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User manual 8002 RD

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2. 9707687_User manual_en zB 00900 SERVICE CODE zB 5596665 Option As soon as the device is switched on the green LED starts flashing slowly thus indicating that the system is in the secured mode Upon delivery of the device you receive a certificate with the system number and the safety code If the device is in the secured mode you can enter two safety codes the service code and the user code 1 Make sure that the LED lights up red each time you press a key 2 Slowly enter the 6 digit safety code followed by the 2 key The green LED starts flashing quickly 3 Now you ve got 30 sec to enter the service code or the user code 4 Slowly enter the desired 6 digit user code followed by the key Slowly enter the desired 6 digit service code followed by the key After each sequence the green LED goes out and lights up again flashing slowly Now you have defined your codes and the system returns to the safety mode To start the machine you must enter the service code or the user code followed by the key 79 Option Standby mode After entering the user code the green LED goes out Now you have got 30 sec to start the device After 30 sec the system returns to the safety mode Safety mode If you shut down the device the system will change to the safety mode after 12 sec green LED flashing slowly Another starting attempt is possible only within this period of
3. 61 El nee b i a 61 Change al on nya a aa oa baa yaaa om 61 A o ba 61 Check coolant system and 61 Check electrical COMA o 61 Check NWN plugis aaa 61 INES anada la aa da a aa E E 61 GRE CK PIM da ad ma DI a a aaa 61 Change hydraulic oil filter return fil ta l wane ee sl 61 62 9707687_User manual_en VII Contents Check ventilation filter and sieve coomiooimmsi ene 62 20 AGA IME 62 2027 Traveling drive b baba 63 Ghanda ACV Ol ec aa sabab 63 21 Maintenance every 1 000 operating hours 22 64 211 Eliginet A tee er nee a Du eee ee eer Ts 64 Check altemator and Stater 64 Clan olla a 64 Replace TUS ETN Mcgee ana AA 64 Ch ck water PU A sp A aa 64 Change ar filteri eae o 64 Change oil and oil Mismas tacto 64 21 2 NAVAN ta AAA ia aia 64 Check hydratlic Olk and Herba ba tado 64 Check ventilation filter and sieve coccninmmsa reee 64 21 3 Traveling and swiveling diyesen Au DAD 64 21 3 1 Traveling drive Change oil sa b 0 64 ZA COM emea 65 21 5 Attachments e e e e a a AAA a 65 22 Maintenance during longer
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5. 3 13 3 14 41 42 43 44 45 4 6 47 48 5 1 5 2 5 3 Safety instructions Loose parts e g tools or other accessories must be secured on the earthmoving machine Doors windows covers flaps etc must be secured against inadvertent closing when in opened state Hazard zone All persons must keep out of the hazard zone of earthmoving machinery The hazard zone is the surrounding area of the earthmoving machine in which persons may be reached by operation induced movements of the earthmoving machine its operating devices and its attachments or by swinging out loads by falling material or by falling operating devices The machine operator may work with the earthmoving machine only if no person is within the hazard zone The machine operator must give a warning signal if persons are exposed to danger The machine operator must stop working with the earthmoving machine if persons fail to leave the hazard zone despite a warning No person may have access to the pivot range of earthmoving machinery with centre pivot steering when the engine is running An adequate safety clearance min 500 mm must be kept from fixed components e g structures quarry faces scaffolding or other machines to prevent the risk of crushing If the safety clearance cannot be observed the area between fixed components and the operating range of the earthmoving machine must be closed off If the machine operator has a restricted
6. 40 C outdoor temperature NOTE All specified greases are suitable between 25 C to 40 C 9707687_User manual_en 67 User manual 24 Trouble shooting Engine cannot be started Insufficient engine power Engine oil pressure indicator lamp comes on during operation Temperature display rises above 100 C Charge monitor lamp comes on during operation ENGINE No fuel Battery power insufficient Fuel filter contaminated Pre glow system defective Fuel line leakage Air filter contaminated Engine not at operating temperature Engine overheated Refuel Charge battery replace Clean fuel filter Replace pre glow system service workshop Replace fuel line Clean air filter Warm up engine Check cooling system INDICATOR LAMPS Oil pressure too low Oil level too low Cooling water level too low Fan blades rotate too slowly Air filter contaminated Generator not charging properly Stop engine immediately check oil level and top up if necessary If oil level is correct oil pump is defective service workshop Re tension V belt Clean air filter Re tension V belt Fuel display illuminated Insufficient fuel 68 9707687_User manual_en User manual WORKING EQUIPMENT Slewing chassis is difficult or impossible Equipment does not work or only at low working grab performance Cylinders lower too quickly Hydraulic lines overheat 9707687_User manual_en Brakes
7. User manual Crawler excavator 8002 RD Edition April 2003 Item No 1000081390 Language English neuson Contents 2 1 2 2 3 1 3 2 3 3 3 4 3 5 3 6 4 1 A a ai aie Instructions for ordering spare pafts Guarantee and Warranty cccsscssssesssssssssssssseeesesssssessssesereres Identification Plate rairai a a Bucket Standard iaa as Noise emissions Crawler Excavator 8002 RD Vibration eve s maa Fire extinguisher AAA o e OOO Primary Dimensions Crawler Excavator 8002 RD Component Designations Cab equipment and controls 9707687_User manual_en 42 43 5 1 5 2 6 1 7 2 Contents Excavator COMMONGIIS asia 25 A e o o aaa anan n eee 26 PCC GIST MOM Or b asa s a da 26 Drivers Dead tad tdt 26 Heater Heating and Air A 27 Windshield Wi pets captan a A A AAA AA aa 27 Hydraulics EA 27 Emergency operation of attachment s ss s sl 3 3333843434 338383838 27 Relgase f residual pressure a DR a 27 Check hydratllic MA an ay d 28 Hydraulic connections for additional attachment 28 Safety EQUINA 29 Parking Brake an
8. A5 Safety instructions 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 6 5 6 5 1 6 5 2 6 6 6 6 1 6 6 2 6 6 3 6 6 4 6 6 5 The machine operator must not swing the operating devices across occupied driving operating and working places of other machines unless they are secured with fall over protective structures FOPS If the required protection above the driver s cab is not present the driver of that vehicle must leave the driver s stand when swinging across it is necessary The vehicles must be loaded in such a way that they are not overloaded and cannot lose any material while being driven They must be loaded from the lowest possible height The unloading locations must be designed to ensure that extensive reversing is avoided as fast as possible Earthmoving machinery must not be operated at dumping sites unless appropriate measures have been taken to prevent inadvertent movement or overturning Marshallers Marshallers must be clearly recognisable e g through special clothing They must be within the visual range of the machine operator During their marshalling activity marshallers must not be given other tasks which might distract them from their functions Deployment with risk of falling objects When there is a risk of heavy objects falling earthmoving machines must not be used unless their operator s stand is fitted with a protective roof FOPS in the case of excavators a protective windsc
9. Dispose of used filter in accordance with environmental laws Check engine rpms and exhaust system See engine operating instructions Hydraulics ATTENTION Always release residual pressure before working on the hydraulic system Check hydraulic oil and filter If itis necessary to replace the hydraulic filter dispose of the used filter in accordance with environmental laws Electrical components Check the cable harness and the battery If necessary tighten and secure to avoid twisting Attachments Check for play and replace damaged or defective parts 9707687_User manual_en 60 20 20 1 20 2 User manual Maintenance every 500 operating hours NOTE In addition to normal weekly maintenance and maintenance every 50 and 250 operating hours the following maintenance should be carried out every 500 operating hours see maintenance schedule 67 2 Engine See engine operating instructions for maintenance instructions Change air filter Open cap unscrew filter replace filter Clean dust trap Check valves See engine operating instructions for the correct valve settings Check coolant system and hoses Check electrical connections Check glow plug Hydraulics Always release residual pressure before working on the hydraulic system Check primary valves Adjust settings if necessary Change hydraulic oil filter return filter 9707687_User manual_en 61 User manual Change hydraulic
10. Prior to leaving the operating stand the operator must set all control devices to neutral and apply the brakes Before leaving the earthmoving machine the operator must first switch off the driving motors and secure them against unauthorised starting Lifting gear deployment Lifting gear deployment covers the lifting transporting and lowering of loads by means of a slinging aid cable chain etc with the assistance of persons being required for slinging and releasing the load 9707687_User manual_en A8 6 11 2 6 11 3 6 11 4 6 11 5 6 11 6 6 11 7 6 11 8 7 2 Safety instructions This means for example the lifting and lowering of pipes shaft rings or containers with earthmoving machinery Earthmoving machinery must not be used in lifting gear deployment unless the prescribed safety devices are present and fully functioning For hydraulic excavators for example these are safe slinging facility for a load bearing device working load table and in addition for hydraulic excavators with a legal working load of more than 1000 kg or a overturning moment of more than 40 000 Nm overload warning system open circuit monitoring system s at boom lifting cylinder s Loads must be slung in such a way that they cannot slip or fall out Persons involved in guiding the load and riggers must remain within the visual field of the machine operator The machine operator must keep loads as clo
11. RD YANMAR 4TNE 98 NSR Water cooled 4 cylinder diesel engine 3318 cm Horsepower in DIN 45 6 kw 62 hp Revolutions per minute 2200 rpm Battery 12V 88Ah Diesel tank 90 Motor oil 10 2 Coolant capacity 8 7 Hydraulic system 8002 RD Pump Double axial piston pump gear pump Pump capacity 80 80 50 l min Operating pressure working and driving 1300 bar Operating pressure swivel unit 250 bar Hydraulic oil cooler standard Hydraulic tank system capacity 122 Dozer blade 8002 RD 2150 mm 540 mm max height above ground level 540 mm max depth below ground level 450 mm Bucket Standard 8002 RD Width 750 mm Volume 260 9707687_User manual_en User manual 3 2 Noise emissions Crawler Excavator 8002 RD 3 3 Vibration levels 3 4 Fire extinguisher 9707687_User manual_en A Certified according to EEC design test 86 662 EEC 8012 Sound level Lwa 96 dB A Sound pressure level Lpa 78 dB A ATTENTION No alterations that would lead to an increase in noise emissions may be made to the excavator Vibration levels are in accordance with EEC guidelines 89 392 EEC Appendix Point 3 6 3 There is a place in the toolbox for a fire extinguisher User manual 3 5 Stickers ATTENTION All safety stickers notes and warnings must be kept legible Clean off dirt Replace with new stickers if they become illegible 9707687_User manual_en 20 970
