine oil and oil filter up to 500 work hours !

The customer can choose between the standard and the extended interval solution.

Standard: Engine oil / filter NEW - „500 hrs“ Engine oil / filter

First Exchange 50 hrs.

50 hrs.

--->

then every 125 - 250 hrs.

500 hrs.

Notice the following qualifications for the interval extension: Page B18

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SERVICE MANUAL

Maintenance

2503 - 3703

Overall : Prerequisite to extend the engine intervals up to "500hrs" Y anmar Neus on E xc avat or Dies el engine t ype E ngine No. : Fab r. No. : 1403 1503 NOT POSSIBLE !

1903 2203 2503 Yanmar 3TNE 88 E NSR1 s t art ing 3003 Yanmar 3TNE 88 E NSR2 NA wit h 3503 Yanmar 4TNE 88 E NSR A D 00001 3703 5002 Yanmar 4TNE 88 E NSW starting 44248 6002 Yanmar 4TNE 98 NSR starting 2956 NA 6502 8002 12002 Yanmar 4TNE 106 TNS Every 2702 Force Yanmar 3TNE 88 ENSR 2902Force 3402 Force Yanmar 4TNE 88 ENSR 3602 Force Detailed explanation - see page 2

starting 23817 NA starting 44209

NA...Not availab le

To extend the maintenance interval of the diesel engine oil / -filter up to 500 hours - the following points have to be fullfilled !: (see SNews 71/02 A) -

For every excavator: In case of extreme working conditions (high dust concentration, high temperature, hydraulic hammer ) the maintenance still has to be done with the standard schedule.

The first exchange of the engine oil and – filter still has to be done after 50 work hours.

The engine oil and – filter have to be exchanged min. once a year !

B)

Excavator Neuson 2503, 3003, 3503 and 3703 The extended maintenance interval up to 500 hrs. is only valid for excavators with Yanmar engines (started with Fabr.No.: AD00001)!. Further the following points have to be fulfilled: First exchange of the engine oil and – filter after 50 hrs.

No modifications at the diesel engine or its cooling system.

Only original Neuson filters with Item No.: 2525409 are accepted ( See new overall ) !.

Engine oil of quality API-CD, API-CE or API-CF has to be used If the ”old“ engine oil filters are used, the standard maintenance interval schedule is required.

Listed filter part numbers can be changed - see spare part list For the excavator types 1403 – 2203 – NO INTERVAL EXTENSION can be offered.

Page B19

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SERVICE MANUAL

Maintenance

2503 - 3703

11. CABIN > REMOVAL. Feature:

Removal: -

Simple removal of frame of driver’s cabin by opening the 4 cabin bolts and the central connector.

The device functions remain active, the cabin cable system is disabled.

Open cabin bolts A. Loosen washing container hose at non-return valve (valve compartment).

Loosen cabin connector (right beside the seat).

Lift the cabin at the lugs provided for this purpose.

Tightening torque of cabin bolts A : M12 , 10.9 - 120 Nm (glued in with Loctite S2420) !

4 cabin bolts„ A“

Page B20

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SERVICE MANUAL

Maintenance

2503 - 3703

12. UNDERCARRIAGE .

> CRAWLER TENSION Lift crawler excavator by means of dozer blade and excavator boom.

The crawlers should no longer rest on the ground If necessary, support the excavator additionally (secure it against tilting).

When tightened, the crawler must not lift from the track rollers by more than 15 - 20 mm .

NOTE:

As far as possible the adjusted dimension should be equal for both crawlers.

> Tightening of crawler 1)

Take off protective cover (1).

2)

Tighten crawler by means of grease gun (2).

> Release of crawler tension 1) 2) 3)

Take off protective cover (1).

Screw out non-return valve (3) (width across 22).

Drain grease slowly until the unit is fully depressurized.

Page B21

Id.No.: Edition:

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Maintenance

Maintenance Supplement to engine/machine fluids and lubricants 3TNV 88 – 4TNV 88 lubricants Yanmar 3TNV 88 Component/ application

Engine/machine fluid

Season/ temperature

Capacities1

-15 °C +45 °C

7.12 l

Year-round

About 1.3 l each

API CD, CF, CF-4, CI-4

Diesel engine

Engine oil

Travelling drive

Gearbox oil3

Fuel tank

Diesel fuel

Diesel engine radiator

Coolant

1.

1.

2.

3.

Specification

SAE2 E3, E4, E5 Q8 T 55, SAE85W-90 FINA PONTONIC GLS, SAE85W-90 No. 2-D, DIN 51601 grade

Over 4 °C

No. 1-D, DIN 51601 grade

Below 4 °C

Water + antifreeze; ASTM 4985, based on ethylene glycol, siliconefree

Year-round

45 l 3.3 l (model 501)

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level Capacities indicated are no system fills According to DIN 51511 Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)

Oil grades for the diesel engine, depending on temperature Engine oil grade

Ambient temperature (C°) °C

-20

-15

-10

-5

0

5

10

15

20

25

30

35

40

95

104

SAE 10W SAE 20W SAE 10W-30 SAE 10W-40 SAE 15W-40

API CD, CF, CF-4, CI-4

SAE 20

SAE E3, E4, E5

SAE 30 SAE 40 °F

-4

5

14

23

32

41

50

59

68

77

86

SAE – according to DIN 51511

SERV-HB 2503-3703 De – Edition 1.0 *2503-3703_EPA2 310.mif

B-22

Maintenance Yanmar 4TNV 88 Component/ application

Season/ temperature

Capacities1

-15 °C +45 °C

5.8 l

Year-round

About 1.3 l each

Year-round

80 l

FINA Energrease L21M

Year-round

As required

Open gear7 (live ring BP Energrease MP-MG2 gears)

Year-round

As required

Grease nipples

Multipurpose grease8 FINA Energrease L21 M

Year-round

As required

Battery terminals

Acid-proof grease9

FINA Marson L2

Year-round

As required

Fuel tank

Diesel fuel

No. 2-D, DIN 51601 grade

Over 4 °C

No. 1-D, DIN 51601 grade

Below 4 °C

Engine and hydraulic oil cooler

Coolant + water

Halvoline XLC (ethylene glycol)

Year-round

7.0 l

Refrigerating agent

R134a10

Year-round

750 g

Compressor oil

Sanden SP10

Year-round

116.5 cm³

Cleaning agent

Water + antifreeze

Year-round

2.0 l

Diesel engine

Engine/machine fluid

Specification API CD, CF, CF-4, CI-4

Engine oil

2

SAE E3, E4, E5 Q8 T 55, SAE85W-90

Travelling drive

Gearbox oil

3

FINA PONTONIC GLS, SAE85W90 HVLP464

Hydraulic oil Hydraulic oil tank

PANOLIN HLP Synth 46 5

Biodegradable oil

FINA BIOHYDRAN SE 46 BP BIOHYD SE-46

Grease

Air conditioning Washer system 1.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Roller and friction bearings6

78 l

The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level Capacities indicated are no system fills According to DIN 51511 Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5) According to DIN 51524 section 3 Hydraulic ester oils (HEES) KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive Standard acid-proof grease According to DIN 8960

B-23

SERV-HB 2503-3703 De – Edition 1.0 * *2503-3703_EPA2 310.mif

Maintenance Oil grades for the diesel engine, depending on temperature Engine oil grade

Ambient temperature (C°) °C

-20

-15

-10

-5

0

5

10

15

20

25

30

35

40

95

104

SAE 10W SAE 20W SAE 10W-30 SAE 15W-40

API CD, CF, CF-4, CI-4

SAE 20

SAE E3, E4, E5

SAE 30 SAE 40 °F

-4

5

14

23

32

41

50

59

68

77

86

SAE – according to DIN 51511

SERV-HB 2503-3703 De – Edition 1.0 *2503-3703_EPA2 310.mif

B-24

Maintenance Explanation of symbols on the maintenance label

Symbol

B-25

Assembly

Explanation

General

Visual check

General

Grease instructions

Fuel system

Drain condensation water

Fuel system

Replace the fuel filter, clean the fuel prefilter

Radiator

Check the coolant level

Radiator

Drain and fill in new coolant

Engine

Check valve tip clearance. Adjust if necessary

Engine

Check the engine oil level

Engine

Change the engine oil

Engine

Replace the oil filter

Engine

Check V-belt tension

Travelling drive

Change oil

Travelling drive

Check oil

Undercarriage

Check chain tension

Hydraulic system

Check oil level

Hydraulic system

Change the hydraulic oil

Hydraulic system

Replace the hydraulic oil filter, replace the breather filter

SERV-HB 2503-3703 De – Edition 1.0 * *2503-3703_EPA2 310.mif

Maintenance Symbol

Assembly

Explanation

Radiator fins

Clean

Heating, air conditioning

Replace the recirculated air filter

SERV-HB 2503-3703 De – Edition 1.0 *2503-3703_EPA2 310.mif

B-26

):

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA-2 311.mif

● ●

Check cooling systems, heating and hoses for leakages and pressure (visual check)

● ●

Air filter (damage)

Prefilter with water separator: drain water • Clean

Replace cab filter for heating and air conditioning

●

●

●

●

●

●

●

●

●

Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary

Clean water ducts 7

●

● ●

●

●

Maintenance work ( once a day)

Check the following material. Refill if necessary: • Engine oil • Engine coolant • Hydraulic oil • Gearbox oil

):

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

Every 50 s/h ●

Every 500 s/h ●

●

Every 1000 s/h once a year

●

Every 1500 s/h

●

●

Customer

Inspection work (

Maintenance plan/service hours (s/h)

workshop

Carry out the following oil and filter changes (check oil levels after test run): • Engine oil1 • Engine oil filter2 • Fuel filter3 • Air filter element as indicated by telltale • Coolant • Hydraulic oil filter insert 4 • Hydraulic oil5 • Breather – hydraulic oil tank • Gearbox oil6

Fluid and filter changes (

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

Maintenance plan 3TNV 88 – 4TNV 88 (overview) Authorised

B-27

B-28 Maintenance plan/service hours (s/h)

