SHB 6003 en 1000129840 2 0

Service Manual
Track excavator
Machine model 6003

Edition 2.0
Language English
Article number 1000129840
Documentation
Description Order no.
Operator's Manual 1000127717
Service manual 1000129840
Spare parts catalogue:up to serial no. AD07210 1000127435
from serial no. AH00645 1000182716
Copyright 2008 Neuson Baumaschinen GmbH, Linz-Leonding

Printed in Austria
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.
Neuson Baumaschinen GmbH

Haidfeldstr. 37
A-4060 Linz-Leonding
Document: SERV-HB 6003 EN
Order no.: 1000129840
Edition: 2.0
Table of contents
Table of contents
Table of contents
Operation
Important information on this service manual .......................................................... 1-1
Identification of warnings and dangers .................................................................... 1-2
Designated use and exemption from liability ........................................................... 1-3
Type labels and component numbers ...................................................................... 1-4
Machine overview .................................................................................................... 1-6
Cab overview ........................................................................................................... 1-7
Up to serial no.: AD07210 ................................................................................. 1-7
From serial no.: AH00645 .................................................................................. 1-8
Cab (legend) ............................................................................................................ 1-9
Instrument panel up to serial no. AC02888: overview ........................................... 1-10
Instrument panel up to serial no. AC02888: legend ............................................... 1-11
Instrument panel from serial no. AC02890 to AD07210: overview ........................ 1-12
Instrument panel from serial no. AC02890 to AD07210: legend ........................... 1-13
Instrument panel from serial no. AH00645: overview ............................................ 1-14
Instrument panel from serial no. AH00645: legend ............................................... 1-15
Engine compartment up to serial no. AD07210: overview ..................................... 1-16
Engine compartment from serial no. AD00611: overview ...................................... 1-17
Chassis overview ................................................................................................... 1-18
Tilting the cab ........................................................................................................ 1-19
Summer/winter operation ....................................................................................... 1-21
Preheated fresh air .......................................................................................... 1-21
Auxiliary hydraulics/boom swivel pedal ................................................................. 1-22
Battery master switch ............................................................................................ 1-22
Specifications
Chassis .................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Fuel injection pump ........................................................................................... 2-2
Capacities .......................................................................................................... 2-2
Tightening torques ............................................................................................. 2-2
Hydraulic system ..................................................................................................... 2-3
Auxiliary hydraulics oil flow* .............................................................................. 2-4
Screwable hose burst valve ............................................................................... 2-4
Undercarriage and swivel unit ................................................................................. 2-4
Stabiliser blade ........................................................................................................ 2-4
Electric system ......................................................................................................... 2-4
Fuse box on the instrument panel up to serial no. AD07210 ............................. 2-5
Main fuse box with relays under the cab up to serial no. AD07210 ................... 2-5
Relays up to serial no. AD07210 ....................................................................... 2-5
Fuse box on the instrument panel from serial no. AH00645 ............................. 2-6
Main fuse box with relays from serial no. AH00645 .......................................... 2-6
Noise levels ............................................................................................................. 2-7
Vibration ................................................................................................................... 2-7
Coolant compound table .......................................................................................... 2-7
Model-specific tightening torques ............................................................................ 2-8
General tightening torques ...................................................................................... 2-8
Tightening torques for hydraulic screw connections (dry assembly) ................. 2-8
Tightening torques for high-resistance screw connections .............................. 2-10
Dimensions model 6003 ........................................................................................ 2-11
Lift capacity table 6003 .......................................................................................... 2-12
Lift capacity table 6003 with long stick option ........................................................ 2-13
Lift capacity table 6003 with counterweight option ................................................ 2-14
Lift capacity table 6003 with long stick and counterweight .................................... 2-15
Lift capacity table 6003 Vario ................................................................................. 2-16
SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm I-1

Table of contents
Kinematics ............................................................................................................. 2-17

Attachments ........................................................................................................... 2-18
Maintenance
Fluids and lubricants ................................................................................................ 3-1
Additional oil change and filter replacement (hydraulics) .................................. 3-2
Maintenance label .................................................................................................... 3-3
Explanation of symbols on the maintenance label ............................................. 3-3
Maintenance plan (overview) ................................................................................... 3-5
Service package ...................................................................................................... 3-8
Up to serial no. AD07210 ................................................................................... 3-8
From serial no. AH00645 ................................................................................... 3-8
Introduction .............................................................................................................. 3-8
Fuel system .............................................................................................................. 3-9
Specific safety instructions ................................................................................ 3-9
Refuelling ........................................................................................................... 3-9
Stationary fuel pumps ...................................................................................... 3-10
Diesel fuel specification ................................................................................... 3-10
Bleeding the fuel system .................................................................................. 3-10
Emptying the fuel tank ..................................................................................... 3-11
Fuel prefilter with water separator ................................................................... 3-11
Replacing the fuel filter .................................................................................... 3-12
Engine lubrication system ...................................................................................... 3-13
Checking the oil level ....................................................................................... 3-13
Filling up engine oil .......................................................................................... 3-14
Changing engine oil ......................................................................................... 3-15
Replacing the engine oil filter cartridge ............................................................ 3-16
Cooling system ...................................................................................................... 3-17
Specific safety instructions .............................................................................. 3-17
Checking/filling up coolant ............................................................................... 3-18
Draining coolant ............................................................................................... 3-19
Air filter ................................................................................................................... 3-20
Replacing the filter ........................................................................................... 3-21
Functional check once a week of the dust valve ............................................. 3-22
V-belt ...................................................................................................................... 3-23
Checking V-belt tension ................................................................................... 3-23
Retightening the V-belt .................................................................................... 3-24
Checking the V-belt of the air conditioning system .......................................... 3-25
Tightening the V-belt of the air conditioning system ........................................ 3-25
Pressure check ...................................................................................................... 3-26
General ............................................................................................................ 3-26
Checking pilot control pressure ....................................................................... 3-26
Pressure check of variable displacement pump P1 ......................................... 3-27
Pressure check of variable displacement pump P2 ......................................... 3-28
Pressure check of gear pump P3 .................................................................... 3-29
Secondary pressure limiting valve of the gear motor ....................................... 3-30
Measuring ports: overview ............................................................................... 3-30
Primary pressure limiting valves ...................................................................... 3-30
Test report .............................................................................................................. 3-31
Hydraulic system .................................................................................................... 3-34
Checking the hydraulic oil level ....................................................................... 3-35
Filling up hydraulic oil ...................................................................................... 3-36
Changing hydraulic oil ..................................................................................... 3-37
Monitoring the hydraulic oil reflux filter ............................................................ 3-37
Checking hydraulic pressure lines ................................................................... 3-38
I-2 SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm

Table of contents
Travelling drive ...................................................................................................... 3-38

Checking the oil level and filling up oil ............................................................. 3-39
Draining oil ....................................................................................................... 3-39
Chains .................................................................................................................... 3-40
Checking chain tension ................................................................................... 3-40
Setting the chains ............................................................................................ 3-41
Lubrication work ..................................................................................................... 3-42
Stabiliser blade ................................................................................................ 3-42
Lubrication points on the swivelling console .................................................... 3-42
Boom lubrication points ................................................................................... 3-43
Lubrication points on the stick ......................................................................... 3-43
Lubrication strip ............................................................................................... 3-44
Maintenance of attachments ........................................................................... 3-44
Electric system ....................................................................................................... 3-45
Service and maintenance work at regular intervals ......................................... 3-45
Instructions concerning specific components .................................................. 3-46
Alternator ......................................................................................................... 3-46
Battery ............................................................................................................. 3-47
Jump-starting the engine ................................................................................. 3-47
Cab ........................................................................................................................ 3-48
Replacing the cab filter .................................................................................... 3-48
General maintenance work .................................................................................... 3-49
Cleaning .......................................................................................................... 3-49
General instructions for all areas of the machine ............................................ 3-49
Inside the cab .................................................................................................. 3-50
Exterior of the machine .................................................................................... 3-50
Engine compartment ....................................................................................... 3-50
Screw connections and attachments ............................................................... 3-50
Pivots and hinges ............................................................................................ 3-50
Engine
Engine 4TNV98-VNS (Tier 2 up to serial no. AD07210) .......................................... 4-1
Fuel system ............................................................................................................. 4-3
Removing the valve cover ....................................................................................... 4-4
Checking and adjusting valve clearance ................................................................. 4-4
Checking valve clearance .................................................................................. 4-4
Setting zero play of the valve bridge ................................................................. 4-5
Setting valve clearance ..................................................................................... 4-5
Tightening order for cylinder head bolts .................................................................. 4-6
Checking the injection nozzles ................................................................................ 4-7
Pressure check .................................................................................................. 4-7
Checking the nozzle jet ............................................................................................ 4-7
Injection time ............................................................................................................ 4-8
Checking injection time ...................................................................................... 4-8
Setting injection time ......................................................................................... 4-8
Replacement of fuel injection pump .................................................................. 4-9
Adjusting engine revs ............................................................................................ 4-10
Compression .......................................................................................................... 4-10
Checking the coolant thermostat ........................................................................... 4-11
Checking the thermal switch .................................................................................. 4-11
Oil pressure switch ................................................................................................ 4-12
Checking the coolant circuit ................................................................................... 4-12
Engine 4TNV98-ZVNS from serial no. AH00645 .................................................. 4-13
Fuel system ........................................................................................................... 4-15
Removing the valve cover ..................................................................................... 4-16

Table of contents
Checking and adjusting valve clearance ................................................................ 4-16

Checking valve clearance ................................................................................ 4-16
Setting zero play of the valve bridge ................................................................ 4-17
Setting valve clearance .................................................................................... 4-17
Tightening order for cylinder head bolts ................................................................. 4-18
Checking the injection nozzles ............................................................................... 4-19
Pressure check ................................................................................................ 4-19
Checking the nozzle jet .......................................................................................... 4-19
Injection time .......................................................................................................... 4-20
Checking injection time .................................................................................... 4-20
Setting injection time ........................................................................................ 4-21
Replacement of fuel injection pump ................................................................. 4-22
Compression .......................................................................................................... 4-23
Checking the coolant thermostat ........................................................................... 4-23
Checking the thermal switch .................................................................................. 4-24
Oil pressure switch ................................................................................................. 4-24
Checking the coolant circuit ................................................................................... 4-24
Engine trouble ........................................................................................................ 4-25
Electronic engine control unit (E-ECU) .................................................................. 4-27
Features ........................................................................................................... 4-27
Engine error codes ................................................................................................. 4-28
Error diagnosis ....................................................................................................... 4-32
E-ECU connector assignment ......................................................................... 4-32
Important information on the ECU maintenance wiring harness ..................... 4-33
Flash code 7 proportional injection pump solenoid (control rack) ................. 4-34
Related DTC (Diagnostic Trouble Codes) ....................................................... 4-34
Diagnosis description ....................................................................................... 4-36
Flash code 5 manual throttle ........................................................................ 4-38
Related DTC .................................................................................................... 4-38
Work description .............................................................................................. 4-40
Flash code 4-1 ECU internal ............................................................................ 4-41
Related DTC .................................................................................................... 4-41
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm .....
4-43
Related DTC .................................................................................................... 4-43
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
4-45
Related DTC .................................................................................................... 4-45
Flash code 2-4 sensor 5 V ............................................................................ 4-49
Related DTC .................................................................................................... 4-49
Flash code 2-3 power supply voltage ........................................................... 4-52
(1) P0562/1: power supply voltage error (voltage too low) .............................. 4-52
DTC detection conditions ................................................................................. 4-52
Troubleshooting ............................................................................................... 4-52
(2) P0563/0: power supply voltage error (voltage too high) ............................. 4-53
DTC detection conditions ................................................................................. 4-53
Flash code 6 revs sensor .............................................................................. 4-54
Flash code 1-1 backup revs sensor .............................................................. 4-57
Related DTC .................................................................................................... 4-57

Table of contents

Flash code 9 overspeed error ....................................................................... 4-60
(1) P0219/0: overspeed error .......................................................................... 4-60
DTC detection conditions ................................................................................ 4-60
Diagnosis description ...................................................................................... 4-60
Flash code 1-7 proportional solenoid relay of the injection pump (control rack) ..
4-61
Related DTC .................................................................................................... 4-61
Flash code 1-5 preheating relay ................................................................... 4-65
Related DTC .................................................................................................... 4-65
Flash code 1-4 CSD (cold start device) solenoid coil ................................... 4-69
Related DTC .................................................................................................... 4-69
Flash code 1-3 EGR (exhaust gas recirculation) valve ................................ 4-72
Related DTC .................................................................................................... 4-72
Flash code 2-1 oil pressure switch and 3-1 oil pressure drop error ........... 4-76
Related DTC .................................................................................................... 4-76
Flash code 8 proportional injection pump solenoid (control rack) ................ 4-80
Related DTC .................................................................................................... 4-80
Flash code 1-6 main relay ............................................................................ 4-84
Related DTC .................................................................................................... 4-84
Flash code 1-2 CAN (Controller Area Network) communication .................. 4-88
Related DTC .................................................................................................... 4-88
Automatic revs setting ........................................................................................... 4-90
How it works .................................................................................................... 4-90
Hydraulic system
Hydraulic pump PVD-3B-56P-21G5-4626F ............................................................. 5-1
Pump unit: exploded view .................................................................................. 5-3
Pilot oil supply unit ............................................................................................. 5-5
Main valve block with 3rd control circuit and triple articulation boom ...................... 5-6
Ports .................................................................................................................. 5-6
Legend ............................................................................................................... 5-7
Main valve block diagram .................................................................................. 5-8
Pressure limiting valves ..................................................................................... 5-9
Pump assignment ............................................................................................ 5-10
Drive counterbalancing system .............................................................................. 5-11
Pump assignment for drive counterbalancing ................................................. 5-11
Drive counterbalancing diagram ...................................................................... 5-12
Regeneration stick section .................................................................................. 5-13
Bucket pre-tension ................................................................................................. 5-13
Boom summation raise ....................................................................................... 5-14
Check valve (load retaining valve) ......................................................................... 5-15
Flow rate adjustment of auxiliary hydraulics .......................................................... 5-16
Pilot valves ............................................................................................................. 5-17
Joystick ............................................................................................................ 5-17
Pilot valve (driving) .......................................................................................... 5-19
Pilot valve for auxiliary hydraulics .................................................................... 5-21
Pilot valve for stabiliser blade .......................................................................... 5-22

Table of contents
Valves .................................................................................................................... 5-23

7/2 directional valve (changeover valve) ......................................................... 5-23
4/3 directional valve ......................................................................................... 5-24
Shuttle valve block ........................................................................................... 5-25
Changeover valve for SAE/ISO controls (option) ............................................ 5-26
Travelling drive ....................................................................................................... 5-27
Function ........................................................................................................... 5-28
2nd speed range function ................................................................................ 5-28
Swivel unit .............................................................................................................. 5-31
Parking brake/multidisc brake function ............................................................ 5-32
Swivel joint ............................................................................................................. 5-37
Breather filter ......................................................................................................... 5-38
Troubleshooting in the hydraulic system ................................................................ 5-39
Hydraulics diagram A4 ........................................................................................... 5-40
Hydraulics diagram (legend) .................................................................................. 5-41
Hydraulics diagram A3 ........................................................................................... 5-42
Options diagrams 1 (from serial no. AC04070) ...................................................... 5-43
Options diagrams 2 (from serial no. AC04070) ...................................................... 5-44
Main valve block A3 diagram ................................................................................. 5-45
Electric system
Ohm's Law (current, voltage, resistance); power ..................................................... 6-1
Measuring equipment, measuring methods ............................................................. 6-1
Cable colour coding ................................................................................................. 6-2
Relays ...................................................................................................................... 6-2
Use, mode of function ........................................................................................ 6-2
Electric units ............................................................................................................. 6-3
Fuse box on the instrument panel up to serial no. AD07210 ................................... 6-3
Main fuse box with relays up to serial no. AD07210 ................................................ 6-3
Relays ...................................................................................................................... 6-4
Fuse box on the instrument panel from serial no. AH00645 .................................... 6-4
Main fuse box with relays from serial no. AH00645 ................................................. 6-5
ECU from serial no. AH00645 .................................................................................. 6-5
Socket ...................................................................................................................... 6-6
Joystick tip switches ................................................................................................. 6-6
Joystick (left) ...................................................................................................... 6-6
Joystick (right) .................................................................................................... 6-6
Instrument panel overview ....................................................................................... 6-7
Switches: overview .................................................................................................. 6-8
Alternator ................................................................................................................. 6-8
Starter ...................................................................................................................... 6-8
Wiring diagram A4 up to serial no. AC02888 (legend) ........................................... 6-10
Wiring diagram A4 up to serial no. AC02888 ......................................................... 6-11
Wiring diagram A4 from serial no. AC02890 (legend) ........................................... 6-12
Wiring diagram A4 from serial no. AC02890 .......................................................... 6-13
Wiring diagram A4 from serial no. AH00645 (legend) ........................................... 6-14
Wiring diagram A4 (1) from serial no. AH00645 ................................................... 6-15
Engine chassis A4 wiring harness 1000109624 up to AD07210 (legend) .......... 6-17
Engine chassis A4 wiring harness 1000109624 up to AD07210 ........................ 6-18
Engine chassis A4 wiring harness 1000173970 from AH00645 (legend) ........... 6-19
Engine chassis A4 wiring harness 1000173970 from AH00645 ......................... 6-20
Switches A4 wiring harness 1000109630 up to serial no. AC02888 (legend) ....... 6-21
Switches A4 wiring harness 1000109630 up to serial no. AC02888 ..................... 6-22
Switches A4 wiring harness from serial no. AC02890 (legend) ............................ 6-23
Switches A4 wiring harness from serial no. AC02890 .......................................... 6-24
Wiring harness 1000109629: cab roof ................................................................... 6-25

Table of contents
Wiring harness 1000109628: armrest .................................................................... 6-26

Wiring harness 1000116138: boom working light .................................................. 6-27
Wiring diagram A3 up to serial no. AC02888 (legend) .......................................... 6-29
Wiring diagram A3 up to serial no. AC02888 ......................................................... 6-30
Wiring diagram A3 from serial no. AC02890 AD07210 (legend) ........................ 6-31
Wiring diagram A3 from serial no. AC02890 AD07210 ...................................... 6-32
Wiring diagram A4 from serial no. AH00645 (legend) ........................................... 6-33
Engine chassis A3 wiring harness 1000109624 (legend) ................................... 6-36
Engine chassis A3 wiring harness 1000109624 ................................................. 6-37
Engine chassis A3 wiring harness 1000173970 from serial no. AH00611 (legend) ...
6-38
Engine chassis A3 wiring harness 1000173970 from serial no. AH00611 ......... 6-39
Switches A3 wiring harness 1000109630 up to serial no. AC02888 (legend) ....... 6-40
Switches A3 wiring harness 1000109630 up to serial no. AC02888 ..................... 6-41
Switches A3 wiring harness from serial no. AC02890 (legend) ............................. 6-42
Switches A3 wiring harness from serial no. AC02890 ........................................... 6-43
Wiring harness 1000109629: cab roof A3 ............................................................. 6-44
Wiring harness 1000109628: armrest A3 .............................................................. 6-45
Wiring harness 1000116138: boom working light A3 ............................................ 6-46
Options
Air conditioning ........................................................................................................ 7-1
Specific safety instructions ................................................................................ 7-1
Specifications .................................................................................................... 7-1
Installation: overview ......................................................................................... 7-2
Components ...................................................................................................... 7-3
Filling up the air conditioning system ................................................................. 7-5
Maintenance ...................................................................................................... 7-6
Troubleshooting ................................................................................................. 7-7
Air-suspension seat ................................................................................................. 7-9
Ports .................................................................................................................. 7-9
Counterweight .......................................................................................................... 7-9
Specifications .................................................................................................... 7-9
Long stick ................................................................................................................. 7-9
Specifications .................................................................................................... 7-9
Control circuit (pipework) connections for grab ..................................................... 7-10
3rd control circuit connections ............................................................................... 7-10
Auxiliary hydraulics connections ............................................................................ 7-11
Quickhitch couplings ........................................................................................ 7-11
Attachments ..................................................................................................... 7-12
Neuson Vario ......................................................................................................... 7-13
Using the Neuson Vario feature ...................................................................... 7-13
Vario diagram .................................................................................................. 7-14
Function ........................................................................................................... 7-14
Neuson Vario warning device .......................................................................... 7-15
Ports ................................................................................................................ 7-16
Fuel-filling pump .................................................................................................... 7-17
Connections up to serial no. AD07210 ............................................................ 7-18
Central lubrication system ..................................................................................... 7-19
Position ............................................................................................................ 7-19
Connections ..................................................................................................... 7-19
Function ........................................................................................................... 7-20
Adjusting breaks and lubrication times ............................................................ 7-21
Repair in case of clogging ............................................................................... 7-21

Table of contents
Service valve .......................................................................................................... 7-23

Function ........................................................................................................... 7-23
Safe load indicator D (safety valve for boom) ........................................................ 7-24
Position ............................................................................................................ 7-24
Function ........................................................................................................... 7-24
Diagram ........................................................................................................... 7-25
Safe load indicator F (safety valves for boom and stick) ....................................... 7-26
Position ............................................................................................................ 7-26
Function ........................................................................................................... 7-27
Diagram ........................................................................................................... 7-28
3rd control circuit .................................................................................................... 7-29
Function ........................................................................................................... 7-29
Diagram ........................................................................................................... 7-30
Triple articulation boom .......................................................................................... 7-31
Function ........................................................................................................... 7-31
Diagram ........................................................................................................... 7-32
Electric auxiliary hydraulics .................................................................................... 7-33
Function ........................................................................................................... 7-33
Auxiliary hydraulics shock cartridge ....................................................................... 7-35
3rd control circuit shock cartridge .......................................................................... 7-36
Drive interlock (antitheft protection) ....................................................................... 7-37
Position ............................................................................................................ 7-37
Disabling the drive interlock ............................................................................. 7-37
Enabling the drive interlock .............................................................................. 7-37
Programming ................................................................................................... 7-37
Quickhitch .............................................................................................................. 7-39
Proportional controls .............................................................................................. 7-40
Function ........................................................................................................... 7-40
Ports ................................................................................................................ 7-40
Overview of auxiliary hydraulics controls ......................................................... 7-41
Hammer operation ........................................................................................... 7-41
Adjusting control response .............................................................................. 7-41
Characteristic curve status display ............................................................... 7-41
Wiring harness ................................................................................................. 7-42
Control unit ...................................................................................................... 7-42
Control valve plug assignment ......................................................................... 7-43
Safety features ................................................................................................. 7-44
Measures to be taken in case of malfunctions ................................................. 7-44
Diagnosis display ............................................................................................. 7-44

Operation
Operation
Operation
1 Operation
1.1 Important information on this service manual
This service manual contains important information on how to service your machine safely,
correctly and economically. Therefore, it aims not only at new operators, but it also serves
as a reference for experienced ones. Your knowledge and skills will help to avoid
dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability
and the service life of the machine will be increased by following the instructions in the
service 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.
Insist on using original spare parts when carrying out maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
Your Neuson After-Sales Service will be pleased to answer any further questions
regarding the machine or the service manual.
Abbreviations/symbols
This symbol stands for a list
Subdivision within lists or an activity. Follow the steps in the recommended
sequence.
This symbol requires you to carry out the activity described
Description of the effects or results of an activity
n. s. = not shown
Option = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
A combination of digits, or a combination of digits and letters, e.g. 40/18 or 40/A used for
identifying the control elements, means:
Figure no. 40/control element no. 18 or position A in figure no. 40
Figures carry no numbers if they are placed to the left of the text.
1-1 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

Operation
1.2 Identification of warnings and dangers

Important indications regarding the safety of the staff and the machine are identified in this
Service Manual with the following terms and symbols:
Danger!
Failure to observe the instructions identified by this symbol can result in
personal injury or death for the operator or other persons.
Measures for avoiding danger
Caution!
Failure to observe the instructions identified by this symbol can result in
damage to the machine.
Measures for avoiding danger for the machine
Important!
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 result in damage to the
environment. The environment is in danger if environmentally hazardous material (e.g.
waste oil) is not subject to proper use or disposal.
SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-2

Operation
1.3 Designated use and exemption from liability

The machine is intended for:
moving earth, gravel, coarse gravel or ballast and rubble as well as for
working with the attachments mentioned in chapter Fields of application
Every other application is regarded as not designated for the use of the machine.
Neuson Baumashinen GmbH will not be liable for damage resulting from use other
than mentioned above. The user alone will bear the risk. Designated use also
includes observing the instructions set forth in the Operator's Manual and observing
the maintenance and service conditions.
The safety of the machine can be negatively affected by carrying out machine
modifications without proper authority and by using spare parts, equipment,
attachments and optional equipment which have not been checked and released by
Neuson Baumaschinen GmbH. Neuson Baumaschinen GmbH will not be liable for
damage resulting from this.
Neuson Baumaschinen GmbH shall not be liable for personal injury and/or damage to
property caused by failure to observe the safety instructions and the Operator's
Manual, and by the negligence of the duty to exercise due care when:
handling
operating
servicing and carrying out maintenance work 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
instructions, the Operator's Manuals and maintenance manuals (machine/engine).
Read and understand the Operator's Manual before starting up, servicing or repairing
the machine. Observe the safety instructions.
The machine may not be used for transport jobs on public roads

Operation
1.4 Type labels and component numbers

Serial number
The serial number is stamped on the machine chassis. It is also located on the type label.
The type label is located at the front right on the machine chassis (at cab level).
Type label information
Fig. 1: Type label: location Model: 6003

Year: 2004
PIN: AC 000000
Power: 42.5 kW (57 hp)
Mass: 5700 kg (12566 lb)
Load: ---------------
Max. gross mass: ---------------
Max. axle load: ---------------
---------------
Other information see chapter 2 Specifications on page 2-1
Fig. 2: Type label
Cab number
The type label (arrow) is located in the cab, on the upper rear right chassis member.
Fig. 3: Cab type label
Engine number
The type label (arrow) is located on the valve cover (engine).
Example: Yanmar 46557
Fig. 4: Diesel engine number

Operation
Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing.
Fig. 5: Hydraulic pump type label
Control valve number

The type label (arrow) is located on the lower side of the main valve block.
Fig. 6: Main valve block type label
Travelling drive number

The type label (arrow) is located on the travelling drive.
Fig. 7: Travelling drive type label
Swivel unit number

The type label (arrow) is located on the swivel unit.
Fig. 8: Swivel unit type label

Operation
1.5 Machine overview
1 Boom light 2
2 Boom
3 Stick
Rubber chains 7
4
Steel chains (option) 3
5 Undercarriage
6 Stabiliser blade
7 Cab 8
8 Engine cover
5 6
2 9 Handles
10 Tank filler inlet
11 Device for counterweight (option)
12 Exhaust pipe
3
1 10 12
11
9 4
Fig. 9: Machine outside views

Operation
1.6 Cab overview

Up to serial no.: AD07210
27 25 26 28 30 29
1 24
2 23
22
21
3
4
20
19
9 6
10
7 8
18
14 15
13
11 12
17 16

Operation
From serial no.: AH00645
27 25 26 28 30 29
2 24
22
21
3
4
20
19
9 6
10
7 8
18
14 15
13
11 12
17 16

Operation
1.7 Cab (legend)
Pos. Description
1 Cover for hammer pedal
2 Hammer pedal
3 Control lever (left)
4 Control lever (right)
5 Control lever base (left)
6 Control lever base (right)
7 Armrest (left)
8 Armrest (right)
9 Lever horizontal seat adjustment
10 Lever horizontal seat adjustment with control lever base
11 Air vent (rear window, on the left)
12 Air vent (rear window, on the right)
13 Radio (option)
14 Seat (backrest adjustment)
15 Seat belt (lock)
16 Cup holder
17 Bracket (storage box for documents)
18 Switch panel
19 Throttle
20 Fuse box
21 Cigarette lighter
22 Preheating start switch
23 Coolant temperature indicator
24 Round display element
25 Drive pedal (left)
26 Drive pedal (right)
27 Drive lever (left)
28 Drive lever (right)
29 Stabiliser blade pedal
30 Stabiliser blade lever

Operation
1.8 Instrument panel up to serial no. AC02888: overview
34
33 35
32 36
39
31 37
41
40
38 23
Temperature range:
Green/yellow 90 C (194 F)
Yellow/red 100 C (212 F )
42 43 44 45 46 47 48 49 50 51

Operation
1.9 Instrument panel up to serial no. AC02888: legend
Pos. Description
31 Hydraulic oil filter telltale (red)
32 Air filter telltale (red)
33 Telltale (red) alternator charge function
34 Engine oil pressure telltale (red)
35 Coolant temperature telltale (red)
36 Cold starter telltale (yellow)
37 Safe load indicator telltale (red)
38 Hour meter
39 Fuel level indicator
40 Telltale not assigned
41 Telltale not assigned
42 High speed
43 Washer system
44 Working lights
45 Roof lights
46 Rotating beacon
47 Ventilation
48 Air conditioning (option)
49 Safe load indicator (option)
50 Not assigned
51 Not assigned

Operation
1.10 Instrument panel from serial no. AC02890 to AD07210: overview
56
55
54 57
58
53
59
60
52
61 62
63 64 65 66 67 68 69 70 71 72

Operation
1.11 Instrument panel from serial no. AC02890 to AD07210: legend
Pos. Description
55 Telltale (red) hydraulic oil temperature
58 Coolant temperature telltale (red)
61 Hour meter
62 Temperature indicator
63 High speed
64 Washer system
65 Working lights
66 Roof lights
67 Rotating beacon
68 Ventilation
71 Not assigned
72 Not assigned

Operation
1.12 Instrument panel from serial no. AH00645: overview
76
77 78
73
75
74
DP
5
DP1
DP
16
10
95
DP
DP
17
D
8
P7 8
DP
DP P1
94
D
6 19
DP
!
DP
5 20
DP
DP 1
4
DP2
DP3
DP22
DP2 DP23
DP1 DP24
82
km/h
mph
!
80
79
81
83 84 85 86 87 88 89 90 91 92 93

Operation
1.13 Instrument panel from serial no. AH00645: legend
Pos. Description
78 Telltale (red) coolant temperature too high
81 Hour meter
82 Coolant temperature indicator
83 High speed
84 Washer system
85 Working lights
86 Roof lights (option)
87 Rotating beacon (option)
88 Automatic revs setting
89 Ventilation
92 Not assigned
93 Proportional controls (option)
94 Telltale (green) high speed enabled
95 Engine error telltale (red)

Operation
1.14 Engine compartment up to serial no. AD07210: overview
96 97 98 99 100 101
Pos. Description For more information see page

96 Main valve block 5-6
97 Measurement ports 3-30
98 Fuel prefilter 3-11
99 Engine 4-1
100 Coolant tank 3-18
101 Oil/water radiator 3-19

Operation
1.15 Engine compartment from serial no. AD00611: overview
102 103 104 105 106 107 108 109 110 111 112

102 Main valve block 5-6
103 Fuel-filling pump 7-17
104 Fuel prefilter 3-11
105 Air filter 3-20
106 Battery master switch 1-22
107 Engine 4-13
108 Fuel filter 3-12
109 Engine oil filter 3-16
110 Coolant tank 3-18
111 Oil filler openings 3-13
112 Oil/water radiator 3-19

Operation
1.16 Chassis overview
113 114 115 116 117 118 119 120 121

113 Swivel joint 5-37
114 Leak oil strip
115 Swivel unit 5-31
116 Opening for cleaning the hydraulic oil tank
117 Position of main fuse box with relays 2-5
118 Shuttle valve block 5-25
119 Pilot valve for stabiliser blade 5-22
120 Changeover valve 5-23
121 Pilot valve (driving) 5-18

Operation
1.17 Tilting the cab
Danger!
Careful when tilting the cab
Danger of accidents!
Always tighten screws A and C when driving and working with the machine.
Always close the door.
Stay clear from underneath the cab as you tilt it.
Switch off the engine.
Remove the ignition key.
Fold the control lever base (left) up.
Slackening the bolts

Unscrew the screw as follows:
Remove the ignition key.
Fold the control lever base (left) up.
Raise floor mat B.
Unscrew screw A with a suitable tool.
A Screw A is located at the front right of the cab.
Slacken screw C with a suitable tool.
B Screw C is located at the rear right of the cab.
Danger!
Always close the door. Even if the door is secured in the open position with the
door arrester
Always close the door before tilting the cab.
Should the door be open as you tilt the cab, do not actuate the door opener
unintentionally.
Fig. 10: Cab floor screw

Operation
Tilting the cab

Proceed as follows:
E Insert tube D onto guide pin E and pump as far as it will go.
F (jack function)
The cab is raised as far as the pump will go.
Pull handle G until the cab is completely tilted beyond the centre of motion.
The cab is secured with safety cable H.
D Remove the split pin from bracket J.
Slide tilt rod K into guide L.
Secure tilt rod K with the split pin in guide L.
Tilting the cab down:
Remove the split pin from guide L.
Slide tilt rod K into bracket J.
H Secure tilt rod K with the split pin in bracket J.
Use handle G to lower the cab until it is back on the pump.
Insert tube D on pin F.
Slowly turn tube D counterclockwise (to the left).
The cab is lowered by its own weight.
G
The lift pump must be opened when driving with the machine (to prevent the
lift piston from touching the cab.)
Mount screws A (front) and C (rear) with suitable tools and the specific torque
see Tightening torques for high-resistance screw connections on page 2-10.
Caution!
Check tilt rod K, the split pin and safety cables H at regular intervals for cracks
and cuts.
Replace defective parts immediately.
J
K
Fig. 11: Tilting the cab

Operation
1.18 Summer/winter operation

Adjust cab temperature as follows:
Position Function
A Summer operation Cools
B Winter operation Heating water circuit open
A
Open the engine compartment.
Turn the ball-type cock as described, to summer or winter operation.
Close the engine compartment.
Important!
Summer and winter operation does not depend on the season, adjust according to
your personal requirements.
Fig. 12: Heating adjustment
Preheated fresh air
Selection of cold or preheated fresh air in winter.
A deflector plate on the heater can be set to two different positions.

Fresh air: heater takes in air from outside the cab fig. 13.
Preheated fresh air: heater takes in air from the chassis fig. 14.
Fig. 13: Fresh air
Change from fresh air to preheated fresh air as follows:

Tilt the cab see Tilting the cab on page 1-19.
The deflector plate is located on the heater under the cab.
Slacken both fastening screws.
Reposition and fit the deflector plate back on again.
Tilt the cab back down again and secure it.
Fig. 14: Preheated fresh air

Operation
1.19 Auxiliary hydraulics/boom swivel pedal

The pedal for the auxiliary hydraulics/swivelling the boom can be rotated by 90.
Slacken 4 screws.
Rotate the pedal by 90.
Retighten the 4 screws.
The length of the hydraulic hoses is sufficient for easily rotating the pedal by 90.
Caution!
Make sure the hydraulic hoses are not squeezed as you tilt the cab.
1.20 Battery master switch
Important!
Power supply is interrupted directly after the battery, by means of a key:
A Before working on the electric system
As an antitheft precaution
B
Interrupting power supply:
C
Turn key A of the battery master switch to position B and remove it.
Switching on power supply:
Fig. 15: Battery master switch Insert key A in the battery master switch.
Turn the key down (C) and let it lock into place.

Operation

Specifications
Specifications
Specifications
2 Specifications
2.1 Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2 Engine
Model 6003
European Tier 3A/
Engine
Tier 2 (up to AD07210) American Tier 3
(from AH00645)
Product Yanmar diesel engine
Type 4TNV98-VNS 4TNV98-ZVNS
Design Water-cooled 4 stroke diesel engine
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 3319 cm (202.5 cu in)
Nominal bore and stroke 98 x 110 mm (3.9 x 4.3)
42.5 kW at 2100 rpm 43.4 kW at 2100 rpm
Output
(57 hp at 2100 rpm) (58.2 hp at 2100 rpm)
246.1 Nm at 1000 rpm 238.3 Nm at 1350 rpm
Max. torque
(181.5 ft. lbs. at 1000 rpm) (175.8 ft. lbs. at 1350 rpm)
Max. engine speed without 2290 25 rpm 2130 25 rpm
load
Idling speed 1100 25 rpm
Valve clearance (intake = out- 0.15 0.25 mm/0.006 0.01 (cold)
let)
Compression 33.3 35.3 bar (483 512 psi) at 250 rpm
Engine oil pressure 2.9 3.9 bar (42.1 56.6 psi)
Pressure switch
0.5 0.1 bar (7.25 1.45 psi)
Engine oil pump
Thermostat
69.5 72.5 C (157.1 162.5 F)
Opening temperature
Thermal switch 107 113 C (224.6 235.4 F)
Firing order 1342
Counterclockwise
Direction of rotation
(as seen from the flywheel)
Glow plug Sheathed-element heater plugs
Starting aid
(preheating time 15 s) (preheating time 15 s)
Max. inclined position 25 in all directions 30 in all directions
(engine no longer Hill climbing ability (30/58 %) Hill climbing ability (30/58 %)
supplied with oil): of the machine! of the machine!
8.7 l/h/2.30 gph 8.0 l/h/2.11 gph
(without air conditioning)1 (without air conditioning)1
Fuel consumption
8.8 l/h/2.32 gph 8.5 l/h/2.25 gph
(with air conditioning)1 (with air conditioning)1
Specific fuel consumption 246 g/kWh/0.404 lb/hph 232 g/kWh/0.381 lb/hph
97/68/EC European Tier 2 97/68/EC European Tier 3A
Exhaust values according to
EPA Tier 2 EPA Tier 3
1. Values based on an average 70 % load of the excavator and a diesel fuel density of 0.83 kg/dm and cannot be used for comparison with
competitors. Specific fuel consumption should be used for this. The air conditioning system has been taken into account with 100 %
operating time.

Specifications
Fuel injection pump
YPD-MP4
Type European Tier 3A/American
Tier 2 (up to AD07210)
Tier 3 (from AH00645)
Design Single piston distributor injection pump
Injection pressure 216 226 bar (3133 3278 psi)
Revs control Mechanical Electronic
Lubrication system Engine oil lubrication
Capacities
Model 6003
Capacities European Tier 3A/American
Tier 2 (up to AD07210)
Tier 3 (from AH00645)
Fuel tank 93 l (24.6 gal)
9.4 l/4.4 l 10.2 l/4.5 l
Engine oil (max./effect.)
(2.5/1.2 gal) (2.7/1.2 gal)
Coolant (without radiator) 4.2 l (1.11 gal)
Radiator 7 l (1.8 gal)
Expansion tank 1.5 l (0.40 gal)
Tightening torques
Tightening torques (Nm) Nm/ft. lbs.

Cylinder-head bolt 103.1 112.9/76.04 83.27 (M11x1.25)
Connecting rod bearing screw 53.9 58.8/39.75 43.37 (M10x1)
Main bearing screw 108.1 117.9/79.73 86.96 (M11x1.25)
Flywheel screw 186.2 205.8/137.33 151.79 (M14x1.5)

Specifications
2.3 Hydraulic system
Hydraulics 6003
Double variable displacement pump + twin gear pump
Tier 2
2 x 28 + 21 + 4.5 cm3 (2 x 1.7 +1.3 + 0.3 in3)
PVD-2B44BP-16G5-4713F (variable displacement pump)
(up to AD07210)
GSP2H-BOF16A16AR-A0-A627-0 (gear pump)
Pump European Tier Double variable displacement pump + twin gear pump
3A/
2 x 28 + 21 + 4.5 cm3 (2 x 1.7 +1.3 + 0.3 in3)
American Tier 3
PVD-3B-56P-21G5-4626F (variable displacement pump)
(from AH00645)
GSP2H-BOF16A16AR-A0-A627-0 (gear pump)
Tier 2 2 x 64.1 + 48 + 10.3 l/min
(up to AD07210) (2 x 17 + 13 + 3 gal/min) at 2290 rpm
European Tier
Flow rate
3A/ 2 x 59.64 + 44.7 + 9.6 l/min
American Tier 3
(from AH00645) (2 x 16 + 12 + 2.5 gal/min) at 2130 rpm
11 sections/12 sections (3rd control circuit or triple articu-
Control valve lation boom)
13 sections (triple articulation boom control)
Max. service pressure 2405 bar (348173 psi)
Main pressure limiting valve for pumps 2403 bar (348143.5 psi)
P1, P2
Main pressure limiting valve for pump 240-0/+3 bar (3481-0/+43.5psi)
P3
Secondary pressure limiting valve for 2750/+0.5 bar (39890/+7 psi) at 20 l/min (at 5.3 gal/min)
main valve block
Main pressure limiting valve for pilot 421 bar (60914.5 psi)
control pressure
Swivel unit main pressure limiting 2153 bar/311843.5 psi (at idling speed)
valve
Hydraulic oil cooler Standard
Hydraulic tank capacity 83 l (22 gal)
2nd speed shift pressure 180 bar (2611 psi)
Gear motor braking deceleration time 3.71.2 s at 50 C/122 F oil temperature
European Tier 3A/
Tier 2
American Tier 3
Circulation pressure P1 (max. revs) 15.0 bar (218 psi) 14.5 bar (210 psi)

Specifications
Auxiliary hydraulics oil flow*

Pressure P2 + P3 (l/min / gal/min) P2 (l/min / gal/min)
American Tier American Tier
(bar/psi) Tier 2 Tier 2
3A 3A
15/218 105/27.7 102/26.9 61/16.1 60/15.9
40/580 104/27.5 101/26.7 60/15.9 59/15.6
60/870 102.5/27.1 100/26.4 60/15.9 58/15.3
90/1305 100/26.4 98/25.9 59/15.6 57/15
120/1740 98/25.9 94/24.8 58/15.3 56/14.8
150/2176 87/23 84/22.2 57/15 55/14.5
180/2611 75/19.8 75/19.8 56/14.8 54/14.3
210/3046 65/17.2 60/15.9 55/14.5 53/14
230/3336 27/7.1 20/5.3 50/13.2 33/8.7
* Output indications for auxiliary hydraulics with unpressurised reflux line
Screwable hose burst valve
Location Thread Gap dimension

Stabiliser blade 1/2 1.2 mm (0.05)
see chapter 5.18 Hydraulics diagram A3 on page 5-42 item 22
2.4 Undercarriage and swivel unit
Undercarriage/swivel unit Model 6003

2 speed ranges 3.0/5.22 kph (1.86/3.24 mph)
Hill climbing ability (briefly) 30/58 %
Chain width 400 mm (15.75)
No. of track rollers on either side 5
Ground clearance 290 mm (11.42)
Ground pressure 0.33 kg/cm (4.69 psi)
Upper carriage swivel speed 9.25 rpm
2.5 Stabiliser blade
Stabiliser blade Model 6003

Width/height 1990/425 mm (78.35/16.73)
Max. lift over/under subgrade 390/400 mm (15.35/15.75)
2.6 Electric system
Electric system
Alternator 12 V 55 A
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 88 Ah
Socket E.g. for cigarette lighter; 15 A max.

