Wacker Neuson 75Z3/75Z32 8003/80032 Track excavators Operator’s Manual – PDF DOWNLOAD
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Wacker Neuson 75Z3/75Z32 8003/80032 Track excavators Operator’s Manual – PDF DOWNLOAD
1 Introduction
1.1 Important information on the Operator’s Manual
- The Operator’s Manual is stored in the document box behind the seat. This Operator’s Manual contains important information on how to work safely, correctly and economically with the machine. Therefore, it aims not only at new staff, but it also serves as a reference for experienced staff.
- It helps 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 Operator’s Manual.
- This is why the Operator’s Manual must always be kept at hand in the machine. Your own safety, as well as the safety of others, depends to a great extent on how the machine is moved and operated. Carefully read the Operator’s Manual before putting the machine into operation.
- This Operator’s Manual will help to familiarise yourself more easily with the machine, thereby enabling you to use it more safely and efficiently.
- Follow chapter “Safety Instructions” in particular. As a rule, keep the following in mind: 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 service work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a Wacker Neuson workshop. Use only original spare parts for repairs. This ensures operational safety and readiness of your machine, and maintains its value.
• Special equipment and superstructures are not described in this Operator’s Manual.
• Wacker Neuson reserves the right to improve the technical standard of our machines without adapting the Operator’s Manual.
• Modifying Wacker Neuson products and fitting them with additional equipment and attachments not included in our delivery program requires Wacker Neuson’s written authorisation, otherwise warranty and product liability for possible damage caused by these modifications shall not be applicable.
• Subject to modifications and printing errors. Your Wacker Neuson dealer will be pleased to answer any further questions regarding the machine or the Operator’s Manual.
TABLE OF CONTENTS:
Wacker Neuson 75Z3/75Z32 8003/80032 Track excavators Operator’s Manual – PDF DOWNLOAD
Introduction
Important information on the Operator’s Manual 1-1
Abbreviations/symbols 1-1
Machine overview 1-2
Brief description 1-3
Travelling drive 1-3
Work hydraulics 1-3
Shock cartridges (option) 1-3
Cooling system 1-3
Cab 1-3
Fields of application, attachments 1-4
Use: attachment 1-4
Regulations 1-6
EC declaration of conformity for all machines delivered before 29 December 2009 1-7
EC declaration of conformity for all machines delivered after 29 December 2009 1-8
Declaration of conformity for machines without CE mark on the type label 1-9
Type labels and component numbers 1-10
Signs and symbols (up to serial no AH01658) 1-13
on the outside of the machine 1-13
Signs and symbols (from serial no AH01659) 1-17
Safety labels 1-22
Fire extinguisher 1-27
Safety instructions
Identification of warnings and dangers 2-1
Warranty 2-1
Disposal 2-1
Designated use and exemption from liability 2-2
General conduct and safety instructions 2-3
Organisational measures 2-3
Selection and qualification of staff, basic responsibilities 2-4
Safety instructions regarding operation 2-5
Normal operation 2-5
Information on visibility 2-6
Cab and protective structures (from serial no AJ02793) 2-7
Installing/removing the Front Guard 2-7
Work range and restricted visibility 2-8
Checks when reversing the machine 2-8
Trailer operation 2-8
Applications with lifting gear 2-9
Instructions on fastening loads 2-9
Prerequisite for safe use 2-10
Attachments 2-10
Safety instructions for maintenance 2-11
Warning of special hazards 2-13
Electrical system 2-13
Working in the area of underground electric lines 2-13
Working near overhead electric lines 2-13
Gas, dust, steam, smoke 2-14
Hydraulics 2-14
Noise 2-14
Oil, grease and other chemical substances 2-14
Using the quickhitches in water 2-14
Battery 2-14
Tracks 2-15
Table of contents
