Wacker Neuson 38Z3 Track excavator Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Wacker Neuson 38Z3 Track excavator Service Manual – PDF DOWNLOAD
1 Operation
1.1 Notices on this service manual
- This service manual contains important information on how to service your machine safely, correctly and economically. Therefore, it aims not only at new operators, but it also serves as a reference for experienced ones. Your knowledge and skills will help to avoid dangerous situations and reduce repair costs and downtimes.
- Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the service manual. Careful and prudent working is the best way to avoid accidents! Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine.
- Insist on using original spare parts when performing maintenance and repair work. This ensures operational safety and readiness of your machine, and maintains its value. Your Neuson After-Sales Service will be pleased to answer any further questions regarding the machine or the service manual.
TABLE OF CONTENTS:
Wacker Neuson 38Z3 Track excavator Service Manual – PDF DOWNLOAD
Operation
Notices on this service manual 1-2
Identification of warnings and dangers 1-2
Designated use and exemption from liability 1-3
Type labels and component numbers 1-4
Machine overview 1-6
Cab overview 1-7
Cab (legend) 1-8
Instrument panel overview (up to serial no AE02803) 1-9
Instrument panel legend 1-10
Instrument panel overview (from serial no AG00573) 1-11
Instrument panel legend 1-12
Engine compartment overview (Tier 2 up to AE02803) 1-13
Engine compartment overview (Tier 3A from AG00573) 1-14
Chassis overview 1-15
Raising/lowering the cab 1-16
Specifications
Chassis 2-2
Engine 2-2
Fuel injection pump 2-3
Engine capacities 2-3
Engine tightening torques 2-3
Hydraulic system 2-4
Auxiliary hydraulics oil flow 2-4
Travel gear and swivel unit 2-5
Stabilizer blade 2-5
Screwable hose burst valve 2-5
Electrical system 2-6
Fuse box in instrument panel 2-6
Main fuse box with relays underneath the cab 2-6
Relays 2-7
Noise levels 2-7
Vibration 2-7
Coolant compound table 2-10
Model-specific tightening torques 2-10
General tightening torques 2-11
Tightening torques for hydraulic screw connections (dry assembly) 2-11
Tightening torques for high-resistance screw connections 2-12
Dimensions model 38Z3 2-14
Lift capacity table 38Z3 2-15
Kinematics 2-15
Attachments 2-16
Maintenance
Fluids and lubricants 3-2
Additional oil change and filter replacement (hydraulic system) 3-3
Maintenance label 3-4
Explanation of symbols on the maintenance label 3-4
Maintenance plan (overview) 3-6
Introduction 3-10
Fuel system 3-11
Specific safety instructions 3-11
Refuelling 3-11
Stationary fuel pumps 3-12
Diesel fuel specification 3-12
Table of contents
I-2 SHB 38Z3 en – Ausgabe 22 * 38z3s2_2IVZfm
Table of contents
Bleeding the fuel system 3-12
Emptying the fuel tank 3-13
Fuel prefilter with water separator 3-13
Replacing the fuel filter 3-14
Engine lubrication system 3-15
Checking the oil level 3-15
Adding engine oil 3-16
Changing engine oil 3-17
Replacing the engine oil filter cartridge 3-18
Cooling system 3-19
Specific safety instructions 3-19
Checking/filling up coolant 3-20
Adding coolant 3-21
Draining coolant 3-21
Air filter 3-22
Replacing the filter 3-23
Functional check once a week of the dust valve 3-24
V-belt 3-25
Checking V-belt tension 3-25
Retightening the V-belt 3-26
Checking the V-belt of the air conditioning system 3-27
Tightening the V-belt of the air conditioning system 3-28
Pressure check 3-29
General 3-29
Checking pilot control pressure 3-29
Pressure check of variable displacement pump P1 3-30
Pressure check of variable displacement pump P2 3-31
Pressure check of gear pump P3 3-32
Secondary pressure limiting valve of the gear motor 3-32
Measuring ports (overview) 3-33
Primary pressure limiting valves 3-33
Test report 3-34
Hydraulic system 3-36
Specific safety instructions 3-36
Checking the hydraulic oil level 3-37
Adding hydraulic oil 3-38
Changing hydraulic oil 3-38
Monitoring the hydraulic oil return filter 3-39
Checking hydraulic pressure lines 3-40
Travelling drive 3-41
Checking the oil level and adding oil 3-41
Draining oil 3-41
Tracks 3-42
Checking track tension 3-42
Setting the tracks 3-43
Lubrication work 3-44
Stabilizer blade 3-44
Lubrication points on the swivelling console 3-44
Boom lubrication points 3-45
Lubrication points on the stick 3-45
Lubrication strip 3-46
Lubrication point of live ring teeth 3-47
Lubrication point of VDS live ring teeth 3-48
Maintenance of attachments 3-48
Electrical system 3-49
Specific safety instructions 3-49
Service and maintenance work at regular intervals 3-49
SHB 38Z3 en – Edition 22 * 38z3s2_2IVZfm I-3
Table of contents
Instructions concerning specific components 3-50
Alternator 3-50
Battery 3-51
Cab 3-52
Replacing the cab filter 3-52
General maintenance work 3-53
