Professional Documents
Culture Documents
Track excavators
2503 3003
3503 3/03
~
W.lCKEit
NEUSON
Documentation
Legend
Edition Issued
I
2.1 11/2012
2.2 05/2015
2.3 08/2015
W~CKER
NE USON
Wacker Neuson Linz GmbH
Flughafenstr. 7
A-4063 Horsching
Phone: +43 (0) 7221 63000
Fax: +43 (0) 7221 63000-2200
E-mail: office.linz@wackerneuson.com
www.wackerneuson.com
e n
TABLE OF CONTENT :
Chapter Page
0 Table of content I Product history
A Technical data
1 Dimensions A2
2 Kinematic A7
3 Lift capacities A9
4 Cycle courses A16
5 Hydraulic settings A26
6 Diesel engine settings A29
Speci cations A33
7 Tightening torques A37
B Maintenance
1 Maintenance schedule 81
2 Lubricants 84
Maintenance label 86
3 Hydraulic system 88
4 Auxiliary hydraulics 815
5 Hydraulic pump 816
6 Hose burst protection valve 816
7 Drive unit 817
8 Swivel unit 817
9 Hydraulic oil tank 818
10 Diesel engine 818
11 Cabin 820
12 Undercarriage 821
c Hydraulic
1 Hydraulic diagram A4 C1
Hydraulic diagram A3 C3
2 Component positions cs
3 Hydraulic pump C7
4 Pilot oil supply unit C12
5 Main valve block C17
6 Pilot control valves C33
7 Swivel unit C36
8 Drive unit C42
9 Swivel joint C55
10 Switch valves C58
11 Way valve (Vario) C61
12 Pressure limiting valve (Vario) C62
13 Hydraulic oil tank C63
n
Chapter Page
D Diesel engine
E Elektric
F Operation elements
Abbreviations:
AP Adjustment point
MP Measuring point
PPLV ... Primary - pressure limiting valve
SPLV ... Sekondary - pressure limiting valve
n Tightening torque
Pb1 Port code at the hydraulic diagram
neuson®
CHAPTER A:
Technical data
( Neuson Service Manual 2503 - 3703 )
Id.No.: 9707748
neuson Page A1
Edition: Jan 03
Technical data W-'CKE~
NEUSON
A Technical data
A.1 Engine
Model 2503 engine
[ Engine
Model 2503 I
Tier 3A
Product Yanmar diesel engine
Type 3TNV88-BSNS
Design Water-cooled 4 stroke diesel engine
Number of cylinders 3
Fuel injection system Direct injection
Aspiration Natural aspiration
Cooling system Water-cooled/aspirating fan
Lubrication system Force-feed lubrication with trochoidal pump
Displacement 1642 cm 3 (100.2 in:s)
Nominal bore and stroke 88 x 90 mm (3.46 x 3.54")
Output 19.4 kW (26 hp) at 2200 rpm
Max. torque 107.3 Nm (79.14 ft.lbs.) at 1320 rpm
Max. engine speed without load 2400 ± 50 rpm
Idling speed 1100 ± 50 rpm
Valve clearance (intake= outlet) 0.15 - 0.25 mm/(0.0059 - 0.0098) cold
33.3 - 35.3 bar at 250 rpm
Compression (483 - 512 psi at 250 rpm)
Engine oil pressure 3.5 - 5.0 bar (50.76 - 72.52 psi)
Pressure switch for engine oil pump 0.5 ± 0.1 bar (7.25 ± 1.45 psi)
Thermostat opening temperature 69.5 - 72.5 °C (157 .1 - 162.5 °F)
Thermal switch 107 -1 13 °C (224.6 - 235.4 °F)
Firing order 1-3-2
Anticlockwise
Direction of rotation (as seen from the flywheel)
Glow elements (preheating time 10 - 15
Starting aid seconds)
Max. inclined position (engine no longer 30° in all directions
supplied with oil): 35° no longer than 3 minutes!
Specific fuel consumption 252 g/kWh (0.414 lb/hph)
97/68/EC Tier 3A
Exhaust values according to
EPA Tier 4 interim
j Type YPD-MP2 I
Design Single piston distributor injection pump
196 - 206 bar
Injection pressure (2843 - 2988 psi)
Engine speed control Mechanical
Lubrication system Engine oil lubrication
Engine capacities
Traveling drive/axles
2503 from serial no. WNCE0304HPAL00199
I Traveling drive Model2503 I
Product Nachi
Type PHV-290-37-5R1-88428
Tracks
2503
Ground clear-
Type Width Ground pressure Remarks
ance
Rubber 250 mm (10 in) 0.34 kg/cm 2 (4.8lbs/in2)1 270 mm (1 1 in) Standard
Rubber 300 mm (12 in) 0.28 kg/cm 2 (4 lbs/in 2)1 270 mm (1 1 in) Option
Steel 250 mm (10 in) 0.36 kg/cm 2 (5.1 lbsfln2l 1 267 mm (1 1 in) Option
1. Ground pressure can be higher depending on the configuration chosen.
Tier Ill
fEi1gine Model 3503 I
Product Yanmar diesel engine
Type 4TNV88-BWNS
Design Water-cooled 4 stroke diesel engine
Number 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 2190 cm 3 (133.6 cu. in.)
Nominal bore and stroke 88 x 90 mm (3.46 x 3.54")
Output 23.7 kW (31 .8 hp) at 2000 rpm
Max. torque 143 Nm (105 ft.lbs.) at 1200 rpm
Max. engine speed without load 2025 ± 25 rpm
Idling speed 1100 ± 25 rpm
Valve clearance (intake = outlet) 0.15 - 0.25 mm/(0.0059 - 0.0098") cold
Compression 33.3 - 35.3 bar (483- 512 psi) at 250 rpm
Engine oil pressure 3.2 - 4.7 bar (46 - 68 psi)
Pressure switch for engine oil pump 0.5 ± 0.1 bar (7.3 ± 1.5 psi)
Thermostat opening temperature 69.5 - 72.5 °C (157 .1 - 162.5 °F)
Thermal switch 107 - 113 °C (224.6 - 235.4 °F)
Firing order 1-3-4-2
Anticlockwise
Direction of rotation (as seen from the flywheel)
Glow plug (preheating time 10 - 15 sec-
Starting aid onds)
Max. inclined position (engine no longer 30° in all directions
supplied with oil):
5.9 1/h (1.6 gal/h)
(without air conditioning) 1
Fuel consumption
5.9 1/h (1 .6 gal/h)
(with air conditioning) 1
Specific fuel consumption 249 g/kWh (0.409 lb/hph)
97/68/EC Tier 3A
Exhaust values according to
EPA Tier 4 interim
1. Values based oo an average 70 % load of Ille excavator and adiesel fuel density of 0.83 kgldm' and cannot be used for comparison with
competitors. Specific fuel consumption sholid be used for this. The air cooditloning system has been taken i110 accou11 with 100 %
operating time.
Tier IV
[ Engine Mooel 3503 I
Product Perkins diesel engine
Type Perkins 404F-22
Design Water-cooled diesel engine
Number of cylinders 4 cylinders
Displacement 2216 cml (135 inl)
Nominal bore and stroke 84 x 100 mm (3.3 x 3.9 in)
Output 29.8 kW at 1975 rpm (40.0 hp at 1975 rpm)
143 Nm at 1800 rpm (105 ft.lbs at 1,800
Max. torque (intermittent)
rpm)
Max. engine speed without load 1975 rpm
Idling speed 800 rpm
Fuel injection system Indirect injection
Lubrication system Force-feed lubrication w~h trochoidal pump
Cooling system Water-cooled/aspirating fan
Aspiration Natural aspiration
Compression 23.3 : 1
Engine oil pressure at rated speed 2.07 - 4.13 bar (30- 60 psi)
Engine oil pressure switch 0.689 bar kPa (10.0 psi)
Thermostat opening temperature 80 - 84 °C (176 -183 °F)
Firing order 1-3-4-2
Intake valve 0.2 mm (0.0078")
Valve clearance
Exhaust valve 0.2 mm (0.0078'1
Direction of rotation Anticlockwise (as seen from the flywheel)
Starting aid Sheathed-element heater plugs
Exhaust values according to US EPA 40 CFR Part 1039 Tier 4 final
Engine capacities
f Hydraulics Model3503 I
Double variable displacement pump + 1
gear pump
Pump Tier 3A 2 x 22.0 + 12.4 cm 3 (2 x 1.34 + 0.76 in3)
PVD-2B-44P-1 2G-4713G
2 x 44.5 + 25.1 I/min
Flow rate Tier 3A (2 x 11.8 + 6.6 gal/min) at 2025 rpm
Control valve 10 sections/1 1 sections (3rd control circuit)
Main pressure limiting valve for pumps P1, 240-01+5 bar (3481-01+73 psi)
P2
Main pressure limiting valve for pump P3 210±3 bar (3046±44 psi)
Secondary pressure limiting valve for main 27 5-rn+u.~ bar (3989·UI+' ·j psi)
valve block at 20 I/min (5.3 gal/min)
Main pressure limiting valve for 35-01+ 4 bar (508-01+58 psi)
pilot control pressure
Main pressure limiting valve for 215.;t.3 bar/3118±44 psi (at idling speed)
swivel unit engine pressure restriction
Hydraulic oil radiator Standard
Hydraulic reservoir capacity 50 I (13.2 gal)
2nd speed shift pressure 180 bar (2611 psi)
3.7 1·21 +1.Zs at 50
°C (122 °F) oil tempera-
Gear motor braking deceleration time
ture.
Circulation pressure P1, P2 15.5 bar (225 psi)/12.5 bar (181 psi)
Circulation pressure P3 18 bar (261 psi)
Stabilizer blade
IStabilizer bla<te Mooel 3503 Mo<tel 3503 tiltable I
Width 1620 mm (64 in)
Height 370 mm (15 in) 350 mm (14 in)
Max. lift over subgrade 410 mm (16 in) 385 mm (15 in)
Scraping depth 480 mm (19 in) 529 mm (21 in)
Tilting angle -- +!- 25°
Tracks 3503
IType Width
Ground pressure Ground clearance Remarks I
Rubber 300 mm (12 in) 0.34 kg/cm 2 (4.8 lbs/in2)1 260 mm (10 in) Standard
Steel 300 mm (12 in) 0.34 kg/cm 2 (4.8 lbs/in2)1 270 mm (11 in) Option
1. Ground pressure can be higher depending on the configuration chosen.
0 Notice!
Measurements performed on asphalted surface.
