Wacker Neuson 1404 ET16 Track excavator Service manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Wacker Neuson 1404 ET16 Track excavator Service manual – PDF DOWNLOAD
1 Operation
1.1 Notices on this service manual
- This service manual contains important information on how to work safely, correctly and economically with the machine. Therefore, it aims not only at new personnel, but it also serves as a reference for experienced personnel.
- It helps to avoid hazardous situations and reduce repair costs and downtimes. Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the service manual. Careful and prudent working is the
- best way to avoid accidents! Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine. This is why regular maintenance and servicing is absolutely necessary. Use only original spare parts for repairs. This ensures operational safety and readiness of your machine, and maintains its value
• Modifying Wacker Neuson products and fitting them with additional equipment and attachments not included in our delivery program requires Wacker Neuson’s written authorization, otherwise warranty and product liability for possible damage caused b these modifications shall not be applicable.
• Subject to modifications and printing errors. Your Wacker Neuson technical support will be happy to answer any further questions regarding the machine or the service manual
TABLE OF CONTENTS:
Wacker Neuson 1404 ET16 Track excavator Service manual – PDF DOWNLOAD
Operation
Notices on this service manual 1-2
Identification of warnings and dangers 1-3
Explanation of symbols and abbreviations 1-3
Abbreviations 1-4
Conversion table 1-5
Warranty and liability 1-6
Exemption from warranty and liability 1-6
Labels 1-7
Machine overview 1-10
Cabin overview 1-11
Cabin overview (legend) 1-12
Instrument panel overview 1-13
Instrument panel overview (legend) 1-14
Engine compartment (overview) 1-15
Chassis overview 1-16
Removing the cabin 1-17
Removing the cabin 1-18
Removing the floor panel 1-18
Battery master switch 1-18
Changeover valve for SAE/ISO controls (option) 1-19
Control lever on the left 1-19
Control lever on the right 1-19
Directional valve position 1-20
Directional valve 1-20
Functional check of control lever base 1-21
Releasing the pressure in the work hydraulics 1-22
Releasing pressure 1-22
Fire extinguisher 1-22
Installation of a fire extinguisher in compliance with DIN-EN 3 in the cabin 1-22
Installation of a fire extinguisher in compliance with DIN-EN 3 in the canopy 1-23
Technical data
Chassis 2-2
Engine 2-2
Fuel injection pump 2-4
Engine capacities 2-4
Engine tightening torques 2-4
Hydraulic system 2-4
Auxiliary hydraulics oil flow 2-5
Operating hydraulics 2-5
Travel gear and swivel unit 2-6
Stabilizer blade 2-6
Electrical system 2-7
Fuses on control lever base on the left 2-7
Main fuse box with relays 2-7
Noise levels 2-8
Vibration 2-8
Coolant compound table 2-8
Hose identification code 2-8
Model-specific tightening torques 2-9
General tightening torques 2-9
Tightening torques for hydraulic threaded fittings (dry assembly) 2-9
Tightening torques for high-resistance threaded fittings 2-11
Dimensions 2-12
Table of contents
I-2 SHB 1404 en – Edition 25 * 1404s20IVZfm
Table of contents
Lift capacity table 2-13
Kinematics 2-14
Measuring live ring tolerance 2-15
Maintenance
Special tools 3-2
Fluids and lubricants 3-2
Oil grades for the diesel engine, depending on temperature 3-3
Additional oil change and filter replacement (hydraulic system) 3-3
Oil grades for the hydraulic system, depending on temperature 3-4
Maintenance label 3-5
Explanation of symbols on the maintenance label 3-5
Maintenance plan (overview) 3-7
Information on maintenance 3-11
Responsibilities and prerequisites 3-11
Important safety instructions on maintenance 3-11
Fuel System 3-12
Specific safety instructions 3-12
Refueling 3-13
Stationary fuel pumps 3-13
Diesel fuel specification 3-13
Bleeding the fuel system 3-13
Emptying the fuel tank 3-14
Fuel prefilter with water separator 3-15
Replace the fuel filter 3-15
Engine lubrication system 3-16
Checking the oil level 3-16
Drain engine oil 3-17
Adding engine oil 3-17
Changing engine oil 3-18
Replacing the engine-oil filter cartridge 3-19
Engine cooling system 3-20
Specific safety instructions 3-20
Checking the coolant level/adding coolant 3-21
Adding coolant 3-22
Draining coolant 3-23
Air filter (up to serial no AG03215) 3-24
Air intake 3-25
Filter replacement 3-25
Air filter (from serial no AG03216) 3-27
Air intake 3-27
