Wacker Neuson 6003 Track Excavator Service Manual 1000129840 PDF

Description

Wacker Neuson 6003 Track Excavator Service Manual 1000129840 – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson 6003 Track Excavator Service Manual 1000129840 – PDF DOWNLOAD 

Language : English
Pages : 342
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Wacker Neuson 6003 Track Excavator Service Manual 1000129840 – PDF DOWNLOAD 

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
Table of contents
I-2 SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm
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
Specific safety instructions 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
SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm I-3
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
Specific safety instructions 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
I-4 SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm
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
Work description 4-42
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
4-43
Related DTC 4-43
Work description 4-44
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
4-45
Related DTC 4-45
Work description 4-47
Flash code 2-4 – sensor 5 V 4-49
Related DTC 4-49
Work description 4-50
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
Diagnosis description 4-52
(2) P0563/0: power supply voltage error (voltage too high) 4-53
DTC detection conditions 4-53
Troubleshooting 4-53
Diagnosis description 4-53
Flash code 6 – revs sensor 4-54
Work description 4-56
Flash code 1-1 – backup revs sensor 4-57
Related DTC 4-57
SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm I-5
Table of contents
Work description 4-59
Flash code 9 – overspeed error 4-60
(1) P0219/0: overspeed error 4-60
DTC detection conditions 4-60
Troubleshooting 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
Work description 4-63
Flash code 1-5 – preheating relay 4-65
Related DTC 4-65
Work description 4-66
Flash code 1-4 – CSD (cold start device) solenoid coil 4-69
Related DTC 4-69
Work description 4-70
Flash code 1-3 – EGR (exhaust gas recirculation) valve 4-72
Related DTC 4-72
Work description 4-74
Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error 4-76
Related DTC 4-76
Work description 4-78
Flash code 8 – proportional injection pump solenoid (control rack) 4-80
Related DTC 4-80
Work description 4-82
Flash code 1-6 – main relay 4-84
Related DTC 4-84
Work description 4-86
Flash code 1-2 – CAN (Controller Area Network) communication 4-88
Related DTC 4-88
Work description 4-89
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
I-6 SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm
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
Wiring diagram A4 (2) from serial no AH00645 6-16
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
SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm I-7
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
Wiring diagram A4 (1) from serial no AH00645 6-34
Wiring diagram A4 (2) from serial no AH00645 6-35
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
I-8 SERV-HB 6003 EN – Edition 2 0 * 6003s2_0IVZ fm
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

DESCRIPTION:

Wacker Neuson 6003 Track Excavator Service Manual 1000129840 – PDF DOWNLOAD 

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.

S.V 31/12/24