A.4 Vibration
Vibration
Effective acceleration value for the upper extremities of the <Trigger value
body (hand-arm vibration) < 2.5 m/s2
Effective acceleration value for the body (whole-body vibra-
< 0.5 m/s2
tion)
IPowertilt Model3503 I
Model size 6
Piston stroke 525 cm3 (32 in3)
Required oil flow 3 - 6 I/min (0.8 - 1.6 gal/min)
Connections 1/4 in
Swiveling range 180°
Weight 65 kg (143.3 lbs)
Drive torque - at 210 bar (3045 psi) 2990 Nm (2,205 ft.lbs)
Holding torque - at 225 bar (3263 psi) 7270 Nm (5,362 ft.lbs)
Minimum hose/pipe size 10 mm (0.4 in)
Connecting hose size 6 mm (0.25 in)
A.6 Weights
Transport weight1 Operating weight2
Type
kg (lbs) kg (lbs)
2503 canopy 2483 (5,474) 2639 (5,818)
2503 cabin 2592 (5,71 4) 2747 (6,056)
3503 canopy 3424 (7,549) 3602 (7,941)
3503 cabin 3551 (7,829) 3728 (8,219)
3503 VOS canopy 3689 (8131) 3866 (8,523
3503 VOS cabin 3815 (8,411) 3993 (8,803)
3503 Vario canopy 3699 (8, 155) 3877 (8,547)
3503 Vario cabin 3826 (8,435) 4003 (8,825)
0 Notice!
The actual machine weight depends on the selected options and must be read off
the type label.
Add the weight of all subsequently installed equipment to the weight of the
machine.
Weight indications can vary by +/- 2 %.
A. 7 Tightening torques
General tightening torques
I Ttirea<te<t fittings witti various seals for hy<traulic applications (light execution) l
Straight pipe fitting with thread and
Non-return
screwed plug Identification aid
valve with
Thread Sealing outside 0
Elastic seal 0-ring elastic seal
washer
Nm (ft.lbs) Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) mm (")
M10X1 .0 9 (7) 18 (13) 15 (11) 1S (13) 10 (0.4)
M12X1 .5 20 (15) 25 (1S) 25 (1S) 25 (1S) 12 (0.5)
M14X1.5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.55)
M16X1 .5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6)
M1SX1 .5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7)
M22X1 .5 65 (4S) 125 (92) 60 (44) 125 (92) 22 (0.9)
M27X2.0 90 (66) 1SO (133) 100 (74) 145 (107) 27 (1 .0)
M33X2.0 150 (111) 310 (229) 160 (11S) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7)
I Threaded fittings with various seals for hydraulic applications (light execution) I
M48X2.0 290 (214) 540 (398) 260 (192) 540 (398) 48 (1.9)
G1/8A 9 (7) 18 (13) 15 (11) 18 (13) 9.73 (0.38)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 (0.52)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 (0.66)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 (0.83)
G3/4A 90 (66) 180 (133) 100(74) 140 (103) 26.44 (1.04)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 (1.31)
G11/4A 240 (177) 450 (332) 210 (155) 360 (266) 41 .91 (1.65)
G11/2A 290 (214) 540 (398) 260 (192) 540 (398) 47.80 (1.88)
I Threaded fittings with various seals for hydraulic applications (heavy execution) l
Straight pipe fitting with thread and
Non-return
screwed plug Identification aid
valve with
Thread Sealing outside 0
Elastic seal 0-ring elastic seal
washer
Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) Nm (ft.lbs.) mm(")
M12X1.5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5)
M14X1.5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.55)
M16X1.5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6)
M18X1.5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7)
M20X1.5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.9)
M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0)
M27X2.0 90 (66) 180 (133) 170 (126) 135 (100) 12 (0.5)
M33X2.0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7)
M48X2.0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9)
G1/8A 35 (26) 55 (41) 45 (33) 45 (33) 13.16 (0.52)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.66)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.83)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.04)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.31)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.65)
G11 /4A 290 (214) 540 (398) 420 (310) 540 (398) 47 .80 (1.88)
Torque tole<ance: - 10 %; countermaterial: steeValuminum
DIN 912 - hexagon socket head cap screw; DIN931/DIN933 - hexagon head screw with/without shaft;
DIN 7984 - hexagon socket head cap screw with short head
All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.
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5456
5546
_J
5546
Fig. 4: Machine dimensions (model 3503 VOS)
A.11 Kinematics
Bucket
Stick
Pin lock
neuson®
CHAPTER B:
Maintenance
( Neuson Service Manual 2503 - 3703 )
Id.No.: 9707748
neuson Page s1
Edition: Jan 03
W~CKEa
Maintenance NE USON
B Maintenance
Fluids and lubricants
I Application Fluid/lubricant
-
Specification
,_
Season/temper-
ature
Capacities 1
I
Diesel engine max. 6.7 1
3TNV88 (Tier Ill) API: CF, CF-4, Cl-4 (1.76 gal)
Engine oil SAE 10W-40 ACEA: E3, E4, ES
Diesel engine JASO: DH-1 - 20 °C (- 4 °F) max. 7.4 1
4TNV88 (Tier Ill) (1.95 gal)
+40 °C (104 °F)
API: CJ-4 10.6 1
Diesel engine Tier IV Engine oil SAE 10W-40 ACEA: E9 (2.8 gal)
ECF-3
About 0.6 I each
Traveling drive Gearbox oil SAE 80W-90 API: GL-4, GL-5 Year-round
(0.2 gal)
Hydraulic oil EUROLUB HVLP462 2503: 27 1
(7 gal)
Hydraulic oil reservoir PANOLIN HLP Synth 46 Year-round 3
3503: 50 I
Biodegradable oil4
BP BIOHYD SE-46 (13 gal)
Roller and friction bear-
ings
Live ring: ball bearings Grease KF2K-20 5 Year-round As required
Live ring gears
Grease zerks
Battery terminals Acid-proof grease6 FINA Marson L2 Year-round As required
2-D ASTM 0975 - 94 (USA)7·8
1-D ASTM 0975- 94 (USA)
EN 590 : 96 (EU) 7·9
Depending on
ISO 8217 OMX (International)
outside tempera-
2503: 41 I (11 gal)
Fuel tank Diesel fuel 7 BS 2869 - A1 (GB) ture
3503: 52 1(14 gal)
Summer or winter
BS 2869-A2 (GB) 7•8
diesel fuel
JIS K2204 (Japan)
KSM-2610 (Korea)
GB252 (China)
Distilled water + antifreeze ASTM 04985
(reddish)10 About 4.5 1
Radiator Coolant Year-round
Distilled water + antifreeze ASTM 06210 (1.2 gal)
(violet)11
Refrigerant R134a12 Year-round - 950 g (2.1 lbs)
Tier 2: 122 cml
Air conditioning (7.45 in3)
Compressor oil Sanden SP20 Year-round
Tier 3A: 90 cml
(5.5 in3)
Washer system Cleaning solution Water + antifreeze Year-round 1.2 I (0.32 gal)
1. The capacities indicated are apprnximate values; !he oil level check alone is relevant for !he correct oil level
Capacities indicated are no system fills
2. According to DIN 51524 section 3 . .
3. Depending on local conditions - see Hydraulics oil grade on page B-4
4. Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value ot < 10. according to DIN 51524Teil3, section . HVLP, HEES
5. SKPF2K-20 l~hium-saponified grease according to DIN 51502/JSO 6743-9
6. Standard acid-proof grea.se
7. In countries without regulations on exhaust gas emissions, diesel fuel with a su~ur content of up to 4000 ppm (0.4 %) can be used.
8. Sulfur content up to 15 ppm (0.0015 %)
9. Sulfur content up to 10 ppm (0.001 %)
10. 2503: up to serial no. WNCE0304PPAL00399; 3503: up to serial no. WNCE0307APAL00999
11. 2503: from serial no. WNCE0304HPAL00400; 3503: from serial no. WNCE0307PPAL01000
12. According to DIN8960
SAE20W
SAE 10W-30
SAE 30
SAE40 I
°F I -4 I 5 I 14 I 23 I 32 I 41 I so I s9 I 68 I 77 I 86 I 95 1104
~ Caution!
An additional oil change and filter replacement can be required depending on
how the machine is used. Failure to observe these replacement intervals can
cause damage to hydraulic components.
~ Observe the following intervals
0 Notice!
Please refer to the maintenance plan on page 8-5 for additional maintenance.
