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28Z3
Wacker Neuson 28Z3 Service Manual
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9-2
SHB 28Z
3 EN
– Edition 2.0
*
28z3schlussbl.fm
Wacker Neuson Linz
GmbH
Haidfeldstr. 37
A-4060 Linz-Leond
ing
Austria
Phone: +43 (0) 732 90
5 90-0
Fax: +43 (0) 732 90 5
90-200
E-mail: office.linz
@wackerneuson.com
www.wackerneuson.co
m
Order no. 1000178347
Language en
263
Table of Contents
Table of Contents
3
Notices on this Service Manual
12
Identification of Warnings and Dangers
13
Designated Use and Exemption from Liability
14
Type Labels and Component Numbers
15
Machine Overview
18
Cab Overview
19
Cab (Legend)
20
Instrument Panel Overview
21
Instrument Panel Legend
22
Overview of Open Engine and Valve Compartment
22
Engine Compartment: Overview
23
Chassis Overview
24
Valve Compartment
25
Stop and Park the Machine
26
Parking the Machine on Slopes
26
Specifications
27
Chassis
28
Engine
28
Fuel Injection Pump
28
Engine Capacities
29
Engine Tightening Torques
29
Hydraulic System
29
Work Hydraulics
29
Auxiliary Hydraulics Oil Flow 28Z3
30
Undercarriage and Swivel Unit
30
Stabiliser Blade
30
Electrical System
30
Noise Levels
31
Vibration
31
Coolant Compound Table
31
Powertilt
31
Model-Specific Tightening Torques
32
General Tightening Torques
32
Tightening Torques for Hydraulic Screw Connections (Dry Assembly)
32
Tightening Torques for High-Resistance Screw Connections
34
Dimensions Model 28Z3
36
Dimensions Model 28Z3 VDS
37
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
Kinematics
45
Maintenance
47
Fluids and Lubricants
48
Oil Grades for the Diesel Engine, Depending on Temperature
49
Additional Oil Change and Filter Replacement (Hydraulic System)
49
Oil Grades for the Hydraulic System, Depending on Temperature
50
Maintenance Label
51
Explanation of Symbols on the Maintenance Label
51
Maintenance Plan (Overview)
57
Service Package
57
Introduction
57
Safety-Relevant Parts
57
Fuel System
58
Refuelling
59
Emptying the Fuel Tank
59
Stationary Fuel Pumps
60
Diesel Fuel Specification
60
Bleeding the Fuel System
60
Water Separator
61
Replacing the Fuel Filter
62
Tank for Washer System
62
Engine Lubrication System
63
Checking the Oil Level
63
Filling up Engine Oil
64
Changing Engine Oil
65
Replacing the Engine Oil Filter Cartridge
66
Engine and Hydraulics Cooling System
67
Specific Safety Instructions
67
Checking/Filling up Coolant
68
Checking the Coolant Level
68
Filling up Coolant
69
Draining Coolant
69
Air Filter
70
Replacing Air Filter Elements
70
Air Intake
72
Change Cab Air Filter
73
V-Belt
74
Checking V-Belt Tension
74
Retightening the V-Belt
75
Pressure Check
77
General
77
Overview of Measuring Ports (up to Serial Number AG02712)
77
Overview of Measuring Ports (from Serial Number AG02713)
77
Checking Pilot Control Pressure
78
Pressure Check of Variable Displacement Pump P1
79
Pressure Check of Variable Displacement Pump P2
80
Pressure Check of Gear Pump P3
81
Secondary Pressure Limiting Valve of the Gear Motor
82
Primary Pressure Limiting Valves
82
Hydraulic System
87
Specific Safety Instructions
87
Checking the Hydraulic Oil Level
88
Filling up Hydraulic Oil
89
Changing Hydraulic Oil
90
Monitoring the Hydraulic Oil Return Filter
90
Replacing the Hydraulic Oil Filter
91
Draining Condensation Water from the Hydraulic Oil Tank
91
Important Information for the Use of Biodegradable Oil
92
Checking Hydraulic Pressure Lines
93
Pilot Valve
94