12. Risk of injury from rotating components and risk of burns Machine keys The machine keys delivered by the factory are unrestricted standard keys driver s cabin and ignition This means that they can be duplicated without specifying the vehicle and chassis type identification number We d like to point out that this is no 100 security against theft For an adequate theft protection as an option please refer to our price list Make sure you inform yourself about the emergency equipment First aid kit Fire extinguisher l Where are the safety devices in and on the vehicle What is their purpose How are they operated Are they in working order Control and functions of the emergency switching system The excavator is not intended to be used with lifting equipment and is not for transporting or lifting people Transporting and lifting people using the attachments or other equipment is PROHIBITED excavator arm is not a ramming device Never attempt to use the attachments to drive piles or other objects into the ground or to flatten earth etc Never attempt to destroy a wall of earth or any other structure by swinging the arm and striking the wall with the attachments Introduction 18 i Never excavate vvhile driving Never dig an attachment into the ground and attempt to excavate by driving and pulling Never swivel the excavator with lowered attachments and never maneuver the vehicle when
13. ahead not Foreign body jammed Remove foreign body possible Differing chain tension Tension chains equally Travel valves damaged Authorized workshop 9707687_User manual_en 70 User manual ty ing capaci ift L 27 Tn al m li O 3JT138V18NH qu 2008 4399v8 Ek cul OSI AT eel uan 48 1Jy9sJeqh 13D 199NH sep juezoJg g yoou spiddiy USy9sI1 D S Jap JUSZOJA Gf 53 yzueJbeq y1eyieyorsddiy lp younp pun 61 1149A3 9n 1p3940 Joep Bun 19 8U13 e1p YIINP 151 siebboqjybduoy sep JDIAANH 810 1960 OSI web e6o0 punibsbunuyosJeg wn ysojddiy JD44qNH lp YyoIs yJobul 19A puls jnpqeGun lbl fsi l qiy e6 jsuos Japo 19 107 ule UIOS Bunyol 1 14DY INZ 06 Bunzynysqopy yosselupjg euyo 775 un q l 1 1404 ul unzinisqopi pr 0 G 194407 euyo pun punibJejun weysey pno Bun 191 19 4989 ifbDA 19q uagebabun ul puls l qD T Y zueJbaq 41 NDIP H 1 piyqnH ayoyuaxDy sD7 200144910 9111 uoa BunpD sny 181 8 8 407 wajy081 se6 l q 1807 blssbinz 0077 06 09 00L7 0582 G6L7 0022 0262 0277 0602 GCLE 6292 0962 612 0 22 dz o Hol wO S 0019
14. an attachment is on the ground ATTENTION The crawler excavator is NOT equipped to be used for lifting or to be fitted with lifting attachments NOTE If substances that could damage the environment or injure people leak out of the crawler excavator take the necessary measures immediately e g hydraulic oil leaks apply an oil binder place a container under the leak find and fix the leak if necessary remove contaminated earth and dispose of it properly 9707687_User manual_en 2 2 Introduction EC Declaration of Conformity EC Declaration of Conformity As defined by the Machinery Directive 98 37 EC Annex II A The company Neuson Baumaschinen GmbH Haidfeldstrafe 37 A 4060 Leonding hereby certifies that the construction equipment 1 Category Crawler excavator 2 Mark Neuson 3 Type 8002 4 Equipment serial number per type v Type plate complies with the following provisions applying to it 98 37 EG 89 336 EG 00 14 EG Applied harmonized standarts EN 292 1 1991 EN 292 2 1995 EN 474 1 1994 EN 474 5 1996 EN 982 1996 Applied national technical standards and specifications Type Measure Sound Power A weighted Sound Certificate No Level Power Level 8002 96 1 97 0 OR 01519 01 The notified body TUV Anlagen und Umwelt GmbH Westendstrafe 199 D 80686 M nchen The notified body according to Annex VII Fachausschuf Tiefbau Landsbergerstr 309 D 80687 M nchen vvas engaged for voluntary type exa
15. can be lowered using the dozer blade lever located on the right side of the driver s seat Never dig under the vehicle When excavating in or near excavated areas ensure that the walls are well supported CAUTION Risk of Collapse In order to obtain maximum performance the excavator arm should not be fully extended Remove the excavated material with long flat movements of the excavator arm The excavator arm can be swung 50 to the right and 80 to the left from its basic position This makes excavation of trenches along walls fences etc possible 37 User manual 10 3 Bulldozing 10 4 Lifting 10 5 Cab protection The dozer blade can be raised or lowered using the dozer blade lever To bulldoze the boom should be completely raised and the bucket turned inward It is possible to push the ground to the front and to the side Raise the dozer blade somewhat if resistance becomes too strong ATTENTION THE CRAWLER EXCAVATOR IS NOT EQUIPPED TO BE USED FOR LIFTINGOR TOBEFITTED WITHLIFTINGATTACHMENTS An optional overload warning indicator is available for use when lifting If the excavator is being used for overhead work quarry work etc it must be equipped with extra protection FOPS Front Guard against falling objects FOPS and Front Guard is available as an option 9707687_User manual_en 38 User manual 10 6 Stability RISK OF OVERTURNING CAUTION Always ensure adequate stabili
16. do not release Insufficient lubrication Slewing motor defective Insufficient hydraulic oil Hydraulic oil not warm Insufficient engine power Coupling or pump damaged Pressure limiting valves set too low Hydraulic cylinder damaged Control valves damaged Seals contaminated or defective Heavy leakage at control spools Secondary cartridges defective Hydraulic oil filter blocked Insufficient hydraulic oil in oil reservoir Seccondary cartridges set too low Cooling system not in working order 69 Authorized workshop Lubricate slewing ring hose connections Authorized workshop Top up hydraulic oil Warm up the engine See engine Authorized workshop Authorized workshop Authorized workshop Authorized workshop Authorized workshop Authorized workshop Authorized workshop Clean or change filter Top up hydraulic oil Authorized workshop Clean oil cooler User manual SEALS HOSES Oil or fuel leakage belovv the Loose hose connections Tighten hose connection engine Sealings and or hoses damaged Change sealings and or hoses and check and refill oil level if necessary Oil loss in hydraulic system Loose hose fittings Tighten hose fittings check hydraulic oil level top up if necessary sealings hoses or piping Change sealings hoses piping damaged service workshop TRAVELLING GEAR Travel not possible Foreign body jammed Remove foreign body Gears defective Authorized workshop Travel straight
17. must be disconnected prior to any work on the electrical system or any arc welding When disconnecting the battery first the negative and then the positive pole must be disconnected Reconnection is done in the reverse sequence 9707687_User manual_en A 10 7 14 7 15 7 16 7 17 7 18 7 19 7 20 7 21 7 22 7 23 7 24 8 1 8 2 8 3 Safety instructions The battery must be covered with insulating material if any maintenance work is done in its vicinity No tools may be laid down on the battery In the case of electrically driven earthmoving machinery the electrical systems and where necessary the mobile connection lines must be switched off and secured against inadvertent or unauthorised switching on Protective devices of moving machine parts must not be opened or removed unless the drive has been stopped and secured against unauthorised starting Protective devices are for example motor compartment flaps doors guards housings On completion of assembly maintenance or repair work all protective devices must be correctly mounted again Welding work on load bearing parts of earthmoving machinery e g lattice booms lifting cranks must be carried out in accordance with the recognised rules of welding technology No welding or drilling may be carried out on roll over tipp over or fall over protective structures ROPS TOPS FOPS Modifications e g welding on the hydraulic or compressed ai
18. oil 2 Check ventilation filter and sieve 20 3 Gear rim The hydraulic oil should only be changed when warm ca 40 C Retract all hydraulic cylinders before changing the hydraulic oil Rotate superstructure 90 1 Open ventilation filter SW 36 to release pressure 2 Open the hydraulic oil tank carefully tank is under pressure 3 Drain oil into a container 4 Clean out the hydraulic tank if necessary Remove cleaning cap 5 return filter cartridge see 18 2 4 6 Screw the drain plug back in properly 7 Refill with clean hydraulic oil 10 mu from a filling station 8 the hydraulic pump plug hexagonal socket head screw SW 6 until clear oil without bubbles comes out close hydraulic pump plug 9 Close hydraulic tank 10 Let the excavator idle unloaded for a few minutes Dispose of used hydraulic oil in accordance with environmental laws Check ventilation filter and replace if necessary Check sieve for damage and replace if necessary Change gear rim grease Remove cap under the gear unscrew plug 2 SW 28 square with grease nipple press out old grease by swiveling superstructure screw plug back in use the grease nipple to fill the gear rim with fresh grease close cap 9707687_User manual_en 62 User manual 20 4 Traveling drive Change drive oil Change the drive oil on the outside of the drive unit 1 Put drive in the position shown Open top and bo
19. periods of inactivity s ccecsecscecsseteecesesesessesecetesesseneseeecteseeeeeesneeetseeas 66 221 Preparation for longer periods of inactivity azana adada a a AAA aaz 66 22 2 Starting the excavator after periods of inactivity oomionmnmmicsmmt e 66 9707687_User manual_en VIII Contents 23 Lubricant al eet aches 67 24 Troll 68 A apayd n ala l ola 71 21 2 Legend of Lifting Power Tables dida 74 DO 75 28 1 Hydraulic connections for additional attachments scccecscessesecesssessesesecsstsseeeeeseseseeeenenserseneees 75 28 2 Additional hydraulics actuated electrically ie eee 75 28 3 Quick change Mec o o at dle 76 28 4 Airconditioning e o 78 Actuation AMM a A AA A Aa SE 78 A la qona a 78 28 5 Diesel PUN AAA AAA A 78 200 Theft Protecton cay a Na te a Ae Nel att eat 79 Operation OF Neuson Vano atada dada 81 28 8 NENA aa s la 81 Driving the Neuson Vario Transverse to the 82 Warning Equipment of Neuson 83 Working with Neuson Vario costas 85 Increased Working Range of Neuson Var iO c cccscecesecsseeecesecsenssneesetersesesesieseseatentecntenenesecsestanens 85 Neuson Vano babas a b E a A E a ub 86 Lubrication Points at Neuson Van
20. prejudicial to safety must be avoided The legal load of earthmoving machinery must not be exceeded The earthmoving machine must be operated only in a safe serviceable state The operating instructions issued by the manufacturer must be observed for operation servicing repair assembling and transport The contractor must supplement safety regulations where necessary with special instructions adapted to local operating conditions Operating instructions and safety relevant instructions must be in safekeeping by the operator s seat In the case of earthmoving machinery without cabs they may be kept at the application site The operating instructions and the safety instructions must be present in full and in a legible state Safety devices on earthmoving machinery must not be disabled during machine operation Protective working gear must be worn during machine operation Rings scarves and open jackets must be avoided Goggles safety footwear safety helmets protective gloves reflective waistcoats ear plugs etc may be needed for specific operations Prior to beginning work information on first aid and on emergency services ambulance fire service helicopter is essential It must be checked that a first aid kit complying with the regulations is present The location and operation of fire extinguishers on the earthmoving machine and the local fire alarm and fire fighting facilities must be known 9707687_User manual_en A2
21. safety of the earthmoving machine it must be taken out of operation until the defects have been rectified 9707687_User manual_en A12
22. the address postal code shipping method and final destination to prevent unnecessary inquiries and delivery errors Please order spare parts only via your NEUSON distributor Introduction 2 42 Safety ATTENTION Read the following safety rules carefully before operating the vehicle The safety rules listed here as well as any other applicable safety rules and regulations should always be observed Operating errors and ignorance regarding potentially dangerous situations that can occur during vehicle operati on can lead to injuries These potentially dangerous errors and situations are indicated by CAUTION in these instructions In addition operating errors and ignorance regarding potentially dangerous situations that can occur during vehicle operation and maintenance can lead to material damage These potentially dangerous errors and situations are indicated by ATTENTION in these instructions Certain instructions are indicated by NOTE The disregard of these instructions can lead to operational malfunctions The observance of these tips can improve the performance of the excavator The national and regional statutory safety and accident prevention regulations are not included in this manual These regulations are provided in the booklet from the Berufsgenossenschaft Tiefbau Civil Engineering Trade Association 9707687_User manual_en 2 1 Safety rules 9707687_User manual_en Introduc