Hydrau-
lics oil Ambient temperature
grade
°C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 50
ISOVG32
HVLP1 ISOVG46
ISOVG68
5 14 23 32 41 50 59 68 77 86 95 104 122
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Drain condensation water from the hydraulic oil reservoir (from serial no. AH02272)
• •
Fuel filter: from AG00580: drain 10 ml (0.3 US fl.oz) of fuel/water mixture
• •
Check V-belt condition and tension
• •
Check the exhaust system for damage and condition
• •
Check valve clearance. Adjust if necessary
• •
Clean and adjust the fuel injection pump 8
• •
Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles
• •
Check and adjust injection time 9
• •
Empty diesel fuel tank
• •
Check battery electrolyte. Add distilled water if necessary
• • •
Check alternator, starter and electric connections, bearing play and function
• •
Check preheating system and electric connections
• •
Check correct function of air filter contamination gage
• •
Pressure check of primary pressure limiting valves
• • •
Check tracks for cracks and cuts
• •
Check the track tension and retension the tracks if necessary
• •
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Check wear on load hook and joint rod Oifting eye)
• • ~~
Check line fixtures
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8 .1 Maintenance plan (Tier Ill)
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Ensure grease supply of central lubrication system (option)
• •
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• •
Check function of engine cover gas strut
• •
Check the hydraulic quickhitch for damage
• •
Check the Powertilt for damage
• •
Check Powertilt for axial play (must not be over 0.38 mm/0.015 in)
• •
Actuate Powertilt swivel device in final position for 1 minute10
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Check for tightness, leaks and chafing: pipes, flexible lines and threaded fittings of the following assemblies and components. Rectify if necessary:
• Visual check
• •
~E ngine and hydraulic system
• •
~ cooling and heating circuit
• •
~ Traveling drive
• •
~ Hydraulic quickhitch (hoses, valve)
-- • -- •
--
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• Check the seat belt for damage
• • ~~
• Check the l~ting gear (load hook.joint rod, l~ting eyes) and slings (option)
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3. Replace the fuel filter the first time after 500 olh. then every 000 o/h
8I
4. Replace the hyaaulicoil filter inSElt the first time after 00 o/h. then every 500 ~h
5. Replace the hyaaulicoil the li"st time after 500 olh. then every 1000 oo
~ 6. Drain the gearbox oil theli"st time after 50 ~h. then !!Nery 1000 ~h
!!l 7. Clean the water ducts every other 1000 o/h servicing
8. Ad}lst andclean the fuel injection pump !!Nery other 1000 o/h servicing
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10.
Check andad}lst injection time every other 1000 ~h servicing
Rinse the system to remCNe dirt. Repeat the procedure in the opposRe flCMI drection. en
11. Twice daily when used in water
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W~CKEa
Maintenance NE USON
1. When in extensive use in dusty environment. Replace the filte< if it shows signs of cracks, damage or clogging.
2. Rinse the system to remove din. Repeat the P"OCedure in the opposite flow direction.
0 Notice!
Check the antifreeze at temperatures below 4 °C (39 °F).
[ Only once after the first 50 operating hours (Wacker Neuson service center) I
Replace the hydraulic oil filter insert --
Replace the gearbox oil in the traveling drive, axles and transfer gearbox --
Check V-belt condition and tension --
Check the threaded fittings for tightness --
Check labels and Operator's Manual for completeness and condition --
Check the pressure of the primary pressure limiting valves of the operating hydraulics --
All steps for maintenance once a day and once a week
IEvery 1000 operating hours or once a year (Wacker Neuson service center) I
Change the hydraulic oil --
Replace the breather filter of the hydraulic oil reservoir --
Replace the gearbox oil in the traveling drive, axles and transfer gearbox --
1
Replace the air filter element --
Replacing the crankcase breather filter --
Check valve clearance, adjust if necessary2 --
Check the pressure of the primary pressure limiting valves of the operating hydraulics --
Check the antifreeze --
Check the battery condition (charge condition. terminals, etc.) --
All steps for maintenance once a day and once a week (and all steps for maintenance at 500 operating
hours)
--
Option
Wear of load hook and joint rod (check at least once a year)
1. Air filte< replacement according to the din indicator, evE!f'j 1000 oni or once a year at the latest. (Replace arte< 50 o/hwhen in extensive use in environments with acidicair, such as acid production
facilities, steel and aluminum mills, chemical plants and other nonfroous-metal plants, independently of the din indicator)
2. If equipped with a Perkins engine: have performed by a Perkins service cente<.
Every 2000 operating hours or every 2 years (Wacker Neuson service center)
Check the bladder type accumulator
All steps for maintenance once a day and once a week (and all steps for maintenance at 500 and 1000 oper-
ating hours)
IEvery 3000 operating hours or every 3 years (Wacker Neuson service center) I
Check the injection nozzles and clean them if necessary --
Clean the diesel particulate filter. replacement program --
Check the exhaust gas recirculation and clean it if necessary --
Draining coolant
Replace the fuel-burner glow plug
Check the water pump (visual check) --
Replace the coolant thermostat --
Replace the radiator cap --
All steps for maintenance once a day and once a week (and all steps for maintenance at 500 and 1000 oper-
ating hours)
--
0 Notice!
Maintenance with the note Wacker Neuson service center must be per-
formed only by the trained and qualified personnel of a Wacker Neuson ser-
vice center.
0 Notice!
The maintenance meter starts at 500.0 hours. It counts down to 0.0 hours. A
wrench symbol flashes as soon as the maintenance meter reaches this value.
& Danger!
Refueling
Filler inlet A for the fuel tank is located behind the cabin, on the right in travel direction.
~ Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner.
Fig. 1:
~
Fuel filler inlet
0 Notice!
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel
system. This requires bleeding the fuel system - see Bleeding the fuel system
on page B-18.
0 Notice!
Fill up the tank with the correct fuel type at the end of each working day. This
prevents condensation water from forming in the fuel tank over night. Do not fill
the tank completely but leave some space for the fuel to expand.
ll$T' Protect the suction pipe opening of the barrel pump with a fine-mesh screen
Draining fuel
~ Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
Filler inlet A for the fuel tank is located in the valve compartment, on the left in travel direc-
tion.
Proceed as follows:
\
ll$T' Open filler inlet A
Fig. 3: Fuel tank
ll$T' Pump out the fuel with a suitable pump
IGrade Use I
1
• 2-D ASTM 0975 - 94
. 1-D ASTM 0975 - 94
USA
. EN 590: 962 EU
. ISO 8217 OMX International
. BS 2869 -A1
. BS 2869 -A2 1 England
0 Notice!
Using biodegradable diesel fuel is prohibited.
~ Unscrew thread A
~ Environment!
Thread A is fitted with a hose. Collect the fuel/water mixture as it drains with a
suitable container and dispose of it in an environmentally friendly manner.
~ Environment!
Collect the fuel/water mixture as it drains with a suitable container and dispose
of it in an environmentally friendly manner.
/i Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
Engine damage and loss of output!
• Perform oil changes according to the maintenance plan.
- see Maintenance plan (Tier Ill) on page 8-5
or - see Maintenance plan (Tier IV) on page B-10 (Tier IV)
0 Notice!
Check the oil level once a day.
We recommend checking it before starting the engine. After stopping a warm
engine, wait at least 5 minutes before checking.
~ Proceed as follows:
~ Park the machine on level ground
~ Stop the engine!
~ Raise the control /ever base
~ Let the engine cool down
~ Open the engine cover
~ Clean the area around the oil dipstick with a lint-free cloth
~ Oil dipstick A (Tier Ill) or B (Tier IV)
~ Pul/itout
0 Notice!
Too much or incorrect engine oil can cause engine damage! For this reason:
• Do not add engine oil above the MAX mark of oil dipstick 8/A
• Use only the specified engine oil
~ Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in
an environmentally friendly manner!
0 Notice!
Adding the engine oil too fast via filler inlet 8 in the valve cover can cause engine
damage.
• Add the engine oil slowly so it can go down without entering the intake sys-
tem.
i& Clean the area around oil filler cap 8 (Tier Ill) or C (Tier JV) with a lint-free cloth
i& Open filler cap 8 (Tier Ill) or C (Tier JV)
i& Raise oil dipstick A slightly to allow any trapped air to escape
i& Add engine oil
i& Wait about 3 minutes until all the oil has run into the oil sump
i& Check the oil level
-see Checking the oil level on page 8-19
i& Add oil if necessary and check the oil level again
i& Close filler cap 8 (Tier Ill) or C (Tier IV)
i& Push oil dipstick A back in as far as possible
i& Completely remove all oil spills from the engine
~ Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in
an environmentally friendly manner!
ts. Caution!
Burn hazard due to hot fluid.
Can cause serious injury or death.
• Wait at least 15 minutes after stopping the engine!
• Wear protective gloves and clothing
• Turn filler cap B to the first notch and release the pressure
• Ensure that the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands
ts. Caution!
Injury hazard when handling flammable and toxic fluids!
Can cause serious injury or death.
• Keep away from flames
• Avoid eye contact with antifreeze
• If antifreeze comes into contact with the eyes
• Immediately rinse with clean water and seek medical assistance
• Add coolant
[)Notice!
Check the coolant level once a day.
We recommend checking it before starting the engine.
(i) Notice!
Do not mix the coolant with other coolants.
• Use only the coolant prescribed by Wacker Neuson
- see chapter Fluids and lubricants on page B-2.
Adding coolant
After the engine has cooled down:
~ Release overpressure in the radiator
~ Carefully open filler cap A (Tier IV) or B (Tier Ill) to the first notch and fully release the
pressure
~ Open filler cap A or B
~ Tier IV: add coolant up to the middle of the sight glass
~ Tier Ill: Add coolant up to the lower edge of the filler inlet (radiator)
~ Close filler cap A or B
~ Start the engine and let it warm up for about 5 - 10 minutes.
~ Stop the engine
~ Remove the key and carry it with you
~ Let the engine cool down
~ Check the coolant level again
• The coolant level must be between the Low and Full reservoir seams
~ If necessary,
add coolant and repeat the procedure until the coolant level remains con-
stant
[ ) Notice!
Check the antifreeze every year before the cold season sets in
Draining coolant
6. Caution!
Burn hazard due to hot fluid.
Can cause serious injury or death.
• Always use appropriate protective equipment. protective gloves, for exam-
ple!
• No smoking. no fire!
Proceed as follows:
~ Stop the engine
~ Environment!
Fig. 14: Removing coolant .,.,;u, a pump Use a suitable container to collect the coolant as it drains and dispose of it in
an environmentally friendly manner!
Ir
!f
11
I I
I I
l~
;
IJ:l Danger!
0 Notice!
Lubricate only over a pit.
Fig. 16: l ull'icating the ball bearing race of the live ring
& Danger!
Do not rotate the upper carriage during lubrication!
Risk of serious crushing that can cause death or serious injury!
LS. Caution!
Lubricate only over a pit.
~ Lower and support the boom to prevent it from lowering into the pit.
~ Stop the engine, remove the starting key and carry it with you.
~ The lubrication point is located on the lower side of the travel gear.
~ Remove cover A by means of screws B on the lower side.
~ Apply grease to lubrication point C with five strokes of the grease gun.
~ Start the engine, raise the boom and the stabilizer blade.