Cleaning 3-53
General instructions for all areas of the machine 3-53
Inside the cab 3-54
Exterior of the machine 3-54
Engine compartment 3-54
Screw connections and attachments 3-54
Pivots and hinges 3-54
Engine
Engine 3TNV88-PNS (up to serial no AE02803) 4-2
Fuel system 4-4
Checking and adjusting valve clearance 4-5
Tightening order for cylinder head bolts 4-6
Checking the injection nozzles 4-7
Pressure check 4-7
Checking the nozzle jet 4-7
Injection time 4-8
Checking injection time 4-8
Setting injection time 4-9
Replacement of fuel injection pump 4-9
Adjusting engine speed 4-10
Compression 4-10
Checking the coolant thermostat 4-11
Checking the thermal switch 4-12
Oil pressure switch 4-12
Checking the coolant circuit 4-12
Engine 3TNV88-BPNS (from serial no AG00573) 4-13
Fuel system 4-15
Removing the valve cover 4-16
Checking and adjusting valve clearance 4-16
Tightening order for cylinder head bolts 4-17
Checking the injection nozzles 4-18
Pressure check 4-18
Checking the nozzle jet 4-18
Injection time 4-19
Checking injection time 4-19
Setting injection time 4-20
Replacement of fuel injection pump 4-21
Adjusting engine speed 4-22
Compression 4-22
Checking the coolant thermostat 4-22
Checking the thermal switch 4-23
Oil pressure switch 4-23
Checking the coolant circuit 4-24
Engine trouble 4-24
Hydraulic system
Hydraulic pump PVD-1B-32BP-11G5-4904A 5-2
Pump unit: exploded view 5-4
Pilot oil supply unit 5-5
Main valve block 5-6
Ports 5-6
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Table of contents
Legend 5-7
Main valve block diagram 5-8
Pressure limiting valves 5-9
Pump assignment 5-10
Drive counterbalancing system 5-11
Pump assignment for drive counterbalancing 5-11
Regeneration – stick section 5-12
Bucket pre-tension 5-12
Flow rate adjustment of auxiliary hydraulics 5-13
Pilot valves 5-14
Joystick 5-14
Drive pilot valve (up to serial no WNCE0701APAL00177) 5-16
Drive pilot valve (from serial no WNCE0701APAL00178) 5-18
Pilot valve for auxiliary hydraulics 5-19
Valves 5-20
7/2 directional valve (changeover valve) 5-20
Changeover valve for SAE/ISO controls (option) 5-21
Travelling drive up to no AE00854 5-22
Function 5-23
Travelling drive starting no AE00855 5-25
Function 5-26
Swivel unit 5-28
Parking brake/multidisc brake function 5-29
Swivel joint 5-32
Sealing 5-32
Breather filter 5-33
Troubleshooting in the hydraulic system 5-34
Hydraulics diagram A4 5-35
Hydraulics diagram (legend) 5-36
Hydraulics diagram 38Z3 A3 5-37
Options diagram 1 5-38
Options diagram 2 5-39
Main valve block diagram 38Z3 A3 5-40
Electrical system
Ohm’s Law (current, voltage, resistance); power 6-2
Measuring equipment, measuring methods 6-2
Cable colour coding 6-4
Relays 6-4
Use, mode of function 6-4
Electric units 6-5
Fuse box in instrument panel 6-5
Main fuse box with relays 6-5
Relays 6-6
Socket 6-6
Joystick tip switches 6-7
Joystick (left) 6-7
Joystick (right) 6-7
Instrument panel overview 6-7
Switches overview (up to serial no AE02803) 6-8
Switch overview (from serial no AG00573) 6-9
Alternator 6-10
Starter 6-10
Wiring diagram (legend) 6-12
Wiring diagram 6-13
Engine wiring harness legend (up to serial no AG03204) 6-14
Engine wiring harness (up to serial no AG03204) 6-15
SHB 38Z3 en – Edition 22 * 38z3s2_2IVZfm I-5
Table of contents
Engine wiring harness legend (from serial no AG03205) 6-16
Engine wiring harness (from serial no AG03205) 6-17
Cab wiring harness legend 6-18
Cab wiring harness 6-19
Roof wiring harness 6-20
Engine speed control wiring harness (option) 6-21
Options
Air conditioning 7-2
Specific safety instructions 7-2
Specifications 7-2
Components 7-4
Compressor 7-5
Filling up the air conditioning system 7-6
Maintenance 7-7
Troubleshooting 7-8
Counterweight 7-9
Specifications 7-9
Long stick 7-9
Specifications 7-9
Control circuit (pipework) connections for grab 7-10
Attachments 7-10
3rd control circuit connections 7-11
Auxiliary hydraulics connections 7-11
Safe load indicator DE (safety valve for boom) 7-12
Position 7-12
Setting the pressure switch 7-12
Function 7-13
Wiring diagram 7-13
Safe load indicator FR (safety valves for boom and stick) 7-14
Position 7-14
Setting the pressure switch 7-14
Function 7-15
Wiring diagram 7-16
3rd control circuit 7-17
Function 7-17
Diagram 7-17
Drive interlock (antitheft protection) 7-18
Position 7-18
Disabling the drive interlock 7-18
Enabling the drive interlock 7-18
Programming 7-18
Proportional controls 7-20
Function 7-20
Ports 7-20
Overview 7-21
Wiring harness 7-22
Control unit connector assignment 7-23
Safety features 7-24
Measures to be taken in case of malfunctions 7-24
Diagnosis display 7-24
Fuel-filling pump 7-26
Connections 7-27
Service valve 7-28
Function 7-28
Automatic engine speed setting (Tier 3A from AG00573) 7-29
Function 7-29
Installation 7-30
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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