Wacker Neuson 6003 Track Excavator Service Manual
342 pages · Publication 1000129840
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- Models
- 6003
- Manual type
- Service Manual
- Pages
- 342
- Publication
- 1000129840
- Condition
- Brand new
What's inside
From the manual's own table of contents: 84 sections, 339 entries. See sample pages (PDF, 744 KB)
General52 topics
- Important information on this service manual
- Identification of warnings and dangers
- Designated use and exemption from liability
- Type labels and component numbers
- Machine overview
- Cab overview
- Up to serial no.: AD07210
- From serial no.: AH00645
- Cab (legend)
- Instrument panel up to serial no. AC02888: overview
- Instrument panel up to serial no. AC02888: legend
- Instrument panel from serial no. AC02890 to AD07210: overview
- Instrument panel from serial no. AC02890 to AD07210: legend
- Instrument panel from serial no. AH00645: overview
- Instrument panel from serial no. AH00645: legend
- Engine compartment up to serial no. AD07210: overview
- Engine compartment from serial no. AD00611: overview
- Chassis overview
- Tilting the cab
- Summer/winter operation
- Preheated fresh air
- Auxiliary hydraulics/boom swivel pedal
- Battery master switch
- Chassis
- Engine
- Fuel injection pump
- Capacities
- Tightening torques
- Hydraulic system
- Auxiliary hydraulics oil flow*
- Screwable hose burst valve
- Undercarriage and swivel unit
- Stabiliser blade
- Electric system
- Fuse box on the instrument panel up to serial no. AD07210
- Main fuse box with relays under the cab up to serial no. AD07210
- Relays up to serial no. AD07210
- Fuse box on the instrument panel from serial no. AH00645
- Main fuse box with relays from serial no. AH00645
- Noise levels
- Vibration
- Coolant compound table
- Model-specific tightening torques
- General tightening torques
- Tightening torques for hydraulic screw connections (dry assembly)
- Tightening torques for high-resistance screw connections
- Dimensions model 6003
- Lift capacity table 6003
- Lift capacity table 6003 with long stick option
- Lift capacity table 6003 with counterweight option
- Lift capacity table 6003 with long stick and counterweight
- Lift capacity table 6003 Vario
Kinematics
Attachments
Fluids and lubricants1 topic
- Additional oil change and filter replacement (hydraulics)
Maintenance label1 topic
- Explanation of symbols on the maintenance label
Maintenance plan (overview)
Service package2 topics
- Up to serial no. AD07210
- From serial no. AH00645
Introduction
Fuel system8 topics
- Specific safety instructions
- Refuelling
- Stationary fuel pumps
- Diesel fuel specification
- Bleeding the fuel system
- Emptying the fuel tank
- Fuel prefilter with water separator
- Replacing the fuel filter
Engine lubrication system4 topics
- Checking the oil level
- Filling up engine oil
- Changing engine oil
- Replacing the engine oil filter cartridge
Cooling system2 topics
- Checking/filling up coolant
- Draining coolant
Air filter2 topics
- Replacing the filter
- Functional check once a week of the dust valve
V-belt4 topics
- Checking V-belt tension
- Retightening the V-belt
- Checking the V-belt of the air conditioning system
- Tightening the V-belt of the air conditioning system
Pressure check8 topics
- General
- Checking pilot control pressure
- Pressure check of variable displacement pump P1
- Pressure check of variable displacement pump P2
- Pressure check of gear pump P3
- Secondary pressure limiting valve of the gear motor
- Measuring ports: overview
- Primary pressure limiting valves
Test report
Hydraulic system53 topics
- Checking the hydraulic oil level
- Filling up hydraulic oil
- Changing hydraulic oil
- Monitoring the hydraulic oil reflux filter
- Checking hydraulic pressure lines
- Travelling drive
- Checking the oil level and filling up oil
- Draining oil
- Chains
- Checking chain tension
- Setting the chains
- Lubrication work
- Lubrication points on the swivelling console
- Boom lubrication points
- Lubrication points on the stick
- Lubrication strip
- Maintenance of attachments