Perform maintenance on the Powertilt unrr once a day with the other maintenance for the
machine.
Perform visual checks for possible malfunctions, damage or cracks.
Remove all dirt on and around moving parts.
Apply grease via grease zerks S.
0 Notice!
Before picking up an attachment, the operator must ensure that it can be hitched
correctly by removing all dirt on errher claw of the quickhitch.
Perform maintenance on the quickhitch once a day with the other maintenance for
the machine.
,_
!Joint rod (lifting eye) Nominal size A M ax. tolerance Bl
2503 32 mm (1 1/4 in) 33.6 mm (1 3/8 in)
Fig. 27: Lifting eyejoint rod (symbolic rei:resentation)
3503 up to WNCE0307 JPAL00239 32 mm (1 1/4 in) 33.6 mm (1 3/8 in)
e Have load hooks (Powertilt, Powertilt for Easylock) with inadmissible wear (beyond max.
tolerance, for example), damage, deformations, surface cracks and corrosion immediately
replaced by a Wacker Neuson service center.
The nominal size must not be worn more than 10 % (max. tolerance). Measurement can
be performed with the accuracy of a slide gage.
Welding is prohibited!
B If the spring mechanism of snap link C does not automatically close any more, stop work-
ing with the load hook and have the error repaired by a Wacker Neuson service center.
~Load hook Nominal size A Max. tolerance A Nominal size B Max. tolerance B Nominal size C Max. tolerance CI
2503/3503 105 mm (4 1/8 in) 115.5 mm (4 1/2 in) 32 mm (11/4 in) 28.8 mm (1 1/8 in) 30 mm (1 1/8 in) 33 mm (1 1/4 in)
B.9 Tracks
Track wear can vary according to work and ground conditions.
11?We recommend checking track wear and tension once a day.
Checking track tension
f:i:. Caution!
Crushing hazard during work under the machine!
Can cause serious injury or death.
• Do not allow anyone to stay in the danger zone!
• Support the machine so as to allow the tracks to sag freely.
Rubber track
It? Position the machine so that mark 8 of the rubber track is in the middle between the
drive pinion C and the track tension roller D.
It? Stop the engine.
It? Operate the control /ever repeatedly to release the pressure in the hydraulic system.
l / \ J l )
It? Adjust the correct track tension if the play between the track roller and the track is not
20 - 25 mm (0.8 - 1 in).
~ 20 - 25 mm
,~.~J~~ in)
c=.; c=.; c=.;
/J:1 Danger!
0 Notice!
Excessive tension of the tracks causes serious damage to the cylinder and the
track.
• Tighten the tracks only up to the prescribed measuring distance
i& Check the tension is correct by starting the engine, letting it run at idling speed and
slowly performing forward and reverse machine travel and switching it off again
i& Check the tension of the tracks again
• If it is not correct:
i& Adjust again
i& Should the track still be slack after injecting more grease, replace the track or the seal
in the cylinder. Contact a Wacker Neuson dealer in this case.
Fig. 33: Tightening the tracks
Reducing tension
• Draining grease in a way different from the one described below is very dangerous.
Also bear in mind the safety instructions on this page.
cw Slowly open the lubricating valve A by 1 turn to allow the grease to flow out.
cw Place a suitable container underneath to collect the grease
• The grease flows out of the groove of the lubricating valve
cw Retighten lubricating valve A
~ Check the tension is correct by starting the engine, letting it run at idling speed and
slowly performing forward and reverse machine travel and switching it off again
~ Check the tension of the tracks again
Fig. 34: Releasing grease
• If it is not correct:
~ Adjust again
~ Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in
an environmentally friendly manner.
Every week
• Check once a week:
~ Electric fuses
- see chapter A.2 Electrical system on page A-9
~ Cable and grounding connections
~ Battery charge condition - see Battery on page B-35
~ Condition of battery terminals
Battery
& Danger!
& Danger!
Battery A is located under the cabin, in front of the fuel tank. The battery is "maintenance-
free". However have the battery checked at regular intervals to ensure that the electrolyte
level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be performed by a Wacker Neu-
son service center.
Always follow the specific battery safety instructions!
0 Notice!
Do not disconnect the battery while the engine is running!
I 3. 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).
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.
Id.No.: 9707748
neuson Edition: Jan 03
SERVICE MANUAL Maintenance
2503 - 3703
MP1 MP3
MP2 MP4
Fig.: Control oil unit left Fig.: Control oil unit right
MP3
MP2
Id.No.: 9707748
neuson Edition: Jan 03
Maintenance SERVICE MANUAL
2503 - 3703
r~•
I I
~
0:::
c
.__
Primary pressure limiting valve@
(2 ) Safty valve
Id.No.: 9707748
neuson Edition: Jan 03
Fabr. No: Ne
AB 00502
~· 2503 Work hrs/Oat. 50 PRESSURE CHECKLIST Sf<.
..................
~~~ 3 ~ -u
µ:
"' (f)
Ol m
NE USON Checked by: Huemer Andreas Neuson Excavators :c::
~ :::0
I Function I Motion I Symbol I Press.limit. valve IMeasuring point I Settings (1) I Checked loK?I fb'~~~~ ~ "'O
<1>?5~~~~ ~
.<
::I o_o'<::o(I) w ()
~a· ~ (I) ~ i::: "'
m
CD
c IPUMP 1 xi ~::J(I)()
:-Cll<1>0 1 ::::,
- ~:::t'3
':""I ;::· 'O s· :;i
::;:
(ti "'
c-,
CD
-.J
C>
(....)~
<1> <1> <o m i::: s·
en 240 *
£.,..,o<ti (U <o
:::.(l)::J~
(")
" ::::r
)>
~ z
Setting bar +/- 3 >
o· '<:"'::;: ~ <::
~ CD
0 Boom
UP Fall: 24 bar > llloO~
o: ~ ::i
'll 0 -~ ca· <1>
(")
,.....
=
c
)>
~
240
~
!!t"0<1><1> (1)
Setting bar +/- 3 > lll(i)~'O "' I
DOWN Fall 24 bar > s. ~ •".""i::;:
..,:E<ti ~
~ -
I
~
PPLV 1 Setting 240 bar +/- 3 > :i:~:::.<Q ~ -0 (1)
(Main valve block)
MP 1 <2'i:ii ~ s . (ti "'
IN (Main valve block) Fall 24 bar > (I) Ill. ~ () s ~ 01
:::.~af <b ~ 8
·~]
Setting 240 bar +/- 3 > Q.<b'l:) ,., (!j
~(I) (i) Cl) (ti 11
FORE WARD Fall 24 bar > Q)~ •.., ~ Q. ~
Drive left
~(ti ;t ~ ?i :-""
~I..
Setting 240 bar +/- 3 > ~
Q)
<b::::Oo :"" §' Z
BACKWARD Fall 24 bar > <:
0
~ ~s ~ <Q" ..
::::.
~
-·-.
2<29?. l ~ )>
' Qict Qi (JJ
IPUMP 2 xi -
Qi
Ill
m: ~
~ ·- &l
C>
g
C>
Qi
"'
<n
Dipper stick
OUT ~
Setting
Fall
240 bar
24 bar
+/- 3 >
> ·-~ (1)
:::::
5'
<C
~~
Setting 240 bar +/- 3 > (f)
m-
c... p..
IN
·~]
Fall
Primary pressure Measuring point Setting 240
24 bar
bar +/- 3
>
> -
::I
0
O"'
s·
c...
;::::;: Z
5· 0 Drive right
FORWARD limiting valve Fall 24 bar > s· ~
m.
~ .. 240
::I : . PPLV 2 MP 2 Setting bar +/- 3 > ~
(Main valve block) (Main valve block) Fall :::::::s
BACKWARD 24 bar > r-+
(._ co CD
o.> ..... Sett.(2): 240 +/- 3 >
::I 0 bar :::::::s
.&
C> ..... Auxiliary A Fall (2): 24 bar > m
(....) ~ :::::::s
00 hydraulics Sett.(2): 240 bar +/- 3 > ~ ("')
:.::;
CD
B Fall (2): 24 bar > ~
~ Neuson 2503 Fabr.No.: AB 00502
Work hrs.: 50
Date: 02.January 2003
Checked by: Andreas Huerrer
PRESSURE CHECKL/S
!P.
0..
~
D>
PUMP 3 x
::s c
..,
c:
:::::::s
ro
CD 210
0
:;:ii;-
:::::::s
D>
c t/j_ Setting bar +/- 3 >
..,
""C
-
:::::::s
UP Fall 20 bar > c:: @
"'0
Dozer blade
Setting 210 > ..,
""C
~·
bar +/- 3
OOVV1V Fall 20 bar > .....
0
0
~ Primary pressure Sett.(2): 210 bar +/- 3 > :;:ii;-
52..
A
l'vJ:Jas uring fXJint
Auxiliary A (2) limiting valve Fall (2): 20 bar >
MP3 I
~~ 210
I Setting bar +/- 3 > N
01
LEFT Fall 20 bar > 0
Boom offset (Sv.ive/ motor) w
RIGHT
ft? (3) Setting
Fall
210 bar +/- 3
20 bar
>
>
11
Ill
O"'
.....
Secondary pressure Sett.(4): 200 bar +/- 5 > 2:
' ·ir
:-"'
LEFT limiung valve Fall N bar > )>
Swvel motor
SPLV 4
( Sv.ive/ motor !)
A Sett.(4): 200 bar +/- 5 > ~
OJ
0
0
~
01
RIGHT Fall N bar > 0
N
..--..
m
IP/LOT PRESSURE SYSTEM xi -
S'
en
( 1)
N (J)
=E
(1)
Ol m
~ :::0
~
::::I-
m -
Press. Reduc. valve Measuring point
Setting 35 bar +/- 2 (1)
.<
0.. P-
PRV 5 MP4 c:
:::J
;:::;.:z Joystick All Pilot oil supply unit Pilot oil supply unit Fall N bar < w ()
5· 0
:::J : •
(1)
.....
O"'
-.J
0
m
S'
0.. w ~
c_ CD c=;·
Ill
:::J
.......
