Wacker Neuson EW65 Mobile Excavator Service Manual – PDF DOWNLOAD
FILE DETAILS:
Wacker Neuson EW65 Mobile Excavator Service Manual – PDF DOWNLOAD
Language : English
Pages : 362
Downloadable : Yes
File Type : PDF
Size: 15.5 MB
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DESCRIPTION:
Wacker Neuson EW65 Mobile Excavator Service Manual – PDF DOWNLOAD
Model E14-02
Edition 1.0
Language en
Article number 1000353770
Operation:
1.1 Information 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 Operator’s 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 by
these modifications shall not be applicable.
• Subject to modifications and printing errors.
Your Wacker Neuson’s technical support will be happy to answer any further questions
regarding the machine or the service manual.
TABLE OF CONTENTS:
Wacker Neuson EW65 Mobile Excavator Service Manual – PDF DOWNLOAD
1 Operation 12
1 1 Information on this service manual 12
1 2 Identification of warnings and dangers 13
1 3 Explanation of symbols and abbreviations 13
Abbreviations 14
Conversion table 15
1 4 Warranty and liability 16
Exemption from warranty and liability 16
1 5 Labels 17
Type labels 17
1 6 Machine overview 21
1 7 Engine compartment (overview) 22
1 8 Chassis overview 23
1 9 Battery master switch 24
2 Technical data 26
2 1 Engine 26
2 2 Traveling drive/axles 27
2 3 Brakes 27
2 4 Tires 28
2 5 Steering system 28
2 6 Operating and machine-travel hydraulics 29
2 7 Travel speed 31
Road-travel mode 31
Operating mode 31
2 8 Electrical system 32
Electrical components 32
Main fuse box 32
Cabin fuse box 33
2 9 Bulbs 34
2 10 Auxiliary hydraulics performance measurement 34
2 11 Payload/stability 35
2 12 Model-specific tightening torques 35
Model-specific tightening torques 35
General tightening torques 36
Tightening torques for high-resistance threaded fittings 38
2 13 Hose identification code 39
2 14 Coolant 39
Compound table 39
2 15 Noise emissions 40
2 16 Vibration 40
2 17 Weight 41
Machine weight 41
Weight of attachments 41
Excavator forces 41
Ground clearance 41
2 18 Dimensions 42
EW65 one-piece boom (overview) 42
EW65 triple articulation boom (overview) 44
2 19 Kinematics 46
2 20 Overload setting 47
3 Maintenance 50
3 1 Special tools 50
3 2 Fluids and lubricants 50
Oil types for hydraulic system (depending on temperature) 51
Engine oil types Tier III (temperature dependent) 52
Engine oil types Tier IV (temperature dependent) 52
3 3 Important information regarding operation with biodegradable oil 52
3 4 Maintenance overview 53
Upper carriage maintenance label 53
Travel gear maintenance label 54
3 5 Maintenance plan 55
3 6 Information on maintenance 61
Responsibilities and prerequisites 61
Important safety instructions on maintenance 61
3 7 Maintenance accesses 62
Engine cover 62
Valve cover 63
Tilting the cabin 64
Lowering the cabin 66
Cabin fuse box 67
Main fuse box 68
Underbody maintenance cover 68
3 8 Cabin 69
Checking the adhesive labels and Operator’s Manual 69
Fire extinguisher 69
3 9 Interlocks 70
3 10 General engine information 71
Checking the engine control, warning system 71
Checking the cold starter 71
Checking valve clearance and adjusting it if necessary 72
Performing a visual check of the engine bearings 72
3 11 Fuel system 73
Important information regarding the fuel system 73
Diesel fuel specification 73
Refueling 73
Checking the sintered metal filter of the fuel tank 76
Fuel prefilter with water separator 76
Emptying the water separator 77
Changing the fuel prefilter 77
Replacing the fuel filter 78