Specifications
Fuse box on the instrument panel up to serial no. AD07210
Fuse no. Rated current (A) Protected circuit

F3 10 A Indicators, engine relay
F4 10 A Boom working light
F5 15 A Cab working light
F6 10 A Valves, horn
F7 15 A Heating, air conditioning
F8 10 A Wiper, interior light
F9 10 A Rotating beacon, radio, drive interlock
F10 15 A Socket, cigarette lighter
Fig. 1: Fuse box
Main fuse box with relays under the cab up to serial no. AD07210
K9 K5 F1
F2 Fuse no. Rated current (A) Protected circuit
F1 40 A Start, preheat, cutoff solenoid
F2 50 A Fuel-filling pump, main fuse, ignition lock
Relay no.
K9 Cutoff solenoid switching relay
Fig. 2: Relay box under the cab
K5 Preheating high current relay
Relays up to serial no. AD07210
Switching relay
Protected circuit
no.
K6 Preheating timer (telltale only) t = 10 s
K7
K7 Starting relay
K8 Cutoff solenoid timer t = 1 s
V1 Cutoff solenoid recovery diode
V1
K6
K81
Fig. 3: Relays

Specifications
Fuse box on the instrument panel from serial no. AH00645

F3 10 A Displays, E-ECU
F4 10 A Boom light
F5 15 A Roof lights
F9 10 A Rotating beacon, radio
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 4: Fuse box
Main fuse box with relays from serial no. AH00645

Main fuse box X is located under the cab, next to the swivelling console.
.
Rated current
Fuse no. Protected circuit
(A)
X F1 40 A Start, preheat
Fig. 5: Main fuse box under the cab F11 10 A E-ECU, engine relay
K2 K5 K7 Relay no.
F2 K1 Engine electronics main relay
F1 K2 Fuel-filling pump relay
K42
F11
K1
V1 K7 Start high current relay
K42 Fuel injection pump relay
V1 Blocking diode

Specifications
2.7 Noise levels
Sound power level Model 6003

Sound power level (LWA) 101 dB (A)
Sound pressure level (LPA) at the
78 dB (A)
driver's ear
Important!
Measurement of sound power level according to EC Directive 2000/14 EC. Noise
level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/
EEC and 95/27/EEC. Measurements carried out on asphalted surface.
2.8 Vibration
Vibration
Effective acceleration value for the < Trigger value
upper extremities of the body *
Effective acceleration value for the < Trigger value
body *
* Measurements as per 2002/44/EC (excavating, driving and hammering with a Neuson hammer). Machine and attachment
operation and maintenance as per Operator's Manual.
2.9 Coolant compound table
Outside Coolant: Halvoline XLC (based on ethylene glycol)

temperature Water Anticorrosion agent Antifreeze agent
% by cm/l
Up to C (F) % by volume % by volume
volume (in3/gal)
4 (39) 99
-10 (14) 79 20
-20 (-4) 65 10 (2.6) 1 34
-25 (-13) 59 40
-30 (-22) 55 44

Specifications
2.10 Model-specific tightening torques
6003 Nm (ft. lbs.)

Live ring M14 10.9 180 (133)*
Track roller M16 10.9 275 (203)*
Drive pinion M14 10.9 180 (133)*
Travelling drive M14 10.9 180 (133)*
Gear motor M16 10.9 275 (203)*
Angled engine bracket M10 8.8 45 (33)
Engine bearing M10 8.8 45 (33)
Pump base M10 8.8 50 (37)
Pump M12 10.9 79 (58)
Swivel joint M10 10.9 64 (47)*
Counterweight/extra weight M20 8.8 290 (214)*
*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.
2.11 General tightening torques

Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)

Tightening
Nominal Outer Thread Wrench size torque
Nm (ft. lbs.)
05 6L M12X1.5 WS 14 15 (11)
06 8L M14X1.5 WS 17 20 (15)
08 10L M16X1.5 WS 19 40 (30)
10 12L M18X1.5 WS 22 50 (37)
12 15L M22X1.5 WS 27 75 (55)
16 18L M26X1.5 WS 32 85 (63)
20 22L M30X2 WS 36 100 (74)
25 28L M36X2 WS 41 180 (133)
32 35L M45X2 WS 55 220 (162)
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 %
Values determined empirically and to be applied as approximate figures.
Metric hose fittings for hydraulic applications (heavy execution, DKOL)

Tightening
Nominal Outer Thread Wrench size torque
Nm (ft. lbs.)
05 8S M16X1.5 WS 19 40 (30)
06 10S M18X1.5 WS 22 50 (37)
08 12S M20X1.5 WS 24 60 (44)
10 14S M22X1.5 WS 27 75 (55)
12 16S M24X1.5 WS 30 90 (66)
16 20S M30X2 WS 36 100 (74)
20 25S M36X2 WS 41 180 (133)
25 30S M42X2 WS 50 270 (199)
32 38S M52X2 WS 60 400 (295)
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 %
Values determined empirically and to be applied as approximate figures.

Specifications
Screw connections with various seals for hydraulic applications

Light execution
Straight pipe fitting with thread and Non-return
Identification
screwed plug valve with
Thread Sealing elastic elastic aid

O-ring
washer seal seal outside
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) mm ()
M10X1.0 9 (7) 18 (13) 15 (11) 18 (13) 10 (0.4)
M12X1.5 20 (15) 25 (18) 25 (18) 25 (18) 12 (0.5)
M14X1.5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.6)
M16X1.5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6)
M18X1.5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7)
M22X1.5 65 (48) 125 (92) 60 (44) 125 (92) 22 (0.9)
M27X2.0 90 (66) 180 (133) 100 (74) 145 (107) 27 (1.0)
M33X2.0 150 (111) 310 (229) 160 (118) 210 (155) 33 (1.3)
M42X2.0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7)
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 (0.4)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13.16 (0.5)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16.66 (0.7)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20.96 (0.8)
G3/4A 90 (66) 180 (133) 100 (74) 140 (103) 26.44 (1.0)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33.25 (1.3)
G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41.91 (1.6)
G1 1/2A 290 (214) 540 (398) 360 (266) 540 (398) 47.80 (1.9)
Torque tolerance: 10 %; countermaterial: steel/aluminium
Screw connections with various seals for hydraulic applications

Heavy execution
Straight pipe fitting with thread and Non-return
Identification
screwed plug valve with
Thread Sealing elastic elastic aid

O-ring
washer Seal Seal outside
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 (0.6)
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 (0.8)
M22X1.5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0)
M27X2.0 90 (66) 180 (133) 170 (125) 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 (0.5)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16.66 (0.7)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20.96 (0.8)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26.44 (1.0)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33.25 (1.3)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41.91 (1.6)
G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47.80 (1.9)
Torque tolerance: 10 %; countermaterial: steel/aluminium

Specifications
Tightening torques for high-resistance screw connections
With coarse-pitch thread

Screws according to DIN 912, DIN
Screws according to
931,
Thread DIN 933 etc. DIN 7984
8.8 10.9 12.9 8.8 10.9
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)
M5 5.5 (4) 8 (6) 10 (7) 5 (4) 7 (5)
M6 10 (7) 14 (10) 17 (13) 8.5 (6) 12 (9)
M8 25 (18) 35 (26) 42 (31) 20 (15) 30 (22)
M10 45 (33) 65 (48) 80 (59) 40 (30) 59 (44)
M12 87 (64) 110 (81) 147 (108) 69 (51) 100 (74)
M14 135 (100) 180 (133) 230 (170) 110 (81) 160 (118)
M16 210 (155) 275 (203) 350 (258) 170 (125) 250 (184)
M18 280 (207) 410 (302) 480 (354) 245 (181) 345 (254)
M20 410 (302) 570 (420) 690 (509) 340 (251) 490 (361)
M22 550 (406) 780 (575) 930 (686) 460 (339) 660 (487)
M24 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620)
M27 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922)
M30 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254)
DIN 912 hexagon socket head cap screw; DIN 931/DIN 933 hexagon head screw with/without shaft;
DIN 7984 hexagon socket head cap screw with short head
All values subject to a friction coefficient of = 0.12 and are to be used as approximate figures.
With fine-pitch thread

Screws according to DIN 912, DIN
Screws according to
931,
Thread DIN 933 etc. DIN 7984
8.8 10.9 12.9 8.8 10.9
Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)
M8X1.0 25 (18) 37 (28) 43 (32) 22 (16) 32 (24)
M10X1.0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48)
M10X1.25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46)
M12X1.25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81)
M12X1.5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77)
M14X1.5 135 (100) 200 (148) 235 (173) 120 (89) 175 (129)
M16X1.5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195)
M18X1.5 315 (232) 450 (332) 530 (391) 270 (1991) 385 (284)
M20X1.5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391)
M22X1.5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524)
M24X2.0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664)
M27X2.0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959)
M30X2.0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364)
DIN 912 hexagon socket head cap screw; DIN 931/DIN 933 hexagon head screw with/without shaft;
DIN 7984 hexagon socket head cap screw with short head
All values subject to a friction coefficient of = 0.12 and are to be used as approximate figures.

Specifications
2.12 Dimensions model 6003

3967 Fig. 6: Machine dimensions (model 6003)
1465
2570
2570
425
400
3280 1190
400
2500
5800 1990
Main data Model 6003 Vario

535 745
Service weight 5500 kg (12125 lb) 5965 kg (13151 lb)
Height 2570 mm (8'5) 2684 mm (8'10)
Width 1990 mm (6'6) 1990 mm (6'6)
Transport length 5800 mm (19) 5800 mm (19)
75 51
Max. digging depth 3845 mm (12'7) 3736 mm (12'3)
Stick length (standard) 1685 mm (5'6) 1685 mm (5'6)
Stick length (long version) 1985 mm (6'6) 1985 mm (6'6)
Max. digging depth for long stick (+ 4140 mm (13'7) 4036 mm (13'3)
300 mm/11.8)
Max. vertical digging depth 2855 mm (9'4) 2735 mm (8'11)
Max. vertical digging depth (long 3135 mm (10'3) 3014 mm (9'11)
stick)
Max. digging height 5660 mm (18'7) 5778 mm (18'11)
Max. digging height (long stick) 5850 mm (19'2) 5967 mm (19'7)
Max. dump height 3995 mm (13'1) 4109 mm (13'6)
R Max. dump height (long stick) 4185 mm (13'9) 4298 mm (14'1)
14
65
Max. digging radius 6210 mm (20'4) 5960/6460 mm (19'7/21'2)
Max. digging radius (long stick) 6490 mm (21'4) 6240/6740 mm (20'6/22'1)
Max. reach at ground level 6090 mm (19'11) 5840/6340 mm (19'2/20'10)
Max. reach at ground level (long 6380 mm (20'11) 6130/6630 mm (20'1/21'9)
1990 stick)
Max. breakout force at bucket tooth 39.70 kN (8925 lbf) 39.70 kN (8925 lbf)
Max. tearout force (standard stick) 28.10 kN (6317 lbf) 28.10 kN (6317 lbf)
Max. tearout force (long stick) 25.10 kN (5643 lbf) 25.10 kN (5643 lbf)
Min. tail end slewing radius 1465 mm (4'10) 1465 mm (4'10)
Max. tail end lateral projection over 470 mm (1'6) 220/720 mm (8.7/2'4)
chains
Max. boom displacement to bucket 745 mm (2'5) 995 mm (3'3)
centre (right-hand side)
Max. boom displacement to bucket 535 mm (1'9) 785 mm (2'7)
centre (left-hand side)

Specifications
2.13 Lift capacity table 6003

All table indications in kg (lb) and horizontal position on firm ground without bucket.
A 5.0 m (16'5) 4.0 m (13'1) 3.0 m (9'10) 2.0 m (6'7)
4.0 m 1310* 1020 1245* 1155

(13'1) (2888*) (2249) (2745*) (2546)
3.0 m 1300* 805 1265* 1145
(9'10) (2866*) (1775) (2789*) (2524)
2.0 m 1320* 710 1330* 775 1490* 1100 1885* 1700
(6'7) (2910*) (1565) (2932*) (1709) (3285*) (2425) (4156*) (3748)
1.0 m 1360* 675 1435* 750 1775* 1035 2615* 1550
Fig. 7: Lift capacity table (model 6003) (3'3) (2998*) (1488) (3164*) (1653) (3913*) (2282) (5765*) (3417)
0.0 m 1410* 690 1495* 730 1970* 990 2970* 1470
(0'0) (3109*) (1521) (3296*) (1609) (4343*) (2183) (6548*) (3241)
-1.0 m 1465* 760 1965* 970 2910* 1450 5010* 2795
(-3'3) (3230*) (1676) (4332*) (2138) (6415*) (3197) (11045*) (6162)
-2.0 m 1495* 965 2450* 1475 4005* 2855
(-6'7) (3296*) (2127) (5401*) (3252) (8830*) (6294)
max Admissible load on extended stick

A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics
With the stabiliser blade in driving direction
Without the stabiliser blade, 90 to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.
Calculation basis: according to ISO 10567

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

Specifications
2.14 Lift capacity table 6003 with long stick option

A 5.0 m (16'5) 4.0 m (13'1) 3.0 m (9'10) 2.0 m (6'7)
4.0 m 1190* 990 1050* 865

(13'1) (2624*) (2183) (2315*) (1907)
3.0 m 1190* 640 1120* 1055
(9'10) (2624*) (1411) (2469*) (2326)
2.0 m 1120* 285 1085* 1670*
1245* 715 1375* 1670*
(2392* (3682*
(6'7) (2469*) (628) (2745*) (1576) (3031*)
)
(3682*)
)
Fig. 8: Lift capacity table (model 6003)
1.0 m 1265* 530 1380* 725 1690* 1030 2400* 1570
(3'3) (2789*) (1168) (3042*) (1598) (3726*) (2271) (5291*) (3461)
0.0 m 1315* 585 1485* 705 1925* 980 2805* 1465
(0'0) (2899*) (1290) (3274*) (1554) (4244*) (2161) (6184*) (3230)
-1.0 m 1375* 665 1990* 955 2855* 1425 4570* 2785
(-3'3) (3031*) (1466) (4387*) (2105) (6294*) (3142) (10075*) (6140)
-2.0 m 1425* 825 2580* 1440 3980 2800
(-6'7) (3142*) (1819) (5688*) (3175) (8774) (6173)

B Load hook height


Specifications
2.15 Lift capacity table 6003 with counterweight option

A 5.0 m (16'5) 4.0 m (13'1) 3.0 m (9'10) 2.0 m (6'7)
4.0 m 1310* 1175 1245* 1245*

(13'1) (2888*) (2590) (2745*) (2745*)
3.0 m 1300* 935 1265* 1265*
(9'10) (2866*) (2061) (2789*) (2789*)
2.0 m 1320* 830 1885*
1330* 905 1490* 1265 1885*
(4156*
(6'7) (2910*) (1830) (2932*) (1995) (3285*) (2789) (4156*)
)
1.0 m 1360* 795 1435* 880 1775* 1205 2615* 1795
(3'3) (2998*) (1753) (3164*) (1940) (3913*) (2657) (5765*) (3957)
0.0 m 1410* 810 1495* 850 1970* 1155 2970* 1715
(0'0) (3109*) (1786) (3296*) (1874) (4343*) (2546) (6548*) (3781)
-1.0 m 1465* 895 1965* 1140 2910* 1695 5010* 3250
(-3'3) (3230*) (1973) (4332*) (2513) (6415*) (3737) (11045*) (7165)
-2.0 m 1495* 1130 2450* 1720 4005* 3310
(-6'7) (3296*) (2491) (5401*) (3792) (8830*) (7297)

B Load hook height


Specifications
2.16 Lift capacity table 6003 with long stick and counterweight
A 5.0 m (16'5) 4.0 m (13'1) 3.0 m (9'10) 2.0 m (6'7)
4.0 m 1190* 1130 1050* 1035

(13'1) (2624*) (2491) (2315*) (2282)
3.0 m 1190* 760 1120* 1120*
(9'10) (2624*) (1676) (2469*) (2469*)
2.0 m 1220* 395 1670*
1245* 845 1375* 1250 1670*
(3682*
(6'7) (2690*) (871) (2745*) (1863) (3031*) (2756) (3682*)
)
1.0 m 1265* 640 1380* 850 1690* 1200 2400* 1515
(3'3) (2789*) (1411) (3042*) (1874) (3726*) (2646) (5291*) (3340)
0.0 m 1315* 700 1485* 835 1925* 1145 2805* 1710
(0'0) (2899*) (1543) (3274*) (1841) (4244*) (2525) (6184*) (3770)
-1.0 m 1375* 785 1990* 1120 2855* 1670 4570* 3240
(-3'3) (3031*) (1731) (4387*) (2469) (6294*) (3682) (10075*) (7143)
-2.0 m 1425* 970 2580* 1685 3980* 3260
(-6'7) (3142*) (2138) (5688*) (3715) (8774*) (7187)

B Load hook height


Specifications
2.17 Lift capacity table 6003 Vario
A 5.0 m (16'5) 4.0 m (13'1) 3.0 m (9'10) 2.0 m (6'7)

max
B/C
4.0 m 1310* 1310* 780 1245* 1245* 885

(13'1) (2888*) (2888*) (1720) (2745*) (2745*) (1951)
3.0 m 1300* 1105 615 1265* 1265* 880
(9'10) (2866*) (2436) (1356) (2789*) (2789*) (1940)
2.0 m 1320* 975 545 1330* 1060 595 1490* 1490* 845 1885* 1885* 1305
(6'7) (2910*) (2150) (1202) (2932*) (2337) (1312) (3285*) (3285*) (1863) (4156*) (4156*) (2877)
1.0 m 1360* 925 520 1435* 1030 575 1775* 1420 795 2615* 2125 1190
(3'3) (2998*) (2039) (1146) (3164*) (2271) (1268) (3913*) (3131) (1753) (5765*) (4685) (2624)
0.0 m 1410* 945 530 1495* 1000 560 1970* 1355 760 2970* 2015 1125
(0'0) (3109*) (2083) (1168) (3296*) (2205) (1235) (4343*) (2987) (1676) (6548*) (4442) (2480)
-1.0 m (- 1465* 1040 585 1965* 1330 745 2910* 1985 1110 5010* 3830 2145
3'3) (3230*) (2293) (1290) (4332*) (2932) (1642) (6415*) (4376) (2447) (11045*) (8444) (4729)
-2.0 m (- 1495* 1320 740 2450* 2020 1130 4005* 3910 2190
6'7) (3296*) (2910) (1631) (5401*) (4453) (2491) (8830*) (8620) (4828)

B Load hook height
C Vario position
Without the stabiliser blade 90 in driving direction Upper

carriage shifted to the rear with Vario option
Without the stabiliser blade 90 in driving direction Upper

carriage shifted to the front with Vario option
Rear Vario
Front Vario or attachment dead weight.
Fig. 11: Lift capacity table Vario (model 6003) Calculation basis: according to ISO 10567

Specifications
2.18 Kinematics
E Pin diameter 50 mm (2)

F Stick width 195 mm (7.7)
L Pin distance to bucket mount 240 mm (9.4)
Bucket Stick
Bucket

Specifications
2.19 Attachments
Description Width (mm/) Capacity Item No. 5002 6002 50Z3 6003
(l/gal)
Rear excavator bucket 400/15.7 94/24.8 1000094242 2 1
5002/6002
5002/6002
5002/6002
5002/6002
Rear excavator bucket 340/13.4 58/15.3 1000112213 2 2 1
50Z3
50Z3
50Z3
50Z3
50Z3
6003
6003
6003
6003
6003
Rear excavator bucket 340/13.4 1000017263 X 2
quickhitch system 5002/
6002
Rear excavator bucket 400/15.7 94/24.8 1000017260 X 2
6002
6002
6002
6002
quickhitch system 50Z3

Specifications
(l/gal)
Rear excavator bucket 340/13.4 74/19.5 1000112229 2 2 X
quickhitch system 6003
Ditch cleaning bucket 1200/47.2 205/54.2 1000096589
5002/6002
5002/6002
4 Attachment designed for this excavator model (optimal excavation output).
1. Attachment can be mounted but may be subject to restrictions regarding excavation forces, dump-in/out angles and productivity
due to possibly reduced bucket volumes.
2. Same restrictions as for 1 but in addition, mounting these attachments can impair machine stability.
Same restrictions as for 1 and 2 but in addition, subject to possible collision with the boom ram.
(l/gal)
6002
6002
Offset bucket 5002/6002 1200/47.2 150/39.6 1000096583 2
short stick
Offset bucket 5002/6002 1400/55.1 180/47.6 1000096584 2
short stick
Offset bucket 5002/6002 1200/47.2 150/39.6 1000096581 2
long stick
Offset bucket 5002/6002 1400/55.1 180/47.6 1000096582 2
long stick
Offset bucket 50Z3 1200/47.2 110/29.1 1000127486 2 2 1
short stick
Offset bucket 50Z3 1400/55.1 130/34.3 1000127487 2 2 1
short stick

Specifications
(l/gal)
Offset bucket 50Z3 1200/47.2 110/29.1 1000127483 2 2 1
long stick
Offset bucket 50Z3 1400/55.1 130/34.3 1000127485 2 2 1
long stick
Offset bucket 5002/6002 1200/47.2 150/39.6 1000017254 X
quickhitch system short
stick
Offset bucket 5002/6002 1400/55.1 180/47.6 1000017255 X
stick
Offset bucket 5002/6002 1200/47.2 150/39.6 1000020878 X
quickhitch system long
stick
Offset bucket 5002/6002 1400/55.1 180/47.6 1000017253 X
stick
Offset bucket 50Z3 1200/47.2 110/29.1 1000127488 2 2 1
stick
Offset bucket 50Z3 1400/55.1 130/34.3 1000127489 2 2 1
stick
Offset bucket 50Z3 1200/47.2 110/29.1 1000127490 2 2 1
stick
Offset bucket 50Z3 1400/55.1 130/34.3 1000127491 2 2 1
stick
Quickhitch system fork 1000012565 1 1
5002/6002
Quickhitch system fork 1000112204 1 1
50Z3/6003
4 Attachment designed for this excavator model (optimal excavation output).
1. Attachment can be mounted but may be subject to restrictions regarding excavation forces, dump-in/out angles and productivity
due to possibly reduced bucket volumes.
2. Same restrictions as for 1 but in addition, mounting these attachments can impair machine stability.
Same restrictions as for 1 and 2 but in addition, subject to possible collision with the boom ram.

Specifications

Maintenance
Maintenance
Maintenance
3 Maintenance
3.1 Fluids and lubricants
Component/ Season/
Engine/machine fluid Specification Capacities1
application temperature
SAE10W-40 2; API: CF, CF-4, CI-4
-20 C (-4 F)
Diesel engine Engine oil ACEA: E3, E4, E5 10.2 l (2.7 gal)
+40 C (104 F)
JASO: DH-1
Q8 T 55, SAE 85W-904
About 1 l each (0.26
Travelling drive Gearbox oil3 Q8 T 55, SAE 80W-905 Year-round
gal)
FINA PONTONIC GLS, SAE85W-90
Hydraulic oil HVLP466
PANOLIN HLP Synth 46
Hydraulic oil tank Year-round 830 l (22 gal)
7 FINA BIOHYDRAN SE 46
Biodegradable oil
BP BIOHYD SE-46
Roller and friction bearings 8 Year-round As required
Grease (live ring ball bearing race) FINA Energrease L21M
Open gear (live ring gears) BP Energrease MP-MG29 Year-round As required
Grease nipples Multipurpose grease FINA Energrease L21 M10 Year-round As required
Battery terminals Acid-proof grease11 FINA Marson L2 Year-round As required
2-D ASTM D975 94 (USA)
1-D ASTM D975 94 (USA)
EN 590 : 96 (EU)
Fuel tank Diesel fuel ISO 8217 DMX (International) 93 l (24.6 gal)
BS 2869 A1 (GB) Summer or winter
diesel depending
BS 2869 A2 (GB) on outside
temperatures
Soft water + antifreeze ASTM D4985
Radiator Coolant Distilled water + antifreeze ASTM Year-round 7 l (1.8 gal)
D4985
Refrigerating agent R134a12 Year-round ~ 950 g (2.1 lb)
Air conditioning 122 cm (7.4 in3)
Compressor oil Sanden SP10 Year-round
from AH00645
Washer system Cleaning agent Water + antifreeze Year-round 2 l (0.5 gal)
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. According to DIN 51502
3. Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)
4. The Q8 T55 SAE 85W-90 gearbox oil is no longer produced
5. The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils!
6. According to DIN 51524 section 3
7. Hydraulic ester oils (HEES)
8. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
9. KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease
10. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS additive
11. Standard acid-proof grease
12. According to DIN 8960

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
SAE 10W
SAE 20W
SAE 10W-30
API CF, CF-4,CI-4 SAE 15W-40

ACEA: E3, E4, E5
JASO: DH-1 SAE 20
SAE 30
SAE 40
F -4 5 14 23 32 41 50 59 68 77 86 95 104
Additional oil change and filter replacement (hydraulics)
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
Application Hydraulic oil Hydraulic oil filter insert

Normal work (excavation work) Every 1000 s/h Replace the first time after 50 s/h, then every 500 s/h
20 % Every 800 s/h
300 s/h
40 % Every 400 s/h
Percentage of hammer work
60 % Every 300 s/h
100 s/h
Over 80 % Every 200 s/h
Important!
Please refer to the maintenance plan on page 3-5 for additional maintenance work.

Maintenance
3.2 Maintenance label

Explanation of symbols on the maintenance label
Symbol 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 clearance. Adjust if necessary
Engine Check the engine oil level
Engine Change 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 hydraulic oil
Hydraulic system Replace the hydraulic oil filter, replace the breather filter

Maintenance
Symbol Assembly Explanation
Radiator fins Clean
Heating, air
Change cab air filter
conditioning
KF K -
KF K - KP - 0
KF K -
KF K - KF K -
KF K -

Maintenance
3-5
Maintenance plan/service hours (s/h)
Maintenance
3.3 Maintenance plan (overview)

Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual
Maintenance
Customer
workshop
Authorised
once a year
Every 50 s/h
(once a day)
of the attachment manufacturer as well.
Every 500 s/h

Every 1000 s/h
Every 1500 s/h
Maintenance work
Fluid and filter changes ( ):
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 oil
Hydraulic oil tank breather
Gearbox oil5,6
Inspection work ( ):
Check the following material. Refill if necessary:
Engine oil
Engine coolant
Hydraulic oil
Gearbox oil
7
Clean water ducts
Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary
Check cooling systems, heating and hoses for leaks and pressure (visual check)
Check the joystick/drive valve pilot control filter for dirt, clean it if necessary8
Replace cab filter for heating and air conditioning
Air filter (damage)
Prefilter with water separator: drain water
Clean
Check V-belt condition and tension
Check exhaust system for damage and condition
Check valve clearance. Adjust if necessary
SERV-HB 6003 EN Edition 2.0 * 6003s311.fm

Work description
Customer
workshop
Authorised
once a year
Every 50 s/h
(once a day)
Every 500 s/h

Every 1000 s/h
Every 1500 s/h
Maintenance work
Clean and adjust the fuel injection pump 9
Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles

Check and adjust injection time 10
Empty diesel fuel tank
Check battery electrolyte. Fill up with 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 gauge
Pressure check of primary pressure limiting valves
Check chains for cracks and cuts
Check chain tension. Retighten if necessary
Check bearing play of tread rollers, track carrier rollers, front idlers
Check piston rods for damage
Check screws for tightness
Check pin lock
Check line fixtures
Check telltales for correct function
Check cab tilt lock, cables and cable holders for damage and correct function
Couplings, dirt pile-up on hydraulic system dust caps
Check insulating mats in the engine compartment for damage/condition
Ensure grease supply of central lubrication system (option)
Check labels and Operator's Manual for completeness and condition
Check function of engine cover gas strut
Lubrication service ( ):
Lubricate the following assemblies/components see Lubrication work on page 3-42:
Stabiliser blade
Swivelling console
3-6
Maintenance
3-7
Work description
Maintenance
Customer
workshop
Authorised
once a year
(once a day)
Every 50 s/h
Every 500 s/h

Every 1000 s/h
Every 1500 s/h
Maintenance work
Boom
Stick
Attachments
Grease strip on chassis see Lubrication strip on page 3-44
Air conditioning ( ):
Carry out the following maintenance and inspection work:
Air conditioning function
Replace cab filter
Check dehumidifier for corrosion, condensation and air bubbles
Replace dehumidifier
Compressor oil 11
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
Lights, signalling system, acoustic warning system
Heating function
Leakage check ( ):
Check for tightness, leaks 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
1. Drain engine oil the first time after 50 s/h, then every 500 s/h
2. Replace the engine oil filter the first time after 50 s/h, then every 500 s/h
3. Replace the fuel filter the first time after 50 s/h, then every 500 s/h
4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h
5. Drain the gearbox oil the first time after 50 s/h, then every 1000 s/h
6. The Q8 T55 SAE 85W-90 gearbox oil is no longer produced. The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils!
7. Clean the water ducts every other 1000 s/h servicing
8. Coarse dirt causes malfunctions and can even destroy the filter screen!
9. Clean and adjust the fuel injection pump every other 1000 s/h servicing
10. Check and adjust injection time every other 1000 s/h servicing
11. Replace the compressor oil every other 1500 s/h servicing

Maintenance
Maintenance
3.4 Service package

Up to serial no. AD07210
1000127022 1 Service package 6003 (Tier 2)
1000125571 1 Engine oil filter
1000106891 1 Fuel filter
1000106892 1 Water separator element
1000069998 1 Seal for diesel fuel filter housing
1000064543 1 O-ring
1000012360 1 O-ring for oil drain plug
1000012847 1 Hydraulic reflux filter insert
1000066727 1 Vent filter
1000022075 1 Air filter insert (inside)
1000022076 1 Air filter insert (outside)
1000115808 1 Cab filter
1000125682 1 Valve cover gasket
1000003894 3 O-ring
From serial no. AH00645
1 Service package 6003 (European Tier 3A American Tier IV
1000178852 interim)
1000018587 1 Engine oil filter
1000172001 1 Fuel filter
1000106892 1 Water separator element
1000069998 1 Seal for diesel fuel filter housing
1000064543 1 O-ring
1000012360 1 O-ring for oil drain plug
1000126919 1 Hydraulic reflux filter insert
1000109215 1 Vent filter
1000113384 1 Air filter insert (inside)
1000113383 1 Air filter insert (outside)
1000115808 1 Cab filter
1000125682 1 Valve cover gasket
1000003894 3 O-ring
3.5 Introduction
Operational readiness and the service life of machines are heavily dependent on
maintenance.
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in
Chapter 2 SAFETY INSTRUCTIONS in the Operator's Manual
The Operator's Manuals of the attachments.
Secure open (engine) covers appropriately. Do not open (engine) covers on slopes or in
strong wind.
Dirt can be blown away and cause severe injuries when using compressed air. Always
wear protective goggles, masks and clothing.
Daily service and maintenance work, and maintenance according to the maintenance plan
must be carried out by a specifically trained driver. All other maintenance work must be
carried out by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be
carried out ( see Maintenance plan (overview) on page 3-5).

Maintenance
3.6 Fuel system

Specific safety instructions
Extreme caution is essential when handling fuel high risk of fire.
Never carry out work on the fuel system in the vicinity of naked flames or sparks.
Do not smoke when working on the fuel system or when refuelling.
Before refuelling, switch off the engine and remove the ignition key.
Do not refuel in closed rooms.
Wipe away fuel spills immediately.
Keep the machine clean to reduce the risk of fire.
Refuelling
Filler inlet A for the fuel tank is located behind the cab, on the left in driving direction. Lock
B on the filler inlet can be opened with the key of the machine. Use handle C to climb onto
A
the chain and as a safe hold during refuelling.
B
Danger!
All work involving fuel carries an increased
Danger of fire and poisoning!
Do not refuel in closed rooms.
Never carry out work on the fuel system in the vicinity of naked flames or
sparks.
Environment!
C Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner.
Important!
Fig. 1: Fuel filler inlet 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 3-10.
Important!
Fill up the tank with the correct fuel type at the end of each working day to prevent
the formation of condensation water in the fuel tank (condensation water damages
the injection pump). Do not fill the tank completely but leave some space for the
fuel to expand.

Maintenance
Stationary fuel pumps General

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually dirty.
Even the smallest particles of dirt can cause
Increased engine wear
Malfunctions in the fuel system and
Reduced effectiveness of the fuel filters
wrong
Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points (see fig. 2):
Barrels must neither be rolled nor tilted before refuelling.
Protect the suction pipe opening of the barrel pump with a fine-mesh strainer.
right Immerse it down to a max. 15 cm (6) above the floor of the barrel.
Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter.
Fig. 2: Refuelling from a barrel Keep all refuelling containers clean at all times.
Diesel fuel specification Use only high-grade fuels.
Grade Use
2-D ASTM D975 94
USA
1-D ASTM D975 94
EN 590: 96 EU
ISO 8217 DMX International
BS 2869 A1
England
BS 2869 A2
Bleeding the fuel system
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
Never bleed the fuel system if the engine is hot.
Bleed the fuel system in the following cases:

After removing and fitting the fuel filter, prefilter or the fuel lines back on again
After running the fuel tank empty
After running the engine again, after it has been out of service for a longer period of
time.
Bleed the fuel system as follows:
Fill up the fuel tank.
Turn the ignition key to the first position.
Wait about 5 minutes while the fuel system bleeds itself automatically.
Start the engine.
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
Bleed the fuel system again as described above.
Have this checked by authorised staff if necessary.

Maintenance
Emptying the fuel tank
A Danger!
Danger of burns!
Never bleed the fuel system if the engine is hot.
Fig. 3: Fuel drain plug

Due to dirt deposits and condensation water in the fuel tank, empty the fuel tank every 500
service hours as follows:
Place a container with sufficient capacity underneath the drain plug A/fig.3 in the
chassis.
Open the drain plug to drain the fuel.
Check the fuel tank for contamination and clean if necessary.
Replace the filter according to the maintenance specifications.
Screw the drain plug back in correctly.
Fill up the fuel tank.
Bleed the fuel system see chapter Bleeding the fuel system on page 3-10.
Fuel prefilter with water separator

Check the fuel prefilter as follows:
On If the red indicator ring rises to position C,
unscrew thread A.
Off The water drains.
Wait until the indicator ring returns to the bottom of the water separator.
Screw thread A back on again.
B
Interrupt fuel supply as follows:
Turn ball-type cock B to the OFF mark.
Fuel supply is interrupted.
Turn ball-type cock B to the ON mark.
C Fuel supply is open again.
A
Environment!
Fig. 4: Fuel prefilter
Thread A is fitted with a hose. Collect the water as it drains with a suitable container and
dispose of it in an environmentally friendly manner.

Maintenance
Replacing the fuel filter

Old engine type (up to serial number AD07210):
B Danger!
Danger of burns!
A
Never change the fuel filter if the engine is hot.
Fig. 5: Fuel filter position

Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
A
New engine type (from serial number AH00645):
Change fuel filter 5/A as follows:

Close the fuel feed line with the stop cock on the fuel prefilter.
Thoroughly clean the outside surfaces of fuel filter 5/A.
Place a suitable container under the filter.
Slacken and unscrew fuel filter cartridge using a commercially available tool.
Collect the fuel as it drains.
Fig. 6: Unscrewing the fuel filter
Clean the sealing surface of the filter carrier if it is dirty.

Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel
fuel to it.
Screw on the cartridge by hand until the gasket makes contact.
Fig. 7: Cleaning the sealing surface and oiling the gasket
Tighten the fuel filter cartridge by turning it a further half revolution.

Open the stop cock on the water separator again.
Bleed the fuel system see Bleeding the fuel system on page 3-10.
Make a test run and check for tightness.
Dispose of the old fuel filter cartridge by an ecologically safe method.
Fig. 8: Tightening the fuel filter

Maintenance
3.7 Engine lubrication system
Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
Engine damage or loss of output!
Have the oil changed by an authorised workshop see Maintenance plan
(overview) on page 3-5.
Checking the oil level
Important!
Check the oil level once a day. We recommend checking it before starting the
engine. After switching off a warm engine, wait at least 5 minutes before checking.
Checking the oil level

Proceed as follows:
Park the machine on level ground.
A Switch off the engine.
max
min
Fold the control lever base up.
Let the engine cool down.
Open the engine cover.
Clean the area around the oil dipstick with a lint-free cloth.
Pull out oil dipstick A.
Wipe it with a lint-free cloth.
Push oil dipstick A back in as far as possible.
Withdraw it and read off the oil level.
However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
Fig. 9: Checking the oil level
oil dipstick A.

Maintenance
Filling up engine oil
Caution!
Too much or incorrect engine oil can result in engine damage! For this reason:
Do not add engine oil above the MAX mark of oil dipstick 10/A.
Use only the specified engine oil.
Use engine oils of the same brand and grade => never mix different oils.
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
Proceed as follows:
Clean the area around oil filler cap B with a lint-free cloth.
B OIL
Open filler cap B.
Raise oil dipstick A slightly to allow any trapped air to escape.
A Fill in engine oil.
Wait about 3 minutes until all the oil has run into the oil sump.
Check the oil level see Checking the oil level on page 3-13.
Fill up if necessary and check the oil level again.
Close filler cap B.
Push oil dipstick A back in as far as possible.
Fig. 10: Oil dipstick and oil filler cap Completely remove all oil spills from the engine.

Maintenance
Changing engine oil
Danger!
Caution when draining hot engine oil
Danger of burns!
+ 80 C
+176 F Wear protective gloves.
Use suitable tools.
OIL
Fig. 11: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
Change the engine oil as follows:

Let the engine run until it reaches its operating temperature (oil temperature about 80
C/176 F).
Place a container under the opening to collect the oil as it drains.
Unscrew the oil drain plug.
Completely drain the oil.
Screw the oil drain plug back on again.
Fill in engine oil see chapter Filling up engine oil on page 3-14.
Start the engine and let it run briefly at low revs.
Wait a moment until all the oil has run into the oil sump.
Check the oil level again.
Fill up if necessary and check again.
Completely remove all oil spills from the engine.

Maintenance
Replacing the engine oil filter cartridge
Danger!
Caution when draining hot engine oil
A
Danger of burns!
Wear protective gloves.
Fig. 12: Engine oil filter position

Environment!
Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an
Change the filter as follows:
Place a suitable container underneath the oil filter to collect the oil as it drains.
Slowly slacken oil filter cartridge A using a commercially available tool.
A Let the oil drain into the container.
Remove the filter cartridge once the oil is completely drained.
Make sure the thread adapter is correctly placed in the filter head.
Fig. 13: Unscrewing the engine oil filter
Clean the inside of the filter head.

Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge.
Tighten the new filter cartridge by hand until the gasket makes contact.
Fig. 14: Cleaning the filter head and oiling the gasket
Tighten oil filter cartridge A by hand by about a further half revolution.

Make sure the oil level is correct.
A
Let the engine run briefly.
Check the seal of oil filter cartridge A and retighten by hand.
Check the oil level and fill in engine oil if necessary.
Dispose of the used oil filter in an environmentally friendly manner.
Fig. 15: Tightening the filter cartridge

Maintenance
3.8 Cooling system

The oil and water cooler is located in the engine compartment, on the right side of the
engine.
The expansion tank for the coolant is also located in the engine compartment, in front of
the oil cooler.
Specific safety instructions Dirt on the radiator fins reduces the cooler's heat dissipation capacity! To avoid this:
Clean the outside of the radiator at regular intervals. Use oil-free compressed air
(2 bar/29 psi max.) to clean. Maintain a certain distance to the radiator to avoid
damage to the radiator fins. Refer to the maintenance plans in the appendix for the
cleaning intervals.
In dusty or dirty work conditions, clean more frequently than indicated in the
maintenance plans.
An insufficient coolant level reduces the heat dissipation capacity as well and can lead
to engine damage. Therefore:
Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals.
If coolant must be added frequently, check the cooling system for leaks and/or
contact your dealer.
Never fill in cold water/coolant if the engine is warm.
After filling the expansion tank, test run the engine and check the coolant level again
after switching off the engine.
The use of the wrong coolant can destroy the engine and the cooler. Therefore:
Add enough antifreeze compound to the coolant but never more than 50 %. If
possible use brand-name antifreeze compounds with anticorrosion additives.
Observe the coolant compound table see Coolant compound table on page 2-7.
Do not use cooler cleaning compounds if an antifreeze compound has been added to
the coolant otherwise this causes sludge to form, which can damage the engine.
Once you have filled the expansion tank:
Test run the engine.
Check the coolant level again.
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in an

Maintenance
Checking/filling up coolant
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
Wait at least 15 minutes after switching off the engine.
Wear protective gloves and clothing.
Open filler cap B to the first notch and release the pressure.
Make sure the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands.
Danger!
Antifreeze is flammable and poisonous
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.
Checking the coolant level
Proceed as follows:
A Park the machine on level ground.
Remove the key and carry it with you.
Let the engine and the coolant cool down.
Check the coolant level on the transparent coolant tank A and on the radiator B.
If the coolant level is below the LOW seam or if there is no coolant at the radiator's
FULL filler inlet:
LOW
Fill up coolant.
Fig. 16: Expansion tank for coolant
Important!
Check the coolant level once a day. We recommend checking it before starting the
engine.

Maintenance
Filling up coolant
After the engine has cooled down:
B Release overpressure in the radiator.
Carefully open the cap to the first notch and fully release the pressure.
Open filler cap B.
Fill in coolant up to the lower edge of the filler inlet (radiator).
Close filler cap B.
Start the engine and let it warm up for about 5 10 minutes
Fig. 17: Radiator filler cap
Check the coolant level again.
The coolant level must be between the LOW and FULL tank seams.
If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant.
Important!
Check the antifreeze every year before the cold season sets in.
Draining coolant
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure
Danger of burns!
Wait at least 10 minutes after switching off the engine.
Wear protective gloves and clothing.
Open filler cap 17/B to the first notch and release the pressure.
After the engine has cooled down:

Release overpressure in the radiator.
Open the cap to the first notch and fully release the pressure.
Open filler cap 17/B.
Open the drain plug of the radiator and drain the coolant.
Close the drain plug again.
Fill up the radiator with suitable coolant see Fluids and lubricants on page 3-1.
Check the coolant level see Checking the coolant level on page 3-18.

Maintenance
3.9 Air filter
Caution!
The filter cartridge is damaged if it is washed or brushed out.
Bear in mind the following to avoid premature engine wear:
Do not clean the filter cartridge.
Replace the filter cartridge when the telltale comes on.
Never reuse a damaged filter cartridge.
Ensure cleanliness when replacing the filter cartridge.
X Telltale X in the round display element monitors the filter cartridge.

Replace outside filter B and inside filter C:
If telltale X in the round display element comes on.
According to the maintenance plan.
Important!
For applications in especially dusty environment, the air filter is fitted with an
extra inside filter C. Do not clean inside filter C.
B
C Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
Replace outside filter B and inside filter C at the latest after 50 service
hours.
Fig. 18: Air filter up to serial no. AD07210
from serial no. AH00645
General instructions for air filter maintenance:
Store filters in their original packaging and in a dry place.
Do not knock the filter against other objects as you install it.
Check air filter attachments, air intake hoses and air filters for damage, and
immediately repair or replace if necessary.
Check the screws at the induction manifold and the clamps for tightness.
Check the function of the dust valve, replace if necessary.
B

Maintenance
Replacing the filter

Replace outside filter 20/B as follows:
D Switch off the engine.
E Open the engine cover.
Remove dirt and dust from the air filter and the area around the air filter.
Fold both bow clips 19/D on lower housing section 19/E to the outside.
Remove lower housing section E.
Fig. 19: Removing the lower housing section Carefully remove outside filter B with slightly turning movements.
Make sure all dirt (dust) inside the upper and lower housing sections, including the dust
valve, has been removed.
B Clean the parts with a clean lint-free cloth, do not use compressed air.
Check the air filter cartridges for damage, only install intact filters.
Carefully insert new outside filter B in the upper housing section.
Position lower housing section E (make sure it is properly seated).
Close both bow clips D.
Fig. 20: Removing the filter element
Replace inside filter 21/C as follows:

F Switch off the engine.
Remove dirt and dust from the air filter and the area around the air filter.
C Fold both bow clips D on lower housing section E to the outside.
Remove lower housing section E.
Fig. 21: Replacing the inside filter up to serial no. Carefully remove outside filter B with slightly turning movements.
AD07210
Carefully remove inside filter C.
Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
F from entering the engine.
Make sure all dirt (dust) inside the upper and lower housing sections 21/F, including
dust valve 22/G, has been removed.
Clean the parts with a clean lint-free cloth, do not use compressed air.
Remove the cloth from the air supply.
Check the air filter cartridges for damage, only install intact filters.
C Carefully insert the new inside filter C in the inside housing section F.
Carefully insert outside filter B in the upper housing section.
D
Position lower housing section E (make sure it is properly seated).
Close bow clips D.
D
Important!
Make sure dust valve G shows downwards once it is installed.