0 PLV... Pressurelimitingvalve PRV... Pressure reducting valve ..=:: )>
0
w ~
....... (1) ... Notice: pressu18 aettings correspond with Ille Fl/Jbr.Nr. d your excavator I z
co
Always compare with the pressure setting in chapter,, Technical data" ! c
(2) ... Notice: Setting only correct without secondary pressure limiting valves! )>
(3) ... Function Swivel: see chapter,, Technical data" and,,Maintenance" I
(4) ... See chapt. ,, Technical data ": different settings
No: f
~· I
NEUSON 2503-3703
I Fabr.No:
Work hrs/Oat.
Checked by:
PRESSURE CHECKLIST
Neuson Excavators
Stand
..................
~~~ 3~
:c::
"' (f)
Ol m
~ :::0
I Function
I Motion
I Symbol IPress.limit. valve IMeasuring point I Settin~s (1l I Checked loK?I (1) 11 <:><::-0
<b§Q.~Q.(ii
.<
::I ~Q.omo~
~ 0 ~ 'c:'i ~ i:::
w ()
m
CD
c IPUMP 1 xi ~::J(/)C)
~(/)<b~ i ~
~ ~· g.~ ~
(ti -.J
C>
(....)~
<b <b <o m i::: s·
en £.~g<ti <a <o )>
~ z
Setting bar > ~. <b - ~ ~ ~
2~;s
0 Boom
UP Fall: bar > Q: :::,. ~ s ca·
'I)~ (ti <b
<;"
<t> c
)>
~ ~
Setting bar > iii (i) C) ~ Ci)
~ ..,~(ti ~ I
DOWN
Measuring
Fall bar > s.&:<b5i:::
\-1;:;: ~ (!j
~ ~~(ti t~
Primary pressure Setting bar >
point (ti
OUT limiting valve Fall bar > ~o1il1'1l :c::
Bucket 1'1l~8g. :
PPLV 1
~ g.~g_~ ~ <b~
MP 1 Setting bar >
IN (Main valve block) <Qiii 'I) ::::.
(Main valve block) Fall bar > Cl> m' ~ 0 S ~
:::.~af <b ~
Drive left
FORE WARD +ii)l Setting
Fall
bar
bar
>
>
Q.<b~ ,., (!j
~~<b e» (ti
'I)
s·...,
i::: _.., ~
':""I '
Q.
i:::
-~«> ~ Q.
Q)
·-
(/) .~ ~
CD
Dipper stick
OUT ~
Setting
Fall
bar
bar
>
> ·-~
~~
Setting bar >
IN Fall bar >
+~]
m- Primary pressure Measuring point Setting bar >
c.. p..
;::::;: Z
5· 0 Drive right
FORWARD limiting valve Fall bar > ~
m.
~j+
::J : . PPLV 2 MP 2 Setting bar >
(Main valve block) (Main valve block) Fall :::::::s
BACKWARD bar > r-+
(._ co CD
o.> ..... Sett(2) >
::J 0 bar :::::::s
A
C> ..... Auxiliary A Fall (2): bar > m
(....) ~ :::::::s
00 hydraulics Sett(2) bar > ~ ("')
:.::;
CD
B Fall (2): bar > ~
~ Type:
Work hrs:
Date:
Checked by:
PRESSURE CHECKL/S
~
D>
PUMP 3 x
::s :::::::s
ro
CD :::::::s
D>
c Dozer blade
UP t./j_ Setting
Fall
bar
bar
>
>
:::::::s
@
"'0
~
OOVV1V ~·
Primary pressure
Setting
Fall
Sett.(2):
bar
bar
bar
>
>
>
A
l'vJ:Jas uring fXJint
Auxiliary A (2) limiting valve Fall (2): bar >
MP3
hydraulics PPLV 3 (Main valve block) Sett.(2): bar >
(Main valve block)
B (2) Fall (2): bar >
\~
I Setting bar >
LEFT Fall bar >
Boom offset (Sv.ive/ motor)
RIGHT
ft? (3) Setting
Fall
bar
bar
>
>
~· ~r
Secondary pressure Sett.(4) bar >
LEFT limiung valve Fall bar >
Swvel motor
SPLV 4
( Sv.ive/ motor!)
A Sett.(4) bar > ~
RIGHT Fall bar > ~
4. AUXILIARY HYDRAULICS
> PILOT PEDAL
Fig.: Pedal auxiliary hydraulic system > CHECK of activation of auxiliary hydraulic system :
>ADJUST
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: Actuate pedal only by hand! - Maladjustment of the pedal might lead to kinking of the cable
because of excessive pedal forces (thrust) !
Id.No.: 9707748
neuson Edition: Jan 03
Maintenance SERVICE MANUAL
2503 - 3703
5. HYDRAULIC PUMP
> BLEED
Id.No.: 9707748
neuson Edition: Jan 03
SERVICE MANUAL Maintenance
2503 - 3703
7. DRIVE UNIT
For gear oil quality - see List of Lubricants (Chapt. Technical Data)
filler screw
drain plug
8. SWIVEL UNIT
As described in chapter Hydraulic System - Swivel Unit the gear box is ,,maintenance-free"
(as lubricated with hydraulic oil).
Id.No.: 9707748
neuson Edition: Jan 03
Maintenance SERVICE MANUAL
2503 - 3703
Id.No.: 9707748
neuson Edition: Jan 03
Maintenance SERVICE MANUAL
2503 - 3703
11. CABIN
>REMOVAL.
Feature: 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.
Removal:
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) !
Id.No.: 9707748
neuson Edition: Jan 03
SERVICE MANUAL Maintenance
2503 - 3703
12. UNDERCARRIAGE
>CRAWLER TENSION
When tightened, the crawler must not lift from the track rollers
by more than 15 - 20 mm .
Id.No.: 9707748
neuson Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
neuson®
CHAPTER C:
Hydraulic
( Neuson Service Manual 2503 - 3703 )
Id.No.: 9707748
neuson Page c1
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
13
14
Id.No.: 9707748
neuson Page c2
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
1 return filter
2 breathing/bleeding filter ( 0.2 bar)
3 hydraulic oil tank
4 hydraulic oil cooler
5 reversing valve auxiliary hydraulics (unpressurized return)
6 inspection glass hydraulic oil tank
7 control oil unit
8 main valve block
9 switch valve ( boom offset I auxiliary hydraulics )
10 fuel tank
11 switch valve (boom I dozer blade cylinder)
3703 > additional switch valve (bucket I tilting cylinder)
12 manifold block pilot control oil
13 swivel unit
14 swivel joint
Id.No.: 9707748
neuson Page c3
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
3. HYDRAULIC PUMP
A
Service News
Theme:
Fabr.Nr.:
New hydraulic pump type starting with
diesel engine Yanmar type (setting!)
AD00001 and higher
port P2
adjusting screw:
start of regulation
TI!
Id.No.: 9707748
neuson Page c4
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
tightening torque:
see
,,Technical Data"
Port P1 + P2
Id.No.: 9707748
neuson Page c5
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
1 case 42 stopper
2 case cover 44 screw
3 primary shaft 49 stopper
4 cylinder drum 56 dowel pin
5 distribution plate 60 screw
6 piston 61 hexagon nut
7 sliding blocks 65 gear pump
8 sliding block bracket 66 coupling
9 centering ring 67 ring
11 spacer pins 68 screw
14 spring 70 washer
24 spacer ring 73 pilot control case
35 Seeger circlip ring 76 solenoid valve
10 swash plate 77 solenoid valve
12 ball 74 screw
13 sealing 75 washer
32 shaft sealing ring
39 0-ring
40 0-ring
62 packing ring
69 0-ring
71 0-ring
72 0-ring
15 spring
18 spring receptacle
19 spring guide
20 centering pin
21 pin
25 piston
26 piston
27 centering pin
30 ball bearing
31 needle bearing
33 spacer ring
34 Seeger circlip ring
36 Seeger circlip ring
Id.No.: 9707748
neuson Page c6
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Id.No.: 9707748
neuson Page c7
Edition: 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
. .
overnmg spmgs
Id.No.: 9707748
neuson Page c8
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
.3
.5 2
.5
1 pump unit
2 control oil unit
3 manifold block
4 main valve block
5 measuring ports
Id.No.: 9707748
neuson Page c9
Edition: Jan 03
SERVICE MANUAL Hydraulic
25 0 3 - 3703
P2 pr------------~
.- RV2 -. -
0
A.v1 · - l.!
5
- • - •
II I iP1
-.
r .:1 1
, av:t
L------ ----~
..J . (3) ~
1
i ~
AP
I r- 1
---, I
I II OMV '
11 I I ' M"" ~
T' ~-- J~ -.) ~ ( 1 ) (4 )
I
L:'.J
. ~· I ·r---.. -,/I
- -~ I ~I I
DBI
I
I -. ~ I ~I ! : 35 bar I
· I ·I : I
L - == ..J ~I ' I
7
A~~~--e--~.._~
RV i4
SP
iL _ _ _ _ .J
I
r-~~~~ ............,. PV
( PT) PR I --av
I
.
I
.I
l - ·- ·-·-·-·~ -- - --- · - !
port P1: >> gear pump P3
port P2: >>variable displacement pump P2
port P3: >>variable displacement pump P1
port T: >>tank
port A : >> driving counterbalancing system (main valve block)
port PR: >> 2"d driving stage (drive units)
valve WK1 - in combination with pushbutton at driving lever
( formerly port PT - control oil unit 1408610)
port BV: >>pilot control valves Uoystick,..) via the safety solenoid valve
in combination with the sensitive micro-switches in the arm rests (WK2).
port PV: >>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
Id.No.: 9707748
neuson Page c10
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
port T - tank
WK2
WK 1
port A
Id.No.: 9707748
neuson Page c11
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
to drive counter
balance syst.