Checking the injection pump and adjusting it if necessary 78
Bleeding the fuel system 78
Draining/pumping off the fuel 79
3 12 Engine lubrication system 80
Important information regarding the engine lubrication system 80
Checking the engine oil level 80
Adding engine oil 80
Changing engine oil 81
Replacing the engine-oil filter cartridge 82
3 13 Cooling system 84
Important information regarding the cooling system 84
Checking the coolant level 85
Adding coolant 85
Draining coolant 86
Checking the antifreeze 87
Replace the radiator cap 87
Checking the water pump 88
Replacing the water pump 88
Replacing the coolant thermostat 88
Cleaning the radiator 90
Air conditioning 91
Specific safety instructions 91
Filling the air conditioning system 91
Replacing the dehumidifier of the air conditioning 92
Checking the air-conditioning compressor threaded fittings 92
3 14 Air filter 93
Important information regarding the air filter 93
Air filter monitoring 93
Checking the intake air line for contaminants and damage 93
Replacing the air filter 94
Checking the air intake 95
Replacing the cabin air filter 95
3 15 Washer system 96
Checking the fluid level and adding fluid 96
3 16 V-belt 97
Checking the V-belt/tension 97
Retensioning the V-belt 98
Replacing the V-belt 98
Checking the V-belt of the air conditioning system 99
Tensioning the V-belt of the air conditioning system (option) 99
Replacing the V-belt of the air conditioning system 99
3 17 Crankcase vent 100
Replacing the crankcase breather filter (Perkins engine 404F-22T) 100
Replacing the crankcase breather filter (Perkins engine 404D-22T) 100
3 18 Gearboxes and axles 101
Checking the differential-oil level on the 20 kph rear axle 101
Replacing the differential oil on the 20 kph rear axle 101
Checking the transfer gearbox oil level on the 20 kph rear axle 102
Replacing the transfer gearbox oil on the 20 kph rear axle 102
Checking the differential-oil level on the 30 kph rear axle 103
Replacing the differential oil on the 30 kph rear axle 103
Checking the selector gearbox oil level on the 30 kph rear axle 104
Replacing the selector gearbox oil on the 30 kph rear axle 104
Checking the front axle differential oil level 105
Changing the front axle differential oil 105
3 19 Planetary drive 106
Checking the planetary drive oil level and adding oil 106
Changing the planetary drive oil 107
3 20 Exhaust system 108
Replacing the diesel particulate filter 109
Replacing the fuel-burner glow plug (exhaust-gas treatment device) 109
Check the exhaust-gas turbocharger 110
3 21 Hydraulic system 111
Important information on the hydraulic system 111
Releasing the pressure in the operating hydraulics 112
Emergency lowering 112
Checking the hydraulic oil level 113
Adding hydraulic oil 114
Changing hydraulic oil 115
Changing the hydraulic oil filter element 116
Draining condensation water from the hydraulic oil reservoir 117
Replacing the hydraulic oil reservoir breather filter 117
Check the bladder-type accumulator 117
Replacing the pressure filter of the steering system/brake 118
Replacing the traveling drive supply-pressure filter 119
Checking the hydraulic system and hoses 120
3 22 Checking the hydraulic system pressure 121
General 121
Prerequisites for pressure check 121
Measurement connections (overview) 122
Checking the pilot control pressure 122
Checking the LS pressure limiting valve 122
Setting the LS pressure limiting valve on the main valve block 123
Setting the secondary pressure limiting valve (PLV) 123
Checking the secondary pressure limiting valve on the gear motor 123