●

Ensure grease supply of central lubrication system (option)

Check insulating mats in the engine compartment for damage/condition ●

● ●

●

Check cab tilt lock, cables and cable holders for damage and correct function

Couplings, dirt pile-up on hydraulic system dust caps

●

●

Check line fixtures

●

Check telltales for correct function

●

●

Check pin lock

Check screws for tightness

Check piston rods for damage

Check bearing play of tread rollers, track carrier rollers, front idlers

Check chain tension. Retighten if necessary

●

●

●

●

●

●

Pressure check of primary pressure limiting valves ●

●

Check correct function of air filter contamination gauge

Check chains for cracks and cuts

●

Check preheating system and electric connections ●

●

●

Check battery electrolyte. Fill up with distilled water if necessary

Check alternator, starter and electric connections, bearing play and function

●

●

Check and adjust injection time 9

Empty diesel fuel tank

●

Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles

●

Every 50 s/h ●

Every 500 s/h

Clean and adjust the fuel injection pump 8

Every 1000 s/h once a year ●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

workshop

Check valve tip clearance. Adjust if necessary

●

Check exhaust system for damage and condition

Maintenance work ( once a day) ●

Customer

Check V-belt condition and tension

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

Maintenance plan 3TNV 88 – 4TNV 88 (overview) Authorised

Every 1500 s/h

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA-2 311.mif

):

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA-2 311.mif

):

● ●

● ●

● ●

Compressor oil 10

●

●

●

●

●

●

●

●

●

●

●

●

Every 1000 s/h once a year

●

Every 1500 s/h

Replace dehumidifier

Check dehumidifier for corrosion, condensation and air bubbles

Replace cab filter

Carry out the following maintenance and inspection work: • Air conditioning function

Air conditioning (

Lubricate the following assemblies/components: • Stabiliser blade • Swivelling console • Boom • Stick • Implements • Grease strip on chassis

Lubrication service (

Maintenance work ( once a day) ●

Every 50 s/h ●

Every 500 s/h

●

Customer

Check function of engine cover gas strut

Maintenance plan/service hours (s/h)

●

●

●

●

●

●

workshop

Check labels and operation manual for completeness and condition

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

Maintenance plan 3TNV 88 – 4TNV 88 (overview) Authorised

B-29

B-30

):

Maintenance work ( once a day)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Drain engine oil the first time after 50 s/h, then every 500 s/h Replace the engine oil filter the first time after 50 s/h, then every 500 s/h Replace the fuel filter the first time after 50 s/h, then every 500 s/h Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h Replace the hydraulic oil the first time after 500 s/h, then every 1000 s/h Drain the gearbox oil the first time after 50 s/h, then every 1000 s/h Clean the water ducts every other 1000 s/h servicing Clean and adjust the fuel injection pump every other 1000 s/h servicing Check and adjust injection time every other 1000 s/h servicing Replace the compressor oil every other 1500 s/h servicing

Check for tightness, leakage and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary: • Visual check ● ☞ Engine and hydraulic system ● ☞ Cooling and heating circuit ● ☞ Travelling drive ●

●

●

●

●

●

Every 1000 s/h once a year

●

Every 1500 s/h ●

Every 50 s/h

):

Customer

● ●

Every 500 s/h

Leakage check (

Maintenance plan/service hours (s/h)

workshop

Check the function of the following assemblies/components. Rectify if necessary: • Lights, signalling system, acoustic warning system • Heating function

Functional check (

For service and maintenance work on the implement, please refer to the operation and maintenance manual of the implement manufacturer as well.

Work description

Maintenance plan 3TNV 88 – 4TNV 88 (overview) Authorised

SERV-HB 2503 – 3703 De – Edition 1.0 * *2503-3703_EPA-2 311.mif

SERVICE MANUAL

Hydraulic

2503 - 3703

CHAPTER C:

Hydraulic ( Neuson Service Manual 2503 - 3703 )

Page C1

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic 1.

2503 - 3703

HYDRAULIC SYSTEM

Legend - hydraulic diagram

2503 / 3003 / 3503 / 3003

1 diesel engine 2 variable displacement + gear pump unit 3 pilot oil supply unit 4 joystick (pilot control valve) left 5 joystick (pilot control valve) right 6 drive pilot control valve 7 main valve block 8 7/2-way valve, electrically driven 9 throttle valve 10,11filter 12 hydraulic oil cooler 13 hydraulic oil return filter 14 ball valve (depressurized return oil flow - auxiliary hydr.)

15 swivel unit 16 drive unit 17 boom offset cylinder 18 dipper stick cylinder 19 boom cylinder 20 bucket cylinder 21 dozer blade cylinder 22 check valve block 23 6/2-way valve - electr. driven 24 tilting cylinder - 3703 25 6/2-way valve - electr. driven- 3703 26 hose burst protection valve 27 piloted check valve - 3703 28 8/2-way valve mech. driven (option) 29 4/2 way valve vario cylinder 30 vario cylinder Warning: Only settings from chapter „Technical Data“ are applicable!

(Settings shown in the hydraulic diagram are not modified).

Page C2

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9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Page C3

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Hydraulic diagram 2503-3703 Option Vario

29

Page C4

30

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

2.

POSITION OF HYDRAULIC COMPONENTS

Fig.: Valve bonnet right

1

2

3

4 5 6

8

7

9

Fig. C003: Area below the cabin

10 11 12 13 14

Page C5

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Legend - position of hydraulic components 1 2 3 4 5 6 7 8 9 10 11 12 13 14

return filter breathing/bleeding filter ( 0.2 bar ) hydraulic oil tank hydraulic oil cooler reversing valve auxiliary hydraulics (unpressurized return) inspection glass hydraulic oil tank control oil unit main valve block switch valve ( boom offset / auxiliary hydraulics ) fuel tank switch valve (boom / dozer blade cylinder) 3703 > additional switch valve (bucket / tilting cylinder) manifold block pilot control oil swivel unit swivel joint

Page C6

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

HYDRAULIC PUMP

3.

Neuson 2503 / 3003 / 3503 / 3703 : Pump:

Neuson 2503 Neuson 3003 Neuson 3503 / 3703

Theme: Service News

Fabr.Nr.:

> 2528402 > 3028402 > 3528402 > 4408302

( PVD-0B-24P) ( PVD-1B-29P) ( PVD-1B-32P) - Fabr.No.: AB00001 - AC09999 ( PVD-2B-44P) - Fabr.No.: AD00001 and higher

Service News 73/02: New hydraulic pump type starting with diesel engine Yanmar type (setting !)

AD00001 and higher

Fig.: Double axial and gear pump ( pressure side view) port P2 air-bleed screw (not active)

adjusting screw:

variable displ. pump unit

start of regulation

port P3 P2

P1

TT!

P3

port pump bleeding hose

port P1

Page C7

gear pump unit

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Double axial and gear pump (suction side view)

type plate

Text am Typenschild

tightening torque: 55 - 65 Nm

tightening torque: see „Technical Data“

port suction line P1 & P2

port suction line P3 Pict.: Hydraulic pump 4408302 Adjustment screw Oil flow rate Qmax

Pump regulator unit

Pump air bleed screw (not activ) Adjustment screw Oil flow rate Qmin

P1

P3

P2

TT

Port P3

Port P1 + P2 Page C8

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Legend: Double variable displacement and gear pump 2503 ( PVD - OB )

1 2 3 4 5 6 7 8 9 11 14 24 35 10 12 13 32 39 40 62 69 71 72 15 18 19 20 21 25 26 27 30 31 33 34 36

case case cover primary shaft cylinder drum distribution plate piston sliding blocks sliding block bracket centering ring spacer pins spring spacer ring Seeger circlip ring swash plate ball sealing shaft sealing ring O-ring O-ring packing ring O-ring O-ring O-ring spring spring receptacle spring guide centering pin pin piston piston centering pin ball bearing needle bearing spacer ring Seeger circlip ring Seeger circlip ring

42 44 49 56 60 61 65 66 67 68 70 73 76 77 74 75

stopper screw stopper dowel pin screw hexagon nut gear pump coupling ring screw washer pilot control case solenoid valve solenoid valve screw washer

Page C9

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Exploded view - double axial and gear pump 2503

Feature : 1 governing spring - linear pump regulation

Page C10

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Exploded view - double axial and gear pump 3003 - 3703

Feature: 2 governing springs - non-linear pump regulation

governing spings

Page C11

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic 4.

2503 - 3703

PILOT OIL SUPPLY UNIT

Neuson 2503 / 3003 / 3503 / 3703 : Fig.: Schematic of pilot control circuit:

4 3

2

5

5

1 P3

P2

P1

1 pump unit 2 control oil unit 3 manifold block 4 main valve block 5 measuring ports

Page C12

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Control oil unit 2503 - 3703 (2)

(3) (1)

AP (4)

( PT )

port P1: port P2: port P3: port T : port A : port PR: port BV: port PV:

>> gear pump P3 >> variable displacement pump P2 >> variable displacement pump P1 >> tank >> driving counterbalancing system (main valve block) >> 2nd driving stage (drive units) valve WK1 - in combination with pushbutton at driving lever ( formerly port PT - control oil unit 1408610) >> pilot control valves (joystick,..) via the safety solenoid valve in combination with the sensitive micro-switches in the arm rests (WK2). >> supply of setting chamber to swivel motor - brake release.

( 1 ) ... safety valve 50 bar - protects the control oil unit in case of defective pressure reducing valve ( 2 ) ... shuttle valves - always accept the highest pump pressure for control oil pressure ( 3 ) ... pressure reducing valve pilot control pressure (PRV) - ADJUSTMENT POINT (AP) ( 4 ) ... accumulator Page C13

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Port assignment of control oil unit 2503 - 3703

(version 1408610 / 1408615 ) (1) safety valve

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

to gear pump P1 BV PV

safety solenoid valve function

PR

port PR (PT) >> 2nd driving stage port PV to variable displacement pump P1

(1) safety valve

port T - tank WK 2

T

P3

WK 1

A

port A P2

to variable displacement pump P2 Page C14

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Pict.: Port position pilot oil supply unit 2503 - 3703

(version 1408615 ) to var.displacement pump P1

to var.displacement pump P2

(1) Safty valve (50bar)

P2

P3

to drive counter balance syst.