Maintenance
Functional check once a week of the dust valve

The air filter is located in the engine compartment, on the right-hand side of the machine.
Proceed as follows:
Apply the parking brake.
Squeeze the discharge slot of dust valve 22/G.
Remove hardened dust by squeezing the upper area of the valve.
Clean the discharge slot if necessary.
Fig. 22: Air filter dust valve

Maintenance
3.10 V-belt
Danger!
Only check or retighten/replace the V-belt when the engine is switched off
Danger of personal injury!
Switch off the engine before carrying out inspection work in the engine
compartment.
Disconnect the battery or the battery master switch.
Caution!
Cracked and stretched V-belts cause engine damage.
Have the V-belt replaced by an authorised workshop.
Check the V-belt once a day, and retighten if necessary!

Retighten new V-belts after about 15 minutes of running time.
Checking V-belt tension

Check as follows:
1
Carefully check V-belt 1 for damage, cracks or cuts.
Replace the V-belt if it touches the base of the V-belt groove or the discs of the
pulley.
Fig. 23: Checking V-belt tension If the V-belt is damaged:
Have the V-belt replaced by authorised staff.
Press with your thumb to check the deflection of the V-belt between the crankshaft
disc and the fan wheel position 23/C. A new V-belt should have a deflection of 6 to
8 mm (0.2 0.3), a used V-belt (after about 5 minutes running time) should have a
deflection of 7 to 9 mm (0.3 0.35)
Retighten the V-belt if necessary.

Maintenance
Retightening the V-belt
Caution!
Overtightening the V-belt can damage the V-belt, the V-belt guide and the
water pump bearing. Avoid contact of oil, grease or similar substances with the
V-belt.
Check V-belt tension see Checking V-belt tension on page 3-23.
Retighten as follows:
2 Fold the control lever base up.
A Open the engine cover.
Slacken fastening screws 2 of alternator 3.
Use a suitable tool to push the alternator in the direction of arrow A until reaching the
correct V-belt tension (fig. 24).
3
Keep the alternator in this position, and at the same time retighten fastening
Fig. 24: Retightening the V-belt screws 2.
Check V-belt tension again and adjust it if necessary.
Connect the battery or the battery master switch.
Close the engine cover.

Maintenance
Checking the V-belt of the air conditioning system
Caution!
Excessive or insufficient tension of the V-belt can cause damage to the V-belt
or to the compressor of the air conditioning system.
Always make sure the V-belt has the correct tension.
Replace V-belts with damage, cracks, cuts etc.
Avoid contact of oil, grease or similar substances with the V-belt.
Check as follows:
2
About 9 mm
1 Let the engine cool down.
Carefully check V-belt 1 for damage, cracks or cuts.
Replace the V-belt if it touches the base of the V-belt groove or the discs of the
Fig. 25: Checking the V-belt tension of the air conditioning pulley.
system
If the V-belt is damaged:
Have the V-belt replaced by authorised staff.
Press with your thumb to check the deflection of the V-belt. A new V-belt should have
a deflection of 7 to 9 mm (0.3 0.35), a used V-belt (after about 5 minutes running
time) should have a deflection of 9 to 11 mm (0.35 0.4).
Retighten the V-belt if necessary.
Tightening the V-belt of the air conditioning system

Retighten as follows:
3 Switch off the engine.
A Slacken fastening screw 3 of alternator 2.
Use a suitable tool to push the compressor in the direction of arrow A until reaching
the correct V-belt tension (fig. 26).
Fig. 26: Retightening the V-belt of the air conditioning sys-
tem Keep the compressor in this position, and at the same time retighten fastening screw
3.
Check V-belt tension again and adjust it if necessary.
Connect the battery or the battery master switch.
Close the engine cover.

Maintenance
3.11 Pressure check

General
Run the machine warm before checking the pressure. The hydraulic oil should have a
minimum temperature of 50 C/122 F (operating temperature).
Pressure drop is checked by reducing revs from maximum to idling speed at constant
load.
Set the primary pressure limiting valves (PPLV) at maximum engine revs.
Pressure settings: see Hydraulic system on page 2-3.
Ensure utmost cleanliness of all measuring points, measuring ports, micro
measuring lines and pressure gauges that are connected for checking pressure
=> even the slightest traces of dirt, e.g. a grain of sand, can impair tightness and
cause leaks.
Checking pilot control pressure

Checking pilot control pressure
Connect a pressure gauge to measuring port MP 4.
Move the control lever base (safety switch) to work position.
Check and make a note of the pressure value.
Fig. 27: Pilot control pressure measuring port
Adjusting pilot control pressure limiting valve 4 (PLV 4)

Adjust the pressure at pressure limiting valve 4 (PLV4) 27/4 at the pilot oil supply unit.
Check the pilot control pressure again once adjustment is over.
Fig. 28: Pressure reducing valve

Maintenance
Pressure check of variable displacement pump P1

Hydraulic supply for boom, bucket and left-hand side drive functions
Checking primary pressure limiting valve 1 (PPLV 1)

Connect a pressure gauge to measuring port MP 1 29/1.
Extend the boom ram as far as it will go at maximum engine revs.

1 Checking pressure drop

Extend the boom ram as far as it will go at maximum engine revs.
Swiftly reduce engine revs from maximum to minimum -> pressure drop.
Fig. 29: Measuring port P1 Check and make a note of the pressure value.
Pressure drop should not exceed the specified value by more than 10 %.
Adjusting primary pressure limiting valve 1 (PPLV 1)

Adjust the pressure at the primary pressure limiting valve (PPLV 1) 30/A on the main
valve block.
Slacken the locknut of the pressure limiting valve.
Unscrew the pressure limiting valve until you can read off a pressure drop on the
pressure gauge.
A The valve seat may be stuck and must be slackened first.
Adjust the pressure limiting valve and tighten the locknut.
Check the primary pressure limiting valve 1 and the pressure drop once adjustment is
over.
Also check with the retract boom, the extend/retract bucket and with the left-hand
side forwards/reverse drive functions!
Fig. 30: Primary pressure limiting valve 1

Maintenance
Pressure check of variable displacement pump P2

Hydraulic supply of stick, right-hand side drive and auxiliary hydraulics functions

Extend the stick ram as far as it will go at maximum engine revs.

Checking pressure drop

2 Extend the stick ram as far as it will go at maximum engine revs.

Adjust the pressure at the primary pressure limiting valve (PPLV 2) 32/B on the main
valve block.
pressure gauge.
The valve seat may be stuck and must be slackened first.
B
over.
Also check with the retract stick and the right-hand side forwards/reverse drive
functions!
Fig. 32: Primary pressure limiting valve 2 Checking the auxiliary hydraulics pressure
Important!
Factory indications for auxiliary hydraulics secondary valves are possibly invalid
since the valves must be adapted to the attachment.

Maintenance
Pressure check of gear pump P3

Hydraulic supply for stabiliser blade, auxiliary hydraulics/boom swivel, upper carriage
rotation

Extend the stabiliser blade ram as far as it will go at maximum engine revs.
Checking pressure drop

3 Extend the stabiliser blade ram as far as it will go at maximum engine revs.

Adjust the pressure at the primary pressure limiting valve (PPLV 3) on the main valve
block.
pressure gauge.
C over.
Also check with the retract stabiliser blade, boom swivel and rotate functions
Checking the auxiliary hydraulics pressure

Fig. 34: Primary pressure limiting valve 3
Important!
Factory indications for auxiliary hydraulics secondary valves are possibly invalid
since the valves must be adapted to the attachment.

Maintenance
Secondary pressure limiting valve of the gear motor

Check (at idling speed)
1 Connect a pressure gauge to measuring port MP 3 of the gear pump.
Place the bucket or the boom against the ground or the stabiliser blade, or drive against
hydraulic resistance.
Adjusting the secondary pressure limiting valve on the gear motor (at idling speed)
Adjust the pressure at the secondary pressure limiting valve on the gear motor.
pressure gauge.
Fig. 35: Secondary pressure limiting valve
Check the secondary pressure limiting valve again once adjustment is over.
Measuring ports: overview
Pos. Description
1 Measuring port for pump 1 MP 1
1 4 Pilot oil supply unit measuring port MP 4
4 3
Fig. 36: Measurement ports
Primary pressure limiting valves
1 2 1 2
4
3
3
Pos. Description
1 Pump primary pressure limiting valve 1 PPLV 1
4 Pilot control pressure limiting valve PLV 4

Maintenance
3-31
3.12 Test report
Pilot control
Specified values 1st measurement 2nd measurement
Pressure limiting
Maintenance
Function Movement Symbol Measuring port Engine

valve Pressure in bar (psi)
speed
Pressure reducing
Measuring port Rated
Joystick ANY valve PRV 4 (pilot 421 (60914.5)
MP 4 (pump) value
oil supply unit)
Pump 1
Pressure limiting
Function Movement Symbol Measuring port Specified values 1st measurement 2nd measurement
valve
max. 2403 (348143.5)
UP
Min. 2163 (313343.5)
Boom 1
max. 2403 (348143.5)
DOWN
Min. 2163 (313343.5)
max. 2403 (348143.5)
EXTEND
Min. 2163 (313343.5)
Bucket
max. 2403 (348143.5)
(pump)
PPLV 1
RETRACT
Min. 2163 (313343.5)
(main valve block)

max. 2403 (348143.5)
Measuring port MP 1
FORWARDS
Left-hand side Min. 2163 (313343.5)
Primary pressure limiting valve

drive max. 2403 (348143.5)
REVERSE
Min. 2163 (313343.5)
Pump 2
Pressure limiting
Function Movement Symbol Measuring port Specified values 1st measurement 2nd measurement
valve
max. 2403 (348143.5)
EXTEND Primary pressure
Measuring port Min. 2163 (313343.5)
Stick limiting valve
MP 2 (pump) max. 2403 (348143.5)
RETRACT PPLV 2 (MVB)
Min. 2163 (313343.5)

3.12 Test report
max. 2403 (348143.5)
FORWARDS
Right-hand Min. 2163 (313343.5)
side drive max. 2403 (348143.5)
REVERSE
Min. 2163 (313343.5)
max. 2403 (348143.5)
A
Auxiliary Min. 2163 (313343.5)

hydraulics max. 2403 (348143.5)
B
Min. 2163 (313343.5)
(MVB)
(pump)
PPLV 2
max. 2403 (348143.5)
LEFT
3rd control Min. 2163 (313343.5)
Measuring port MP 2
circuit (option) max. 2403 (348143.5)
RIGHT
Primary pressure limiting valve

Min. 2163 (313343.5)
max. 2403 (348143.5)
Boom 2 UP
Min. 2163 (313343.5)
Pump 3
Specified values
Pressure limiting
Function Movement Symbol Measuring port Engine 1st measurement 2nd measurement
speed
max. 240-0/+3 (3481-0/+43.5)
UP
Stabiliser Min. 216-0/+3 (3133-0/+43.5)
blade Primary pressure max. 240-0/+3 (3481-0/+43.5)
DOWN Measuring port
limiting valve Min. 216-0/+3 (3133-0/+43.5)
MP 3
PPLV 3 max. 240-0/+3 (3481-0/+43.5)
A (2) (pump)
Auxiliary (main valve block) Min. 216-0/+3 (3133-0/+43.5)
hydraulics max. 240-0/+3 (3481-0/+43.5)
B (2)
Min. 216-0/+3 (3133-0/+43.5)
3-32
Maintenance
3-33
3.12 Test report
Primary pressure max. 240-0/+3 (3481-0/+43.5)
LEFT Measuring port
limiting valve Min. 216-0/+3 (3133-0/+43.5)
Swivel boom MP 3
Maintenance
PPLV 3 max. 240-0/+3 (3481-0/+43.5)

RIGHT (pump
(main valve block) Min. 216-0/+3 (3133-0/+43.5)
Specified values
Pressure limiting
Function Movement Symbol Measuring port Engine 1st measurement 2nd measurement
speed
Primary pressure max. 240-0/+3 (3481-0/+43.5)
Triple articula- UP limiting valve Measuring port Min. 216-0/+3 (3133-0/+43.5)
tion boom PPLV 3 (main MP 3 (pump) max. 240-0/+3 (3481-0/+43.5)
(option) DOWN valve block) Min. 216-0/+3 (3133-0/+43.5)
LEFT Secondary Rated
Upper 2153 (311843.5)
pressure limiting value
carriage Gear motor
valve SPLV 4 Rated
rotation RIGHT 2153 (311843.5)
(gear motor) value

Maintenance
Maintenance
3.13 Hydraulic system

Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
Lower all hydraulically controlled attachments to the ground
Move all control levers of the hydraulic control valves several times.
Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Therefore always consult a doctor immediately, even in the case of minor
wounds otherwise serious infections could set in.
If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This can cause damage to the hydraulic pump.
Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slack nuts and damaged
hoses and lines are detected.
Contact your Neuson dealer immediately.
Replace the hose or line if one of the problems mentioned below is detected.
Damaged or leaky hydraulic seals.
Worn or torn shells or uncovered reinforcement branches.
Expanded shells in several positions.
Entangled or crushed movable parts.
Foreign bodies jammed or stuck in protective layers.
Caution!
Dirty hydraulic oil, lack of oil or wrong hydraulic oil
Danger of severe damage to the hydraulic system!
Take care to avoid dirt when working.
Always fill in hydraulic oil by means of a strainer or the reflux filter.
Only use authorised oils of the same type see Fluids and lubricants on
page 3-1.
Always fill up hydraulic oil before the level gets too low see Filling up
hydraulic oil on page 3-36.
If the hydraulic system is filled with biodegradable oil, then only fill up with
biodegradable oil of the same type observe the sticker on the hydraulic oil
tank.
Contact customer service if the hydraulic system filter is dirty and contains
metal chippings. Otherwise, follow-on damage can result.
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container. Dispose of
drained oil and used filters by an ecologically safe method. Always contact the relevant
authorities or commercial establishments in charge of oil disposal before disposing of
biodegradable oil.

Maintenance
Checking the hydraulic oil level
Caution!
Do not fill up oil if the oil level is above the FULL mark, otherwise the hydraulic
system can be damaged and escaping oil can cause serious injuries.
Check the hydraulic oil level each time the machine is put into operation or
once a day.
If the attachment is not positioned as shown:

Start the engine and let it run at idling speed
Retract the bucket and boom rams, lower the boom and the bucket teeth to the
ground
Fig. 37: Parking the excavator Switch off the engine again.
B Proceed as follows:
B Park the machine on level ground.
FULL
LOW
Sight glass B is located on hydraulic oil tank.
Check the oil level on sight glass B.
The oil level must be at the FULL level.
A gauge element in sight glass B indicates the oil level.
If the oil level is lower,
Fill up hydraulic oil.
The oil level varies according to the machine's operating temperature:
Machine condition Temperature Oil level

Before putting into Between 10 and 30 C LOW mark
operation (50 and 86 F)
Normal operation Between 50 and 90 C FULL mark
(122 and 194 F)
Fig. 38: Oil level indicator on the hydraulic oil tank
Important!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.

Maintenance
Filling up hydraulic oil

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will
overflow at the filler opening on the hydraulic tank.
Fill up as follows:
Position the machine as shown in fig. 37.
Clean the area around filler opening C with a lint-free cloth.
Open filler opening C.
Fill in clean hydraulic oil through the screen.
Check the hydraulic oil level on sight glass B.
Close filler opening C.
Fig. 39: Hydraulic oil filler inlet with screen
Important!
You can also refill through the reflux filter to avoid contamination of the hydraulic
oil as you fill up.

Maintenance
Changing hydraulic oil
Important!
Only change the hydraulic oil if it is warm (about 50 C/122 F). Retract all
hydraulic rams before changing the oil.
Open the breather filter to release pressure.

Open drain plug 40/B and let the oil drain into a container.
B
Check the hydraulic oil tank for dirt and clean if necessary.
Replace the filter according to the maintenance specifications.
Screw the drain plug back in correctly.
Fill in clean hydraulic oil through the strainer see Filling up hydraulic oil on page 3-36.
Fig. 40: Hydraulic oil drain plug
Close the hydraulic oil tank correctly.
Let the machine run at idling speed without load for some minutes.
Monitoring the hydraulic oil reflux filter
Pressure switch A activates the red telltale X in the instrument panel which monitors the
X reflux filter.
The filter element must be replaced by an authorised workshop:
If telltale X comes on when the hydraulic oil is at operating temperature,
at the latest after 1000 service hours (once every year).
In cold weather telltale X can come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
Set engine speed so that telltale X goes out.
Fig. 41: Telltale for reflux filter
Fig. 42: Reflux filter pressure switch

Maintenance
Checking hydraulic pressure lines

Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
Always consult a doctor immediately, even if the wound seems insignificant
otherwise serious infections could set in.
Always observe the following instructions:
Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines.
Never weld or solder damaged or leaking pressure lines and screw
connections. Replace damaged parts with new ones.
Never search for leaks with your bare hands, but wear protective gloves.
Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame.
Have damaged flexible lines replaced by authorised workshops only.
Leaks and damaged pressure lines must be immediately repaired or replaced by an

authorised workshop or after-sales staff. This not only increases the operating safety of
your machine but also helps to protect the environment.
Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged.
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and
occupational health and safety in your country. Also observe DIN 20066, part 5.
1 Q/06 The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication 1 Q/06 means manufactured in the 1st quarter of 2006.
3.14 Travelling drive

Danger!
Immediately after switching off the engine, the engine's components and the
oil are very hot. This can cause burns. If the inside of the drive gear is under
pressure, the oil or the plug can be squeezed out.
Danger of injury and scalding!
Wait until the engine has cooled down before taking up work.
Slowly open the plug to reduce the pressure inside.

Maintenance
Caution!
The Q8 T55 SAE 85W-90 gearbox oil is no longer produced.
Therefore the Q8 T55 80W-90 gearbox oil is used from 10/2006 onwards.
Do not mix both oils under no circumstances!
Checking the oil level and filling up oil
Park the machine on firm and horizontal ground.
A
Place the machine so that filler plug A is at the top.
B Let the engine cool down.
Unscrew screws A and B with a suitable tool.
Fig. 43: Checking the oil level A small quantity of oil must flow out of opening B.
If the oil does not flow out of opening B, fill up oil:
Fill in oil through opening A,
until a small quantity of oil flows out of opening B.
Screw screws A and B back in again.
Move the machine a few metres.
If the oil level is not correct:
Repeat the procedure.
Draining oil
B
Place the machine so that filler plug A is at the bottom.
A Let the engine cool down.
Unscrew screws A and B with a suitable tool.
Fig. 44: Draining oil The oil now flows out of opening A.
Use a suitable container to collect the oil as it drains.
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly
manner.

Maintenance
3.15 Chains
Chain wear can vary according to work and ground conditions.
We recommend checking chain wear and tension once a day.
Park the machine on firm and level ground to check and carry out maintenance.
Checking chain tension
Danger!
Working under the machine with the chains off the ground and only supported
by the attachment is extremely dangerous.
Caution, danger!
Firmly support the machine with chocks or suitable brackets.
Check chain tension as follows:

The rubber chain has a mark B as shown in Fig. 45.
Place the excavator so that mark B of the rubber chain is between the drive pinion C
and the chain tension roller D.
B
Important!
D C
There is no mark on the steel chains (options). Positioning the steel chains is not
possible.
No specific position is required for the steel chains (option).
Fig. 45: Rubber chain mark
Park the machine on firm and level ground.

Raise the excavator with the boom and the stick.
Slowly and carefully actuate the control levers.
Fig. 46: Raising the excavator Use suitable auxiliary means to support the machine.
Standard play between the sliding block's shoulder and the contact area of the second
support roller of the drive pinion is 20 25 mm (1.0 1.2).
Set the tension as follows if it is not in accordance with the rated value.
20 25 mm
(1.0 1.2)
Fig. 47: Measuring distance

Maintenance
Setting the chains
Danger!
The lubricating valve can be squeezed out due to the high grease pressure in
the hydraulic ram.
Do not slacken and unscrew the lubricating valve by more than one turn.
Slacken no other component except the lubricating valve.
Keep your face away from the lubricating valve connection.
Contact your Neuson dealer if this does not reduce the tension of the
rubber sliding block.
Caution!
Excessive tension of the chains causes severe damage to the ram and the
chain.
Tighten the chains only up to the prescribed measuring distance.
Tightening the chains

Inject grease with the pump through lubricating valve A.
Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again.
Check the tension of the track chains again.
If it is not correct:
Adjust again.
Should the track chain still be slack after injecting more grease, replace the chain or the
seal in the ram. Contact a Neuson dealer in this case.
A
Fig. 48: Tightening the chains 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.
Slowly open the lubricating valve A by 1 turn to allow the grease to flow out.
Place a suitable container underneath to collect the grease.
The grease flows out of the groove of the lubricating valve.
Retighten the lubricating valve A.
A Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again.
Fig. 49: Draining grease
Check the tension of the track chains again.
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

Maintenance
3.16 Lubrication work

Apply multipurpose lithium grease with an MoS additive to all lubrication points indicated.
Stabiliser blade
Apply grease to lubrication points A on the stabiliser blade ram.
Apply grease to lubrication points B on the stabiliser blade.
Fig. 50: Lubrication points on the stabiliser blade
Lubrication points on the swivelling console

Apply grease to lubrication points C of the swivelling console.
Fig. 51: Lubrication points on the swivelling console

Maintenance
Boom lubrication points

Apply grease to lubrication points D on the boom.
Fig. 52: Boom lubrication points
Lubrication points on the stick

Apply grease to lubrication points E on the stick.
Fig. 53: Lubrication points on the stick

Maintenance
Lubrication strip
Apply grease to the lubrication strip as follows:
Lubrication point A for live ring ball bearing
Grease: BP Energrease MP-MG2
C
Lubrication point B for the offset ram
A Important!
Apply grease to lubrication points A and B once a day.
B
A portable lamp can be connected to the lubrication strip's 12 V connection C.
Fig. 54: Lubrication strip on the chassis
Maintenance of attachments
Important!
Correct maintenance and service is absolutely necessary for smooth and
continuous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments.

Maintenance
3.17 Electric system

The battery contains sulphuric acid. This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
Always wear goggles and protective clothing with long sleeves.
If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water.
Thoroughly wash any part of the body touched by the sulphuric acid immediately with
plenty of water and seek medical attention at once.
Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells danger of explosion.
Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode.
Replace the battery immediately.
Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells
otherwise the gas produced during normal battery operation can ignite.
Use only 12 V power sources. Higher voltages will damage the electric components.
When connecting the battery leads, make sure the poles +/ are not inverted, otherwise
sensitive electric components will be damaged.
Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking.
Never place tools or other conductive articles on the battery danger of short circuit.
Disconnect the negative () battery terminal from the battery before starting repair work
on the electric system.
Dispose of used batteries properly.
Service and maintenance work at regular intervals
Before driving the machine

Check every time before driving the machine:
Is the light system OK?
Is the signalling and warning system OK?
Every week
Check once a week:
Electric fuses see Fuse box on the instrument panel up to serial no. AD07210 on
page 2-5.
Cable and earth connections.
Battery charge condition see Battery on page 3-47.
Condition of battery terminals.

Maintenance
Instructions concerning specific components

Cables, bulbs and fuses
Defective components of the electric system must always be replaced by an authorised
expert. Bulbs and fuses may be changed by unqualified persons.
When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses.
Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse.
Only use fuses with the specified load capacity (amperage) see Fuse box on the
instrument panel up to serial no. AD07210 on page 2-5.
Important!
Always disconnect and remove the battery before carrying out welding work on the
machine, and short-circuit the terminal cables of the machine to avoid damage to
the electronic components.
Alternator Always observe the following instructions:

Only test run the engine with the battery connected.
When connecting the battery, make sure the poles (+/) are not inverted.
Always disconnect the battery before carrying out welding work or connecting a quick
battery charger.
Replace defective charge telltales immediately see Telltale (red) alternator charge
function on page 1-11.

Maintenance
Battery
Danger!
Battery acid is highly caustic.
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
Always wear goggles and protective clothing with long sleeves.
If acid is spilt:
Thoroughly rinse all affected surfaces immediately with plenty of water.
Thoroughly wash any part of the body touched by the sulphuric acid
immediately with plenty of water and seek medical attention at once.
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells
Danger of explosion!
Avoid naked lights and sparks in the vicinity of the battery and do not
smoke.
Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode.
Replace the battery immediately.
Always disconnect the negative terminal () from the battery before starting
repair work on the electric system.
A The battery A is located in the chassis underneath the cab behind the gear motor. The
battery is maintenance-free. However have the battery checked at regular intervals to
make sure the electrolyte level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be carried out by an authorised
workshop.
Always follow the specific battery safety instructions.
Fig. 55: Battery
Important!
Do not disconnect the battery while the engine is running.
Jump-starting the engine

Connect the plus lead of the starting aid with plus lead B on the battery master switch of
A the machine requiring jump-start.
Connect the earthing lead of the starting aid to a bare part of the chassis of the machine
with the flat battery.
Charge the flat battery for a few minutes.
+ Start the engine.
Remove the earthing lead of the starting aid from the chassis.
Remove the plus lead of the starting aid from the emergency off switch.
Fig. 56: Battery master switch

Maintenance
3.18 Cab
Check cab bearings B for damage.
Important!
B
Check the cab fastening screws for tightness, retighten with a suitable tool if
necessary see chapter Tightening torques for high-resistance screw
connections on page 2-10.
Fig. 57: Cab bearing
Replacing the cab filter

Tilt the cab to replace the filter see Tilting the cab on page 1-19.
The heater is located at the rear half of the cab.
Replacing the filter:

Slacken the heater cover.
The cab filter can be accessed fig. 58.
Remove the cab filter.
Insert a new cab filter.
Fit the heater cover back on again.
Fig. 58: Cab filter

Maintenance
3.19 General maintenance work

Cleaning
Cleaning the machine is divided into 3 separate areas:
Inside the cab
Exterior of the machine
Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. It is therefore essential to observe the following instructions.
General instructions for all areas of the machine
When using washing solvents

Ensure adequate room ventilation.
Wear suitable protective clothing.
Do not use flammable liquids, such as petrol or diesel.
When using compressed air
Work carefully.
Wear goggles and protective clothing.
Do not aim the compressed air at the skin or at other people.
Do not use compressed air for cleaning your clothing.
When using a high-pressure cleaner or steam jet

Electric components and damping material must be covered and not directly exposed
to the jet.
Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
Protect the following components from moisture:
Engine
Electric components such as the alternator etc.
Control devices and seals
Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays:
Ensure adequate room ventilation.
Do not use unprotected lights or naked flames.
Do not smoke.

Maintenance
Inside the cab

Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure can
penetrate into the electric system and cause short circuits and
damage seals and disable the controls.
We recommend using the following aids to clean the cab:
Broom
Vacuum cleaner
Damp cloth
Bristle brush
Water with mild soap solution
Cleaning the seat belt:
Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they can destroy the fabric.
Exterior of the machine
The following articles are generally suitable:
High-pressure cleaner
Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only
Switch off the engine before cleaning.
Caution!
When cleaning the engine with a water or steam jet
The engine must be cold
and do not point the jet directly at electric sensors such as the oil pressure
switch.
The humidity penetrating any such sensors causes them to fail and leads to
engine damage.
Screw connections and attachments

All screw connections must be checked regularly for tightness, even if they are not listed in
the maintenance schedules.
Retighten loose connections immediately. Contact an authorised workshop if necessary.
Pivots and hinges

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

Maintenance

Engine
Engine 4TNV98-VNS (Tier 2 up to serial no. AD07210)
Engine
4 Engine
4.1 Engine 4TNV98-VNS (Tier 2 up to serial no. AD07210)
Fuel injection
Oil filler neck
pump
Fuel filter
Air intake
Engine oil filter

Oil dipstick
Oil drain plug
Oil pressure switch

Exhaust manifold

Tightening bracket
Starter
Alternator
Valve cover
V-belt
Coolant thermostat
Fan blade

4.2 Fuel system
Fuel injection
pump
with stop cock

Fuel filter
Water separator
with stop cock
Feed line
Fuel pump
Reflux

4.3 Removing the valve cover
Important!
The injection lines on this engine run through the valve cover. Therefore, remove
the valve cover with extreme care.
Remove as follows:
Unscrew all fuel injection lines from the valve cover.
Slightly fold the injection lines away from the engine.
Carefully remove the rubber grommets from the valve cover with a screw driver.
Unscrew the valve cover.
Fig. 1: Removing the valve cover
4.4 Checking and adjusting valve clearance

Standard setting of valve clearance is possible:
On a cold engine
Checking valve clearance Remove the valve cover.

Turn the engine until the respective cylinder reaches the top dead centre of the
compression cycle.
Valve overlapping
Check the valve cap for abnormal wear.

normal abnormal
Fig. 2: Valve cap wear
Check valve clearance 3/A with a feeler gauge.

Valve clearance: 0.15 0.25 mm (0.006 0.01)
Repeat the procedure for each cylinder.
Place the valve cover gasket
Mount the valve cover
Fig. 3: Checking valve clearance

Setting zero play of the valve bridge
Remove the valve cover.

B
C Slacken locknut 4/C and unscrew set screw 4/B by one revolution.
Press the valve bridge against valve 4/D by hand until it makes contact.
D
Turn the set screw clockwise at the same time until it touches the valve.
Tighten locknut 4/C.
Fig. 4: Setting valve clearance
Setting valve clearance
E compression cycle.
Valve overlapping
Slacken locknut 5/E.

Set valve clearance by turning set screw 5/F.
F
Tighten the locknut.
Check the setting again with the feeler gauge.


4.5 Tightening order for cylinder head bolts

Mount the cylinder-head bolts.
Tightening moments:
1st pass 49 58.8 Nm (36.1 43.4 ft. lbs.)
2nd pass 103.1 112.9 Nm (76 83.3 ft. lbs.)
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

4.6 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 (3191 3336 psi)
Spacer thickness of 0.1 mm (0.004) corresponds to modification by 19 bar (276 psi).
Fig. 6: Nozzle tester Check the nozzle for drips after it has ejected fuel.
Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel drips from the nozzle.
Upper nozzle screw Lower nozzle screw
fitting Spacers Pressure spring centring Nozzle needle fitting
Compression Compression Nozzle body

spring spring seat
4.7 Checking the nozzle jet

Remove the injection lines and the injection nozzles.
Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times).
Hold a white sheet of paper about 30 cm (12) away from the nozzle and let the nozzle
eject fuel.
The nozzle jet must create a shape on the paper as shown in fig. 8/1.
Normal atomisation
optimal --------------variation--------------
Fig. 8: Shape of nozzle jet
Bad atomisation
Fig. 7: Nozzle jet

4.8 Injection time

Checking injection time
Preparatory work:
Remove the injection lines from the fuel injection pump.
Remove plug 9/1 from the piston.
Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
1 Screw the dial gauge into the bore of the piston as shown in Fig. 9.
Measurement:
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 suitable equipment (at the ring gear) to turn the flywheel to the top until the piston
Fig. 9: Measuring equipment of the fuel injection pump reaches a stroke of 2.5 mm (0.1).
Read the degrees before top dead centre by means of the indentations on the flywheel.
Indentations 1/4 and 2/3 stand for the top dead centre of the respective cylinders.
Scaling: 10/15/20 before top dead centre
Rated value: 14.5 + 1 before top dead centre (~ second indentation)
Fig. 10: 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. 11.
Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
about a revolution (do not unscrew completely).
Rotate the pump in the required direction, and tighten one of the screws before you
check the setting.
Rotated towards the engine: later injection time.
Label for setting
Rotated away from the engine: earlier injection time.
Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted.
Fig. 11: Mark on housing
Check injection time again.
Adhesive label number 1000158808

Replacement of fuel injection pump
Mark on pump housing Mark the initial position on the pump and wheel case housing before removing the fuel
Labels injection pump see fig. 12.
Remove gear casing cover 13/1 of the fuel injection pump.
Mark the position of the gear of the fuel injection pump 14/A with respect to gear 14/B
see fig. 14.
Completely slacken lock nut 14/2 of the drive pinion.
Example: +1 Example: +0.25
Fig. 12: 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.
Fig. 13: Gear casing
Difference of Angle of new pump Angle of old pump gives you the mounting angle
2 of the new fuel injection pump see fig. 12.
Positive value: later injection time (towards the engine).
A Negative value: earlier injection time (away from the engine).
Install the fuel injection pump

Check the marked position of the drive pinion of the fuel injection pump (fig. 14).
B Screw on and tighten nut 14/2.
Fig. 14: Gear casing Check injection time.
Mount gear casing cover 13/1 of the fuel injection pump.
Important!
Do not slacken screws 15/3 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
A manufacturer.
3 B

4.9 Adjusting engine revs
Important!
Maximum engine revs are sealed in the factory and may not be modified.
Adjust engine revs without load

B
Run the diesel engine until it reaches operating temperature.
Check idling speed A and maximum revs B with all attachment functions in neutral.
Idling speed 1050 50 rpm
Max. revs: 2575 50 rpm.
Correct the idling speed with set screw 16/A if it is not correct.
Fig. 16: Adjusting engine revs
4.10 Compression
Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid).
Turn the engine.
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 (508 14.5 psi) at 250 rpm
Threshold value: 28 1 bar (406 14.5 psi) at 250 rpm
Fig. 17: Compression

4.11 Checking the coolant thermostat

Remove the thermostat.
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 18: Coolant thermostat
Warm up the thermostat in a container with water.

Temperature gauge
Check whether the thermostat opens at the specified temperature (check with a
Thermostat temperature gauge).
Thermostat opening temperature: 69.5 72.5 C (157.1 162.5 F)
4.12 Checking the thermal switch

Remove the thermal switch.
Temperature gauge
Warm up the thermal switch in a container with antifreeze or oil.
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
(224.6-235.4 F).
Test prods
Fig. 19: Checking the thermal switch

4.13 Oil pressure switch

Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid).
Measurement
Start the engine, check for correct idling speed.
prod
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. 20: Oil pressure switch
4.14 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
(15 psi).
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge.
Fig. 21: Checking the radiator for leaks
Check the radiator cap:

Remove the radiator cap and mount it onto the adapter as shown.
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
Fig. 22: Checking the radiator cap

EGR valve Coolant hose (EGR intake
4-13
4.15
valve)
Coolant hose (EGR
exhaust valve)
Exhaust silencer Oil filler neck

Engine 4TNV98-ZVNS from serial no. AH00645
Cold starter
Exhaust gas
recirculation
(EGR line)
Air intake (incl.
preheater)
Fuel injection pump
Revs sensor
Fuel injection pump regulator Fuel filter
(incl. water separator)
Engine oil filter
Flywheel
Oil dipstick
Oil pressure switch Oil drain plug

Starter
Tightening bracket
Alternator
V-belt
Coolant thermostat
Fan wheel

4.16 Fuel system
Fuel radiator
Fuel filter with water

separator
Water separator
with stop cock
Feed line
Fuel pump
Reflux

4.17 Removing the valve cover
Important!
The injection lines on this engine run through the valve cover. Therefore, remove
the valve cover with extreme care.
Allow the engine to cool down for at least 30 minutes before removing (engine oil
temperature < 80 C/< 176 F), then drain the coolant in an environmentally friendly way.
Remove as follows:
Unscrew all fuel injection lines from the valve cover.

Slightly fold the injection lines away from the engine.
Carefully remove the rubber grommets from the valve cover with a screw driver.
Fig. 23: Removing the valve cover Unscrew the valve cover.
4.18 Checking and adjusting valve clearance

Standard setting of valve clearance is possible:
On a cold engine.
Checking valve clearance Remove the valve cover.

compression cycle.
Valve overlapping.
Check the valve cap for abnormal wear.
normal abnormal
Fig. 24: Valve cap wear
Check valve clearance 25/A with a feeler gauge.

Fig. 25: Checking valve clearance

Setting zero play of the valve bridge

Remove the valve cover.
B
C Slacken locknut 26/C and unscrew set screw 26/B by one revolution.
Press the valve bridge against valve 26/D by hand until it makes contact.
D
Turn the set screw clockwise at the same time until it touches the valve.
Tighten locknut 26/C.
Setting valve clearance

E compression cycle.
Valve overlapping.
Slacken locknut 27/E.

Set valve clearance by turning set screw 27/F.
F
Tighten the locknut.
Check the setting again with the feeler gauge.


4.19 Tightening order for cylinder head bolts

Order for removing the cylinder-head bolts
Flywheel Fan
Oil the threads and the contact surfaces of the cylinder-head bolts before mounting them.
Caution!
Bear in the mind the order for tightening the cylinder-head bolts.
See figure
Flywheel Fan
Mount the cylinder-head bolts.

Tightening moments:
1st pass 51.5 56.5 Nm (38 41.7 ft. lbs.)
2nd pass 103.1 112.9 Nm (76 83.3 ft. lbs.)

4.20 Checking the injection nozzles

Pressure check
Remove the injection line and the injection nozzle.
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: 216 226 bar (3133 3278 psi)
Fig. 28: Nozzle tester
Spacer thickness of 0.1 mm (0.004) corresponds to modification by 19 bar (276 psi).
Check the nozzle for drips after it has ejected fuel.
Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel escapes from the nozzle.
Upper nozzle screw Lower nozzle screw
fitting Spacers Pressure spring centring Nozzle needle fitting
Compression Compression Nozzle body

spring spring seat
4.21 Checking the nozzle jet

Quickly create pressure until the nozzle ejects fuel (ejection 3 4 times).
Hold a white sheet of paper about 30 cm (12) away from the nozzle and let the nozzle
eject fuel.
The nozzle jet must create a shape on the paper as shown in fig. 30/left.
Normal atomisation
optimal --------------variation--------------
Fig. 30: Shape of nozzle jet
Bad atomisation
Fig. 29: Nozzle jet

4.22 Injection time

Checking injection time
Caution!
Oil can escape.
Take measures to collect the oil.
Preparatory work:
Clean the surface of the injection pump.
Remove the injection lines from the fuel injection pump.
Remove plug 31/1 from the piston.
Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
1 gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
Mount the dial gauge into the bore of the piston as shown in Fig. 31.
Measurement:
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.
Fig. 31: Measuring equipment
Use suitable equipment (at the ring gear) to turn the flywheel to the top until the piston
of the fuel injection pump reaches a stroke of 2.5 mm (0.1).
Read the degrees before top dead centre by means of the indentations on the flywheel.
Indentations 1/4 and 2/3 stand for the top dead centre of the respective cylinders.
Scaling: 10/15/20 before top dead centre
Fig. 32: Top dead centre indentation and 10 before top

dead centre
Rated value: 12.5 + 1 before top dead centre (~ second indentation) -> up to serial
no. AD07209
From serial no. AH00646 -> calculation according to Yanmar manual:
Value on injection pump (in this case: 6.8 see Fig. 32) x 2 + FIR

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. 33.
Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
Label for setting
about a revolution (do not unscrew completely).
Rotate the pump in the required direction, and tighten one of the screws before you
check the setting.
Rotated towards the engine: later injection time
Rotated away from the engine: earlier injection time
Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted.
Fig. 33: Mark on housing
Check injection time again.

Replacement of fuel injection pump

Mark on pump housing Remove the injection lines from the fuel injection pump.
Labels
Mark the initial position on the pump and wheel case housing before removing the fuel
injection pump see fig. 34.
Remove gear casing cover 35/1 of the fuel injection pump.
Check the position of the gear of the fuel injection pump 36/A with respect to the
position of gear 36/B see fig. 36 (gears have marks).
Example: +1 Example: +0.25 Completely slacken lock nut 36/2 of the drive pinion.
Fig. 34: 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. 35: Imprint on gear casing cover
Tightening torque: 23 28 Nm (17 21 ft. lbs.)
Mounting angle of the new fuel injection pump see fig. 34.
2
Positive value: later injection time (towards the engine)
Negative value: earlier injection time (away from the engine)
A Install the fuel injection pump.
Make the marks on the gears coincide, fig. 36.
Screw on and tighten nut 36/2 (tightening torque: 23 28 Nm/17 21 ft. lbs.).
B Check injection time.
Mount gear casing cover 35/1 of the fuel injection pump.
Tightening torque: 113 123 Nm (83 91 ft. lbs.)
If a front housing cover is installed, the drive wheel of the injection pump is adapted to
the running wheel by means of marks A,B,C (see Fig. 36):
1...Injection pump drive wheel 2...Camshaft drive wheel
3...Auxiliary drive wheel (option) 4...Crankshaft drive wheel
5...Direction of rotation 6...Fuel pump drive wheel (4TNV only)
7...Running wheel
Important!
Do not slacken screws 37/3 of the drive pinion of the fuel injection pump. These
A screws specify the precision setting of the fuel injection pump set by the manufac-
turer.
3 B

4.23 Compression
Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid).
Turn the engine.
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: 33.3 35.3 bar (483 512 psi) at 250 rpm
Threshold value: 26.5 28.5 bar (384 413 psi) at 250 rpm
Fig. 38: Compression
4.24 Checking the coolant thermostat

Remove the thermostat.
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 39: Coolant thermostat
Warm up the thermostat in a container with water.