Checking the standby pressure (circulation pressure) 123
Checking the pressure difference (delta P) 124
3 23 Test report, pressure test (in operating mode) 125
3 24 Measuring live ring tolerance 126
3 25 Maintenance of attachments 127
Load hook wear 127
Check the Powertilt axial play 127
3 26 Lubrication work 128
Preparing lubrication 128
One-piece boom lubrication schedule 129
Triple articulation boom lubrication schedule 131
Lubrication schedule, travel gear 133
Cabin lubrication schedule 134
Powertilt lubrication schedule 135
Powertilt with Easy Lock – operation in water 135
Steering housing lubrication 136
Cardan shaft lubrication 137
Oscillating axle bearing mount lubrication 137
Lubricating the live ring (ball bearing race) 138
Lubricating the teeth of the live ring 139
Control lever base lubrication points 140
Lubrication points for oscillating-axle cylinder 140
Maintenance of attachments 140
3 27 Tires 141
Inspection work 141
Tires 141
Removing the wheels 142
Mounting the wheels 142
3 28 Electrical system 143
Important information regarding the electrical system 143
Fuses and relays 144
Checking electric cables and connectors 144
Battery state of charge 145
Charging the battery 145
Replacing the battery 145
3 29 Cleaning and maintenance 146
Information on cleaning and maintenance 147
Inside the cabin 147
Cleaning outside the machine 148
Cleaning the engine compartment 148
Cleaning the seat belt 148
Cleaning the machine in a saline environment 148
Threaded fittings and attachments 148
3 30 Resetting the maintenance meter 149
4 Engine 152
4 1 Perkins engine 404F-22T/404D-22T 152
Engine overview 152
Exhaust-gas treatment system 153
Fuel injection system 154
Engine malfunctions 155
5 Traveling drive 160
5 1 Traveling drive overview 160
Traveling drive (20 kph or 30 kph) 160
5 2 Traveling drive circuit (20 kph) 161
5 3 Traveling drive circuit (30 kph) 162
5 4 Towing the machine 163
5 5 Machine repair after towing 163
Enabling the pressure limiting valves 163
Enabling the mechanical hydraulic parking brake 163
5 6 Loading the machine 164
Driving onto transport vehicles 164
6 Brakes 168
6 1 Service brake 168
6 2 Parking brake 169
7 Steering system 172
7 1 Front axle steering 172
8 Hydraulic system 174
8 1 Overview of components 174
8 2 Hydraulic oil reservoir 175
Components 175
8 3 Pump unit 176
8 4 Hydraulic pump 177
Variable displacement pump design 178
Malfunctions of the hydraulic pump 179
8 5 Hydraulic pump 180
8 6 Gear pump for steering system/brakes 181
8 7 Pilot oil supply unit 20 kph 182
8 8 Pilot oil supply unit 30 kph 183
8 9 Main control block 184
Features 184
Main control block functions 184
Diagram 185
Main control block connections 186
8 10 Input segment 187
Input segment diagram 187
Inlet segment (exploded view) 188
8 11 Swivel unit 189
8 12 Swivel joint 190
8 13 Counterbalance valves 191
Counterbalance valve 4 (stabilizer blade) 191
Counterbalance valves 4 (parallel blade) 192
Counterbalance valve 1 (boom swivel) 193
Counterbalance valves 2 and 3 (triple articulation boom) 193
8 14 Hose burst valves 1 and 2 194
8 15 Joysticks left and right 195
8 16 Pedals 196
Left pedal, triple articulation boom C010 196
Right pedal, brake C013 197
8 17 4-fold proportional valve C018 198
8 18 3rd control circuit C019 199
8 19 Shuttle valve block 200
8 20 Steering valve 201
8 21 Stabilizer leg valve (2-fold) 202
8 22 Stabilizer leg valve, 4-fold 203
8 23 Performance measurement 204
Prerequisites for performance measurement 204
Auxiliary hydraulics flow rate EW65 204