23. view of his driving and operating area due to deployment induced influences he must be assisted by a marshaller or the driving and operating area must be secured by a fixed barrier Stability Earthmoving machinery must be used driven and operated in such a way that its stability or its security against overturning is guaranteed The machine operator must adapt the travelling speed to local conditions and keep the operating device as close as possible to the ground when driving over sloping or uneven terrain In the case of earthmoving machinery fitted with additional stabilising devices to increase stability the manufacturer s operating instructions must be observed 9707687_User manual_en A3 Safety instructions 5 4 5 5 6 1 6 1 1 6 1 2 6 1 4 6 2 6 2 1 6 2 2 Earthmoving machinery must be kept sufficiently far away from the edge of quarries trenches stockpiles and slopes to prevent any risk of overturning Earthmoving machinery must be secured against inadvertent movement or slippage when working close to the edges of excavations shafts ditches trenches and slopes Operation General Machine operators must be appointed by the contractor to operate or service the earthmoving machine Operating devices adjusting components may be activated only by the operator or from the operator s console The steps and areas provided must be used for access to the machine They must be kept in a non slip
24. 12 sec Starting sequence 1 Switch on ignition 2 Enter user code 3 Switch off ignition 4 Startwithin 30 sec R 80 x 9707687 User manual en 28 8 NEUSON VARIO Operation of Neuson Vario 9707687_User manual_en Option To change the eccentric position the following steps must be absolutely observed 1 The dipper stick must be supported on the ground 2 To open the lock of Neuson Vario both front switches at the left and the right joystick must be pushed and kept pressed At Neuson Vario there are four locking positions each offset by 90 0 360 90 180 270 To reach the correct position the left joystick must be pushed left or right After the excavator has moved the two buttons may be released After turning by 90 the Neuson Vario engages automatically If the Neuson Vario shall be offset by more than 90 the buttons at the joystick must be kept pressed beyond the 90 offset As soon as the buttons are released the Neuson Vario engages at the next possible lock 81 Option Driving the Neuson Vario Transverse to the Slope To achieve a better stability when driving transverse to the LA N ope the excavator should be shifted towards the slope l VVARNING For reasons of safety only the eccentric position indicated above may be chosen for driving transverse to the slope To achieve a better climbing ability when driving uphill the centre of gravity of the Neuson Var
25. 25 User manual Work lights OFF Position 1 Position 2 Accelerator 1 Driver s Seat There is 1 work light with a H3 55W Halogen bulb on the arm of the excavator This light can be turned on and off with the switch on the instrument panel see section 6 for the position of the light switch There are four more lights with H3 55W Halogen bulbs on the chassis 2 in the front and 1 on each side The 2 front headlights are on when the switch is the Position 1 The side lights are turned on by pushing the switch to Position 2 see section 6 for the position of the light switch With the accelerator lever the engine speed can be varied between Position 0 idle neutral 1100 rpms and Position 1 2200 rpms The following options are available to change the position of the driver s seat CAUTION Only adjust seat when the excavator is stopped a Adjustment of the seat position The seat can be adjusted horizontally back and forth using the seat adjustment lever see 25 under Cab Controls 4 1 When the lever is released the seat locks in the appropriate position b Adjustment of the seat back position in the middle of the seat The seat can be leaned forward and back see 5 under Cab Controls 4 1 using the seat back adjustment lever Adjustment ofthe seat spring tension in the middle of the seat The seat spring tension can be adjusted to accommodate see 3 under Cab Controls 4 1 th
26. 7687_User manual_en User manual tickers 8002 RD 11VVarning symbol 2 Symbol Read operating instructions 3 Cleaning 6 Lubricant recommendations 7 Dozer blade up down windshield 8 up down Bucket open closed Horn windshield 9 Travel right foward reserve windshield 10 Travel left forward reverse windshield 11 Stick out in Swing swivel left right windshield 121ildentification plate with CE Symbol 13 Environmental symbol blue angel 14 Direction arrows left and right on the guard 15 Fastening points for lifting the excavator swiveling console and right and left on dozer blade 16 Tie down points swiveling console and left and right on dozer blade 17 Symbol Danger Do not open while engine is running 18 Diesel 19 Hydraulic oil 20 Attention hydraulic tank under pressure 21 User manual 3 6 Primary Dimensions Crawler Excavator 8002 RD 3502 K 2097 pte E x m r he on n 2 caba fra ere l k Fi re OR s rr sir sd gt a ee 4 5 5 we a y A k s b yin oo 1 T MFP 9707687 User manual en 22 User manual 4 Component Designations 2 3 AG AT Component Designations 8002 RD 1 Bucket stick 11 Boom cylinder 2 Bucket stick cylinder 12 Steering control console 13 D
27. 8 1 Hydraulic connections for additional attachments Lever on the bucket stick Hydraulic connections for supplying additional attachments are Position for use of grab located at the end of the bucket sticket The hydraulics supply for additional attachments can be activated by turning the levers on the bucket stick and in the main hydraulic Crs valve area Position for use of bucket Lever on the main valve Position for auxiliary hydraulics Op Position for use of hammer 28 2 Additional hydraulics actuated electrically At this function the control of the additional hydraulics is shifted from the foot pedal to the joystick By this function the operation of the built on tool is considerably simplified for the excavator driver The following items must be observed by all means 1 At this option the function Additional hydraulics Black White is switched i e a fine control like with the foot pedal is not possible 2 this option is used for the employment of swivelling shovels e g at earth levelling work jerky movements of the lifting arm or shovel arm can arise 9707687_User manual_en 75 Option 28 3 Quick change mechanism ATTENTION In order to change attachments the excavator MUST always be in a depressurized state Assembly Note 1 Lower boom and bucket stick until they lock around bolt 2 Engage the clamping device 3 Lock the quick change mechanism into place A ATTENTION A
28. AUTION Release residual pressure when working on the hydraulic system The hydraulic oil quality can be checked on the list of lubricants Always only use the same quality hydraulic oil 41 User manual 12 4 Check coolant level 12 5 Refuelling 12 6 Check safety equipment Y CAUTION Check coolant level only when engine is cold A A Check coolant level in the reservoir Top off coolant if necessary Turn the radiator cap counter clockwise and remove ATTENTION If coolant is added ensure the water antifreeze mixture is correct After operation always refill the fuel tank until it is full This is to prevent the formation of water condensation in the interval between uses Ensure that fuel is not spilt when refuelling ATTENTION Make sure that you never run out of fuel otherwise you must bleed fuel system Check the brakes and swivel lock to ensure they are functioning properly The brakes and swivel lock are automatically activated when the excavator is at a complete stop no pilot control pressure The brakes only release when a drive or control lever is activated pressure builds up 9707687_User manual_en 42 13 Startingthe excavator 9707687_User manual_en A A A User manual o Adjust driver s seat spring tension position seat back 9 Place all switches and levers in their neutral position s Insert the key in the ignition and turn Starting procedure Accelerator in id
29. Change gear rim grease see 20 3 Check for play in bushings Replace damaged or defective parts Lubricate attachments at lubrication points see 17 5 65 User manual 22 Maintenance during longer periods of inactivity 22 1 Preparation for longer periods of inactivity Carefully clean and dry all parts NOTE When possible do not leave the Crawler Excavator out in the open If this is unavoidable park the Crawler Excavator on wooden boards and cover it with a tarp Lubricate all lubricated parts o Change the motor oil Grease piston rods of the hydraulic cylinders 9 Disconnect cabels from battery or remove battery and store in a protected place o Check antifreeze levels in coolant 22 2 Starting the excavator after periods of inactivity VVipe off grease from piston rods 9 Reconnect or install battery Start engine and operate unloaded N ATTENTION During longer periods of inactivity the excavator should be operated unloaded once a month 9707687_User manual_en 66 User manual 23 Lubricant table Q8 T660 10 W 40 API CH4 CE SJ HVLP 46 Hydraulic oil Bio l Panolin HLP Synth 46 Fina Biohydran SE 46 BP Biohyd SE 46 Live ring BP Energrease MP MG 2 Gearing BP Energrease L 21 M Ball bearing Travelling gear unit Q8 T 55 SAE 85 W 90 Fina Pontonic GLS SAE 85 W 90 BP Energrease L 21 M All lubrications points BP Energrease L 21 M Range of application of motor oil from 20 C bis
30. PS system or a TOP protective structure The windows must be clean and free from condensation and ice Cold start aids ether must not be used near sources of heat or open flames or on poorly ventilated premises The roadways must be designed so as to ensure smooth safe operation i e they must be adequately wide with the lowest possible gradient and laid on a base with a good bearing capacity The bearing capacity of bridges basement ceilings vaulting etc must be checked before driving over them The clearance dimensions of underpasses tunnels etc must be checked prior to driving into them On high gradients and slopes the load must be kept towards the incline if possible to increase stability The engine must not be out of gear when driving downhill Prior to driving down the slope the gear suited to the terrain must be selected and no gear change made while driving downhill Slopes on driveways must be designed to ensure that earthmoving machinery can be safely braked Extensive reversing should be avoided Earthmoving machinery must not be driven on the public highway unless an operating and driving licence compatible with the national traffic legislation is available Outside the public transport area e g on construction sites traffic regulations should be applied analogously This point should also be taken into account there with respect to the driving licence Loading unloading 9707687_User manual_en
31. a iq 43 Jump starts with aa aa a 44 Driving the crawler l l a a adal 46 a a 46 Travel on dangerous ground and on slopes 46 O I 46 Traveling Speeds isc rapaces 47 SOMA CO WIM st aa s ea an E 47 Care and MAMA NC e 48 Generalaren aaa ial cg a a ab a 48 Maihenancee ehedule lap us tee urban 50 id AAA A ANA 53 EM e 53 Check OUT Oil b bulaq 53 A IE o gn Gt ee iat acc te 53 Check fuel filter with water separator sack way ey eu tte tte sta cvs 54 AA A b n 54 Bolu OO s p diB3 54 PAY CANN CS tars a aa ad 54 Check ydra lic oil level aid A cs 54 Undercarriage and atacimentS acota s aa ab al dict 54 9707687_User manual_en Contents 17 5 18 1 18 2 18 3 18 4 18 5 18 6 Track a bb b 54 Check attachments bucket grab etc dol 55 Lubrication PONS iiiaae a a ba 55 Weekly maintenance or every 50 operating hours 2222 222 56 e E Ans ee oie 56 Check engine MUA IO eo act a A A din 56 Check fan DEIS sla lodo la 56 Change oil and oil filter asa a o o Dd 56 A A A 56 Check fuel filter with water separator iii a A ie t