Temperature gauge
Check whether the thermostat opens at the specified temperature (check with a
Thermostat temperature gauge).
Thermostat opening temperature: 69.5 72.5 C (157.1 162.5 F)

4.25 Checking the thermal switch

Remove the thermal switch.
Temperature gauge
Warm up the thermal switch in a container with antifreeze or oil.
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
(224.6-235.4 F).
Test prods
Fig. 40: Checking the thermal switch
4.26 Oil pressure switch

Remove the cable connection from the oil pressure switch (in the area of the cutoff
solenoid).
Measurement
Start the engine, check for correct idling speed.
prods
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. 41: Oil pressure switch
4.27 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
(15 psi).
Check the lines and the connections for leaks if the pressure drops at the pressure
gauge.
Fig. 42: Checking the radiator for leaks
Checking the radiator cap

Remove the radiator cap and mount it onto the adapter as shown.
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
Fig. 43: Checking the radiator cap

4.28 Engine trouble
Problem Possible causes

No fuel
Air in fuel system
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
Engine does not start or is not easy to start
Wrong valve clearance
Defective fuel injector
Defective starting relay
Defective glow plug
Close the injection pump
Cutoff solenoid does not attract
High pressure created immediately in the hydraulic system
Engine starts, but does not run smoothly or faultless Injection line leaks
Air in fuel system
Oil level too low
Damaged water pump
Oil level too high
Dirty air filter
Engine overheats. Temperature warning system responds Dirty cooler fins
Defective fan, torn or loose V-belt
Defective thermostat
Resistance in cooling system too high, flow capacity too low
Oil level too high
Dirty air filter
Insufficient engine output Wrong valve clearance
Air in fuel system
Injection line leaks
Injection line leaks
Engine does not run on all cylinders


Oil level too low
Defective engine oil pump
Insufficient or no engine oil pressure Machine inclination too high
Clogged engine oil intake filter
Wrong SAE grade of engine lubrication oil
Oil level too high
Engine oil consumption too high
Machine inclination too high
Oil level too high
Blue Machine inclination too high
Engine oil combustion (defective cylinder-head gasket)
Engine starting temperature too low
White
Engine smoke Wrong valve clearance
Coolant combustion (defective cylinder-head gasket)
Exteme misalignment of injection time
Dirty air filter
Black
Defective fuel injector (drips)
Wrong fuel injection pump setting

Electronic engine control unit (E-ECU)
4.29 Electronic engine control unit (E-ECU)

The Electronic Engine Control Unit (E-ECU) replaces the mechanical engine control used
so far.
Features The electronic engine control unit controls the engine revs, injection pump (flow rate),
intake-air preheating, starting relay, cold start device (CSD) and exhaust gas recirculation
(EGR) electronically as a function of engine load and temperature.
The following figure shows how the electronic engine control unit works:
CSD Cold Start Device Injection pump CSD

Proportional solenoid
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation OFF

Revs sensor ON
E-ECU Start
Ignition lock
EGR
Preheating system
Display element
Coolant temperature
sensor
Manual throttle
Starter Engine

4.30 Engine error codes

The ECU saves all important engine data. Error messages can be read out by means of a
cable and software (diagnosis kit: 1000184395).
In the case of specific errors:

Engine revs and output are reduced.
The engine is switched off.
The engine no longer starts.
95
DP
DP15
DP
6
10
DP1
DP
17
D
8
P7 8
DP
DP P1
D
6 19
DP
!
DP
5 20
DP
DP
4
DP21
DP3
DP22
DP2 DP23
DP1 DP24
km/h
mph
!
Example for flash codes:
Example A 5 5x short
5x short
Ignition ON
1x long 3x short
1x long 3x short
Example B 1-3
Ignition ON
Example C 5 and 1-3 5x short 1x long 3x short 5x short
Ignition ON

Engine diagnosis codes Page

Error
Flash
Component Troubleshooting diagno-
code
sis
Loose connector Tighten the connector
Proportional injection pump
Check and replace the defective 4-34
7 solenoid (control rack) (Rack Wiring error
component
position sensor failure)
Defective sensor Contact an authorised workshop
Wiring error
Check and replace the defective
Sensor voltage: component
Manual throttle lever 4-38
5 4.6 V or more, or 0.2 V or less
(Accelerator sensor failure)
Replace the manual throttle lever
Defective manual throttle lever sensor
sensor
ECU internal 4-41
( ECU internal)
4-1 Internal ECU error Contact your dealer
ECU failure 4-44
(ECU failure)
ECU overheated 4-44
2-5 ECU temperature too high Allow to cool down
(ECU overheat alarm)
Wiring harness error
Coolant temperature sensor Check and replace the defective
Sensor voltage: component 4-45
4 (Coolant temperature sensor
4.8 V or more, or 0.2 V or less
failure)
Defective coolant temperature sensor Replace the sensor
Overheated engine Let the engine cool down
Not enough coolant Fill up coolant
Coolant temperature too high
3-6 (Coolant temperature high Check the engine cooling system 4-47
alarm) Defective engine cooling system and replace the defective
component if necessary
Defective coolant temperature sensor Replace the sensor
5 V sensor Sensor voltage: less than 4.5 V or more than component 4-49
2-4
(Sensor 5 V failure) 5.5 V
Internal ECU error Contact an authorised workshop
Old battery Replace the battery
Oxidised battery terminals Clean the battery terminals
Power supply Defective alternator Replace the alternator 4-52
2-3
(Power supply voltage abnormal)
Battery voltage: more than 10 V or more than component
16 V


Defective starter Replace the starter
Revs sensor Defective fuel injection Contact an authorised workshop 4-54
6
(Speed sensor failure)
Battery voltage too low Charge the battery
component
Backup revs sensor (alternator) Check and replace the defective 4-59
1-1 Defective wiring harness
(Backup speed sensor failure) component
component
Overspeed 4-60
9 Reduce engine revs and brake the
(Overspeed) Engine runs at overspeed
machine
Proportional solenoid relay of Defective relay Contact an authorised workshop

1-7 injection pump (control rack) Internal ECU error Contact an authorised workshop 4-61
(Rack actuator relay failure)
component
Preheating relay Wiring harness error
1-5 component 4-65
(Air heater relay failure)
Defective relay Replace the start relay
Cold start device Wiring harness error
1-4 component 4-69
(CSD solenoid valve failure)
Defective solenoid valve of cold start device Contact an authorised workshop
Exhaust gas recirculation valve Wiring harness error
1-3 component 4-72
( EGR valve failure)
Defective EGR valve stepping motor Contact an authorised workshop
Oil pressure switch Wiring harness error
2-1 component 4-76
(Oil pressure switch failure)
Defective oil pressure switch Replace oil pressure switch


Oil pressure loss Wiring harness error
3-1 component 4-76
(Oil pressure descend error)
Defective oil pressure switch Replace oil pressure switch
component
Proportional injection pump sole- Defective regulator Contact an authorised workshop
8 noid (control rack) 4-80
(Rack actuator failure) Internal ECU error Contact an authorised workshop
Regulator is stuck Contact an authorised workshop
Reduce engine revs and brake the
Engine runs at overspeed
machine
Main relay Wiring harness error
1-6 component 4-84
(Main relay failure)
Defective main relay Replace main relay
Battery voltage too low Charge the battery
CAN (Controller Area Network) Loose connector Tighten the connector

1-2 connection Check and replace the defective 4-88
(CAN communication failure) Wiring harness error
component
( ) Text in brackets appears in the diagnosis tool display.

4.31 Error diagnosis

E-ECU connector assignment
Connector on wiring harness side Connectors on ECU side
Number Description Code Number Description Code

E01 4-A D-phase stepping motor STPM-D E06 4-F Automatic idling speed setting APP-IP6
E07 4-G Ignition lock IGNSW E08 4-H Engine start recognition STARTSW
E10 4-K Backup revs sensor RENRPM E11 3-A C-phase stepping motor STPM-C
E12 3-B Telltale failure FAIL-LMP E14 3-D Oil pressure APP-IP2
E16 3-F RET E17 3-G Automatic idling speed pressure APP-IP4
Coolant temperature
switch
E18 3-H Speed input (-) NRPM-GND E19 3-J Speed input (+) NRPM
E20 3-K Start relay APP-OP1 E21 2-A B-phase stepping motor STPM-B
E23 2-C Preheating telltale PREHT-LMP E24 2-D Drop mode APP-IP1
E28 2-H GND sensor GND-A E30 2-K CAN terminal resistor RECAN
E31 1-A STPM-A E33 1-C Proportional solenoid relay of RACK-RLY

A-phase stepping motor
injection pump (control rack)
E34 1-D Main relay MAIN-RLY E35 1-E Manual throttle sensor APS
E36 1-F Proportional injection pump RPS E38 1-H AVCC

5 V sensor
solenoid (control rack)
E39 1-J CANL CANL E40 1-K CANH CANH
E41 4-L CSD-CL E42 4-M Proportional injection pump RACKSOL

CSD solenoid coil
solenoid (control rack)
E43 3-L 12 V sensor AVB E44 3-M Preheating relay AIRHT-RLY
E45 2-L Power GND GND E47 1-L GND CSD GND-P
E48 1-M 12 V power VB

Important information on the ECU maintenance wiring harness

Error diagnosis within the scope stated in this document includes measuring voltages with
the maintenance wiring harness. Therefore, disconnect the E-ECU and the machine wiring
harness before carrying out error diagnosis, and connect the maintenance wiring harness
between the E-ECU and the machine wiring harness.
The ECU maintenance wiring harness can be ordered stating no. 1000188305.
See below for details on the error diagnosis for the specific areas.
Use a multimeter to measure the voltage in accordance with the following list.
Maintenance wiring harness: Pin assignment list
Machine
Connection between E-ECU wiring
wiring har-
harness and machine wiring harness.
ness
Measure the voltage between the speci-

fied terminals by means of a multimeter.

Flash code 7 proportional injection pump solenoid (control rack)
Related DTC (Diagnostic Trouble Codes)
P1202/4 Proportional solenoid position sensor error (voltage too low)

DTC
P1203/3 Proportional solenoid position sensor error (voltage too high)
Initial diagnosis with the diagnosis tool
DTC in the error history display Check the error

A. Check the error dis-
play. conditions.
Error is dis-
played.
[Check items]:
B. Check the detected Proportional solenoid position sensor voltage (D/A value) Signal data (SD)
value to assess the SD=0 (OV) or equivalent => signal line disconnected?
cause of the error.
SD=5000 (5.0 V) or equivalent => sensor GND line disconnected?
Error diagnosis
1. Check input voltage of

NG 2. Check the wiring
NG
proportional solenoid Replace the wiring harness.
position sensor (wiring harness for continu-
harness + E-ECU). ity.
OK
OK
3. Carry out propor- NG

tional solenoid posi- Replace the injection pump.
tion control (with
diagnosis tool).
OK Replace the E-ECU.

Wiring diagram
Check points
Battery
Main relay K1
Fuse F11
Proportional injection pump solenoid
Proportional solenoid position sensor
Connector
Connectorononproportional
proportionalsolenoid
solenoidside Connector on wiring harness side
*E-ECU connector assignment see E-ECU connector assignment on page 4-32.

Diagnosis description 1. Check the input voltage of the proportional injection pump solenoid (wiring
harness + E-ECU).
Switch off ignition and disconnect connector of proportional solenoid from injection
pump. Do not disconnect the E-ECU connector from the E-ECU.
Switch on ignition to switch on E-ECU voltage.
Measure the voltage between sensor terminals E43 and E28 by means of a multimeter.
Terminal Normal value
Sensor connectors E43 E28 Equivalent to the battery voltage
NG Check the wiring harness for continuity. -> Next: [2. Check the wiring harness for continuity:]
With the diagnosis tool Diagnosis test: active control, check whether Position control for proportional injection
OK pump solenoid can be carried out. -> Next: [3. Check the execution of the position control of the proportional
injection pump solenoid:]
2. Check the wiring harness for continuity:

Disconnect the connector from the proportional injection pump solenoid, and the
E-ECU from the wiring harness.
Check the wiring harness for continuity by means of a multimeter.
Terminal Continuity Status
Sensor signal line E36 Yes OK: normal
[between E-ECU and sensor connector] No NG: open wiring harness
Sensor GND line E28 Yes OK: normal
12 V sensor line E43 Yes OK: normal
No OK: normal
Between E36 and other terminal/GND and
between E43 and other terminal/GND Yes NG: wiring harness short-circuited to GND
Yes OK: normal

Between E28 and GND/E45/E47
No NG: open wiring harness
No OK: normal
Between E28 and other terminals
Yes NG: wiring harness short-circuited with other cable
Check whether the wiring harness is damaged, or whether the wiring is correct.
NG
Replace the wiring harness.
With the diagnosis tool Diagnosis test: active control, check whether Position control for proportional injection
OK pump solenoid can be carried out. -> Next: [3. Check the execution of the position control of the proportional
injection pump solenoid:]

3. Check the execution of the position control of the proportional injection pump
solenoid:
Connect all connectors (sensors, E-ECU).
Connect the diagnosis tool, switch on ignition and log in to the diagnosis tool.
With the diagnosis tool Diagnosis test: active control, carry out the position control for
the proportional injection pump solenoid. Place the control rack in any position within
the admissible setting range.
Then check whether the proportional injection pump solenoid has moved to the control
rack position that has been set.
NG Replace the injection pump.

Flash code 5 manual throttle
Related DTC
P1125/1 Manual throttle sensor error (manual throttle in closed position)
P1126/0 Manual throttle sensor error (manual throttle in open position)

DTC
P1225/1 Manual throttle backup sensor error (manual throttle in closed position)
P1226/0 Manual throttle backup sensor error (manual throttle in open position)

conditions.
play.
Error is dis-
played.
B. Check the
detected value to
assess the cause of
the error.
Error diagnosis
NG Replace the manual throttle.

1. Continuity check
(manual throttle
only):
OK
NG
2. Continuity check
NG 3. Continuity check Replace the wiring harness.
(manual throttle + wir- (wiring harness)
ing harness)
OK
OK
4. Movement check NG Replace the E-ECU or

(with diagnosis tool) manual throttle.
OK
Replace the E-ECU.

Wiring diagram
Check points
Manual throttle sensor (standard)

Work description 1. Check the wiring harness for continuity:

Disconnect the manual throttle sensor and the E-ECU from the wiring harness.
5 V sensor line E38 Yes OK: normal

No OK: normal
Between E35 and other terminal/GND and
between E38 and other terminal/GND Yes NG: wiring harness short-circuited to GND
Yes OK: normal
No OK: normal
Between E28 and other terminals NG: wiring harness short-circuited with other
Yes
cable
NG
OK Check output voltage of manual throttle sensor. -> Next: [4. Check manual throttle sensor output voltage:]
2. Check manual throttle sensor output voltage:

Connect the maintenance wiring harness between the E-ECU and the machine wiring
harness (see [Important information on the maintenance wiring harness] 4-33 for
details). Connect all connectors (sensors, E-ECU).
Voltage Status Action

E35 0.2 [V] NG
Replace the manual throttle sensor.
0.2 [V] < E35 < 3.8 [V] OK (normal range) Replace the E-ECU.

3.8 V E35 NG
NG

Flash code 4-1 ECU internal
Related DTC
P0601/12 EEPROM error (read/write error)
P1601/2 EEPROM error (check sum)
P0605/12 ROM error flashes (check sum A)
P1605/2 ROM error flashes (check sum B)

DTC P1606/2 ROM error flashes (check sum C)
P1610/12 Error A with sub-CPU
P1611/12 Error B with sub-CPU
P1612/12 Error C with sub-CPU
P1620/12 Map format error
DTC in the error history display Check the error con-

ditions.
play.
Error is dis-
played.
[Check items]: error code
Error diagnosis
Repeat
Switch ignition ON/
OFF.
1. Carry out the same

steps as in the initial
diagnosis above. conditions.
OK
Overwrite the E-ECU

software or replace the
E-ECU.

Work description 1. Work with the diagnosis tool:

Switch off ignition.
Connect the diagnosis tool and check whether errors have been detected on the error
display.
No Check the error history display, confirm errors if an error history is displayed.
Switch ignition ON/OFF. -> Next: [1. Work with the diagnosis tool:]
Yes Overwrite the E-ECU software.
Replace the E-ECU.

Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
Related DTC
P0668/4 ECU temperature sensor error (voltage too low)
DTC P0669/3 ECU temperature sensor error (voltage too high)
P1644/2 Intermittent error with ECU temperature sensor

conditions.
play.
Error is dis-
played.
[Check items]: ECU temperature

B. Check the ECU temperature remains constant at 30 C => ECU possibly defective.
detected value to
ECU temperature equivalent to ambient temperature => normal
assess the cause of
the error.
Error diagnosis
Repeat Switch ignition ON/OFF.
1. Carry out the

same steps as in the
initial diagnosis conditions.
above.
OK
Replace the E-
ECU.

Work description 1. Work with the diagnosis tool:

Check the error display.
Switch ignition off and on again.
Connect the diagnosis tool and check whether errors have been detected on the error
display.
No Check the error history display, confirm errors if an error history is displayed.
Yes Check the detected value by means of the diagnosis tool. -> Next: [ Check the detected value]
Check the detected value.

Check the value indicated in the E-ECU temperature with the Diagnosis test
diagnosis tool function.
Displayed value Status Action
Constant at 30 C/86 F NG Replace the E-ECU.
Ambient temperature OK Replace the E-ECU.
NG Replace the E-ECU.

Switch ignition ON/OFF again and carry out [ Check the error display] [Check the detected value].
OK
Replace the E-ECU.

Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
Related DTC
P0117/4 Coolant temperature sensor error (voltage too low)
DTC P0118/3 Coolant temperature sensor error (voltage too high)
P0119/2 Intermittent coolant temperature sensor error

conditions.
play.
Error is dis-
played.
[Check items]: engine coolant temperature Signal Data (SD)
B. Check the SD 200 (0.2 V) => short-circuited to GND?
detected value to 200 (0.2 V) < SD < 4800 (4.8 V) => normal
assess the cause 4800 (4.8 V) SD => disconnected?
of the error.
Error diagnosis
1. Check the sensor NG Replace the sensor.

resistance value
(sensor only).
2. Check the sen- NG 3. Check the wiring NG Replace the wiring harness.
sor resistance harness for continu-
value (sensor + ity.
wiring harness):

OK
4. Check the output NG Replace the E-ECU or

voltage of the cool- sensor.
ant temperature sen-
sor.
OK
Replace the E-ECU.

Sensor drawing
Wiring diagram
Check points
Coolant temperature sensor (high accuracy)
Connector on wiring har-

Work description 1. Check the sensor resistance value (sensor only)

Disconnect the wiring harness from the coolant temperature sensor.
Measure the resistance between the terminals A and B of the coolant temperature
sensor by means of a multimeter.
Check whether the measured resistance value is within the normal range. See the
following table <Parameters of coolant temperature sensor>.
Parameters of coolant temperature sensor
Ratio between coolant temperature and sensor resistance:
Resistance (k)
Temperature (C/F)
High accuracy
-30/-22 25.4
-20/- 4 15.04
-10/14 9.16
0/32 5.74
10/50 3.7
20/68 2.45
30/86 1.66
40/104 1.15
50/122 0.811
60/140 0.584
70/158 0.428
80/176 0.318
90/194 0.24
100/212 0.1836
110/230 0.1417
120/248 0.1108
NG Replace the coolant temperature sensor.
OK Check the sensor resistance with the sensor and the wiring harness connected. -> Next: [2. Check the sensor
resistance value (sensor + wiring harness):]
2. Check the sensor resistance value (sensor + wiring harness):

Connect the coolant temperature sensor and the wiring harness, and disconnect E-
ECU from the wiring harness.
Measure the resistance between the E-ECU connector terminals E16 and E28 on the
wiring harness side by means of a multimeter.
Check whether the measured resistance value is within the normal range. See the
previous table <Parameters of coolant temperature sensor>.
OK Check the output voltage of the coolant temperature sensor. -> Next: [4. Check the output voltage of the coolant
temperature sensor:]


Disconnect the coolant temperature sensor and E-ECU from the wiring harness.
[E-ECU between sensor connector] No NG: open wiring harness
No OK: normal
Between E16 and other terminal/GND
Yes NG: wiring harness short-circuited to GND
Yes OK: normal

E28 GND/E45/E47
No OK: normal
Between E28 and other terminals
NG
OK Check the output voltage of the coolant temperature sensor. -> Next: [4. Check the output voltage of the coolant
temperature sensor:]
4. Check the output voltage of the coolant temperature sensor.

Measure the voltage between sensor terminals E16 and E28 (E35 and E28) by means
of a multimeter.

E16 0.2 [V] NG
Replace the coolant temperature sensor.

4.8 V E16 NG
Replace the coolant temperature sensor.
NG

Flash code 2-4 sensor 5 V
Related DTC
P0642/4 SENSOR 5 V error (voltage too low)
DTC P0643/3 SENSOR 5 V error (voltage too high)
P1644/2 Intermittent SENSOR 5 V error

ditions.
play.
Error is dis-
played.
[Check items]: SENSOR 5 V voltage
B. Check the
SENSOR 5V voltage 4.5 V => short-circuited to GND?
detected value to 4.5 V < SENSOR 5 V voltage < 5.5 V => normal
assess the cause of 5.5 V SENSOR 5 V voltage => short-circuited with power supply?
the error.
Error diagnosis
NG Replace the sensor.

1. Check the manual
throttle sensor.
*See [Manual throttle sensor] for the check procedure.
OK
2. Check output
voltage (sensor NG 3. Check the wiring NG Replace the wiring harness.
not connected) harness for continu-
ity.
OK
OK
4. Check the output NG Replace the E-ECU.

voltage (with the sen-
sor connected):
OK
Replace the E-ECU.

Work description 1. Check the manual throttle sensor.

For details, see [Manual throttle sensor] (see page 4-38).
2. Check output voltage (sensor not connected)
Disconnect the manual throttle sensor from the wiring harness. Do not disconnect the
E-ECU connector from the E-ECU.
Switch on ignition to switch on E-ECU voltage.
Measure the voltage between the wiring-harness side connector terminals E38 and
GND of the manual throttle sensor by means of a multimeter.
Terminal Normal value
Sensor connectors E38 GND 5V
OK With the manual throttle sensor connected, check the output voltage. -> Next: [4. Check the output voltage (with the
sensor connected):]

Disconnect the manual throttle sensor and the E-ECU from the wiring harness.
No OK: normal
Between E38 and E28/E45/E47/GND
No OK: normal
Between E38 and E43/E48
Yes NG: wiring harness short-circuited with power supply
Between E-ECU and sensor connector No NG: open wiring harness
Yes OK: normal

No OK: normal
Between E38/E28 and other terminals
NG
OK With the manual throttle sensor connected, check the output voltage. -> Next: [4. Check the output voltage (with the
sensor connected):]

4. Check the output voltage (with the sensor connected):


E38 4.5 [V] NG

5.5 V E38 NG
NG

Flash code 2-3 power supply voltage
(1) P0562/1: power supply voltage error (voltage too low)
DTC P0562/1 Power supply voltage error (voltage too low)
DTC detection conditions
1 Prerequisite; 2 Detection condition(s); 3 Flash code in error display Check points
1. Engine runs. Battery
2. E-ECU supply voltage below 10 [V] Alternator
3. 2 flash pulses followed by 3 flash pulses. Wiring harness
Troubleshooting
[Operation is resumed]: The system lets the engine run without any restrictions after the error has been
Error mode
detected.
Operation restric-
No.
tions?
Recovery conditions Yes: This error is automatically reset if a normal supply voltage (10 to 16 [V]) is applied.
Remarks
Possible error cause/condition

Bad battery condition.
Wrong battery connection.
Alternator defect.
Wiring harness disconnected or short-circuited.
Defect in internal E-ECU circuit.
Diagnosis description
1) Initial diagnosis with the diagnosis tool
Check the battery voltage.
Switch off ignition to stop the engine.

Check battery voltage with a multimeter.
2) Engine Inspect the charging system of the engine.

inspection Switch on ignition after a short time to check whether a DTC has
been detected.
*Refer to the Service Manual (Engine) for a description of the engine
inspection and how to carry it out.
Check whether the battery connections are OK

3) Error diagnosis
and whether the cable insulation is undamaged.

(2) P0563/0: power supply voltage error (voltage too high)
DTC P0563/0 Power Supply Voltage Error (High Voltage)
1. Engine runs. Battery
2. E-ECU supply voltage over 16 [V] Alternator
3. 2 flash pulses followed by 3 flash pulses. Wiring harness
Troubleshooting
[Operation is resumed]: The system lets the engine run without any restrictions after the error has been
Error mode
detected.
Operation restric-
No.
tions?
Recovery conditions Yes: This error is automatically reset if a normal supply voltage (10 to 16 [V]) is applied.
Remarks

An incompatible battery (such as a 24 V battery) has possibly been used.
Wrong battery connection.
Alternator defect.
Wiring harness disconnected or short-circuited.
1) Initial diagnosis with the diagnosis tool
Check the battery voltage.

Inspect the charging system of the engine.
2) Engine
inspection Switch on ignition after a short time to check whether a DTC has
been detected.
Check whether the battery connections are OK

3) Error diagnosis
and whether the cable insulation is undamaged.

Flash code 6 revs sensor

Related DTC
DTC P0340/4 Revs sensor error

ditions.
play.
Error is dis-
played.
B. Check the [Check items]: actual revs [value]

detected value to
assess the cause Value = 0 => disconnected? Sensor error?
of the error.
Error diagnosis
1. Check the sensor NG Replace the sensor.

resistance value
(sensor only).
OK
2. Check the sen- NG 3. Check the wiring NG Replace the wiring harness.
sor resistance harness for continu-
value (sensor + ity.
wiring harness):
OK
4. Check the wir- NG Replace the wiring harness.

ing harness for
wrong connec-
tions.

Wiring diagram
Check points
Connector on sensor side
Connector on wiring
harness side

Work description 1. Check the sensor resistance value (sensor only)

Disconnect the revs sensor from the wiring harness.
Measure the resistance between the revs sensor terminals A and B by means of a
multimeter.
Coil resistance value of standard Yanmar revs sensor.
Terminal Specification
Sensor A B 500 100 k
NG Replace the revs sensor.
OK With the revs sensor and the wiring harness connected, check the resistance between sensor terminals A and B. -
> Next: [2. Check the sensor resistance value (sensor + wiring harness):]
2. Check the sensor resistance value (sensor + wiring harness):

Connect the revs sensor and the wiring harness, and disconnect the E-ECU from the
wiring harness.
Measure the resistance between the E-ECU connector terminals E19 and E18 on the
wiring harness side by means of a multimeter.
*See above, Coil resistance value of standard Yanmar revs sensors.
NG Replace the wiring harness.
OK Check the wiring harness for continuity. -> Next: [3. Check the wiring harness for continuity:]

Disconnect the revs sensor and the E-ECU from the wiring harness.
Sensor signal line (+) E 19 Yes OK: normal
Sensor signal line (-) E 18 Yes OK: normal

Between E 19 and GND/E45/E47 No OK: normal
(between E 18 and GND/E45/E47) Yes NG: wiring harness short-circuited to GND
NG

Flash code 1-1 backup revs sensor
Related DTC
DTC P1340/4 Backup revs sensor error

ditions.
play.
Error is dis-
played.
B. Check the
[Check items]: backup revs sensor Value
detected value to
assess the cause Value = 0 => disconnected? Sensor error?
of the error.
Error diagnosis
NG Replace the battery or

1. Check battery voltage check the alternator.
OK
NG
2. Check the wiring Replace the wiring harness.
harness for continu-
ity.
OK Check the alternator or replace the

E-ECU.

Wiring diagram
Check points
Battery
Starter
Fuse
Ignition lock in ON
or START position
Fuse
Revs sensor
Backup revs sensor (option) Connector on wiring

(alternator) harness side

Work description 1. Battery voltage check:

Set the manual throttle lever to the Iowest position and start the engine.
Battery voltage (in normal condition) 10 to 16 [V]
Check the alternator.

NG
Replace the battery.

Disconnect the connector from the backup revs sensor, and the E-ECU from the wiring
harness.
Alternator terminal P (E10) Yes OK: normal
[between E-ECU and alternator] No NG: open wiring harness
Alternator terminal IG Yes OK: normal
[between ignition lock and alternator] No NG: open wiring harness

Alternator terminal B Yes OK: normal
[between battery and alternator] No NG: open wiring harness
No OK: normal
NG
Check the alternator.

OK
Replace the E-ECU.

Flash code 9 overspeed error

(1) P0219/0: overspeed error
DTC P0219/0 Overspeed error

1. Engine runs. Wiring harness
2. Sensor signal at or above the upper limit (high idling speed +600[min-1]) Revs sensor
3. 2 flash pulses followed by 3 flash pulses. solenoid
E-ECU
Troubleshooting
Error mode [Immediate stop]: The engine stops running.
Operation restric- Yes: The proportional solenoid relay of the injection pump is switched off and the control rack position is
tions? forced to the engine stop position.
Recovery conditions No.
Remarks

Wiring defect in wiring harness
The wiring of the proportional injection pump solenoid is possibly short-circuited to
GND.
Revs sensor signal pulse created incorrectly
Incorrect wiring of revs sensor
Engine overspeed due to consumer
Control error of injection pump
The wiring of the proportional injection pump solenoid is possibly short-circuited to
GND.
1) Initial diagnosis with the diagnosis tool Check the error display.

Inspect the engine and the machine.
2) Engine Switch on ignition after a short time to check whether a DTC has
inspection been detected.
3) Error diag- Check the proportional injection pump solenoid.

nosis *See 4-57 for more details on the diagnosis method and procedure

Flash code 1-7 proportional solenoid relay of the injection pump (control rack)
Related DTC
P1222/4 Error A on proportional solenoid relay of the injection pump
DTC P1223/3 Error B on proportional solenoid relay of the injection pump
P1224/2 Intermittent error A on proportional solenoid relay of the injection pump

ditions.
play.
Error is dis-
played.
B. Check the [Check item]: Proportional solenoid relay of injection pump

detected value to Contact status -> ON => normal?
assess the cause
of the error. Contact status -> OFF => abnormal?
Error diagnosis
1. Check the relay NG Replace the relay.

coil resistance
(relay only).
2. Check the relay

coil resistance NG 3. Check the wiring NG Replace the wiring harness.
(relay + wiring harness for continu-
harness). ity.
OK
OK
4. Check the relay NG Replace the E-ECU or

for movement the wiring harness.
(with the diagno-
sis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Relay-side connector
Proportional solenoid Battery

relay K42 of injection
pump Main relay K1
Fuse F11
Fuse F2 50 A
Ignition
ON
Fuse F3 10 A
Connector on wiring
harness side

solenoid to coil input

Work description 1. Check the relay coil resistance value (relay only):
Disconnect the proportional solenoid relay of the injection pump from the wiring
harness.
Measure the resistance between terminals C and D on the relay side by means of a
multimeter.
Measurement conditions
Measured value Status
Tester (+) side Tester (-) side
Terminal C Terminal D Existing (*)
OK if both are normal
Terminal D Terminal C Infinite (*)
Terminal C Terminal D
Infinite (*) NG: internal relay circuit error
Terminal D Terminal C
*A series-connected diode integrated in reverse direction requires using the checking method mentioned above and causes the measured
value to vary depending on the multimeter used.
NG Replace the proportional solenoid relay of the injection pump.
OK With the proportional solenoid relay of the injection pump and the wiring harness connected, check the relay coil
resistance. -> Next: [2. Check the relay coil resistance value (relay + wiring harness side):]
2. Check the relay coil resistance value (relay + wiring harness side):
Connect the proportional solenoid relay of the injection pump onto the wiring harness.
Disconnect the E-ECU from the wiring harness.
Measure the resistance between E-ECU connectors E07 and E33 by means of a
multimeter.
E07 E33 Existing (*)
OK: normal
E33 E07 Infinite (*)
E07 E33
Infinite (*) NG: wiring harness error
E33 E07
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next:
[4. Check the relay for movement:]


Disconnect the proportional solenoid relay of the injection pump and the E-ECU from
the wiring harness.
Relay coil (output side) E33 Yes OK: normal
Relay coil (input side) E07 Yes OK: normal
No OK: normal
Between E33 and GND/E28/E45/E47
No OK: normal
NG
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next:
[4. Check the relay for movement:]
4. Check the relay for movement:

details). Connect all connectors (proportional solenoid relay of injection pump, E-ECU).
Activate the proportional solenoid relay of the injection pump by means of the diagnosis
tool Diagnosis test: active control, and measure the voltage between terminals E33
and E45.
ON/OFF setting status Voltage Status
1.75 [V] and below OK: normal

ON
Over 1.75 [V] NG: wiring harness short-circuited with power supply or E-ECU error
2.5 [V] and above OK: normal

OFF
Under 2.5 [V] NG: wiring harness short-circuited to GND or E-ECU error
NG

Flash code 1-5 preheating relay
Related DTC
P1232/4 Error A of preheating relay
DTC P1233/3 Error B of preheating relay
P1234/2 Intermittent error B of preheating relay

conditions.
play.
Error is displayed.
B. Check the [Check items]: air heater relay 1

assess the cause
Error diagnosis
1. Check the re- NG Replace the relay.

lay coil resist-
ance (relay only).
2. Check the relay NG NG

coil resistance
harness for continu-
(relay + wiring
ity.
harness).
OK
OK
4. Check the relay NG Replace the E-ECU or

(with the diagno-
sis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Air heating relay
Fuse F1 50 A
C
Air heater
Disconnect the preheating relay from the wiring harness.
multimeter.
Total resistance value of Yanmar preheating relay.
Relay coil side C D (40 A relay) 103 10 % (at 20 C/68 F)
Relay coil side C D (70 A relay) 103 10 % (at 20 C/68 F)
Relay coil side C D (90 A relay) 80 (at 20 C/68 F)

NG Replace the preheating relay.
OK With the preheating relay and the wiring harness connected, check the relay coil resistance. -> Next: [2. Check the
relay coil resistance value (relay + wiring harness side):]
2. Check the relay coil resistance value (relay + wiring harness side):
Connect the preheating relay onto the wiring harness.
Measure the resistance between E-ECU connectors E44 and B00 with a multimeter.
*See above, Coil resistance value of standard Yanmar preheating relay.
OK Check the movement of the preheating relay with the diagnosis tool. -> Next: [4. Check the relay for movement:]

Disconnect the preheating relay and the E-ECU from the wiring harness.
Relay coil (input side) E44 Yes OK: normal
Relay coil (output side) B00 Yes OK: normal

No OK: normal
No OK: normal
NG
OK Check the movement of the proportional solenoid relay of the injection pump with the diagnosis tool. -> Next: [4.
Check the relay for movement:]

4. Check the relay for movement:

details). Connect all connectors (preheating relay, E-ECU).
Activate the preheating relay by means of the diagnosis tool Diagnosis test: active
control, and measure the voltage between terminals E44 and E45.

ON

OFF
NG

Flash code 1-4 CSD (cold start device) solenoid coil
Related DTC
P1242/4 Error A at CSD solenoid valve
DTC P1243/3 Error B at CSD solenoid valve
P1244/2 Intermittent CSD solenoid valve error

conditions.
play.
Error is dis-
played.
[Check items]: CSD solenoid valve

B. Check the
assess the cause Contact status -> OFF => abnormal?
of the error.
Error diagnosis
1. Check the
resistance value of NG Replace the relay.
the CSD solenoid
valve coil (sole-
noid valve only):
2. Check the resist- NG

ance value of the CSD NG 3. Check the wiring Replace the wiring harness.
solenoid valve coil harness for continu-
(solenoid valve + wir- ity.
ing harness).
OK
OK
4. Check the CSD sole- NG Replace the E-ECU or

noid valve for move- the wiring harness.
ment (with the
diagnosis tool)
OK
Replace the E-ECU.

Wiring diagram
Check points
Injection pump
CSD solenoid valve
C
Connector on wiring
harness side
Work description 1. Check the resistance value of the CSD solenoid valve coil (solenoid valve only):
Disconnect the CSD solenoid valve connector from the wiring harness.
Measure the resistance between terminals C and D on the side of the CSD solenoid
valve by means of a multimeter.
Coil resistance of the CSD solenoid valve
CSD solenoid valve side C D (400W) 8 (at 23 C/73.4 F)
NG Replace the solenoid valve.
With the CSD solenoid valve connector and the wiring harness connected, check the coil resistance of the CSD
OK solenoid valve. -> Next: [2. Check the resistance value of the CSD solenoid valve coil (solenoid valve + wiring
harness):]

2. Check the resistance value of the CSD solenoid valve coil (solenoid valve +
wiring harness)
Connect the CSD solenoid valve and the wiring harness.
Measure the resistance between E-ECU connectors E41 and B00 by means of a
multimeter.
*See Coil resistance of standard Yanmar CSD solenoid valve above
OK Check the movement of the CSD solenoid valve by means of the diagnosis tool. -> Next: [4. Check the CSD
solenoid valve for movement:]

Disconnect the CSD solenoid valve connector and the E-ECU from the wiring harness.
CSD solenoid valve (input side) E41 Yes OK: normal
No OK: normal
No OK: normal
NG
OK Check the movement of the CSD solenoid valve by means of the diagnosis tool. -> Next: [4. Check the CSD
solenoid valve for movement:]
4. Check the CSD solenoid valve for movement:

details). Connect all connectors (CSD solenoid valve connector, E-ECU).
Activate the preheating relay by means of the diagnosis tool Diagnosis test: active
control, and measure the voltage between terminals E41 and E45.
ON
OFF
NG

Flash code 1-3 EGR (exhaust gas recirculation) valve
Related DTC
P1402/4 Error A at EGR valve (stepping motor A-phase)

P1403/3 Error B at EGR valve (stepping motor A-phase)
P1412/4 Error A at EGR valve (stepping motor B-phase)
P1413/3 Error B at EGR valve (stepping motor B-phase)
DTC
P1422/4 Error A at EGR valve (stepping motor C-phase)
P1423/3 Error B at EGR valve (stepping motor C-phase)
P1432/4 Error A at EGR valve (stepping motor D-phase)
P1433/3 Error B at EGR valve (stepping motor D-phase)

ditions.
play.
B. Check the
[Check items]: stepping motor A-phase (B-phase, C-phase, D-phase)
detected value to
assess the cause Contact status -> ON => normal?
Error diagnosis
1. Check the NG
resistance of the Replace the sensor.
EGR stepping
motor coil (EGR
2. Check the resist- NG 3. Check the wiring

ance of the EGR
stepping motor coil harness for continu-
(EGR valve + wiring ity.
harness)
OK
4. Check the EGR NG Replace the E-ECU or

(with the diagno-
sis tool).
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Connector on EGR side Main relay K1

Fuse
Valve
Connector on wiring
harness side

Work description 1. Check the resistance of the EGR stepping motor coil (EGR only):
Disconnect the EGR valve from the wiring harness.
Measure the resistance between the coil terminals 4-5, (1-2, 5-6, 2-3) on the EGR side
by means of a multimeter.
Resistance value of standard Yanmar EGR stepping motor coil
Coil terminal 4 5 (A-phase)
Coil terminal 1 2 (B-phase)

15 2
Coil terminal 5 6 (C-phase)
Coil terminal 2 3 (D-phase)
NG Replace the EGR valve.
OK With the EGR valve and the wiring harness connected, check the EGR stepping motor coil resistance. -> Next: [2.
Check the resistance of the EGR stepping motor coil (relay + wiring harness side):]
2. Check the resistance of the EGR stepping motor coil (relay + wiring harness
side):
Connect the EGR valve with the wiring harness.
Measure the coil resistance at the E-ECU connector by means of a multimeter.
*See Resistance of standard Yanmar EGR stepping motor coil above.
Stepping motor ECU connector terminal number
A-phase E31-E48
B-phase E21-E48
C-phase E11-E48
D-phase E01-E48
OK Check the EGR for movement by means of the diagnosis tool. -> Next: [4. Check the EGR for movement:]


Disconnect the EGR valve and the E-ECU from the wiring harness.
Motor coil (output side) E31 (E21/E11/E01) Yes OK: normal
[between E-ECU and EGR connector] No NG: open wiring harness
Motor coil (input side) E48 Yes OK: normal
[between E-ECU and EGR connector] No NG: open wiring harness
Between E31 (E21/E11/E01) and No OK: normal
GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
Between E31 (E21/E11/E01) and No OK: normal
E43/E48 Yes NG: wiring harness short-circuited with power supply
NG
OK Check the EGR for movement by means of the diagnosis tool. -> Next: [4. Check the EGR for movement:]
4. Check the EGR for movement:

details). Connect all connectors (EGR valve, E-ECU).
Activate each stepping motor of the EGR valve by means of the diagnosis tool
Diagnosis test: active control, and measure the voltage between stepping motor coil
terminals E31 E45, (E21 E45, E11 E45, E01 E45).

ON

OFF
NG

Flash code 2-1 oil pressure switch and 3-1 oil pressure drop error
Related DTC
P1192/4 Oil pressure switch error

DTC
P1198/1 Abnormal oil pressure drop

ditions.
play.
Error is dis-
played.
[Check items]: oil pressure switch terminal ON/OFF status

B. Check the Oil pressure switch
detected value to
assess the cause Before engine start: ON => normal
of the error. : OFF => disconnected?
Error diagnosis
1. Continuity check (oil NG Replace the separate oil pres-

pressure switch only) sure switches.
OK
2. Continuity NG 3. Continuity check (wir-

check (oil pres- ing harness)
sure switch + wir-
ing harness)
OK
OK
Replace the wiring harness or

4. Check oil pres- NG the separate oil pressure
sure switch for switches.
movement
OK
Replace the E-ECU.

Wiring diagram
Check points
Battery
Ignition lock
Fuse F3 10 A
Telltale
(see instrument panel 57)
Automatic idling speed setting S87
switch S86
Automatic idling speed setting pressure
Oil pressure
switch

Work description 1. Continuity check (oil pressure switch only)

Disconnect the wiring harness from the separate oil pressure switches.
Check the continuity between the oil pressure switch terminal and the chassis by
means of a multimeter and the following table.
Terminal name Continuity

Pos. Status
(terminal no.) [between terminal and chassis]
Yes OK: normal
Oil pressure switch APP-IP2 (E14)
No NG: internal circuit error
NG Replace the oil pressure switch.
OK Check the continuity with the oil pressure switch and the wiring harness connected. -> Next: [2. Continuity check
(oil pressure switch + wiring harness):]
2. Continuity check (oil pressure switch + wiring harness)

Connect the oil pressure switch and the wiring harness, and disconnect the E-ECU
from the wiring harness.
Check the continuity between the ECU connector terminal on the wiring harness and
the chassis by means of a multimeter. Refer to the text above for the contact to be
checked [1. Continuity check (oil pressure switch only):].
OK Use the diagnosis tool Diagnosis test to check whether the movement of the oil pressure switch is correctly
detected. -> Next: [4. Check the oil pressure switch for movement:]

Disconnect the oil pressure switch and the E-ECU from the wiring harness.
Switch signal line E14 (*) Yes OK: normal
[between E-ECU and switch connector] No NG: open wiring harness
Between E14 (*) and E38/E43/E48 No OK: normal
Yes NG: wiring harness short-circuited with power

(power supply line)
supply
Between E14 (*) and E28/E45/E47 No OK: normal
(GND line)/GND Yes NG: wiring harness short-circuited to GND
*An oil pressure switch is used as an example in this table. Use the same procedure to check the coolant temperature switch (E17) for
continuity.
NG
OK Use the diagnosis tool Diagnosis test to check whether the movement of the oil pressure switch is correctly
detected. -> Next: [4. Check the oil pressure switch for movement:]

4. Check the oil pressure switch for movement:

Connect all connectors (oil pressure switch, E-ECU).
Monitor the separate components displayed with the diagnosis tool Diagnosis test:
digital input etc.. Check ON/OFF display of the oil pressure switch under the
circumstances indicated.
Pos. Check conditions ON/OFF display Status

ON OK: normal
Before engine start
OFF NG: wiring harness error or internal circuit error
Oil pressure switch
OFF OK: normal
With the engine running
ON NG: wiring harness error or internal circuit error
Replace the oil pressure switch.

Flash code 8 proportional injection pump solenoid (control rack)
Related DTC
P1212/4 Proportional injection pump solenoid error (voltage too low)
DTC P1213/3 Proportional injection pump solenoid error (voltage too high)
P1211/7 Proportional injection pump solenoid, mechanical error

ditions.
play.
Error is dis-
played.
[Check items]: error code
Error diagnosis
1. Check the NG
resistance of the Replace the sensor.
proportional sole-
noid coil (sole-
noid only).
2. Check the resist- NG 3. Check the wiring

ance of the propor- harness for continu-
tional solenoid coil ity.
(solenoid + wiring
harness).
OK
OK
Replace the E-ECU or the
4. Check the pro- NG injection pump.
portional solenoid
for movement.
OK
Replace the E-ECU.

Wiring diagram
Check points
Proportional
Battery
solenoid relay of
injection pump Main relay K1
Fuse F11
Fuse F2 50 A
Ignition ON
Fuse F3 10 A
Connectors on solenoid side
Connector on wiring harness side
Proportional injection
pump solenoid
Proportional sole-
noid position sensor

Work description 1. Check the coil resistance of the proportional injection pump solenoid (solenoid
only):
Disconnect the wiring harness from the proportional injection pump solenoid.
Measure the resistance between terminals A and B of the proportional injection pump
solenoid by means of a multimeter.
Coil resistance value of standard Yanmar proportional injection pump solenoid.
Coils A B 1 10 %
NG Replace the injection pump.

