BA_1200RD_AA02418V-AB03158_en_1000081376

User manual

Crawler excavator12002 RD

Edition:Item No.:Language:

April 20039707672English

Contents

Introduction .............................................................................................................................................10

1.2

1

1.1

2

2.1

2.2

3

3.1

Instructions for ordering spare parts ....................................................................................................... 11

Guarantee and warranty .......................................................................................................................... 11

Identification Plate ................................................................................................................................... 11

Safety ...................................................................................................................................................... 12Safety rules .............................................................................................................................................13

EC - Declaration of Conformity ............................................................................................................... 19

Specifications .........................................................................................................................................20

Technical Data Crawler Excavator 12002 RD .......................................................................................... 20

Principal Data ..........................................................................................................................................20

Driving and swiveling specifications ......................................................................................................20

Engine ....................................................................................................................................................21Hydraulic system ....................................................................................................................................21

Dozer blade ............................................................................................................................................21

Bucket (Standard) ...................................................................................................................................21

3.2

3.3

3.4

3.5

3.6

4

4.1

Noise emissions Crawler Excavator 12002 RD ...................................................................................... 22

Vibration levels .......................................................................................................................................22

Fire extinguisher ..................................................................................................................................... 22

Stickers ................................................................................................................................................... 23Primary Dimensions Crawler Excavator 12002 RD ................................................................................ 25

Component Designations .......................................................................................................................26

Cab equipment and controls ..................................................................................................................27

9707672_User manual_en

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Contents

4.2 Excavator components .......................................................................................................................... 29

Work lights ..............................................................................................................................................30

Accelerator (Joystick right) .....................................................................................................................30

Driver's Seat ...........................................................................................................................................30

Heater, Heating and Air Vents .................................................................................................................31

Windshield Wipers .................................................................................................................................31

Diesel pump (Optional) .......................................................................................................................... 31

4.3 Hydraulic system ....................................................................................................................................31

Emergency operation of attachments .................................................................................................... 31

Release of residual pressure .................................................................................................................31

Hydraulic connections for additional attachments ..................................................................................32

Check hydraulic oil level ........................................................................................................................32

5

5.1

5.2

6

Safety Equipment ...................................................................................................................................33

Parking Brake and Locking Mechanism ................................................................................................ 33

Seat ........................................................................................................................................................33Instrument Panel Functions ....................................................................................................................34

Round display element .......................................................................................................................... 34

6.1 Fuse box ................................................................................................................................................36Order of fuses .........................................................................................................................................36

7

7.1

7.2

Swinging and swiveling the excavator equipment ................................................................................. 36

Left control lever ..................................................................................................................................... 37

Right control lever ..................................................................................................................................37


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Contents

7.3

7.4

7.5

8

9

10

Excavator arm movements ....................................................................................................................38

Dozer blade ............................................................................................................................................38

Changing attachments ............................................................................................................................39

Towing equipment ..................................................................................................................................40

Lifting the Crawler Excavator ..................................................................................................................40

Excavating options .................................................................................................................................41

10.1 Digging ................................................................................................................................................... 41

10.2 Excavator arm swing angle ....................................................................................................................41

10.3 Bulldozing ............................................................................................................................................... 42

10.4 Lifting .......................................................................................................................................................42

10.5 Cab protection ........................................................................................................................................42

10.6 Stability ...................................................................................................................................................43

11 Transport instructions ..............................................................................................................................44

11.1 After loading ...........................................................................................................................................44

12 Things to check before starting the excavator ....................................................................................... 45

12.1 Visual inspection .................................................................................................................................... 45

12.2 Check motor oil ......................................................................................................................................45

12.3 Check hydraulic oil level ........................................................................................................................45

12.4 Check coolant level ................................................................................................................................46

12.5 Refuelling ................................................................................................................................................ 46

12.6 Check safety equipment......................................................................................................................... 46

13 Starting the excavator .............................................................................................................................47


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Contents

13.1 Jump starts (with jumper cables) ............................................................................................................48

14 Driving the crawler excavator .................................................................................................................50

14.1 Driving .....................................................................................................................................................50

Travel on dangerous ground and on slopes .........................................................................................50

14.2 Turning .................................................................................................................................................... 50

14.3 Traveling speeds ...................................................................................................................................51

15

16

Shutting down .........................................................................................................................................51

Care and Maintenance............................................................................................................................ 52

16.1 General ................................................................................................................................................... 52

16.2 Maintenance Schedule ........................................................................................................................... 54

17 Daily maintenance ..................................................................................................................................57

17.1 General visual inspection and leak check .............................................................................................57

17.2 Engine .................................................................................................................................................... 57

Check motor oil ...................................................................................................................................... 57

Check coolant level ................................................................................................................................57

Check fuel filter with water separator ......................................................................................................57

Clean air filter ..........................................................................................................................................58

Refuelling ................................................................................................................................................58

17.3 Hydraulics ...............................................................................................................................................58

Check hydraulic oil level ........................................................................................................................58

17.4 Undercarriage and attachments .............................................................................................................. 58

Tracks .....................................................................................................................................................58


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Contents

Check attachments (bucket, grab, etc.) .................................................................................................58

17.5 Lubrication points ...................................................................................................................................59

18 Weekly maintenance or every 50 operating hours ................................................................................ 60

18.1 Engine ....................................................................................................................................................60

Check engine mounting .........................................................................................................................60

Check fan belt tension ............................................................................................................................60

Change oil and oil filter ........................................................................................................................... 60

Battery .....................................................................................................................................................60Check fuel filter with water separator ......................................................................................................60

Clean radiator .........................................................................................................................................61

18.2 Hydraulics ...............................................................................................................................................61

Hydraulic pump ......................................................................................................................................61

Clean hydraulic cooler............................................................................................................................61

Change hydraulic oil filter (return filter) ................................................................................................... 61

18.3 Undercarriage .........................................................................................................................................61

Check track tension ................................................................................................................................61

Check the track rollers and wheels for play, also check track tension! .................................................62

18.4 Traveling and swiveling drives ............................................................................................................... 62

18.5 Turntable .................................................................................................................................................62

Bearing system ...................................................................................................................................... 62

18.6 Cab heating ............................................................................................................................................ 63

18.7 Attachments ............................................................................................................................................63


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Contents

18.8 Check windshield washer system ..........................................................................................................63

19 Maintenance every 250 operating hours ................................................................................................ 64

19.1 Engine .................................................................................................................................................... 64

Change oil and oil filter ........................................................................................................................... 64

Replace fuel filter ....................................................................................................................................64

Check engine rpms and exhaust system ..............................................................................................64

19.2 Hydraulics ...............................................................................................................................................64

Check hydraulic oil and filter ..................................................................................................................64

19.3 Electrical components ............................................................................................................................ 64

19.4 Attachments ............................................................................................................................................64

20 Maintenance every 500 operating hours ................................................................................................ 65

20.1 Engine .................................................................................................................................................... 65

Change air filter ....................................................................................................................................... 65

Check valves ..........................................................................................................................................65

Check coolant system and hoses..........................................................................................................65

Check electrical connections .................................................................................................................65

Check glow plug..................................................................................................................................... 65

20.2 Hydraulics ...............................................................................................................................................65

Check primary valves .............................................................................................................................65

Change hydraulic oil filter (return filter) ................................................................................................... 65

Change hydraulic oil ...............................................................................................................................66

Check ventilation filter and sieve ...........................................................................................................66


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Contents

20.3 Gear rim .................................................................................................................................................. 66

20.4 Traveling drive ........................................................................................................................................67

Change drive oil .....................................................................................................................................67

21 Maintenance every 1,000 operating hours .............................................................................................68

21.1 Engine ....................................................................................................................................................68

Check alternator and starter ....................................................................................................................68

Clean fuel tank ........................................................................................................................................68

Replace fuel filter ....................................................................................................................................68

Check water pump..................................................................................................................................68

Change air filter ....................................................................................................................................... 68

Change oil and oil filter ...........................................................................................................................68

21.2 Hydraulics ............................................................................................................................................... 68

Check hydraulic oil and filter ..................................................................................................................68

Check ventilation filter and sieve ...........................................................................................................68

21.3 Traveling and swiveling drives ............................................................................................................... 68

Traveling drive - Change oil ...................................................................................................................68

21.4 Gear rim .................................................................................................................................................. 69

21.5 Attachments ............................................................................................................................................ 69

22 Maintenance during longer periods of inactivity .................................................................................... 70

22.1 Preparation for longer periods of inactivity ............................................................................................ 70

22.2 Starting the excavator after periods of inactivity..................................................................................... 70

23 Lubricant table ........................................................................................................................................71


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Contents

24 Trouble shooting..................................................................................................................................... 72

27.2 Lifting Power Table 12002 Vario ............................................................................................................. 76

27.3 Legend of Lifting Power Tables ................................................................................................................ 77

28 Options ................................................................................................................................................... 78

28.1 Hydraulic Connections for Accessory Equipment .................................................................................. 78

28.2 Overload Warning Device for .................................................................................................................78

Hoisting Operation ..................................................................................................................................78

28.3 Electrically Actuated Auxiliary Hydraulics ...............................................................................................79

28.4 Theft Protection ....................................................................................................................................... 80

28.5 Diesel Pump ...........................................................................................................................................81

28.6 Air-Conditioning Unit ...............................................................................................................................81

Control Elements ....................................................................................................................................81

Function .................................................................................................................................................. 81

28.7 NEUSON VARIO ..................................................................................................................................... 82

Operation of Neuson Vario .....................................................................................................................82

Driving the Neuson Vario Transverse to the Slope ................................................................................ 83

Warning Equipment of Neuson Vario .....................................................................................................84

Working with Neuson Vario ....................................................................................................................86

Increased Working Range of Neuson Vario...........................................................................................86

Neuson Vario Labels ..............................................................................................................................87

Lubrication Points at Neuson Vario ........................................................................................................88

A Safety instructions for the operation of earth-moving machinery .......................................................... A1


- IX -

Introduction

Introduction

This manual and all supplementary pages must be kept accessible in the proper placein the vehicle!

