Wacker Neuson 28Z3

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Table of Contents3
Notices on this Service Manual12
Identification of Warnings and Dangers13
Designated Use and Exemption from Liability14
Type Labels and Component Numbers15
Machine Overview18
Cab Overview19
Cab (Legend)20
Instrument Panel Overview21
Instrument Panel Legend22
Overview of Open Engine and Valve Compartment22
Engine Compartment: Overview23
Chassis Overview24
Valve Compartment25
Stop and Park the Machine26
Parking the Machine on Slopes26
Specifications27
Chassis28
Engine28
Fuel Injection Pump28
Engine Capacities29
Engine Tightening Torques29
Hydraulic System29
Work Hydraulics29
Auxiliary Hydraulics Oil Flow 28Z330
Undercarriage and Swivel Unit30
Stabiliser Blade30
Electrical System30
Noise Levels31
Vibration31
Coolant Compound Table31
Powertilt31
Model-Specific Tightening Torques32
General Tightening Torques32
Tightening Torques for Hydraulic Screw Connections (Dry Assembly)32
Tightening Torques for High-Resistance Screw Connections34
Dimensions Model 28Z336
Dimensions Model 28Z3 VDS37
Lift Capacity Table 28Z3 (Short Stick)39
Lift Capacity Table 28Z3 Long Stick (Option)40
Lift Capacity Table 28Z3 Short Stick and Extra Weight (Option)41
Lift Capacity Table 28Z3 Long Stick (Option) and Extra Weight (Option)42
Lift Capacity Table 28Z3 VDS (Short Stick)43
Lift Capacity Table 28Z3 Long Stick VDS (Option)44
Kinematics45
Maintenance47
Fluids and Lubricants48
Oil Grades for the Diesel Engine, Depending on Temperature49
Additional Oil Change and Filter Replacement (Hydraulic System)49
Oil Grades for the Hydraulic System, Depending on Temperature50
Maintenance Label51
Explanation of Symbols on the Maintenance Label51
Maintenance Plan (Overview)57
Service Package57
Introduction57
Safety-Relevant Parts57
Fuel System58
Refuelling59
Emptying the Fuel Tank59
Stationary Fuel Pumps60
Diesel Fuel Specification60
Bleeding the Fuel System60
Water Separator61
Replacing the Fuel Filter62
Tank for Washer System62
Engine Lubrication System63
Checking the Oil Level63
Filling up Engine Oil64
Changing Engine Oil65
Replacing the Engine Oil Filter Cartridge66
Engine and Hydraulics Cooling System67
Specific Safety Instructions67
Checking/Filling up Coolant68
Checking the Coolant Level68
Filling up Coolant69
Draining Coolant69
Air Filter70
Replacing Air Filter Elements70
Air Intake72
Change Cab Air Filter73
V-Belt74
Checking V-Belt Tension74
Retightening the V-Belt75
Pressure Check77
General77
Overview of Measuring Ports (up to Serial Number AG02712)77
Overview of Measuring Ports (from Serial Number AG02713)77
Checking Pilot Control Pressure78
Pressure Check of Variable Displacement Pump P179
Pressure Check of Variable Displacement Pump P280
Pressure Check of Gear Pump P381
Secondary Pressure Limiting Valve of the Gear Motor82
Primary Pressure Limiting Valves82
Hydraulic System87
Specific Safety Instructions87
Checking the Hydraulic Oil Level88
Filling up Hydraulic Oil89
Changing Hydraulic Oil90
Monitoring the Hydraulic Oil Return Filter90
Replacing the Hydraulic Oil Filter91
Draining Condensation Water from the Hydraulic Oil Tank91
Important Information for the Use of Biodegradable Oil92
Checking Hydraulic Pressure Lines93
Pilot Valve94
Travelling Drive95
Checking the Oil Level and Filling up Oil95
Draining Oil95
Tracks96
Checking Track Tension96
Adjusting Track Tension97
Maintenance of Attachments98
Lubrication Points98
Parking the Machine98
Overview of Lubrication Points99
Lubrication Points on the Stabiliser Blade and Stabiliser Blade Ram100
Lubrication Points on the Swivelling Console and Slewing Ram100
Lubrication Points on the Boom, Bucket and Stick Rams101
Lubrication Points on the Boom and Stick102
Lubrication Point on the Joint Rod102
Lubrication Point on Ball Bearing Race of Live Ring103
Lubrication Point of Live Ring Teeth103
Lubrication Point of VDS Live Ring Teeth104
VDS Lubrication Points (Option)105
Powertilt Lubrication Points (Option)105
Lubrication Points of Hydraulic Quickhitch (Option)106
Lubrication Points of Mechanical Quickhitch (Option)106
Cab106
Electrical System107
Service and Maintenance Work at Regular Intervals107
Instructions Concerning Specific Components107
Alternator107
Battery108
General Maintenance Work109
Cleaning109
General Instructions for All Areas of the Machine109
Inside the Cab109
Cleaning the Seat Belt109
Exterior of the Machine110
Engine Compartment110
Shatter Protection110
Screw Connections and Attachments110
Pivots and Hinges110
Preparatory Work before Taking out of Service111
Maintenance if the Machine Is out of Service for a Longer Period of Time111
Putting into Operation Again111
Fire Extinguisher112
Engine113
3TNV76-NNS Engine Overview114
Fuel System116
Cooling System117
Checking and Adjusting Valve Clearance118
Lapping the Intake and Exhaust Valves119
Tightening Order for Cylinder Head Bolts119
Order for Removing the Cylinder-Head Bolts119
Order for Mounting the Cylinder-Head Bolts119
Checking the Injection Nozzles120
Pressure Check120
Checking the Nozzle Jet121
Injection Time121
Checking Injection Time121