Main valve block
WK 1 WK2
to gear pump P3
to pilot control valves Port PR (PT) >>
to drive unit
Port SP >>
Accumulator
to swivel unit
(3) Pressure reduction Park brake valve
valve (AP ) block
WK2 WK 1
Id.No.: 9707748
neuson Page c12
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Pict.: Port position pilot oil supply unit 1408615 (5002 - 6002)
1a... 150 Nm
1e... 10 Nm
2g... 100 Nm
3n... 100 Nm
Sr... 10 Nm
Ss, 6s30 Nm
8, 9 15-20 Nm
Id.No.: 9707748
neuson Page c13
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
Type: Neuson KVSE-36-9 identical design for 2503 -3703 - different piston valve!
(see different item.No.)
View B J
Id.No.: 9707748
neuson Page c14
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Fig.:
E
z
L()
en
N
I
L()
cD
N
II
PLV- P2
11 section bucket
10 section boom supplied by P1
9 section driving right I
Id.No.: 9707748
neuson Page c18
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
1 2 3 4 5 6
Fig.: Valves - view 8
7 8 9 10 11 12 13 14 15
1 sec. pressure limiting valve bucket bottom side 9 flow rate adjusting screw AH
2 primary pressure limiting valve P1 10 stopper (option sec. press. lim. val. AH)
3 sec. pressure limiting valve dipper stick rod side 11 sec. press. lim. val. dipper stick
4 stopper auxiliary hydraulics (option PLV) bottom side
5 flow rate adjusting screw auxiliary hydraulics 12 primary pressure limiting valve P2
6 stopper 13 sec. press. lim. val. boom bot. side
7 primary pressure limiting valve P3 14 sec. press. lim. val. boom rod side
8 sec. press. limiting valve dozer blade bottom side 15 sec. press. lim. val. bucket rod side
Id.No.: 9707748
neuson Page c16
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
,- - - ·---:- ·- - -:--1
section bucket I
'!SE._
1
section boom
~
z;Oc( • •• .
.-... ""U..L.LJ.J..J..~u...L.UJ..UPT
Ii!l«I
.............
I .____~_.__._~
'" .
'·~ .
i 1· - ------.i.-1 I~q.i
i'JL~- --v - -f"M'l''P'""i'l"'H'l'ff'H'l'TTfi-.. • •
section swivelling
-~
~ ~:::~---. ..,.~.-__-_-~h -k
i l ~a.&.f.+~JJJ""
,.----~,.J·
Id.No.: 9707748
neuson Page c17
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
General:
Without counterbalancing: If an arm function is activated during driving, the device leaves
its track! (P1 , P2 supply one drive unit, each).
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
I
~,
C
I
i
.: .:
'
i
n
' '
'
' i
.
I
~
j
I :
~j
,
i :
I -
0
c ..
::::!.
~ ~ ii i.f '
!1 r¢1~
P
3
_. • rt
~ ~
ti"---- - -
i
, -
w Ll
-
Ll
-
I
!I
<
(1)
8c
®)
rQ--:W - .q-:LJ H ®
:::::J
CD
IJ
f
I
I
I
T: g
~ n;
2 ·> _
:--
· ~ u
-
-Qr9' '-
D
-
-\t
-
u
" r ..,. T :!.__!
u n
'--Q' - ~ f '
!
I
fY a-
Q)
:Ii
P2 P1 - - - Q)
m
~J a ~ ~ ~). nJ ~
: :
:::::J
<O 7 I : :
I : : :~~ ~f'~
~= :- ~ ~ -+!-~ I
t
ct> Q .
0
......... I
I
•
•
'
' : .....
•
H -~ ·
---..-...-- l'1.... .... :
'
:
' ~
. ~~ ' ~ .
'
:::::J
co
<.O I . ' I II • - I CJ)
I t .,.. ....
di
------..
0
@ L
' ' : ~ ' ' I • • i CD
~--w- ij------------------if --~l·---- ,~- -- 1f-·--- r~ --- --~~-- --_) 3
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 stopper
10 metal
11 pilot control cap
12 0-ring
Id.No.: 9707748
neuson Page c20
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
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.
regener.
r -
1 case 11 0-ring
2 spool valve 12 screws
3 spring collar 13 valve head
4 centering spring 14 spring
5 stopper 15 stopper
6 0-ring 16 stopper plug
7 spring collar 17 stopper
8 spring 18 0-ring
9 spring collar 19 0-ring J
10 pilot control cap 20 0-ring ~
Id.No.: 9707748
neuson Page c21
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
For pressure-related flow rates of aux. hydraulics - see chapt. Technical Data
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
13 valve head
Id.No.: 9707748
neuson Page c22
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
1 case
2 spool valve
3 0-ring
4 supporting ring
5 cover of case
6 screw
7 stopper
8 stopper
Id.No.: 9707748
neuson Page c23
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
Function Bucket
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
13 valve head
Id.No.: 9707748
neuson Page c24
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Function Boom
!illl~d.
Bleeding facility:
case without valve
section boom
H'B:.l
1 case 14 supporting ring
2 spool valve 15 0-ring
3 spring collar 16 case
4 centering spring 17 stopper
5 spring collar 18 screw
6 pilot control cap 19 0-ring
7 0-ring 20 stopper
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
13 bush
Id.No.: 9707748
neuson Page c25
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
1T1mr-r
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
Id.No.: 9707748
neuson Page c26
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
1 case
2 spool valve
3 0-ring
4 pilot control cap
5 pilot control cap
6 screws
7 stopper
8 0-ring
9 metal filter
<< P... port counterbalancing system coming from the control oil unit
Id.No.: 9707748
neuson Page c27
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
13 0-ring
Id.No.: 9707748
neuson Page c28
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
1 case
2 spool valve
3 spring collar
4 centering spring
5 spring collar
6 pilot control cap
7 0-ring
8 screw
9 valve head
10 spring
11 stopper
12 0-ring
13 0-ring
Id.No.: 9707748
neuson Page c29
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
"· "'~------.---.
--
-·-
T p
Fig.: Manual control valve Uoystick)
r-- -- ---·------- -- i
I I
I I
1 control lever I I
3 rod assembly I I
4 rubber collar I I
6 joint ! --J ~ ~ ~ i
7 guide plate L - -· - - - - - - - - - - - - - -'
10 tappet 1 2 3 4
Id.No.: 9707748
neuson Page c30
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
1
ll
P T
--------------,
Id.No.: 9707748
neuson Page c31
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
Id.No.: 9707748
neuson Page c32
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
7. SWIVEL UNIT
Neuson 25031300313503 / 3703:
.&
Service News
Theme:
Fabr.No.:
New swivel unit 2503-3703 (Type 490")
See list
Swivel gear box still free of maintenance !
leak oil DR
shock
shock
suction valve
suction valve
(AP )
Id.No.: 9707748
neuson Page c33
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
Brake block:
port S:
control line
port P:
supply control oil unit
Dr-.
brake block \ RI G. f-----..---+--~
·~-----1
F
SH.
- - - - - - I
PG.
2 00bo. r .
shock
A. B.
suction valve @
( AP )
Id.No.: 9707748
neuson Page c34
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
shock
suction valve
brake block:
port PG
port SH ports A I B
from main valve block
leak oil DR
Id.No.: 9707748
neuson Page c35
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
SH
r
• i
(O-
r I
,..,
Tightening torques:
No. 3 25 Nm
No.4 50 Nm
No. 10 120 Nm
Id.No.: 9707748
neuson Page c36
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
.,...
'!""'
I
tighteining torque
120 Nm
--
rN ~1
Id.No.: 9707748
neuson Page c37
Edition: Jan 03
::!1
<O
I "'m
Olm
Cf) ~~
'-
:J ~. w()
< m
(I) (1) -.J
0
c c
=:J
;:::;:
w~
)>
UJ N
(.Tl z
0 N
00
..j:::..
c
)>
::S. <.D
0 I
I
fn
~-
<
!!?.
3
-u 2.
Ill
.S:J 0
""'I
<O
ct>
.34
8
00
8. DRIVE UNIT
leak oil
(always connect on top for
better venting of motor)
damping valve
~ leakoil
5/2-way valve
2nd driving stage
damping valves
~
A-B ports ~trol oil unit
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.
Id.No.: 9707748
neuson Page c40
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
.3 5 03 u . 37 03
oil leakage
shock valves
brake piston
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.
Id.No.: 9707748
neuson Page c41
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
Id.No.: 9707748
neuson Page c42
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Id.No.: 9707748
neuson Page c43
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
324
~
310
30 1
302
Id.No.: 9707748
neuson Page c44
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
Id.No.: 9707748
neuson Page c45
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
hydraulic
brake piston
@
l(j
piston 5/2-way
~ valve for 2nd driving stage
Id.No.: 9707748
neuson Page c46
Edition: Jan 03
Hydraulic SERVICE MANUAL
2503 - 3703
cylinder drum
, - - - - · - · -·-· --~
\ \
\q \
\
\
\
\
\
\
~
~ swash plate
\
'\
\
\
\
\
'
\
\
\\ '
brake piston
piston
parking brake
Id.No.: 9707748
neuson Page c47
Edition: Jan 03
SERVICE MANUAL Hydraulic
2503 - 3703
lifetime sealing
Id.No.: 9707748
neuson Page c48
Edition: 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.
, -- - - -- -- - - -- - - - -- ·- · - -- -- ·- ·1
l..!:I I
Q:
I
IL __V- __ _ __y __ JI
,,...... ,,......
Pos. Description
1 Drive port (-> swivel joint 2/7
2 Brake release piston
3 Drive port (-> swivel joint 6/5)
4 Leak oil port (-> swivel joint 1)
5 Brake piston
6 2nd speed range port (-> swivel joint 8)
7 2nd speed range directional valve
8 Brake piston
• Id.No.: 9707748
neuso Page C49
Edition: Aug 03
Hydraulic SERVICE MANUAL
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.
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.