This manual contains precise operating and handling, maintenance and service instructions aswell as the safety instructions required for operation of the vehicle.

-

-

-

-

You should be shown how to operate the vehicle by qualified personnel and carefully readthe operating instructions before starting the vehicle.

The safety, reliability, and operational life of the excavator depend primarily on properoperation and maintenance.

NEUSON accepts no liability according to product liability laws for any initial or subsequentdamage 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 informationprovided in these operating instructions including illustrations and data--in particular concerning construction.NEUSON reserves the right to make technical alterations and/or improvements withoutbeing bound to make these alterations to previously manufactured vehicles.

We continuously strive to improve our products. It is therefore possible that alterations havebeen made to the vehicle which could not be included in these operating instructions beforethey were printed.The vehicle described in this handbook corresponds to the technical standards and safetyrequirements 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!


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Introduction

1 Guarantee and warranty

Warranty claims may be asserted only against the Neusondistributor.Moreover, the directions given in this instruction manualmust be complied with.

1.1 Identification Plate

This identification plate is attached to the front of the chassis.

1.2 Instructions for ordering spare parts

Use only original NEUSON spare parts!The complete part number, designation, and number ofparts required must be indicated oneach order.Indicate the type of machine and works number (seeidentification plate) on each order.

NOTE: The ordering party is responsible fordelivery errors resulting fromincomplete information. Preparetelephone orders carefully. The ordershould include complete, correct, andclearly legible information on theaddress, postal code, shippingmethod, and final destinationto prevent unnecessary inquiries anddelivery errors.

Please order spare parts only via your NEUSONdistributor!


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Introduction

2 Safety

ATTENTION: Read the following safety rulescarefully before operating thevehicle.

The safety rules listed here, as well as any other applicablesafety rules and regulations, should always be observed.Operating errors and ignorance regarding potentiallydangerous situations that can occur during vehicle operation can lead to injuries.

These potentially dangerous errors and situations areindicated by

CAUTION

in these instructions.

In addition, operating errors and ignorance regardingpotentially dangerous situations that can occur duringvehicle operation and maintenance can lead to materialdamage.These potentially dangerous errors and situations areindicated by

ATTENTION

in these instructions.

Certain instructions are indicated by

NOTE

The disregard of these instructions can lead to operationalmalfunctions.

The observance of these tips can improve the performanceof the excavator.

The national and regional statutory safety and accidentprevention regulations are not included in this manual.These regulations are provided in the booklet from theBerufsgenossenschaft Tiefbau (Civil Engineering TradeAssociation).


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Introduction

The safety regulations must be kept clearly visible andaccessible at all times for operating personnel.Read these operating instructions as often as required, untilyou are familiar with all the safety regulations, operatingequipment, components, and functions of the machine.All safety stickers (notes and warnings) must be keptlegible. Clean off dirt Replace with new stickers if theybecome illegible!Operate the vehicle with care and prudence and in such away that neither you nor your colleagues are put at risk. Afteryou have carefully studied these operating instructions,practice operating the machine in an open space wherethere is no risk of endangering others or causing materialdamage.

The safety of the driver and other persons in theworking area depends on the ability of the driver. Thedriver must therefore be familiar with how theopera ting levers function.

Every unit has limits to its performance:

Before starting up the crawler excavator the drivermust familiarize himself with the characteristics of theexcavator, in particular with the speed, the brakingand drive systems, the control and drive levers, thesafety equipment and instructions, its stability, and itslifting capacity.

ATTENTION: The NEUSON CRAWLEREXCAVATOR is designedand constructed solely for usewith NEUSON attachments orattachments which have beenapproved by NEUSON.NEUSON can accept no liabilityfor the safety of the driver if thecrawler excavator is used with anattachment which is notrecommended or approved.

2.1 Safety rules

* For road travel, the vehicle must be equippedaccording to traffic laws and these laws must beobserved.

Adapt working speed to local visibility.

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*


Introduction

* No one except the driver may occupy the crawlerexcavator.

RIDING IN THE EXCAVATOR IS PROHIBITED!

*

*

Use the towing bracket provided to tow the vehicle.

The operating area, steps, and grips must be freefrom oil, dirt, ice, and unsecured objects.

Risk of injury through slipping etc.

* The lighting system must be checked before andduring work in darkness to ensure it is in properworking order.

Always keep the windshield and windows clean.Poor visibility can cause accidents.

Only operate the crawler excavator from the driver'sseat. Always keep the crawler excavator undercontrol.

Do not operate equipment too quickly or in anuncontrolled manner.

Handle the crawler excavator cautiously and carefullyuntil you are fully familiar with it.

Pay attention to the movements of machines andvehicles 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:HelmetWork glovesStrong work shoesReflective items of clothingAnd if necessaryEarmuffsProtective glasses, etc.


*

*

*

*

*

*

*

*

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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

* Before working 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).ATTENTION: Damaging a cable or pipe can

endanger everyone present and theenvironment.

*

* Never dig under the vehicle. When excavating inor near excavated areas, ensure that the walls arewell supported!

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 workingequipment (bucket, grab, etc.) fully raised. Loweringthe working equipment provides improved visibilityand better weight distribution.Never drive across a slope on an incline.

Unauthorized persons are not allowed to start oroperate the excavator.

*

*

*


- 15 -

Introduction

* The driving speed must always be appropriate for theroad and ground conditions and the visibility.Allow someone to guide you on roads with impededvisibility and at obstacles.Particular caution is required when working onslopes.

ATTENTION: Angle of inclination ofvehicle in all directions oftravel: max. 30 degrees

*

*

-

Before leaving the vehicle

Safe parking:

Park the excavator on firm, even underground and pull theparking brake. If the excavator is parked in hillsidepositionsor on sloping ground, secure the excavator againstmoving sidewards sufficiently by means of blocks.When parking on streets, barriers, warning boards, lampsetc. must be used in order that the excavator can also berecognized when it is dark and a collision is prevented.Before leaving the excavator proceed as follows:

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 slopeor changingdirection on an incline.

CAUTION: Risk of overturning

* Never use the weight of the crawler excavator toobtain more force whenexcavating.

1.

CAUTION: Risk of overturning


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Introduction

* Use the warning devices (e.g. horn) to warn anypersonnel working on the crawler excavator or anyother persons in the working area before starting thecrawler 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 ortuning the excavator.

*

* The engine cover must not be opened while the engine is running. Risk of injury from rotating components and risk of burns.* Machine keys

The machine keys delivered by the factory are unrestrictedstandard keys (driver’s cabin and ignition).

This means that they can be duplicated without specifyingthe vehicle and chassis type identification number.

We’d like to point out that this is no 100% security againsttheft. For an adequate theft protection as an option pleaserefer to our price list.* Make sure you inform yourself about the emergency equipment - First aid kit - Fire extinguisher*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 switchingsystem

* The excavator is not intended to be used with liftingequipment and is not for transporting or lifting peopleTransporting and lifting people using theattachments or other equipment is PROHIBITED!

The excavator arm is not a ramming device!Never attempt to use the attachments to drive piles orother objects into the ground, or to flatten earth, etc.Never attempt to destroy a wall of earth or any otherstructure by swinging the arm and striking the wall withthe attachments.

*


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Introduction

*Never excavate while driving.Never dig an attachment into the ground and attempt to excavateby driving and pulling. Never swivel the excavator with loweredattachments and nevermaneuver the vehicle when an attachment is on the ground.ATTENTION: The crawler excavator is NOT

equippedto be used for lifting or to be fitted withlifting attachments.

NOTE: If substances that could damage theenvironment or injure people leak out of thecrawler excavator, take the necessarymeasures immediately (e.g., hydraulic oilleaks:apply an oil binder, place a container underthe leak, find and fix the leak, if necessaryremove contaminated earth anddispose of it properly).


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Introduction

2.2 EC - Declaration of Conformity

EC-Declaration of Conformity

As defined by the Machinery Directive 98/37/EC, Annex II A

The company Neuson Baumaschinen GmbHHaidfeldstraße 37A-4060 Leonding

hereby certifies that the construction equipment

1.

2.

3.

4.

Category

Mark

Type

Equipment serial number ( per type )

Crawler excavator

Neuson

12002

v. Type plate

98/37/EG89/336/EG00/14/EG

EN 292-1:1991, EN 292-2:1995EN 474-1:1994, EN 474-5:1996EN 982:1996

complies with the following provisions applying to it

Applied harmonized standarts

Applied national technical standards and specifications

Type

12002

Measure Sound Power Level 101,2

„A“ weighted Sound Power Level

Certificate No.

OR/01520/01102,0

The notified body TÜV Anlagen und Umwelt GmbHWestendstraße 199D-80686 München

Fachausschuß TiefbauLandsbergerstr. 309D – 80687 München

The notified body according to Annex VII

was engaged for voluntary type-examination

Examination certificate No.) 00147-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 warningdevice.