32. acks and bridges are strong enough Supervision The prescribed deadlines for recurring tests must be observed Before starting his work the machine operator must also check as specified by the manufacturer that safety driving and operating devices e g overload warning system brakes steering lighting are fully functioning When mounting operating devices on quick change systems the firm fit of the operating device must be checked by moving it in all directions During this process all persons must keep out of the hazard zone Hydraulic hoses must be replaced as soon as the following damage is noticeable damage to the outer layer through to the intermediate layer brittleness in the outer layer distortions in pressurised or unpressurised state not conforming with the original shape of the installed hose leakages damage to the hose fittings or to the connection between fittings and hose storage damage the shelf life of the hose should not exceed 2 years damage resulting from exceeding the standard service life the service life under normal conditions should not exceed 6 years The coolant level must be checked only when the lid is cool the lid must be turned carefully to reduce the pressure The machine operator must report any recorded defects without delay to the supervisor and in the event of a change of operator to the operator replacing him In the event of defects endangering the operational
33. akage lines pumps cylinders Hydraulic oil level Oil cooler fins x n o m o o Primary and secondary pressure limiting valves r lt A V nm Breather filter Filling strainer A gt mi ndicator lamps Chain after vvorking Chain tension Bearring play of tread rollers track carrier rollers front idlers Check 0 Change Replace A Clean 0 1 Change Replace the first time 9707687 User manual en 51 User manual every 10h every 50 h every 250 h every 500 h every 1000 h Servicing activity component daily weekly 6 months 12 months 18 months annual Seals Leakage cooling and heating circuit Fan 2 1 a 1 x 14 1 C SEA ME mx 1 1 man 5 ESE Leakage check visual check 0 Change Replace A Clean 0 1 Change Replace the first time 9707687 User manual en 52 17 Daily maintenance User manual 17 1General visual inspection and leak check 17 2 Engine Check motor oil Check coolant level 9707687 User manual en A A Also see the maintenance schedule 16 2 5 Check controls to ensure precision operation x Check hydraulic fittings Pressure hoses hose connections and hydraulic cylinder seals for oil leaks The radiator for water leaks Engine for water and oil leaks Battery connections Check indicator lights when sta
34. be supported on the ground 2 indicated buttons at the two joysticks must be pressed 3 Wait for at least 5 sec with buttons pressed 4 Now the Neuson Vario can be shifted by means of the left joystick A WARNING The sense of rotation of Neuson Vario is opposite to the normal sense of rotation 9707687_User manual_en 86 z Option Lubrication Points at Neuson Vario There is another lubrication nipple on the top side of the eccentric disk 9707687_User manual_en 2 87 m 2 1 2 2 2 3 Safety instructions Safety instructions for the operation of earth moving machinery Preface The following are designated as earthmoving machinery excavators loaders excavator loaders bulldozers dump trucks scrapers graders pipe laying machines trench cutting machines compactors and special purpose earthmoving machines Instructions on the safe operation of earthmoving machinery are given below When operating and servicing earthmoving machinery the respective national safety instructions e g in the Federal Republic of Germany the accident prevention regulations for earthmoving machinery VBG 40 vehicles VBG 12 and the safety regulations for vehicle maintenance ZH 1 454 must also be observed As a supplement to the operating instructions the statutory regulations for public road transport and for accident prevention must be observed Such regulations may f
35. c 57 Glean radiator Ri al b 57 Hydraulics iS a 57 Hydraulic OMIA sass n ea gaa bal pt dace 57 A 57 Change hydraulic oil filter return filter 57 O ZD 58 Check WACK tensiones o ls cola eho des 58 Check the track rollers and wheels for play also check track tension 222 22225255 58 Traveling and swiveling drives criada 59 MUTA ADIGE tt b c ad ob b b 59 Bearing System etanol 59 Cabiheatihg sd tt ls 59 9707687_User manual_en VI 18 7 18 8 19 1 19 2 19 3 19 4 20 20 1 20 2 Contents Bilacl man s a aa are cereal 59 Check windshield washer 5 5 611 59 Maintenance every 250 operating hours ivi AA aa A AAA sas 60 60 Change Oil and ol Mier escocia 60 Replace fuel Mein dido ida d 60 Check engine rpms and exhaust system vii Ai 60 Aral urraca ENANA eens 60 Check hydraulic oil and filter ARA 60 apa 60 A a al aS ee 60 Maintenance every 500 operating hours sssss ss ssssseseseses sss s 3333838383
36. ce or repair work in a closed room Dispose of oil oil filters etc in accordance with environmental laws When working on or under the excavator put a warning sign on the seat or somewhere that it is clearly visible and legible Remove the key from the ignition Never work in a damp area or with wet hands or gloves on the electrical system Remove the negative pole from the battery when working on the electrical system 9707687_User manual_en 48 User manual If sealing elements O rings flange seals etc are removed always replace them with new ones After tightening bolts lock them against rotation Always clean dirt and oil residues from the vehicle after maintenance or repair work RISK OF SLIPPING The hours indicated for servicing intervals correspond to those indicated on the operating hours counter AN ATTENTION No smoking or open flames are allowed during servicing and repair work RISK OF FIRE ATTENTION The operating pressure settings of the hydraulic system should only be set by trained qualified personnel If malfunctions are caused by unauthorized alteration of operating pressure settings all warranty responsibility on the part of the manufacturer is automatically forfeited NOTE The hydraulic displacement pump must be bled after working on the hydraulic system especially after using a vacuum pump Starting the excavator without bleeding the the system can damage the pump For the
37. correct procedure see 20 2 3 Bleed the cylinders on the first or on subsequent installation as follows to avoid leaving air in the system that can damage components 1 Extend the piston rod slowly and completely do not apply any pressure at the end of the stroke 2 Move the cylinder through at least 5 complete working cycles extending retracting before using the excavator for normal work 9707687_User manual_en 49 User manual 16 2 Maintenance Schedule every 10 h every 50h every 250 h every 500 h levery 1000 h Servicing activity compone nt daily w eekly 6 months 12 months 18 months annual MOTOR Leakage Visual check Air filter lt gt lt gt Seating of mounting bolts Coolant Engine speed regulation Exhaust system Engine oil lt gt Oil filter lt gt V belt condition and tension Cooler fins Valve clearance Generator starter Fuel tank Water pump Fuel filter lt gt Cooling system and hoses Electrical connections Pre glow system Coolant thermostat Battery fluid A yx Check 0 Change Replace A Clean 1 Change Replace the first time 9707687_User manual_en 50 User manual every 10 h Jevery 50 hlevery 250 h every 500 h every 1000 h Servicing activity component daily 6 months 12 months 18 months 582 fe HYDR p r O 0 lt 0 m Fastening bolts Hydraulic pump Le
38. current 9707687_User manual_en A7 Safety instructions 6 8 5 6 9 6 10 6 10 1 6 10 2 6 10 3 6 10 4 6 10 5 6 11 6 11 1 moving the overhead line cabling or limiting the working range of earthmoving machinery In the event of a voltage transfer the following rules must be observed Do not leave the operator s cab Warn other persons not to approach or touch the machine f possible bring the operating device or the entire earthmoving machine out of the hazard zone Have the current switched off Never leave the machine until the contacted damaged line has been switched off Operation below ground and in enclosed areas If earthmoving machinery is used below ground or in enclosed areas adequate ventilation must be provided and the valid regulations must be observed Stoppages Prior to breaks or finishing work the operator must move the earthmoving machine to level ground with an adequate bearing capacity and secure it from movement The operating devices must be set down or secured in such a way that no inadvertent movement is possible The operator must not leave the earthmoving machine unless the operating devices are set down or secured Earthmoving machines must be parked only where they present no obstacle e g to public highway or site traffic If necessary they must be secured by warning devices such as warning triangles warning cords flashing or warning lamps
39. d If underground lines or their protective coverings are contacted or damaged inadvertently the machine operator must stop work immediately and notify the supervisor Operation close to overhead electric lines When working with earthmoving machinery close to overhead electric lines and contact lines a safety clearance dependent on the voltage rating of the overhead line must be kept between such lines and the earthmoving machine and its operating devices to prevent a voltage transfer This also applies to the clearance between such lines and attachments or slung loads The following safety clearances are applicable in Germany Voltage rating Safety clearance up to 1000 V 1 0m more than 1 kV to 110 kV 3 0m more than 110 kV to 220 kV 40m more than 220 kV to 380 kV or for unknown voltage rating 5 0 m All working movements of earthmoving machinery e g the boom positions the swinging of cables and the dimensions of slung loads must be taken into account as must ground irregularities through which the earthmoving machine is tilted and thus comes closer to overhead lines Wind may make overhead lines and operating devices swing out reducing the clearance If adequate clearance from electrical transmission lines and contact lines cannot be maintained the contractor must implement other safety measures against voltage transfer by agreement with the owner or operator of the lines This may be done for example by switching off the
40. d Lock the cab Park on level ground If the excavator has to be parked on an incline place chocks under the tracks 47 User manual 16 Care and Maintenance 16 1 General Care and maintenance have a lot to do with the reliability and operating life of the excavator Washing during the first three months the excavator should only be cleaned with cold water no high pressure or steam cleaning systems after the first three months keep the spray nozzle at least 30 cm from the vehicle the water temperature should not exceed 60 C and no aggressive cleaning agents should be used It is in the owner s interest to adhere to the maintenance schedule The manufacturer requires that all prescribed maintenance work be carried out Neglected maintenance will result in limitations on the guarantee See the engine operating instructions for engine maintenance The use of lubricants other than those recommended by the manufacture invalidates all warranty claims Before you undertake any maintenance or repair work find out if there is any damage to the vehicle Lower attachments to the ground before starting maintenance or repair work Engage locking and safety levers Release residual pressure from hydraulic system Allow engine to cool radiator fluid is hot If the machine must be raised to carry out work make sure it is secured supported appropriately Make sure there is an adequate flow of air before undertaking maintenan