Replacing air filter elements 3-28
Replacing the cabin air filter 3-29
V-belt 3-30
Checking V-belt tension 3-30
(Re)tensioning the V-belt of the alternator 3-31
Hydraulic system 3-32
General 3-32
Checking the hydraulic oil level 3-33
Adding hydraulic oil 3-34
Replace the hydraulic oil 3-35
Replace the hydraulic oil filter 3-36
Draining condensation water from the hydraulic oil reservoir 3-36
Important information for the use of biodegradable oil 3-37
Checking the hydraulic system and hydraulic hoses 3-38
Pilot control filter (from serial no AF01441) 3-39
Pressure check 3-40
SHB 1404 en – Edition 25 * 1404s20IVZfm I-3
Table of contents
General 3-40
Prerequisites for pressure check 3-40
Checking pilot control pressure 3-40
3-40
Pressure reducing valve (PRV) 3-41
Gear pump P1 3-41
Setting the secondary pressure limiting valve (PLV) 3-42
Gear motor 3-42
Test report 3-43
Traveling drive 3-45
Checking the oil level and adding oil 3-45
Draining oil 3-45
Tracks 3-46
Checking track tension 3-46
Setting the tracks 3-47
Lubrication points 3-49
Parking the machine 3-49
Overview of lubrication points 3-50
Lubrication work 3-51
Lubrication points on the stabilizer blade 3-51
Lubrication points on the swiveling console 3-51
Lubrication points on the stick and boom cylinders 3-52
Boom lubrication points 3-52
Lubrication points on the stick 3-52
Lubrication point on the joint rod 3-53
Lubrication point for slewing cylinder 3-53
Lubrication points on live ring (ball bearing) 3-53
Lubrication points of live ring teeth 3-54
Lubrication points of mechanical quickhitch (option) 3-54
Lubrication points of hydraulic quickhitch (option) 3-54
Maintenance of attachments 3-55
Electrical system 3-56
Specific safety instructions 3-56
Servicing and maintenance at regular intervals 3-56
Instructions concerning specific components 3-56
Alternator 3-56
Battery charge condition 3-57
Charging the battery 3-57
Replacing the battery 3-57
General maintenance 3-58
Cleaning 3-58
General instructions for all areas of the machine 3-58
Inside the cabin 3-59
Cleaning the seat belt 3-59
Exterior of the machine 3-59
Engine compartment 3-59
Threaded fittings and attachments 3-59
Pivots and hinges 3-60
Preparatory work before taking out of service 3-60
Maintenance when out of service for a longer period of time 3-61
Putting into operation again 3-61
Engine
Overview of engine 3TNV76-SNS2 (Tier IV final up to 2012) 4-2
Fuel system 4-4
Cooling system 4-5
Checking and adjusting valve clearance 4-6
I-4 SHB 1404 en – Edition 25 * 1404s20IVZfm
Table of contents
Lapping the intake and exhaust valves 4-7
Tightening order for cylinder head bolts 4-7
Order for removing the cylinder-head bolts: 4-7
Order for installing the cylinder-head bolts: 4-7
Checking the injection nozzles 4-8
Pressure check 4-8
Checking the nozzle jet 4-8
Injection time 4-9
Checking injection time 4-9
Setting injection time 4-11
Removing and installing the injection pump 4-12
Removing the injection pump 4-12
Fitting the fuel injection pump 4-13
Tightening torques 4-14
Measuring and adjusting the engine speed 4-14
Checking compression 4-15
Checking the coolant thermostat 4-15
Checking the thermal switch 4-16
Oil pressure switch 4-16
Checking the coolant circuit 4-16
Cleaning the cooling water channels 4-17
Coolant and fuel hoses 4-17
Crankcase vent 4-17
Replacing the glow plugs 4-17
Overview of engine 3TNV80F-SSNS2 (TIER IV final from 2012) 4-18
Fuel system 4-20
Cooling system 4-21
Altitude-dependent output reduction 4-22
Checking and adjusting valve clearance 4-23
Tightening order for cylinder head bolts 4-25
Order for removing the cylinder-head bolts: 4-25
Order for installing the cylinder-head bolts: 4-25
Checking the injection nozzles 4-26
Pressure check 4-26
Checking the nozzle jet 4-27
Injection time 4-27
Checking injection time 4-27
Setting injection time 4-29
Removing and installing the injection pump 4-30
Removing the injection pump 4-30
Fitting the fuel injection pump 4-31
Measuring and adjusting the engine speed 4-33
Compression 4-33
Checking the coolant thermostat 4-34
Checking the temperature sensor 4-34
Oil pressure switch 4-35
Checking the coolant circuit 4-35
Cleaning the cooling water channels 4-35
Coolant and fuel hoses 4-36
Crankcase vent 4-36
Replacing the glow plugs 4-36
Engine malfunctions 4-37
Hydraulic system
How the load-sensing control works 5-2
Overview of hydraulic components 5-2
Gear pump AZPS-11-014 RRR 20 MB-N 5-3
SHB 1404 en – Edition 25 * 1404s20IVZfm I-5
Table of contents
Pump unit exploded view 5-4
Pilot oil supply unit 5-5