Leonding, (v. delivery note)


...........................................................(Hans Neunteufel, executive director)

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User manual

3

3.1

Specifications

Technical Data Crawler Excavator 12002 RD

Principal Data

Principal data 12002 RD

Unladen weight with cabHeight to top of cabWidthLengthmax. digging depthmax. digging heightmax. dumping heightmax. digging radiusForce per bucket toothmin. rear swiveling clearancemin. excavator arm clearanceExcavator arm angle leftExcavator arm angle right

Driving and swiveling specifications

Driving and swiveling specifications 12002 RD

2 speedsClimbing abilityTrack widthNumber of track rollers per sideTrack tensioner

Ground clearanceGround pressure (of excavator when level)Swiveling speed of revolving superstructure

3 & 6 km/h 30degrees (58%) 500 mm 6 per sideGrease cylinder withtension spring 420 mm 0,43 kg/cm²11 revolutions per min

standard

11520 kg 2790 mm 2400 mm 4150 mm 4480 mm 7850 mm 5480 mm 7760 mm 7100 kp 1645 mm 2100 mm80 degrees50 degrees

Vario

12190 kg 2933 mm 2400 mm 4150 mm 4337 mm 7993 mm 5623 mm 7760 mm 7100 kp 1645 mm 2100 mm80 degrees50 degrees

9707672_user manual_en

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User manual

Engine

Engine 12002 RD

Yanmar 4 TNE 106-NS Wassergekühlter 4 cyl. turbo diesel engineCapacity4412 cm²Horsepower in DIN73,4 kw 98 HPRevolutions per min2100 rpmBattery12V 120AhDiesel tank130 lMotor oil14 lCoolant capacity8,7 l

Hydraulic system

ModelType

Hydraulic system 12002 RD

Pump

Pump capacityOperating pressure (working and driving)Operating pressure (swivel unit)Hydraulic oil coolerHydraulic tank (system capacity)

Dozer blade

Dozer blade 12002 RD

WidthHeightmax. height above ground levelmax. depth below ground level

Bucket (Standard)

Bucket (standard) 12002 RD

WidthVolume

600 mm255 l

2400 mm 550 mm 620 mm 470 mm

Double axial piston pump+ gear pump120 + 120 + 22 l/min300/320 bar230 barstandard128 l


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User manual

3.2 Noise emissions Crawler Excavator 12002 RD

Certified according to EEC - design test (86/662/EEC)

Noise emissions Crawler Excavator 12002 RD

Sound level (LWA)

Sound pressure level (LPA)

101 dB(A)

80 dB(A)

ATTENTION: No alterations that would lead to an increase in noiseemissions may be made to the excavator.

3.3 Vibration levels

Vibration levels are in accordance with EEC guidelines.89/392/EEC (Appendix I, Point 3.6.3)

3.4 Fire extinguisher

There is a place in the toolbox for a fire extinguisher.


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User manual

3.5 Stickers

ATTENTION: All safety stickers (notes and warnings) mustbe kept legible. Clean off dirtReplace with newstickers if they become illegible!

1 23 4 5 6 789 10 11

1516

12151614 13

20 19 18 17


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User manual

Stickers 12002 RD

1 Warning symbol 2 Symbol "Read operating instructions" 3 Cleaning 4 LWA 101 6 Lubricant recommendations 7 Dozer blade up/down (windshield) 8 Boom up/down, Bucket open/closed, Horn (windshield) 9 Travel right, forward, reverse (windshield)10 Travel left, forward, reverse, (windshield)11 Stick out/in, Swing (swivel) left/right (windshield)12 Identification plate with CE-Symbol13 Euro Test14 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 Smbol "Danger" (Do not open while engine is runing)18 Diesel19 Hydraulic oil20 Attention hydraulic tank under pressure


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User manual

3.6 Primary Dimensions Crawler Excavator 12002 RD


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User manual

4 Component Designations

1

7

2 3 16,17 8,9

4 5 6

101112

20

18

1 2 3 4 5 6 7 8 910

14 19

11121314151617181920

15 20 13Component Designations 12002 RD

Bucket stickBucket stick cylinderBoomCabDriver's seatEngine coverBucket cylinderLeft control leverRight control leverBackhoe bucket

Boom cylinderSteering control consoleDozer bladeUndercarriageChassisLeft drive leverRight drive leverTraveling driveProtective cover for track tensionerEyes for lifting and tying down excavator


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User manual

4.1 Cab equipment and controls


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User manual

Cab equipment and controls 12002 RD

1 Hammer pedal with cover 2 Left drive lever and overdrive switch foot pedal 3 Seat spring tension adjustment 4 Right drive lever with foot pedal 5 Seat back adjustment 6 Footrest 7 Dozer blade lever with foot pedal 8 Heating and air vents 9 Round display element10 Throttle control11 Armrest12 Right control lever for boom and bucket caylinder, Horn13 Ashtray14 Radio15 Ignition16 Storage17 Fuse box18 Heizung19 Left control lever for swiveling and controlling bucket stick, swinging arm20 Lever to fold back left steering control console21 Seat adjustment


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User manual

4.2 Excavator components

1 2

4

5

6

7

8

9

10

11

3 13 12

Excavator components 12002 RD

1 Main hydraulic valve unit2 Hydraulic-oil level indicator3 Location of fire extinguisher within toolbox4 Oil drain5 Diesel drain6 Opening for filling hydraulic oil7 Tank supports


8 Diesel tank 9 Return filter10 Diesel pump (Optional)11 Battery12 Oil tank13 Engine cover

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User manual

Work lights

OFF

Position 1

There is 1 work light with a H3/55W Halogen bulb on the arm of theexcavator. This light can be turned on and off with the switch on theinstrument panel (see section 6 for the position of the light switch).There are four more lights with H3/55W Halogen bulbs on the chassis (2in the front and 1 on each side). The 2 front headlights are on when theswitch is the Position 1. The side lights are turned on by pushing theswitch to Position 2. (see section 6 for the position of the light switch).

Position 2

Accelerator (Joystick right)

+L

With the ”-/+” buttons the rpm is variable controlled between idle and max.rpm.

Dropping to idle by pressing the button ”L”.Returning to the last rpm setting by pressing ”L” again.

Driver's Seat

The following options are available to change the position of the driver'sseat:CAUTION: Only adjust seat when the excavator is stopped.

a) Adjustment of the seat positionThe seat can be adjusted horizontally back and forth using the seatadjustment lever (see 26 under Cab Controls 4.1). When the lever isreleased, 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.c) Adjustment of the seat spring tension (in the middle of the seat)The seat spring tension can be adjusted to accommodate (see 3 underCab Controls 4.1) the needs of different operators:- for lighter persons- for medium persons- for heavier persons

-


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User manual

Heater, Heating and Air Vents

The heater is located under the driver's seat and can be turned onand off with the heater switch.The heating vents are in the front of the cab and under the driver'sseat.

Windshield Wipers

The motor for the windshield wipers is located inside the cab at thetop of the front windshield.The windshield wipers can be turned on and off with a switch on theinstrument panel.

Diesel pump (Optional)

The diesel pump is located on the diesel tank.

NOTE: The diesel pump must be turned off immediately afterfilling up the excavator, otherwise defects may occur.

4.3 Hydraulic system

Emergency operation of attachments

Turn on ignition and use servo pressure valve (emergencyoperation) to lower the attachments.

Release of residual pressure

¨¨¨¨

Turn off engineTurn ignition onActivate servo pressure valveSlowly open the hydraulic-oil cap (to allow pressure toescape)

CAUTION: Hydraulic system under pressure.


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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 valvecover)

The oil level should be between the black andred marks.

Refill hydraulic oil as necessaryIndicator

Black mark

Red mark

Hydraulic connections for additional attachments

CAUTION: See also Exclusion of warranty (1.2.3). Changes of hydraulic settings must be approved by NEUSON and must done by a specialist.

Hydraulic connections for supplying additional attachments are locatedon the left and right side of the bucket sticket.The hydraulics supply for additional attachments can be activated byturning the lever on distributor block.

Hydraulic connections

Distributer block

CLOSED

lever

OPENHammeroperation


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User manual

5

5.1

Safety Equipment

Parking Brake and Locking Mechanism

The brakes and parking brake as well as the locking mechanismare automatically activated when the excavator is at a completestop (no pilot control pressure).The brakes and locking mechanism only release when a drive orcontrol lever is activated (pressure builds up).

5.2 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 functionsoperationalConsole up = Work and hydraulic functionsinterruptedConsole down

Work functions operational

Console up

Work functions interrupted


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User manual

6 Instrument Panel Functions

1 Dashboard right2 Control lever right3 Ignition lock4 Instrument panel5 Fuse box

12

345

2

1

5

3 4

1 Dashboard left2 Control lever left3 Cold/hot adjustment4 Pumping delivery reduction5 Pumping output regulator

Round display element

234

1 Round display element2 Lamps3 Fuel gauge4 Operating hours meter1

1 2 1 Clogging indicator for hydraulic filter (o)2 Clogging indicator for air filter

1 2

1 charge control2 Motor oil pressure

1 2

1 Water temperature indicator2 Preheating pilot lamp


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User manual

1 Overload pilot lamp1

1 21 Switch for overdrive2 Switch for chassis headlights

1 2 1 Pilot lamp for headlights2 Switch for screen wiper and washer

11 Switch for cabin heating

1 Ingnition lock with two keys

1

1 Fuse box

1


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User manual

6.1 Fuse box

The fuses are integrated into the instrument panel.

Order of fuses

Order of fuses 12002 RD

No. 1 2 3 4 5 6 7 8 91011

Capacity (A) 7,5 10 25 20 10 15 30 15 10 20 15

Applicationswitch lights, controll lampsanti thift device, engine relaislights chassis, armheating van, clima, hornarmrest left, engine speed, pumpregulationwindscreenwiper, cabinstop solenoid, alternatorvalvesoption cabinsocket, refuelling pumprotating light, cabin, anti thief device

The main fuse (50 amps) for the igniton and the glow plug is located inthe relay box. Another main fuse (40 amps) is located in the right controlconsole. This is the fuse for the light on the arm, the side work lights andthe rear work lights (optional). The time relay fuses for the rear work lights(optional) and the main relays for the work lights are also located in theright control console.

7 Swinging and swiveling the excavator equipment

The excavating equipment is operated using the left and right controllevers on the driver's seat console.