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Hammer operation 2-15
Safety instructions 2-15
Working with a hammer 2-16
Transport and towing 2-17
Towing 2-17
Transport 2-17
Operation
Cab 75Z3/8003 (up to serial no AH00610) 3-2
Control elements 75Z3/8003 (up to serial no AH00610) 3-4
Cab 75Z3/8003 (serial nos AH00611 to AH02749) 3-6
Control elements 75Z3/8003 (serial nos AH00611 to AH02749) 3-8
Cab 75Z3 2/8003 2 (from serial no AJ02793) 3-10
Control elements 75Z3 2/8003 2 (from serial no AJ02793) 3-12
Indicator lights and warning lights: overview 3-14
Putting into operation 3-17
Safety instructions 3-17
Putting the machine into operation for the first time 3-17
Running-in period 3-17
Check lists 3-17
Start-up checklist 3-18
Operation checklist 3-18
Parking checklist 3-19
Driving the machine 3-20
Preheating start switch 3-20
Throttle 3-20
Automatic engine speed setting 3-21
Before starting the engine 3-22
Starting the engine: general 3-23
Starting with the drive interlock (option) 3-24
Drive interlock (up to serial no AH02749) 3-24
Drive interlock – internal transponder (from serial no AJ02793) 3-25
Jump-starting the engine (supply battery) 3-26
Starting at low temperatures 3-27
When the engine has started 3-27
Special instructions for driving on public roads 3-28
Drive position 3-28
Drive levers 3-28
High speed 3-29
Moving off 3-29
Hydraulic brake 3-29
Mechanical brake 3-29
Working on slopes 3-30
Stabiliser blade operation 3-32
Parking the machine 3-33
Parking the machine on slopes 3-33
Light system 3-34
Working light 3-34
Front and rear roof lights (option) (up to serial no AH02749) 3-35
Rotating beacon (option) 3-36
Interior light 3-36
Cab heating and ventilation 3-37
Summer/winter operation (up to serial no AD04617) 3-38
Heating controls (from serial no AD04618) 3-38
Air conditioning (option) 3-39
Recirculated air mode 3-39
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Table of contents
Wiper/wash system 3-40
Tank for washer system 3-40
Seat (standard) 3-41
Seat depth adjustment 3-42
Horizontal adjustment 3-42
Weight adjustment 3-42
Adjusting the head rest 3-42
Backrest adjustment 3-43
Height adjustment 3-43
Seat (air suspension option) 3-44
Seat depth adjustment 3-45
Horizontal adjustment 3-45
Weight adjustment 3-45
Height adjustment 3-45
Adjusting the head rest 3-46
Backrest adjustment 3-46
Horizontal suspension 3-46
Seat belt 3-47
Retracting lap belt (option) 3-48
Mirrors (option) 3-49
Safety instructions 3-49
Adjusting the mirrors 3-50
Emergency exit 3-51
Emergency exit on machines equipped with protective Front Guard structures
(option) 3-51
Front window (up to serial no AD06526) 3-52
Front window (from serial no AD06527) 3-53
Opening the front window 3-53
Closing the front window 3-54
Opening the lower front window 3-54
Closing the lower front window 3-55
Opening the whole front window 3-55
Closing the whole front window 3-56
Opening the front window to a gap 3-57
Opening the side window 3-57
Engine cover 3-57
Battery master switch 3-58
Tilting the cab 3-59
Door 3-62
Door 75Z3 3-62
Door 8003 3-62
Exit through the door (up to serial no AH02749) 3-64
Exit through the door (from serial no AJ02793) 3-65
Armrest adjustment (75Z3/8003 up to serial no AH02749) 3-66
Armrest adjustment (75Z3/8003 from serial no AJ02793) 3-66
Towing the machine 3-67
Crane handling the machine 3-68
Loading and transporting the machine 3-70
Safety instructions 3-70
Tying down the machine 3-71
Driving signal (option) 3-71
Working with the machine 3-72
General safety instructions 3-72
Control levers/ISO controls: overview 3-73
Left-hand control lever 3-73
Hammer pedal lock (up to serial no AH02749) 3-73
Boom/triple articulation boom operation (up to serial no AH02749) 3-74
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Hammer pedal lock (from serial no AJ02793) 3-74
Boom/triple articulation boom operation (from serial no AJ02793) 3-75
Right-hand control lever 3-75
Lowering the boom with the engine stopped 3-76
Rotating the upper carriage 3-76
Swivel unit brake 3-77
Changeover valve for SAE/ISO controls (option) 3-78