41. d Locking Mechanism 00 AA LA si 29 E 29 Instrument Panel Functions cosida eii 30 Round display element s aaa aba 30 Eaa aa AAA 30 Fuse DOK OO PERA o a 32 Ordet a l x b 32 Swinging and swiveling the excavator 32 LOT control A a A 33 A aa ele eed l 33 9707687_User manual_en Contents 73 74 7 5 10 1 10 2 10 3 10 4 10 5 10 6 12 1 12 2 12 3 12 4 12 5 12 6 Excavator arm movements tata 34 D z Blade o cia hea DUL A Aa ota Utes m aa 34 Changing attachments Ac 35 TOWING CL ea nue ea a AA A 36 Lifting e da AA a n n 36 Excavating DOR a 37 LIQ A o sal b air 37 Excavator arm swing andl ote 37 B ll l zina aa a e e ed 38 MMPOG te eae ia esac Sota tal at ns dos 38 Cab Protec Aaaa alas 38 siab ll Dan 39 Transport instrUCtion AAA a a aye a a anda 40 Afterloading nr MOORE E lala 40 Things to check before starting the excavator coccion 41 sual Paid 41 Check Motorolie ed 41 Check hydraulic oil eve lucir 41 Check coolant yel sa 42 A a a Da d ad da n 42 Gheck satety equipe Disaster 42 9707687 User manual en 14 1 14 2 14 3 16 1 16 2 17 2 17 3 17 4 Contents Starting the excavator heat atest yal
42. d marks A Refill hydraulic oil as necessary Red mark Hydraulic connections for additional attachments Hydraulic connections for supplying additional attachments are located on the left and right side of the bucket sticket The hydraulics supply for additional attachments can be activated by turning the lever on distributor block Distributor block O gt CLOSED lever f OPEN Hammer operation 9707687_User manual_en 28 User manual 5 Safety Equipment 5 1 Parking Brake and Locking Mechanism The brakes and parking brake as well as the locking mechanism are automatically activated when the excavator is at a complete stop no pilot control pressure The brakes and locking mechanism only release when a drive or control lever is activated pressure builds up 52 Seat CAUTION The steering control console MUST be folded back when getting into or out of the crawler excavator in order to block the function of the hydraulic system ATTENTION Console down Work and hydraulic functions operational Console up Work and hydraulic functions interrupted Work functions operational Console u Work functions interrupted 9707687_User manual_en 29 User manual 6 Instrument Panel Functions 1 Dashboard right 2 Control lever right 3 Ignition lock 4 Instrument panel 5 Fuse box 1 Dashboard left 2 Con
43. ds of the jumper cables around the battery terminals several times to ensure good contact 6 Now start the excavator If it does not start immediately start the engine of the assisting vehicle to avoid draining the starting battery 7 After the excavator has been started and is running evenly have another person disconnect the jumper cables from the battery of the started engine first disconnect cable from negative terminal and then from positive terminal and disconnect the jumper cables from the battery of the assisting vehicle first disconnect cable from negative terminal and then from positive terminal Ensure that the cables do not short circuit touch Ensure that the excavator alternator has sufficient time to charge the battery before setting the excavator in motion or stopping the engine Make sure the cloth is removed and screw the filler caps back on 45 User manual 14 Driving the crawler excavator 14 1 Driving A The front is the side with the dozer blade Raise the excavating bucket and the dozer blade The excavator can be controlled using the drive levers or the foot pedals Forward Push left and right drive levers forward Reverse Pull left and right drive levers toward seat ATTENTION If a 180 rotation has been carried out dozer blade at rear the drive levers have the opposite effect Travel on dangerous ground and on slopes 14 2 Turning CAUTION Due to the
44. e needs of different operators for lighter persons for medium persons for heavier persons 9707687_User manual_en 26 User manual Heater Heating and Air Vents The heater is located under the driver s seat and can be turned on and off with the heater switch The heating vents are in the front of the cab and under the driver s seat Windshield Wipers The motor for the windshield wipers is located inside the cab at the top of the front windshield The windshield wipers can be turned on and off with a switch on the instrument panel 4 3 Hydraulic system Emergency operation of attachments Turn on ignition and use servo pressure valve emergency operation to lower the attachments Release of residual pressure Turn off engine Turn ignition on Activate servo pressure valve Slowly open the hydraulic oil cap to allow pressure to escape Y CAUTION Hydraulic system under pressure 9707687_User manual_en 27 User manual Check hydraulic oil level Position of arm while checking hydraulic oil level Excavator should be on level ground Extend arm Extend bucket bucket cylinder fully retracted Completely retract bucket stick cylinder Lower dozer blade Turn off engine Check the hydraulic oil level in the indicator visible by opening the valve cover Black mark indicator The oil level should be between the black and re
45. ed is frozen This can cause damage or an explosion Follow the instructions completely and in the correct order to avoid injury Check before connecting batteries The good battery must also be a 12 volt battery Examine jumper cables and terminals for damage rust etc 1 Turn the ignition keys of both vehicles to off and ensure that the operating levers of both vehicles are in neutral position and that the vehicles are not touching 2 Remove the battery filler caps and ensure that the battery fluid level is correct A clean cloth must also be placed over the Openings to prevent battery acid from boiling over CAUTION If acid splashes onto skin eyes or clothing wash immediately with large amounts of water 3 Use jumper cables to connect the positive terminals of the batteries Ensure that cable and terminal are properly secured CAUTION Never attempt to connect the jumper cable directly to the starter solenoid switch always connect it to the positive terminal of the excavator battery Connection of the jumper cable to the negative terminal should always be carried out last 9707687_User manual_en 44 9707687_User manual_en User manual 4 Connect a jumper cable to the negative terminal of the dead or run down battery 5 Finally connect the jumper cable to the negative terminal of the battery of the assisting vehicle Ensure that cable and terminal are properly secured Turn the en
46. en Introduction Make sure you have sufficient knowledge of the working area Location of supply lines electricity water gas telephone etc Load bearing capacity of ground 2 Before vvorking in the vicinity of supply lines Contact the respective authority e g gas electricity etc Your responsibilty Together determine the appropriate safety measures Only do work together with a signaller better visibility A ATTENTION Damaging a cable or pipe can endanger everyone present and the environment Never dig under the vehicle When excavating in or near excavated areas ensure that the walls are well supported Y CAUTION Risk of collapse Working inside buildings Watch height of ceiling Check load bearing capacity of floor Ensure a flow of fresh air because of exhaust fumes Never drive longer distances with the working equipment bucket grab etc fully raised Lowering the working equipment provides improved visibility and better weight distribution A Never drive across a slope on an incline i Unauthorized persons are not allovved to start or operate the excavator 9707687 User manual en Introduction The driving speed must always be appropriate for the road and ground conditions and the visibility Allow someone to guide you on roads with impeded visibility and at obstacles Particular caution is required when working on slopes ATTENTION Angle of inclinat
47. ete stop After loading place chocks under the tracks of the crawler excavator and secure it to prevent slipping overturning and moving tie down Tie down the excavator at the points indicated on the stickers 9707687_User manual_en 40 User manual 12 T ings to check before starting the excavator 12 1 Visual inspection 12 2 Check motor oil A Checking the excavator before operating it can prevent malfunctions during operation Therefore never neglect these checks Check Pressure hoses hose connections and hydraulic cylinder seals for oil leaks The radiator for water leaks Engine for water and oil leaks Battery connections Check the oil level using the dipstick The vehicle must be horizontal and the engine off NOTE The marks on the dipstick indicate the minimum and maximum oil levels Top off engine oil if necessary by opening the cap and adding oil from a clean container ATTENTION See the lubricant list for engine oil grade Only use engine oil of the same quality 12 3 Check hydraulic oil level 9707687_User manual_en Check the hydraulic oil level in the indicator in the main valve area Position of excavator arm while checking hydraulic oil levels Extend arm Extend bucket outward and lower it to the ground piston rods in cylinders Turn off engine Refill hydraulic oil as necessary Open the cap and refill the hydraulic oil from a clean container Close the cap C
48. f protective cover 1 2 _ Tighten track using grease gun 2 B Decreasing the track tension 1 Take off protective cover 1 2 Unscrew the return valve SW 22 3 3 Allow grease to come out until pressure has been completely released Check the track rollers and wheels for play also check track tension 9707687_User manual_en 58 User manual 18 4 Traveling and swiveling drives Check seals for leaks 18 5 Turntable Bearing system Turn the superstructure slowly and lubricate both nipples in the lubrication block see lubrication points 17 5 Fresh grease should appear all around the edge of the seals 18 6 Cab heating Check function Check cooling and heating circuit for leakage Seals Fan 18 7 Attachments Lubricate attachments at lubrication points see Lubrication Points 17 5 18 8 Check windshield washer system Add water to fluid container if necessary 9707687_User manual_en 59 User manual 19 19 1 19 2 19 3 19 4 Maintenance every 250 operating hours 4 NOTE In addition to normal weekly maintenance and maintenance every 50 operating hours the following maintenance should be carried out every 250 operating hours see maintenance schedule 16 2 Engine See engine operating instructions for maintenance schedule Change oil and oil filter See engine operating instructions Dispose of used oil in accordance with environmental laws Replace fuel filter
49. f the crawler excavator is used with an attachment which is not recommended or approved For road travel the vehicle must be equipped according to traffic laws and these laws must be observed Adapt working speed to local visibility Introduction 14 k No one except the driver may occupy the cravvler excavator RIDING INTHE EXCAVATOR IS PROHIBITED Use the towing bracket provided to tow the vehicle operating area steps and grips must be free from oil dirt ice and unsecured objects Risk of injury through slipping etc The lighting system must be checked before and during work in darkness to ensure it is in proper working order Always keep the windshield and windows clean Poor visibility can cause accidents Only operate the crawler excavator from the driver s seat Always keep the crawler excavator under control Do not operate equipment too quickly or in an uncontrolled manner Handle the crawler excavator cautiously and carefully until you are fully familiar with it Pay attention to the movements of machines and vehicles in the working area Staying longer than necessary in the danger area working area is forbidden Never operate the attachments bucket grab etc above persons Always wear appropriate protective clothing Helmet Work gloves Strong work shoes Reflective items of clothing And if necessary Earmuffs Protective glasses etc 9707687_User manual_