Main valve block

A T

(3) Press.reduction valve( AP ) - version 1408615 : Metal cap with ring see next page

Port SP >> Accumulator

WK 1

WK 2

Port T - tank

to gear pump P3 Port PR (PT) >> to drive unit

to pilot control valves P1

BV

(1) Safty valve (50bar)

PR

Port SP >> Accumulator

PV

to swivel unit Park brake valve block

(3) Pressure reduction valve ( AP ) WK 2

WK 1 Page C15

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Pict.: Port position pilot oil supply unit 1408615 (5002 - 6002)

(3) Pressure reduction valve ( AP )

1...

2...

3...

5-6 8-9

(1) Safty valve

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

Fig.: Version 1408610

Tightening torques: 1a... 150 Nm 1e... 10 Nm 2g... 100 Nm 3n... 100 Nm 5r... 10 Nm 5s, 6s 30 Nm 8, 9 15 - 20 Nm

Pict.: Structure pilot oil supply unit

(version 1408610 ) Page C16

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

MAIN VALVE BLOCK

5.

Neuson 2503 / 3003 / 3503 / 3703 : Type: Neuson KVSE-36-9 identical design for 2503 -3703 - different piston valve! (see different item.No.) Features: regenerating function of dipper stick, drive counterbalancing system, standard functions Fig.: Sections at main valve block view A

1

2

34

5

6

7

8

9

10 14 11 Pa2

Pa3

A7

A8

T2

A6

A5

A4

P1

A3

A1

Type plate

Tightening torque

Pa4

T1

A2

P3

B8

B7

Pb8

12

Pa7

Pa8

A

T1

DR

13

B6

B5

B4

P2

B2

B1

Pb2

Pb1

Pb3

Pb4

15

B3

A

16 View B

Page C17

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic 1 2 3 4 5 6 7 8 9 10

2503 - 3703

counterbalancing system (port A control oil unit) swivel unit dozer blade flow rate adjustment of auxiliary hydraulics auxiliary hydraulics, mechanically driven dipper stick driving right variable displacement pump P1 driving left boom

11 12 13 14 15 16

bucket port gear pump P3 hydraulic oil cooler (tank-T2) suction hose T1 swivel motor port A (counter balancing) port variable displacement pump P2

Fig. : Primary pressure limiting valves (PLV) - ( AP )

TT

= 26,5 - 29,5 Nm

PLV- P1

PLV- P3

PLV- P2 11 10 9 7 6 5 4 3 2 1

section bucket section boom section driving left section driving right section dipper stick section auxiliary hydraulics section flow rate AH section dozer blade section swivelling drive section counterbalancing

supplied by P1 supplied by P2 supplied by P3

Page C18

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Valves - view A

1

2

3

4

5

6

Fig.: Valves - view B

7 1 2 3 4 5 6 7 8

8

9

10

11

sec. pressure limiting valve bucket bottom side primary pressure limiting valve P1 sec. pressure limiting valve dipper stick rod side stopper auxiliary hydraulics (option PLV) flow rate adjusting screw auxiliary hydraulics stopper primary pressure limiting valve P3 sec. press. limiting valve dozer blade bottom side Page C19

12 9 10 11 12 13 14 15

13

14

15

flow rate adjusting screw AH stopper (option sec. press. lim. val. AH) sec. press. lim. val. dipper stick bottom side primary pressure limiting valve P2 sec. press. lim. val. boom bot. side sec. press. lim. val. boom rod side sec. press. lim. val. bucket rod side Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Hydraulic circuit diagram - main valve block

section bucket

section boom

section driving left

section driving right

section dipper stick section aux. hydraulics and boom offset flow rate adjustment aux. hydraulics

section dozer blade section swivelling section counterbalancing system

Page C20

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Drive Counterbalancing System General: Without counterbalancing: If an arm function is activated during driving, the device leaves its track! (P1, P2 supply one drive unit, each).

All Neuson 2503-3703 are equipped with drive counterbalancing function!

If an arm function is activated when driving straight, the device keeps track - the driving speed remains constant. The drive counterbalancing system is activated only, if both driving valves are active.

Function: Both piston valves for driving and one arm function must be actuated.

The valve (V1) of the drive counterbalancing system is activated because of an increased banking-up pressure.

P3 - assumes the supply of arm functions.

Section auxiliary hydraulics Switching pressure of valve V1: Fig.: Hose piping of drive counterbalancing system

A

A

tank DR control oil unit port

A >> Page C21

Id.No.: Edition:

9707748 Jan 03

section driving left secion driving right section bucket section boom section dipper stick section auxiliary hydraulics section flow rate AH section dozer blade section swivel unit section drive counterbalancing

Page C22 supplied by P3

supplied by P1 supplied by P2

Hydraulic SERVICE MANUAL

2503 - 3703

Fig.: Circuit diagram of drive counterbalancing system

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig. : Section drive counterbalancing system

<< A

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw stopper metal pilot control cap O-ring

Page C23

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Regeneration - Section Dipper Stick Situation: Because of heavy loads at the dipper stick the dipper stick cylinder may become „evacuated“ on the bottom side, which might lead to a dipper stick standstill in vertical position.

Solution: Regeneration of the rod-side dipper stick cylinder oil to the cylinder bottom side. To this end the spool valve is provided with a non-return valve.

Fig.: Section dipper stick

regener.

1 2 3 4 5 6 7 8 9 10

case spool valve spring collar centering spring stopper O-ring spring collar spring spring collar pilot control cap

12

11 O-ring screws 13 valve head 14 spring 15 stopper 16 stopper plug 17 stopper 18 O-ring 19 O-ring 20 O-ring Page C24

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Auxiliary Hydraulics ( AH ) -

Mechanically actuated via cable pull ( maintenance) !

2 flow rates adjustable : standard -> P2 + P3 regulating screw -> P2 Options: secondary pressure limiting valves (in case of stoppers) electrically driven auxiliary hydraulic system For pressure-related flow rates of aux. hydraulics - see chapt. Technical Data

Warning: In case of thermal problems, please make sure that: the shut-off valve for unpressurized return flow AH is always open when in hammering mode! the flow rate adjusting screw is not in an intermediate position ! the spool valve AH is switching correctly - see maintenance - adjustment of cable pull for spool valve of auxiliary hydraulics.

Fig.: Section auxiliary hydraulics

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

Page C25

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring valve head

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Oil Flow Adjusting Screws - Auxiliary Hydraulics ( AH )

1 2 3 4 5 6 7 8

case spool valve O-ring supporting ring cover of case screw stopper stopper

A C Fig.: Adjustment of flow rate AH

To reduce the flow rate of the auxiliary hydraulic system the stoppers A and/or B must be turned out, each, by 2 turns.

Warning: No intermediate position - overheating !

Stoppers A and B - closed (factory setting) >> supply AH: P2 + P3 Stoppers A and B - turned out 2 turns >> supply AH : P2 For pressure-related flow rates of AH - see chapt.

Technical Data.

B

Stopper C - receptacle option sec. press. limit. valve - AH

Page C26

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Bucket

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring valve head

Page C27

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Function Boom

Bleeding facility: case without valve section boom

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring bush Page C28

15

14 supporting ring O-ring 16 case 17 stopper 18 screw 19 O-ring 20 stopper

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Section Drive ( Left / Right )

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring

Page C29

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Section Input ( P1 / P2 ) - with primary pressure limiting valves P1 and P2 ( AP )

<<-- P

1 2 3 4 5 6 7 8 9

case spool valve O-ring pilot control cap pilot control cap screws stopper O-ring metal filter

<< P... port counterbalancing system coming from the control oil unit

Page C30

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Section Dozer Blade

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring O-ring

Page C31

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Section Swivel Unit

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

case spool valve spring collar centering spring spring collar pilot control cap O-ring screw valve head spring stopper O-ring O-ring

Page C32

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

6.

PILOT CONTROL VALVES

Type: Neuson 2528415, 2708313 (4TH5) Features: - progressive hydraulic pilot control device - operation: directly controlled pressure reducing valve

Fig.: Manual control valve (joystick)

1 3 4 6 7 10

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

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic Fig:

Type:

2503 - 3703

Driving pedal with hydraulic damper Neuson 2528409 (4TH6NR)

Page C34

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL Type:

Driving pedal with hydraulic damper Neuson 2528409 (4TH6NR)

1 2 5 6 7 8 12 14

Fig.:

foot rest pedal assembly expansion bellows indexing table plate assembly tappet assembly damping assembly non-return valve assembly

Hydraulic

2503 - 3703

Page C35

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic 7.

2503 - 3703

SWIVEL UNIT

Neuson 2503 / 3003 / 3503 / 3703 : Type:Neuson 2503 Neuson 30 - 3703

Service News

> 2528401, 2528490 ( Fabr.Nr.: AC00901 and higher) > 3028401, 3028490 ( Fabr.Nr.: AC00904 and higher) Theme: Fabr.No.:

Service News 72/02: New swivel unit 2503-3703 (Type 490“) See list Swivel gear box still free of maintenance !

Features: - Maintenance-free gear box (swivel motor lubricated by hydraulic oil) Warning: Use only the specified hydraulic oil !