Left-hand control lever 3-78
Right-hand control lever 3-78
Directional valve position 3-78
Directional valve 3-79
Control lever with proportional controls (option): overview 3-80
Function 3-80
Left-hand control lever 3-81
Changeover between auxiliary hydraulics and boom swivel 3-81
Switching the status indicator on/off for auxiliary hydraulics/boom swivel 3-81
Operating the boom/auxiliary hydraulics 3-82
Hammer operation 3-82
Adjusting control response 3-82
Characteristic curves – status indicator 3-83
Right-hand control lever 3-83
Releasing pressure 3-83
Control lever if equipped with 3rd control circuit (option): overview 3-84
Left-hand control lever 3-84
Boom swivel (up to serial no AH02749) 3-84
Boom swivel (from serial no AJ02793) 3-85
Right-hand control lever 3-85
Releasing pressure 3-85
Vario (8003 option) 3-86
Vario operation 3-86
Driving across slopes with the Vario feature 3-86
Vario warning device 3-87
Warning ranges 3-87
Working with the Vario feature 3-88
Improved reach with the Vario feature 3-88
Releasing the pressure on the work hydraulics 3-89
Releasing pressure 3-89
Pressure release with proportional controls (option) 3-89
Re-equipping attachments 3-90
Specific safety instructions 3-90
Removing a bucket 3-90
Mounting a bucket 3-91
Quickhitch (option) 3-91
Hydraulic quickhitch – Easy Lock (option) 3-92
Picking up an attachment 3-93
Setting down an attachment 3-94
Shovel bucket operation 3-95
Powertilt (option) 3-95
Re-equipping 3-96
Operation 3-96
Right-hand control lever (Powertilt) 3-96
Connections for auxiliary hydraulics 3-97
Quickhitch couplings 3-97
Safe load indicator (option) 3-98
Safety feature “Hose burst valve” (option) 3-99
Applications with lifting gear 3-99
Lifting gear applications 3-100
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Table of contents
Fastening loads 3-100
Work area assessment and preparation 3-100
Examining the site 3-100
Preparing the ground 3-100
Working with the machine 3-101
Working with the standard bucket 3-101
Inadmissible work procedures 3-101
Work position of machine 3-102
Bucket position when digging 3-102
Excavating trenches 3-103
Loading 3-103
Grading 3-104
Excavating trenches laterally 3-104
Working alongside trenches 3-105
Stabiliser blade at rear 3-105
Further practical hints for digging 3-106
Loading vehicles 3-106
Freeing the machine 3-106
Grading 3-106
Grading 3-106
Increased volume of auxiliary hydraulics 8003 (from serial no AJ02782) 3-107
Troubleshooting
Troubleshooting the engine 4-1
Indicator lights 4-3
Seals, hoses 4-3
Undercarriage 4-4
Engine error codes: 4-5
Malfunctions of the Powertilt unit 4-9
Troubleshooting the central lubrication system (option) 4-10
Proportional controls (option) diagnosis display 4-11
Maintenance
Introduction 5-1
Safety-relevant parts 5-1
Fuel system 5-2
Refuelling 5-3
Fuel-filling pump (option) (75Z3 up to serial no AD07209; 8003 up to serial no
AD07187) 5-3
Fuel-filling pump (option) (75Z3 from serial no AH00646; 8003 from serial no
AH00611) 5-4
Stationary fuel pumps 5-4
Diesel fuel specification 5-5
Bleeding the fuel system 5-5
Fuel prefilter with water separator 5-6
Engine lubrication system 5-7
Checking the engine oil level 5-7
Filling up engine oil 5-8
Engine and hydraulics cooling system 5-9
Specific safety instructions 5-9
Checking/filling up coolant 5-10
Air filter 5-12
Replacing the air filter 5-13
Air intake 5-14
Change cab air filter 5-14
Replacing the filter element of the air conditioning system (option) 5-15
Diesel particulate filter (option) 5-16
Main components of diesel particulate filter system 5-16
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How the diesel particulate filter works 5-17
Machine operation with diesel particulate filter 5-17
Display 5-19
Temperature scale 5-19
Exhaust gas back pressure scale 5-19
Alarm messages 5-20
Maintenance 5-23
Oils and fuels 5-24
Troubleshooting 5-24
Warranty 5-24
V-belt 5-25
Checking V-belt tension 5-25
Retightening the V-belt 5-26
Checking the V-belt of the air conditioning system (option) 5-27