50. g instructions before they were printed The vehicle described in this handbook corresponds to the technical standards and safety requirements which applied when the manual was printed Subject to technical alteration If you have any further questions please don t hesitate to contact your NEUSON distributor 9707687_User manual_en 1 Guarantee and warranty 1 1 Identification Plate O TYPE BAUJAHR FZ IDENT NR MOTORLEISTUNG EIGENGEWICHT NUTZLAST ZULASSIGES GESAMTGEWICHT ZULASSIGE ACHSLAST ZULASSIGE ACHSLAST A ELETEN KG A KG KG VORN KG HINTEN neusen Baumaschinen GmbH Haidfeldstrafie 37 A 4060 Linz Leonding O Tel 43 0 732 90590 0 O Introduction Warranty claims may be asserted only against the Neuson distributor Moreover the directions given in this instruction manual must be complied with This identification plate is attached to the front of the chassis 1 2 Instructions for ordering spare parts 9707687_User manual_en Use only original NEUSON spare parts The complete part number designation and number of parts required must be indicated oneach order Indicate the type of machine and works number see identification plate on each order NOTE The ordering party is responsible for delivery errors resulting from incomplete information Prepare telephone orders carefully The order should include complete correct and clearly legible information on
51. io shall be shifted towards the slope MARIO 82 m 9707687 User manual en Option Warning Equipment of Neuson Vario 9707687_User manual_en 1 Depending on the position of the Vario stability might be increased or reduced warning range A compared with the standard excavator Please confer the Lifting Power Table and the figure Warning range Explanation of warning ranges A digging above crawler WARNING reduced stability B digging in longitudinal direction superstructure in the unfavourable range compared with Vario no change of stability hydraulically limited 2 The warning device is set to 73 of the static tilting load in case of unfavourable superstructure position As soon as this load is exceeded and working is done with the superstructure in an unfavourable position warning range or when slewing into such range a short warning sound is emitted once and a warning lamp lights up for position of warning lamp see figure Warning lamp 3 WARNING If the stick system is not lowered and slewed out of the danger area when the warning sound lamp is emitted braking of superstructure and opposite control or if the warning is ignored the machine may tilt 4 The warning lamp is equipped with a function check Upon each start the lamp lights up for a short time Always make sure that the warning lamp is working properly Operation of the excavator is permitted only with the lam
52. ion of vehicle in all directions of travel max 30 degrees Before leaving the vehicle Safe parking Park the excavator on firm even underground and pull the parking brake If the excavator is parked in hillside positionsor on sloping ground secure the excavator against moving sidewards sufficiently by means of blocks When parking on streets barriers warning boards lamps etc must be used in order that the excavator can also be recognized when it is dark and a collision is prevented Before leaving the excavator proceed as follows 1 Lower the boom and the earth levelling scoop on the ground 2 Bring the locking lever in locking position 3 Switch off the motor and withdraw the key 4 Lock the cabin and the covers Extreme caution is required when working across a slope or changing direction on an incline CAUTION Risk of overturning k Never use the vveight of the cravvler excavator to obtain more force when excavating CAUTION Risk of overturning 9707687_User manual_en 9707687_User manual_en Introduction Use the warning devices e g horn to warn any personnel working on the crawler excavator or any other persons in the working area before starting the crawler excavator or setting it in motion Hang a clearly visible and legible OUT OF ORDER sign on the vehicle if it is defective or if repairing or tuning the excavator The engine cover must not be opened vhile the engine is running
53. k lights optional The time relay fuses for the rear work lights optional and the main relays for the work lights are also located in the right control console 7 Swinging and swiveling the excavator equipment The excavating equipment is operated using the left and right control levers on the driver s seat console To operate the bucket stick and swivel the superstructure use the left control lever The boom and bucket are operated using the right control lever Button for Horn Leftcontrollever Right controllever 9707687_User manual_en 32 7 1 Left control lever 7 2 Right control lever 9707687_User manual_en 1 forward 2 backward 3 left 4 right 5 forward 6 backward 7 left 8 right 33 User manual bucket stick away from excavator bucket stick toward excavator turn superstructure to the left turn superstructure to the right lower boom raise boom bring bucket in extend bucket User manual 7 3 Excavator arm movements In order to swing the arm using the hammer pedal the button on the left control lever must also be pushed in swing arm to the left arm to the right gt 7 4 Dozer blade The dozer blade can be raised or lowered using the dozer blade lever lower dozer blade dozer blade lever 9707687_User manual_en ll 7 5 Changingattachments A 9707687_User manual_en User manual ATTENTION Tochange attach
54. ling position Step 1 Ignition on NOTE Oil pressure and charge indicator lights should come on warning light test Step 2 Turn key to warm up glow plug hold key for about 15 seconds Step 3 Start Release ignition key as soon as the engine is running NOTE The ignition key automatically returns to the ON position Do not engage the starter for more than 10 seconds at a time If the engine does not start pause for at least 30 seconds to let the battery recover before trying again Leave the key in the ON position during operation If the key is turned to O the engine is turned off ATTENTION Indicator lights oil pressure and charge indicator should go out after starting ATTENTION If they do not go out or if one comes on during operation stop the engine and have maintenance personnel or the repair shop look into the problem ATTENTION Let the engine warm up for approx 5 minutes to allow the hydraulic oil to get hot 43 User manual 13 1 Jump starts with jumper cables If the battery is dead another battery 12 Volt can be used in conjunction with suitable jumper cables to start the excavator ATTENTION The following procedure requiring two people is the only safe method for bridging a dead or run down battery Two people are required so that the jumper cables can be removed without the driver having to leave the cab CAUTION Never attempt to connect a jumper cable when the battery to be charg
55. llow lever to lock into place and then secure with a locking pin 9707687_User manual_en 76 Option 4 Ensure that locking device cannot accidentally release Locking pin Safety chain 27 nr b z mk 2 Y CAUTION The stability of the excavator can be affected by changing attachments risk of overturning 9707687_User manual_en 77 Option 28 4 Air conditioning unit Actuation equipment Function N 9706368 28 5 Diesel pump The first actuation equipment serves to switch the air conditioning function on and or off The next actuation equipment is for the cold warm setting The third actuation equipment is the blower At the blower three settings are possible These settings only determine the strength The grid for the air conditioning unit is in the foot area of the seat which can be opened manually as well as can be closed again when required HINT In order to have an optimum cooling capacity all windows and doors must be closed ATTENTION Grid closed air conditioning function interrupted Grid open air conditioning function ready for Operation The diesel pump is located on the hydraulic tank under the valve cover NOTE The diesel pump must be turned off immediately after filling up the excavator otherwise defects may occur 9707687_User manual_en 78 28 5 Theft Protection SICHERHEITS CODE FB BENUTZER CODE
56. ments the excavator MUST always be in a depressurized state Place attachments in a depressurized state on the ground and remove locking pins and bolts Remove locking pins1 2 and bolts 1 2 35 User manual 8 9 P1 Towing equipment To tow the excavator use the towing equipment provided Only use the towing bracket for towing Secure the shackle with the locking pin Towing bracket Shackle Locking pin and safety chain Max towing capacity of towing bracket 150 kN Lifting the Crawler Excavator Raise arm and dozer blade Fasten rope chains etc to the swiveling console and to the dozer blade on the left and the right 3 point suspension To prevent damage ensure there is enough distance between the ropes chains and the excavator L2 7 The fastening points are indicated with stickers Ensure that the ropes chains etc cannot come undone P2 Minimum force required per lift 80 kN L1 about 3 5m 12 2X about 4 m P1 Fastening point swiveling console P2 Fastening points left and right side of dozer blade 9707687_User manual_en 36 10 Excavating options 10 1 Digging 10 2 Excavator arm swing angle 9707687_User manual_en User manual Optimal stability while excavating Place the dozer blade against the ground for additional stability The dozer blade
57. mination Examination certificate No 01059 E The option Neuson Vario deviates from standards EN 474 1 1994 and EN 474 5 1996 Other than specified in standard EN 474 5 1996 any exceeding of stability is announced by a vvarning device Leonding v delivery note 0555507077 ii AR 9707687 User manual en 3 Specifications User manual 3 1 Technical Data Crawler Excavator 8002 RD Principal Data Principal Data 8002 RD Standard Unladen weight with cab 7900 kg 8520 kg Height to top of cab 2570 mm 2700 mm Width 2150 mm 2150 mm Lenght 3800 mm 3800 mm max digging depth 4400 mm 4270 mm max digging height 7220 mm 7350 mm max dumping height 5180 mm 5310 mm max digging radius 7240 mm 7240 mm Force per bucket tooth 4960 kp 4960 kp min rear swiveling clearance 1590 mm 1590 mm min excavator arm clearance 1670 mm 1670 mm Excavator arm angle left 80 80 Excavator arm angle right 50 50 Driving and swiveling specifications 9707687_User manual_en Driving and swiveling specifications 8002 RD 2 speeds 4 and 6 km h Climbing ability 30 58 Track width 450 mm Number of track rollers per side 5 per side Track tensioner Grease cylinder with Ground clearance Ground pressure of excavator when level 0 38 kg cm Swiveling speed of revolving superstructure 9 5 revolutions per min User manual Engine Hydraulic system Dozer blade Bucket Standard Engine 8002
58. must bleed fuel system 17 3 Hydraulics Check hydraulic oil level Check the hydraulic oil indicator in the main hydraulic valve unit Position of excavator arm while checking hydraulic oil levels Extend arm Extend shovel bucket outward and lower it to the ground piston rods in cylinders Turn off engine Refill hydraulic oil as necessary Open the cap and refill the hydraulic oil from a clean container CAUTION Release residual pressure when working on the hydraulic sytem The hydraulic oil quality can be checked on the list of lubricants Always only use the same quality hydraulic oil 17 4 Undercarriage and attachments Tracks AN ATTENTION Check tracks immediately after operation Replace damaged tracks 9707687_User manual_en 54 User manual Check attachments bucket grab etc Bucket teeth wear and tightness pin tightness Line tightness piston rod Behavior of the hydraulic cylinder when loaded Replace damaged or defective parts 17 5 Lubrication points Lubricate all other points daily blue caps Lubricate the points marked W weekly green caps daily _ di 7 Bearings uppercarriage Swingcylinder Turntable 9707687 User manual en 55 User manual 18 Weekly maintenance or every 50 operating hours 18 1 Engine Check engine mounting Check fan belt tension A Change oil and oil filter Battery NOTE In addition to n
59. narrow width of the excavator extreme caution is required when traveling on dangerous ground or on slopes On a slope which is steeper than 15 the superstructure must never be swivelled crosswise to the direction of travel When traveling the working equipment bucket grab etc must always be kept 30 40 cm above the ground and the dozer blade must be raised Turning left Pull left drive lever back and push right drive lever forward Turning right Push left drive lever forward and pull right drive lever back right 9707687_User manual_en 46 14 3 Traveling speeds Slow an Fast Overdrive a 15 Shutting down 9707687_User manual_en User manual a gears are regulated by a switch on the instrument panel b There is an additional switch on the left drive lever to switch quickly to overdrive while driving ATTENTION Do not use the overdrive when traveling around a curve c The speed is controlled with the drive lever pedal Pressed all the way max speed for that gear 2 Stop the machine Lovver bucket and dozer blade to the ground 2 Let engine idle Accelerator position 0 Turn off ignition ATTENTION Never turn off the engine at full power Allow the engine to idle for at least 1 Min before turning the engine off 9 Turn the key to the O position and remove it before leaving the vehicle CAUTION Unauthorized use of the excavator must be prevente