With the proportional injection pump solenoid and the wiring harness connected, check the resistance between
OK solenoid terminals A and B. -> Next: [2. Check the coil resistance of the proportional injection pump solenoid (relay
+ solenoid):]
2. Check the coil resistance of the proportional injection pump solenoid (solenoid +
wiring harness):
Connect the proportional injection pump solenoid and the wiring harness, and
disconnect the E-ECU and the proportional injection pump solenoid from the wiring
harness.
Measure the resistance between the E-ECU connector terminal E42 on the wiring
harness side and the relay contact of the proportional injection pump solenoid E18 on
the output side by means of a multimeter.
*See above, Coil resistance value of standard Yanmar revs sensors.
OK Check the solenoid for movement by means of the diagnosis tool. -> Next: [4. Check the proportional injection
pump solenoid for movement:]

Disconnect the proportional injection pump solenoid and the E-ECU from the wiring
harness.
Solenoid coil line (output side) E42 Yes OK: normal
Between solenoid coil (input) and Yes OK: normal
relay contact of proportional injection pump solenoid (output) No NG: open wiring harness
Between relay contact of proportional injection pump Yes OK: normal
solenoid (output)
and main relay contact (output) No NG: open wiring harness
NG

4. Check the proportional injection pump solenoid for movement:

Connect all connectors (proportional injection pump solenoid, E-ECU).
With the diagnosis tool Diagnosis test: active control, carry out the position control for
the proportional solenoid. Place the control rack in any position within the settings.
Then check whether the proportional injection pump solenoid has moved to the control
rack position that has been set.
OK Check the solenoid for movement by means of the diagnosis tool. -> Next: [4. Check the proportional injection
pump solenoid for movement:]

Flash code 1-6 main relay
Related DTC
DTC P0686/4 Main relay error

ditions.
play.
Error is dis-
played.
Ignition OFF
[Check items]: log onto the diagnosis tool

Cannot log in -> normal
B. Log onto diagno-
sis tool. Can log in -> main relay contact stuck?
Main relay coil output short-circuited to GND?
Error diagnosis
1. Check the relay NG Replace the relay.

contact for continu-
ity.
OK
2. Check the relay NG

coil resistance Replace the relay.
(relay only).
OK
3. Check the relay OK 4. Check the wiring

coil resistance harness for continu-
(relay + wiring har- ity.
ness).
NG OK Replace the E-ECU.

Wiring diagram
Check points
Relay-side connector
Battery
Lock-up relay K1
Fuse F11
Fuse F2 5 A
Ignition ON
Connector on wiring
harness side
Fuse F3 10 A

Disconnect the E-ECU main relay from the wiring harness.
Check the continuity between terminals A and B on the relay side by means of a
multimeter.
NG Replace the E-ECU main relay.
OK Check the resistance of the E-ECU main relay coil. -> Next: [2. Check the resistance value of the relay coil (relay
only):]
2. Check the relay coil resistance value (relay only):

Disconnect the E-ECU main relay from the wiring harness.
multimeter.
Terminal C Terminal D Existing (*)
OK if both are normal
Terminal D Terminal C Infinite (*)
Terminal C Terminal D
Infinite (*) NG: internal relay circuit error
Terminal D Terminal C
NG Replace the E-ECU main relay.
OK With the E-ECU main relay and the wiring harness connected, check the relay coil resistance. -> Next: [3. Check
the resistance value of the relay coil (relay + wiring harness side):
3. Check the resistance value of the relay coil (relay + wiring harness side):
Connect the E-ECU main relay onto the wiring harness.
Measure the resistance between the battery cable (+) and the E-ECU connector E34
on the wiring harness side.
Battery (+) line E34 Existing (*)
OK: normal
E34 Battery (+) line Infinite (*)
Battery (+) line E34
Infinite (*) NG: wiring harness error
E34 Battery (+) line



Disconnect the E-ECU main relay and the E-ECU from the wiring harness.
Between relay coil (output side) E34 No OK: normal
and GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
Between relay contact (output side) No OK: normal
E48 and E43/battery (+) Yes NG: wiring harness short-circuited with power supply
NG
Connect all connectors (E-ECU main relay, E-ECU) and check again whether all errors have been detected with
OK the diagnosis tool Error code: error display.
Replace the E-ECU.

Flash code 1-2 CAN (Controller Area Network) communication
Related DTC
DTC U0001/12 CAN communication error

ditions.
play.
Error is dis-
[Check Items]: battery voltage
played.
12 [V] or equivalent battery voltage < 16 [V]
-> open CAN wiring?
B. Check the
detected value to 10.5 [V] battery voltage <12 [V] or equivalent
assess the cause -> Battery voltage drop?
of the error. Another ECU deactivated?
Error diagnosis
1. Check battery NG
voltage (diagnosis Charge or replace battery.
tool).
OK
NG
harness for continuity.
OK Check other ECUs for movement or

replace the E-ECU.

Work description 1. Battery voltage check:

With the engine running, connect the diagnosis tool and log in to the diagnosis tool.
Check the battery voltage with the diagnosis tool Diagnosis test: pulse/analog etc..
OK
Approx.12 [V] battery voltage < 16 [V] Check the wiring harness for continuity.
(normal range)
Charge or replace the battery.
10.5 [V] battery voltage < approx.12 [V] NG
Check the movement of other E-ECUs.
Charge or replace the battery.

NG
Check the movement of other E-ECUs.

CAN wiring (high side) E40 Yes OK: normal
(between E-ECU and sensor connector) No NG: open wiring harness
CAN wiring (low side) E39 Yes OK: normal
(between E-ECU and sensor connector) No NG: open wiring harness
Between E39/E40 and No OK: normal
GND/E28/E45/E47 Yes NG: wiring harness short-circuited to GND
NG
Check the other E-ECUs for movement.
OK
Replace the E-ECU.

4.32 Automatic revs setting

How it works
3 4 1
The required engine revs are transmitted to the E-ECU 3 by means of the electronic
manual throttle lever 1. The ECU enables the proportional solenoid 2 (on the diesel
engine) which controls engine revs together with the ECU 3. The automatic revs setting
can be enabled by means of switch 4 (88) with optical monitoring in the cab.
Automatic revs setting enabled

If automatic revs setting is enabled and no work operation is carried out with the machine
for about 4 seconds, the diesel engine is set to idling speed by means of the proportional
solenoid and the ECU. As soon as a work operation is carried out, the engine is
immediately reset to the revs that have been set previously.
Automatic revs setting not enabled

Revs are not reduced automatically. It reacts purely electronically by means of the manual
throttle lever.
Automatically lowering revs significantly reduces fuel consumption and noise.


Hydraulic system
Hydraulic system
Hydraulic system
5 Hydraulic system
5.1 Hydraulic pump PVD-3B-56P-21G5-4626F
Double variable displacement pump + twin gear pumps
Pilot oil supply unit

3
1 4
10 9
7 6 5
Gear pump unit Variable displacement pump unit
Pos. Description
1 Oil flow set screw Qmax
2 Pressure reducing valve PRV 4
3 Bleed screw (not active)
4 Oil flow set screw Qmin
5 Type label
6 Port P2
7 Control initiation set screw
8 Port P1
9 Port P3
10 Port P4

Hydraulic system
8 2
7
3
6 5
Gear pump unit Variable displacement pump unit
Pos. Description
2 Suction line port to variable displacement pump
3 Oil flow set screw Qmin
4 Port PR (2nd speed range)
5 Port PV (gear motor brake release supply)
6 Pilot valve supply
7 Oil flow set screw Qmax
8 Suction line port to gear pump

Hydraulic system
Pump unit: exploded view
4 12
2
8 7 6
13
9
11 16
15
10
17
14 18 19

Hydraulic system
Pos. Description
1 Input shaft
2 Shaft seal
3 Bearing
4 Set screw Qmin
5 Bearing
6 Swash plate
7 Piston
8 Pressure plate
9 Cylinder drum
10 Control disc
11 Drive unit
12 Springs for control characteristics
14 Gear pump
15 Set screw Qmax
16 Governor housing
17 2nd speed range solenoid valve
18 Solenoid valve for safety valve
19 Pilot oil supply unit

Hydraulic system
Pilot oil supply unit
1 2 3 4 5
6
BAR
5 3
9 8 7
Pos. Description Port

1 Gear motor brake release supply PR
2 Pilot valve supply
3 Solenoid valve for safety valve
4 Drives/2nd speed range supply PV
5 2nd speed range solenoid valve
6 Pump 4 supply Internal to P4
7 Pressure limiting valve
8 Tank line
9 Accumulator
10 Shuttle valve block/main valve block swivelling segment

Hydraulic system
5.2 Main valve block with 3rd control circuit and triple articulation boom
Ports
B1 A1
Bucket
T1 A2
Boom
Pi1
B2
Left-hand B3 A3
side drive
Input P1 P2 P1 P2
Right-hand B4 A4
side drive
Boom 2
Stick B5 A5
Auxiliary
hydraulics B6 A6
Auxiliary hydraulics
flow rate adjustment T3
Swivel boom
B7 A7
3rd control circuit/triple
articulation boom A8
B8
Stabiliser blade
B9 A9
Rotating the upper
carriage
B10 A10
Straight-ahead
driving B11 A11
Input P3 out-
put T2 T2 P3

Hydraulic system
Legend
Pilot control lines
Port Legend Controlled via

Pa1, Pb1 Bucket control Joystick (right)
Pa2, Pb2 Boom control Joystick (right)
Pa3, Pb3 Left-hand side drive control Drive pedal (left)
Pa4, Pb4 Right-hand side drive control Drive pedal (right)
Pa5, Pb5 Stick control Joystick (left)
Pa6, Pb6 Auxiliary hydraulics control Auxiliary hydraulics pedal
Pa7, Pb7 Boom swivel control Auxiliary hydraulics pedal
3rd control circuit/triple articulation see Triple articulation boom,
Pa8, Pb8
boom control page 7-29
Pa9, Pb9 Stabiliser blade control Stabiliser blade pedal
Pa10, Pb10 Upper carriage rotation control Joystick (left)
Pi3 Straight-ahead driving control Joystick (left)
Pi1 Pi2 Boom summation control Joystick (right)
Main control lines
Port Legend
A1 rod side, B1 base side Bucket ram
A2 rod side, B2 base side Boom ram
A3, B3 Drive unit (left) via swivel joint
A4, B4 Drive unit (right) via swivel joint
A5 base side, B5 rod side Stick
A6, B6 Auxiliary hydraulics
A7 rod side, B7 base side Swivel boom
A8, B8 3rd control circuit/triple articulation boom
A9 rod side, B9 base side Stabiliser blade
A10, B10 Rotate
Pump/tank lines
Port Legend
P1 Pump 1 port
P2 Pump 2 port
P3 Pump 3 port
T1 Tank line via non-return valve and filter in tank
T2, T3 Tank line via oil cooler and filter in tank
DR1, DR2 Boom summation tank lines
S: bucket pre-tension
see Bucket pre-tension on page 5-13

Hydraulic system
Main valve block diagram
7
EDU
$
% Bucket
3D
3E
% 6 Bucket pre-tension
'5
3L
EDU
$
Boom
3D
3E
$
D
$
% Left-hand side drive

3D
3E
$
D
Input P1
3 3
3
EDU
$, 3S
7
3 EDU
Input P2
3D
3E
Right-hand side drive
$
%
D
$
D
$
'5
Boom summation
3L
3D
Triple articulation boom option

3E
%
$
3E
3D
Stick
EDU
%
$
3E
3D
%
$ Flow rate adjustment of auxiliary hydraulics
'5
7
$
%
Swivel boom
3D
3E
$
%
3rd control circuit option

3D
3E
$
D
EDU
$
%
D
$
3E
3D
Stabiliser blade
$
%
Rotating the upper carriage

3D
3E
3
3L
Drive counterbalancing system

EDU
7
3

Hydraulic system
Pressure limiting valves
5
1
6
7
2 8
3 3
4 9
3 3
10
11
Pos. Description
1 Secondary pressure limiting valve (bucket base side)
2 Primary pressure limiting valve P1
3 Plug (secondary pressure limiting valve option see 5-15)
4 Secondary pressure limiting valve (stick rod side)
5 Secondary pressure limiting valve (bucket rod side)
6 Secondary pressure limiting valve (rod side)
7 Secondary pressure limiting valve (boom base side)
9 Secondary pressure limiting valve (stick base side)
10 Secondary pressure limiting valve stabiliser blade rod side

Hydraulic system
Pump assignment Hydraulic supply by pump 1

Bucket section
Boom section
Left-hand side drive section
Hydraulic supply by pump 2
Right-hand side drive section
Boom section 2
3rd control circuit option with additional triple articulation boom option
Stick section
Auxiliary hydraulics section
Boom swivel section
3rd control circuit option with additional triple articulation boom option Only triple
articulation boom option Only 3rd control circuitoption
Stabiliser blade section
Rotate section
Drive counterbalancing system section
Bucket
Boom Pump 1
Left-hand side drive

Input P1 P2

Boom 2
Stick Pump 2
flow rate
Swivel boom
3rd control circuit/tri-
ple articulation boom Pump 3
Stabiliser blade
Rotating the upper
carriage
Straight-ahead
driving
Input P3 out-
put T2

Hydraulic system
5.3 Drive counterbalancing system

Without drive counterbalancing system
Actuating the boom as you drive causes the machine to leave its track.
(P1, P2 each supply a drive, and the alarm function is also governed by P1 or P2.)
With drive counterbalancing system
If the boom is actuated as you drive straight ahead, the machine stays in its track, but drive
speed does not remain constant.
The drive counterbalancing system is only enabled if both drive valves are enabled.
Function
The drive counterbalancing system is enabled by means of an increased banking-up
pressure if both piston valves for driving and a boom function are activated.
P3 takes over all boom functions.
Pump assignment for drive counterbalancing

Left-hand side drive section
Right-hand side drive section
Bucket section
Boom section
Stick section
Swivel section
Stabiliser blade section
Swivel unit section
Drive counterbalancing section

Hydraulic system
Drive counterbalancing diagram
7
$
Bucket
EDU
%
3D
3E
% 6
'5
EDU
3L
Boom
$
3D
3E
$
D
$
% 3E
Left-hand side drive
3D
$
D
Input P1
3
3
EDU
$, 3S
7
Input P2
3
3 EDU
3E
3D

D
$
%
$
D
$
'5 3L Boom summation

3D

3E
%
$
3E
3D
% Stick
EDU
$
3D
3E
%
$
'5
7
$
%
Swivel
3D
3E
$
%
3D
3E
$
$
D
EDU
%
Stabiliser blade
D
$
3E
3D
$
%
Rotate
3D
3E
3
Drive counterbalancing
3L system
EDU
7
3

Hydraulic system
5.4 Regeneration stick section

Problem
High loads on the stick can cause the stick ram to be emptied on the base side, which
can cause the stick to stop in vertical position.
Solution
A non-return valve is integrated in the spool valve so the rod-side oil can flow to the base
side.
Location
The regeneration valve is located between the stick and (for 3rd control circuit or triple
articulation boom options) the boom summation segments
5.5 Bucket pre-tension

A nozzle is integrated in the pressure line of the bucket segment. If the bucket and the
boom (both supplied with oil by the same pump) are actuated at the same time, both move
simultaneously, and not the bucket (with its smaller mass) first, and then the boom with its
larger mass see Main valve block with 3rd control circuit and triple articulation boom on
page 5-6.
Location:

Hydraulic system
5.6 Boom summation raise

Both P1 & P2 pumps are used to raise the boom at higher speed.
Raising the boom

Moving the joystick also controls a second segment (boom 2).
Pump P2 supplies the boom 2 segment with oil.
The summation time (the time the boom 2 segment is switched) is specified by the
piston spring in the boom 2 segment.
Lowering the boom

see Lowering the boom: on page 5-15
D D D D
Boom base
3D 3D
$ $ 7 $ $
3D
3 3
side
3D 3D
'5
$
%
%
$,
$
3L
'5
%
3
$
3
%
$
$
%
7
EDU
EDU
EDU EDU
3E
3E
3E
3L
3S
3E
6
3E
Joystick control

Hydraulic system
5.7 Check valve (load retaining valve)

Boom ram base side
A pilot-operated load retaining valve is used to prevent spool leakage, which allows the
ram to retain its home position.
Raising the boom:

The oil opens the check valve and flows to the base side of the boom ram.
Lowering the boom:

The load on the check valve is reduced by means of the pilot control line and a piston
(reflux to tank). This allows the base side oil to flow back via the check valve.
Joystick
control
Boom base D D D D
3D 3D
side $ $ 7 $ $
3 3 3D
3D
'5
$
%
%
$,
$
3L
3
3
%
$
$
%
7
EDU
EDU
EDU
EDU
3E
3E
3E
3S
3E
6

Hydraulic system
5.8 Flow rate adjustment of auxiliary hydraulics

The available oil quantity at the auxiliary hydraulics ports can be modified by means of the
set screw on the main valve block.
Set screw see Pressure limiting valves on page 5-9
There are two possible positions: see Auxiliary hydraulics oil flow* on page 2-4.
Set screw against hydraulic resistance
The valve seat is closed.
P2 + P3 supply the auxiliary hydraulics section with oil.
Factory setting
Open set screw
Unscrew the valve seat by at least 2 revolutions, but no more than 3, to open the valve
seat completely.
P2 supplies the auxiliary hydraulics section with oil.
The oil supplied by P3 flows to the tank via the open valve seat.
Important!
Intermediate positions of the set screws cause the hydraulic oil to warm up
danger of overheating.

Hydraulic system
5.9 Pilot valves

Joystick Pilot valve for bucket, boom, stick and upper carriage rotation
Consists of a lever and four pressure reducing valves
Numbering for right-hand side joy-

stick. Left-hand side joystick: 3-1-2-4
A
2 4 3 1
Set of tappets
E Article no.: 1000021259
F P T
Pressure (bar) Joystick characteristic

curve
Joystick
position
(degrees)
Pos. Description Pos. Description (left-hand side joystick) Description (right-hand side joystick)
A Control lever 1 Stick extension control Boom ram extension control
B Rubber collar 2 Left-hand side rotation control Bucket ram extension control
C Linkage 3 Stick retraction control Boom ram retraction control
D Universal joint 4 Right-hand side rotation control Bucket ram retraction control
E Guide plate P Supply from pilot oil supply unit Supply from pilot oil supply unit
F Tappet T Tank line Tank line

Hydraulic system
Joystick up to model: AD05131 Joystick from model: AD051132
Pilot control filter V is inserted in the pump line instead of the GE

screw fitting.
Important!
Check the pilot control filter screen for dirt and clean or
replace if necessary. Coarse dirt causes joystick and drive
valve malfunctions and can even destroy the filter insert.

Hydraulic system
Pilot valve (driving) Pedal with hydraulic damping

Consists of two pedals and four pressure reducing valves
3 7

Characteristic curve for

drive pilot valve
Pressure (bar)

7

3
3
Pilot valve piston stroke (mm)

g g g

g g
Joystick position (degrees)
V
Pos. Description
1 Left-hand side drive segment control
2 Left-hand side drive segment control
3 Right-hand side drive segment control
4 Right-hand side drive segment control
P Pilot control pressure
T Tank line
V Pilot control filter

Hydraulic system
2 3
5
4
Pos. Description
1 Bellows
2 Shift unit (kit)
3 Plate (kit)
4 Tappet
5 Non-return valve (also bleeds the pedal)
6 Damping

Hydraulic system
Pilot valve for auxiliary hydraulics

Pilot control unit with pedals for remote control of directional valves
Consists of a pedal and two pressure reducing valves
1 2
0$ 1P
B
0 1P
$
C
E 3
4
Characteristic curve for

Pressure (bar) drive pilot valve
Set of tappets
F Article no.: 1000012382

Pilot valve piston stroke (mm)

j
j
j

Joystick position (degrees)
Pos. Description Pos. Description

A Pedal 1 Auxiliary hydraulics control/offset ram extension control
B Pedal fixture 2 Auxiliary hydraulics control/offset ram retraction control
C Protective caps 3 Tank line
D Mounting plate 4 Supply from pilot oil supply unit
E Tappet
F Spring

Hydraulic system
Pilot valve for stabiliser blade

Pilot control unit with pedals for remote control of directional valves
Consists of a pedal and two pressure reducing valves
1 2
B 3
0$ 1P 4 Characteristic curve for
Pressure (bar) drive pilot valve
0 1P
$
C
D

E Pilot valve piston stroke (mm)

g g g

g g
Pedal position (degrees)
Set of tappets
F Article no.: 1000012382
1 2
Set pedal slack to minimum with screws B bearing in mind that the pedal does not
actuate the valve pistons when it is in home position.
.
Pos. Description Pos. Description

A Pedal 1 Stabiliser blade ram extension control
B Pedal fixture 2 Stabiliser blade ram retraction control
C Protective caps 3 Tank line
D Mounting plate 4 Supply from pilot oil supply unit
E Tappet
F Springs

Hydraulic system
5.10 Valves
7/2 directional valve (changeover valve)
Switches from auxiliary hydraulics (valve de-energised) to boom swivel and vice versa
(valve energised).
Electric control via push button on left-hand side joystick.
3 2
8 7
4 5 6
2 8
3 7
4 5 6
Pos. Description
1 Solenoid
2 Main valve block for auxiliary hydraulics segment
4 Pilot valve for auxiliary hydraulics
5 Pilot valve for auxiliary hydraulics
6 Tank line
7 Shuttle valve block/main valve block, offset ram retraction control
8 Shuttle valve block/main valve block, offset ram extension control

Hydraulic system
4/3 directional valve

Used for electric auxiliary hydraulics and 3rd control circuit.
Valve is located in pilot control branch and is controlled via tip switches on left-hand side
joystick.
2 3
1 6 5 4
5
3
Pos. Description
1 Solenoid 1
4 Solenoid 2
5 Supply from pilot oil supply unit
6 Tank line

Hydraulic system
Shuttle valve block

Actuating upper carriage rotation, boom swivel and stick retraction must release the gear
motor's brake.
High forces act on the brake and destroy it if it is not released during these operations.
$
$
%
%
)
&
&
'
'
(
(
A B
C D
E
A1
B1 C1 D1 E1
Pos. Description
A Right-hand side rotation control (from the joystick)
A1 Right-hand side rotation control (to the main valve block)
B Left-hand side rotation control (from the joystick)
B1 Left-hand side rotation control (to the main valve block)
C Offset ram extension control (from the joystick)
C1 Offset ram extension control (to the main valve block)
D Offset ram retraction control (from the joystick)
D1 Offset ram retraction control (to the main valve block)
E Stick ram extension control (from the joystick)
E1 Stick ram extension control (to the main valve block)
F Gear motor brake release control

Hydraulic system
Changeover valve for SAE/ISO controls (option)

The directional valve is located on the left in base plate I of the chassis.
I
Fig. 1: Directional valve position
Switching from ISO to SAE controls and vice versa with the directional valve
1 5
Position Function
A ISO controls
6 B SAE controls
2
Tighten wing nut J after changing control mode.
3 7
Danger!
Changing the directional valve over modifies the controls (control levers)
4 8
Make sure you know which control mode has been selected before starting
work.
Always secure wing nut J on the changeover lever of the directional valve.
J
Directional valve ports
A B
1 Joystick (right) port 1
2 Main valve block, boom ram retraction control
Fig. 2: Directional valve 3 Joystick (right) port 3
4 Main valve block, boom ram extension control
5 Main valve block, stick ram extension control
6 Joystick (left) port 1
7 Main valve block, stick ram retraction control
8 Joystick (left) port 3

Hydraulic system
5.11 Travelling drive

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.
.
2'
8
1 2 3 4
6
Pos. Description
1 Drive port (-> swivel joint 4a/7a)
2 Brake release piston
3 Drive port (-> swivel joint 6a/5a)
4 Leak oil port (-> swivel joint 8a)
5 Brake piston
6 2nd speed range port (-> swivel joint 1a)
7 2nd speed range directional valve
8 Brake piston

Hydraulic system
Function Driving:
If high pressure is applied to one of the drive ports, 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 piston
slowly returns to home position by means of the throttle orifices. 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.
2nd speed range function 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 2nd speed range valve: 180 bar (2611 psi)

Hydraulic system
3
1
2
4
5
9
7
8

Hydraulic system
Pos. Description
1 Circlip
2 Plug
3 O-ring
4 Bearing
5 Seal
6 Anticavitation valve
7 Piston valve for speed range
8 Brake valve
9 Engine brake set

Hydraulic system
5.12 Swivel unit

Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox
and mechanical motor brake.
2'
9
X
8
7
X
1 2 3 4 5 6
2
7
Pos. Description
1 SH brake release port (-> shuttle valve block)
2 Pilot control pressure port (-> pilot oil supply unit)
3 Brake release valve
4 Right-hand side rotation port (-> main valve block)
5 Anticavitation line port (-> main valve block/tank)
6 Left-hand side rotation port (-> main valve block)
7 Shock anticavitation valves
8 Leak oil port (-> tank)
9 Brake piston
The shock anticavitation valves are dampened for smooth braking.

Hydraulic system
Parking brake/multidisc brake function

Opening the brake
The shuttle valve block directs the pilot control pressure to the SH input if upper carriage
rotation, boom swivel or stick retraction is carried out. The pilot control pressure at the SH
input causes the piston in the brake release valve to shift to active state (brake release).
This directs the pilot control pressure at the PG input to the brake cylinder and releases
the brake.
Movement: upper carriage rotation, boom swivel or stick retraction

Pilot control pressure is present at the SH input.
The piston of the brake release valve moves to work position.
Pilot control pressure is directed to the brake piston.
Brake is released.
Closing the brake

The shuttle valve block causes the pilot control pressure to drop and the SH input is
unpressurised upon termination of upper carriage rotation, boom swivel or stick retraction.
The piston in the brake release valve switches to home position (brake) if there is no
pressure at the SH input. The pressure in the brake cylinder escapes via the brake release
valve to the leak oil system. This enables the brake with some delay (depending on oil
viscosity and brake valve leakage).
End of movement: upper carriage rotation, boom swivel or stick retraction

The pilot control pressure at the SH input drops.
The piston of the brake release valve moves to home position.
No more pilot control pressure on the brake piston.
The oil in the brake piston flows to the tank via a throttle orifice.
The brake is enabled.
Time for releasing the brake: 3.7 sec 1.2 at 50 C (122 F) oil temperature

Hydraulic system

Hydraulic system
Pos. Description
1 Pinion shaft
2 Spacer washer
3 Bearing seal ring
4 Bearing
5 Gear housing
6 Sealing ring
7 Bearing
8 Round nut
9 Complete drive
10 Spacer washer
11 O-ring
12 Ring gear
13 Gear reduction
14 Gear reduction
15 Sun gear
16 Motor flange
17 Hydraulic motor
18 Screw
19 Screw
20 Plug

Hydraulic system

Hydraulic system
Pos. Description
1 O-ring
2 Motor housing
3 O-ring
4 Plug
5 O-ring
6 Bearing
7 Motor shaft
8 Plate
9 Piston
10 Plate
11 Bush
12 Pin
13 Cylinder block
14 Plate
15 Spring
16 Plate
17 Circlip
18 Control disc
19 Parking brake steel ring
20 Brake disc
21 O-ring
22 Spacer washer
23 O-ring
24 O-ring
25 Parking brake piston
26 Brake piston spring
27 Bearing
28 Pin
29 Motor head
30 Anticavitation valve
31 Spring
32 O-ring
33 Plug
34 O-ring
35 Shock valve
36 O-ring
37 O-ring
38 Plug
39 Screw
40 O-ring
41 Brake release valve block
42 Screw

Hydraulic system
5.13 Swivel joint

8-port swivel joint
Pos. Description
1 High speed
2 Blade (base side)
3 Blade (rod side)
4 Drive (upper right)
5 Drive (upper left)
6 Drive (lower right)
7 Drive (lower left)
8 Leak oil

Hydraulic system
5.14 Breather filter

The breather filter is in charge of:
Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil
level) prevents the oil tank from inflating.
Pre-tension of the oil tank to the specified overpressure -> supports the variable
displacement pump's suction.
Filtering the intake air.
The breather filter is located under the tank cover, between the hydraulic filler inlet and the
fuel filler inlet.
Replace the breather filter according to the instructions in the maintenance plan
see Maintenance plan (overview) on page 3-5.
Important!
The breather filter must be replaced at 1000 s/h.
Fig. 3: Breather filter position
Pos. Description
1 Filter fabric
2 Bleeder valve
Fig. 4: Breather filter

Hydraulic system
5.15 Troubleshooting in the hydraulic system

Defective safety switch on control lever base
Wrong setting of safety switch on control lever base
Defective solenoid valve on pilot oil supply unit
Hydraulic system without function Contaminated solenoid valve on pilot oil supply unit
Hydraulic oil level too low
Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Quickhitch couplings not connected correctly
Hydraulic hammer does not work correctly. Hydraulic oil quantity too high/too low
Hydraulic oil pressure too high/too low
Defective switch for 2nd speed range
Defective solenoid valve on pilot oil supply unit
Contaminated solenoid valve on pilot oil supply unit
Excavator runs in 1st speed only.
Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Counterpressure in travelling drive does not drop below control pressure

Hydraulic system
5.16 Hydraulics diagram A4
3rd control circuit

Triple articulation
drive (right)
Gear motor
drive (left)
Travelling
Travelling
boom option
Bucket ram
Offset ram
Boom ram
blade ram
Stick ram
Stabiliser
option
2'
'%
X
'%
5*
5*

EDU

3rd control
3
3
3
3
circuit
X
$ *
side drive
Blade
Left-hand
6+ 3* * % 0
Right-hand
Stick
Bucket
side drive
Swivel

35
Articulated
Boom
D D D D D D
3D
3D
$ $ 7 $ $
3D
boom
3D
3D
$ $

3 3 3D

3D 3D 3
3D
3D
D D
3D
'5
$
%
%
Rotate
$,
$
3L
'5
%
$
3L
$
%
%
$
%
%
%
$
$
3
$
$
3
%
$
$
%
%
$ $
39
EDU
7
3
EDU
EDU
EDU EDU
EDU
EDU
7
'5
3E
3E
3E
3E
3E
3E
3L
3S
3E
7
6
3E 3E
3E
3E
3D
3E
3D
3D 3D 3D
3D

Left-hand Right-
Rotate 3D
Bucket side drive hand side Stick 9
Boom drive

$ $ % % & # ' ' ( (
3D
3E
)
Joystick Joystick 3D
(left) Auxiliary
(right) 3E

hydraulics/ Blade 3D
swivel

35 39
3 3 3 3
9 9

EDU 7:PD[

EDU

0

3EDUFFP8a/PLQ
3EDUFFP8a/PLQ
3EDUFFP8a/PLQ
3EDUFFP8a/PLQ
Q8PLQ

Hydraulic system
5.17 Hydraulics diagram (legend)
Pos. Description
1 Diesel engine
2 Variable displacement pump + gear pump
3 Pilot oil supply unit
4 Left-hand side joystick pilot valve
5 Right-hand side joystick pilot valve
6 Main valve block
7 Left-hand side drive pilot valve
8 Boom swivel pilot valve
9 Stabiliser blade pilot valve
10 Changeover valve: boom swivel/auxiliary hydraulics
11 Oil cooler
12 Oil filter
13 Shuttle valve block
14 Swivel unit
15 Travelling drive
16 Travelling drive
17 Offset ram
18 Stick ram
19 Boom ram
20 Bucket ram
21 Stabiliser blade ram
22 Hose burst valve
23 Electric pilot valve: auxiliary hydraulics (option)
24 Pilot control filter
25 Throttle non-return valve
26 Breather filter
27 Measuring port
28 Throttle non-return valve
29 Swivel joint
30 Triple articulation boom segment (option)
31 Triple articulation boom ram (option)
32 3rd control circuit segment (option)
Pressure accu- Spring-loaded so- Pressure limiting Fixed displacement Variable displace- Fixed displace- Double variable dis-
mulator lenoid valve valve motor ment motor ment pump placement pump
Tank line Measur- Stop cock Non-return valve Throttle ori- Oil cooler Filter Double-acting ram
ing port fice

Hydraulic system
Hydraulic system
5.18 Hydraulics diagram A3
Gear motor
Rotate
Stabiliser blade ram
Blade Blade

Articulated
boom
Offset ram
Swivel
Auxiliary hydraulics Auxiliary hydrau-

Auxiliary hydraulics lics/swivel
Stick ram Stick

Rotate
3rd control circuit
Right-hand Stick Joystick

side drive (left)
Travelling drive (right)
Right-hand
side drive
Left-hand
side drive Left-hand
side drive
Travelling drive (left)
Boom
Boom ram Boom
Bucket
Bucket ram Joystick
Bucket (right)

Hydraulic system
5.19 Options diagrams 1 (from serial no. AC04070)

Safe load indicator DE Triple articulation boom Proportional controls (auxiliary hydraulics) Proportional controls (auxiliary hydraulics) + 3rd control circuit (proportional)
Triple articulation boom

Boom
Auxiliary hydraulics Offset ram Auxiliary hydraulics Offset ram 3rd control circuit
Offset ram
3rd control circuit

Offset ram
Triple articu-
lation boom
Auxiliary hydraulics shock car- 3rd control circuit shock cartridge
tridge
Offset ram Offset ram
Hammer pedal
Hammer pedal
Joystick (left)
Joystick (left)
Joystick (right)
Triple articulation
boom/offset ram

Hydraulic system
5.20 Options diagrams 2 (from serial no. AC04070)

Vario Grab Safe load indicator FR Triple articulation boom + 3rd control circuit (propor-
tional) + proportional controls (auxiliary hydraulics)
Vario ram Boom Stick

Bucket ram
Triple articulation boom Offset ram
Offset ram
The grab is controlled by the
bucket pilot valve.
3rd control circuit SAE valve

Auxiliary 3rd control circuit
hydraulics
3rd control circuit
Triple articulation boom

Stick Boom
RETRACT EXTEND EXTEND RETRACT
Triple articulation
boom/offset ram
Joystick (right)
Joystick (left)
Right-hand side
Left-hand side joy-
Joystick (left) joystick pilot valve
stick pilot valve

Hydraulic system
5.21 Main valve block A3 diagram
D D D D D D
3D 3D
$ $ $ $ 7 $ $
3D 3D 3D
3 3D 3D
3D
3 3
3D
3D
3D
'5
$
%
%
$
3L
'5
%
$
3L
$
%
%
$
%
%
%
$
$
$
3
$
3
%
$
$
%
%
$,
EDU
7
3
EDU
EDU
EDU
EDU
EDU
EDU
7
'5
3E
3E
3E
3E
3E
3E
3L
3S
3E
7
6
3E 3E
3E
3E
Pilot control lines Main control lines Pump/tank lines
Port Legend Controlled via Port Legend Port Legend

Pa1, Pb1 Bucket control Joystick (left) A1, B1 Bucket ram P1 Pump 1 port
Pa2, Pb2 Boom control Joystick (left) A2, B2 Boom ram P2 Pump 2 port
Pa3, Pb3 Left-hand side drive control Drive pedal (left) A3, B3 Drive unit (left) via swivel joint P3 Pump 3 port
Pa4, Pb4 Right-hand side drive control Drive pedal (right) A4, B4 Drive unit (right) via swivel joint P4 Pump 4 port
see chapter 7.15 Triple articulation boom on A5, B5 Stick ram T1 Tank line via non-return valve and filter in tank
Pa5, Pb5 Triple articulation boom control
page 7-31 T2 Tank line via oil cooler and filter in tank
A6, B6 Auxiliary hydraulics
Pa6, Pb6 Stick control Joystick (left) DR1, DR2 Tank lines for boom summation
A7, B7 Offset ram
Pa7, Pb7 Auxiliary hydraulics control Auxiliary hydraulics pedal
A8, B8 Stabiliser blade ram
Pa8, Pb8 Swivel control Stabiliser blade pedal S: bucket pre-tension see S: bucket pre-tension on page 5-7
A9, B9 Gear motor
Pa9, Pb9 3rd control circuit (control) see chapter 7.14 3rd control circuit on page 7-29
Pi1 Pi2 Boom summation control Joystick (right)

Electric system
Electric system
Electric system
6 Electric system
6.1 Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current I Ampere (A)

Voltage U Volt (V)
Resistance R Ohm (W)
Mnemonic: U
R I
Output
Power P Watt (W)
P = U x I = R x I = U/R
6.2 Measuring equipment, measuring methods

Multifunction measuring device
Measurements of values (U, R, I, f)
Continuity test
Diode test
Calculate the measuring range using known data (P, U, R, I) and set before measuring.
Observe AC/DC basic setting:
AC = alternating current/voltage;
DC = direct current/voltage.
Test device with acoustic and optical signal output
Continuity test in de-energised machine electric system and of wiring harnesses
Measuring methods multifunction measuring device
Measuring current (ignition switched on):
Black cable in COM socket (earth),
red cable in A socket or mA socket; connect in series to consumer.
Measuring voltage (ignition switched on):
red cable in V socket;
connect in parallel to consumer.
Measuring resistance (ignition switched off):
red cable in socket;
connect in parallel to consumer (see measuring voltage).

Electric system
Test lamp
The test lamp is used to test lines and functions with the ignition switched on.
Line test (testing voltage):
Connect test lamp between test point (live cable) and machine earth or between test point
(earth line) and a live cable.
Functional check (testing current):
Connect test lamp between a connection on the consumer to be tested and the connection
line.
6.3 Cable colour coding
Colour Code
Black blk
Brown brn
Red red
Orange org
Yellow yel
Green grn
Blue blu
Violet vio
Grey gry
White wht
Pink pnk
6.4 Relays
Use, mode of function Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by microelectronics or
microswitches (e.g. touchpad keyboards, sensors). The switch contacts can be make-
contact, break-contact or changeover switches. These undertake the actual switching
function.
Zero-centre relay
86 = Start of coil (control line)
86 30
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
87 a= Break-contact switch output (load line)
85 87 87a
Fig. 5: Terminal description on relay

Electric system
6.5 Electric units
Units
Alternator 12 V 55 A
Starter 12 V 2.3 kW (3.1 hp)
Battery 12 V 88 Ah
Socket E.g. for cigarette lighter; 15 A max.
6.6 Fuse box on the instrument panel up to serial no. AD07210

F3 10 A Indicators, engine relay
F4 10 A Boom working light
F5 15 A Cab working lights
F9 10 A Rotating beacon, radio, drive interlock
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 6: Fuse box
6.7 Main fuse box with relays up to serial no. AD07210

The main fuse box is located under the cab, next to the swivelling console.
K9 K5 F1
F2 Fuse no. Rated current (A) Protected circuit
F1 40 A Start, preheat, cutoff solenoid
Relay no.
Fig. 7: Relay box under the cab K9 Cutoff solenoid switching relay

Electric system
6.8 Relays
The relays are located in the relay box under the cab, next to the swivelling console.
Switching relay
Protected circuit
no.
K6 Preheating timer (telltale only); black plug t = 10 s
K7
K7 Starting relay
K8 Cutoff solenoid timer; white plug t = 1 s
V1 Cutoff solenoid recovery diode
V1
K6
K81
Fig. 8: Relays
6.9 Fuse box on the instrument panel from serial no. AH00645

F3 10 A Displays, E-ECU
F4 10 A Boom light
F5 15 A Roof lights
F9 10 A Rotating beacon, radio
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 9: Fuse box

Electric system
6.10 Main fuse box with relays from serial no. AH00645
Main fuse box X is located under the cab, next to the swivelling console.
.
Rated current
Fuse no. Protected circuit
(A)
X F1 40 A Start, preheat
Fig. 10: Main fuse box under the cab F11 10 A E-ECU, engine relay
K2 K5 K7 Relay no.
K1 Engine electronics main relay
F2
F1 K2 Fuel-filling pump relay
K42
F11 K5 Preheating high current relay
K1
K7 Start high current relay
V1
K42 Fuel injection pump relay
V1 Blocking diode
6.11 ECU from serial no. AH00645

The ECU is located above the main fuse box, under the cab.
Fig. 11: ECU

Electric system
6.12 Socket
The socket A is located above the lubrication strip B.
Fig. 12: Lubrication strip on the chassis
6.13 Joystick tip switches

Joystick (left)
2 3
Pos. Description
1 Changeover between Boom swivel and auxiliary hydraulics (S27)
2 Tip switch for additional control circuit (S30)
3 Tip switch for additional control circuit (S31)
1 1
Fig. 13: Left-hand side joystick (standard and option)
Joystick (right)
2 3
Pos. Description
1 Horn (S55)
2 Not assigned
3 Automatic idling speed feature (S48)
1 1
Fig. 14: Right-hand side joystick (standard and option)

Electric system
6.14 Instrument panel overview
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Pos. Description
1 Instrument panel (X10)
2 Temperature indicator diesel engine (X13)
3 Cigarette lighter (E15)
4 Preheating start switch (S1)
5
Fuse box ( see Fuse box on the instrument panel up to serial no. AD07210 on
page 6-3)
6 Switch panel
7 Radio option (A1)

Electric system
6.15 Switches: overview
8 9 10 11 12 13 14 15 16 17 18
Pos. Description
8 Switch high speed (S21)
9 Switch wiper/washer system (S20)
10 Switch boom working light (S16)
11 Roof lights (option) switch (S17)
12 Rotating beacon (option) switch (S18)
13 Automatic revs setting switch
14 Switch ventilation (S15)
15 Air conditioning (option) switch (S51)
16 Safe load indicator (option) switch (S42)
17 Not assigned
18 Proportional controls switch
6.16 Alternator
The alternator charges the battery and supplies direct current to electric consumers.
Pos. Description
1 Connection B (battery)
Connection P starting relay
2 Connection IG telltale (12 V)
Connection L telltale (earth)
1 2
Fig. 15: Alternator
6.17 Starter
2
Pos. Description
1 1 Connection S starting relay
2 Connection B battery
Fig. 16: Alternator

Electric system
6-9
Electric system
Wiring harnesses: overview
Wiring diagrams include all options.

