Wacker Neuson 6003 Track excavator Service Manual – PDF DOWNLOAD
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DESCRIPTION:
Wacker Neuson 6003 Track excavator Service Manual – PDF DOWNLOAD
1 Operation
1.1 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 hazardous 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 performing 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.
TABLE OF CONTENTS:
Wacker Neuson 6003 Track excavator Service Manual – PDF DOWNLOAD
Operation
Information on this service manual 1-2
Identification of warnings and dangers 1-3
Designated use and exemption from liability 1-4
Labels 1-5
Machine overview 1-7
Cabin overview 1-8
Up to serial no: AD07210 1-8
From serial no: AH00645 1-9
Cabin (legend) 1-10
Instrument panel up to serial no AC02888 (overview) 1-11
Instrument panel up to serial no AC02888 (legend) 1-12
Instrument panel serial nos AC02890 to AD07210 (overview) 1-13
Instrument panel serial no AC02890 to AD07210 (legend) 1-14
Instrument panel overview (serial nos AH00579 to AH02750) 1-15
Instrument panel legend (serial nos AH00579 to AH02750) 1-16
Control elements 50Z3 2 / 6003 2 (from serial noAJ02777) 1-17
Engine compartment up to serial no AD07210: overview 1-19
Engine compartment from serial no AH00611 (overview) 1-20
Chassis overview 1-21
Raising/lowering the cabin 1-22
Summer/winter operation 1-24
Preheated fresh air 1-24
Auxiliary hydraulics/boom swivel pedal 1-25
Battery master switch 1-25
Technical data
Chassis 2-2
Engine 2-2
Fuel injection pump 2-3
Capacities 2-3
Tightening torques 2-3
Hydraulic system 2-4
Auxiliary hydraulics oil flow* 2-4
Screwable hose burst valve 2-5
Travel gear and swivel unit 2-5
Stabilizer blade 2-5
Electrical system 2-5
Fuse box on the instrument panel up to serial no AD07210 2-6
Main fuse box with relays under the cabin up to serial no AD07210 2-6
Relays up to serial no AD07210 2-6
Fuse box on the instrument panel (from serial no AH00645) 2-7
Main fuse box with relays (from serial no AH00645) 2-7
Noise levels 2-8
Vibration 2-8
Coolant compound table 2-8
Model-specific tightening torques 2-9
General tightening torques 2-9
Tightening torques for hydraulic threaded fittings (dry assembly) 2-9
Tightening torques for high-resistance threaded fittings 2-11
Dimensions model 6003 2-12
Lift capacity table 6003 2-13
Kinematics 2-13
Maintenance
Table of contents
I-2 SHB 6003 en – Edition 23 * 6003s2_0IVZfm
Table of contents
Fluids and lubricants 3-2
Additional oil change and filter replacement (hydraulic system) 3-3
Oil grades for the hydraulic system, depending on temperature 3-4
Maintenance label 3-5
Explanation of symbols on the maintenance label 3-5
Maintenance plan (overview) 3-7
Introduction 3-12
Fuel system 3-13
Specific safety instructions 3-13
Refueling 3-13
Stationary fuel pumps 3-14
Diesel fuel specification 3-14
Bleeding the fuel system 3-14
Emptying the fuel tank 3-15
Fuel prefilter with water separator 3-15
Replacing the fuel filter 3-16
Engine lubrication system 3-17
Checking the oil level 3-17
Adding engine oil 3-18
Changing engine oil 3-19
Replacing the engine-oil filter cartridge 3-20
Cooling system 3-21
Specific safety instructions 3-21
Checking the coolant level/adding coolant 3-22
Draining coolant 3-24
Air filter 3-25
Replacing the filter 3-26
Functional check once a week of the dust valve 3-27
Diesel particulate filter (option) 3-28
Main components of diesel particulate filter system 3-28
Maintenance 3-29
Oils and fuels 3-30
Malfunctions 3-30
Warranty 3-30
V-belt 3-31
Checking V-belt tension 3-31
Retensioning the V-belt 3-32
Checking the V-belt of the air conditioning system 3-33
Tightening the V-belt of the air conditioning system 3-33
Pressure check 3-34
General 3-34
Checking pilot control pressure 3-34
Pressure check of variable displacement pump P1 3-35
Pressure check of variable displacement pump P2 3-36
Pressure check of gear pump P3 3-37
Secondary pressure limiting valve of the gear motor 3-38
Measurement connections (overview) 3-38
Primary pressure limiting valves 3-38