To operate the bucket stick and swivel the superstructure use the leftcontrol lever. The boom and bucket are operated using the right controllever.

Left control leverButton for change-overSpeed control

Right control lever


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User manual

7.1 Left control lever

13

2

4

1234

forward backwardleftright

bucket stick away from excavatorbucket stick toward excavatorturn superstructure to the leftturn superstructure to the right

7.2 Right control lever

5

76

8

5678

forward backwardleftright

lower boomraise boombring bucket inextend bucket


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User manual

7.3 Excavator arm movements

In order to swing the arm using the hammer pedal, the button on the leftcontrol lever must also be pushed in.

swing arm to the left

swing arm to the right

7.4 Dozer blade

The dozer blade can be raised or lowered using the dozer blade lever.

lower dozer blade

raise dozer blade dozer blade lever


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User manual

7.5 Changing attachments

ATTENTION: To change attachments, the excavator MUSTalways be in a depressurized state.

12

Place attachments in a depressurized state on the ground andremove locking pins and bolts 1and 2.


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User manual

8 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 pinand safety chain

Max. towing capacity of towing bracket: 200 kN

9 Lifting the Crawler Excavator

Raise arm and dozer blade.

Fasten rope, chains etc. to the swiveling console and to the dozer bladeon the left and the right (3-point suspension).To prevent damage, ensure there is enough distance between theropes/chains and the excavator.The fastening points are indicated with stickers.

L1

L2

Ensure that the ropes/chains etc. cannot come undone.

Minimum force required per lift 100 kN

L1 = about 3.5 m L2 (2X)= about 4 m

P1 ... Fastening point swiveling consoleP2 ... Fastening points left and right side of dozer blade

P1P2


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User manual

10 Excavating options

10.1 Digging

Optimal stability while excavatingPlace the dozer blade against the ground for additional stability.The dozer blade can be lowered using the dozer blade leverlocated on the right side of the driver's seat.

Never dig under the vehicle. When excavating in or nearexcavated areas, ensure that the walls are well supported!CAUTION: Risk of Collapse

In order to obtain maximum performance, the excavator armshould not be fully extended.Remove the excavated material with long, flat movements of theexcavator arm.

10.2 Excavator arm swing angle

The excavator arm can be swung 50° to the right and 80° to the leftfrom its basic position. This makes excavation of trenches alongwalls, fences, etc. possible. It is under certain circumstancespossible that the offset cylinder stops while moving the functionoffsetting. This can occur if both the dipper stick and the bucket arefully activated. The function offsetting is mostly used in confinedareas instead of cab rotation. Since in confined areas the functionof the arm system is hardly ever fully activated, if so only inextraordinary circumstances which do not distract the completefunction of the machine.


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Supplementary SheetFor Neuson Compact Excavators

0.1 Working at ditches

Warning!

When working at ditches, slopes, etc., the piston rod A at the boom cylindermay get damaged because of inexpert handling of the dozer blade and theboom.

BFig. 66: Working at ditches

A☞Always support the excavator on the dozer blade B during digging☞Make sure that the dozer blade B never touches the piston rod A Fig. 66☞In case of deep excavation with the dozer blade B in front make sure thatthe piston rod A never weights down on the dozer blade B

Fig. 67

the rear Fig. 68☞In case of deep excavation always work with the dozer blade B pointing to

☞In case of deep excavation don’t work with the dozer blade B pointing to the front avoidA that the piston rod A weights down on the dozer

blade B.

B

wrongFig. 67: Deep excavation

A☞In case of deep excavation work with the dozer blade B pointing to the rear.➥ Thus the piston rod A cannot weigh down on the dozer blade B.

B

correctFig. 68: Dozer blade pointing to the rear

01_Erg_blatt_22_01_04.fm

User manual

10.3 Bulldozing

The dozer blade can be raised or lowered using the dozer blade lever.To bulldoze the boom should be completely raised and the bucketturned 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.

10.4 Lifting

ATTENTION: THE CRAWLER EXCAVATOR IS NOT EQUIPPED TOBE USED FOR LIFTING OR TO BE FITTED WITHLIFTING ATTACHMENTS.

ion there is a overload system available for the lifting application of themachine. Using the machine for lifting applications should not be morethan 10%.

CAUTION: Lifting application is lifting, transporting and lowering of weights with the usage of either a rope or chain where the help of people is needed to connect or disconnect. E.g.: lifting and lowering sewage pipes and containers with the excavator. According to EN474-5 all excavators for lifting applications must be equipped with:

Load fixing pointOverload systemHose brake valve

10.5 Cab protection

If the excavator is being used for overhead work, quarry work, etc. it mustbe equipped with extra protection (FOPS/Front Guard) against fallingobjects.FOPS and Front Guard is available as an option.


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User manual

10.6 Stability

Care for the lift capacity chart in the cabin or appendix A.

RISK OF OVERTURNING!

CAUTION: Always ensure adequate stability when working with the crawler excavator.Particularly when working to the side withattachments (bucket, grab, etc.).

Changing the attachments alters the stability (weight).

80°

E.g.: One of the situations (excavating to the sidewith the arm swung to the max. angle) in which overturning to theleft is possible.

CAUTION: All the lift capacity’s are rated on a level, secured ground. Vary the circumstances e.g. soft or uneven ground, non level surface, side load, ...., the driver must consider while operating.


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User manual

11 Transport instructions

o Use only transport vehicles which are in proper working order andare approved for use on public roads.

When using ramps to load the excavator onto the transport vehicledo not exceed an incline of 18°the ramp width must be at least 1 or 2 times the width of the tracksclean dirt, mud, ice, and snow from the ramps and the tracksThe ramp ends should be bevelled (see below) to

preventdamage to the rubber tracks.

o

¨¨¨

NOTE:

o Attach the ramps securely to the transport vehicle to prevent themfrom slipping off. (e.g. hook on)

As a safety precaution, provide additional support in the middle ofthe ramps.

Load the machine on solid, even ground.

When loading, apply the parking brake of the transport vehiclesecurely and place chocks under the wheels.

o

o

o

11.1 After loading

o Lower the dozer blade and the excavator arm onto the loadingsurface of the transport vehicle. Stop the engine.

Lock the cab. The swivel lock is automatically applied when theexcavator is at a complete stop.

After loading place chocks under the tracks of the crawlerexcavator and secure it to prevent slipping, overturning, andmoving (tie down).Tie down the excavator at the points indicated on the stickers.

o

o

o


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User manual

12 Things to check before starting the excavator

Checking the excavator before operating it can preventmalfunctions during operation. Therefore never neglect thesechecks.

12.1 Visual inspection

Check:

¨

¨¨¨

12.2 Check motor oil

Check the oil level using the dipstick. The vehicle must behorizontal and the engine off.

NOTE: The marks on the dipstick indicate the minimum andmaximum oil levels.

Pressure hoses, hose connections, and hydraulic cylinderseals for oil leaksThe radiator for water leaksEngine for water and oil leaksBattery connections

Top off engine oil if necessary by opening the cap and adding oilfrom a clean container.

ATTENTION:

12.3 Check hydraulic oil level

Check the hydraulic oil level in the indicator in the main valve area.

Position of excavator arm while checking hydraulic oil levels:Extend armExtend bucket outward and lower it to the ground (piston rods incylinders)Turn off engineRefill hydraulic oil as necessary. Open the cap and refill thehydraulic oil from a clean container. Close the cap.

CAUTION: 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.


See the lubricant list for engine oil grade. Onlyuse engine oil of the same quality.

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User manual

12.4 Check coolant level

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 andremove.

ATTENTION: If coolant is added, ensure the water/antifreeze mixture is correct.

12.5 Refuelling

After operation, always refill the fuel tank until it is full. This is to preventthe 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, otherwiseyou must bleed fuel system.

12.6 Check safety equipment

Check the brakes and swivel lock to ensure they are functioningproperly.

The brakes and swivel lock are automatically activated when theexcavator is at a complete stop (no pilot control pressure).

The brakes only release when a drive or control lever is activated(pressure builds up).


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User manual

13 Starting the excavator

o Adjust driver's seat (spring tension, position, seat back).

Place all switches and levers in their neutral position.

Insert the key in the ignition and turn.

o

o

Starting procedure

Accelerator in idling position.

Step 1:

NOTE:

Step 2:

Step 3:

o

Ignition on

Oil pressure and charge indicator lights should comeon--warning light test

Turn key to warm up glow plug, hold key for about 15seconds

Start

Release ignition key as soon as the engine is running.

The ignition key automatically returns to the ONposition.

NOTE:

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 thebattery recover before trying again.

Leave the key in the ON position during operation. If the key isturned to "O", the engine is turned off.

ATTENTION:

ATTENTION:

Indicator lights (oil pressure and chargeindicator) should go out after starting.

If they do not go out, or if one comes on duringoperation, stop the engine and havemaintenance personnel or the repair shoplook into the problem.

Let the engine warm up for approx. 5 minutesto allow the hydraulic oil to get hot.

ATTENTION:


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User manual

13.1 Jump starts (with jumper cables)

If the battery is dead, another battery (12 Volt) can be used in conjunctionwith suitable jumper cables to start the excavator.

ATTENTION: The following procedure requiring two people is theonly safe method for bridging a dead or run downbattery. Two people are required so that the jumpercables can be removed without the driver having toleave the cab.Never attempt to connect a jumper cable when thebattery to be charged is frozen. This can causedamage or an explosion. Follow the instructionscompletely and in the correct order to avoid injury.

CAUTION:

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 theoperating levers of both vehicles are in "neutral position" and that thevehicles are not touching.2. Remove the battery filler caps and ensure that the battery fluid levelis correct. A clean cloth must also be placed over the openings toprevent 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 thebatteries. 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.