3rd control circuit flow rate EW65 206
9 Electrical system 208
9 1 Ohm’s Law (current, voltage, resistance); power 208
9 2 Measuring equipment, measuring methods 208
9 3 Cable color coding 209
9 4 Relays 210
Use, mode of function 210
9 5 Electrical system 210
Alternator 210
Starter 210
9 6 Chassis wiring harness legend E14 Perkins 404D Tier III 212
9 7 Chassis wiring harness E14 Perkins 404D Tier III 215
9 8 Chassis wiring harness legend E14 Perkins 404D Tier IV 217
9 9 Chassis wiring harness E14 Perkins 404F Tier IV 221
9 10 Chassis wiring harness legend (also for stabilizers) 223
9 11 Travel gear wiring harness 224
9 12 Chassis wiring harness with stabilizers 225
9 13 Boom light wiring harness 227
9 14 Safe load indicator wiring harness 228
9 15 Cabin wiring harness (legend) 229
9 16 Cabin wiring harness 231
9 17 Steering column wiring harness legend 232
9 18 Steering column wiring harness 233
9 19 Seat console wiring harness legend 234
9 20 Seat console wiring harness 238
9 21 Numberplate light wiring harness 240
9 22 Wiring harness legend 7” display 241
9 23 Wiring harness 7” display 242
9 24 Air conditioning wiring harness 243
9 Wiring harnesses (overview) 211
10 Diagrams 244
11 Air conditioning 326
Specific safety instructions 326
Overview 327
Air conditioning components 327
Filling up the air conditioning system 328
Malfunctions 329
12 Air-suspension comfort seat 332
Connections 332
13 Stick 333
13 1 Long stick 333
14 Service valve 334
Function 334
15 “Hose burst valve” safety feature 335
Hose burst valve 335
16 Telematic 336
Connections 336
Functional check/diode 336
17 Diagnosis code list (SPN) 337
17 1 Diagnosis code list (SPN) 338
ED EW65 Tier3_03 pdf 0
Stromlaufplan 251
0 251
1 | ECU Fahrzeug 252
2 | ECU Motor 253
3 | Zentralelektriken 254
4 | Zentralelektriken 255
5 | Hauptversorgung 256
6 | Versorgung ECU-Motor 257
7 | Starten, Glühen 258
8 | ECU Dieselmotor 259
9 | IO Dieselmotor 260
10 | IO Dieselmotor 261
11 | Masse Controller 262
12 | Zündung 263
13 | Ladekontrolle, Dieseltank 264
14 | CAN Motor 265
15 | CAN Fahrzeug 266
16 | Versorgung Contoller 267
17 | Joystick rechts 268
18 | Steuerhebel rechts 269
19 | Joystick links 270
20 | Steuerhebel links 271
21 | Steuerhebel links 272
22 | Sensoren 273
23 | Steuerung Relais 274
24 | Arbeitsbeleuchtung 275
25 | Wischer, Radio 276
26 | Ventile Prop 277
27 | Ventile 278
28 | Ventile, Sitz, Steckdosen 279
29 | Heizung Klima 280
30 | Haizung Klima 281
31 | Fahrantrieb (EW) 282
32 | Fahrantrieb (EW) 283
33 | Fahrantrieb (EW) 284
34 | Blinker 285
35 | STVO Beleuchtung 286
36 | Display 7″ 287
ED EW65 Tier4_02 pdf 0
Stromlaufplan 289
0 289
1 290
2 291
3 292
4 293
5 | Hauptversorgung 294
6 | Versorgung ECU-Motor 295
7 | Starten, Glühen 296
8 | ECU Dieselmotor 297
9 | IO Dieselmotor 298
10 | IO Dieselmotor 299
11 | Masse Controller 300
12 | Zündung 301
13 | Ladekontrolle, Dieseltank 302
14 | CAN Motor 303
15 | CAN Fahrzeug 304
16 | Versorgung Contoller 305
17 | Joystick rechts 306
18 | Steuerhebel rechts 307
19 | Joystick links 308
20 | Steuerhebel links 309
21 | Steuerhebel links 310
22 | Sensoren 311
23 | Steuerung Relais 312
24 | Arbeitsbeleuchtung 313
25 | Wischer, Radio 314
26 | Ventile Prop 315
27 | Ventile 316
28 | Ventile, Sitz, Steckdosen 317
29 | Heizung Klima 318
30 | Haizung Klima 319
31 | Fahrantrieb (EW) 320
32 | Fahrantrieb (EW) 321
33 | Fahrantrieb (EW) 322
34 | Blinker 323
35 | STVO Beleuchtung 324
36 | Display 7″ 325
PLEASE NOTE:
- 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.V