Test report 3-39
Hydraulic system 3-42
Specific safety instructions 3-42
Checking the hydraulic oil level 3-43
Adding hydraulic oil 3-44
Changing hydraulic oil 3-45
Monitoring the hydraulic oil return filter 3-45
Checking hydraulic pressure lines 3-46
SHB 6003 en – Edition 23 * 6003s2_0IVZfm I-3
Table of contents
Traveling drive 3-46
Checking the oil level and adding oil 3-47
Draining oil 3-47
Tracks 3-48
Checking track tension 3-48
Setting the tracks 3-49
Overview of lubrication points 3-50
Parking the machine 3-51
Lubrication points on the boom, bucket and stick cylinders 3-51
Lubrication points on the boom and stick 3-52
Joint rod lubrication point 3-53
Lubrication points on the stabilizer blade and stabilizer blade cylinder 3-53
Lubrication points on the swiveling cylinder and swiveling console 3-54
Lubrication points on ball bearing race of live ring 3-55
Lubrication points of live ring teeth 3-56
Powertilt lubrication points (option) 3-57
Lubrication points of hydraulic quickhitch (option) 3-57
Lubrication points of control lever base (from serial no AJ02777) 3-58
VDS lubrication points (option) 3-58
Maintenance of attachments 3-58
Central lubrication system (option) 3-59
Function 3-59
Status LEDs 3-59
Adjusting cycle time and lubrication time 3-60
Repair in case of clogging 3-60
Electrical system 3-61
Specific safety instructions 3-61
Servicing and maintenance at regular intervals 3-61
Instructions concerning specific components 3-62
Alternator 3-62
Jump-starting the engine 3-62
Battery charge condition 3-63
Charging the battery 3-63
Replacing the battery 3-63
Cabin 3-64
Replacing the cabin filter 3-64
General maintenance 3-65
Cleaning 3-65
General instructions for all areas of the machine 3-65
Inside the cabin 3-66
Exterior of the machine 3-66
Engine compartment 3-66
Threaded fittings and attachments 3-66
Pivots and hinges 3-66
Engine
Engine 4TNV98-VNS 4-2
Tier 2 (up to serial no AD07210) 4-2
Fuel system 4-4
Removing the cylinder-head cover 4-5
Checking and adjusting valve clearance 4-5
Checking valve clearance 4-5
Setting zero play of the valve bridge 4-6
Setting valve clearance 4-6
Tightening order for cylinder head bolts 4-7
Checking the injection nozzles 4-8
Pressure check 4-8
I-4 SHB 6003 en – Edition 23 * 6003s2_0IVZfm
Table of contents
Checking the nozzle jet 4-8
Injection time 4-9
Checking injection time 4-9
Setting injection time 4-9
Replacement of fuel injection pump 4-10
Adjusting engine speed 4-11
Compression 4-11
Checking the coolant thermostat 4-12
Checking the thermal switch 4-12
Oil pressure switch 4-13
Checking the coolant circuit 4-13
Engine 4TNV98-ZVNS 4-14
from serial no AH00645 4-14
Fuel system 4-16
Removing the cylinder-head cover 4-17
Checking and adjusting valve clearance 4-17
Checking valve clearance 4-17
Setting zero play of the valve bridge 4-18
Setting valve clearance 4-18
Tightening order for cylinder head bolts 4-19
Checking the injection nozzles 4-20
Pressure check 4-20
Checking the nozzle jet 4-20
Injection time 4-21
Checking injection time 4-21
Setting injection time 4-22
Replacement of fuel injection pump 4-23
Compression 4-24
Checking the coolant thermostat 4-24
Checking the thermal switch 4-25
Oil pressure switch 4-25
Checking the coolant circuit 4-25
Engine malfunctions 4-26
Electronic engine control unit (E-ECU) 4-28
Features 4-28
Engine error codes 4-29
Error diagnosis 4-33
E-ECU connector assignment 4-33
Important information on the ECU maintenance wiring harness 4-34
Flash code 7 – proportional injection pump solenoid (control rack) 4-35
Related DTC (Diagnostic Trouble Codes) 4-35
Diagnosis description 4-37
Flash code 5 – manual throttle 4-39
Related DTC 4-39
Work description 4-41
Flash code 4-1 ECU internal 4-42
Related DTC 4-42
Work description 4-43
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
4-44
Related DTC 4-44
Work description 4-45
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
4-46
Related DTC 4-46
Work description 4-48
Flash code 2-4 – sensor 5 V 4-50
SHB 6003 en – Edition 23 * 6003s2_0IVZfm I-5