4. Connect a jumper cable to the negative terminal (-) of the dead or rundown battery.

5. Finally, connect the jumper cable to the negative terminal (-) of thebattery of the assisting vehicle. Ensure that cable and terminal areproperly secured.


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User manual

Turn the ends of the jumper cables around the battery terminalsseveral times to ensure good contact.

6. Now start the excavator. If it does not start immediately, start theengine of the assisting vehicle to avoid draining the startingbattery.

7. After the excavator has been started and is running evenly, haveanother person

¨ disconnect the jumper cables from the battery of thestarted engine, first disconnect cable from negativeterminal (-) and then from positive terminal (+), anddisconnect the jumper cables from the battery of theassisting vehicle, first disconnect cable fromnegative terminal (-) and then from positiveterminal (+).

¨

Ensure that the cables do not short circuit (touch).

Ensure that the excavator alternator has sufficient time to chargethe battery before setting the excavator in motion or stopping theengine.Make sure the cloth is removed and screw the filler caps back on.


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User manual

14 Driving the crawler excavator

The front is the side with the dozer blade.Raise the excavating bucket and the dozer blade.

14.1 Driving

The excavator can be controlled using the drive levers or the foot pedals.

Forward:Reverse:

Push left and right drive levers forward Pull left and right drive levers toward seat

If a 180° rotation has been carried out (dozer bladeat rear), the drive levers have the opposite effect.

ATTENTION:

Travel on dangerous ground and on slopes

CAUTION: Due to the 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.

14.2 Turning

Turning left:

Turning right:

Pull left drive lever back and push right drive leverforwardPush left drive lever forward and pull right drive leverback

left

right


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User manual

14.3 Traveling speeds

Slow a) The gears are regulated by a switch on the instrument panel.

Fast (overdrive)

b) There is an additional switch on the left drive lever to switchquickly to overdrive while driving.

ATTENTION: Do not use the overdrive when traveling arounda curve!

c) The speed is controlled with the drive lever (pedal).Pressed all the way = max. speed for that gear.

15 Shutting down

o Stop the machine.

Lower bucket and dozer blade to the ground.

Let engine idle (Accelerator position "0").Turn off ignition.

Never turn off the engine at full power. Allowthe engine to idle for at least 1 Min. beforeturning the engine off.

o

o

ATTENTION:

o Turn the key to the "O" position and remove it before leavingthe vehicle.

CAUTION: Unauthorized use of the excavator must be prevented. Lock the cab.

Park on level ground.If the excavator has to be parked on an incline, place chocks underthe tracks.

o


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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 cmfrom the vehicle, the water temperature should not exceed 60° C and no aggressive cleaning agentsshould 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 maintenancewill 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 safetylevers. 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 maintenance 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 clearlyvisible 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.

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!


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User manual

The hours indicated for servicing intervals correspond to thoseindicated on the operating hours counter.

ATTENTION: No smoking or open flames are allowedduring servicing and repair work.

RISK OF FIRE!

ATTENTION: The operating pressure settings of thehydraulic system should only be set by trainedqualified personnel. If malfunctions are causedby unauthorized alteration of operatingpressure settings, all warranty responsibilityon the part of the manufacturer is automaticallyforfeited.

NOTE: The hydraulic displacement pump must be bled afterworking on the hydraulic system, especially afterusing a vacuum pump. Starting the excavator withoutbleeding the the system can damage the pump.

Bleed the cylinders on the first or on subsequent installation asfollows to avoid leaving air in the system that can damagecomponents:

1.

2.

Extend the piston rod slowly and completely, do notapply any pressure at the end of the stroke.

Move the cylinder through at least 5 complete workingcycles (extending/ retracting) before using the excavatorfor normal work.


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User manual

16.2 Maintenance Schedule

Servicing activity component every 10 h

(daily)

every 50 h every 250 h every 500 h every 1000 h

(w eekly) (6 months) (12 months) (18 months) annual

MOT OR

Oil level

Fuel level

Leakage

Visual check

Air filter

Seating of mounting bolts

Coolant

Engine speed regulation

Exhaust system

Engine oil

Oil filter

V-belt: condition and tension

Cooler fins

Valve clearance

Generator, starter

Fuel tank

Water pump

Fuel filter

Cooling system and hoses

Electrical connections

Pre-glow system

Coolant thermostat

Battery fluid O

O <>

O

O

O

O

O <>(1)

<>(1)

O

X

O O

O

X

O

<>

O

O

O

<>

<>

<>

<>

O

O

O

O

O/X

O

<> <>

OX

- Check- Clean

<>- Change/Replace<> (1) - Change/Replace the first time


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User manual

Servicing activity component every 10 h every 50 h every 250 h every 500 h every 1000 h

(daily) (w eekly) (6 months) (12 months) (18 months) annual

HY DRAUL I C S Y S T E M

Fastening bolts Hydraulic pump

Leakage (lines, pumps, cylinders)

Hydraulic oil level

Oil cooler fins

Filter insert

Primary and secondary pressure limiting

valves

Hydraulic oil

Breather filter Filling strainer

O

O

X

<>(1) O <>

O

<>(1) <>

O

<>

<>

O

O

E L E C T RI CAL

Indicator lamps

Function of system

Fastenings

O

O

O

T RAV E L L GE AR

Chain after working

Chain tension

Bearring play of tread rollers, track carrier

rollers, front idlers

O

O

O

TRAVEL G E A R U N I TLeakage

Gear oil

O

<>(1) <> <>

GEAR RINGBearing system

Gearing

O

<>

OX


- Check- Clean


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User manual

Servicing activity componentevery 10 h every 50 h every 250 h every 500 h every 1000 h

(daily) (w eekly) (6 months) (12 months) (18 months) annual

HE AT I NG

Function

Leakage (cooling and heating circuit)

Seals

Fan

O

O

O

O

WO RK I NG E Q UI P M E NT

Lubricate lubricating points

Bucket teeth (fastening and wear)

Pin fastening

Line fastenings

Piston rods

Behaviour of hydraulic cylinder under load

Bush bearing play

Bearing play O

O

O

O

O

O

O

O

O

G E NE RAL

Operating elements

Hydraulic fittings

Bolts

Lights

Windscreen washing system

Leakage check - visual check O

O

O

O

O

O

OX

- Check- Clean



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User manual

17 Daily maintenance

17.1 General visual inspection and leak check

Also see the maintenance schedule 16.2

¨¨¨

¨¨¨¨

17.2 Engine

Check motor oil

Check the oil level using the dipstick. The vehicle must behorizontal and the engine off. Check the quality of the oil as well.If the oil is very dirty, change the oil before the next maintenanceinterval.NOTE: The marks on the dipstick indicate the minimum

andmaximum oil levels.

Check controls to ensure precision operationCheck hydraulic fittingsPressure hoses, hose connections, and hydraulic cylinderseals for oil leaksThe radiator for water leaksEngine for water and oil leaksBattery connectionsCheck indicator lights (when starting the engine)

Top off engine oil if necessary by opening the cap and adding oilfrom a clean container.

ATTENTION:

Check coolant levelCAUTION: 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:

Check fuel filter with water separator

The container must be emptied if the indicator goes up(condensation).


See the lubricant list for engine oil grade. Onlyuse engine oil of the same quality.

If coolant is added, ensure the water/antifreeze mixture is correct.

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User manual

Clean air filterOpen housing, clean dust trap.Unscrew and remove filter.Clean the filter using compressed air (3 - 5 bar).

ATTENTION: If the warning light on the instrument panel goes off,clean air filter immediately. Important when workingin dusty conditions.

RefuellingAfter operation, always refill the fuel tank until it is full. This is to preventthe formation of water condensation in the interval between uses.Ensure that fuel is not spilt when refuelling.ATTENTION:

17.3 Hydraulics

Check hydraulic oil levelCheck the hydraulic-oil indicator in the main hydraulic valve unit.

Position of excavator arm while checking hydraulic oil levels:Extend armExtend shovel bucket outward and lower it to the ground (piston rods incylinders)Turn off engine

Refill hydraulic oil as necessary. Open the cap and refill the hydraulic oilfrom a clean container.

CAUTION: 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.17.4 Undercarriage and attachments

TracksATTENTION:

Check attachments (bucket, grab, etc.)

- Bucket teeth wear and tightness, pin tightness- Line tightness, piston rod- Behavior of the hydraulic cylinder when loadedATTENTION: Replace damaged or defective parts!

Check tracks immediately after operation! Replacedamaged tracks.

Make sure that you never run out of fuel,otherwise you must bleed fuel system.


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17.5 Lubrication points

Lubricate all other points daily (blue caps)Lubricate the points marked W weekly (green caps)

daily

weekly

Greesing block

Bearings uppercarriage

Swingcylinder Turntable


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User manual

18 Weekly maintenance or every 50 operating hours

NOTE: In addition to normal daily maintenance, the followingmaintenance should be carried out weekly or every 50operating hours, see maintenance schedule 16.2.

18.1 Engine

Check engine mounting

See engine operating instructions.

Check fan belt tension

See the engine operating instructions for how to check the belt tension.Replace the belt if cracks or other damage becomes evident.

ATTENTION:

Change oil and oil filter

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 operatinginstructions.Dispose of used oil in accordance with environmental laws.

Battery

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 inaccordance with environmental laws.

NOTE: The battery fluid levels must be between the min. and max.marks. Only add distilled water to battery fluid.

Do not check with engine running.

Check fuel filter with water separator

The container must be emptied if the indicator goes up (condensation).Clean the sieve if it is dirty.


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User manual

Clean radiator

Remove dirt, dust, leaves etc. from the slits in the radiator. Cleanin shorter intervals when working in dusty conditions.Check hoses and clamps and replace if necessary.

18.2 Hydraulics

ATTENTION:

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)

The return filter is tobe changed for the first time after 50 operatinghours.