- Mech. motor brake (multiple-disk brake), hydr. driven - Swash-plate piston motor Fig.: Port assignment - swivel unit 2528401, 3028401

leak oil DR

shock suction valve

shock suction valve

( AP )

( AP )

tank line (MU) T1 (suction line from valve block)

ports A / B from main valve block Page C36

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Port assignment - swivel unit 2528401, 3028401

Brake block: port S: control line port P: supply control oil unit

Fig.: Hydraulic diagram - swivel unit 2528401, 3028401

brake block SH

F

K

Dr

R/G

PG

PV

200bar

shock suction valve

B

A

T3

( AP ) T1

Page C37

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Port assignment - swivel unit 2528490, 3028490

shock suction valve

( AP ) tank line T1 (MU) (suction line from valve block) brake block: port PG

port SH

ports A / B from main valve block

leak oil DR Function: Mechanical parking brake Opening the brake (release) : This is effected via the pilot control pressure of the function swivelling left and/or right via port S (SH). As soon as pressure is applied to this port, the piston (K) is displaced, and via port P (PG) the pilot control pressure gets to the brake cylinder and opens it against spring froce (F).

Closing the brake: As soon as the pressure of port S drops, the piston (K) is moved to its original position by spring force and the brake cylinder chamber is no longer supplied; application of the brake is effected via restrictor (B) at a certain delay of approx. 8 sec when at operating temperature.

Page C38

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Swivel unit 2528401, 3028401

SH

PG

10

10

Tightening torques: No. 3 No. 4 No. 10

25 Nm 50 Nm 120 Nm

Page C39

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Swivel unit 2528490 - gear box

tighteining torque 120 Nm

Page C40

Id.No.: Edition:

9707748 Jan 03

Page C41

9 10 24 31 35 42

steel disk - brake (2 pcs.) brake disk (2 pcs.) brake piston suction valve pressure reducing valve (secondary) brake block (valve)

Legend of fig. C041 - swivel motor

2503 - 3703

SERVICE MANUAL Hydraulic

Fig.: Swivel Unit 2528490 - swivel motor

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

8.

DRIVE UNIT

Neuson

2503 / 3003 :

Features: Neuson

swash-plate piston motor, 2 positions for absorption capacity maintenance intervals - see chapter Maintenance mo mechanical motor brake

3503 / 3703 :

Features: -

like 2503 - 3003, with mech. motor brake (multiple-disk brake), hydr. driven

Attention: Traction drive down only up to serial number AE01100, starting from AE01101 traction drive 1000125872 inserted which is described afterwards.

2nd driving stage

damping valve tightening torque ( TT) : 123 Nm, glued in leak oil (always connect on top for better venting of motor) A and B - driving motor ports hydraulic brake piston

damping valve Fig.: Port assignment of driving motor

Page C43

Id.No.: Edition:

9707748 Aug 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Schematic diagram of driving motor without mechanical parking brake

Neuson 2503 - version 2528403 Neuson 3003 - version 3028403

leak oil

5/2-way valve 2nd driving stage brake piston with suction valves

damping valves

PR

A-B ports

control oil unit

Function - Hydraulic Brake Piston: The hydraulic brake piston prevents overspeeding of the motor and keeps speed constant when driving downhill by blocking the relevant return flow. The damping valves prevent jerking motions to avoid any building up of vibrations.

Page C43

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Circuit diagram of driving motor with mechanical parking brake

Neuson 3503, 3703 - design 2608505

3503 u. 3703

oil leakage

235bar/255bar

B

mech. parking brake

shock valves 5/2 -way valve 2nd driving stage

PR

B3

A3

brake piston

A / B ports

control oil unit

Function - Mechanical Parking Brake: The brake is released automatically via high-pressure from the brake piston; as soon as the brake piston goes back to neutral position, the brake is applied via a restrictor (B) at a certain time delay to avoid damage to the brake linings.

Page C44

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Gear box - drive unit 2503 - 3003

Subassembly 2528403, 3028403

Page C45

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Driving motor - drive unit 2503 - 3003

Subassembly 2528403, 3028403

Page C46

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Brake valve block - drive unit 2503 / 3003

Subassembly 2528403, 3028403

Page C47

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Shock valve block - drive unit 2503 / 3003

Subassembly 2528403, 3028403

Legend: drive unit complete 2503 - 3003 117, 118 134 204 205 206, 207 210 211 219 220 302 303 305 306 402

lifetime sealing hydraulic motor cylinder drum distribution plate motor piston, sliding block swash plate setting piston of swash plate oil sealing swash plate bearing brake piston non-return valve / check valve piston - 2nd driving speed shuttle spool valve damping valves ( shock valve cartridge )

Page C48

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Brake valve block - drive unit 3503 / 3703

Subassembly 2608505

hydraulic brake piston

piston 5/2-way valve for 2nd driving stage damping - shock valve

Page C49

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig. : Driving motor - drive unit 3503 / 3703

Subassembly 2608505

cylinder drum

swash plate

brake disk parking brake

brake piston parking brake

piston

Page C50

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig. : Gear box - drive unit 2608505

lifetime sealing

Page C51

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

The travelling drive now has an „automatic powershift“ gearbox. The travelling drive is basically in 2nd speed if the switch for 2nd speed range is switched on (high speed).

1st speed is automatically engaged if more power is required.

Pos.

Description

1 2 3 4 5 6 7 8

Drive port (-> swivel joint 2/7 Brake release piston Drive port (-> swivel joint 6/5) Leak oil port (-> swivel joint 1) Brake piston 2nd speed range port (-> swivel joint 8) 2nd speed range directional valve Brake piston

Page C53

Id.No.: Edition:

9707748 Aug 03

SERVICE MANUAL

Hydraulic

2503 - 3703

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 afterwards.

2 speed range functions Speed range 1 2nd speed range switch: switched off The directional valve for the 2nd speed range remains in home position (position as shown in diagram), and the hydraulic motor’s swash plate is in maximum capacity position.

The motor runs at low speed.

Speed range 2 2nd speed range switch: switched on The directional valve for the 2nd speed range is enabled, and the hydraulic motor’s swash plate is in minimum capacity position.

The motor runs at high speed.

If the pressure rises in the travelling drive, the directional valve for the 2nd speed range is forced back to home position and and hydraulic motor’s swash plate returns to maximum capacity.

The motor now runs at low speed.

The directional valve returns to 2nd speed range as soon as the pressure in the travelling drive drops again.

The motor runs at high speed again.

Switch operating point of valve pos. 6: 180 bar

Page C54

Id.No.: Edition:

9707748 Aug 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Pos

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Travelling drive Screw connection Screw connection Screw connection Hydraulic motor Hydraulic motor sealing kit Hydraulic motor Bearing Cover O-ring Snap ring Valve set Piston valve for speed range Brake valve Travelling drive brake

Page C55

Id.No.: Edition:

9707748 Aug 03

SERVICE MANUAL

Hydraulic 9.

2503 - 3703

SWIVEL JOINT

Types:

Neuson 2503 - 8-port swivel joint Neuson 3003, 3503 - 8-port swivel joint Neuson 3703 - 10-port swivel joint

Fig.: Swivel joint 1408050 - port assignment 2503

5

1

2

8

4

3

7

6

1 3 5

2

7

4 6 8

TT- tightening torque M8 x 20 - 8.8 = 24 Nm Port 1 3 5 7

driving motor left top driving motor left bottom dozer blade cyl. rod side 2nd driving stage

Port 2 4 6 8 Page C52

driving motor right top driving motor right bottom dozer blade cylinder bottom side leak oil duct Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Swivel joint 2608500 - port assignment 3003 - 3503

5

1

2

8

4

3

7

6 1 3

2

5

4

7

6 8

TT- tightening torque M8 x 20 - 8.8 = 24 Nm Port 1 3 5 7

leak oil dozer blade cyl. bottom side 4 driving motor left top driving motor left bottom

Port 2 6 8

Page C53

dozer blade cyl. rod side driving motor right top driving motor right bottom 2nd driving stage

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

Fig.: Swivel joint 2808510 - port assignment 3703

8

4

5

10

7

6

9 1

3

3

2 4

5

6

7

8

9

10 TT - tightening torque

Port 1 3 5 7 9

2 driving stage dozer blade cyl. rod side driving motor left top driving motor left bottom tilting cylinder bottom side nd

Port 2 4 6 8 10

Page C54

dozer blade cyl. bottom side driving motor right top driving motor right bottom tilting cylinder rod side leak oil

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

10.

SWITCH VALVE

Neuson

2503 / 3003 / 3503 :

Features: - switch valve controlled electrically via pushbutton at the joystick, neutral - de-energized Function: - switch valve A: auxiliary hydraulics <<>> boom offset - switch valve B: boom <<>> dozer blade (SNews 50/01!)

Neuson 3703 : Additional - switch valve C:

bucket

<<>>

tilting of uppercarriage

> Fig. C055,C056: SWITCH VALVE A : ( additional hydraulics <<>> boom offset) offset cylinder

secondary pressure limiting valves

auxiliary hydraulics

main valve block section auxiliary hydraulics

position of switch valve A Page C55

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic > Fig. :

2503 - 3703

SWITCH VALVE B : ( boom cylinder<<>> boom offset) section boom main valve block

tank

right joystick

section dozer blade main valve block

Fig. : Position of switch valve B

Access:

> via covering of seat bracket

fuel tank

switch valve B

fuel tank sensor swivel unit

manifold block pilot control Page C56

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

> Fig.:SWITCH VALVE C - Neuson 3703 : ( function bucket <<>> tilting of uppercarriage) solenoid main valve block bucket section

valve leakage relief line -> tank * >

bucket cylinder

>

swivel joint-> pilot controlled check valve -> tilting cylinder

main valve block bucket section leak oil tank position of switch valve C

Service News

Theme: Solution:

Service News 59/01: Switch valve leckage- tiltcylinder pos.

Release hose - tilt cylinder (valve C)

Possible problem: Due to the leckage of the switch valve (C), the tilt cylinder can`t hold its position Solution: ( starting with Fabr.No.: AB01031 modified by Neuson! ) Neuson uses a release hose and a check valve to connect the pressure line (switch valve-check valve block) to tank.

Page C57

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

11. WAY VALVE Type: Function: Feature:

Option: Vario

Neuson 3808610 The 4/2 wayvalve is piloted by the two front bottoms at the joysticks The wayvalve operates the vario cylinder in the vario plate 4/2 Way valve, elektrical piloted Vario lock cylinder (part of vario plate)

Check valve

-->

4 3

to Swivel joint / Vario cyl.