6.18 Wiring diagram A4 up to serial no. AC02888 (legend)
No. Description Section No. Description Section No. Description Section
A1 Radio E14 Option K9 Cutoff solenoid switching relay E3 X3 2 pole main connection D0
B1 Fuel indicator F6 M1 Starter F2 X4 9 pole connection drive interlock C/D1
B2 Horn D/E10 M2 Wiper motor F13 Option X5 7 pole connection armrest/chassis D11/12
B6 Engine oil temperature sensor E6 M4 Fan C12 Option X6 5 pole connection armrest switch C11/12
B11 Loudspeaker E15 Option M5 Washer pump F8 Option X7 6 pole connection joystick (right) C11
B12 Loudspeaker E15 Option M7 Fuel-filling pump F1 Option X8 6 pole connection joystick (left) D11
E7 Rear roof lights F14 Option M9 Fuel pump F3 X10 15 pole connection instrument panel B/C3
E9 Front roof light F13 Option P1 Hour meter B3 X11 2 pole connection Vario indicator B6

E10 Front roof light Option P2 Fuel level indication B3 X12 9 pole connection cab C13/14
E11 Boom light F8/9 P3 Engine oil temperature gauge A3 X13 5 pole connection engine temperature A3
E14 Interior light E/F13 R1 Glow plug F5 X14 2 pole connection automatic revs setting C/D 3
E15 Cigarette lighter A14 S1 Preheating start switch A1 X15 1 pole connection drive alarm D/E 1
F1 Main fuse: starter, preheating E2 S2 Engine oil pressure switch F5 X16 3 pole connection drive alarm E2
F2 Main fuse + fuel-filling pump E1 S3 Engine temperature switch E5 X19 1 pole connection socket F7
F3 Indicators, engine relay A5 S4 Air filter pressure switch F6 XE11 2 pole connection boom working light E9
F4 Boom working light A7 S5 Hydraulic oil pressure switch F7 XS41 2 pole connection safe load indicator E8
F5 Cab working lights A8 S8 Battery master switch E/F 1 Y1 Cutoff solenoid F4
F6 Valves, horn A9 S15 Ventilation switch A10 Y3 High-speed solenoid valve F9
F7 Fan, air conditioning A10 S16 Boom working light switch A7 Y13 Solenoid valve for safety valve F11
F8 Wiper, interior light A12 S17 Cab working light switch A8 Option Y14 Solenoid valve automatic idling speed set- F9 Option
ting
F9 Rotating beacon, radio, drive interlock A13 S18 Rotating beacon switch A/B 13 Option
Y15 Solenoid valve auxiliary hydraulics/swivel F10
F10 Socket, cigarette lighter A14 S20 Wiper/washer switch A12 Option
Y16 Solenoid valve additional control circuit F10 Option
G1 Alternator F3 S21 High speed switch A9
G2 Battery F1 S21.1 High-speed tip switch (prepared) E9 Option
Y31 Solenoid valve air conditioning F12 Option
H2 Preheating telltale B3 S27 Additional hydraulics/swivel tip switch D10
H3 Engine temperature telltale B3 S28 Safety switch C12
H4 Engine oil pressure telltale B3 S30 Additional control circuit tip switch D9 Option
H5 Alternator charge function telltale B3 S31 Additional control circuit tip switch D9 Option
H6 Air filter telltale B3 S41 Safe load indicator pressure switch E8 Option
H7 Hydraulic oil filter telltale B3 S42 Safe load indicator switch A6 Option
H9 Safe load indicator telltale C3 Option S48 Automatic idling speed tip switch C9 Option
H28 Rotating beacon F13 Option S51 Air conditioning switch A11 Option
H33 Spare telltale B3 S52 Air conditioning pressure switch E12 Option
H30 Spare telltale C3 S54 Air conditioning thermostat D12 Option
K5 Preheating high current relay E4 S55 Horn tip switch C10
K6 Preheating time lag relay D5 V1 Recovery diode E4
K7 Start high current relay E2 X1 13 pole connection engine/chassis D4-6
K8 Cutoff solenoid time lag relay E3 X2 11 pole connection engine/chassis D7-9
Electric system
6-10
Electric system
6.19 Wiring diagram A4 up to serial no. AC02888

6.20 Wiring diagram A4 from serial no. AC02890 (legend)
A1 Radio E14 Option M1 Starter F2 X4 9 pole connection drive interlock C/D3
B1 Fuel indicator F6 M2 Wiper motor F13 Option X5 7 pole connection armrest/chassis D11/12
B2 Horn D/E10 M4 Fan C12 Option X6 5 pole connection armrest switch C11/12
B6 Engine oil temperature sensor E6 M5 Washer pump F8 Option X7 6 pole connection joystick (right) C/D 11
B11 Loudspeaker E15 Option M7 Fuel-filling pump F1 Option X8 6 pole connection joystick (left) D11
B12 Loudspeaker E15 Option M9 Fuel pump F3 X10 15 pole connection instrument panel B/C 1/2
B14 Warning buzzer C2 P1 Hour meter B1 X11 2 pole connection Vario indicator B6
E7 Rear roof lights F14 Option P2 Fuel level indication B1 X12 9 pole connection cab C13/14

E9 Front roof light F13 Option P3 Engine oil temperature gauge A3 X13 5 pole connection engine temperature A3
E10 Front roof light Option R1 Glow plug F5 X14 2 pole connection automatic revs setting D4
E11 Boom light F8/9 S1 Preheating start switch A1 X15 1 pole connection drive alarm D/E 1
E14 Interior light E/F13 S2 Engine oil pressure switch F5 X16 3 pole connection drive alarm E2
E15 Cigarette lighter A14 S3 Engine temperature switch E5 X19 1 pole connection socket F7
F1 Main fuse: starter, preheating E2 S4 Air filter pressure switch F6 XE11 2 pole connection boom working light E9
F2 Main fuse + fuel-filling pump E1 S5 Hydraulic oil pressure switch F7 XS41 2 pole connection safe load indicator E8
F3 Indicators, engine relay A5 S8 Battery master switch F1 Y1 Cutoff solenoid F4
F4 Boom working light A7 S15 Ventilation switch A10 Y3 High-speed solenoid valve F9
F5 Cab working lights A8 S16 Boom working light switch A7 Y13 Solenoid valve for safety valve F11
F6 Valves, horn A9 S17 Cab working light switch A8 Option Y14 Solenoid valve automatic idling speed set- F9 Option
ting
F7 Fan, air conditioning A10 S18 Rotating beacon switch A/B 13 Option
Y15 Solenoid valve auxiliary hydraulics/swivel F10
F8 Wiper, interior light A12 S20 Wiper/washer switch A12 Option
F9 Rotating beacon, radio, drive interlock A13 S21 High speed switch A9
F10 Socket, cigarette lighter A14 S21.1 High-speed tip switch (prepared) E9 Option
Y31 Solenoid valve air conditioning F12 Option
G1 Alternator F3 S27 Additional hydraulics/swivel tip switch D10
G2 Battery F1 S28 Safety switch C28
H2 Preheating telltale B1 S30 Additional control circuit tip switch D9 Option
H3 Engine temperature telltale C1 S31 Additional control circuit tip switch D9 Option
H4 Engine oil pressure telltale B1 S41 Safe load indicator pressure switch E8 Option
H5 Alternator charge function telltale B1 S42 Safe load indicator switch A6 Option
H6 Air filter telltale B1 S48 Automatic idling speed tip switch C9 Option
H7 Hydraulic oil filter telltale B1 S51 Air conditioning switch A11 Option
H9 Safe load indicator telltale C1 Option S52 Air conditioning pressure switch E12 Option
H28 Rotating beacon F13 Option S54 Air conditioning thermostat D12 Option
K7 Start high current relay E2 X1 13 pole connection engine/chassis D4-6
K8 Cutoff solenoid time lag relay D3 X2 11 pole connection engine/chassis D7-9
K9 Cutoff solenoid switching relay E3 X3 2 pole main connection D0
Electric system
6-12
Electric system
6.21 Wiring diagram A4 from serial no. AC02890

6.22 Wiring diagram A4 from serial no. AH00645 (legend)
No. Description Section No. Description Section
A1 Radio (2) E12 Option M9 Fuel pump (1) E3
B1 Fuel level indicator (1) E13 N5 Diesel engine electronics (1)C-E/6-7
B2 Horn (2) D4 R1 Glow plug (1) E4
B6 Engine temperature sensor (1) E9 R12 Engine speed potentiometer (1) A9
B11 Loudspeaker (2) E12 Option S1 Preheating start switch (1) A1
B12 Loudspeaker (2) E12 Option S2 Engine oil pressure switch (1) E8
B19 Quickhitch warning buzzer (2) C3 S3 Engine temperature switch (1) E11
B20 Engine revs (1) C/D11 S4 Air filter pressure switch (1) B5

E7 Rear working lights (2) E8 Option S5 Hydraulic oil pressure switch (1) E12
E9 Front working light (2) E8 Option S8 Battery master switch (1) D0
E11 Boom working light (2) E1 S15 Heating switch (2) B6
E14 Interior light (2) E10 S16 Working light switch (2) B1
E15 Cigarette lighter (2) B13 S17 Working light switch (2) B8 Option
F1 Main fuse: starter, preheating (1) D2 S18 Rotating beacon switch (2) B11 Option
F2 Main fuse (1) D0 S20 Wiper/washer switch (2) B9 Option
F3 Displays, E-ECU (1) A3 S21 1st/2nd speed switch (2) B2
F4 Boom working light (2) A1 S27 Changeover valve tip switch (2) D5
F5 Roof working lights (2) A8 S28 Left-hand side safety switch (2) D4-5
F6 Valves, horn (2) A2 S40 Quickhitch lock switch (2) B3 Option
F7 Fan, air conditioning (2) A6 S41 Safe load indicator pressure switch (1) E13 Option
F8 Wiper, interior light (2) A9 S42 Safe load indicator switch (1) A13 Option
F9 Rotating beacon, radio (2) A11 S51 Air conditioning switch (2) B7 Option
F10 Socket, cigarette lighter (2) A13 S52 Air conditioning pressure switch (2) D7 Option
F11 E-ECU, engine relay (1) C2 S54 Air conditioning temperature switch (2) C7 Option
G1 Alternator (1) E4 S55 Horn tip switch (2) D6
G2 Battery (1) E0 S79 Fuel-filling pump switch (1) C1
H28 Rotating beacon (2) E11 Option S86 Automatic revs setting pressure switch (1) E5
K1 Engine electronics main relay (1) C4 S87 Automatic revs setting switch (1) A10
K2 Fuel-filling pump relay (1) D1 Y3 Normal speed solenoid valve (2) E2
K5 Preheating high current relay (1) D4 Y13 Pilot control safety valve (2) E4-5
K7 Start high current relay (1) D2 Y15 Auxiliary hydraulics/boom swivel changeo- (2) E5
ver solenoid valve
K42 Fuel injection pump relay (1) C5
Y25 Quickhitch lock solenoid valve (2) E3 Option
M1 Starter (1) E2
Y31 Electro-magnetic clutch compressor (2) E7 Option
M2 Front wiper motor (2) E10 Option
Y60 Fuel injection pump (1) C10 Option
M4 Fan (2) D6 Option
Y61 Cold start valve (1) C11
M5 Front washer pump (2) E9 Option
Y76 Exhaust gas recirculation (1) D5
M7 Fuel-filling pump (1) E1 Option
Electric system
6-14
Electric system
6.23 Wiring diagram A4 (1) from serial no. AH00645

Electric system

6.25 Engine chassis A4 wiring harness 1000109624 up to AD07210 (legend)
6-17
No. Up to To Colour mm No. Up to To Colour mm
1 G1/B alternator M1 starter red 10 36 S4 air filter pressure switch GND blk 1
2 G1/B alternator F1 main fuse red 6 37 B1 fuel level indicator X1/11 engine/chassis connection vio/blk 1
3 M1 starter F2 main fuse red 6 38 GND X16/2 drive alarm connection blk 1
4 F1 main fuse K5/30 preheating relay red 4 38A B1 fuel level indicator X16/2 drive alarm connection blk 1
5 K5/30 preheating relay K9/30 cutoff solenoid relay red 4 39 B1 fuel level indicator S5 preheating start switch blk 1
Electric system
6 F1 main fuse K7/A start high current relay red 4 40 S5 preheating start switch X2/1 engine/chassis connection org/wht 1
7 F2 main fuse X3/A main connection red 6 41 X16/1 drive alarm connection X1/1 engine/chassis connection blu 1
8 F2 main fuse M7 fuel-filling pump red 4 44 S21.1 high-speed tip switch (prepared) X2/2 engine/chassis connection gry 1
9 GND M7 fuel-filling pump blk 4 45 S21.1 high-speed tip switch (prepared) B2 horn gry 1
10 K7/B start high current relay M1 starter wht/red 4 46 B2 horn X5/5 armrest/chassis connection org 1
11 K5/87 preheating relay R1 glow plug brn 6 47 X19 socket X2/4 engine/chassis connection red/blk 1.5
12 K9/87 cutoff solenoid switching relay Y1/1 cutoff solenoid wht 4 48 X19 socket GND blk 1.5
13 M9/1 fuel pump Y1/2 cutoff solenoid blu 1 49 M5 washer pump X2/5 engine/chassis connection blk/wht 1
14 GND Y1/3 cutoff solenoid blk 2.5 50 M5 washer pump GND blk 1
15 K8 cutoff solenoid time lag relay X1/2 engine/chassis connection blu 1 51 XS41/1 safe load indicator X2/6 engine/chassis connection vio/blu 1
16 K8 cutoff solenoid time lag relay V1 blocking diode blu 1 52 XS41/2 safe load indicator GND blk 1
16 V1 blocking diode K7/1 start high current relay blu 1 53 XE11/1 boom working light X2/7 engine/chassis connection grn/yel 1
A 54 XE11/2 boom working light GND blk 1
17 M9/1 fuel pump X1/2 engine/chassis connection blu 1 55 S21.1/1 high-speed tip switch (prepared) X2/8 engine/chassis connection brn/blk 1
18 G1/2 alternator X1/1 engine/chassis connection blu 1 56 Y3 high-speed solenoid valve X2/8 engine/chassis connection brn/blk 1
19 K6 preheating time lag relay X1/3 engine/chassis connection brn 1 57 Y3 high-speed solenoid valve GND blk 1
20 K6 preheating time lag relay K5/86 preheating relay brn 1 58 Y13 solenoid valve for safety valve X5/4 armrest/chassis connection brn/wht 1
21 K6 preheating time lag relay X1/4 engine/chassis connection wht/blk 1 60 GND Y13 solenoid valve for safety valve blk 1
22 K6 preheating time lag relay K7/3 start high current relay wht/blk 1 61 GND M9/2 fuel pump blk 1
23 K6 preheating time lag relay X1/5 engine/chassis connection gry/red 1 62 Y15/1 auxiliary hydraulics/swivel solenoid valve X5/1 armrest/chassis connection blu/yel 1
24 K8 cutoff solenoid time lag relay K9/86 cutoff solenoid switching relay blu/blk 1 63 Y15/2 auxiliary hydraulics/swivel solenoid valve GND blk 1
25 K8 cutoff solenoid time lag relay K9/85 cutoff solenoid switching relay pnk/blk 1 64 Y16/1 electr. auxiliary hydraulics solenoid valve X5/2 armrest/chassis connection gry/yel 1
26 K7/6 start high current relay G1/3 alternator blk/blu 1 65 Y16/2 electr. auxiliary hydraulics solenoid valve GND blk 1
27 GND K5/85 preheating relay blk 1 66 Y17/1 electr. auxiliary hydraulics solenoid valve X5/3 armrest/chassis connection gry/grn 1
28 K5/85 preheating relay K6 preheating time lag relay blk 1 67 Y17/2 electr. auxiliary hydraulics solenoid valve GND blk 1
29 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1 68 S52 air conditioning pressure switch X5/7 armrest/chassis connection yel/red 1
30 K8 cutoff solenoid time lag relay V1 blocking diode blk 1 69 S52 air conditioning pressure switch X2/11 engine/chassis connection yel/red 1
30A V1 blocking diode K7/5 start high current relay blk 1 70 X2/11 engine/chassis connection Y31 air conditioning solenoid valve yel/red 1
31 G1/1 alternator X1/6 engine/chassis connection pnk 1 71 Y14/1 changeover valve solenoid valve X2/9 engine/chassis connection brn/grn 1
32 S2 engine oil pressure switch X1/7 engine/chassis connection wht/grn 1 72 Y14/2 changeover valve solenoid valve GND blk 1
33 S3 engine temperature switch X1/8 engine/chassis connection blk/grn 1 73 GND X5/6 armrest/chassis connection blk 1
34 S3 engine temperature switch X1/9 engine/chassis connection grn/wht 1 79 X15 drive alarm connection X16/3 drive alarm connection gry/blk 1
35 S4 air filter pressure switch X1/10 engine/chassis connection gry/blu 1 80 GND X3/B main connection blk 6

6.26 Engine chassis A4 wiring harness 1000109624 up to AD07210
Auxiliary hydrau- Main fuses
Changeover lics/swivel changeo- Electr. AH Electr. AH
valve valve Preheat- Cutoff Starting Cutoff Preheat & &
valve ver valve ing solenoid relay solenoid ! !
9 9 9 9 + + +
+ +

! 8

!

"

6 8 !

8
Blocking !

!
diode


8
8
Wiring harness connection

8 1000124173
8

8
"

-
Horn Washer pump

" !

8 8
Air condition-
High-speed 8 8
ing pressure Socket 83

Drive
8 switch
switch
Fuel-filling alarm (prepared) Safe load indicator

3
pump

3
8
- 3
High-speed valve
8%
Air filter pres-
Boom working light
sure switch

1000124101 9
'.$
Safety valve

9

3
Alternator

Hydraulic oil Fuel pump

pressure switch
'

! -
8

Drive alarm

" !

Fuel level indicator Starter

-

Air condition- Water temperature switch

ing valve Engine oil
pressure 3
9 2 9
Preheating sys- 3 Cutoff solenoid
tem
Electric system
6-18
6.27 Engine chassis A4 wiring harness 1000173970 from AH00645 (legend)
6-19
1 G1/B alternator M1 starter red 10 51 G-ECU Y60/6 fuel injection pump blk/wht 0.75
2 Battery F1 main fuse red 6 52 N5/38 diesel engine electronics X1/6 engine/chassis connection red/wht 0.5
3 Battery F2 main fuse red 6 53 N5/35 diesel engine electronics X1/7 engine/chassis connection org/blk 0.5
4 F1 main fuse F11 E-ECU, engine relay fuse red 2.5 54 N5/16 diesel engine electronics B6 engine temperature sensor grn/blk 0.5
5 F1 main fuse K5/30 preheating relay red 4 55 N5/33 diesel engine electronics K42/85 fuel injection pump blk/red 0.5
Electric system
6 F1 main fuse K7/30 start high current relay red 4 56 N5/1 diesel engine electronics Y76/1 exhaust gas recirculation (EGR) wht 0.5
7 F2 main fuse X3/A cab connection red 6 57 N5/11 diesel engine electronics Y76/6 exhaust gas recirculation (EGR) yel/red 0.5
8 F2 main fuse K2/30 fuel-filling pump red 4 58 N5/21 diesel engine electronics Y76/3 exhaust gas recirculation (EGR) blu/yel 0.5
10 K7/87 start high current relay M1 starter wht/red 4 59 N5/31 diesel engine electronics Y76/4 exhaust gas recirculation (EGR) brn/blk 0.5
11 K5/87 preheating relay R1 glow plug brn 6 60 CANL (low) N5/39 diesel engine electronics brn/red 0.5
12 K2/87 fuel-filling pump M7 fuel-filling pump wht 4 61 CANL (low) X20/3 brn/red 1
17 K7/86 start high current relay X1/1 engine/chassis connection wht/blk 1 62 CANL (low) X21/1 brn/red 1
18 K7/86 start high current relay N5/8 diesel engine electronics wht/blk 0.5 63 X22/1 X22/2 wht/blu 1
19 K7/85 start high current relay N5/20 diesel engine electronics blk/red 0.5 64 X21/2 N5/39 diesel engine electronics wht/blu 0.5
21 K42/86 fuel injection pump X1/2 engine/chassis connection blu 1 65 N5/40 diesel engine electronics X20/2 wht/red 0.5
22 K42/86 fuel injection pump V1 blocking diode blu 1 66 N5/44 diesel engine electronics K5/86 preheating relay brn 1
23 G1/2 alternator V1 blocking diode blu 1 67 N5/23 diesel engine electronics X1/8 gry/red 0.5
24 M9 fuel feed pump X1/2 engine/chassis connection blu 1 68 N5/17 diesel engine electronics S86 automatic revs setting pressure yel/blk 0.5
25 M9 fuel feed pump S4 air filter pressure switch blu 1 switch
26 X20/1 S4 air filter pressure switch blu 1 69 N5/6 diesel engine electronics X1/9 engine/chassis connection gry/yel 0.5
30 F11 E-ECU, engine relay fuse K1/30 engine electronics main relay red 1 70 S2 engine oil pressure switch N5/14 diesel engine electronics wht/grn 0.5
31 K1/86 engine electronics main relay K1/30 engine electronics main relay red 1 71 S2 engine oil pressure switch X1/10 engine/chassis connection wht/grn 1
32 N5/34 diesel engine electronics K1/85 engine electronics main relay blk/blu 0.5 73 N5/12 diesel engine electronics X1/11 armrest/chassis connection gry/blu 0.5
33 N5/48 diesel engine electronics K1/87 engine electronics main relay red/blk 1 74 S3 engine temperature switch X1/12 grn/blk 1
34 K42/30 fuel injection pump K1/87 engine electronics main relay red/blk 1 75 S4 air filter pressure switch X1/13 gry/blu 1
35 K42/30 fuel injection pump Y76/2 exhaust gas recirculation (EGR) red/blk 1 129 Y31 air conditioning X1/14 red/yel 1
36 K42/30 fuel injection pump Y76/5 exhaust gas recirculation (EGR) red/blk 1 146 S79.1 fuel-filling pump switch X1/15 red/blk 1
37 K42/87 fuel injection pump Y60/1 fuel injection pump blu/blk 0.75 147 S79/2 fuel-filling pump switch K2/86 fuel-filling pump relay vio 1
38 N5/7 diesel engine electronics X1/3 engine/chassis connection blu/grn 0.5 149 S79.1 fuel-filling pump switch K2/87 fuel-filling pump relay vio/wht 1
39 N5/24 diesel engine electronics X1/3 engine/chassis connection blu/grn 0.5 149A S79.1 fuel-filling pump switch S79/1 fuel-filling pump switch vio/wht 1
40 G1/2 alternator X1/4 engine/chassis connection pnk 1 150 K2/85 fuel-filling pump relay K5/85 fuel-filling pump relay blk 1
41 G1/3 alternator N5/10 diesel engine electronics hblu/wht 0.5 151 GND K5/85 fuel-filling pump relay blk 1
42 N5/42 diesel engine electronics Y60/2 fuel injection pump org/blk 0.75 152 GND3 N5/45 diesel engine electronics blk 1
43 N5/36 diesel engine electronics Y60/4 fuel injection pump wht/blk 0.5 153 GND3 N5/47 diesel engine electronics blk 1
44 N5/43 diesel engine electronics Y60/5 fuel injection pump wht/red 0.75 154 GND S86 automatic revs setting pressure blk 1
45 N5/19 diesel engine electronics B20 revs sensor pnk/blk 0.5 switch
46 N5/18 diesel engine electronics B20 revs sensor pnk/wht 0.5 155 GND M9 fuel feed pump blk 1
47 N5/41 diesel engine electronics Y61 cold start device (CSD) yel/red 1 156 GND X20/4 blk 1
48 G-ECU N5/28 diesel engine electronics blk/wht 0.5 157 GND M7 fuel-filling pump blk 4
49 G-ECU X1/5 engine/chassis connection blk/wht 1 158 GND X3/B blk 2.5
50 G-ECU B6 engine temperature sensor blk/wht 1

6.28 Engine chassis A4 wiring harness 1000173970 from AH00645
Fuse: ECU,
Start- Main fuses engine relais Fuel-filling
Fuel pump switch
Fuel-filling ing
Blocking injection pump relay Preheat
diode pump Main
relay relay
ECU engine Coolant tem-

tempera- peratur: sen-
Air condi- ture sensor sor + switch
tioning
Glow plug Air filter pres-

sure switch Engine oil pres-
sure switch
Starter
Battery
Automatic revs set-

ting pressure switch
CSD cold
start device
Alternator
Revs sen-
sor
Fuel injec-
EGR exhaust gas tion pump
Fuel-filling pump recirculation
switch Fuel pump
Fuel-filling
pump
Electric system
6-20
6.29 Switches A4 wiring harness 1000109630 up to serial no. AC02888 (legend)
6-21
7 X3/A main connection S1/1 preheating start switch red 6 95 F5 cab working light fuse S17/1 cab working light switch grn 1
7A S1/1 preheating start switch F10 socket and cigarette lighter fuse red 4 96 S17/1 cab working light switch S17/2 cab working light switch grn 1
15 X1/2 engine/chassis connection X4/9 drive interlock connection blu 1 97 S17/1 cab working light switch S17/10 cab working light switch grn 1
15A X4.1/9 drive interlock connection X4.1/5 drive interlock connection blu 1 98 F8 wiper and interior light fuse X12/7 cab connection blu 1
19 X1/3 engine/chassis connection S1/8 preheating start switch brn 1 98A X12/7 cab connection X12/8 cab connection blu 1
Electric system
19A S1/3 preheating start switch S1/6 preheating start switch brn 1 99 S17/1 cab working light switch X12/5 cab connection grn/red 1
21 X1/4 engine/chassis connection X4/8 drive interlock connection wht/blk 1 101 S17/3 cab working light switch X12/9 cab connection grn/blu 1
21A X4.1/4 drive interlock connection X4.1/8 drive interlock connection wht/blk 1 102 F9 rotating beacon, radio and drive interlock fuse S18/5 rotating beacon switch red 1
23 X1/5 engine/chassis connection X10/10 instrument panel connection gry/red 1 103 S18/1 rotating beacon switch X12/2 cab connection vio 1
31 X1/6 engine/chassis connection X10/7 instrument panel connection pnk 1 105 F7 fan and air conditioning fuse S15/2 ventilation switch yel 1
32 X1/7 engine/chassis connection X10/8 instrument panel connection wht/grn 1 106 S15/1 ventilation switch S15/2 ventilation switch yel 1
33 X1/8 engine/chassis connection X10/9 instrument panel connection blk/grn 1 107 S15/1 ventilation switch S15/10 ventilation switch yel 1
34 X1/9 engine/chassis connection X13 engine temperature connection grn/wht 1 108 S51/10 air conditioning switch S15/10 ventilation switch yel 1
35 X1/10 engine/chassis connection X10/6 instrument panel connection gry/blu 1 109 S15/3 ventilation switch S51/1 air conditioning switch yel/blk 1
37 X1/11 engine/chassis connection X10/4 instrument panel connection vio/blk 1 110 S42/1 safe load indicator switch X10/14 instrument panel connection vio/blu 1
40 X2/1 engine/chassis connection X10/12 instrument panel connection org/wht 1 112 F3 indicators and engine relay fuse X13 engine temperature connection blu 1
41 X1/1 engine/chassis connection F3 indicators and engine relay fuse blu 1 113 X10/1 instrument panel connection X13 engine temperature connection blu 1
42 X1/1 engine/chassis connection X4/5 drive interlock connection blu 1 114 F3 indicators and engine relay fuse X14/1 automatic revs setting connection blu 1
42A X4/7 drive interlock connection X4/5 drive interlock connection blu 1 115 S18/10 rotating beacon switch X14/1 automatic revs setting connection blu 1
43 X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse red 1 116 S18/10 rotating beacon switch S42/10 safe load indicator switch vio/blu 1
44 X2/2 engine/chassis connection F6 valves and horn fuse gry 1 117 S16/B boom working light switch E15 cigarette lighter grn/yel 1
47 X2/4 engine/chassis connection F10 socket and cigarette lighter fuse red/blk 1.5 118 X13 engine temperature connection E15 cigarette lighter grn/yel 1
49 X2/5 engine/chassis connection S20/3 wiper/washer system switch blk/wht 1 119 X13 engine temperature connection X10/2 instrument panel connection grn/yel 1
51 X2/6 engine/chassis connection S42/5 safe load indicator switch vio/blu 1 120 F10 socket, cigarette lighter E15 cigarette lighter red/blk 1.5
53 X2/7 engine/chassis connection S16/1 boom working light switch grn/yel 1 121 F9 rotating beacon, radio and drive interlock fuse X12/8 cab connection red 1
55 X2/8 engine/chassis connection S21/1 high-speed switch brn/blk 1 122 X11/1 Vario indicator connection X2/3 engine/chassis connection brn/blu 1
58A X4.1/1 drive interlock connection X4.1/6 drive interlock connection brn/wht 1 123 X10/5 instrument panel connection X11/2 Vario indicator connection blk 1
59 X4/1 drive interlock connection X6/5 armrest switch connection gry 1 124 X13 engine temperature connection X11/2 Vario indicator connection blk 1
71 X2/9 engine/chassis connection X6/1 armrest switch connection brn/grn 1 125 X13 engine temperature connection X13 engine temperature connection blk 1
76 F6 valves and horn fuse X4/6 drive interlock connection gry 1 126 X14/2 automatic revs setting connection X13 engine temperature connection blk 1
78 X4/3 drive interlock connection X12/3 cab connection blk 1 127 X14/2 automatic revs setting connection S21/9 high-speed switch blk 1
82 S51/5 air conditioning switch X6/2 armrest switch connection yel/red 1 128 S20/9 wiper/washer system switch S21/9 high-speed switch blk 1
83 S15/3 ventilation switch X6/3 armrest switch connection yel/blk 1 129 S20/9 wiper/washer system switch S16/9 boom working light switch blk 1
84 S15/6 ventilation switch X6/4 armrest switch connection yel/blu 1 130 S17/9 cab working light switch S16/9 boom working light switch blk 1
86 X4/4 drive interlock connection S1/7 preheating start switch wht/blk 1 131 S17/9 cab working light switch S18/9 rotating beacon switch blk 1
87 F6 valves and horn fuse S21/5 high-speed switch gry 1 132 S15/9 ventilation switch S18/9 rotating beacon switch blk 1
88 S21/10 high-speed switch S21/5 high-speed switch gry 1 133 S15/9 ventilation switch S51/9 air conditioning switch blk 1
89 F8 wiper and interior light fuse S20/2 wiper/washer system switch blu 1 134 S42/9 safe load indicator switch S51/9 air conditioning switch blk 1
90 S20/10 wiper/washer system switch S20/2 wiper/washer system switch blu 1 135 S42/9 safe load indicator switch X3/B main connection blk 1
91 X12/4 cab connection S20/6 wiper/washer system switch blu/wht 1 136 E15 cigarette lighter X3/B main connection blk 1.5
92 S20/7 wiper/washer system switch S20/6 wiper/washer system switch blu/wht 1 137 X12/3 cab connection X3/B main connection blk 1.5
93 S20/5 wiper/washer system switch X12/1 cab connection blu/red 1 138 S1/5 preheating start switch F4 boom working light fuse blu 2.5
94 F4 boom working light fuse S16/5 boom working light switch grn 1 139 S1/6 preheating start switch F7 fan and air conditioning fuse blu 2.5
94A S16/10 boom working light switch S16/5 boom working light switch grn 1

6.30 Switches A4 wiring harness 1000109630 up to serial no. AC02888
Air Rotating Boom working light High speed

conditioning beacon switch switch
switch switch Cab working light Wiper/washer
Safe load indicator Ventilation
switch switch
switch switch
S42 S51 S15 S18 S17 S16 S20 S21
107 106 106 53

110 X 109 X 105 103 X 95 96 96 97 117 X X 89 90 55 X
X X X X 84 X X X 101 X X X 49 X X X Preheating start
83
51 X 82 X X 109 102 X X 99 94 94A X 93 91 92 87 88 X switch

X X X X X X X X X X X X 92 X X X
S1
135 133 133 107 131 115 129 129 127 Automatic revs Engine temperature Instrument panel
134 116 134 108 132 108 132 116
131 97
130 130 94A 128 90 128 88
setting connection
Cigarette lighter connection connection
19A

X
X10
139
138
7
X14
7A
86 E15 X13

114
19A

115
19
X
126 117 126 125 112 119
120 136 34 113 35 X
127 118 125 124 113 118
119 31 40
32 32 X
37 33 110
123 23 X

122
123
124
X11
X 41 Indicators, controls, engine and cutoff solenoid holding Vario indicator
!
X 112 contact connection
!& 114
X 94
"
"& 138 X Boom working light
X 95
# Cab working lights
#& X X
X 76
X 32 40 53 84 71 98A 93 59 76 $
A B 44 Valves
135 98A
$& X 87
X 31 44 55 103 43 42A
136 82 98
37
7 137
23 122 71 137 78
59 83 78 X4 X 105
% Heating, air conditioning
21 %& 139 X
47 121 91 86 21
35 19
49
X3 101 X 89
X 99 42 42A 15
&
34 15 Main connec- X6 Drive interlock Wiper, interior light
51 X
&& X 98
33 41 42 tion connection
Armrest switch X12 58 58 X 43
121
connection ' Rotating beacon, radio, drive interlock
X2 '& X 102
X1 Cab con- X4.1 7A 120
Engine/chas- Engine/chas- Socket, cigarette lighter
nection 21A 21A (& ( X 47
sis connection sis connection
15A 15A
Electric system
6-22
6.31 Switches A4 wiring harness from serial no. AC02890 (legend)
6-23
7 X3/A main connection S1/1 preheating start switch red 6 94 F4 boom working light fuse S16/5 boom working light switch grn 1
7A S1/1 preheating start switch F10 socket and cigarette lighter fuse red 4 94A S16/10 boom working light switch S16/5 boom working light switch grn 1
15 X1/2 engine/chassis connection X4/9 drive interlock connection blu 1 95 F5 cab working light fuse S17/1 cab working light switch grn 1
15A X4.1/9 drive interlock connection X4.1/5 drive interlock connection blu 1 96 S17/1 cab working light switch S17/2 cab working light switch grn 1
19 X1/3 engine/chassis connection S1/8 preheating start switch brn 1 97 S17/1 cab working light switch S17/10 cab working light switch grn 1
Electric system
19A S1/3 preheating start switch S1/6 preheating start switch brn 1 98 F8 wiper and interior light fuse X12/7 cab connection blu 1
21 X1/4 engine/chassis connection X4/8 drive interlock connection wht/blk 1 98A X12/7 cab connection X12/8 cab connection blu 1
21A X4.1/4 drive interlock connection X4.1/8 drive interlock connection wht/blk 1 99 S17/1 cab working light switch X12/5 cab connection grn/red 1
23 X1/5 engine/chassis connection X10/10 instrument panel connection gry/red 1 101 S17/3 cab working light switch X12/9 cab connection grn/blu 1
31 X1/6 engine/chassis connection X10/8 instrument panel connection pnk 1 102 F9 rotating beacon, radio and drive interlock fuse S18/5 rotating beacon switch red 1
32 X1/7 engine/chassis connection B14/5 warning buzzer connection wht/grn 1 103 S18/1 rotating beacon switch X12/2 cab connection vio 1
32A X10/10 instrument panel connection B14/5 warning buzzer connection wht/grn 1 105 F7 fan and air conditioning fuse S15/2 ventilation switch yel 1
33 X1/8 engine/chassis connection B14/6 warning buzzer connection blk/grn 1 106 S15/1 ventilation switch S15/2 ventilation switch yel 1
33A X10/14 instrument panel connection B14/6 warning buzzer connection blk/grn 1 107 S15/1 ventilation switch S15/10 ventilation switch yel 1
34 X1/9 engine/chassis connection X13 engine temperature connection grn/wht 1 108 S51/10 air conditioning switch S15/10 ventilation switch yel 1
35 X1/10 engine/chassis connection X10/3 instrument panel connection gry/blu 1 109 S15/3 ventilation switch S51/1 air conditioning switch yel/blk 1
37 X1/11 engine/chassis connection X10/4 instrument panel connection vio/blk 1 110 S42/1 safe load indicator switch B14/3 warning buzzer connection vio/blu 1
40 X2/1 engine/chassis connection X10/6 instrument panel connection org/wht 1 111 X10/13 instrument panel connection B14/3 warning buzzer connection vio/blu 1
41 X1/1 engine/chassis connection F3 indicators and engine relay fuse blu 1 112 F3 indicators and engine relay fuse X13 engine temperature connection blu 1
42 X1/1 engine/chassis connection X4/5 drive interlock connection blu 1 113 B14/1 warning buzzer connection X13 engine temperature connection blu 1
42A X4/7 drive interlock connection X4/5 drive interlock connection blu 1 113A B14/1 warning buzzer connection X10/1 instrument panel connection blu 1
43 X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse red 1 114 F3 indicators and engine relay fuse X14/1 automatic revs setting connection blu 1
44 X2/2 engine/chassis connection F6 valves and horn fuse gry 1 115 S18/10 rotating beacon switch X14/1 automatic revs setting connection blu 1
47 X2/4 engine/chassis connection F10 socket and cigarette lighter fuse red/blk 1.5 116 S18/10 rotating beacon switch S42/10 safe load indicator switch vio/blu 1
49 X2/5 engine/chassis connection S20/3 wiper/washer system switch blk/wht 1 117 S16/B boom working light switch E15 cigarette lighter grn/yel 1
51 X2/6 engine/chassis connection S42/5 safe load indicator switch vio/blu 1 118 X13 engine temperature connection E15 cigarette lighter grn/yel 1
53 X2/7 engine/chassis connection S16/1 boom working light switch grn/yel 1 119 X13 engine temperature connection X10/2 instrument panel connection grn/yel 1
55 X2/8 engine/chassis connection S21/1 high-speed switch brn/blk 1 120 F10 socket, cigarette lighter E15 cigarette lighter red/blk 1.5
58A X4.1/1 drive interlock connection X4.1/6 drive interlock connection brn/wht 1 121 F9 rotating beacon, radio and drive interlock fuse X12/8 cab connection red 1
59 X4/1 drive interlock connection X6/5 armrest switch connection gry 1 122 X11/1 Vario indicator connection X2/3 engine/chassis connection brn/blu 1
71 X2/9 engine/chassis connection X6/1 armrest switch connection brn/grn 1 123 X10/5 instrument panel connection X11/2 Vario indicator connection blk 1
76 F6 valves and horn fuse X4/6 drive interlock connection gry 1 124 X13 engine temperature connection X11/2 Vario indicator connection blk 1
78 X4/3 drive interlock connection X12/3 cab connection blk 1 125 X13 engine temperature connection X13 engine temperature connection blk 1
82 S51/5 air conditioning switch X6/2 armrest switch connection yel/red 1 126 X14/2 automatic revs setting connection X13 engine temperature connection blk 1
83 S15/3 ventilation switch X6/3 armrest switch connection yel/blk 1 127 X14/2 automatic revs setting connection S21/9 high-speed switch blk 1
84 S15/6 ventilation switch X6/4 armrest switch connection yel/blu 1 128 S20/9 wiper/washer system switch S21/9 high-speed switch blk 1
86 X4/4 drive interlock connection S1/7 preheating start switch wht/blk 1 129 S20/9 wiper/washer system switch S16/9 boom working light switch blk 1
87 F6 valves and horn fuse S21/5 high-speed switch gry 1 130 S17/9 cab working light switch S16/9 boom working light switch blk 1
88 S21/10 high-speed switch S21/5 high-speed switch gry 1 131 S17/9 cab working light switch S18/9 rotating beacon switch blk 1
89 F8 wiper and interior light fuse S20/2 wiper/washer system switch blu 1 132 S15/9 ventilation switch S18/9 rotating beacon switch blk 1
90 S20/10 wiper/washer system switch S20/2 wiper/washer system switch blu 1 133 S15/9 ventilation switch S51/9 air conditioning switch blk 1
91 X12/4 cab connection S20/6 wiper/washer system switch blu/wht 1 134 S42/9 safe load indicator switch S51/9 air conditioning switch blk 1
92 S20/7 wiper/washer system switch S20/6 wiper/washer system switch blu/wht 1 135 S42/9 safe load indicator switch X3/B main connection blk 1
93 S20/5 wiper/washer system switch X12/1 cab connection blu/red 1

6.32 Switches A4 wiring harness from serial no. AC02890
Air Boom working light High speed

Rotating switch
conditioning switch
beacon
switch Wiper/washer
Safe load indicator Ventilation switch Cab working light
switch
switch switch
switch
S42 S51 S15 S18 S17 S16 S20 S21
107 106 106

110 X 109 X 105 103 X 95 96 96 97 53 117 X X 89 90 55 X
83

51 X 82 X X 109 102 X X 99 94 94A X 93 91 92 87 88 X switch
Automatic revs S1 Instrument panel
135 133 133 107 131 115 129 129 127
134 116 134 108 132 108 132 116
131 97
130 130 94A 128 90 128 88 Cigarette lighter Engine temperature connection
setting connection
connection

19A
X
139
138
7
X14
7A
86 E15 X13

114
19A
115
19
X 8
126 117 126 125 112 119
120 136 34
127 118 125 124 113 118
! 8
8

8 !
! 8

! 122
!
Warning 123
8
124
buzzer

8 !
" X11
X 41
Indicators, controls, engine and cutoff solenoid holding Vario indicator
!
X 112 contact connection
!& 114
X 94 Boom working light

"
"& 138 X
X 95 Cab working lights

#
#& X X
X 76 Valves
X 32 40 53 84 71 98A 93 59 76 $
A B
X 44
98A
$& 87
X 31 44 55 135 98 103 43 42A
136 82
7
137 137
37 23 122 71 59 83 78 X 105 Heating, air conditioning
78 X4 %
21 47
121 91 86 21 %& 139 X
Main X3
connec- Drive interlock X 89
35 19 49 X X6 101 99 42 42A 15
&
Wiper, interior light
34 15 51
tion
X connection && X 98
41
Armrest switch
33 42 X12 58 58 43 Rotating beacon, radio, drive interlock
connection X 121
'
X2 '& X 102
Cab con-
X1 Engine/chas- X4.1 7A 120 Socket, cigarette lighter
nection
Engine/chassis connection 21A 21A (& ( X 47
sis connection 15A 15A
Electric system
6-24
6.33 Wiring harness 1000109629: cab roof
6-25
" " Radio
!

Loudspeaker 8 8
8 8

Electric system

8 ! 8
! 8 8 8

Cab connection

%
Front roof light
%
Interior light 8
%
Rear roof lights

(
Rotating beacon

'.$ '.$
GRNYEL8
BLU8
GRNYEL BLU
BRN8
L
BLK'.$
-
Wiper No. Up to To Colour mm
BLK BRN
1 X12 (1) 9 pole plug and socket connector cab M2 wiper motor grn/yel 0.75
2 X12 (2) 9 pole plug and socket connector cab H28 rotating beacon vio 1
3 X12 (3) 9 pole plug and socket connector cab GND1 blk 1
4 X12 (4) 9 pole plug and socket connector cab M2 wiper motor brn 0.75
5 X12 (5) 9 pole plug and socket connector cab E9 front roof light grn/red 1
6 X12 (6) 9 pole plug and socket connector cab M2 wiper motor blu 0.75
7 X12 (7) 9 pole plug and socket connector cab E14 interior light blu 1
8 X12 (8) 9 pole plug and socket connector cab A1.1/4 radio red 1
8A A1.1/4 radio A1.1/7 radio red 1
9 X12 (9) 9 pole plug and socket connector cab E7 rear roof lights grn/blu 1
10 A1/6 radio B11 loudspeaker wht 0.5
11 A1/5 radio B11 loudspeaker wht/blk 0.5
14 GND1 GND2 blk 1.5
15 GND1 A1.1/8 radio blk 1
16 GND1 M2 wiper motor blk 0.75

6.34 Wiring harness 1000109628: armrest
Heater fan
-

8

Air conditioning
thermostat 3
Safety switch


3

Armrest switch connection

8
Joystick (left)

8

8

Armrest/chassis connection
Joystick (right) connection

8

8

46 X5/5 armrest/chassis connection X7/85 joystick (right) connection org 1 75 M4/2 fan X8/4 joystick (left) connection blk 1
58 X5/4 armrest/chassis connection S28 safety switch brn/wht 1 76 X6/5 armrest switch connection S28 safety switch gry 1
62 X5/1 armrest/chassis connection X8/2 joystick (left) connection blu/yel 1 77 S28 safety switch X8/1 joystick (left) connection gry 1
64 X5/2 armrest/chassis connection X8/3 joystick (left) connection gry/yel 1 81 X6/5 armrest switch connection X7/1 joystick (right) connection gry 1
66 X5/3 armrest/chassis connection X8/6 joystick (left) connection gry/grn 1 82 X6/2 armrest switch connection S54 air conditioning thermostat yel/red 1
68 X5/7 armrest/chassis connection S54 air conditioning thermostat yel/red 1 83 X6/3 armrest switch connection M4/1 fan yel/blk 1
71 X6/1 armrest switch connection X7/2 joystick (right) connection brn/grn 1 84 X6/4 armrest switch connection M4/3 fan yel/blu 1
73 X5/6 armrest/chassis connection X7/4 joystick (right) connection blk 1 85 X8/5 joystick (left) connection X7/3 joystick (right) connection gry/blk 1
74 X5/6 armrest/chassis connection M4/2 fan blk 1
Electric system
6-26
6.35 Wiring harness 1000116138: boom working light
6-27
Electric system

No. Up to To Colour mm
53 XE11/1 boom working light E1 boom working light grn/yel 1
54 XE11/2 boom working light E1 boom working light blk 1

Electric system
Electric system
Wiring harnesses: overview
Wiring diagrams include all options.