Travelling Drive
95
Checking the Oil Level and Filling up Oil
95
Draining Oil
95
Tracks
96
Checking Track Tension
96
Adjusting Track Tension
97
Maintenance of Attachments
98
Lubrication Points
98
Parking the Machine
98
Overview of Lubrication Points
99
Lubrication Points on the Stabiliser Blade and Stabiliser Blade Ram
100
Lubrication Points on the Swivelling Console and Slewing Ram
100
Lubrication Points on the Boom, Bucket and Stick Rams
101
Lubrication Points on the Boom and Stick
102
Lubrication Point on the Joint Rod
102
Lubrication Point on Ball Bearing Race of Live Ring
103
Lubrication Point of Live Ring Teeth
103
Lubrication Point of VDS Live Ring Teeth
104
VDS Lubrication Points (Option)
105
Powertilt Lubrication Points (Option)
105
Lubrication Points of Hydraulic Quickhitch (Option)
106
Lubrication Points of Mechanical Quickhitch (Option)
106
Cab
106
Electrical System
107
Service and Maintenance Work at Regular Intervals
107
Instructions Concerning Specific Components
107
Alternator
107
Battery
108
General Maintenance Work
109
Cleaning
109
General Instructions for All Areas of the Machine
109
Inside the Cab
109
Cleaning the Seat Belt
109
Exterior of the Machine
110
Engine Compartment
110
Shatter Protection
110
Screw Connections and Attachments
110
Pivots and Hinges
110
Preparatory Work before Taking out of Service
111
Maintenance if the Machine Is out of Service for a Longer Period of Time
111
Putting into Operation Again
111
Fire Extinguisher
112
Engine
113
3TNV76-NNS Engine Overview
114
Fuel System
116
Cooling System
117
Checking and Adjusting Valve Clearance
118
Lapping the Intake and Exhaust Valves
119
Tightening Order for Cylinder Head Bolts
119
Order for Removing the Cylinder-Head Bolts
119
Order for Mounting the Cylinder-Head Bolts
119
Checking the Injection Nozzles
120
Pressure Check
120
Checking the Nozzle Jet
121
Injection Time
121
Checking Injection Time
121
Setting Injection Time
123
Removing and Installing the Injection Pump
124
Removing the Injection Pump
124
Fitting the Injection Pump
125
Measuring and Adjusting the Engine Speed
126
Compression
126
Checking the Coolant Thermostat
127
Checking the Thermal Switch
127
Oil Pressure Switch
128
Checking the Coolant Circuit
128
Cleaning the Cooling Water Channels
128
Coolant and Fuel Hoses
128
Crankcase Vent
129
Replacing the Glow Plugs
129
Engine Trouble
130
Hydraulic System
133
Hydraulic Pump PVD-0B-23BP-8G3-5083A
134
Pump Unit: Exploded View
136
Pilot Oil Supply Unit
137
Dismantling the Hydraulic Pump
138
Assembling the Hydraulic Pump
140
Troubleshooting on the Hydraulic Pump
144
Main Valve Block
145
Ports
145
Main Control Lines (Legend)
146
Pump/Tank Lines
146
Main Valve Block Diagram
147
Pressure Limiting Valves
148
Pump Assignment
149
Drive Counterbalancing System
150
Pump Assignment for Drive Counterbalancing
150
Regeneration - Stick Section
151
Bucket Pre-Tension
151
Auxiliary Hydraulics Flow Rate Adjustment
152
Travelling Drive
153
Function
154
Swivel Unit
156
Swivel Unit Brake
157
Swivel Joint
159
Replace the Sealing Rings
159
Swivel Joint VDS (Option)
160
Pilot Valves
161
Joystick
161
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 Filter
166
Auxiliary Hydraulics Connections
167
Troubleshooting in the Hydraulic System
168
Electrical System
175
Ohm's Law (Current, Voltage, Resistance); Power
176
Measuring Equipment, Measuring Methods
176
Cable Colour Coding
177
Relays
177
Use, Mode of Function
177
Socket
178