1)

2)3)4)5)6)

18.3 Undercarriage

Check track tension

Use the excavator arm and dozer blade to raise the excavator.

Open the hydraulic oil tank carefully (tank is underpressure). Remove the screws (6).Remove the screws from the return filter cover (4).Replace return filter cartridge.Put return filter cover back on and screw screws back in.Close the hydraulic oil tank properly.Let the crawler excavator idle in neutral for a few minutes.

Always release residual pressure beforeworking on the hydraulic system!

Dispose of used filter in accordance with environmental laws.


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User manual

Tracks should no longer be touching the ground.If necessary, use additional supports (make sure the excavator cannotoverturn).

Measurements are taken at the two lower central track rollers.

The sag of the rubber chain, when tightened, shall not exceed 40 mm.The sag of the iron chain, when tightened, shall not exceed 55 mm.NOTE: If possible, the distance from the rollers should be the

samefor both tracks.

A) Increasing the track tension

1 1) Take off protective cover (1)2) Tighten track using grease gun (2)

2

B) Decreasing the track tension

11)2)3)

Take off protective cover (1)Unscrew the return valve (SW 22) (3)Allow grease to come out until pressurehas been completely released.

3

Check the track rollers and wheels for play, also check track tension!

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 lubricationblock (see lubrication points 17.5).

Fresh grease should appear all around the edge of the seals.


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User manual

18.6 Cab heating

¨¨¨¨

Check functionCheck cooling and heating circuit for leakageSealsFan

18.7 Attachments

Lubricate attachments at lubrication points (see LubricationPoints 17.5)

18.8 Check windshield washer system

Add water to fluid container if necessary.


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User manual

19 Maintenance every 250 operating hours

NOTE: In addition to normal weekly maintenance and maintenanceevery 50 operating hours, the following maintenance shouldbe carried out every 250 operating hours, see maintenanceschedule 16.2.

19.1 Engine

See engine operating instructions for maintenance schedule.


See engine operating instructions.Dispose of used oil in accordance with environmental laws.

Replace fuel filter

Dispose of used filter in accordance with environmental laws.

Check engine rpms and exhaust system

See engine operating instructions.

19.2 Hydraulics

ATTENTION:

Check hydraulic oil and filter

If it is necessary to replace the hydraulic filter, dispose of the used filterin accordance with environmental laws.

19.3 Electrical components

Check the cable harness and the battery. If necessary tighten and secureto avoid twisting.

19.4 AttachmentsCheck for play and replace damaged or defective parts!

Always release residual pressure before working onthe hydraulic system!


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User manual

20 Maintenance every 500 operating hours

NOTE: In addition to normal weekly maintenance andmaintenance every 50 and 250 operating hours, thefollowing maintenance should be carried out every500 operating hours, see maintenance schedule67.2.

20.1 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

20.2 Hydraulics

ATTENTION:

Check primary valves

Adjust settings if necessary.

Change hydraulic oil filter (return filter)

Always release residual pressure beforeworking on the hydraulic system!


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User manual

Change hydraulic oil

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)2)3)4)5)6)7)8)

9)10)

Open ventilation filter (SW 36) to release pressureOpen the hydraulic oil tank carefully (tank is under pressure)Drain oil into a containerClean out the hydraulic tank if necessary (Remove cleaning cap)Replace return filter cartridge (see 18.2.4)Screw the drain plug back in properlyRefill with clean hydraulic oil (10 mµ) from a filling stationOpen the hydraulic pump plug (hexagonal socket head screw, SW6) until clear oil (without bubbles) comes out, close hydraulic pumpplugClose hydraulic tankLet the excavator idle unloaded for a few minutesDispose of used hydraulic oil in accordance with environmental

laws.1

5

4

8

2 /6

Check ventilation filter and sieve

Check ventilation filter and replace if necessaryCheck sieve for damage and replace if necessary

20.3 Gear rim

Change gear rim grease:Remove cap under the gear, unscrew plug (2", SW 28 - square) withgrease nipple, press out old grease by swiveling superstructure, screwplug back in, use the grease nipple to fill the gear rim with fresh grease,close cap.


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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 shownOpen top and bottom screw plugsDrain oil, collect in a containerClose bottom screw plug properly

2) With the drive in the position shownOpen middle screw plugRefill with fresh oil in the top opening until it comes out of themiddle openingClose both openings properly

ATTENTION: Dispose of used oil in accordance withenvironmental laws.


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User manual

21 Maintenance every 1,000 operating hours

NOTE: In addition to normal weekly maintenance and maintenanceevery 50, 250, and 500 operating hours, the followingmaintenance should be carried out every 1,000 operatinghours, 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


Dispose of used oil in accordance with environmental laws.

21.2 Hydraulics

ATTENTION:

Check hydraulic oil and filter

Check ventilation filter and sieve

Check ventilation filter and replace if necessaryCheck sieve for damage and replace if necessary

21.3 Traveling and swiveling drives

Traveling drive - Change oil

Always release residual pressure before working onthe hydraulic system!


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User manual

21.4 Gear rim

Change gear rim grease (see 20.3)

21.5 Attachments

Check for play in bushings

Replace damaged or defective parts

Lubricate attachments at lubrication points (see 17.5)

1


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User manual

22 Maintenance during longer periods of inactivity

22.1 Preparation for longer periods of inactivity

¨ Carefully clean and dry all parts

When possible, do not leave the Crawler Excavator out inthe open. If this is unavoidable, park the Crawler Excavatoron wooden boards and cover it with a tarp.

NOTE:

¨

¨

¨

¨

¨

Lubricate all lubricated parts

Change the motor oil

Grease piston rods of the hydraulic cylinders

Disconnect cabels from battery or remove battery and store in aprotected place

Check antifreeze levels in coolant

22.2 Starting the excavator after periods of inactivity

¨

¨

¨

Wipe off grease from piston rods

Reconnect or install battery

Start engine and operate unloaded

During longer periods of inactivity, the excavatorshould be operated unloaded once a month.

ATTENTION:


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User manual

23 Lubricant table

Lubrication point

Motor oil

Hydraulic oil

Fina Hydrav TSX 46

Live ringBP Energrease MP-MG2

Gearing

BP Energrease L 21 M

Ball bearing

Travelling gear unit

Excavator arm

All lubrications points

Range of application of motor oil:

from - 25 °C bis + 40 °C outdoor temperature

NOTE: All specified greases are suitable between - 25 °C to + 40 °C

Fina Pontonic GLS SAE 85 W 90


Gleitmo 800 (for initial lubrication of bolts, slewing bracketand clamping sleeves)


BP Energol SHF 46

Lubricant

Fina Kappa 10 W 40 CF - 4 / SG


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User manual

24 Trouble shooting

Defect

Engine cannot be started No fuel

Cause Rectification

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

E NGINE

Battery power insufficient

Fuel filter contaminated

Pre-glow system defective

Fuel line leakage

Insufficient engine power Air filter contaminated

Engine not at operating temperature

Engine overheated

INDICAT OR L AMP SEngine oil pressure indicatorlamp comes on duringoperation

Oil pressure too low Stop engine immediately, checkoil level and top up if necessary

Check oil level If oil level is correct, oil pump isdefective(service workshop)

Top up oil

Top up coolant

Re-tension V-belt

Clean air filter

Re-tension V-belt

Temperature display risesabove 100 °C

Oil level too low

Cooling water level too low

Fan blades rotate too slowly

Air filter contaminated

Charge monitor lamp comeson during operation

Fuel display illuminated

Generator not charging properly

Insufficient fuel Refuel


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User manual

Defect

Slewing chassis is difficult orimpossible

Cause

Brakes do not release

Insufficient lubrication

Rectification

Authorized workshop

Lubricate slewing ring hoseconnections

Authorized workshop

Top up hydraulic oil

Warm up the engine

See engine

Authorized workshop

Authorized workshop

W ORKING E QUIP ME NT

Slewing motor defective

Equipment does not work, or onlyat low working/grab performance

Insufficient hydraulic oil

Hydraulic oil not warm

Insufficient engine power

Coupling or pump damaged

Pressure limiting valves settoo low

Hydraulic cylinder damaged

Control valves damaged

Cylinders lower too quickly Seals contaminated or defective

Heavy leakage at control spools

Secondary cartridges defective

Hydraulic lines overheat Hydraulic oil filter blocked

Insufficient hydraulic oil in oilreservoir

Seccondary cartridges set too low

Cooling system not in workingorder

Authorized workshop

Authorized workshop

Authorized workshop

Authorized workshop

Authorized workshop

Clean or change filter

Top up hydraulic oil

Authorized workshop

Clean oil cooler


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User manual

Defect

Oil or fuel leakage below theengine

Cause Rectification

Tighten hose connection

Change sealings and/or hoses andcheck and refill oil level, if necessary

Tighten hose fittings, checkhydraulic oil level, top up if necessary

Change sealings, hoses, piping(service workshop)

S E A L S + HOS E SLoose hose connections

Sealings and/or hoses damaged

Oil loss in hydraulic system Loose hose fittings

sealings, hoses, or pipingdamaged

T R A VE L L I NG GE A RTravel not possible Foreign body jammed

Gears defective

Travel straight-ahead notpossible

Foreign body jammed

Differing chain tension

Travel valves damaged

Remove foreign body

Authorized workshop

Remove foreign body

Tension chains equally

Authorized workshop


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User manual


- 75 -

User manual

27.2 Lifting Power Table 12002 Vario


- 76 -

User manual

27.3 Legend of Lifting Power Tables

maxAB*

admissible load with dipper stick straightprojection from live ring centreheight of lifting hooklifting power limited by hydraulic system

All values of the table are specified in kg, in horizontal positionon 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 directionsuperstructure 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 poweror tilting load is reduced by the empty weight of such facilities.Position on solid subsoil and without bucket.Design fundamentals: acc. to ISO 10567The lifting power of the compact excavator is limited by the settingof the pressure control valves and the stabilizer system. Neither75% of the static tilting load nor 87% of the hydraulic lifting powerare exceeded.WARNING! The Vario system deviates form ISO 10567 insome excavator positions. Other than specified by standardISO 10567 any exceeding of the tilting load is announced by means of a warning device.