Electric system
6.36 Wiring diagram A3 up to serial no. AC02888 (legend)

No. Description Section No. Description Section
A1 Radio E14 Option S2 Engine oil pressure switch F5
B1 Fuel indicator F6 S3 Engine temperature switch E5
B2 Horn D/E10 S4 Air filter pressure switch F6
B6 Engine oil temperature sensor E6 S5 Hydraulic oil pressure switch F7
B11 Loudspeaker E15 Option S8 Battery master switch F1
B12 Loudspeaker E15 Option S15 Ventilation switch A10
E7 Rear roof lights F14 Option S16 Boom working light switch A7
E9 Front roof light F13 Option S17 Cab working light switch A8 Option
E10 Front roof light Option S18 Rotating beacon switch A13 Option
E11 Boom light F8/9 S20 Wiper/washer switch A12 Option
E14 Interior light E/F13 S21 High speed switch A9
E15 Cigarette lighter A14 S21.1 High-speed tip switch (prepared) E9 Option
F1 Main fuse: starter, preheating E2 S27 Additional hydraulics/swivel tip switch D10
F2 Main fuse + fuel-filling pump E1 S28 Safety switch C28
F3 Indicators, engine relay A5 S30 Additional control circuit tip switch D9 Option
F4 Boom working light A7 S31 Additional control circuit tip switch D9 Option
F5 Cab working lights A8 S41 Safe load indicator pressure switch E8 Option
F6 Valves, horn A9 S42 Safe load indicator switch A6 Option
F7 Fan, air conditioning A10 S48 Automatic idling speed tip switch C9 Option
F8 Wiper, interior light A12 S51 Air conditioning switch A11 Option
F9 Rotating beacon, radio, drive interlock A13 S52 Air conditioning pressure switch E12 Option
F10 Socket, cigarette lighter A14 S54 Air conditioning thermostat D12 Option
G1 Alternator F3 S55 Horn tip switch C10
G2 Battery F1 V1 Recovery diode E4
H2 Preheating telltale B3 X1 13 pole connection engine/chassis D4-6
H3 Engine temperature telltale B3 X2 11 pole connection engine/chassis D7-9
H4 Engine oil pressure telltale B3 X3 2 pole main connection D0
H5 Alternator charge function telltale B3 X4 9 pole connection drive interlock C/D1
H6 Air filter telltale B3 X5 7 pole connection armrest/chassis D11/12
H7 Hydraulic oil filter telltale B3 X6 5 pole connection armrest switch C11/12
H9 Safe load indicator telltale C3 Option X7 6 pole connection joystick (right) C/D 11
H28 Rotating beacon F13 Option X8 6 pole connection joystick (left) D11
H33 Spare telltale B3 X10 15 pole connection instrument panel B/C3
H30 Spare telltale C3 X11 2 pole connection Vario indicator B6
K5 Preheating high current relay E4 X12 9 pole connection cab C13/14
K6 Preheating time lag relay D5 X13 5 pole connection engine temperature A3
K7 Start high current relay E2 X14 2 pole connection automatic revs setting C/D3
K8 Cutoff solenoid time lag relay D3 X15 1 pole connection drive alarm D/E 1
K9 Cutoff solenoid switching relay E3 X16 3 pole connection drive alarm E2
M1 Starter F2 X19 1 pole connection socket F7
M2 Wiper motor F13 Option XE11 2 pole connection boom working light E9
M4 Fan C12 Option XS41 2 pole connection safe load indicator E8
M5 Washer pump F8 Option Y1 Cutoff solenoid F4
M7 Fuel-filling pump F1 Option Y3 High-speed solenoid valve F9
M9 Fuel pump F3 Y13 Solenoid valve for safety valve F11
P1 Hour meter B3 Y14 Solenoid valve automatic idling speed setting F9 Option
P2 Fuel level indication B3 Y15 Solenoid valve auxiliary hydraulics/swivel F10
P3 Engine oil temperature gauge A3 Y16 Solenoid valve additional control circuit F10 Option
R1 Glow plug F5 Y17 Solenoid valve additional control circuit F11 Option Wiring diagram (legend)
S1 Preheating start switch A1 Y31 Solenoid valve air conditioning F12 Option

Electric system
6.37 Wiring diagram A3 up to serial no. AC02888

Electric system
6.38 Wiring diagram A3 from serial no. AC02890 AD07210 (legend)

A1 Radio E14 Option M4 Fan C12 Option X4 9 pole connection drive C/D3
B1 Fuel indicator F6 M5 Washer pump F8 Option interlock
B2 Horn D/E10 M7 Fuel-filling pump F1 Option X5 7 pole connection armrest/ D11/12
B6 Engine oil temperature sensor E6 M9 Fuel pump F3 chassis
B11 Loudspeaker E15 Option P1 Hour meter B1 X6 5 pole connection armrest C11/12
B12 Loudspeaker E15 Option P2 Fuel level indication B1 switch
B14 Warning buzzer C2 P3 Engine oil temperature gauge A3 X7 6 pole connection joystick C/D 11
E7 Rear roof lights F14 Option R1 Glow plug F5 (right)
E9 Front roof light F13 Option S1 Preheating start switch A1 X8 6 pole connection joystick (left) D11
E10 Front roof light Option S2 Engine oil pressure switch F5 X10 15 pole connection instrument B/C1/2
E11 Boom light F8/9 S3 Engine temperature switch E5 panel
E14 Interior light E/F13 S4 Air filter pressure switch F6 X11 2 pole connection Vario B6
indicator
E15 Cigarette lighter A14 S5 Hydraulic oil pressure switch F7
X12 9 pole connection cab C13/14
F1 Main fuse: starter, preheating E2 S8 Battery master switch F1
X13 5 pole connection engine A3
F2 Main fuse + fuel-filling pump E1 S15 Ventilation switch A10
temperature
F3 Indicators, engine relay A5 S16 Boom working light switch A7
X14 2 pole connection automatic D4
F4 Boom working light A7 S17 Cab working light switch A8 Option
revs setting
F5 Cab working lights A8 S18 Rotating beacon switch A13 Option
X15 1 pole connection drive alarm D/E1
F6 Valves, horn A9 S20 Wiper/washer switch A20 Option
X16 3 pole connection drive alarm E2
F7 Fan, air conditioning A10 S21 High speed switch A9
X19 1 pole connection socket F7
F8 Wiper, interior light A12 S21. High-speed tip switch (prepared) E9 Option
XE1 2 pole connection boom E9
F9 Rotating beacon, radio, drive A13 1
1 working light
interlock S27 Additional hydraulics/swivel tip D10
XS4 2 pole connection safe load E8
F10 Socket, cigarette lighter A14 switch
1 indicator
G1 Alternator F3 S28 Safety switch A12
Y1 Cutoff solenoid F4
G2 Battery F1 S30 Additional control circuit tip D9 Option
Y3 High-speed solenoid valve F9
H2 Preheating telltale B1 switch
Y13 Solenoid valve for safety valve F11
H3 Engine temperature telltale C1 S31 Additional control circuit tip D9 Option
Y14 Solenoid valve automatic idling F9 Option
H4 Engine oil pressure telltale B1 switch
speed setting
H5 Alternator charge function telltale B1 S41 Safe load indicator pressure E8 Option
Y15 Solenoid valve auxiliary F10
H6 Air filter telltale B1 switch
hydraulics/swivel
H7 Hydraulic oil filter telltale B1 S42 Safe load indicator switch A6 Option
Y16 Solenoid valve additional F10 Option
H9 Safe load indicator telltale C1 Option S48 Automatic idling speed tip switch C9 Option
control circuit
H28 Rotating beacon F13 Option S51 Air conditioning switch A11 Option
Y17 Solenoid valve additional F11 Option
H33 Spare telltale B1 S52 Air conditioning pressure switch E12 Option control circuit
H30 Spare telltale C3 S54 Air conditioning thermostat D12 Option Y31 Solenoid valve air conditioning F12 Option
K7 Start high current relay E2 X1 13 pole connection engine/ D4-6
K8 Cutoff solenoid time lag relay D3 chassis
K9 Cutoff solenoid switching relay E3 X2 11 pole connection engine/ D7-9
chassis
M1 Starter F2
M2 Wiper motor F13 Option X3 2 pole main connection D0 Wiring diagram (legend)

Electric system
6.39 Wiring diagram A3 from serial no. AC02890 AD07210

Electric system
6.40 Wiring diagram A4 from serial no. AH00645 (legend)
No. Description Section Loc. No. Description Section Loc. No. Description Section Loc.
A1 Radio (2) E12 Option M7 Fuel-filling pump (1) E1 Option Y25 Quickhitch lock solenoid valve (2) E3 Option
B1 Fuel level indicator (1) E13 M9 Fuel pump (1) E3 Y31 Electro-magnetic clutch (2) E7 Option
B2 Horn (2) D4 N5 Diesel engine electronics (1)C-E/6-7 compressor
B6 Engine temperature sensor (1) E9 R1 Glow plug (1) E4 Y60 Fuel injection pump (1) C10 Option
B11 Loudspeaker (2) E12 Option R12 Engine speed potentiometer (1) A9 Y61 Cold start valve (1) C11
B12 Loudspeaker (2) E12 Option S1 Preheating start switch (1) A1 Y76 Exhaust gas recirculation (1) D5
B19 Quickhitch warning buzzer (2) C3 S2 Engine oil pressure switch (1) E8
B20 Engine revs (1) C/D11 S3 Engine temperature switch (1) E11
E7 Rear working lights (2) E8 Option S4 Air filter pressure switch (1) B5
E9 Front working light (2) E8 Option S5 Hydraulic oil pressure switch (1) E12
E11 Boom working light (2) E1 S8 Battery master switch (1) D0
E14 Interior light (2) E10 S15 Heating switch (2) B6
E15 Cigarette lighter (2) B13 S16 Working light switch (2) B1
F1 Main fuse: starter, preheating (1) D2 S17 Working light switch (2) B8 Option
F2 Main fuse (1) D0 S18 Rotating beacon switch (2) B11 Option
F3 Displays, E-ECU (1) A3 S20 Wiper/washer switch (2) B9 Option
F4 Boom working light (2) A1 S21 1st/2nd speed switch (2) B2
F5 Roof working lights (2) A8 S27 Changeover valve tip switch (2) D5
F6 Valves, horn (2) A2 S28 Left-hand side safety switch (2) D4-5
F7 Fan, air conditioning (2) A6 S40 Quickhitch lock switch (2) B3 Option
F8 Wiper, interior light (2) A9 S41 Safe load indicator pressure (1) E13 Option
F9 Rotating beacon, radio (2) A11 switch
F10 Socket, cigarette lighter (2) A13 S42 Safe load indicator switch (1) A13 Option
F11 E-ECU, engine relay (1) C2 S51 Air conditioning switch (2) B7 Option
G1 Alternator (1) E4 S52 Air conditioning pressure switch (2) D7 Option
G2 Battery (1) E0 S54 Air conditioning temperature (2) C7 Option
H28 Rotating beacon (2) E11 Option switch
K1 Engine electronics main relay (1) C4 S55 Horn tip switch (2) D6
K2 Fuel-filling pump relay (1) D1 S79 Fuel-filling pump switch (1) C1
K5 Preheating high current relay (1) D4 S86 Automatic revs setting pressure (1) E5
K7 Start high current relay (1) D2 switch
K42 Fuel injection pump relay (1) C5 S87 Automatic revs setting switch (1) A10
M1 Starter (1) E2 Y3 Normal speed solenoid valve (2) E2
M2 Front wiper motor (2) E10 Option Y13 Pilot control safety valve (2) E4-5
Wiring diagram (legend)
M4 Fan (2) D6 Option Y15 Auxiliary hydraulics/boom swivel (2) E5
M5 Front washer pump (2) E9 Option changeover solenoid valve

Electric system

Electric system

Electric system
6.43 Engine chassis A3 wiring harness 1000109624 (legend)

1 G1/B alternator M1 starter red 10 51 XS41/1 safe load indicator X2/6 engine/chassis connection vio/blu 1
2 G1/B alternator F1 main fuse red 6 52 XS41/2 safe load indicator GND blk 1
3 M1 starter F2 main fuse red 6 53 XE11/1 boom working light X2/7 engine/chassis connection grn/yel 1
4 F1 main fuse K5/30 preheating relay red 4 54 XE11/2 boom working light GND blk 1
5 K5/30 preheating relay K9/30 cutoff solenoid relay red 4 55 S21.1/1 high-speed tip switch (prepared) X2/8 engine/chassis connection brn/blk 1
6 F1 main fuse K7/A start high current relay red 4 56 Y3 high-speed solenoid valve X2/8 engine/chassis connection brn/blk 1
7 F2 main fuse X3/A main connection red 6 57 Y3 high-speed solenoid valve GND blk 1
8 F2 main fuse M7 fuel-filling pump red 4 58 Y13 solenoid valve for safety valve X5/4 armrest/chassis connection brn/wht 1
9 GND M7 fuel-filling pump blk 4 60 GND Y13 solenoid valve for safety valve blk 1
10 K7/B start high current relay M1 starter wht/red 4 61 GND M9/2 fuel pump blk 1
11 K5/87 preheating relay R1 glow plug brn 6 62 Y15/1 auxiliary hydraulics/swivel solenoid valve X5/1 armrest/chassis connection blu/yel 1
12 K9/87 cutoff solenoid switching relay Y1/1 cutoff solenoid wht 4 63 Y15/2 auxiliary hydraulics/swivel solenoid valve GND blk 1
13 M9/1 fuel pump Y1/2 cutoff solenoid blu 1 64 Y16/1 electr. auxiliary hydraulics solenoid valve X5/2 armrest/chassis connection gry/yel 1
14 GND Y1/3 cutoff solenoid blk 2.5 65 Y16/2 electr. auxiliary hydraulics solenoid valve GND blk 1
15 K8 cutoff solenoid time lag relay X1/2 engine/chassis connection blu 1 66 Y17/1 electr. auxiliary hydraulics solenoid valve X5/3 armrest/chassis connection gry/grn 1
16 K8 cutoff solenoid time lag relay V1 blocking diode blu 1 67 Y17/2 electr. auxiliary hydraulics solenoid valve GND blk 1
16 A V1 blocking diode K7/1 start high current relay blu 1 68 S52 air conditioning pressure switch X5/7 armrest/chassis connection yel/red 1
17 M9/1 fuel pump X1/2 engine/chassis connection blu 1 69 S52 air conditioning pressure switch X2/11 engine/chassis connection yel/red 1
18 G1/2 alternator X1/1 engine/chassis connection blu 1 70 X2/11 engine/chassis connection Y31 air conditioning solenoid valve yel/red 1
19 K6 preheating time lag relay X1/3 engine/chassis connection brn 1 71 Y14/1 changeover valve solenoid valve X2/9 engine/chassis connection brn/grn 1
20 K6 preheating time lag relay K5/86 preheating relay brn 1 72 Y14/2 changeover valve solenoid valve GND blk 1
21 K6 preheating time lag relay X1/4 engine/chassis connection wht/blk 1 73 GND X5/6 armrest/chassis connection blk 1
22 K6 preheating time lag relay K7/3 start high current relay wht/blk 1 79 X15 drive alarm connection X16/3 drive alarm connection gry/blk 1
23 K6 preheating time lag relay X1/5 engine/chassis connection gry/red 1 80 GND X3/B main connection blk 6
24 K8 cutoff solenoid time lag relay K9/86 cutoff solenoid switching relay blu/blk 1
25 K8 cutoff solenoid time lag relay K9/85 cutoff solenoid switching relay pnk/blk 1
26 K7/6 start high current relay G1/3 alternator blk/blu 1
27 GND K5/85 preheating relay blk 1
28 K5/85 preheating relay K6 preheating time lag relay blk 1
29 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1
30 K8 cutoff solenoid time lag relay V1 blocking diode blk 1
30A V1 blocking diode K7/5 start high current relay blk 1
31 G1/1 alternator X1/6 engine/chassis connection pnk 1
32 S2 engine oil pressure switch X1/7 engine/chassis connection wht/grn 1
33 S3 engine temperature switch X1/8 engine/chassis connection blk/grn 1
34 S3 engine temperature switch X1/9 engine/chassis connection grn/wht 1
35 S4 air filter pressure switch X1/10 engine/chassis connection gry/blu 1
36 S4 air filter pressure switch GND blk 1
37 B1 fuel level indicator X1/11 engine/chassis connection vio/blk 1
38 GND X16/2 drive alarm connection blk 1
38A B1 fuel level indicator X16/2 drive alarm connection blk 1
39 B1 fuel level indicator S5 preheating start switch blk 1
40 S5 preheating start switch X2/1 engine/chassis connection org/wht 1
41 X16/1 drive alarm connection X1/1 engine/chassis connection blu 1
44 S21.1 high-speed tip switch (prepared) X2/2 engine/chassis connection gry 1
45 S21.1 high-speed tip switch (prepared) B2 horn gry 1
46 B2 horn X5/5 armrest/chassis connection org 1
47 X19 socket X2/4 engine/chassis connection red/blk 1.5
48 X19 socket GND blk 1.5
49 M5 washer pump X2/5 engine/chassis connection blk/wht 1
50 M5 washer pump GND blk 1
Engine chassis wiring harness 1000109624 (legend)

Electric system
6.44 Engine chassis A3 wiring harness 1000109624
Auxiliary hydrau- Electr. AH Electr. AH Main fuses

Changeover
lics/swivel change- valve valve
valve Preheating Cutoff Starting Cutoff
over valve Preheat & &
solenoid relay solenoid ! !
9 9 9 9 + + +
+ +

! 8

!

6
"

8 !

8

Blocking !

diode !

8
8

8 1000124173
8

8

"
-
Horn Washer pump

" !

8

8
83
8 High-speed
8 8
Socket
Drive alarm switch
(prepared) Air conditioning Safe load indicator

Fuel-filling
3 pressure switch
pump

3

8

- 3

High-speed 8%
Wiring harness connection valve Air filter pres-

Boom working light

sure switch

1000124101

9
'.$
Safety valve

9
3

Alternator
Hydraulic oil pressure
Fuel pump
switch
'

8

!

-

Drive alarm

" !

Fuel level indicator Starter

-

Air condi- Water temperature switch

tioning valve Engine oil
pressure 3
9 2 9
Preheating 3 Cutoff solenoid
system

Electric system
6.45 Engine chassis A3 wiring harness 1000173970 from serial no. AH00611 (legend)

1 G1/B alternator M1 starter red 10 40 S5 preheating start switch X2/1 engine/chassis connection org/wht 1
2 G1/B alternator F1 main fuse red 6 41 X16/1 drive alarm connection X1/1 engine/chassis connection blu 1
3 M1 starter F2 main fuse red 6 44 S21.1 high-speed tip switch X2/2 engine/chassis connection gry 1
4 F1 main fuse K5/30 preheating relay red 4 (prepared)
5 K5/30 preheating relay K9/30 cutoff solenoid relay red 4 45 S21.1 high-speed tip switch B2 horn gry 1
6 F1 main fuse K7/A start high current relay red 4 (prepared)
7 F2 main fuse X3/A main connection red 6 46 B2 horn X5/5 armrest/chassis connection org 1
8 F2 main fuse M7 fuel-filling pump red 4 47 X19 socket X2/4 engine/chassis connection red/blk 1.5
9 GND M7 fuel-filling pump blk 4 48 X19 socket GND blk 1.5
10 K7/B start high current relay M1 starter wht/red 4 49 M5 washer pump X2/5 engine/chassis connection blk/wht 1
11 K5/87 preheating relay R1 glow plug brn 6 50 M5 washer pump GND blk 1
12 K9/87 cutoff solenoid switching relay Y1/1 cutoff solenoid wht 4 51 XS41/1 safe load indicator X2/6 engine/chassis connection vio/blu 1
13 M9/1 fuel pump Y1/2 cutoff solenoid blu 1 52 XS41/2 safe load indicator GND blk 1
14 GND Y1/3 cutoff solenoid blk 2.5 53 XE11/1 boom working light X2/7 engine/chassis connection grn/yel 1
15 K8 cutoff solenoid time lag relay X1/2 engine/chassis connection blu 1 54 XE11/2 boom working light GND blk 1
16 K8 cutoff solenoid time lag relay V1 blocking diode blu 1 55 S21.1/1 high-speed tip switch X2/8 engine/chassis connection brn/blk 1
16 V1 blocking diode K7/1 start high current relay blu 1 (prepared)
A 56 Y3 high-speed solenoid valve X2/8 engine/chassis connection brn/blk 1
17 M9/1 fuel pump X1/2 engine/chassis connection blu 1 57 Y3 high-speed solenoid valve GND blk 1
18 G1/2 alternator X1/1 engine/chassis connection blu 1 58 Y13 solenoid valve for safety valve X5/4 armrest/chassis connection brn/wht 1
19 K6 preheating time lag relay X1/3 engine/chassis connection brn 1 60 GND Y13 solenoid valve for safety valve blk 1
20 K6 preheating time lag relay K5/86 preheating relay brn 1 61 GND M9/2 fuel pump blk 1
21 K6 preheating time lag relay X1/4 engine/chassis connection wht/blk 1 62 Y15/1 auxiliary hydraulics/swivel X5/1 armrest/chassis connection blu/yel 1
22 K6 preheating time lag relay K7/3 start high current relay wht/blk 1 solenoid valve
23 K6 preheating time lag relay X1/5 engine/chassis connection gry/red 1 63 Y15/2 auxiliary hydraulics/swivel GND blk 1
24 K8 cutoff solenoid time lag relay K9/86 cutoff solenoid switching blu/blk 1 solenoid valve
relay 64 Y16/1 electric auxiliary hydraulics X5/2 armrest/chassis connection gry/yel 1
25 K8 cutoff solenoid time lag relay K9/85 cutoff solenoid switching pnk/blk 1 solenoid valve
relay 65 Y16/2 electric auxiliary hydraulics GND blk 1
26 K7/6 start high current relay G1/3 alternator blk/blu 1 solenoid valve
27 GND K5/85 preheating relay blk 1 66 Y17/1 electric auxiliary hydraulics X5/3 armrest/chassis connection gry/grn 1
28 K5/85 preheating relay K6 preheating time lag relay blk 1 solenoid valve
29 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1 67 Y17/2 electric auxiliary hydraulics GND blk 1
30 K8 cutoff solenoid time lag relay V1 blocking diode blk 1 solenoid valve
30A V1 blocking diode K7/5 start high current relay blk 1 68 S52 air conditioning pressure switch X5/7 armrest/chassis connection yel/red 1
31 G1/1 alternator X1/6 engine/chassis connection pnk 1 69 S52 air conditioning pressure switch X2/11 engine/chassis connection yel/red 1
32 S2 engine oil pressure switch X1/7 engine/chassis connection wht/grn 1 70 X2/11 engine/chassis connection Y31 air conditioning solenoid valve yel/red 1
33 S3 engine temperature switch X1/8 engine/chassis connection blk/grn 1 71 Y14/1 changeover valve solenoid X2/9 engine/chassis connection brn/grn 1
34 S3 engine temperature switch X1/9 engine/chassis connection grn/wht 1 valve
35 S4 air filter pressure switch X1/10 engine/chassis connection gry/blu 1 72 Y14/2 changeover valve solenoid GND blk 1
36 S4 air filter pressure switch GND blk 1 valve
37 B1 fuel level indicator X1/11 engine/chassis connection vio/blk 1 73 GND X5/6 armrest/chassis connection blk 1
38 GND X16/2 drive alarm connection blk 1 79 X15 drive alarm connection X16/3 drive alarm connection gry/blk 1
38A B1 fuel level indicator X16/2 drive alarm connection blk 1 80 GND X3/B main connection blk 6
39 B1 fuel level indicator S5 preheating start switch blk 1
Engine chassis wiring harness 1000173970 (legend)

Electric system
6.46 Engine chassis A3 wiring harness 1000173970 from serial no. AH00611
Main fuses Fuse: ECU, engine

relais Fuel-filling pump
Fuel-filling pump Starting switch
relay Preheat
Blocking Fuel injection Main relay
diode pump relay
ECU engine tem- Coolant temperatur:

Air condition- perature sensor sensor + switch
ing
Glow plug
Air filter pres- Engine oil pres-
sure switch sure switch
Starter
Battery
Automatic revs
setting pressure
switch
CSD cold start

device
Alternator
Revs sensor
Fuel injection
Fuel-filling pump switch EGR exhaust gas pump
recirculation
Fuel pump
Fuel-filling pump

Electric system
6.47 Switches A3 wiring harness 1000109630 up to serial no. AC02888 (legend)

No. Up to To Colour No. Up to To Colour
7 X3/A main connection S1/1 preheating start switch red 6 103 S18/1 rotating beacon switch X12/2 cab connection vio 1
7A S1/1 preheating start switch F10 socket and cigarette lighter fuse red 4 105 F7 fan and air conditioning fuse S15/2 ventilation switch yel 1
15 X1/2 engine/chassis connection X4/9 drive interlock connection blu 1 106 S15/1 ventilation switch S15/2 ventilation switch yel 1
15A X4.1/9 drive interlock connection X4.1/5 drive interlock connection blu 1 107 S15/1 ventilation switch S15/10 ventilation switch yel 1
19 X1/3 engine/chassis connection S1/8 preheating start switch brn 1 108 S51/10 air conditioning switch S15/10 ventilation switch yel 1
19A S1/3 preheating start switch S1/6 preheating start switch brn 1 109 S15/3 ventilation switch S51/1 air conditioning switch yel/blk 1
21 X1/4 engine/chassis connection X4/8 drive interlock connection wht/blk 1 110 S42/1 safe load indicator switch X10/14 instrument panel connection vio/blu 1
21A X4.1/4 drive interlock connection X4.1/8 drive interlock connection wht/blk 1 112 F3 indicators and engine relay fuse X13 engine temperature connection blu 1
23 X1/5 engine/chassis connection X10/10 instrument panel connection gry/red 1 113 X10/1 instrument panel connection X13 engine temperature connection blu 1
31 X1/6 engine/chassis connection X10/7 instrument panel connection pnk 1 114 F3 indicators and engine relay fuse X14/1 automatic revs setting connection blu 1
32 X1/7 engine/chassis connection X10/8 instrument panel connection wht/grn 1 115 S18/10 rotating beacon switch X14/1 automatic revs setting connection blu 1
33 X1/8 engine/chassis connection X10/9 instrument panel connection blk/grn 1 116 S18/10 rotating beacon switch S42/10 safe load indicator switch vio/blu 1
34 X1/9 engine/chassis connection X13 engine temperature connection grn/wht 1 117 S16/B boom working light switch E15 cigarette lighter grn/yel 1
35 X1/10 engine/chassis connection X10/6 instrument panel connection gry/blu 1 118 X13 engine temperature connection E15 cigarette lighter grn/yel 1
37 X1/11 engine/chassis connection X10/4 instrument panel connection vio/blk 1 119 X13 engine temperature connection X10/2 instrument panel connection grn/yel 1
40 X2/1 engine/chassis connection X10/12 instrument panel connection org/wht 1 120 F10 socket, cigarette lighter E15 cigarette lighter red/blk 1.5
41 X1/1 engine/chassis connection F3 indicators and engine relay fuse blu 1 121 F9 rotating beacon, radio and drive interlock fuse X12/8 cab connection red 1
42 X1/1 engine/chassis connection X4/5 drive interlock connection blu 1 122 X11/1 Vario indicator connection X2/3 engine/chassis connection brn/blu 1
42A X4/7 drive interlock connection X4/5 drive interlock connection blu 1 123 X10/5 instrument panel connection X11/2 Vario indicator connection blk 1
43 X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse red 1 124 X13 engine temperature connection X11/2 Vario indicator connection blk 1
44 X2/2 engine/chassis connection F6 valves and horn fuse gry 1 125 X13 engine temperature connection X13 engine temperature connection blk 1
47 X2/4 engine/chassis connection F10 socket and cigarette lighter fuse red/blk 1.5 126 X14/2 automatic revs setting connection X13 engine temperature connection blk 1
49 X2/5 engine/chassis connection S20/3 wiper/washer system switch blk/wht 1 127 X14/2 automatic revs setting connection S21/9 high-speed switch blk 1
51 X2/6 engine/chassis connection S42/5 safe load indicator switch vio/blu 1 128 S20/9 wiper/washer system switch S21/9 high-speed switch blk 1
53 X2/7 engine/chassis connection S16/1 boom working light switch grn/yel 1 129 S20/9 wiper/washer system switch S16/9 boom working light switch blk 1
55 X2/8 engine/chassis connection S21/1 high-speed switch brn/blk 1 130 S17/9 cab working light switch S16/9 boom working light switch blk 1
58A X4.1/1 drive interlock connection X4.1/6 drive interlock connection brn/wht 1 131 S17/9 cab working light switch S18/9 rotating beacon switch blk 1
59 X4/1 drive interlock connection X6/5 armrest switch connection gry 1 132 S15/9 ventilation switch S18/9 rotating beacon switch blk 1
71 X2/9 engine/chassis connection X6/1 armrest switch connection brn/grn 1 133 S15/9 ventilation switch S51/9 air conditioning switch blk 1
76 F6 valves and horn fuse X4/6 drive interlock connection gry 1 134 S42/9 safe load indicator switch S51/9 air conditioning switch blk 1
78 X4/3 drive interlock connection X12/3 cab connection blk 1 135 S42/9 safe load indicator switch X3/B main connection blk 1
82 S51/5 air conditioning switch X6/2 armrest switch connection yel/red 1 136 E15 cigarette lighter X3/B main connection blk 1.5
83 S15/3 ventilation switch X6/3 armrest switch connection yel/blk 1 137 X12/3 cab connection X3/B main connection blk 1.5
84 S15/6 ventilation switch X6/4 armrest switch connection yel/blu 1 138 S1/5 preheating start switch F4 boom working light fuse blu 2.5
86 X4/4 drive interlock connection S1/7 preheating start switch wht/blk 1 139 S1/6 preheating start switch F7 fan and air conditioning fuse blu 2.5
87 F6 valves and horn fuse S21/5 high-speed switch gry 1
88 S21/10 high-speed switch S21/5 high-speed switch gry 1
89 F8 wiper and interior light fuse S20/2 wiper/washer system switch blu 1
90 S20/10 wiper/washer system switch S20/2 wiper/washer system switch blu 1
91 X12/4 cab connection S20/6 wiper/washer system switch blu/wht 1
92 S20/7 wiper/washer system switch S20/6 wiper/washer system switch blu/wht 1
94 F4 boom working light fuse S16/5 boom working light switch grn 1
95 F5 cab working light fuse S17/1 cab working light switch grn 1
96 S17/1 cab working light switch S17/2 cab working light switch grn 1
98 F8 wiper and interior light fuse X12/7 cab connection blu 1
98A X12/7 cab connection X12/8 cab connection blu 1
99 S17/1 cab working light switch X12/5 cab connection grn/red 1 Wiring harness 1000109630
101 S17/3 cab working light switch X12/9 cab connection grn/blu 1
102 F9 rotating beacon, radio and drive interlock fuse S18/5 rotating beacon switch red 1 switches (legend)

Electric system
6.48 Switches A3 wiring harness 1000109630 up to serial no. AC02888
Rotating beacon Boom working light High speed switch

Air condition- switch
switch
ing switch Wiper/washer
Cab working light
Safe load indicator Ventilation switch
switch
switch switch
S42 S51 S15 S18 S17 S16 S20 S21
110 X 109 X 107 106 106

105 103 X 95 96 96 97 53
117 X X 89 90 55 X
51 X 82 X X 83
109
102 X X 99 94 94A X 93 91 92 87 88 X switch
135

133

133 107

131

115

131 97 129

129

127

Automatic revs set-
S1 Engine temperature Instrument panel
116 108 94A 90 88
134 134 132 108 132 116 130 130 128 128
ting connection Cigarette lighter connection connection

19A
X10

X14
139
138
E15 X13
7A
7
86

19A
114
115
X

19
126 120 136
117 126 125
34 112 119 113 35 X
127 118 125 124 113 118
119 31 40
32 32 X
37 33 110
123 23 X

122
123
124
X11
X 41 Indicators, controls, engine and cutoff solenoid holding con- Vario indicator
!& !
X 112
114

tact connection
X 94
"& "
138 X

Boom working light
X 95
Cab working lights
#& #
X X

X 76
32
X 40 53
A B
84 71 98A 93 59 76
$& $
X 44
87

Valves
X 31 44 135 98A
55 82 98 103 43 42A
37
7 136
137
23 122 71 59 83
137
78 X4 78 X 105
Heating, air conditioning
21
47 121 91 86 21 %& %
139 X

35 19 X3
49 X Main connec- X6 101 99 42 42A 15
Drive interlock
X 89
34 15
tion
&& &
X 98

33 41
42
51 X
connection
Armrest switch con- X12 58 58 43
nection
X 121 Rotating beacon, radio, drive interlock
X2 '& '
X 102

X1 Cab con- X4.1 7A 120

Engine/chassis Engine/chassis nection (& ( Socket, cigarette lighter
21A 21A X 47
connection connection
15A 15A

Electric system
6.49 Switches A3 wiring harness from serial no. AC02890 (legend)

No. Up to To Colour No. Up to To Colour
7 X3/A main connection S1/1 preheating start switch red 6 101 S17/3 cab working light switch X12/9 cab connection grn/blu 1
7A S1/1 preheating start switch F10 socket and cigarette lighter fuse red 4 102 F9 rotating beacon, radio and drive interlock fuse S18/5 rotating beacon switch red 1
15 X1/2 engine/chassis connection X4/9 drive interlock connection blu 1 103 S18/1 rotating beacon switch X12/2 cab connection vio 1
15A X4.1/9 drive interlock connection X4.1/5 drive interlock connection blu 1 105 F7 fan and air conditioning fuse S15/2 ventilation switch yel 1
19 X1/3 engine/chassis connection S1/8 preheating start switch brn 1 106 S15/1 ventilation switch S15/2 ventilation switch yel 1
19A S1/3 preheating start switch S1/6 preheating start switch brn 1 107 S15/1 ventilation switch S15/10 ventilation switch yel 1
21 X1/4 engine/chassis connection X4/8 drive interlock connection wht/blk 1 108 S51/10 air conditioning switch S15/10 ventilation switch yel 1
21A X4.1/4 drive interlock connection X4.1/8 drive interlock connection wht/blk 1 109 S15/3 ventilation switch S51/1 air conditioning switch yel/blk 1
23 X1/5 engine/chassis connection X10/10 instrument panel connection gry/red 1 110 S42/1 safe load indicator switch B14/3 warning buzzer connection vio/blu 1
31 X1/6 engine/chassis connection X10/8 instrument panel connection pnk 1 111 X10/13 instrument panel connection B14/3 warning buzzer connection vio/blu 1
32 X1/7 engine/chassis connection B14/5 warning buzzer connection wht/grn 1 112 F3 indicators and engine relay fuse X13 engine temperature connection blu 1
32A X10/10 instrument panel connection B14/5 warning buzzer connection wht/grn 1 113 B14/1 warning buzzer connection X13 engine temperature connection blu 1
33 X1/8 engine/chassis connection B14/6 warning buzzer connection blk/grn 1 113A B14/1 warning buzzer connection X10/1 instrument panel connection blu 1
33A X10/14 instrument panel connection B14/6 warning buzzer connection blk/grn 1 114 F3 indicators and engine relay fuse X14/1 automatic revs setting connection blu 1
34 X1/9 engine/chassis connection X13 engine temperature connection grn/wht 1 115 S18/10 rotating beacon switch X14/1 automatic revs setting connection blu 1
35 X1/10 engine/chassis connection X10/3 instrument panel connection gry/blu 1 116 S18/10 rotating beacon switch S42/10 safe load indicator switch vio/blu 1
37 X1/11 engine/chassis connection X10/4 instrument panel connection vio/blk 1 117 S16/B boom working light switch E15 cigarette lighter grn/yel 1
40 X2/1 engine/chassis connection X10/6 instrument panel connection org/wht 1 118 X13 engine temperature connection E15 cigarette lighter grn/yel 1
41 X1/1 engine/chassis connection F3 indicators and engine relay fuse blu 1 119 X13 engine temperature connection X10/2 instrument panel connection grn/yel 1
42 X1/1 engine/chassis connection X4/5 drive interlock connection blu 1 120 F10 socket, cigarette lighter E15 cigarette lighter red/blk 1.5
42A X4/7 drive interlock connection X4/5 drive interlock connection blu 1 121 F9 rotating beacon, radio and drive interlock fuse X12/8 cab connection red 1
43 X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse red 1 122 X11/1 Vario indicator connection X2/3 engine/chassis connection brn/blu 1
44 X2/2 engine/chassis connection F6 valves and horn fuse gry 1 123 X10/5 instrument panel connection X11/2 Vario indicator connection blk 1
47 X2/4 engine/chassis connection F10 socket and cigarette lighter fuse red/blk 1.5 124 X13 engine temperature connection X11/2 Vario indicator connection blk 1
49 X2/5 engine/chassis connection S20/3 wiper/washer system switch blk/wht 1 125 X13 engine temperature connection X13 engine temperature connection blk 1
51 X2/6 engine/chassis connection S42/5 safe load indicator switch vio/blu 1 126 X14/2 automatic revs setting connection X13 engine temperature connection blk 1
53 X2/7 engine/chassis connection S16/1 boom working light switch grn/yel 1 127 X14/2 automatic revs setting connection S21/9 high-speed switch blk 1
55 X2/8 engine/chassis connection S21/1 high-speed switch brn/blk 1 128 S20/9 wiper/washer system switch S21/9 high-speed switch blk 1
58A X4.1/1 drive interlock connection X4.1/6 drive interlock connection brn/wht 1 129 S20/9 wiper/washer system switch S16/9 boom working light switch blk 1
59 X4/1 drive interlock connection X6/5 armrest switch connection gry 1 130 S17/9 cab working light switch S16/9 boom working light switch blk 1
71 X2/9 engine/chassis connection X6/1 armrest switch connection brn/grn 1 131 S17/9 cab working light switch S18/9 rotating beacon switch blk 1
76 F6 valves and horn fuse X4/6 drive interlock connection gry 1 132 S15/9 ventilation switch S18/9 rotating beacon switch blk 1
78 X4/3 drive interlock connection X12/3 cab connection blk 1 133 S15/9 ventilation switch S51/9 air conditioning switch blk 1
82 S51/5 air conditioning switch X6/2 armrest switch connection yel/red 1 134 S42/9 safe load indicator switch S51/9 air conditioning switch blk 1
83 S15/3 ventilation switch X6/3 armrest switch connection yel/blk 1 135 S42/9 safe load indicator switch X3/B main connection blk 1
84 S15/6 ventilation switch X6/4 armrest switch connection yel/blu 1 136 E15 cigarette lighter X3/B main connection blk 1.5
86 X4/4 drive interlock connection S1/7 preheating start switch wht/blk 1 137 X12/3 cab connection X3/B main connection blk 1.5
87 F6 valves and horn fuse S21/5 high-speed switch gry 1 138 S1/5 preheating start switch F4 boom working light fuse blu 2.5
88 S21/10 high-speed switch S21/5 high-speed switch gry 1 139 S1/6 preheating start switch F7 fan and air conditioning fuse blu 2.5
89 F8 wiper and interior light fuse S20/2 wiper/washer system switch blu 1
90 S20/10 wiper/washer system switch S20/2 wiper/washer system switch blu 1
91 X12/4 cab connection S20/6 wiper/washer system switch blu/wht 1
92 S20/7 wiper/washer system switch S20/6 wiper/washer system switch blu/wht 1
94 F4 boom working light fuse S16/5 boom working light switch grn 1
95 F5 cab working light fuse S17/1 cab working light switch grn 1
98 F8 wiper and interior light fuse X12/7 cab connection blu 1 Wiring harness 1000109630
98A X12/7 cab connection X12/8 cab connection blu 1
99 S17/1 cab working light switch X12/5 cab connection grn/red 1
switches (legend)

Electric system
6.50 Switches A3 wiring harness from serial no. AC02890
Rotating bea- Boom working light High speed switch

Air condition- switch
con switch
ing switch Wiper/washer
Cab working light
Safe load indicator switch Ventilation switch
switch
switch
S42 S51 S15 S18 S17 S16 S20 S21
110 X 109 X 107 106 106

105 103 X 95 96 96 97 53 117 X X 89 90 55 X
51 X 82 X X 83
109
102 X X 99 94 94A X 93 91 92 87 88 X switch
135

133

133 107

131

115

131 97 129

129 90 127

Automatic revs set-
S1 Engine temperature Instrument panel
116 108 94A 88
134 134 132 108 132 116 130 130 128 128
ting connection Cigarette lighter connection connection
19A

X14
139
138
E15 X13
7A
7
86

19A
114
8

115
X
19
126 117 126 125 112 119
127
120 136
118 125 124
34 113 118

! 8
8

8 !
! 8

! 122
! 123
8
124

8 !
" X11
Vario indicator
X 41 Indicators, controls, engine and cutoff solenoid Warning
!& !
connection
X 112
114 holding contact buzzer
X 94
"& "
138 X

Boom working light
X 95
Cab working lights
#& #
X X

X 76
X 32 40 53
A B
84 71 98A 93 59 76
$& $
X 44
Valves
98A 87
X 31 44 55 135 98 103 43 42A
136 82
7
137
37 23 122 71 59 83
137
78 X4 78 X 105 Heating, air conditioning
21 47
121 91 86 21 %& %
139 X

X3
35 19 49 X Main connec- X6 101 99 42 42A 15 Drive interlock X 89
34 15 51 X tion connection
&& &
X 98

33 41 42 Armrest switch con- X12 58 58

nection
X 43
121 Rotating beacon, radio, drive interlock
X2 '& '
X 102

X1 Cab con- X4.1

Engine/chassis Engine/chassis nection
7A 120
Socket, cigarette lighter
connection connection 21A 21A (& ( X 47

15A 15A

Electric system
6.51 Wiring harness 1000109629: cab roof A3

" " Radio

!