Tightening the V-belt of the air conditioning system (option) 5-27
Hydraulic system 5-28
Specific safety instructions 5-28
Checking the hydraulic oil level 5-29
Filling up hydraulic oil 5-30
Important information for the use of biodegradable oil 5-31
Checking hydraulic pressure lines 5-32
Tracks 5-33
Checking the track tension of the rubber tracks 5-33
Checking the track tension of the steel tracks (option) and hybrid tracks (option)
5-34
Adjusting track tension 5-34
Travelling drive 5-36
Checking the oil level and filling up oil 5-36
Draining oil 5-36
Maintenance of attachments 5-37
Electrical system 5-37
Service and maintenance work at regular intervals 5-37
Instructions concerning specific components 5-37
Alternator 5-37
Battery 5-38
General maintenance work 5-40
Cleaning 5-40
General instructions for all areas of the machine 5-40
Inside the cab 5-40
Cleaning the seat belt 5-41
Exterior of the machine 5-41
Engine compartment 5-41
Screw connections and attachments 5-41
Pivots and hinges 5-41
Overview of lubrication points 5-42
Parking the machine 5-43
Lubrication points on the boom, bucket and stick rams 5-43
Lubrication points on the boom and stick 5-44
Joint rod lubrication point 5-45
Lubrication points on the stabiliser blade and stabiliser blade ram 75Z3 5-45
Lubrication points of stabiliser blade ram 8003 5-46
Lubrication points on the slewing ram and swivelling console 5-46
Lubrication points of ball bearing race of live ring 5-47
Lubrication points of live ring teeth 5-48
Powertilt lubrication points (option) 5-49
Lubrication points of hydraulic quickhitch (option) 5-49
Lubrication points of control lever base (from serial no AJ02793) 5-50
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Table of contents
Central lubrication system (option) 5-51
Function 5-51
Status LEDs 5-51
Adjusting cycle time and lubrication time 5-52
Repair in case of clogging 5-52
Preparatory work before taking the machine out of service 5-53
Maintenance if the machine is out of service for a longer period of time 5-53
Putting into operation again 5-53
Fluids and lubricants 5-54
Oil grades for the diesel engine, depending on temperature 5-55
Additional oil change and filter replacement (hydraulic system) 5-55
Oil grades for the hydraulic system, depending on temperature 5-56
Maintenance plan (overview) 5-57
Maintenance label 5-62
Explanation of symbols on the maintenance label 5-62
Specifications
Chassis 6-1
Engine 6-1
Hydraulic system 6-2
Work hydraulics 6-2
Undercarriage and swivel unit 6-2
Stabiliser blade 6-3
Electrical system 6-3
Fuse box on instrument panel (75Z3/8003 up to serial no AD07209/AD07187)
6-3
Main fuse box with relays (75Z3/8003 up to serial no AD07209/AD07187) 6-3
Fuse box on instrument panel (75Z3/8003 serial nos AH00646/AH00611 to
AH02749/AH02747) 6-4
Main fuse box with relays (75Z3/8003 from serial no AH00646/AH00611) 6-4
Fuse box on instrument panel (75Z3/8003 from serial no AJ02793 /AH02798)
6-5
ECU control unit (75Z3/8003 from serial no AH00646/AH00611) 6-5
Noise levels 6-6
Vibration 6-6
Coolant compound table 6-6
Powertilt 6-7
Weight indications 6-7
Dimensions model 75Z3 6-8
Dimensions model 8003 Vario (option) 6-10
Dimensions model 8003 triple articulation boom (option) 6-12
Lift capacity table 75Z3 6-14
Lift capacity table 75Z3 counterweight (option) 6-15
Lift capacity table 75Z3 long stick (option) 6-16
Lift capacity table 75Z3 long stick, counterweight (option) 6-17
Lift capacity table 8003 6-18
Lift capacity table 8003 counterweight (option) 6-19
Lift capacity table 8003 long stick (option) 6-20
Lift capacity table 8003 long stick, counterweight (option) 6-21
Lift capacity table 8003 triple articulation boom (option) 6-22
Lift capacity table 8003 triple articulation boom, counterweight (option) 6-23
Lift capacity table 8003 long stick, triple articulation boom (option) 6-24
Lift capacity table 8003 long stick, triple articulation boom, counterweight (option)
6-25
Lift capacity table 8003 Vario (option) 6-26
Applications with lifting gear
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