2 to sec. pressure limiting valve vario cylinder (cabin bottom)

PV pilot oil supply unit Tank (Collectiong panel) Valve position Neuson 3003

Valve position Neuson 3503

Page C58

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic

2503 - 3703

12. PRESSURE LIMITING VALVE Type: Function:

Option: Vario

Neuson 7008713 50 bar Secondary pressure limiting valve for vario cylinder P...

T...

SPLV

SPLV...

Secondary pressure limiting valve

T P

Pressure line to the Vario lock cylinder Tank T

P

P

Vario lock cylinder (part of vario plate)

SPLV alve position

Page C59

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Hydraulic 13.

2503 - 3703

OIL TANK - hydraulic

A) Breather filter

>>see also chapt. Maintenance

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

breather 5001161 ( hydraulic tank)

Fig. C063: Hydraulic oil tank

filter cloth

breather valve

Fig. : Breather Page C60

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Diesel engine

2503 - 3703

CHAPTER D:

Diesel engine ( Neuson Service Manual 2503 - 3703 )

Page D1

Id.No.: Edition:

9707748 Jan 03

3703

3503

KUBOTA D 1703

3003

KUBOTA D 1703 4 TNE 88 ENSR

3TNE 88 ENSR2

3TNE 88 ENSR1

KUBOTA D 1403

2503

2203

Page D2 Abk.: F... Force P...Primus

12002

8002

6502

6002

5002

3602 F

3402 F

2902 F

2702 F

2202 F

4 TNE 106 TNS

4 TNE 98 NSR

4 TNE 88 NSW 4 TNE 88 ENSW

4 TNE 88 NSR 4 TNE 88 ENSR

3 TNE 88 NSR 3 TNE 88 ENSR

3 TNE 74 NSR-2 3 TNE 74 ENSR-2

3 TN 100 TENS

5001 5501

4 TNE 88 NSW

4 TNE 88 NSR

3 TNE 88 NSR

3 TNE 74

3 TNE 68 NSR

Types

3802

3602

3402

2902

2702

2202

1902

1702

1903 1902 F

3TNE 74 ENSR2 (03Se)

1402

1302

Neuson

1502

1402 F

3TNE 68 NSR 3TNE 74 ENSR2 (03Se)

1503

3 TNE 68 NSR 3 TNE 68 ENSR

Types

1502 F

1402

3 TNE 68 ENSR

1403

Neuson

2700 RD

2500 RD

2000 RD

2100 RD

5000 RD

3800 RD

3200 RD

3000 RD

2800 RD

2600 RD

2201 RD

2200 RD

1900 RD

1700 RD

1501 RD

1500 RD

1200 RD

Neuson

Types

Neuson

V 1505

2G30

3 TNA 72 EUNS

KUBOTA D 850

3 TNA 72

Kubota D 850

Hatz

4 TNE 84 NS

4 TNE 82 NS

4 TNE 88 NSW

Kubota

3 TNE 74 NSR

3 TNA 72 UNS 3 TNE 74 NSR

Types

E 04/99, T40/00, T58/01

DAZU

D I E S E L E N G I N E S O V E R A L L Neuson

Diesel engine SERVICE MANUAL

2503 - 3703

Fig.: Diesel engine oveall

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Diesel engine

2503 - 3703

Theme: Service News

A)

Fabr.No.:

Service News 73/02: New diesel engine type Yanmar for 2503-3703 (settings !)

AD00001 and higher

GENERATOR

.

Valid: Kubota Diesel engine type - Neuson Fabr.No.: AB00001 to AC09999 Disassembling - Type 2525520 Prepare:

1)

Remove battery

-

Side rear counter weight - right open, Maintenance cover generator exists !!

(Right position next the drivers seat, under the isolation mat !)

2)

Disassemble the engine van cover

3)

Remove the air filter and the air filter suction hose

4)

Remove the exhaust

5)

Remove the wiring of the generator

Page D3

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Diesel engine A)

2503 - 3703

GENERATOR

.

Disassembling - Type 2525520 6)

Open fixing screw generator

7)

Remove the tension adjuster

Assembling - Type 2525520 Assemble the generator by reversed steps B)

STARTER

.

Disassembling - Type 2525519 : Prepare: 1) 2) 3) 4)

Open the side - rear counter weights left/right

Disconnect wiring of the starter Remove tool box Remove exhaust silencer (muffler) Remove the starter via the left rear side counter weight area

Assembling - Type 2525519 : Assemble the starter by reversed steps

Page D4

Id.No.: Edition:

9707748 Jan 03

Engine

Engine

DEngine D.1

Engine overview

Kubota D2503-3703

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

Intake manifold Speed regulation lever Engine stop lever Fuel injection pump Fuel pump Fan V-belt pulley (crankshaft pulley) Oil filter insert Water drain cock Oil fill cover Exhaust manifold AC alternator Starter Oil dipstick Oil pressure switch Flywheel Oil drain plug Oil sump

D-5

D-6

Engine oil filter

Oil pressure switch

Cutoff solenoid

Oil drain plug

Fuel pump

Cylinder-head gasket Water pump Alternator

Fuel injection pump

Injection nozzle

V-belt Fan wheel

Water temperature switch

Engine

Engine overview 3TNE-88

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

Alternator

Starter

Fuel filter

Oil dipstick

Oil filler neck

Oil filter

Air intake incl. preheater

Fuel injection

V-belt

Fan wheel

Tightening

Engine

3TNV88 engine: overview

D-7

D-8

Oil pressure

Exhaust mani-

Oil dipstick

Fuel filter

Fan blade

Fuel injection

Oil filler neck

Engine oil filter

Air intake incl. preheater

Water pump

V-belt Alternator Tightening

Starter

Cylinder-head

Engine

Yanmar 4TNV 88

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine D.2

Fuel supply systems

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

Fuel filter

Fuel pump

Water separator

Feed line

Kubota 2503-3703

D-9

Engine

Water separator

Vent filter

Feed line

Fuel filter

Fuel pump

Yanmar 3TNE engine

D-10

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine

Fuel pump

Feed

Reflux

Water separator

Fuel filter

Yanmar 3TNV engine

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-11

Engine

D-12

Fuel pump

Feed line

Reflux

Water separator with stop cock

Fuel filter

Fuel injection pump

Yanmar 4TNV 88

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine D.3

Kubota settings

Checking and adjusting valve tip clearance A

Setting valve tip clearance

Important!

Always measure and set valve tip clearance on a cold engine.

☞ Remove the cylinder-head cover ☞ Align the TDC mark on the flywheel with the mark on the edge of the flywheel housing so that the first piston is in the TDC compression position (both rocker arms on the 1st cylinder can be moved).

Setting valve tip clearance

☞ Measure valve tip clearance with a feeler gauge (A) according to the table below. ➥ Valve tip clearance 0.18 – 0.22 mm ☞ Adjust valve tip clearance with the set screw if the values do not coincide with the specified values.

☞ After setting the first group, turn the engine to overlapping TDC (both rocker arms on the first cylinder are firm), then check and if necessary, set the remaining valve tip clearances.

☞ Mount the cylinder-head cover back on again The TDC mark on the flywheel applies to the first cylinder only. The other cylinders have no TDC marks.

Cylinder

1

2

Inlet

Exhaust

X

X

1 cylinder compression TDC 1 cylinder overlapping TDC

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

Inlet

X

3 Exhaust

Inlet

X

X

Exhaust

X

D-13

Engine Removing the cylinder head

☞ Remove the injection lines and the overflow line. ☞ Remove the glow plug cables and the glow plugs. ☞ Remove nozzle holder (1) and copper washer (2). ☞ Remove heat seal (3). ☞ Remove the cylinder-head cover.

Removing the cylinder head

Removing valves

☞ Remove valve cap (1) ☞ Remove spring retaining rings (2) with a valve spring lifter ☞ Remove valve spring cap (3), valve spring (4) and valves (5) Installing the valves

☞ Clean the valve rods and valve guides, and apply sufficient engine oil. ☞ Once you have installed the valve retaining rings, ensure the correct seat of the valve rods by applying slight blows with a plastic hammer Installing the cylinder head back on again

☞ Check the gasket of the cylinder-head cover for damage ☞ Check whether you have inserted the heat seal.

Tightening order for cylinder head bolts

Caution!

Tighten the cylinder-head bolts consecutively, in the order from (1) to (14; 18; 22). Apply engine oil first.

Tight the cylinder-head bolts again after you have run the engine for 30 minutes.

☞ Tightening torques see page A-29 A29

3-cylinder engine Gearbox housing side

Flywheel side

4-cylinder engine Flywheel side

D-14

Gearbox housing sid

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine Important!

Mark the number of the cylinder on the tappets to avoid mistakes.

Always carry out work on the cylinder head on a cold engine

Checking the injection nozzles

☞ Connect the fuel injection pump to a nozzle tester. ☞ Move the handle slowly to measure the pressure at which the fuel starts to flow out. ☞ If the measurement does not provide results within the manufacturer's specifications, dismantle the injection nozzle and replace spacer (1).

➥ Injection pressure: 137 – 147 bar

Important!

Removing the injection nozzles

A difference of 0.025 mm in spacer thickness modifies the pressure by 5.9 bar.

Fuel injection pump: design

1 Nozzle holder 2 Adjusting washer 3 Nozzle spring 4 Push rod 5 Spacer 6 Nozzle element 7 Nozzle lock nut Checking the nozzle jet

☞ Connect the nozzle to a nozzle tester and check the injection output of the nozzle ☞ Replace the nozzle element if injection output is not satisfactory ➥ -a; OK ➥ -b; poor

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-15

Engine Adjusting injection

Important!

Make sure the fuel injection pump is positioned correctly to ensure the prescribed injection time. Make sure the marks of the fuel injection pump and the gear housing are aligned.