Setting Injection Time123
Removing and Installing the Injection Pump124
Removing the Injection Pump124
Fitting the Injection Pump125
Measuring and Adjusting the Engine Speed126
Compression126
Checking the Coolant Thermostat127
Checking the Thermal Switch127
Oil Pressure Switch128
Checking the Coolant Circuit128
Cleaning the Cooling Water Channels128
Coolant and Fuel Hoses128
Crankcase Vent129
Replacing the Glow Plugs129
Engine Trouble130
Hydraulic System133
Hydraulic Pump PVD-0B-23BP-8G3-5083A134
Pump Unit: Exploded View136
Pilot Oil Supply Unit137
Dismantling the Hydraulic Pump138
Assembling the Hydraulic Pump140
Troubleshooting on the Hydraulic Pump144
Main Valve Block145
Ports145
Main Control Lines (Legend)146
Pump/Tank Lines146
Main Valve Block Diagram147
Pressure Limiting Valves148
Pump Assignment149
Drive Counterbalancing System150
Pump Assignment for Drive Counterbalancing150
Regeneration - Stick Section151
Bucket Pre-Tension151
Auxiliary Hydraulics Flow Rate Adjustment152
Travelling Drive153
Function154
Swivel Unit156
Swivel Unit Brake157
Swivel Joint159
Replace the Sealing Rings159
Swivel Joint VDS (Option)160
Pilot Valves161
Joystick161
Pilot Valve (Driving)162
Changeover Valve for SAE/ISO Controls (Option)164
Proportional Valve (Option)164
Changeover Valve VDS (Option)165
3/2 Directional Valve (Option)165
Easy Lock Valve (Option)165
Hydraulic Oil Tank Service Valve (Option)166
Breather Filter166
Auxiliary Hydraulics Connections167
Troubleshooting in the Hydraulic System168
Electrical System175
Ohm's Law (Current, Voltage, Resistance); Power176
Measuring Equipment, Measuring Methods176
Cable Colour Coding177
Relays177
Use, Mode of Function177
Socket178
Electric Units178
Fuse Box178
Alternator179
Starter179
Switches: Overview180
Switch Legend180
Cigarette Lighter181
Radio and Mounting/Wiring for Radio Installation (Option)181
Front Working Light182
Cab Lights (Option)182
Rotating Beacon (Option)183
Driving Signal (Option)183
Driving Signal Wiring Harness (Option)183
Counterweight202
Specifications202
Long Stick202
Automatic Engine Speed Setting203
Installation204
Grab Pipework205
Attachments205
3Rd Control Circuit/Powertilt Ports206
Safe Load Indicator207
Safe Load Indicator de (from Serial No. AG04828) (Safety Valves for Boom)208
Safe Load Indicator de (up to Serial No. AG02443)210
Function210
Setting the Pressure Switch211
Safe Load Indicator FR (from Serial No. AG04828) (Safety Valves for Boom, Stick and Stabiliser Blade)212
Safe Load Indicator FR (Serial Nos. AG02444 to AG04827) (Safety Valves for Boom, Stick and Stabiliser Blade)213
Safe Load Indicator FR (up to Serial No. AG02443)214
Function214
Diagram (from Serial No. AG04828)215
Diagram (Serial Nos. AG02444 to AG04827)216
Diagram (up to Serial No. AG02443)216
Setting the Pressure Switch217
Hose Burst Valve Safety Feature218
Mechanical Quickhitch219
Hydraulic Quickhitch (Easy Lock)220
3Rd Control Circuit220
Function220
Diagram220
Drive Interlock (Antitheft Protection)221
Position221
Disabling the Drive Interlock221
Enabling the Drive Interlock221
Programming221
Proportional Controls223
Function223
Ports224
Measures to be Taken in Case of Malfunctions224
Left-Hand Control Lever224
Boom Swivel Controls225
Auxiliary Hydraulics225
Hammer Operation225
Adjusting Control Response226
Characteristic Curves - Status Indicator226
Wiring Harness227
Control Unit Connector Assignment227
Measures to be Taken in Case of Malfunctions228
Diagnosis Display228
Engine Oil Service Valve229
Function229
Powertilt PTS06 General Instructions232
General Safety Instructions232
Checking the Product233
Internal Decompression Valve233
Testing the Hydraulic System of the Machine233
Specifications/Requirements234
Tools235
Making a Tool VI for Removing the Seals236
Separating the Bucket or Equipment from the Powertilt Swivel Device236
Separating the Powertilt Swivel Device from the Machine236
Exploded Views PTS06237
PTS06 Components237
Sealing Kit a and Bearing Kit B PTS06 (Overview)238
Assembly Drawing239
Removing the Standard Journal Coupling240
Removing the End Cap, Securing Ring and Internal Decompression Valve242
Removing the Shaft243
Removing the Piston Tube Body244
Removing the Seals (Kit A), Shaft Bearings and Pressure Discs (Kit B)245
Checking Components and Dead Centre Marks246
Trial Assembly247
Installing the Seals (Kit A), Shaft Bearings and Pressure Discs (Kit B)247
Installing the End-Cap Seals and Bearings248
Installing the Piston Seals and Bearings249
Fitting the Shaft Seal and the Bearing250
Installing the Piston Tube251
Installing the Shaft252
Installing the End Cap and the Securing Ring253
Installing the Internal Decompression Valve254
Installing the Standard Journal Coupling254
Lubrication and Tests257
Lubrication257
Test for Internal Leaks257
Testing the Internal Decompression Valve258
Securing the Powertilt Swivel Device on the Machine259
Fitting a Bucket or Equipment Onto the Powertilt Swivel Device259
Troubleshooting260
Adjusting the Play on the Powertilt261
Checking the Circumferential Play261

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