- 77 -

Option

28 Options

hydraulic connections

28.1 Hydraulic Connections for Accessory Equipment

At the dipper stick there are hydraulic connections for the supplyof accessory equipment.

Ball valve at dipper stick

lever position for grab operation

The hydraulic connections for accessory equipment aresupplied by switching over the ball valve at the dipper stickauxiliary hydraulics and the ball valve at the main valve block.

lever position for bucket operation

Ball valve at manifold blocklever position for auxiliary hydraulics

lever postion for hammering mode

28.2 Overload Warning Device for Hoisting Operation

Hoisting operation means the lifting, handling and lowering ofloads by means of a slinging device (rope, chain), requiring theassistance of persons for attaching and loosening the load. Thisinlcudes, for example, the lifting and lowering of tubes, shaft liningrings or containers by means of excavators. Operating sequenceswhere the material is taken up by self-gripping devices and theassistance of persons is not necessary are defined as excavatoroperations.


- 78 -

Option

Overload warning device:

This is a visual or acoustic warning device indicating to the driver that theadmissible useful load or the burden and/or the load moment equivalentto the useful load or burden is reached.

The option hoisting operation is provided with the following equipment:-safeguarding facility against breakage at jib cylinder-visual/acoustic warning device when the admissible useful load or burden is exceeded

28.3 Electrically Actuated Auxiliary Hydraulics

In this case the auxiliary hydraulic system is controlled via the joystickinstead of the pedal. Due to this function operation of the attached toolbecomes much easier for the driver.The following must be absolutely observed:

1. In case of this option the function of the auxiliary hydraulic systemis switched "black and white". This means that precisioncontrol is not possible as it would be in case of pedal control.If this option is used for offset buckets (e.g. in case of levelling)there may be jerking motions of the boom or the dipper stick.

2.

control lever leftpushbuttons


- 79 -

Option

28.4 Theft Protection

As soon as the device is switched on the green LED starts flashingslowly, thus indicating that the system is in the secured mode.Upon delivery of the device you receive a certificate with thesystem number and the safety code.If the device is in the secured mode, you can enter two safetycodes, the service code and the user code.1.

2.

3.

4.

Make sure that the LED lights up red each time you pressa key.

Slowly enter the 6-digit safety code followed by the # key.The green LED starts flashing quickly.

Now you've got 30 sec to enter the service code or the usercode.Slowly enter the desired 6-digit user code followed by the# key.

Slowly enter the desired 6-digit service code followed bythe * key.

After each sequence the green LED goes out and lights up again- flashing slowly. Now you have defined your codes and thesystem returns to the safety mode.

To start the machine you must enter the service code or the usercode followed by the # key.Standby mode: After entering the user code the green LED

goes out. Now you have got 30 sec to startthe device. After 30 sec the systemreturns to the safety mode.

If you shut down the device, the system willchange to the safety mode after 12 sec - greenLED flashing slowly. Another startingattempt is possible only within this period of 12sec.

Safety mode:

Starting sequence:

1.2.3.4.

Switch on ignitionEnter user codeSwitch off ignitionStart within 30 sec


- 80 -

Option

28.5 Diesel Pump

The diesel pump is situated at the hydraulic oil tank below the valvecover.

NOTE:

28.6 Air-Conditioning Unit

Control Elements

Function

The first control element serves for switching on and/or off the air-conditioning function. The next one serves for adjusting cold/hot. Theblower is situated at the third control element. There are three differentsettings for the blower. These settings determine only the intensity ofblowing .The grille screen of the air-conditoining unit is situated in the foot area ofthe seat and can be openend manually and closed again, if required.

NOTE: To achieve an optimum cooling effect, all windosand doors must be closed.

Switch off the diesel pump immediately after refuelling theexcavator, otherwise defects may occur.

WARNING: grille screen closed = air-conditioning function interrupted grille screen open = air-conditioning function ready


- 81 -

Option

28.7 NEUSON VARIO

Operation of Neuson Vario

To change the eccentric position, the following steps must beabsolutely observed.

1. The dipper stick must be supported on the ground.

2. To open the lock of Neuson Vario both front switches at theleft and the right joystick must be pushed and kept pressed.

At Neuson Vario there are four locking positions, each offset by90° (0°/360°, 90°, 180°, 270°).

To reach the correct position the left joystick must be pushed leftor right.

After the excavator has moved the two buttons may be released.After turning by 90° Neuson Vario engages automatically.

If the Neuson Vario shall be offset by more than 90°, the buttonsat the joystick must be kept pressed beyond the 90° offset.

As soon as the buttons are released, the Neuson Vario engagesat the next possible lock.


- 82 -

Option

WARNING: Make movements only with boom supported.Always make sure that lock is engaged!

Driving the Neuson Vario Transverse to the Slope

To achieve a better stability when driving transverse to the slope theexcavator should be shifted towards the slope.

WARNING: 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 ofgravity of the Neuson Vario shall be shifted towards the slope.


- 83 -

Option

Warning Equipment of Neuson Vario

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 incase of unfavourable superstructure position. As soon asthis load is exceeded and working is done with thesuperstructure in an unfavourable position (warning range)or when slewing into such range, a short warning sound isemitted once and a warning lamp lights up (for position of thewarning lamp see figure "Warning lamp".

WARNING: If the stick system is not lowered and slewed outof the danger area when the warning (sound, lamp) isemitted (braking of superstructure and opposite control) orif the warning is ignored, the machine may tilt!The warning lamp is equipped with a function check. Uponeach 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 withthe lamp being functioning properly!

Fig.: Warning lamp

3)

4)


- 84 -

Option

Figure: Warning range

warning range A........ digging above crawlerwarning range B........digging in longitudinal direction

warning range ADanger of tilting!

warning range B

warning range B

warning range ADanger of tilting!

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.

!!!


DANGER TO LIFE !!!

- 85 -

Option

Working with Neuson Vario

When excavating a pit, the superstructure can be slewed to theside of the dozer blade. Thus a higher stability is achieved fordigging on the side opposite the blade, at the same time providingfree 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 thedipper can be moved right to the blade.


- 86 -

Option

Neuson Vario Labels

Operation of Neuson Vario

¨

¨

Make sure to read and observe theoperating instructions.

Support dipper stick on the ground.

In case of non-compliance persons and/or the machine driver maybe endangered, the machine may tilt or other danger may occur.Situated inside cabin roof lining.

Shifting of Neuson Vario

1.

2.

3.

4.

Dipper stick must be supported on the ground.

The indicated buttons at the two joysticks must bepressed.

Wait for at least 5 sec with buttons pressed.

Now the Neuson Vario can be shifted by meansof the left joystick.

Situated inside cabin roof lining.

WARNING: The sense of rotation of Neuson Vario is opposite to the normal sense of rotation.


- 87 -

Option

Lubrication Points at Neuson Vario

At the lower live ring there is a total of 4 lubrication points.

Opposite side

There is another lubrication nipple at the top side of the eccentric disk.


- 88 -

Safety instructions

A

1

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 andspecial-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 earthmovingmachinery (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 transportand for accident prevention must be observed. Such regulations may, for example, also relate tothe 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.).

2

2.1

2.2

Intended use

Earthmoving machinery must be operated only under the intended operating conditions providedby the manufacturer in the operating instructions.The use is as intended when the earthmoving machine is used with the corresponding operatingdevices in accordance with the European or national safety regulations or for other work for whichit is suitable according to the manufacturer’s instructions.Changes to the safety systems of the earthmoving machine by the owner without the prior consentof the manufacturer are inadmissible.

2.3


-A1-

Safety instructions

2.4

3

3.1

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.

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.93.10

Any working method 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 instructionsadapted to local operating conditions.

Operating instructions and safety-relevant instructions must be in safekeeping by the operator’sseat. 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 jacketsmust be avoided. Goggles, safety footwear, safety helmets, protective gloves, reflectivewaistcoats, ear plugs etc. may be needed for specific operations.Prior to beginning work, information on first aid and on emergency services (ambulance, fireservice, helicopter) is essential.

It must be checked that a first-aid kit complying with the regulations is present.

3.12 The location and operation of fire extinguishers on the earthmoving machine and the local fire-alarm and fire-fighting facilities must be known.

3.11


-A2-

Safety instructions

3.13

3.14

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 openedstate.

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 bereached by operation-induced movements of the earthmoving machine, its operating devices andits attachments or by swinging-out loads, by falling material or by falling operating devices.4.2

4.3

4.4

4.5

4.6

4.7

4.8

The machine operator may work with the earthmoving machine only if no person is within thehazard 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 thehazard zone despite a warning.

No person may have access to the pivot range of earthmoving machinery with centre pivotsteering 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 operatingrange of the earthmoving machine must be closed off.

If the machine operator has a restricted 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 mustbe secured by a fixed barrier.

Stability

Earthmoving machinery must be used, driven and operated in such a way that its stability or itssecurity against overturning is guaranteed.

The machine operator must adapt the travelling speed to local conditions and keep the operatingdevice 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.

4

4.1

5

5.1

5.2

5.3


-A3-

Safety instructions

5.4

5.5

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 workingclose 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 earthmovingmachine.

Operating devices (adjusting components) may be activated only by the operator or from theoperator’s console.

The steps and areas provided must be used for access to the machine. They must be kept in anon-slip state.

For earthmoving machinery fitted with quick-change devices for mounting and discharging theoperating 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.- If 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.