- Service and maintenance work at regular intervals
- Instructions concerning specific components
- Alternator
- Battery
- Jump-starting the engine
- Replacing the cab filter
- General maintenance work
- Cleaning
- General instructions for all areas of the machine
- Inside the cab
- Exterior of the machine
- Engine compartment
- Screw connections and attachments
- Pivots and hinges
- Engine 4TNV98-VNS (Tier 2 up to serial no. AD07210)
- Fuel system
- Removing the valve cover
- Checking and adjusting valve clearance
- Checking valve clearance
- Setting zero play of the valve bridge
- Setting valve clearance
- Tightening order for cylinder head bolts
- Checking the injection nozzles
- Pressure check
- Checking the nozzle jet
- Injection time
- Checking injection time
- Setting injection time
- Replacement of fuel injection pump
- Adjusting engine revs
- Compression
- Checking the coolant thermostat
- Checking the thermal switch
- Oil pressure switch
- Checking the coolant circuit
- Engine 4TNV98-ZVNS from serial no. AH00645
Checking and adjusting valve clearance
Tightening order for cylinder head bolts
Checking the injection nozzles
Checking the nozzle jet
Injection time
Compression
Checking the coolant thermostat
Checking the thermal switch
Show all 85 sections
Oil pressure switch
Checking the coolant circuit
Engine trouble
Electronic engine control unit (E-ECU)1 topic
- Features
Engine error codes
Error diagnosis49 topics
- connector assignment
- Important information on the ECU maintenance wiring harness
- Flash code 7 – proportional injection pump solenoid (control rack)
- Related DTC (Diagnostic Trouble Codes)
- Diagnosis description
- Flash code 5 – manual throttle
- Related DTC
- Work description
- Flash code 4-1 ECU internal
- Flash code 2-4 – sensor 5 V
- Flash code 2-3 – power supply voltage
- (1) P0562/1: power supply voltage error (voltage too low)
- DTC detection conditions
- Troubleshooting
- (2) P0563/0: power supply voltage error (voltage too high)
- Flash code 6 – revs sensor
- Flash code 1-1 – backup revs sensor
- Flash code 9 – overspeed error
- Flash code 1-5 – preheating relay
- Flash code 1-4 – CSD (cold start device) solenoid coil
- Flash code 1-3 – EGR (exhaust gas recirculation) valve
- Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error
- Flash code 8 – proportional injection pump solenoid (control rack)
- Flash code 1-6 – main relay
- Flash code 1-2 – CAN (Controller Area Network) communication
- Automatic revs setting
- How it works
- Hydraulic pump PVD-3B-56P-21G5-4626F
- Pump unit: exploded view
- Pilot oil supply unit
- Main valve block with 3rd control circuit and triple articulation boom
- Ports
- Legend
- Main valve block diagram
- Pressure limiting valves
- Pump assignment
- Drive counterbalancing system
- Pump assignment for drive counterbalancing
- Drive counterbalancing diagram
- Regeneration – stick section
- Bucket pre-tension
- Boom summation – raise
- Check valve (load retaining valve)
- Flow rate adjustment of auxiliary hydraulics
- Pilot valves
- Joystick
- Pilot valve (driving)
- Pilot valve for auxiliary hydraulics
- Pilot valve for stabiliser blade
Valves4 topics
- 7/2 directional valve (changeover valve)
- 4/3 directional valve
- Shuttle valve block
- Changeover valve for SAE/ISO controls (option)
Travelling drive2 topics
- Function
- 2nd speed range function
Swivel unit1 topic
- Parking brake/multidisc brake function
Swivel joint
Breather filter
Troubleshooting in the hydraulic system
Hydraulics diagram A4
Hydraulics diagram (legend)
Hydraulics diagram A3
Options diagrams 1 (from serial no. AC04070)
Options diagrams 2 (from serial no. AC04070)
Main valve block A3 diagram
Ohm's Law (current, voltage, resistance); power
Measuring equipment, measuring methods
Cable colour coding
Relays1 topic
- Use, mode of function
Electric units
Fuse box on the instrument panel up to serial no. AD07210
Main fuse box with relays up to serial no. AD07210
Fuse box on the instrument panel from serial no. AH00645
Main fuse box with relays from serial no. AH00645
ECU from serial no. AH00645
Socket
Joystick tip switches2 topics