60. o ab da d bl Ras 87 A Safety instructions for the operation of earth moving machinery 5 A1 9707687_User manual_en Introduction 10 Introduction This manual and all supplementary pages must be kept accessible in the proper place in the vehicle This manual contains precise operating and handling maintenance and service instructions as well as the safety instructions required for operation of the vehicle You should be shown how to operate the vehicle by qualified personnel and carefully read the operating instructions before starting the vehicle The safety reliability and operational life of the excavator depend primarily on proper operation and maintenance accepts no liability according to product liability laws for any initial or subsequent damage which results from improper use and handling of the products supplied by us Please note that claims or complaints cannot be made on the basis of the information provided in these operating instructions including illustrations and data in particular con cerning construction NEUSON reserves the right to make technical alterations and or improvements without being bound to make these alterations to previously manufactured vehicles continuously strive to improve our products It is therefore possible that alterations have been made to the vehicle which could not be included in these operatin
61. or example also relate to the handling of hazardous substances or the wearing of personal protective gear In addition existing safety requirements must also be observed for special locations tunnels galleries quarries pontoons contaminated areas etc Intended use Earthmoving machinery must be operated only under the intended operating conditions provided by the manufacturer in the operating instructions The use is as intended when the earthmoving machine is used with the corresponding operating devices in accordance with the European or national safety regulations or for other work for which it is suitable according to the manufacturer s instructions Changes to the safety systems of the earthmoving machine by the owner without the prior consent of the manufacturer are inadmissible 9707687_User manual_en A1 Safety instructions 24 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 Spare parts must comply with the technical requirements specified by the manufacturer General information Earthmoving machinery must be operated or serviced independently only by persons who are physically and mentally suited who are instructed in the operation or servicing of the earthmoving machine and have furnished proof of their capacity to do so to the contractor and who can be expected to perform the tasks assigned to them reliably The statutory minimum age must be observed Any working method
62. ore working on the hydraulic system Hydraulic pump Check tightness of screws and bolts Check the hydraulic system lines pumps cylinder etc for leaks Clean hydraulic cooler Remove dirt dust leaves etc from the slits in the hydraulic cooler Clean in shorter intervals when working in dusty conditions Change hydraulic oil filter return filter 4 k 1 5 a gt The return filter is tobe changed for the first time after 50 operating hours 1 the hydraulic oil tank carefully tank is under pressure Remove the screws 6 2 Remove the screws from the return filter cover 4 3 Replace return filter cartridge 4 Put return filter cover back on and screw screws back in 5 Close the hydraulic oil tank properly 6 Let the crawler excavator idle in neutral for a few minutes Dispose of used filter in accordance with environmental laws See the operating instructions for other filter change intervals 9707687_User manual_en 5 User manual 18 3 Undercarriage Check track tension Use the excavator arm and dozer blade to raise the excavator Tracks should no longer be touching the ground If necessary use additional supports make sure the excavator cannot overturn The track when taut should never be more than 15 20 mm from the rollers NOTE If possible the distance from the rollers should be the same for both tracks A Increasing the track tension 1 Take of
63. ormal daily maintenance the following maintenance should be carried out weekly or every 50 operating hours see maintenance schedule 16 2 See engine operating instructions See the engine operating instructions for how to check the belt tension Replace the belt if cracks or other damage becomes evident ATTENTION Do not check with engine running See engine operating instructions The motor oil and oil filter must be changed after 50 operating hours The schedule for further oil changes can be found in the engine operating instructions Dispose of used oil in accordance with environmental laws For battery maintenance follow the manufacturer s instructions Check battery fluid levels The battery is located on the left side of the engine compartment If it is necessary to replace the battery dispose of the old battery in accordance with environmental laws NOTE The battery fluid levels must be between the min and max marks Only add distilled water to battery fluid 9707687_User manual_en 56 User manual Check fuel filter with water separator The container must be emptied if the indicator goes up condensation Clean the sieve if it is dirty Clean radiator Remove dirt dust leaves etc from the slits in the radiator Clean in shorter intervals when working in dusty conditions Check hoses and clamps and replace if necessary 18 2 Hydraulics Always release residual pressure bef
64. ozer blade 14 Undercarriage 5 Driver s seat 151Chassis 6lEngine cover 16 Left drive lever 7 Bucket cylinder 17 Right drive lever 8 Left control lever 18 Traveling drive 9 Right control lever 19 Protective cover for track tensioner 101Backhoe bucket 20 Eyes for lifting and tying down excavator 9707687_User manual_en 23 User manual 4 1 Cab equipment and controls I 1 17 ial 18 KG 10 EE Cab equipment and controls 1 Hammer covering 2 Drive pedal left and switch 3 Seat spring tension adjustment 4 Drive pedal right and feet pedal 5 Seat back adjustment 6 Feet rest 7 Lever for dozer plade with 8 Heating and air vents 9 lighting 10 Accelerator 111Amrest 12 Cable to open side cover 131Cable to open engine cover 24 14 Right control lever for boom and bucket 16 Instrument panel 19 Ignition lock 20 Storage 21 Fuse box 23 Left control lever for bucket stick and swiveling swing arm 24 Lever to fold back left steering control console 25 Seat adjustment 9707687_User manual_en 4 2 Excavator components 9707687_User manual_en User manual Excavator components 8002 1 Control block 8 Diesel tank 2 Hydraulicoillevel indicator 9iRetum filter 3 Place for quencher 10 Diesel pump 4 plug oil tank 5 Drain plug diesel tank 1210il tank 6lOpening for filling hydraulic oil 13 Engine cover TiTank support
65. p being functioning properly 83 Option Figure Warning range warning range A digging above crawler warning range B digging in longitudinal direction vvarning range A Danger of tilting warning range B k warning range B Danger of tilting Y WARNING This safety device must be checked upon each service every 250 op hours by authorized personnel This warning device must not be bypassed or rendered ineffective I I DANGER TO LIFE 9707687_User manual_en 84 3 ual Option Working with Neuson Vario When excavating a pit the superstructure can be slewed to the side of the dozer blade Thus a higher stability is achieved for digging on the side opposite the blade at the same time providing free visibility to the pit Increased Working Range of Neuson Vario The working range of Neuson Vario can be increased by 250 mm By shifting the superstructure to the side opposite the blade the bucket can be moved right up to the blade WARIO 9707687_User manual_en 2 85 2 Option Neuson Vario Labels Operation of Neuson Vario Make sure to read and observe the operating instructions Support dipper stick on the ground In case of non compliance persons and or the machine driver may be endangered the machine may tilt or other danger may occur Shifting of Neuson Vario 1 Dipper stick must
66. r system must not be undertaken except with the authorisation of the manufacturer The control pressure dynamic pressure and internal tank pressure must be reduced before starting work on the hydraulic system Only those hoses and lines prescribed by the manufacturer may be used Hydraulic hoses and lines must be skilfully laid and installed Smoking and the use of open flames are forbidden during refuelling Recovery towing transport The recovery and towing of earthmoving machinery must be done with adequately dimensioned towing devices only The towing points or blocks prescribed by the manufacturer e g lugs hooks must be used The towing vehicle must be driven slowly All persons must keep out of the range of towing devices 9707687_User manual_en 11 Safety instructions 8 4 8 5 8 6 8 7 9 1 9 2 9 3 9 4 9 5 9 6 During loading and transport earthmoving machinery and any necessary auxiliary devices must be secured against inadvertent movement The travelling gear and crawler unit of earthmoving machinery must be cleaned of mud snow and ice to such an extent that ramps can be negotiated without a risk of slippage Low loader access ramps must be fitted with wooden planks before being negotiated by tracked vehicles Before the actual transport the route to be covered should be inspected to ensure that the roads are wide enough bridge and underpass openings large enough and roads tr
67. red against swivelling In the case of earthmoving machinery with centre pivot steering the pivot joint must be positively locked when work is being done in that area When installing and dismantling counterweights they must be placed only at the locations prescribed by the manufacturer For jacking up earthmoving machinery lifting gear must be used in such a way as to prevent any slippage Tilted positions of the lifting gear or their inclined application are inadmissible Lifted earthmoving machinery must be secured by shoring up e g with diagonal stacks of planks or squared timbers or with jacks Earthmoving machinery which is lifted with operating devices must be supported immediately after being lifted No work may be done under raised earthmoving machinery which is held in place only by the hydraulic system Prior to replacing the bucket scrapers of scraper vehicles or scraper dozers the scraper buckets must be set down on a non tilting unbreakable base Maintenance and repair work on scraper buckets must be done only when the closing flap is secured Prior to any maintenance and repair work the driving motors must be stopped Only maintenance or repair work which cannot be carried out with a drive is exempt from these requirements It must be ensured that the drive can be stopped immediately in any hazardous situation prior to beginning such work In the case of earthmoving machinery with a combustion engine the battery
68. reen FGPS must also be present Close to earth and rock walls excavators should be set up and operated in such a way that the operator s stand and the steps leading to it are on the side of the earthmoving machine away from the wall Demolition work must not be done with earthmoving machinery unless it is assured that persons are not at risk Prior to carrying out demolition work with excavators e g demolishing with demolition pendulums the weight of the pendulum must be coordinated with the load capacity of the machine and the boom length The highest point of the operating device of the earthmoving machine should be above the component to be demolished 9707687_User manual_en A6 6 7 6 7 1 6 7 2 6 7 3 6 7 4 6 8 6 8 1 6 8 2 6 8 3 6 8 4 Safety instructions Operation in areas carrying underground lines Prior to carrying out excavation work with earthmoving machinery a check must be made in the area to be excavated for underground lines which might present a risk to persons If underground lines are present their location and course must be determined by agreement with the owner or operator of the line and the necessary safety measures must be stipulated and taken The course of lines in the construction site zone must be clearly marked under supervision prior to earthmoving work being commenced If the location of lines cannot be determined exploratory trenches must be dug if necessary by han