☞ Remove the injection lines. ☞ Set the throttle to maximum fuel feed position. ☞ Turn the flywheel counterclockwise until fuel fills the bore of the feed valve bracket of the 1st cylinder.

☞ Continue turning the flywheel until the fuel overflows and then determine the injection time.

☞ With the help of the TDC mark and the auxiliary marks, calculate the angle and if necessary, add or remove a spacer to adjust the angle.

Rated value: 9° to 17° (depending on engine type)

Important!

The flywheel has a TDC mark and 4 lines in steps of 5° for indicating the crankshaft angle in a range of 10° to 25°.

Adding or removing a spacer ( 0.15 mm) modifies the angle by 1.5° and results in an earlier or later injection setting. A combination of these spacers (0.15 – 0.3 mm) can be used too.

Removing and installing

Important!

Adjust the injected fuel quantity on a test bench (in compliance with requirements) as you replace the pump element.

1. Pump housing 2. Adjusting lever 3. Pressure valve housing 4. Pressure valve spring 5. Pressure valve 6. Push roller 7. Cylinder 8. Piston

D-16

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine D.4

Settings: Yanmar 3TNE 88, 3TNV 88, 4TNV 88

Valve tip clearance

☞ Standard setting of valve tip clearance is possible: ➥ On a cold engine Procedure

☞ Remove the cylinder-head cover ☞ Turn the engine until the cylinder reaches top dead centre of the compression cycle. ➥ Valve overlapping (both rocker arms move freely) ☞ Check the valve cap for abnormal wear abnormal

normal Valve cap wear

B

☞ Check valve tip clearance A with a feeler gauge ➥ Valve tip clearance:0.15 – 0.25 mm ☞

C

Set the valve tip clearance on the cylinder by turning set screw B.

☞ Tighten locknut C.

A

➥ Check the setting again with the feeler gauge. ☞ Repeat the procedure for each cylinder ☞ Placing the cylinder-head cover gasket ☞ Mount the cylinder-head cover Setting valve tip clearance

Order for setting valve tip clearance on 3-cylinder engine Cylinder

1

2

Inlet

Exhaust

Inlet

X

X

X

1 cylinder TDC compression 1 cylinder overlapping TDC

3 Exhaust

Inlet

Exhaust

X X

X

Order for setting valve tip clearance on 4-cylinder engine Cylinder

1 cylinder compression TDC

1

2

Inlet

Exhaust

Inlet

X

X

X

4 cylinder overlapping TDC

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

3 Exhaus t

Inlet

4 Exhaus t

Inlet

Exhaust

X

X

X X

X

D-17

Engine Tightening order for cylinder head bolts

☞ Mount the cylinder-head bolts ➥ Tightening torque: • 1st pass

41.1 – 46.9 Nm

• 2nd pass

85.3 – 91.1 Nm

Caution!

Bear in the mind the order for tightening the cylinder-head bolts!

☞ See figure

Flywheel

Fan

Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them!

☞ Order for removing the cylinder-head bolts Flywheel

Fan

4 cylinders

Flywheel

Fan

☞ Order for removing the cylinder-head bolts Flywheel

Fan

Important!

Always carry out work on the cylinder head on a cold engine!

D-18

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine Checking the injection nozzles Pressure check

☞ Remove the injection line and the injection nozzle ☞ Connect the injection nozzle with the high pressure line of the nozzle tester ☞ Slowly increase pressure until the nozzle ejects fuel and read the pressure off the pressure gauge

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

➥ Injection pressure: 220 – 230 bar Fig. 1:

• Spacer thickness of 0.1 mm corresponds to modification by 19 bar • Check the injection nozzle nozzle for drips after it has ejected fuel

Nozzle tester

☞ Create a pressure of about 20 bar below injection pressure and check whether fuel escapes from the nozzle

Leak oil line

Upper nozzle screw fitting Spacers

Pressure spring centring Nozzle needle

Compression

Compression

Lower nozzle screw fitting

Nozzle body

Checking the nozzle jet

☞ 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 (ejection 3 – 4 times) ☞ Hold a white sheet of paper about 30 cm away from the nozzle and let the nozzle eject fuel Normal atomisation

☞ The nozzle jet must create a shape on the paper as shown in fig.3/1

optimal Fig. 3:

--------------variation-------------Shape of nozzle jet

Bad atomisation Fig. 2:

Nozzle jet

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-19

Engine 3TNE injection time

Checking and adjusting

☞ Preparatory work: remove the injection lines, set the engine to full-load position ☞ Turn crankshaft pulley (1) of the engine counterclockwise.

As you continue turning the crankshaft pulley, the fuel level rises in the bore of the 1st cylinder on the fuel injection pump.

1

Keep turning the engine until the fuel starts overflowing at the fuel injection pump.

Determine the injection time on cylinder 1 (2) by means of the mark on the flywheel (sight hole (3)) and compare it with the engine data.

2

➥ ➥ -9°-17°. Depending on engine type.

• Modify the injection time by turning the fuel injection pump on the engine if the values do not coincide with the specified values. Slacken lock screws (5) on the fuel injection pump to do so.

➥ If injection time is too late, turn the fuel injection pump away from the engine. ➥ If injection time is too early, turn the fuel injection pump towards the engine. ☞ Retighten the lock screws and install the injection lines.

4

3

5

D-20

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine 3TNV88, 4TNV88 injection time Checking injection time

• Preparatory work: ☞ Remove the injection lines from the fuel injection pump ☞ Remove plug 6/1 from the piston ☞ Install a dial gauge in the piston bore as shown in fig. 4

• Measurement 1

☞ Remove the rubber cover from the flywheel housing ☞ Turn the crankshaft (ring gear on flywheel) until the piston in the fuel injection pump reaches the lowest point (pay no attention to the position of the cylinders)

☞ Set the measuring equipment to "0" ☞ Use a suitable tool to turn the flywheel on the ring gear counterclockwise (i.e. in the direction of rotation of the engine) until the piston of the fuel injection pump has a stroke of 2.5 mm.

Fig. 4:

Measuring equipment

☞ Read the degrees before top dead centre by means of the indentations on the flywheel • Indentations "1”, “2" and "3" stand for the top dead centre of the respective cylinders • Scaling: 12°/15°/20°/25° before top dead centre

➥ Rated value: 25° + 1° before TDC (fourth indentation depends on the engine type) Fig. 5:

Top dead centre indentation and 10° before top dead centre

Setting injection time

• Variations outside the tolerance range can be corrected by turning the fuel injection pump.

☞ Mark the initial position on the pump and wheel case housing before setting the fuel injection pump – see fig. 6

☞ Rotate the pump in the required direction, and tighten one of the screws before you check the setting

➥ Rotated towards the engine: earlier injection time ➥ Rotated away from the engine: later injection time Label for setting

☞ Tighten the flange screws on the fuel injection pump (see 5, page D-17). ☞ Check injection time again ☞ Bend each of the injection lines before you mount them so they are not subject to tension once they are mounted, then mount and tighten them.

Fig. 6:

Mark on housing

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-21

Engine Replacement of fuel injection pump (valid for Yanmar engines after November 2004)

☞ Remove gear casing cover 8/1 of the fuel injection pump ☞ Turn the engine until the marks on the gear of fuel injection pump A and on the flywheel

Mark on pump housing Label

gear B are opposite, see fig. 9 (ignition time of 1st cylinder)

☞ Before removing the fuel injection pump, mark its position by affixing adhesive labels or marks onto the wheel case housing (see fig.7).

Ensure the exact position opposite the groove mark on the fuel injection pump!

Example: +1° Fig. 7:

☞ Completely slacken lock nut 9/2 of the drive pinion ☞ Slacken screws (AA) on the fuel injection pump

Example: +0.25°

Correction of injection angle

☞ Remove the fuel injection pump ☞ Read off the injection angle on the pump ☞ Read off the injection angle on the new pump ➥ Read off the imprint on the engine side of the fuel injection pump 1 Fig. 8:

Gear casing cover

☞ Difference of “Angle of new pump” – “Angle of old pump” gives you the mounting angle of the new fuel injection pump

2

➥ Positive value: later injection time (away from the engine) ➥ Negative value: earlier injection time (towards the engine) A

B Fig. 9:

Gear casing

☞ Install the fuel injection pump ☞ Check the marked position of the drive pinion of the fuel injection pump (fig. 9) ☞ Screw on and tighten nut 9/2 ☞ Tighten screws (AA) on the fuel injection pump ☞ Check injection time ☞ Mount gear casing cover 8/1 of the fuel injection pump

Important!

AA

Do not slacken screws 3 of the drive pinion of the fuel injection pump. These screws specify the precision setting of the fuel injection pump set by the manufacturer!

A

_______________________________________________________________________ 3

B

Fig. 11: Gear casing

D-22

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine Adjusting engine revs

Important!

The maximum engine revs are set and sealed by the manufacturer without the hydraulic pump and may not be modified!

Adjust engine revs without load!

A

☞ Run the diesel engine until it reaches operating temperature ☞ Check idling speed A, all machine functions in neutral position ➥ Idling speed is indicated in the specifications for each engine type. ☞ Adjust as shown if values differ.

Caution: Only idling speed is allowed to be set!

B Adjusting engine revs

Compression

☞ Remove the injection lines and the injection nozzles ☞ Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid) ☞ Mount the compression gauge on the cylinder you want to measure ☞ Turn the engine with the starter and read the pressure off the pressure gauge ➥ Specified value: 35 +/- 1 bar @ 250 rpm ➥ Limit value: 28 +/- 1 bar @ 250 rpm Fig. 10: Compression

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-23

Engine Checking the coolant thermostat

☞ Remove the thermostat ➥ The thermostat is located on the water pump – see Engine overview 3TNE-88 on page D-6 Housing cover

Fig. 1:

Thermostat

Gear casing

Seal Housing Thermal switch Fig. 11: Coolant thermostat

Thermometer Thermal switch

☞ Warm up the thermostat in a container with water ☞ Check whether the thermostat opens at the prescribed temperature (check with a temperature gauge)

➥ Thermostat opening temperature: 69.5 – 72.5 °C (the thermostat opens fully from 85 °C onwards only)

Checking the thermal switch

☞ Remove the thermal switch ☞ Warm up the thermal switch in a container with coolant ☞ Measure the resistance of the thermal switch as shown by means of an ohmmeter. ➥ The switch must allow the coolant to pass at a temperature of 107 – 113 °C.