• Id.No.: 9707748
neuso Page cso
Edition: Aug 03
SERVICE MANUAL Hydraulic
2503 - 3703
Pos Description
1 Travelling drive
2 Screw connection
3 Screw connection
4 Screw connection
5 Hydraulic motor
6 Hydraulic motor sealing kit
7 Hydraulic motor
8 Bearing
9 Cover
10 0-ring
11 Snap ring
12 Valve set
13 Piston valve for speed range
14 Brake valve
15 Travelling drive brake
..... 5
• Id.No.: 9707748
neuso Page C51
Edition: Aug 03
Hydraulic
9. SWIVEL JOINT
5 1 2 8 4 3 7
6
I
JI t'1,' ~
• ,. ' ,/
;. / 1' 8
d' v
\, I
.J1.1 -~ - ~
~~ - ~,../
;
~...)/~
~ m@tightening torque
~ M8 x 20 - 8.8 = 24 Nm
Port Port
1 driving motor left top 2 driving motor right top
3 driving motor left bottom 4 driving motor right bottom
5 dozer blade cyl. rod side 6 dozer blade cylinder bottom sid
7 2nddriving stage 8 leak oil duct
5 1 2 8 4 3 7
~ ~ @ tightening torque
~ MB x 20 - 8.8 = 24 Nm
Port Port
1 leak oil 2 dozer blade cyl. rod side
3 dozer blade cyl. bottom side 4 driving motor right top
5 driving motor left top 6 driving motor right bottom
7 driving motor left bottom 8 2nd driving stage
8 4 10 7 6
8 ---~~ 9
10 -----'r.'~
~ m ®tightening torque
Port Port
1 2nddriving stage 2 dozer blade cyl. bottom side
3 dozer blade cyl. rod side 4 driving motor right top
5 driving motor left top 6 driving motor right bottom
7 driving motor left bottom 8 tilting cylinder rod side
9 tilting cylinder bottom side 10 leak oil
Neuson 3703:
Additional - switch valve C: bucket <<>> tilting of uppercarriage
secondary
pressure limiting
valves
auxiliary
hydraulics
tank
switch valve B
swivel unit
manifold block
pilot control
swivel joint->
bucket cylinder
pilot controlled check
valve ->
> tilting cylinder
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 modi ed by Neuson!)
Neuson uses a release hose and a check valve to connect the pressure line (switch valve-check
valve block) to tank.
Check valve
--> 3
2
to sec. pressure limiting valve
,.
_PV vario cylinder
pilot oil suppl (cabin bottom)
unit
Tank
(Collectiong panel)
,_- ..........
/.[ T "
\
I \
I\ ) Vario lock cylinder
/ (part of vario plate)
- 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 de ned overpressure -> to support intake of the variable
displacement pump
- Filtering of intake air
breather 5001161
( hydraulic tank)
lter cloth
breather valve
Fig . : Breather
Pos. Designation I
PS 2nd speed range connection
T1 Reservoir line (leak oil)
P1 Drive connection (swivel joint)
P2 Drive connection (swivel joint)
A Brake piston
-·
P T
r·-~·~=-~~-=--- - -----:==--~~
I I I
I I I
~I
~ Ii
I
I I I
I I j
L-....L J.- -~ I
I
~~.i.-~10 I
L-·--·--· -·--·--·--·2 ·--L-·-
5
·--·--·--·-
3
·--·--·j
4
0
Pedal operating angle ( )
I Pos. Designation I
1 Machine travel, left forward
2 Machine travel, left reverse
3 Machine travel, right forward
4 Machine travel, right reverse
p Supply from pilot oil supply unit
T Reservoir line
Swivel joint
• The swivel joint is used in the same way as for the VDS option.
• Channels 8 and 9 are used either for the VDS option or for the slewable stabilizer blade
(option).
0 Notice!
The VDS option is not possible if the machine is equipped with the "Slewable
stabilizer blade" option.
I Pos. Designation I
1 2nd speed range pilot control line
2 Stabilizer blade cylinders (base side)
3 Stabilizer blade cylinders (rod side)
4 Traveling drive (right)
5 Traveling drive (left)
6 Traveling drive (right)
7 Traveling drive (left)
8 Stabilizer blade slewing cylinder (rod side)
9 Stabilizer blade slewing cylinder (base side)
10 Traveling drive reservoir line (leak oil)
ECFD
A~11~1i~
- ___ J
AY B
y
Pos. Designation I
A,B,C, D, E, F Work lines
y Reservoir connec-
tion
Counterbalance valve
0 Notice!
The unlockable non-return valve of the "UP/DOWN" stabilizer blade function has
been replaced by this counterbalance valve to improve the function in the
precision-control range.
Counterbalance valve C is located under the machine near the swivel joint.
Pos. Designation I
V1 Stabilizer blade cylinder connection (rod side)
V2 Stabilizer blade cylinder connection (base side) via hose burst valve
F1 , F2 Changeover valve connections via swivel joint
Diagram
,----------,
27 r·-·-·-·-·- -·-·-·--·,
. 38 .
I Pos. Designation I
22 Counterbalance valve
26 Hose burst valve
27 Stabilizer blade cylinder
28 Unlockable non-return valve
; 31 Swivel joint
12e: -=_: :
i I ........... II
38 Stabilizer blade slewing cylinder
L. ___ ,: -::::::. ~--j
39 Changeover valve
r - - - - - ,.,,,...-,,.__ _ ~
I
I
I
I
I
I
I
L __ _
@@>
Maintenance
- see chapter 8.1 Maintenance plan (Tier JI/) on page B-5
~ ~ ~ : ~
.__..
lie
t-7< -f><r
~ """"::=::"'"
I
11
Reservoir MeasLJ Stop cock Non-retL.Jn valve Throttle Oil Filter Double-acting
ement orifice cylinder
swiveVauxiliary hydraulics
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neuson®
CHAPTER D:
Diesel engine
( Neuson Service Manual 2503 - 3703 )
Id.No.: 9707748
neuson Page o1
Edition: Jan 03
W~CKEa
Engine NE USON
DEngine
D.1 Engine overview
3TNV 88 (Tier 3) 2503: from serial no. AG 00597
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0 Notice!
In order to avoid damage to the glow elements. remove them before removing the
cylinder head.
Remove as fallows:
~
A: , 1& Remove all dirt on the engine with a lint-free cloth
~ ........ 1& Unscrew all hoses and fuel injection lines from the valve cover
1& Remove the air intake and the exhaust manifold
~ ~ ..~~~ ·~ ~;,
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Fig. 1: Removing the cylinder-head colef---'
Checking and adjusting valve clearance
1& Standard setting of valve clearance is possible:
• On a cold engine
1& Turn the engine with a screwdriver (as described in "Injection time" from page D-24)
until the cylinder reaches the top dead center of the compression cycle.
Flywheel Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before installing them!
Li Caution!
Bear in the mind the order for tightening the cylinder-head bolts!
1& See figure
Flywheel
4 cylinders
(J) @ @l ®
Flywheel Fan
® @ ® ®
llW Order for installing the cylinder-head bolts
Flywheel © @ ® ©l
Fan
0 Notice!
Always perform work on the cylinder head on a cold engine!
Normal atomization
Fig. 5: Nozzlejet
optimal --------------variation-------------
Fig. 6: Shape of nozzlejet
Bad atomization
\
(1
~ Check injection time again
~ Difference of "Angle of new pump" - "Angle of old pump" gives you the mounting angle
of the new fuel injection pump
• Positive value: earlier injection time (toward the engine)
• Negative value: later injection time (away from the engine)
~ Install the new fuel injection pump
~ Check the marked position of the drive pinion of the fuel injection pump (fig. 12)
~ Screw on and tighten nut 1212 (tightening torque: 23 - 28 Nm/17 - 21 ft.lbs.)
0 Notice!
Do not loosen screws 13/3 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
manufacturer!
0 Notice!
The maximum engine speed is set and sealed by the manufacturer without the
hydraulic pump and may not be modified!
• Idling speed is indicated in the technical data for each engine type.
~ Adjust as shown if values differ.
Tier 3
• Specified value: 33.3- 35.3 bar (483 - 512 psi) at 250 rpm
• Threshold value: 26.5 - 28.5 bar (384- 413 psi) at 250 rpm
Housing cover
Thermostat
Seal
Housing
Thermal swrtch/J?
~ Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid)
~ 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 malfunctioning if the oil can pass
Leakage check
~ Fill up the radiator completely
~Increase the pressure to about 1 bar/15 psi (stamped onto the radiator cap) with the
hand pump
• The radiator cap must open
Radiator cap
I Pos. Designation I
1 Aftertreatment system
2 Flywheel housing
3 Starter solenoid valve
4 Starter
5 Oil-drain plug
6 Alternator V-belt
7 Air pump V-belt
8 Alternator
9 Water pump
10 Air pump
Symbolic representation
Pos. Designation I
Crankcase breather
2 Diesel oxidation catalyst (DOC)
3 Flywheel
4 Diesel particulate filter (DPF)
5 Aftertreatment system
I Pos. Designation I
1 Intake-air temperature sensor
2 Oil pressure switch
3 Secondary engine-speed sensor
4 Control-rack solenoid valve and position sensor
5 Fuel pump/breather pump
6 Resistor of ARD glow plug
7 Glow plugs
Symbolic representation
I Pos. Designation I
1 Intake manifold air-pressure sensor
2 NRS control valve
3 Starter solenoid valve
4 Starter
5 Primary engine-speed sensor
6 Alternator
7 Coolant temperature sensor
8 Air pump
I Pos. Designation I
1 DPF pressure-difference sensor
2 ARD injection nozzles
3 ARD temperature sensor
4 DOC intake temperature sensor
5 DPF intake temperature sensor
6 DPF outlet temperature sensor
7 Engine control unit (ECM)
8 ARD glow plugs
0 Notice!
These activities may only be performed by authorized Perkins service centers dur-
ing the warranty period.
0 Notice!
These activities may only be performed by authorized Perkins service centers dur-
ing the warranty period.
0 Notice!
The water pump seal is lubricated by the coolant in the cooling system. A small
amount of leakage when the engine cools down is normal because the warm
engine components contract as they cool down.