Pilot oil control unit (from serial number WNCE0901KPAL02194) 5-6
Main valve block SX 10 5-7
Function description 5-7
Sectional view 5-7
Exploded view of main valve block 5-8
Possible configurations 5-8
Connections 5-9
Legend 5-9
Main valve block diagram 5-10
Pressure limiting valves 5-11
Swivel unit 5-12
Function description 5-12
Swivel unit overview 5-13
Exploded view of secondary pressure limiting valve 5-13
Overview of swivel unit 5-14
Replacing the seals 5-15
Swivel joint 5-18
Replace the sealing rings 5-18
Swivel implementation (from serial number WNCE0901KPAL02194) 5-19
Traveling drive 5-20
Function description 5-20
Exploded view of traveling drive 5-21
drive system (from serial number WNCE0901KPAL02194) 5-22
Function 5-23
Pilot valves 5-24
Control levers 5-24
Control lever functions 5-25
Valves 5-25
8/2 directional valve – changeover valve SAE/ISO controls (option) 5-25
Hydraulic quickhitch/Easy Lock valve (option) 5-26
Service valve of hydraulic oil reservoir (option) 5-27
3/2 ball-type cock (option) 5-27
Mechanical control 5-28
Overview of pedals and levers 5-28
Breather filter 5-30
Auxiliary hydraulics connections 5-31
Malfunctions of the hydraulic system 5-31
Hydraulics diagram (legend) 5-34
5-34
Hydraulics diagram 1404 version 1 5-35
Hydraulics diagram 1404 version 2 5-36
Main valve block diagram 1404 5-37
Legend of hydraulic diagram 1404 with second driving speed / ET16
5-38
Hydraulic diagram 1404 with second driving speed / ET 16 5-39
5-40
Electrical system
Ohmic law (current, voltage, resistance); Power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-3
Relays 6-3
Use, mode of function 6-3
Electrical system 6-4
I-6 SHB 1404 en – Edition 25 * 1404s20IVZfm
Table of contents
Fuses on control lever base on the left 6-4
Main fuse box with relays 6-5
Relay connector assignment 6-5
Instrument panel overview 6-6
12 V power outlet 6-7
Power outlet 6-7
Control lever push button 6-7
Starter 6-8
Dynamo and alternator 6-8
Regulator 6-9
Radio and mounting/wiring for radio installation (option) 6-10
Front working lights 6-10
Cabin lights (option) 6-11
Rotating beacon (option) 6-11
Travel signal (option) 6-12
Wiring diagram (legend) 6-14
Wiring diagram 6-15
Wiring diagram 1404 with second driving speed 6-16
Wiring diagram ET16 6-17
Wiring diagram legend with alternator (option) 6-18
Wiring diagram with alternator (option) 6-19
Wiring diagram for hydraulic quickhitch (option) 6-20
Engine wiring harness legend (up to serial no WNCE0901CPAL00410) 6-22
Engine wiring harness (up to serial no WNCE0901CPAL00410) 6-23
Engine wiring harness legend (TIER IV final up to 2012) 6-24
Engine wiring harness (TIER IV final up to 2012) 6-25
Engine wiring harness legend (Tier IV final from 2012) 6-26
Engine wiring harness (Tier IV final from 2012) 6-27
Legend engine wiring harness 1404 / ET16 (TIER IV final from serial number
WNCE0901KPAL02194) 6-28
Engine wiring harness 1404 / ET16 (TIER IV final from serial number
WNCE0901KPAL02194) 6-29
Seat console wiring harness (TIER IV final up to 2012) 6-30
Seat console wiring harness V1 (Tier IV final from 2012) 6-31
Seat console wiring harness legend V1 (Tier IV final from 2012) 6-32
Seat console wiring harness V2 (Tier IV final from 2012) 6-34
Legend of seat console wiring harness 1404 / ET16 (TIER IV final from serial number
WNCE0901KPAL02194) 6-35
Seat console wiring harness 1404 / ET16 (TIER IV final from serial number
WNCE0901KPAL02194) 6-37
Legend wiring harness seat console 1404 / ET16 (from serial number
WNCE0902TPAL00418) 6-38
Legend wiring harness seat console 1404 / ET16 (from serial number
WNCE0902TPAL00418) 6-40
Cabin (option) wiring harness V1 6-41
Cabin (option) wiring harness V2 6-42
Traveling signal wiring harness 6-43
Hydraulic quickhitch wiring harness (option) 6-44
Battery lead 6-45
Battery lead 6-46
Alternator cable (option) 6-47
Loudspeaker cable (option) 6-48
Immobilizer cable (option) 6-49
Working lights cable (option) 6-50
Options
Long stick 7-2
SHB 1404 en – Edition 25 * 1404s20IVZfm I-7
Table of contents
Technical data 7-2
SAE/ISO controls 7-3
Telescopic travel gear 7-4
3/2 ball-type cock 7-4
Traveling alarm/traveling signal 7-5
Hose burst valve of stabilizer blade 7-5
Hydraulic quickhitch/Easy Lock 7-6
Mechanical quickhitch 7-7
Flat seal couplings 7-8
Drive interlock (antitheft protection) KAT (1404 from serial number AG00673) 7-9
Troubleshooting 7-10
Service valve 7-10
Telematic 7-11
Connections 7-11
Functional check/diode
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M