Table of contents
Related DTC 4-50
Work description 4-51
Flash code 2-3 – power supply voltage 4-53
(1) P0562/1: power supply voltage error (voltage too low) 4-53
DTC detection conditions 4-53
Troubleshooting 4-53
Diagnosis description 4-53
(2) P0563/0: power supply voltage error (voltage too high) 4-54
DTC detection conditions 4-54
Troubleshooting 4-54
Diagnosis description 4-54
Flash code 6 – engine speed sensor 4-55
Work description 4-57
Flash code 1-1 – backup engine speed sensor 4-58
Related DTC 4-58
Work description 4-60
Flash code 9 – overspeed error 4-61
(1) P0219/0: overspeed error 4-61
DTC detection conditions 4-61
Troubleshooting 4-61
Diagnosis description 4-61
Flash code 1-7 – proportional solenoid relay of the injection pump (control rack)
4-62
Related DTC 4-62
Work description 4-64
Flash code 1-5 – preheating relay 4-66
Related DTC 4-66
Work description 4-67
Flash code 1-4 – CSD (cold start device) solenoid coil 4-70
Related DTC 4-70
Work description 4-71
Flash code 1-3 – EGR (exhaust gas recirculation) valve 4-73
Related DTC 4-73
Work description 4-75
Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error 4-77
Related DTC 4-77
Work description 4-79
Flash code 8 – proportional injection pump solenoid (control rack) 4-81
Related DTC 4-81
Work description 4-83
Flash code 1-6 – main relay 4-85
Related DTC 4-85
Work description 4-87
Flash code 1-2 – CAN (Controller Area Network) communication 4-89
Related DTC 4-89
Work description 4-90
Automatic engine speed setting 4-91
How it works 4-91
Hydraulic system
Hydraulic pump PVD-3B-56P-21G5-4626F 5-2
Pump unit: exploded view 5-4
Pilot oil supply unit 5-6
Main valve block with 3rd control circuit and triple articulation boom 5-7
Connections 5-7
Legend 5-8
Main valve block diagram 5-9
I-6 SHB 6003 en – Edition 23 * 6003s2_0IVZfm
Table of contents
Pressure limiting valves 5-10
Pump assignment 5-11
Drive counterbalancing system 5-12
Pump assignment for drive counterbalancing 5-12
Drive counterbalancing diagram 5-13
Regeneration – stick section 5-14
Bucket pre-tension 5-14
Boom raise summation 5-15
Check valve (load retaining valve) 5-16
Flow rate adjustment of auxiliary hydraulics 5-17
Pilot valves 5-18
Joystick 5-18
Pilot valve (machine travel) 5-20
Pilot valve for auxiliary hydraulics 5-22
Stabilizer blade pilot valve 5-23
Valves 5-24
7/2 directional valve (changeover valve) 5-24
4/3 directional valve 5-25
Shuttle valve block 5-26
Changeover valve for SAE/ISO controls (option) 5-27
Traveling drive 5-28
Trasmital drive (up to serial no AH01729) 5-28
Function 5-29
2nd speed range function 5-29
Kayaba drive (serial nos AH01730 to AJ04340) 5-32
Trasmital drive (from serial no AJ04341) 5-35
Function 5-36
2nd speed range function 5-36
Swivel unit 5-39
Parking brake/multidisk brake function 5-40
Swivel joint 5-45
Breather filter 5-46
Malfunctions in the hydraulic system 5-47
Hydraulics diagram A4 5-48
Hydraulics diagram (legend) 5-49
Hydraulics diagram 5-51
Options diagrams 1 from serial no AC04070 5-52
Options diagrams 2 from serial no AC04070 5-53
Proportional controls diagram 5-54
Main valve block A3 diagram 5-55
Electrical system
Ohm’s Law (current, voltage, resistance); power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-3
Relays 6-3
Use, mode of function 6-3
Electric units 6-4
Fuse box on the instrument panel up to serial no AD07210 6-4
Main fuse box with relays (up to serial no AD07210) 6-4
Relays 6-5
Fuse box on the instrument panel (from serial no AH00645) 6-5
Main fuse box with relays (from serial no AH00645) 6-6
ECU (from serial no AH00645) 6-6
Socket 6-7
Control lever push button 6-7
Control lever on the left 6-7
SHB 6003 en – Edition 23 * 6003s2_0IVZfm I-7
Table of contents
Control lever on the right 6-7
Instrument panel overview 6-8
Switches (overview) 6-9
Alternator 6-9
Starter 6-9
Wiring diagram A4 up to serial no AC02888 (legend) 6-11
Wiring diagram A4 up to serial no AC02888 6-12
Wiring diagram A4 from serial no AC02890 (legend) 6-13
Wiring diagram A4 from serial no AC02890 6-14