0 Notice!
If engine coolant penetrates into the engine-lubrication system, replace the lube oil
and the engine oil filter. Draining the oil removes all dirt particles and ensures cor-
rect sampling
neuson®
CHAPTER E:
Electric
( Neuson Service Manual 2503 - 3703 )
Id.No.: 9707748
neuson Page E1
Edition: Jan 03
W.\CKE~
Electrical system NEUSON
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tart so 43 KS 8S EC1 24 J.S grn :>reheating
3
red IECU start release 44 KS 87 XM1 4 2 t:Jrn :>reheating
cu start release 4S KS 37 XM1 s 2 t:Jrn :>reheating
red IECU start release 46 F7 7 K89 30 2 ed 2 V/30
wred IECU main relay 47 F7 7 K88 30 2 ed 2 V/30
grymru IECU main relay 48 F8 8 K90 30 2 ed 12 V/30
grymru IECU main relay 49 K90 8S EC1 74 J.S yel/wht JPF glow plugs
2 V/1S so K90 87 XM1 6 2 t:Jrn JPF glow plugs
2 V/1S S1 K89 8S EC1 S4 J.S t:Jlk/yel JPF pump
2 V/1S S2 K89 87 XM1 3 J.7S wht JPF pump
2 V/1S S3 K88 8S EC1 S3 J.S yeI/red uel pump
2 V/1S S4 K88 87 XM1 2 J.7S ed uel pump
2 V/1S SS F2 ]
EC1 S8 J.7S ed/blk 2 V/1S
2 v/1 Spreheating S6 F2 2 EC1 78 J.7S ed/blk 2 V/1S
2 V/1 S DPF heating relay S7 F3 3 EC1 18 J.7S ed/wht 2 V/1S
2 V/1 S DPF pump S8 F3 3 EC1 38 J.7S ed/wht 2 V/1S
2V/1S fuel pump S9 F4 4 ~ C1 1 J.7S wht/yel 2 V/1S
2 V/1 Smicro SPC 60 F4 4 EC1 21 J.7S wht/yel 2 V/1S
2 V/1 S DPF switch light 61 CAN-H XE1 G J.S wht/blu . . ANO - H (twisted wire 61 /62)
2 V/1 S DPF switch 62 CAN-L XE1 F J.S Prg/blu ::ANO - L (twisted wire 61/62)
2 V/1 S DPF switch light 63 F1 1 ~ X1 2 J.7S wht-red CU start release
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PF switch GND 64 FS s EC1 32 J.7S t:Jlu 2 V/1S
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112c X3 7 Y59 1 1 grn/blk Valve (automatic engine speed set- 169 Y15 1 X9 7 1 blu/yel Changeover valve
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112d X3 8 X9 2 1 grn/blk Pressure switch for automatic engine 170 X10 2 537 1 1 brn/grn VOS/blade swivel
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112e X3 9 589 c 1 grn/blk $ignal pressure switch 171 X2 8 541 1 1 blu 2 V/15 pressure switch, travel sig-
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112f SP2 589.1 1 1 blu/red Pressure switch for automatic engine 172 X2 8 543 1 1 blu 2 V/15 pressure switch, travel sig-
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l lZg St-'L ;)tj~ A l DIU :> V pressure switch l /J 1:33 z S4J z l grytgm raveling signal
113 :::i~u 1 :::iw 1:3 0.5 grrvrnK Automatic engine speed setting 174 S41.l z S41.l J 1 VIO/OIU )verload jumpering
11 b xz l S4 l O./!> gry/DIU Air filter clogging l /b xz 9 xtl b l gry 2 V/15 valves
117 xz z S5 0.75 orgtwht Hydraulic oil filter 177 XlO 1 xtl ti 1 gry 2 V/15 valves
lHl xz J tfl l VIO·DIK uel level indicator l /ts xz 9 "~ b l gry 2 V/15 valves
119 xz 5 ::>LI 1:3 1 orrvrnK :>nd speed range 179 ::>j7 5 x~ ti 1 gry 12 V/15 valves
lLU :'.:>.::'.I l :'.:>LI 1:3 l orrvrnK Jnd speed range l tsU ;)j/ !> SJ/ 10 l gry 2 V/15 valves
121 ::>LI l XJ 4 l orrvrnK :>nd speed range 181 S40 !> SJ/ 10 l gry 2 V/15 valves
IZ4 J..L b tll I I grrvye1 Boom light ltsZ ::>40 !> ::>40 10 I gry 2 V/15 valves
lLtl J..L 11 M4 J l ye11rnu Heating 2 183 ::>LI !> S40 10 l gry 2 V/15 valves
IZ\:J J..L 10 M4 I I yel/DIK Heating 1 184 :'.:>.::'.I !> :::>LI 10 I gry 2 V/15 valves
131 J..L I S41 z l VIO/DIU Overload indicator light 18!> :::i~u 10 ::>LI 10 l gry 2 V/15 valves
rn:1 J..L IZ M!> I wnt/DIK Washer pump ltsb ;::,~u !> "~ J l gry ) V automatic enqine speed settinq
147 X2 4 540 1 0.75 gry/yel Puickhitch buzzer 186a 590 10 X9 1 1 gry 12 V automatic engine speed set- t!:!
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Operation
W~CKEa
Operation NE USON
F Operation
F.1 Information on this service manual
This service manual contains important information on how to work safely, correctly and
economically with the machine. Therefore, it aims not only at new personnel, but it also
serves as a reference for experienced personnel. It helps to avoid hazardous situations
and reduce repair costs and downtimes.
Furthermore, the reliability and the service life of the machine will be increased by follow-
ing the instructions in the Operator's Manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine. This is why regular maintenance and ser-
vicing is absolutely necessary.
Extensive maintenance and repair work must always be performed by a Wacker Neuson
service center. Use only original spare parts for repairs. This ensures operational safety
and readiness of your machine, and maintains its value.
• We reserve the right to improve the technical standard of our machines without
adapting the service manual.
• Modifying Wacker Neuson products and fitting them with additional equipment and
attachments not included in our delivery program requires Wacker Neuson's written
authorization, otherwise warranty and product liability for possible damage caused by
these modifications shall not be applicable.
• Subject to modifications and printing errors.
Your Wacker Neuson dealer will be happy to answer any further questions regarding the
machine or the service manual.
& Danger!
Failure to observe the instructions identified by this symbol can cause injury or
death for the operator or other persons.
~ Measures for avoiding danger
LS:. Caution!
Failure to observe the instructions identified by this symbol can cause damage
to the machine.
~ Measures for avoiding danger for the machine
0 Notice!
This symbol identifies instructions for a more efficient and economical use of the
machine.
~ Environment!
Failure to observe the instructions identified by this symbol can cause damage
to the environment. The environment is in danger if environmentally hazardous
material (for example waste oil) is not subject to proper use or disposal.
~ subdivision of an activity
Follow the order of the activity.
• Identifies a result after a list
• Subdivision of a result after a list.
Follow the order of the activity.
Cross reference: see page 1-1 (page)
Cross reference: 7 (pos. no. or table no.)
Cross reference: fig. 1 (fig. no. 1)
Cross references: - see chapter "5 Operation" on page 5-1 (see chapter)
Cross references: - see "Operation" on page 5-1 (-see text)
Abbreviations
max. maximum
min. minimum
Conversion table
The rounded imperial values are indicated in brackets. for example 1060 cm 3(64.7 in3).
IVolume unit I
1 cm3 (0.061 inl)
1 m3 (35.31 ft3)
1 ml (0.034 US fl.oz.)
1I (0.26 gal)
11/min (0.26 gal/min)
I Unit of length I
1 mm (0.039 in)
1m (3.28 ft)
Weight
1 kg (2.2 lbs)
1g (0.035 oz)
Pressure
1 bar (14.5 psi)
1 kg/cm2 (14.22 lbs/in2)
I Force/output I
1 kN (224.81 lbO
1 kW (1.34 hp)
1 PS (0.986 hp)
ITorque I
1 Nm (0.74 ft.lbs.)
Speed
1 kph (0.62 mph)
Acceleration
1 m/s 2 (3.28 ft/s 2)
Warranty
Warranty claims can be made only if the conditions of warranty have been observed. They
are included in the General Conditions of Sales and Delivery for new machines and spare
parts sold by the dealers of Wacker Neuson Linz GmbH. Furthermore. all instructions in
this service manual must be observed.
Have the maintenance, delivery inspection and the entries in the service booklet per-
formed by a Wacker Neuson service center. otherwise warranty claims will not be
acknowledged.
Exemption from liability
• Modifying Wacker Neuson products and fitting them with additional equipment and
attachments that are not included in our delivery program requires Wacker Neuson's
written authorization. otherwise warranty and product liability for possible damage
caused by these modifications shall not be applicable.
• The safety of the machine can be negatively affected by performing machine modifica-
tions without proper authority and by using spare parts, equipment, attachments and
optional equipment that have not been checked and released by Wacker Neuson.
Warranty and product liability for possible damage caused by these modifications shall
not be applicable.
• Wacker Neuson Linz GmbH shall not be liable for injury and/or damage to property
caused by failure to observe the safety instructions and the service manual, and by the
negligence of the duty to exercise due care when:
• handling
• operating
• servicing and performing maintenance and
• repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care. in the safety instruc-
tions as well as in the Operator's and maintenance manuals.
• Read and understand the service manual before servicing or repairing the machine.
Observe all safety instructions.
F.5 Labels
/J:;. Danger!
Accident hazard! Remove missing or damaged labels immediately.
Can cause serious injury or death.
~ Check warning and information labels regularly whether they are missing or
damaged.
~ Never remove warning and information labels.
Type labels
Serial number
The serial number is located on the type label.
The serial number is also stamped on the machine chassis.
Refer to the Operator's Manual of the machine for more information.
Cabin number
The type label is located on the B pillar on the left.
Engine number
The type label is located at the lower left of the engine block.
1 Boom light
2 Boom
3 Stick
4 Rubber tracks
5 Travel gear
6 Stabilizer blade
7 Cabin
8 Valve cover
9 Handhold
13 Exhaust pipe
14 Lifting eye/tie-down point
15 Lubrication point for track tension
16 Engine cover
~
Fax: +43 (O) 7221 63000-2200
W4CKEil E-mail: office.linz@wackemeuson.com
www.wackemeuson.com
NE USON Order no. 1000081433
Language en