6.2

6.2.1

Transport of persons

Apart from the machine operator, no persons may be transported on earthmoving machineryunless special places have been provided for this purpose by the manufacturer.

These special places must be equipped with fixed seats and securing devices to preventpersons from falling from the earthmoving machine.

6.2.2 No one may mount or alight from earthmoving machinery except with the prior consent of themachine operator and when the machine is stationary.

6

6.1

6.1.1

6.1.2

6.1.3

6.1.4


-A4-

Safety instructions

6.3

6.3.1

6.3.2

6.3.3

6.3.4

6.3.5

Driving

Prior to starting up the earthmoving machine, the operator’s seat, the mirror and the adjustableparts 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 ROPS system or aTOP 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 poorlyventilated premises.

The roadways must be designed so as to ensure smooth, safe operation, i.e. they must beadequately wide with the lowest possible gradient and laid on a base with a good bearingcapacity.The bearing capacity of bridges, basement ceilings, vaulting etc. must be checked before drivingover them.

The clearance dimensions of underpasses, tunnels etc. must be checked prior to driving intothem.

On high gradients and slopes, the load must be kept towards the incline if possible to increasestability.

The engine must not be out of gear when driving downhill. Prior to driving down the slope, thegear 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 safelybraked.

Extensive reversing should be avoided.

Earthmoving machinery must not be driven on the public highway unless an operating and drivinglicence compatible with the national traffic legislation is available.

Outside the public transport area, e.g. on construction sites, traffic regulations should be appliedanalogously. This point should also be taken into account there with respect to the driving licence.

Loading, unloading

6.3.6

6.3.7

6.3.8

6.3.9

6.3.10

6.3.11

6.3.12

6.3.13

6.4


-A5-

Safety instructions

6.4.1 The machine operator must not swing the operating devices across occupied driving, operatingand 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 mustleave 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 anymaterial 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 fastas possible.

Earthmoving machinery must not be operated at dumping sites unless appropriate measures havebeen taken to prevent inadvertent movement or overturning.

Marshallers

Marshallers must be clearly recognisable, e.g. through special clothing. They must be within thevisual range of the machine operator.

During their marshalling activity, marshallers must not be given other tasks which might distractthem 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 theiroperator’s stand is fitted with a protective roof (FOPS); in the case of excavators a protectivewindscreen (FGPS) must also be present.Close to earth and rock walls, excavators should be set up and operated in such a way that theoperator’s stand and the steps leading to it are on the side of the earthmoving machine away fromthe wall.Demolition work must not be done with earthmoving machinery unless it is assured that personsare 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 theboom length.The highest point of the operating device of the earthmoving machine should be above thecomponent to be demolished.

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


-A6-

Safety instructions

6.7

6.7.1

6.7.2

6.7.3

Operation in areas carrying underground lines

Prior to carrying out excavation work with earthmoving machinery, a check must be made in thearea 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 withthe 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 toearthmoving work being commenced. If the location of lines cannot be determined, exploratorytrenches must be dug, if necessary by hand.If underground lines or their protective coverings are contacted or damaged inadvertently, themachine 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, asafety clearance dependent on the voltage rating of the overhead line must be kept between suchlines and the earthmoving machine and its operating devices to prevent a voltage transfer. Thisalso applies to the clearance between such lines and attachments or slung loads.The following safety clearances are applicable in Germany:

Voltage ratingSafety clearanceup to 1000 V1.0 mmore than 1 kV to 110 kV3.0 mmore than 110 kV to 220 kV4.0 mmore than 220 kV to 380 kVor for unknown voltage rating5.0 m

6.8.3 All working movements of earthmoving machinery, e.g. the boom positions, the swinging ofcables and the dimensions of slung loads must be taken into account, as must groundirregularities through which the earthmoving machine is tilted and thus comes closer to overheadlines.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 withthe owner or operator of the lines. This may be done, for example, by- switching off the current,

6.7.4

6.8

6.8.1

6.8.2

6.8.4


-A7-

Safety instructions

- moving the overhead line,- cabling or- limiting the working range of earthmoving machinery.

6.8.5 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.- If 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.

6.9 Operation below ground and in enclosed areas

If earthmoving machinery is used below ground or in enclosed areas, adequate ventilation mustbe provided and the valid regulations must be observed.

6.10

6.10.1

Stoppages

Prior to breaks or finishing work, the operator must move the earthmoving machine to level groundwith 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 movementis possible.

6.10.2

6.10.3

The operator must not leave the earthmoving machine unless the operating devices are set downor securedEarthmoving machines must be parked only where they present no obstacle, e.g. to publichighway or site traffic. If necessary they must be secured by warning devices such as warningtriangles, warning cords, flashing or warning lamps.Prior to leaving the operating stand, the operator must set all control devices to neutral and applythe brakes.

Before leaving the earthmoving machine, the operator must first switch off the driving motors andsecure them against unauthorised starting.

Lifting-gear deployment

Lifting-gear deployment covers the lifting, transporting and lowering of loads by means of aslinging aid (cable, chain etc.), with the assistance of persons being required for slinging andreleasing the load.

6.10.4

6.10.5

6.11

6.11.1


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Safety instructions

This means, for example, the lifting and lowering of pipes, shaft rings or containers withearthmoving machinery.

6.11.2 Earthmoving machinery must not be used in lifting-gear deployment unless the prescribed safetydevices 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 aoverturning moment of more than 40 000 Nm

- overload warning system,- open-circuit monitoring system(s) at boom lifting cylinder(s).

6.11.3

6.11.4

6.11.5

6.11.6

6.11.7

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 machineoperator.

The machine operator must keep loads as close as possible to the ground and prevent theirswinging.

Earthmoving machinery must not be driven with a slung load unless the roadway is as even aspossible.

When earthmoving machinery is in lifting-gear deployment, riggers may approach the boom onlywith the consent of the machine operator and only from the side. The machine operator must notgive his consent unless the earthmoving machine is stationary and the operating device is notbeing 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 thedirection of qualified personnel appointed by the contractor and with the manufacturer’s operatinginstructions being observed.Work on such components as- braking,

6.11.8

7

7.1

7.2


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Safety instructions

---of

7.3

7.4

steering, hydraulic and electrical systemsthe 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 withequivalent measures, e.g. supporting sleeves or jacks. If necessary, the superstructure ofexcavators must be secured against swivelling.In the case of earthmoving machinery with centre pivot steering, the pivot joint must be positivelylocked when work is being done in that area.

When installing and dismantling counterweights, they must be placed only at the locationsprescribed by the manufacturer.

For jacking up earthmoving machinery, lifting gear must be used in such a way as to prevent anyslippage. 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 planksor squared timbers or with jacks.

Earthmoving machinery which is lifted with operating devices, must be supported immediatelyafter being lifted. No work may be done under raised earthmoving machinery which is held inplace only by the hydraulic system.

7.5

7.6

7.7

7.8

7.9

7.10

7.11

Prior to replacing the bucket scrapers of scraper vehicles or scraper-dozers, the scraper bucketsmust be set down on a non-tilting, unbreakable base.

Maintenance and repair work on scraper buckets must be done only when the closing flap issecured.

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 theserequirements. It must be ensured that the drive can be stopped immediately in any hazardoussituation prior to beginning such work.

7.12

7.13

In the case of earthmoving machinery with a combustion engine, the battery must be disconnectedprior to any work on the electrical system or any arc welding.

When disconnecting the battery, first the negative and then the positive pole must bedisconnected. Reconnection is done in the reverse sequence.


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Safety instructions

7.14 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 wherenecessary the mobile connection lines must be switched off and secured against inadvertent orunauthorised switching on.Protective devices of moving machine parts must not be opened or removed unless the drive hasbeen stopped and secured against unauthorised starting.

Protective devices are, for example, motor compartment flaps, doors, guards, housings.

7.17

7.18

7.19

7.20

7.21

7.22

7.23

7.24

8

8.1

8.2

8.3

On completion of assembly, maintenance or repair work, all protective devices must be correctlymounted 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 air system, must not be undertakenexcept with the authorisation of the manufacturer.

The control pressure, dynamic pressure and internal tank pressure must be reduced beforestarting 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 dimensionedtowing 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 towingdevices.

7.15

7.16


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Safety instructions

8.4

8.5

8.6

8.7

During loading and transport, earthmoving machinery and any necessary auxiliary devices mustbe secured against inadvertent movement.

The travelling gear and crawler unit of earthmoving machinery must be cleaned of mud, snow andice 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 trackedvehicles.

Before the actual transport, the route to be covered should be inspected to ensure that the roadsare wide enough, bridge and underpass openings large enough, and roads, tracks and bridgesare 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 manufacturerthat 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 devicemust be checked by moving it in all directions. During this process, all persons must keep out ofthe hazard zone.

9.3 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 theinstalled 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 normalconditions should not exceed 6 years).

9.4

9.5

9.6

The coolant level must be checked only when the lid is cool; the lid must be turned carefully toreduce the pressure.

The machine operator must report any recorded defects without delay to the supervisor and, in theevent of a change of operator, to the operator replacing him.

In the event of defects endangering the operational safety of the earthmoving machine, it must betaken out of operation until the defects have been rectified.

9

9.1

9.2


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NK Lifton LimitedStation Road Ind ParkBrompton-on-SwaleRichmond, North Yorkshire, DL 107 SNUnited KingdomPhone (+44) 1748 81 06 66Fax(+44) 1748 81 07 77e-Mail: [email protected]

Neuson Kramer France SA43, Rue du Landy - 93211 Saint DenisLaplaine cedexFranceTél(+33) 141624162Fax(+33) 141624165E-mail: [email protected]

Neuson Baumaschinen GmbHHaidfeldstraße 37A-4060 Linz-LeondingAustriaTel.: (+43) 732 90 5 90 - 0Fax: (+43) 732 90 5 90 - 200e-mail: [email protected]

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