- Joystick (left)
- Joystick (right)
Instrument panel overview
Switches: overview
Alternator
Starter
Wiring diagram A4 up to serial no. AC02888 (legend)
Wiring diagram A4 up to serial no. AC02888
Wiring diagram A4 from serial no. AC02890 (legend)
Wiring diagram A4 from serial no. AC02890
Wiring diagram A4 from serial no. AH00645 (legend)
Wiring diagram A4 (1) from serial no. AH00645
Wiring diagram A4 (2) from serial no. AH00645
Engine – chassis A4 wiring harness 1000109624 up to AD07210 (legend)
Engine – chassis A4 wiring harness 1000109624 up to AD07210
Engine – chassis A4 wiring harness 1000173970 from AH00645 (legend)
Engine – chassis A4 wiring harness 1000173970 from AH00645
Switches A4 wiring harness 1000109630 up to serial no. AC02888 (legend)
Switches A4 wiring harness 1000109630 up to serial no. AC02888
Switches A4 wiring harness from serial no. AC02890 (legend)
Switches A4 wiring harness from serial no. AC02890
Wiring harness 1000109629: cab roof44 topics
- Wiring harness 1000109628: armrest
- Wiring harness 1000116138: boom working light
- Wiring diagram A3 up to serial no. AC02888 (legend)
- Wiring diagram A3 up to serial no. AC02888
- Wiring diagram A3 from serial no. AC02890 – AD07210 (legend)
- Wiring diagram A3 from serial no. AC02890 – AD07210
- Wiring diagram A4 from serial no. AH00645 (legend)
- Wiring diagram A4 (1) from serial no. AH00645
- Wiring diagram A4 (2) from serial no. AH00645
- Engine – chassis A3 wiring harness 1000109624 (legend)
- Engine – chassis A3 wiring harness 1000109624
- Engine – chassis A3 wiring harness 1000173970 from serial no. AH00611
- Switches A3 wiring harness 1000109630 up to serial no. AC02888 (legend)
- Switches A3 wiring harness 1000109630 up to serial no. AC02888
- Switches A3 wiring harness from serial no. AC02890 (legend)
- Switches A3 wiring harness from serial no. AC02890
- Wiring harness 1000109629: cab roof A3
- Wiring harness 1000109628: armrest A3
- Wiring harness 1000116138: boom working light A3
- Air conditioning
- Specifications
- Installation: overview
- Components
- Filling up the air conditioning system
- Maintenance
- Air-suspension seat
- Counterweight
- Long stick
- Control circuit (pipework) connections for grab
- 3rd control circuit connections
- Auxiliary hydraulics connections
- Quickhitch couplings
- Attachments
- Neuson Vario
- Using the Neuson Vario feature
- Vario diagram
- Neuson Vario warning device
- Fuel-filling pump
- Connections up to serial no. AD07210
- Central lubrication system
- Position
- Connections
- Adjusting breaks and lubrication times
- Repair in case of clogging
Service valve
Safe load indicator D (safety valve for boom)1 topic
- Diagram
Safe load indicator F (safety valves for boom and stick)
3rd control circuit
Triple articulation boom
Electric auxiliary hydraulics
Auxiliary hydraulics shock cartridge
3rd control circuit shock cartridge
Drive interlock (antitheft protection)3 topics
- Disabling the drive interlock
- Enabling the drive interlock
- Programming
Quickhitch
Proportional controls10 topics
- Overview of auxiliary hydraulics controls
- Hammer operation
- Adjusting control response
- Characteristic curve – status display
- Wiring harness
- Control unit
- Control valve plug assignment
- Safety features
- Measures to be taken in case of malfunctions
- Diagnosis display
Inside this manual
Real pages from this service manual (342 pages). Open the sample pages (PDF, 743 KB)
- Specifications, page 46: SERV-HB 6003 EN – Edition 2.0 * 6003s210.fm
- Troubleshooting, page 161: SERV-HB 6003 EN – Edition 2.0 * 6003s430.fm
- Diagram, page 176: SERV-HB 6003 EN – Edition 2.0 * 6003s430.fm
- Color page, page 28: SERV-HB 6003 EN – Edition 2.0 * 6003s110.fm
- Color page, page 207: SERV-HB 6003 EN – Edition 2.0 * 6003s510.fm
- Foldout diagram (color), page 246: Hydraulic system
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 6003 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 1000129840$69.91
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 342 pages
Quantity one is the manual described above.
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