Electric Units
178
Fuse Box
178
Alternator
179
Starter
179
Switches: Overview
180
Switch Legend
180
Cigarette Lighter
181
Radio and Mounting/Wiring for Radio Installation (Option)
181
Front Working Light
182
Cab Lights (Option)
182
Rotating Beacon (Option)
183
Driving Signal (Option)
183
Driving Signal Wiring Harness (Option)
183
Counterweight
202
Specifications
202
Long Stick
202
Automatic Engine Speed Setting
203
Installation
204
Grab Pipework
205
Attachments
205
3Rd Control Circuit/Powertilt Ports
206
Safe Load Indicator
207
Safe Load Indicator de (from Serial No. AG04828) (Safety Valves for Boom)
208
Safe Load Indicator de (up to Serial No. AG02443)
210
Function
210
Setting the Pressure Switch
211
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
Function
214
Diagram (from Serial No. AG04828)
215
Diagram (Serial Nos. AG02444 to AG04827)
216
Diagram (up to Serial No. AG02443)
216
Setting the Pressure Switch
217
Hose Burst Valve Safety Feature
218
Mechanical Quickhitch
219
Hydraulic Quickhitch (Easy Lock)
220
3Rd Control Circuit
220
Function
220
Diagram
220
Drive Interlock (Antitheft Protection)
221
Position
221
Disabling the Drive Interlock
221
Enabling the Drive Interlock
221
Programming
221
Proportional Controls
223
Function
223
Ports
224
Measures to be Taken in Case of Malfunctions
224
Left-Hand Control Lever
224
Boom Swivel Controls
225
Auxiliary Hydraulics
225
Hammer Operation
225
Adjusting Control Response
226
Characteristic Curves - Status Indicator
226
Wiring Harness
227
Control Unit Connector Assignment
227
Measures to be Taken in Case of Malfunctions
228
Diagnosis Display
228
Engine Oil Service Valve
229
Function
229
Powertilt PTS06 General Instructions
232
General Safety Instructions
232
Checking the Product
233
Internal Decompression Valve
233
Testing the Hydraulic System of the Machine
233
Specifications/Requirements
234
Tools
235
Making a Tool VI for Removing the Seals
236
Separating the Bucket or Equipment from the Powertilt Swivel Device
236
Separating the Powertilt Swivel Device from the Machine
236
Exploded Views PTS06
237
PTS06 Components
237
Sealing Kit a and Bearing Kit B PTS06 (Overview)
238
Assembly Drawing
239
Removing the Standard Journal Coupling
240
Removing the End Cap, Securing Ring and Internal Decompression Valve
242
Removing the Shaft
243
Removing the Piston Tube Body
244
Removing the Seals (Kit A), Shaft Bearings and Pressure Discs (Kit B)
245
Checking Components and Dead Centre Marks
246
Trial Assembly
247
Installing the Seals (Kit A), Shaft Bearings and Pressure Discs (Kit B)
247
Installing the End-Cap Seals and Bearings
248
Installing the Piston Seals and Bearings
249
Fitting the Shaft Seal and the Bearing
250
Installing the Piston Tube
251
Installing the Shaft
252
Installing the End Cap and the Securing Ring
253
Installing the Internal Decompression Valve
254
Installing the Standard Journal Coupling
254
Lubrication and Tests
257
Lubrication
257
Test for Internal Leaks
257
Testing the Internal Decompression Valve
258
Securing the Powertilt Swivel Device on the Machine
259
Fitting a Bucket or Equipment Onto the Powertilt Swivel Device
259
Troubleshooting
260
Adjusting the Play on the Powertilt
261
Checking the Circumferential Play
261
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Wacker Neuson 28Z3 Specifications
General
Brand
Wacker Neuson
Model
28Z3
Category
Excavators
Language
English
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