Loudspeaker 8 8
8 8

8 ! 8
! 8 8 8

Cab connection

%
Front roof light

%
Interior light
8
%
Rear roof lights

(
Rotating beacon

'.$ '.$
GRNYEL8
BLU8
GRNYEL BLU
BRN8
L
BLK'.$
-
Wiper
BLK BRN
1 X12 (1) 9 pole plug and socket connector cab M2 wiper motor grn/yel 0.75
2 X12 (2) 9 pole plug and socket connector cab H28 rotating beacon vio 1
3 X12 (3) 9 pole plug and socket connector cab GND1 blk 1
4 X12 (4) 9 pole plug and socket connector cab M2 wiper motor brn 0.75
5 X12 (5) 9 pole plug and socket connector cab E9 front roof light grn/red 1
6 X12 (6) 9 pole plug and socket connector cab M2 wiper motor blu 0.75
7 X12 (7) 9 pole plug and socket connector cab E14 interior light blu 1
8 X12 (8) 9 pole plug and socket connector cab A1.1/4 radio red 1
8A A1.1/4 radio A1.1/7 radio red 1
9 X12 (9) 9 pole plug and socket connector cab E7 rear roof lights grn/blu 1
14 GND1 GND2 blk 1.5
15 GND1 A1.1/8 radio blk 1
16 GND1 M2 wiper motor blk 0.75

Electric system
6.52 Wiring harness 1000109628: armrest A3
Fan heater
-

8

Air conditioning
thermostat 3
Safety switch

3

Armrest switch connection

8

Joystick (left)

8
8

Armrest/chassis connection
Joystick (right) connection
8

8

46 X5/5 armrest/chassis connection X7/85 joystick (right) connection org 1 75 M4/2 fan X8/4 joystick (left) connection blk 1
58 X5/4 armrest/chassis connection S28 safety switch brn/wht 1 76 X6/5 armrest switch connection S28 safety switch gry 1
62 X5/1 armrest/chassis connection X8/2 joystick (left) connection blu/yel 1 77 S28 safety switch X8/1 joystick (left) connection gry 1
64 X5/2 armrest/chassis connection X8/3 joystick (left) connection gry/yel 1 81 X6/5 armrest switch connection X7/1 joystick (right) connection gry 1
66 X5/3 armrest/chassis connection X8/6 joystick (left) connection gry/grn 1 82 X6/2 armrest switch connection S54 air conditioning thermostat yel/red 1
68 X5/7 armrest/chassis connection S54 air conditioning thermostat yel/red 1 83 X6/3 armrest switch connection M4/1 fan yel/blk 1
71 X6/1 armrest switch connection X7/2 joystick (right) connection brn/grn 1 84 X6/4 armrest switch connection M4/3 fan yel/blu 1
73 X5/6 armrest/chassis connection X7/4 joystick (right) connection blk 1 85 X8/5 joystick (left) connection X7/3 joystick (right) connection gry/blk 1
74 X5/6 armrest/chassis connection M4/2 fan blk 1

Electric system
6.53 Wiring harness 1000116138: boom working light A3

53 XE11/1 boom working light E1 boom working light grn/yel 1
54 XE11/2 boom working light E1 boom working light blk 1

Electric system

Options
Options
Options
7 Options
Article numbers for options and retrofit kits: please refer to the 6003 spare parts list
7.1 Air conditioning
Danger!
Avoid contact with the heat exchanger or the condenser and the supply lines.
Lines and hoses carrying refrigerating agents or coolants can be pressurised
and hot.
Danger of burns!
Always empty the system before carrying out maintenance work on the
cooling circuit.
Avoid contact with parts carrying coolant.
Carry out maintenance work with the fan at a standstill only.
Have maintenance and repair work carried out by specialised staff only.
Important!
Make sure the cooling system does not come into contact with chlorine, choric
substances, oil, grease or humidity. Use drain and fill systems for R134a only.
Important!
The air conditioning system runs best by taking in outside air see Summer/
winter operation on page 1-21.
Specifications
Air conditioning Model 6003
Refrigerating agent R134a ~ 950 g (2.1 lb)
Control pressure high pressure on 192 bar (27629 psi)
Control pressure high pressure off 252 bar (36329 psi)
Control pressure low pressure on 2.4 bar (34.8 psi)
Control pressure low pressure on 1.20.3 bar (17.44 psi)
Thermostat switch-on temperature + 2.2 C (+36 F)
Thermostat switch-off temperature - 1.1 C (+30 F)

Options
Installation: overview
Condenser
Dehumidifier
Compressor
Air conditioning unit
Diesel engine

Options
Components
Heater/air conditioning unit
The air conditioning unit consists of:
Evaporator: this is where the liquid refrigerating agent evaporates, and the air taken in
by the fan is cooled.
Expansion valve: installed in the evaporator and controls the quantity of liquid
refrigerating agent injected.
Ice guard: a fixed-setting thermostat with sensors placed between the evaporator fins
prevents them from icing up due to freezing condensation water. The thermostat
switches the evaporator's refrigerating agent supply off at 1.1 0.8 C (30 34 F)
and on again at +2.2 0.8 C (36 34 F) as required.
Heat exchanger
Twin radial fan: can be controlled in steps and is overload-protected by means of a
temperature microfuse.
1 2 3 4
Pos. Description
1 Thermostat cable
2 Fan cable
3 Expansion valve
4 Service cover
5 Intake/outlet

Options
Compressor
The compressor takes in the gaseous refrigerating agent from the evaporator, compresses
it and presses the refrigerating agent into the condenser. The diesel engine drives the
compressor via a V-belt and an electro-magnetic clutch.
Condenser
The condenser condenses the compressed refrigerating agent, i.e. it is delivered to the
condenser in gaseous state and emerges at the lowest position of the condenser in liquid
form.
Dehumidifier with pressure switch
Fig. 1: Compressor
The dehumidifier consists of a collector with integrated dryer, a sight glass and a pressure
switch.
The dehumidifier serves as an expansion receptacle and tank for the refrigerating agent. It
can bind a small quantity of water chemically, thereby withdrawing it from the circuit.
A sight glass on the dehumidifier enables to check the level of the circuit.
Important!
The cooling system is not working properly if gas bubbles appear in the sight
glass. Replace the dehumidifier if the sight glass is cloudy or shows traces of
corrosion.
Caution!
Always keep the dehumidifier closed otherwise the dryer is saturated by the
humidity in the air and is no longer serviceable.
Fig. 2: Dehumidifier with pressure switch

Options
Filling up the air conditioning system
Important!
Always have the air conditioning system filled up by an authorised workshop with
specialised staff.
Only use refrigerating agent R134a according to DIN 8960 see Fluids and
lubricants on page 3-1.
Fill up the system in accordance with the Operator's Manual of the manufacturer
of the fill station.
Fill up the system with enough refrigerating agent. Make sure no bubbles appear
in the sight glass.
Start evacuation 20 min-

utes min. < 20 mbar
(0.29 psi)
Interrupt evacuation
Check or rectify the con-
nections
Check whether the vac- Pressure
uum is stable. Wait at gauge rises
System is tight
Evacuate for a further 25

minutes min.
Fill in gaseous refrigerat-

ing agent to a pressure of
3 bar (44 psi)
Pressure
Check for leaks gauge rises
System is tight
Fill in required quantity of

refrigerating agent
Caution!
Do not overfill the system.
Overfilling reduces the system's cooling capacity and can cause damage to
the system.

Options
Maintenance
Important!
Important information for maintenance and repair work:
There may be residual pressure in the system even if it is empty. Release this
pressure with extreme care as you remove the connections.
When working on the cooling circuit, close all openings tightly to prevent
humidity from penetrating into the system.
Do not open the cooling circuit outdoors in humid weather or rain.
Checking the compressor oil

Check the oil level if:
a system component has been replaced.
the system leaks oil.
the maintenance interval is due see Maintenance plan (overview) on page 3-5.
Proceed as follows:
Let the compressor run at idling speed with the diesel engine for 10 minutes.
Open the oil filler opening.
Push the oil dipstick into the oil filler opening.
Article number for oil dipstick: 1000136739
Fig. 3: Oil filler inlet for the air conditioning compressor Withdraw the oil dipstick from the compressor and read off the oil level at the grooves
on the oil dipstick.
The oil level must reach 5 7 grooves.
Fill in oil of the same grade if the oil level is lower see Fluids and lubricants on
page 3-1.
Fresh/recirculated air filter

Tilt the cab to replace the filter see Tilting the cab on page 1-19.
The air conditioning system is located at the rear half of the cab.
Replacing the filter:

Remove the cover between the air conditioning unit and the front air duct.
You can now access the cab filter.
Remove the cab filter.
Insert a new cab filter.
Fit the cover between the air conditioning unit and the front air duct back on again.

Options
Troubleshooting
Problem Possible causes Troubleshooting
Check the fuse's seat, insert correctly if

necessary. Replace a defective fuse. Trouble
Defective or loose fuse occurring again within short time indicates
there is a short circuit or obstruction in the
system. Check the fan for obstruction or a
Fan does not work. defect and rectify the cause.
Line interruption Check the line for loose contacts or ruptures.
Defective fan motor Replace the fan.
Defective fan switch Check or replace the switch.
Fan cannot be switched off. Short circuit in cable or fan switch Eliminate the short circuit. Install a new cable
and/or switch if necessary.
Contaminated contacts. Clean the pins. Proceed with extreme care to

avoid short circuits.
Reduced fan output.
Heavily contaminated heat exchanger. Clean carefully and avoid damage that could
cause leaks.
Flow temperature too low Wait for the engine to warm up.
Defective thermostat Replace the thermostat.
No or insufficient heating output Heat exchanger fins contaminated Check and/or clean the heat exchanger.
Folded or pinched line Eliminate the cause for the error and reroute
the hoses.
Loose hose connection Check the seat of the flexible lines and
tighten the clamps.
Coolant leaks from the unit
Damaged hose Mount and connect a new hose.
Damaged heat exchanger Replace the heat exchanger.
Loose or torn V-belt Adjust V-belt tension, replace the V-belt.
Interruption in the compressor's solenoid
Check the current to the clutch.
coil
Compressor does not work.
V-belt pulley does not turn even though
Check and/or replace the compressor.
electro-magnetic clutch is applied.
Compressor clutch slips. Repair the clutch or replace the compressor.
Expansion valve is blocked or stuck in open
Condenser overflow. Replace the expansion valve.
position.
Thermostat sensor in wrong position Place the sensor in new position.
Iced condenser.
Defective expansion valve or thermostat Replace the expansion valve or thermostat.
Interruption of refrigerating agent line Check all lines for external damage or
Loss of refrigerating agent chafing.
System leak Evacuate, fill up, check for leaks and repair.

Options
Fan duct obstructed. Check air intake and outlet for obstruction.
Eliminate the cause for trouble.
Refrigerating agent level too low Fill up refrigerating agent.
Insufficient cooling output Humidity in system Empty the air conditioning system, replace
the dehumidifier, evacuate and fill up.
Dehumidifier saturated or clogged Replace the dehumidifier.
Condenser fins contaminated Clean the fins. Important: no use of high-

pressure cleaners.
Line interruption Check, repair and/or replace the lines.
System cools with interruptions.
Defective fan motor Replace the fan.
Loose or excessively worn V-belt. Retighten or replace the V-belt.
Loose compressor bracket or worn inside
Repair the bracket, replace the compressor.
parts of the compressor.
System runs very loudly
Excessive wear of fan motor Replace the fan
System too full. Suck off refrigerating agent.
Not enough refrigerating agent in the system Check for leaks, fill up the system.

Options
7.2 Air-suspension seat

Ports The air compressor of the air-suspension seat requires a 12 Volt power supply.
Tension is picked off the connector on the right-hand side joystick X7.
No. Up to To
81 X7/1 joystick (right) connection Seat +12 V
73 X7/4 joystick (right) connection Seat earth
7.3 Counterweight
Specifications Lock the screw connection with Loctite S2420 or VaryBond 12-43.
Counterweight Model 6003

Weight 300 kg/661 lb
Tightening torque for screws 290 Nm/214 ft. lbs.
Max. tail end lateral projection over chains 60 mm/2.4
Important!
Bear in mind the lift capacity table when using a counterweight.
7.4 Long stick

Specifications
Long stick 6003
Length 1985 mm/78
Important!
Bear in mind the lift capacity table when using a counterweight.

Options
7.5 Control circuit (pipework) connections for grab

Connect and disconnect the grab couplings as follows:
Removing the coupling:
Extend stick ram A halfway through.
Release the pressure on the stick ram by moving the right-hand side control lever to the
A left and right.
Turn lock sleeve C towards lock ball B.
Pull lock sleeve C upwards.
The coupling opens.
Connecting the coupling:

Connect the coupling onto the stick ram connection making sure it is straight.
Wait until you hear a hissing sound of the connection.
B Fully connect the coupling on the connection.
Turn back the lock again (away from lock ball B).
C
Flat-seal couplings (can be coupled under residual pressure)
ISO designation Thread

Fig. 4: Grab couplings Plug 12.5 1/2 BSP
Sleeve 12.5 1/2 BSP
Couplings according to ISO 16028
7.6 3rd control circuit connections
Important!
Follow the instructions in the Operator's Manual of the attachment manufacturer
for connecting the 3rd control circuit to attachments.
Standard connections:
Port Bush
Standard Bulkhead coupling 1/2
Quick coupler option Quick coupler 12.5 1/2

Options
7.7 Auxiliary hydraulics connections
Port Function
S 3rd control circuit (option)
T Auxiliary hydraulics
U Hammer reflux line
V Auxiliary hydraulics
W 3rd control circuit (option)
Important!
Follow the instructions given in the Operator's Manuals of the attachments as you
connect them.
Stick (left-hand side) Stick (right-hand side)
S
T
U V W
Fig. 5: Auxiliary hydraulics connections
Quickhitch couplings
Connect and disconnect the quickhitch couplings as follows:
Removing the hose from the coupling:
A
Switch on ignition.
Release the load only after you have switched on ignition and waited 2 seconds
(otherwise if actuated too early, the characteristic curve is shifted and the load is not
released).
B
Release the pressure on the auxiliary hydraulics or the 3rd control circuit by pressing
the auxiliary hydraulics pedal or moving the left or right-hand side proportional joystick
C to the left and right.
Raise the control lever base and turn lock sleeve C towards lock ball B straight away
(otherwise pressure is created again).
Fig. 6: Quickhitch couplings Pull lock sleeve C upwards.
The coupling opens.

Options
Connecting the hose onto the coupling:

Switch on ignition.
Release the load only after you have switched on ignition and waited about 2
seconds (otherwise if actuated too early, the characteristic curve is shifted and the
load is not released).
Release the pressure on the auxiliary hydraulics or the 3rd control circuit by pressing
the auxiliary hydraulics pedal or moving the left or right-hand side proportional joystick
to the left and right.
Remove dirt from the coupling (extends the service life of the coupling).
Then firmly insert the coupling into the port of the stick ram straight away.
Turn back the lock again (away from lock ball B).
Attachments
Important!
Please refer to the Operator's and maintenance manual of the attachment
manufacturer for using and carrying out maintenance on attachments such as
hammers, grabs etc.

Options
7.8 Neuson Vario
Danger!
Lower the excavator arm to the ground when using the Neuson Vario feature,
otherwise
Danger of accidents
Support the machine with the excavator arm when using the Vario feature.
Using the Neuson Vario feature The following steps must be followed under all circumstances when changing the eccentric
position:
Brace excavator arm 6/A on the ground with the boom ram.
To unlock the Neuson Vario feature, press and hold both front switches on the left-hand
side 6/B and right-hand side 6/C joystick.
A Press and hold both buttons B and C about 5 seconds without moving the joysticks to
unlock.
The Neuson Vario feature has four lock positions at offset positions of 90 each (0/360,
90, 180, 270).
D Press the left-hand side joystick D to the left or right for a 90 rotation, press and hold
buttons B and C as you do so.
Both buttons B and C can be released once the excavator has moved.
B C The Neuson Vario feature automatically engages after a 90 rotation.
Fig. 7: Using the Neuson Vario feature If repositioning beyond 90 is required with the Neuson Vario feature, press buttons B
and C beyond the 90 lock position.
As soon as buttons B and C are released, the Neuson Vario feature engages in the
next possible lock position.
Important!
Always check whether the lock position is engaged.
For improved driving features on slopes, reposition the centre of gravity towards the slope
with the Neuson Vario feature.

Options
Vario diagram
B8 B
PR E F
! "
"
A T

Fig. 8: Neuson Vario valve
PBAR
4
02
Description Description
B8 Boom rod side port
B Lock ram rod side port
A Lock ram base side port
T Tank line port
PR Pilot control pressure port
E Solenoid valve
F Solenoid valve
G Lock ram
Function Opening the lock

Brace the excavator arm on the ground with the boom ->
Pressure is applied to boom ram rod side port B8.
Press buttons B and C on the joysticks on either side
Solenoid valves E and F are enabled -> pressure from B8 to B.
Pressure is applied to lock ram rod side port.
Lock ram base side port is switched to tank.
The lock opens.
Locking
Release buttons B and C.
Solenoid valves return to initial position -> pressure is interrupted.
Pilot control pressure is applied to lock ram base side port A.
Lock ram rod side port B is switched to tank.
Keep on rotating the upper carriage
Lock ram engages in the next possible lock position.

Options
Neuson Vario warning device

Danger!
Do not bypass the warning device or make it inoperative. Working with the
excavator is only allowed with a fully functional warning light.
Caution, danger!
This safety feature must be checked by an authorised workshop every time
maintenance is carried out.
The warning light features a functional check. The warning light comes on
briefly every time the machine is started. Always make sure the warning
light is fully functional.
Depending on the position of the Vario feature, stability is higher or lower with respect to a
standard excavator. Observe the lift capacity table and the warning ranges in Fig. 9.
Warning ranges:
A B
Crosswise excavation Lengthwise excavation
Upper carriage not in proper range with
Reduced stability respect to Vario feature, no modification of
stability (hydraulically limited).
Warning range A danger of Warning range B Warning range A danger of

tilting! tilting!
Fig. 9: Warning range

Options
A Danger!
The machine can tilt if the boom is not lowered and swivelled out of the danger
area as soon as the alarm is given (warning sound, warning light A), or if the
alarm is ignored.
Brake the upper carriage and rotate it in the other direction.
The warning device is set to 73 % of the static tilt load in an unfavourable position of the
upper carriage. As soon as the load is exceeded and work is carried in an unfavourable
position of the upper carriage (warning range), or if the upper carriage is rotated into the
warning range, the warning sounds briefly and warning light A comes on.
Fig. 10: Warning light
Ports
"

WH

BN BL

BK
+ +
! !
8
"
BK
BN
! !
BL !
" ! ! "
!

"
9

6 "
! !
(

9
! !
8
8
Col-
No. From Via Up to
our
1 X14 supply port K15 Vario switching relay blu
2 X14 supply port B13 proximity switch Y19 Vario solenoid valve blk
2A Y19 Vario solenoid valve Y19.1 Vario solenoid valve blk
2B X14 supply port H32 Vario telltale blk
3 B13 proximity switch K14 Vario time lag relay yel
3A K14 Vario time lag relay K15 Vario switching relay yel
4 B13 Vario proximity switch K14 Vario time lag relay K15 Vario switching relay vio
4A K15 Vario switching relay X2/6 pressure switch connection vio
4b K14 Vario time lag relay B16 Vario buzzer vio
6 X6/1 armrest connection Y19 Vario solenoid valve brn
6A Y19 Vario solenoid valve Y19.1 Vario solenoid valve brn
7 H32 Vario telltale K15 Vario switching relay gry
7A S1 start switch K15 Vario switching relay gry
8 K14 Vario time lag relay B16 Vario buzzer

Options
7.9 Fuel-filling pump
B Important!
Up to serial number AC02650: use of sight glass instead of telltale.
A
Up to serial number AD07210
Refuel with the fuel-filling pump 11/A as follows:

Place the machine on level ground.
Insert the hose of fuel-filling pump A into the container with the fuel see Stationary
fuel pumps on page 3-10.
Fig. 11: Fuel-filling pump up to AD07210 Press button B to switch on fuel-filling pump 11/A.
The fuel tank is full as soon as telltale 12/C comes on.
C Press button B to switch off fuel-filling pump A.
Important!
Switch off the fuel-filling pump as soon as telltale C comes on, otherwise the fuel
tank may overflow and can be damaged.
Fig. 12: Fuel-filling pump telltale Bear in mind the fuel tank's maximum capacity.
The float switch screwed into the fuel tank triggers the telltale.
Fig. 13: Float switch
From serial number AH00645

A
Refuel with the fuel-filling pump 14/A as follows:
Place the machine on level ground.
B
Insert the hose of fuel-filling pump A into the container with the fuel see Stationary
fuel pumps on page 3-10.
Fig. 14: Fuel-filling pump from AH00645

Press button B to switch on fuel-filling pump 14/A.
As soon as the fuel tank is full, the fuel-filling pump is automatically switched off by
means of float switch 13 screwed into the fuel tank.
Press button B to switch off fuel-filling pump A.

Options
Connections up to serial no. AD07210 The electric connection for the fuel-filling pump is already installed.
The telltale has its own wiring harness, connected to the engine/chassis wiring harness by
means of plug X16.
Strand no. From Up to Colour mm

1 X16/1 X18/1 blu 2.5
2 X16/1 X17 blu 1
3 X16/2 X18/1 blk 2.5
4 X16/2 S60 blk 1
5 X17 S60 vio 1

Options
7.10 Central lubrication system

Grease-based central lubrication system with 12 lubrication points
Position
The electric pump for the central lubrication system is installed over the hydraulic pump.
The electric pump presses the grease through the lubrication line towards the distributing
block on the boom.
From the distributing block, the grease passes on to the lubrication points.
Fig. 15: Central lubrication system pump
Connections
1
2
3
4
5

Pos. Description
1 Earth (brown)
2 + Intermediate lubrication tip switch connection (orange)
3 + Ignition (black)
4 Error telltale (red)
5 + Lubrication telltale (green)

Options
Function
1 5 4 3 2
Pos. Description
1 Push button on motor housing
2 Red LED
3 Green LED
4 Cycle time potentiometer
5 Break time potentiometer
The green LED comes on for about 1.5 sec once ignition is switched on to indicate
readiness.
Pressing the push button on the pump's motor housing switches on the pump and starts
the lubrication cycle. The pump drive motor is switched off and cycle time begins once
lubrication time is over.
All further lubrications start automatically according to the cycle time set.
Lubrication time is stopped and saved if ignition or lubrication is switched off during cycle
time. The data is read from the memory upon switching ignition on again, and lubrication is
resumed where it was interrupted.
Pressing the push button on the motor housing or on the instrument panel starts
intermediate lubrication at any given time if ignition is switched on.
Status LEDs
Fig. 16: Central lubrication system push button
Display Meaning
Green LED 1.5 sec Ignition on (operational readiness)
Steady green light Comes on during lubrication
Steady red light Grease level error Remains lit until grease tank is refilled
Blinking red light Overpressure error

Options
Adjusting breaks and lubrication times

Adjust breaks and lubrication times with potentiometers.
Lubrication time 1 Break 0.5 h to 8 h

min to 16 min
1
0.5
16
8
Repair in case of clogging

Clogging indication
Overpressure beyond service pressure means the system is clogged and is indicated as
follows:
Grease escapes by the pressure limiting valve.
Blinking red LED on the pump housing.
Causes for clogging in the system
Crushed or clogged lubrication line
Bearing overfilled or clogged with lubricant
Inadequate lubricant for central lubrication systems
Clogged distributor output
Clogged distributor
Detecting clogging
Unscrew the main line off the main distributor.
Actuate the pump with the push button and check whether the lubricant is delivered
correctly.
Screw the main line onto the main distributor.
Unscrew the lines one after another and actuate the pump every time.
Repairing a clogged distributor

Remove the distributor from the system.
Unscrew the screw plugs of the piston bore.
Move the piston back and forth (do not remove).
Screw the screw plugs back in again.
You can remove the piston of a defective distributor and check it for scratches or damage.
If there are traces of hardened grease on the piston or the bores, remove the grease with
compressed air or by washing the piston.
Important!
Traces of hardened grease are a sign that the grease is not suitable for central
lubrication systems.

Options
Defective integrated electronic controls Replace the controls and the cap
Pump does not work Electric line interrupted Replace the electric line
Defective pump Replace the pump
Air inclusions in piston Bleed the pump
Pump works but does not supply grease Level too low Fill up the tank
Defective pump element Replace the pump element
Pump does not work See Pump does not work
Breaks too long or lubrication time too short Shorten breaks or increase lubrication time
No grease rims on all lubrication points
System clogged See Grease escapes by the pressure
limiting valve
Burst or leaky supply lines to secondary
Replace the lines
No grease rims on some lubrication points distributor
Leaky screw connections Retighten or replace the screw connections
Burst or leaky lubrication line to lubrication
Replace the line
No grease rim on one lubrication point point
Leaky screw connections Retighten or replace the screw connections
High system pressure Check system bearings
Low ambient temperatures No damage (intermediate lubrication once or

Reduced pump revs
twice if necessary)
System pressure too high Detect and eliminate clogging
System pressure too high Detect and eliminate clogging
Grease escapes by the pressure limiting Clogged distributor Replace the distributor
valve Clogged system Repair clogged/stuck bearings
Defective valve spring Replace the pressure limiting valve

Options
7.11 Service valve

Function The service valve replaces the conventional oil drain plug by a quick coupler for draining
the engine oil more easily.

B Let the engine run until it reaches its operating temperature (oil temperature about 80
C C/176 F).
Place a container under the opening to collect the oil as it drains.
Unscrew cap A of oil drain valve B.
Screw in the drain coupling with a sufficiently long hose D, making sure the end of the
hose is in oil drip tray E.
A Oil drain valve B opens and the engine oil drains.
Fig. 17: Drain coupling with hose
Completely drain the oil.

Unscrew drain coupling C.
B
Screw on cap A of the oil drain valve.
Fill in engine oil see chapter Filling up engine oil on page 3-14.
C
Start the engine and let it run briefly at low revs.
D Switch off the engine.
E Wait a moment until all the oil has run into the oil sump.
Fig. 18: Drain coupling with hose

Options
7.12 Safe load indicator D (safety valve for boom)

Position
5 3
Pos. Description
1 Boom segment pilot control port
2 Joystick connection
3 Boom pressure line port
4 Hose burst valve
5 Pressure switch
6 Leak oil strip port
Function The valve is mounted direct on the base-side port of the boom ram.
Extend ram function:
Ram can be extended as usual (always free flow towards the ram)
The built-in non-return valve safely holds the load in rest position.

Options
Retract ram function:

Pilot control pressure moves valve (1) to work position (free oil reflux from the base
side).
The valve moves back to home position if the pilot control pressure drops.
In addition, a safety valve (2) protects the hydraulic ram from overload. Overload actuates
the pressure switch (M), the warning device lights up and the buzzer sounds.
Important!
The valve settings are sealed.
Diagram
237,21
0
$
Boom control
3E
2
%
C2 V2

Options
7.13 Safe load indicator F (safety valves for boom and stick)
Position
8
6
Pos. Description
1 Boom segment pilot control port
4 Stick pressure line port
5 Leak oil strip port
6 Pressure switch
7 Hose burst valve
8 Boom pressure line port

Options
Function One valve is mounted direct on the base-side port of the boom ram, the other valve is
mounted on the rod-side port of the stick ram.
Extend boom ram function:

Ram can be extended as usual (always free flow towards the ram)
Retract boom ram function:

Pilot control pressure moves valve (1) to work position (free oil reflux from the base
side).
Retract stick ram function:
Ram can be retracted as usual (always free flow from the ram)
Extend stick ram function:

Pilot control pressure moves valve (1) to work position (free oil flow to the base side).
In addition, a safety valve (2) protects the hydraulic ram from overload. Overload actuates
the pressure switch (M), the warning device lights up and the buzzer sounds.
Important!
The valve settings are sealed, no modifications for legal reasons.

Options
Diagram
0
0
2
2
1 1
237,21
7 7
1 1
$ 3E % % $
3E
Boom control Stick control
C2 V2

Options
7.14 3rd control circuit

Function The 3rd control circuit allows you to operate a range of attachments with up to 3 hydraulic
circuits.
The 3rd control circuit is actuated electrically by means of tip switches (S30, S31) on
the joystick on the left. The solenoid valve Y16 is moved to the corresponding position.
If the machine is equipped with the triple articulation boom option, the 3rd control
circuit is operated by means of the joystick on the right.
If the machine is equipped with the electric auxiliary hydraulics option, the 3rd
control circuit is operated by means of the hammer pedal.
Fig. 19: 3rd control circuit

Options
Diagram
237,21
%
$
3D
7
3S 3L
'5
3 7
Y16
7
3D
3E
35

Pa9 3rd control circuit (control)
Pb9 3rd control circuit (control)
A9 3rd control circuit (connection)
B9 3rd control circuit (connection)
P3 High-pressure supply Pump 3
Circulation pressure of drive counterbalancing
Pp
system
PR Pilot control pressure Pilot oil supply unit

Options
7.15 Triple articulation boom

Function The triple articulation boom increases the machine's reach and flexibility.
The triple articulation boom and slewing is controlled by means of the hammer pedal.
3E
3D 3E
Solenoid valve Y15 (20/1) is switched via the tip switch function (S27) on the left-hand
3D side joystick.
The auxiliary hydraulics is operated electrically via the left-hand side joystick.
Hammer pedal The 3rd control circuit option is operated electrically via the right-hand side joystick.
35
Fig. 20: Triple articulation boom control

Options
Diagram
3E
3D 3E
3D
35

Pa5 Triple articulation boom extension control Hammer pedal
Pb5 Triple articulation boom retraction control Hammer pedal
Pa8 Offset ram retraction control Hammer pedal
Pb8 Offset ram extension control Hammer pedal
P3 High-pressure supply Pump 3
A5 Triple articulation boom ram (base side) Pump 3
B5 Triple articulation boom ram (rod side) Pump 3
PR Pilot control pressure Pilot oil supply unit
Circulation pressure of drive counterbalanc-
Pp
ing system

Options
7.16 Electric auxiliary hydraulics

Function The auxiliary hydraulics segment is not controlled via the hammer pedal, but electrically
via the tip switch function (S30, S31) on the joystick on the left.
Pressing the tip switch on the joystick activates the solenoid valve Y15 (fig. 19)
see 4/3 directional valve on page 5-24.
Fig. 21: Solenoid valve Y15

Options
$
%
3D
7
3L
7
3S '5 Unpressurised reflux to hydraulic tank
3
7
3E
3D
237,21
35
Port Legend
Pa7 Auxiliary hydraulics control
Pb7 Auxiliary hydraulics control
A7 Auxiliary hydraulics connection
B7 Auxiliary hydraulics connection
P3 Pump P3 port
Circulation pressure of drive counterbal-
Pp
ancing system
PR Pilot control pressure

Options
7.17 Auxiliary hydraulics shock cartridge

Overpressure protection for consumers in secondary circuit
7
3S
3
3D
e.g. hydraulic hammer
3E
%
$
Important!
'5
7
3L
The attachment manufacturer (e.g. hammer, offset bucket ...) is in charge of

237,21
overpressure protection for his attachments. Neuson Baumaschinen GmbH shall
Fig. 22: Auxiliary hydraulics shock cartridges
not be liable for damage to attachments.
Problem:
The secondary circuit is also protected by the primary pressure limiting valve if the spool
valve is enabled. There is no protection if the spool valve is not enabled see Pressure
limiting valves on page 5-9.
Ensuring protection with the spool valve disabled requires two secondary pressure limiting
valves instead of the plugs.
Adjusting the secondary pressure limiting valves:

The pressure limiting valves must be set at 275 bar (3989 psi).
Please observe the following should the pressure limiting valves be set to less than 275
bar (3989 psi):
Have the pressure setting carried out by a specialist.
The pump's high flow rate, and the fact that the pressure peaks are now reduced by the
secondary pressure limiting valve cartridges at the auxiliary hydraulics section, can
cause the hydraulic oil to overheat.
Reset the pressure setting to the initial 275 bar (3989 psi) when changing attachment.
Location:
Shock cartridges 23/A are screwed into the main valve block at the auxiliary hydraulics
A A segment (see figure without options 3rd control circuit/triple articulation boom)
see Pressure limiting valves on page 5-9.
Fig. 23: Position of secondary pressure limiting valve for

auxiliary hydraulics (standard)

Options
7.18 3rd control circuit shock cartridge

Overpressure protection for consumers in secondary circuit
237,21
e.g. demolition tongs
'5
7
$
%
Important!
3D
3E
The attachment manufacturer is responsible for overpressure protection of his

7
3S
3
Fig. 24: Auxiliary hydraulics shock cartridges

attachments. Neuson Baumaschinen GmbH shall not be liable for damage to
attachments.
Problem:
The secondary circuit is also protected by the primary pressure limiting valve if the spool
valve is enabled. There is no protection if the spool valve is not enabled see Pressure
limiting valves on page 5-9.
Ensuring protection with the spool valve disabled requires two secondary pressure limiting
valves instead of the plugs.
Adjusting the secondary pressure limiting valves:

The pressure limiting valves must be set at 275 bar (3989 psi).
Please observe the following should the pressure limiting valves be set to less than 275
bar (3989 psi):
Have the pressure setting carried out by a specialist.
The pump's high flow rate, and the fact that the pressure peaks are now reduced by the
secondary pressure limiting valve cartridges at the auxiliary hydraulics section, can
cause the hydraulic oil to overheat.
Reset the pressure setting to the initial 275 bar (3989 psi) when changing attachment.
Location:
A
Boom 2 Shock cartridges 25/A are screwed into the auxiliary hydraulics segment of the main valve
block see Pressure limiting valves on page 5-9.
Stick
Fig. 25: Position of secondary pressure limiting valve for

3rd control circuit

Options
7.19 Drive interlock (antitheft protection)

Position
2 Pos. Description
1 Transponder receiver surface
1 2 Red LED
Fig. 26: Drive interlock
Disabling the drive interlock Approach the transponder to 2 cm (0.79) to the transponder receiver surface.
The red LED goes out.
Insert the ignition key into the ignition lock within 30 seconds and turn it at least to
position 1.
The drive interlock remains disabled.
Enabling the drive interlock Remove or turn the ignition key to position 0.
The drive interlock is enabled after 30 seconds.
The blinking red LED indicates the drive interlock is enabled.
Programming Coding transponder keys

The so-called main or master key is required for coding a new or uncoded key, or a key
with different coding, for the drive interlock.
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45 seconds see Disabling the drive interlock on
page 7-37.
The LED changes to a steady green light.
The system is in programming mode now (coding mode).
Remove the master key from the transponder receiver surface.
The LED changes to a rapidly blinking green light.
Hold the key to be programmed against the transponder receiver surface.
The key is coded once the diode comes on slowly three times.
Hold further keys next to the transmitter/receiver surface to code them as mentioned
above.
The drive interlock is enabled as soon as there is no key contact for 30 seconds.
Blinking red light

Options
Deleting programming/coding
Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 45 seconds see Disabling the drive interlock on
page 7-37.
The LED changes to a steady green light.
The system is in programming mode now (coding mode).
Hold the master key against the transponder receiver surface for a further 30 seconds.
The LED changes to a steady red light.
The system is in delete mode now (coding mode).
Remove the master key
The LED changes to a rapidly blinking red light.
You have 30 seconds to hold the master key again to the transponder receiver surface
to confirm deletion.
The system is deleted once the diode comes on slowly three times.
Caution!
Deletion deletes all normal transponders and the master!
Reason: once a key is lost, you can no longer delete it.
Therefore, the entire system is deleted for safety reasons and can be
completely recoded with the remaining (or newly ordered) keys.
Configuration of the deleted system

Once deletion is over, the system recognises any TREBE transponder key, i.e. the system
can be disabled with any key.
The first transponder key to be recoded for the system is automatically the new master and
can be used for coding the normal transponder keys see Programming on page 7-37.
Important!
The following applies both to the coding and programming mode: the system
leaves the coding and programming modes and is disabled as soon as the ignition
key is inserted in the ignition lock and turned to the first position.

Options
7.20 Quickhitch
M
Danger!
The attachment must always be safely locked onto the quickhitch
Before starting work, make sure the attachment is securely locked onto the
L quickhitch by means of the lock mechanism. You must be able to see the
lock on either side of the mounting bore of the attachment.
Re-equip as follows:
Approach the machine to the attachment.
Hitch coupling bar M onto coupling claws L of the quickhitch to pick up the bucket.
Engage lock mechanism N in mounting bores O.
Place the bucket on level ground.
N
Fig. 27: Bucket with quickhitch
Lock as follows:
S Switch off the engine.
Insert tube P (included in scope of delivery) in clamping sleeve Q.
Press the tube downwards.
The lock pin must be in position R.
Insert the spring plug in fixture T to lock the quickhitch.
Q
Caution!
Always make sure the spring plug is inserted correctly.
Unlock as follows:
R
Remove the spring plug from fixture T.
Insert tube P (included in scope of delivery) in clamping sleeve Q.
Press the tube upwards.
The lock pin must be in position S.
T
Fig. 28: Bucket with quickhitch

Options
7.21 Proportional controls

Function This control mode offers proportional operation of the auxiliary hydraulics circuit depending
on the position of switch B on the joystick.
You can also modify the properties of the characterisitic curve. Precision work, for instance
with the offset bucket, does not require the full throughput of the auxiliary hydraulics.
Therefore we recommend setting the controls to the low characteristic curve 1 (slow
movements) see chapter Adjusting control response on page 7-41.
The slide switch is not pressed fully in this position and you can move the machine more
smoothly (flat characteristic curve).
If you require the full throughput then characteristic curve 2 will be the choice to make
(slide switch pressed as far as it will go).
Caution!
Always use button B ( see chapter on page 7-41) on the joystick for hammer
operation.
Do not operate the hammer with characteristic curve 1 too often since the
slide switch described above does not ensure full throughput, causing
power loss and system overheating.
Ports
Ports Hose designation

H T line
I P line
J Auxiliary hydraulics (left)
K Auxiliary hydraulics (right)

Options
Overview of auxiliary hydraulics controls

Move slide switch A to the left or right.
Ensures proportional control of the auxiliary hydraulic circuit.
Hammer operation
Switching on hammer operation
Press button B on the control lever.
Adjusting control response

Characteristic curve 1 (slow movements)
Switch off ignition, hold slide switch A to the left and switch on ignition at the same time.
Then wait 2 seconds and release the slide switch. The status display acknowledges by
flashing once.
A Characteristic curve 2 (fast movements):
Switch off ignition, hold slide switch A to the right and switch on ignition at the same
time. Then wait 2 seconds and release the slide switch. The status display
acknowledges by flashing twice.
Characteristic curve status display

Displays the characteristic curve that has been selected for the control valve.
Characteristic curve 1 (slow movements)
Telltale 1 in the status display flashes once after switching on ignition.
Characteristic curve 2 (fast movements maximum throughput)
Telltale 1 in the status display flashes twice after switching on ignition.

Options
Wiring harness
X10 Connector 1 control unit

X11 Connector 2 control unit
F14 Blade-type fuse
X12 Joystick (left)
X13 Joystick (right)
X14 Power supply
X15 Plug for telltales
S45 Pressure switch (automatic revs setting only)
Y16 Plug 1 proportional circuit 1
Y17 Plug 2 proportional circuit 1
Y18 Plug 1 (3rd control circuit only)
Y19 Plug 2 (3rd control circuit only)
M8 Motor for automatic revs setting
Control unit
Pos. Connections
1 Plug X10
2 Plug X11

Options
Control valve plug assignment X10 digital/analog inputs
1 TX Serial interface
2 SW2 Hammer operation
3 SW4 Power
4 A_POT2 Joystick signal channel 2
5 A_POT1 Joystick signal channel 1
6 U-analog Analogous supply +5 V
7 R_POT1 GND joystick
8 R_POT2 GND potentiometer
9 A_POT3 Potentiometer signal
10 SW3 Auto
11 SW1 Pressure switch
12 RX Serial interface
X11 supply outputs
1 M_ECU Earth
2 MVH1 + channel 1
3 MVH2 + channel 2
4 MVL1A Pulse modulation channel 1/magnet 1
5 LSW2 Telltale
6 LSW3 Telltale
7 MVL2A Pulse modulation channel 2/magnet 1
8 MVL2B Pulse modulation channel 2/magnet 2
9 MVL1B Pulse modulation M channel 1/magnet 2
10 MOT2 Engine
11 MOT1 Engine
12 U_ECU +12 V supply

Options
Safety features
Microcontroller ... diagnoses errors supplied by the output stage.
Monitor...disables the output stage if the microcontroller breaks down.
Output stage...controls the status of the supply lines from the pressure regulating
valves.
Watchdog...disables the microcontroller in case the microcontroller breaks down.
Switch for valve supply...disables the power supply to the valves if a critical error is
detected.
Measures to be taken in case of malfunctions
Caution!
System breakdowns can never be excluded, therefore:
Disconnect the electronic controls from the power supply before carrying out repair
work or maintenance on the hydraulic system.
Stay clear of areas and parts with danger of crushing.
Stay clear of in-between moving hydraulic components and fixed obstacles. DANGER
OF CRUSHING!
The operator of the machine or hydraulic system must be aware of possible machine or
system errors.
Diagnosis display
The control valve status is displayed to the user by means of a flashing code. The
following errors are identified by the number of flash pulses:
Critical
No. Pin no. Description Error Troubleshooting
error
0 - - No error - -
Check voltage
1 B5 Channel 1 input (left) Defective input voltage Home position: 2.5 V -
Deflected: 0.7 to 4.3 V
2 A4, A9 Channel 1 output; Y16/Y17 Overload or overheating (output stage) Check magnet on valve -
3 A4, A9 Channel 1 output; Y16/Y17 Short circuit on earth or operating voltage Check wiring x
Check voltage
4 B4 Channel 2 input (right) Defective input voltage Home position: 2.5 V -
Deflected: 0.7 to 4.3 V
5 A7, A8 Channel 2 output; Y18/Y19 Overload or overheating (output stage) Check magnet on valve -
6 A7, A8 Channel 2 output; Y18/Y19 Short circuit on earth or operating voltage Check wiring x
7 - System start - x
8 A10, A11 Motor output Overheating (output stage) Check motor x
9 - - EEProm data error - x
10 B6 +5 V joystick Defective 5 V supply - x

Options
The system switches off automatically if a critical error is detected. Activating the control
unit is only possible by repeatedly switching on the supply voltage.
Only the error occurring last is issued if several errors occur at the same time. We
therefore recommend troubleshooting one error after another until the diagnosis telltale no
longer flashes.
In order to obtain a detailed status of the output stage for channels no. 1 and 2, the
hammer operation input must be activated during system start. The system flashes only
briefly if there are no errors.
In case of an error, the error code is issued in the following order of the pulse modulation
outputs:
Channel 1/Magnet 1 > Pause > Channel 1/Magnet 2 > Pause > Channel 2/Magnet 1 >
Pause > Channel 2/Magnet 2
An error code (number of flash pulses) is assigned to each of the pulse modulation
outputs:
Error code Error

1 No error
2 overload, overtemp
3 open load
4 Short circuit on earth
The error code ends at the last output stage by displaying an error.
Examples:
A: channel 2/magnet 1 has an open load interruption. The following flash sequence is
then issued:
1 > Pause > 1 > Pause > 3
Cause of error: interruption of coil from solenoid valve (Y19), wiring interrupted, contact
error on plug (Y16; X11)
B: channel 1/magnet 1 has an Overtemp error and channel 2 has a Short circuit to
earth error, the following flash sequence is issued:
2 > Pause > 1 > Pause > 1 > Pause > 4
Cause of error:
Channel 1: output stage overload; short circuit of coil from solenoid valve, short circuit
of valve wiring (not to earth or operating voltage)
Channel 2: wiring, earth contact in valve

Options

Neuson Baumaschinen GmbH
Haidfeldstrae 37
A-4060 Linz / Leonding
Telefon +43 (0) 732 / 90590-0
Fax +43 (0) 732 / 90590-200
E-Mail: [email protected]
www.wackerneuson.com
Kramer-Werke GmbH
Nussdorfer Str. 50
D-88662 berlingen/Germany
Tel. +49 (0 7551 802-0
Fax +49 (0) 7551 802-260
E-mail [email protected]
www.neusonkramer.com
Neuson Limited
Crown Business Park
Dukestown, Tredegar
Gwent South Wales NP22 4EF
United Kingdom
Phone +44 (0) 1495 723083
Fax +44 (0) 1495 713941
E-Mail: [email protected]
www.wackerneuson.com

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Service Manual

Machine model 6003

Description Order no.

Operator's Manual 1000127717

Service manual 1000129840

Spare parts catalogue:up to serial no. AD07210 1000127435

from serial no. AH00645 1000182716

Copyright 2008 Neuson Baumaschinen GmbH, Linz-Leonding

Neuson Baumaschinen GmbH

SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm I-1

Kinematics ............................................................................................................. 2-17

I-2 SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm

Travelling drive ...................................................................................................... 3-38

SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm I-3

Checking and adjusting valve clearance ................................................................ 4-16

I-4 SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm

Work description .............................................................................................. 4-59

SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm I-5

Valves .................................................................................................................... 5-23

I-6 SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm

Wiring harness 1000109628: armrest .................................................................... 6-26

SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm I-7

Service valve .......................................................................................................... 7-23

I-8 SERV-HB 6003 EN - Edition 2.0 * 6003s2_0IVZ.fm

1-1 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

1.2 Identification of warnings and dangers

SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-2

1.3 Designated use and exemption from liability

1-3 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

1.4 Type labels and component numbers

Type label information

Fig. 1: Type label: location Model: 6003

Fig. 3: Cab type label

Example: Yanmar 46557

Fig. 4: Diesel engine number

SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-4

Hydraulic pump number

Fig. 5: Hydraulic pump type label

Control valve number

Fig. 6: Main valve block type label

Travelling drive number

Fig. 7: Travelling drive type label

Swivel unit number

Fig. 8: Swivel unit type label

1-5 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

1.5 Machine overview

Fig. 9: Machine outside views

SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-6

1.6 Cab overview

1-7 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

From serial no.: AH00645

SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-8

1.7 Cab (legend)

1-9 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

1.8 Instrument panel up to serial no. AC02888: overview

SERV-HB 6003 EN Edition 2.0 * 6003s110.fm 1-10

1.9 Instrument panel up to serial no. AC02888: legend

1-11 SERV-HB 6003 EN Edition 2.0 * 6003s110.fm

1.10 Instrument panel from serial no. AC02890 to AD07210: overview