Thermometer

Test prods

Fig. 12: Checking the thermal switch

D-24

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine Oil pressure switch

☞ Remove the cable connection from the oil pressure switch (in the area of the cutoff solenoid) Measurement

☞ Start the diesel engine ☞ Measure the resistance of the oil pressure switch as shown by means of an ohmmeter. ➥ Oil pressure switch OK: infinite resistance ➥ The oil pressure switch is defective if the oil can pass

Fig. 13: Oil pressure switch

Checking the coolant circuit Leakage check

☞ Fill up the radiator completely ☞ Mount an adapter on the radiator as shown ☞ Increase the pressure in the cooling system by means of a hand pump to about 1 bar ➥ Check the lines and the connections for leaks if the pressure drops at the pressure gauge Fig. 14: Checking the radiator for leakage

Checking the radiator cap

☞ Remove the radiator cap and mount it onto the adapter as shown ☞ Increase the pressure to about 0.9 bar (stamped onto the radiator cap) with the hand pump

➥ The radiator cap must open Radiator cap Fig. 15: Checking the radiator cap

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-25

Engine Engine trouble Problem

Possible causes Wrong SAE grade of engine lubrication oil Fuel grade does not comply with specifications Defective or flat battery Loose or oxidised cable connections in starter circuit Defective starter, or pinion does not engage Wrong valve tip clearance Defective fuel injector Defective starting relay

Engine does not start or is not easy to start

Defective glow plug/defective intake-air preheating Defective solenoid switch Cutoff solenoid does not attract (Yanmar)/magnet attracts (Kubota) No current on cutoff solenoid (Yanmar)/current on magnet (Kubota) Clogged filter Defective fuel pump Air in fuel system Defective cutoff solenoid, timer or relay High pressure created immediately in the hydraulic system Fuel grade does not comply with specifications Wrong valve tip clearance

Engine starts, but does not run smoothly or faultless

Air in fuel system Injection line leaks Defective fuel injector Oil level too low Oil level too high Fouled air filter Fouled cooler fins

Engine overheats. Temperature warning system responds

Defective fan, torn or loose V-belt Resistance in cooling system too high, flow capacity too low Damaged seal on radiator Coolant level too low Defective fuel injector

D-26

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

Engine Problem

Possible causes Oil level too high Fuel grade does not comply with specifications Fouled air filter Defective air filter maintenance switch or gauge

Insufficient engine output

Wrong valve tip clearance Injection line leaks Defective fuel injector Injection line leaks

Engine does not run on all cylinders

Defective fuel injector Oil level too low Machine inclination is too high (see engine specifications)

Insufficient or no engine oil pressure

Fouled oil intake filter Wrong SAE grade of engine lubrication oil Oil level too high

Engine oil consumption too high

Machine inclination is too high (see engine specifications) Oil level too high Blue

Machine inclination is too high (see engine specifications) Engine oil combustion (defective cylinder-head gasket) Engine starting temperature too low

White Engine smoke

Fuel grade does not comply with specifications Defective fuel injector Coolant combustion (defective cylinder-head gasket) Fouled air filter Defective air filter maintenance switch or gauge

Black

Wrong valve tip clearance Defective fuel injector (drips) Wrong fuel injection pump setting

SERV-HB 2503 – 3703 – Edition 1.0 *2503-3703_EPA2 410.mif

D-27

Engine

D-28

SERV-HB 2503 – 3703 – Edition 1.0 * *2503-3703_EPA2 410.mif

SERVICE MANUAL

Electric

2503 - 3703

CHAPTER E:

Electric ( Neuson Service Manual 2503 - 3703 )

Page E1

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric 1.

DIAGRAM

2503 - 3703

for Kubota Diesel engine /starting Fabr.No. AB00001

Page E2

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Page E3

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AB00001 - AC09999)

Page E4

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AB00001 - AC09999)

Page E5

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AB00001 - AC09999)

Page E6

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AB00001 - AC09999)

Page E7

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric 1.

2503 - 3703

DIAGRAM

for Yanmar Dieselmotoren / starting Fabr.No. AD00001

Komponentenliste / Legend electric diagram 2503-3703 B2 B3

horn fuel level sensor

Hupe Dieseltank geber

G1

alternator

Lichtmaschine

H3 H12 H13 H14 H15 H16 H17 H18 H19 H20 H21 H22

arm light control lamp preheating control lamp load control control lamp engine temperature control lamp engine oil pressure control lamp air filter clogged control lamp hydraulic oil filter clogged control lamp overload warning indoor lighting cabin roof light front cabin roof light back rotating lamp

Armscheinwerfer Kontrolllampe Vorglühen Kontrolllampe Ladek ontrolle Kontrolllampe Motortemperatur Kontrolllampe Motöröldruck Kontrolllampe Luftfilterverschmutzung Kontrolllampe Hydraulik ölfilterverschmutzung Kontrolllampe Überlastwarnung Innenbeleuchtung Dachscheinwerfer vorne Dachscheinwerfer hinten Drehleuchte

K2 K4 K5 K6

timer preheating 10 sec. starting relais solenoid engine stop timer solenoid engine stop

Timer Vorglühen 10sec Startrelais Zeitrelais Abstellmagnet Relais Abstellmagnet Ziehk ontak t

M1 M5 M6 M7

heating van starter windscreen wiper windscreen washer

Heizungslüfter Starter Scheibenwischermotor Scheibenwaschpumpe

S1 alternator speed pick up Drehzahlsignal Lichtmaschine S2 water temperature switch Wassertemperaturschalter S4 air filter is clogged Schalter Luftfilter verschmutzt S5 engine oil pressure Motoröldruck S6 3rd hydraulik circuit button Taster 3. Steuerk reis S7 boom swing / extended hydraulic button Taster Zusatzhydr./Schwenk en S8 3rd hydraulik circuit button Taster 3. Steuerk reis S10.2 safety switch left Sicherheitsschalter rechts S11 fast speed switch Schnellfahrschalter S12 pressure switch overload warn device Druck schalter Überlastwarneinrichtung S14 hydraulik oil filter is clogged Hydraulik ölfilter ist verschmutzt S15 windscreenwiper / washer Scheibenwischer / wascher S16 heating van switch Schalter Heizung S17 fast speed switch Schnellfahrschalter S18 arm light switch Armscheinwerfer Schalter S20 starting switch Zündschloss S21 rotation light switch Schalter Drehleuchte S22 switch overload warn device Schalter Überlastwarneinrichtung

Page E8

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Komponentenliste / Legend electric diagram 2503-3703 S23 S27 S32 S33

switch roof light switch shield / boom pressure switch back drive warn-signal switch tilt valve

Schalter Dachscheinwerfer Taster Hubarm / Planierschild Druck schalter Rück fahr Warn-Signal Taster Tilt-Ventil

R1

preheating

Vorglühanlage

X0 X1 X2 X4 X5 X6 X9 X10 X17 X18 X19 X26 X27 X28 X29

cigarette lighter main connector engine cable tree main connector engine cable tree some engine relays alternator load control alternator main plus starter main plus starter solenoid main connector armrest cable tree ground sock et connector to horn button connector anti thieft device cabin connector connector instrumenten panel

Zigarettenanzünder Hauptsteck er Motork abelbaum Hauptsteck er Motork abelbaum einige Motorrelais Lichtmaschine Ladek ontrolle/Erregung Lichtmaschine Hauptplus Starter Hauptplus Starterritzel Spule Hauptsteck er Armlehnenk abelbaum Masse Steck dose Steck er Hupentaster Steck er Diebstahlsicherung Kabinensteck er Steck er Anzeigeinstrument

Y2 Y3 Y4 Y5 Y6 Y9 Y10

boom swing / extended hydraulik valve 3 rd hydraulic circuit 3 rd hydraulic circuit safety valve fast speed valve shiel up / down tilt valve

Armschwenk / Zusatzhydraulik Ventil 3. Steuerk reis 3. Steuerk reis Sicherheitsventil Schnellfahrventil Planiersschild auf / ab Tilt Ventil

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11

switch lights, controll lamps lights arm, cabin 12V15 Cabin heating van, horn valves windscreenwiper, cabin alternator res rotating light, cabin, anti thief device sock et res

Schalterbeleuchtung, Kontrollanzeigen, Motorrelais Beleuchtung Hubarm, Dachscheinwerfer 12V/15 Kabine Heizung, Hupe Ventile Scheibenwischer, Kabine Erregung Lichtmaschine res Drehleuchte, Radio, Zigarettenanz., Diebstahlsich.

Steck dose res

Q1 Q2

main fuse main fuse

Hauptsicherung Hauptsicherung

Page E9

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AC00001 and higher)

Page E10

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Fig.: Electric wiring diagram 2503 - 3703 (valid: Fabr.No.: AC00001 and higher)

Page E11

Id.No.: Edition:

9707748 Jan 03

SERVICE MANUAL

Electric

2503 - 3703

Pict : Relais position

Pict: Position relais + main fuse

Relais solenoid stop Main fuse ( 20A, 50A ) Relais glow control

Tab: Fuse box The fuses are integrated into the instrument panel.