Wiring diagram A4 from serial no AH00645 (legend) 6-15
Wiring diagram A4 (1) from serial no AH00645 6-16
Wiring diagram A4 (2) from serial no AH00645 6-17
Engine/chassis A4 wiring harness 1000109624 up to AD07210 (legend) 6-18
Engine/chassis A4 wiring harness 1000109624 up to AD07210 6-19
Engine/chassis A4 wiring harness 1000173970 from AH00645 (legend) 6-20
Engine/chassis A4 wiring harness 1000173970 from AH00645 6-21
Wiring harness 1000109630: switches A4 up to serial no AC02888 (legend) 6-22
Wiring harness 1000109630: switches A4 up to serial no AC02888 6-23
Wiring harness: switches A4 from serial no AC02890 (legend) 6-24
Wiring harness: switches A4 from serial no AC02890 6-25
Cabin roof wiring harness 1000109629 6-26
Wiring harness 1000109628: armrest 6-27
Wiring harness 1000116138: boom working light 6-28
Wiring diagram A3 up to serial no AC02888 (legend) 6-30
Wiring diagram A3 up to serial no AC02888 6-31
Wiring diagram A3 from serial no AC02890-AD07210 (legend) 6-32
Wiring diagram A3 from serial no AC02890-AD07210 6-33
Wiring diagram A4 from serial no AH00645 (legend) 6-34
Wiring diagram A4 (1) from serial no AH00645 6-35
Wiring diagram A4 (2) from serial no AH00645 6-36
Engine/chassis wiring harness 1000109624 (legend) A3 6-37
Engine/chassis wiring harness 1000109624 A3 6-38
Engine/chassis A3 wiring harness 1000173970 from serial no AH00611 (legend)
6-39
Engine/chassis A3 wiring harness 1000173970 from serial no AH00611 6-40
Wiring harness 1000109630: switches A3 up to serial no AC02888 (legend) 6-41
Wiring harness 1000109630: switches A3 up to serial no AC02888 6-42
Wiring harness: switches A3 from serial no AC02890 (legend) 6-43
Wiring harness: switches A3 from serial no AC02890 6-44
Cabin roof A3 wiring harness 1000109629 6-45
Wiring harness 1000109628: armrest A3 6-46
Wiring harness 1000116138: boom working light A3 6-47
Options
Air conditioning 7-2
Specific safety instructions 7-2
Technical data 7-2
Installation overview 7-3
Components 7-4
Filling up the air conditioning system 7-6
Maintenance 7-7
Troubleshooting 7-8
Air-suspension seat 7-10
Connections 7-10
Counterweight 7-10
Technical data 7-10
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Table of contents
Long stick 7-10
Technical data 7-10
Control circuit (pipework) connections for grab 7-11
3rd control circuit connections 7-11
Auxiliary hydraulics connections 7-12
Quickhitch couplings 7-12
Attachments 7-13
Neuson Vario 7-14
Using the Neuson Vario feature 7-14
Vario diagram 7-15
Function 7-15
Neuson Vario warning device 7-16
Connections 7-17
Fuel-filling pump 7-18
Connections up to serial no AD07210 7-19
Central lubrication system 7-20
Position 7-20
Connections 7-20
Function 7-21
Adjusting breaks and lubrication times 7-22
Repair in case of clogging 7-22
Service valve 7-24
Function 7-24
Safe load indicator D (safety valve for boom) 7-25
Position 7-25
Function 7-25
Diagram 7-26
Safe load indicator F (safety valves for boom and stick) 7-27
Position 7-27
Function 7-28
Diagram 7-29
3rd control circuit 7-30
Function 7-30
Diagram 7-30
Triple articulation boom 7-31
Function 7-31
Diagram 7-31
Electric auxiliary hydraulics 7-32
Function 7-32
Auxiliary hydraulics shock cartridge 7-33
3rd control circuit shock cartridge 7-34
Immobilizer (antitheft protection) 7-35
Position 7-35
Disabling the immobilizer 7-35
Enabling the immobilizer 7-35
Programming 7-35
Quickhitch 7-37
Proportional controls 7-38
Function 7-38
Connections 7-38
Overview of auxiliary hydraulics controls 7-39
Hammer operation 7-39
Adjusting control response 7-39
Characteristic curve – status indicator 7-39
Wiring harness 7-40
Control valve 7-40
Control unit connector assignment 7-41
SHB 6003 en – Edition 23 * 6003s2_0IVZfm I-9
Table of contents
Safety features 7-42
Measures to be taken in case of malfunctions 7-42
Diagnosis display 7-42
Telematic 7-44
Connections 7-44
Functional check/diode 7-44
VIDEO PREVIEW OF THE MANUAL:
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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