69. rting the engine Check the oil level using the dipstick The vehicle must be horizontal and the engine off Check the quality of the oil as well If the oil is very dirty change the oil before the next maintenance interval NOTE The marks on the dipstick indicate the minimum and maximum oil levels Top off engine oil if necessary by opening the cap and adding oil from a clean container ATTENTION See the lubricant list for engine oil grade Only use engine oil of the same quality CAUTION Check coolant level only when engine is cold Check coolant level in the reservoir Top off coolant if necessary Turn the radiator cap counter clockwise and remove ATTENTION If coolant is added ensure the water antifreeze mixture is correct 53 User manual Check fuel filter with water separator The container must be emptied if the indicator goes up condensation Clean air filter Open housing clean dust trap Unscrew and remove filter Clean the filter using compressed air 3 5 bar A ATTENTION If the warning light on the instrument panel goes off clean air filter immediately Important when working in dusty conditions Refuelling After operation always refill the fuel tank until it is full This is to prevent the formation of water condensation in the interval between uses Ensure that fuel is not spilt when refuelling Make sure that you never run out of fuel otherwise you
70. se as possible to the ground and prevent their swinging Earthmoving machinery must not be driven with a slung load unless the roadway is as even as possible When earthmoving machinery is in lifting gear deployment riggers may approach the boom only with the consent of the machine operator and only from the side The machine operator must not give his consent unless the earthmoving machine is stationary and the operating device is not being moved No damaged or inadequately dimensioned slinging aids cables chains must be used Protective gloves must always be worn when working with slinging aids Assembly servicing repair maintenance Earthmoving machinery must not be assembled converted or dismantled except under the direction of qualified personnel appointed by the contractor and with the manufacturer s operating instructions being observed Work on such components as braking 9707687_User manual_en AQ Safety instructions T 74 7 5 7 6 EE 7 8 7 9 7 10 7 11 7 12 7 13 steering hydraulic and electrical systems of the earthmoving machine must be performed by specially trained skilled personnel only Stability must be ensured at all times including during maintenance work The operating devices must be secured from moving by being set down on the ground or with equivalent measures e g supporting sleeves or jacks If necessary the superstructure of excavators must be secu
71. sej no Gun 418 A 53 1041 l 1915 13 wn jsojddiy Jopo JDJAqNH lp 15 puls uaqoyos 18A funlu l a 900028 IAA bunlu li noqebun eb1 suos Japo jejjo ule l YODU QIYYA 01100 S16 1111 usbomieqo 840 Jyp4 INZ 06 Hunzjnjsqop yosierudjg euyo UeJUIY YODU QIYYA 001140 S1 w uabomJeqo Jyp4 INZ 06 BUNZ N SqDP 1YISJ91UD H euyo NYYo J JyO4 U unzin sqopi lu siolubid yu 191107 suyo pun punsbJajuy wejsej pno Gun 19q ul puls 9 0 12 J INDIP H t yoyu yoy s0 77 ZUDIAYOJO 9111 UOA bunpo sny 1911819107 Wayy98 s86 l q 507 e615sp nz D 1915 ally 37138 11 8 uapiem sapo g nz pun soqoys 45 D nzin d n PUN s p n BunBurysueg Y Z OSJBUBPOYIS IZ s lq aJasun UYO JJOP pun IZINYISIO q l d q qin isi Bunu
72. state For earthmoving machinery fitted with quick change devices for mounting and discharging the operating device of which locking mechanism is not clearly visible from the operator s workplace design soiling the following additional safety measures are essential The firm fit of the operating device at the connection of the quick change device must be controlled directly by the operator or another person lf this is not feasible the operating device must be lifted only to such an extent that the firm fit can be checked by rearward tilting and dumping All persons must keep out of the hazard zone during this test run Transport of persons Apart from the machine operator no persons may be transported on earthmoving machinery unless special places have been provided for this purpose by the manufacturer These special places must be equipped with fixed seats and securing devices to prevent persons from falling from the earthmoving machine No one may mount or alight from earthmoving machinery except with the prior consent of the machine operator and when the machine is stationary 9707687_User manual_en A4 6 3 10 6 3 11 6 3 12 6 3 13 6 4 Safety instructions Driving Prior to starting up the earthmoving machine the operator s seat the mirror and the adjustable parts must be set in such a way as to ensure operational safety The safety belt must be applied when earthmoving machinery is fitted with a RO
73. tion The safety regulations must be kept clearly visible and accessible at all times for operating personnel Read these operating instructions as often as required until you are familiar with all the safety regulations operating equipment components and functions of the machine All safety stickers notes and warnings must be kept legible Clean off dirt Replace with new stickers if they become illegible Operate the vehicle with care and prudence and in such a way that neither you nor your colleagues are put at risk After you have carefully studied these operating instructions practice operating the machine in an open space where there is no risk of endangering others or causing material damage The safety of the driver and other persons in the working area depends on the ability of the driver The driver must therefore be familiar with how the opera ting levers function Every unit has limits to its performance Before starting up the crawler excavator the driver must familiarize himself with the characteristics of the excavator in particular with the speed the braking and drive systems the control and drive levers the safety equipment and instructions its stability and its lifting capacity A ATTENTION The NEUSON CRAWLER EXCAVATORis designed and constructed solely for use with NEUSON attachments or attachments which have been approved by NEUSON NEUSON can accept no liability for the safety of the driver i
74. trol lever left 5 Cold hot adjustment 1 Round display element 2 Lamps 3 Fuel gauge 4 Operating hours meter 1 Clogging indicator for hydraulic filter 0 2 Clogging indicator for air filter 1 charge control 2 Motor oil pressure 1 Water temperature indicator 2 Preheating pilot lamp 9707687_User manual_en 30 User manual 1 Overload pilot lamp 1 Switch for overdrive 2 Switch for chassis headlights 1 Pilot lamp for headlights 2 Switch for screen wiper and washer 1 Switch for cabin heating 1 Ingnition lock with two keys 1 Fuse box 9707687_User manual_en 31 User manual 6 1 Fusebox The fuses are integrated into the instrument panel Order of fuses Arrangements of the fuses in the fuse box 8002 RD Ca No Capacity AA 7 9 Overdrive toggle switch and drive lever 7 5 Windshield wipers and washer 30 Turn engine off stop solenoid 7 5 Switch and Instrument panel lighting 15 Front work lights 15 Heater horn 10 Turning lights free 10 Cab lighting Socket Radio 10 Alternator Starter 15 Fuel pump free 10 Change over valve Safety solenoid valve 1 2 3 4 5 6 T 8 9 x The main fuse 50 amps for the igniton and the glow plug is located in the relay box Another main fuse 40 amps is located in the right control console This is the fuse for the light on the arm the side work lights and the rear wor
75. ttom screw plugs Drain oil collect in a container Close bottom screw plug properly 2 With the drive in the position shown Open middle screw plug Refill with fresh oil in the top opening until it comes out of the middle opening Close both openings properly ATTENTION Dispose of used oil in accordance with environmental laws 9707687_User manual_en 63 User manual 21 Maintenance every 1 000 operating hours NOTE n addition to normal weekly maintenance and maintenance every 50 250 and 500 operating hours the following maintenance should be carried out every 1 000 operating hours see maintenance schedule 16 2 21 1 Engine See engine operating instructions for maintenance instructions Check alternator and starter Clean fuel tank Replace fuel filter Dispose of filter in accordance with environmental laws Check water pump Change air filter Change oil and oil filter Dispose of used oil in accordance with environmental laws 21 2 Hydraulics Always release residual pressure before working on the hydraulic system Check hydraulic oil and filter Check ventilation filter and sieve Check ventilation filter and replace if necessary Check sieve for damage and replace if necessary 21 3 Traveling and swiveling drives 21 3 1 Traveling drive Change oil 9707687_User manual_en 64 21 4 Gear rim 21 5 Attachments 9707687 User manual en User manual
76. ty when working with the crawler excavator Particularly when working to the side with attachments bucket grab etc Changing the attachments alters the stability weight E g One of the situations excavating to the side with the arm swung to the max angle in which overturning to the left is possible 9707687_User manual_en 39 User manual 11 Transportinstructions 11 1 After loading o Use only transport vehicles which are in proper working order and are approved for use on public roads When using ramps to load the excavator onto the transport vehicle do not exceed an incline of 18 the ramp width must be at least 1 or 2 times the width of the tracks Clean dirt mud ice and snow from the ramps and the tracks NOTE The ramp ends should be bevelled see below to o o o o o o o o prevent damage to the rubber tracks Attach the ramps securely to the transport vehicle to prevent them from slipping off e g hook on As a safety precaution provide additional support in the middle of the ramps Load the machine on solid even ground When loading apply the parking brake of the transport vehicle securely and place chocks under the wheels Lower the dozer blade and the excavator arm onto the loading surface of the transport vehicle Stop the engine Lock the cab The swivel lock is automatically applied when the excavator is at a compl
77. uaf UP YOU 01301310 9707687_User manual_en ae User manual 27 2 Legend of Lifting Power Tables TE THT l CTH max admissible load with dipper stick straight A projection from live ring centre B height of lifting hook x lifting power limited by hydraulic system All values of the table are specified in kg in horizontal position on solid subsoil and without bucket with dozer blade supported in travelling direction without dozer blade supported 90 to travelling direction without dozer blade supported 90 to travelling direction superstructure shifted backward by means of option VARIO without dozer blade supported 90 to travelling direction superstructure shifted forward by means of option VARIO If a bucket or other working facilities are installed the lifting power or tilting load is reduced by the empty weight of such facilities Position on solid subsoil and without bucket Designfundamentals acc to ISO 10567 The lifting power of the compact excavator is limited by the setting of the pressure control valves and the stabilizer system Neither 75 of the static tilting load nor 87 of the hydraulic lifting power are exceeded WARNING The Vario system deviates form ISO 10567 in some excavator positions Other than specified by standard ISO 10567 any exceeding of the tilting load is announced by means of a warning device 9707687_User manual_en 74 Option 28 Option 2

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