The main fuse 50 amps for ignition, glow plug

No. Capacity (A) 1 10 2 15 3 10 4 15 5 10 6 10 7 10 8 reserve 9 10 10 10 11 10

Application switch lights lights arm, cabin 12V/15 cabin Heating, horn Valves Windshield wiper and washer Generator reserve 12V/30 cabin socket reserve

Page E12

Id.No.: Edition:

9707748 Aug 03

SERVICE MANUAL

Operating elements

2503 - 3703

CHAPTER F:

Operating elements ( Neuson Service Manual 2503 - 3703 )

Page F1

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Pict.: Major components

1

2 3 20 16,17 8,9

7

4 5 6

10

11 12

18 1 2 3 4 5 6 7 8 9 10

Bucket stick Bucket stick cylinder Boom Cab Driver`s seat Engine cover Bucket cylinder Left control lever Right control lever Bucket

14 11 12 13 14 15 16 17 18 19 20

19

15

20

13

Boom cylinder Steering control console Dozer blade Under carriage Chassis Left drive lever Right drive lever Drive unit Protective cover for track tensioner Lifting eye

Page F2

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Cab equipment and controls 1 2 3 4 5

Drive pedals and levers with overdrive switch Pedal for auxilliary hydraulic and arm-swing (by pressing the button on the left joystick) Heating vents Cigarette-ignitor Lever to fold back the left armrest (Safety function: All hydraulic controlled functions are switched off, if the armrest is in back position) 6 Left Joystick 7 Instruments 8 Right Joystick (SNews 50/01- Step relay function boom/dozerblade) 9 Cables for opening the engine- and side valve bank cover 10 Switches and ignition lock

1

9

5

2

3

4

7 8

6

10 Bild F002: Betriebseinrichtungen

Page F3

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Pict.: Instrument Panel Functions 8 9 10 11 12 13 14 15 16

1 2 3 4

Fuel gauge Charge indicator Engine oil pressure Water temperature warning signal 5 Clogged air filter 6 Glow plug indicator 7 Clogged hydraulic filter

Over load warning signal free Operating hours counter Ignition lock Windshield wiper/washer switch Fan switch Overdrive Light switch Free

Pict.: Instrument Panel functions

1 6 7 8 9 10 11 12 13 14 15 16

2 3 4 5

Page F4

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Pict.: Joystick consol right

Gas lever Ignition lock

Switch panel

Fuse box

Pict.: Bowdenzug - operation inside the cabine

Side valve cover

Engine bonnet

Pict.: Canopy version

Side valve cover

Safty lock Page F5

Engine bonnet Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Hydraulic connections for additional attachments Hydraulic connections for supplying additional attachments are located at the end of the bucket sticket.

The hydraulics supply for additional attachments can be activated by turning the levers on the bucket stick and in the main hydraulic valve area.

Lever on bucket stick Pict. 014: Position for use of grab

Position for use of bucket

The lever is positioned under side valve bank cover Pict. 015: Position for auxiliary hydraulics

Position for use of hammer

Brakes and swivel lock mechanism The brakes (3503 and 3703) and swivel lock are automatically activated when the excavator is at a complete stop (no pilot control pressure).

The brakes only release when a drive or control lever is activated (pressure builds up).

Page F6

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Tilting the superstructure In order to facilitate vertical digging on a slope, the superstructure of the Crawler Excavator 3703 can be tilted hydraulically 15° by means of a lever. This helps keep the chassis horizontal.

Pict.: Tilting cylinder 3703

Hydraulic cylinder for tilting superstructure

Covers for maintenance Pict.: Rear counter weight: 1.

Open engine cover 2.

Loosen the screws for the counter weight (4 screws each side) 3.

Swing out the counter weigths Attentione: On the new generation the rear counter weights opens with loosening both side and the inne upper screws The are mounted on sliding rails, on which it´s possible to pull them out More space for working on the hydraulic pump and dieselengine Pict. 018: Side valve bank cover: 1.

To open the cover, use the bowdenzug inside the cabin Following components are located: Main valve bank, hydraulic tank- and filter, pilot valve, change over valve for swing-arm and aux. hydraulic.

Page F7

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Operating elements

2503 - 3703

Page F8

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Attachment

2503 - 3703

CHAPTER G:

Attachment ( Neuson Service Manual 2503 - 3703 )

Page G1

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Attachment

2503 - 3703 Additional to:

SERVICE NEWS 52/01T

BUCKET LIST B UCK E TS

With

B UCK E T

260 mm 300 mm 400 mm 500 mm 600 mm 700 mm

36 l 43 l 59 l 75 l 91 l 107 l

2526025 2526001 2526013 2526009 2526017 2526018

260 mm 300 mm 400 mm 500 mm 600 mm

33 l 39 l 54 l 69 l 84 l

2206053 2206054 2206055 2206056 2206057

260 mm 300 mm 400 mm 500 mm 600 mm 700 mm

36 l 43 l 59 l 75 l 91 l 107 l

2526037 2526036 2526035 2526034 2526033 2526032

260 mm 300 mm 400 mm 500 mm 600 mm

33 l 39 l 54 l 69 l 84 l

1706134 1706135 1706136 1706137 1706138

2503 Advantage : more Buck et volume than the 02 generation !

B UCK E T

1902 / 2202

B UCK E T fo r quick hitch co .

2503 Advantage : more buck et volume that the 02 generation B UCK E T f or quic k hit c h c oupler

1902 / 2202

Volume P art No. :

Q UIC K H IT C H C O UPLER

1706149

1902 / 2202 DI TCHI NG B UCK E T

1902 / 2202 D IT C H IN G BUC KET fo r qu i c k hi tc h c o.

850 mm 1000 mm

69 l 82 l

2206058 2206059

850 mm 1000 mm

68 l 80 l

1706125 1706126

1902 / 2202 T ILT IN G BUC KET hydr . for qu i c k hi tc h c ou pl er

Us ab le f or . . .

2503 1902 / 2202 (except 700 mm - too heavy )

2503 ( but less buck et volume ) 1902 / 2202

2503 1902 / 2202 (except 700 mm too heavy)

2503 ( less buck et volume) 1902 / 2202

2503 1902 / 2202

2503 1902 / 2202

2503 1902 / 2202

1902 / 2202 TI LTI NG B UCK E T hydr.

2503

850 mm 1000 mm

73 l 87 l

2206060 2206061

850 mm 1000 mm

73 l 87 l

1706147 1706148

1902 / 2202

2503 1902 / 2202

2503 1902 / 2202 Page 5/7

Page G2

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Attachment

2503 - 3703

SERVICE NEWS 52/01T

Additional to:

B UCK E T LI S T

3003 / 3503 / 3703

B UCK E T

Width

Vol ume

P art . No. :

Us ab le f or. . .

B UCK E T

300 mm 400 mm 500 mm 600 mm 700 mm

50 l 69 l 88 l 107 l 127 l

3026003 3026005 3026007 3026009 3026011

3003 3503 3703

300 mm 400 mm 500 mm 600 mm 700 mm

50 l 69 l 88 l 107 l 127 l

3006045 3006048 3006046 3006300 3006047

Neuson 3003 : only usealbe with bucket connecting link Part No.: 3027033.

3503 u. 3703 : only usable with bucket connecting link Part No. 3527045

300 mm 400 mm 500 mm 600 mm 700 mm

50 l 69 l 88 l 107 l 127 l

3006163 3006137 3006161 3006192 3006162

3003 3503 3703 2702 3402

3026014

3003 3503 3703

3003 / 3503 / 3703 B UCK E T

2702 / 3402

B UCK E T f or quic k hit c h c oupler

2702 / 3402 QU I C K H I TC H C OU PL E R k om pl.

3003 / 3503 / 3703 QUI CK HI TCH COUP LE R k om pl.

2702 / 3402 3006182

2702 / 3402

3003 / 3503 / 3703

1000 mm 1400 mm

117 l 166 l

3026015 3026017

DI TCHI NG B UCK E T

1000 mm 1400 mm

117 l 166 l

3006200 3006201

1000 mm 1400 mm

116 l 164 l

3006166 3006172

DI TCHI NG B UCK E T

2702 / 3402

DI TCHI NG B UCK E T

2702 / 3402

2702 / 3402

Neuson 3003: only usable with bucket connecting link Part No. 3027033 , 3503 u. 3703: only usable with bucket connecting link Part No.: 3527045

3003 3503 3703 2702 / 3402 Neus on 3003: only usable with bucket connecting link Part No: 3027033 , 3503 u. 3703: only usable with bucket connecting link Part No: 3527045

3003 / 3503 / 3703 2702 / 3402

Page 6/7

Page G3

Id.No.: 9707748 Edition: Jan 03

SERVICE MANUAL

Attachment

2503 - 3703

Additional to:

B UCK E T LI S T B UCK E T TI LTI NG B UCK E T hydr.

3003 / 3503 / 3703 T ILT IN G BUC KET hydr . F or qu i c k hi tc h c oup l e r

With

Volume

P art No. :

1000 mm 1400 mm

111 l 158 l

3026401 3026402

1000 mm 1400 mm

111 l 158 l

3006189 3006190

2702 / 3402

SERVICE NEWS 52/01T

3003 / 3503 / 3703 Us ab le f or. . .

3003 3503 3703

3003 / 3503 / 3703 2702 / 3402

NOTICE: Neuson 2503 : Us ab ilit y: + Buck ets OLD (see A) >> for >> excavator - 03Generat ion: It is possible to use the buck ets from excavator (A) 1700 / 1900 / 1901 / 1902 / 2200 / 2201 / 2202 f or t he new Neus on 2503 . + Buck ets 03-Gen. >> for >> excavator OLD (see A) : Can be assembled, but collision - buck et / boom possible !

Neuson 3003 / 3503 / 3703 : Us ab ilit y : + Buck et OLD (siehe B) >> for>> excavator - 03Generat ion : Older buck ets, which were used by the types (B>) 2600 / 2702 / 2800 / 2902 / 3000 / 3200 / 3402 / 3602 / 3800 / 3802 can also be used for the: 3003 / 3503 / 3703 Therefore, the buck et connecting link must be changed for the original to a modified version !

(See Part.No. in the lists) + Buck et 03-Gen. >> for >> excavators OLD (see B) : It is not possible to use this 03-Generation ("new") buck ets on the listed old models of excavators (B) !

For detailed information - please check the enclosed lists.. .

Page7/7 C hanges possible.

Page G4

Id.No.: 9707748 Edition: Jan 03