Wacker Neuson EZ38

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1-6 OM EZ38 us 1.1 * ez38v100.fm

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Table of Contents3
EC Declaration of Conformity (Tier IV Interim)5
Operator's Manual7
Explanation of Symbols and Abbreviations8
Conversion Table10
Warranty and Liability11
Safety Information13
Safety Symbols Found in this Manual13
Designated Use14
Warranty14
Preparing to Use the Machine15
Conditions for Use15
Operator Training and Knowledge15
Modifications and Spare Parts16
Applications with Lifting Gear16
Instructions on Fastening Loads16
General Instructions17
Safety Instructions Regarding Operation18
Operator/Machine Owner Responsibility18
Repair Person Qualifications18
Operator and Technician Qualifications and Basic Responsibilities18
Starting and Stopping19
Job Site Awareness19
Danger Zone Awareness20
Operating the Machine20
Carrying Passengers20
Mechanical Integrity20
Traveling21
General Information21
Safety Criteria21
Conditions for Safe Operation21
Applications with Lifting Gear21
Attachments22
General Information Regarding Attachments22
Installation Notes22
Transport and Towing23
Safety Guidelines for Maintenance23
General Maintenance Notes23
Personal Safety Measures23
Preparing for Maintenance and Repair Work24
Performing Maintenance and Repairs24
Tracks26
Electric Energy26
Hydraulics27
Noise27
Msds27
Gas, Dust, Steam, Smoke27
Safety Guidelines During Using Internal Combustion Engines28
Running the Engine28
Fueling the Engine28
Machine Overview29
Brief Description of the Machine30
Schock Cartridges for Auxiliary Hydraulics (Option)30
Zero Tail30
Cooling System30
Cabin/Canopy31
Definition of Fops/Front Guard Categories31
Notices and Regulations on Use32
Fields of Application and Use of Attachments33
EZ38 Without Quickhitch33
EZ38 with Hydraulic Easy Lock Quickhitch33
EZ38 Equipment34
Labels35
Type Labels35
Serial Number35
Cabin Number36
Engine Number36
Hydraulic Quickhitch36
Powertilt with Hydraulic Quickhitch36
FOPS Type Label – Large Screen37
FOPS Type Label – Small Screen37
Front Guard Type Label37
Warning Labels38
Safety Instructions Regarding Entry and Exit49
Cabin Entry and Exit (Option)49
Putting into Operation 4.1 Cabin/Control Stand49
Locking and Unlocking the Door50
Opening the Door from the Inside50
Securing an Open Door51
Releasing the Door Arrester51
Opening/Closing the Front Window52
Closing the Front Window53
Opening the Lower Front Window54
Closing the Lower Front Window54
Opening the Whole Front Window55
Closing the Whole Front Window56
Opening the Front Window to a Gap (Ventilation Position)57
Opening/Closing the Side Window57
Emergency Exit58
Seat Adjustment59
Weight Adjustment59
Backrest Adjustment59
Horizontal Adjustment60
Seat Belt Adjustment61
Fastening the Seat Belt62
Unfastening the Seat Belt62
Longer Seat Belt Adjustment62
Shorter Seat Belt Adjustment62
Adjusting the Retracting Seat Belt (Option)63
Fastening the Retracting Seat Belt64
Unfastening the Retracting Seat Belt64
Adjusting the Rearview Mirrors (Option)65
Adjusting the Mirrors66
Control Lever Base67
Control Lever Base Raised67
Control Lever Base Lowered67
Functional Check of Control Lever Base67
Armrest68
Fire Extinguisher68
Protective Structures69
Responsibility for Machine Equipped with Protective Structures69
Protective FOPS Structure/Small Screen – Level I (Option)70
Protective FOPS Structure/Large Screen – Level I (Option)72
Protective Front Guard Structure Level I (Option)74
Shatter Protection (Option)76
Job Site77
Checking the Screw Connections of the Cabin78
Document Box (Option)79
Socket79
Overview of Control Elements79
Cabin80
Display Element and Switches82
Switch Panel on Left-Hand Control Lever Base82
Right Switch Panel (Cabin)82
Right Switch Panel (Canopy)82
Indicator Lights and Warning Lights (Overview)84
Display Element84
Coolant Temperature85
Hydraulic Oil Filter Monitoring85
Air Filter Monitoring85
Fuel Level Indicator85
Hour Meter/Maintenance Meter86
Hour Meter86
Maintenance Meter (Service Hours up to Next Servicing)86
Preparatory Work87
Information before Putting the Machine into Operation87
Requirements and Notices for the Operating Personnel87
Check Lists88
Start-Up Checklist88
Operation Checklist89
Parking Checklist89
Putting Machine into Operation for First Time and Running-In Period90
Traveling on Public Roads90
Starting and Stopping the Engine91
Preparations for Starting the Engine91
Starter Lock91
Starting the Engine92
Warm-Up Phase of Machine92
Jump-Starting the Engine93
Low-Load Operation95
Stopping the Engine95
Battery Master Switch96
Interrupting Power Supply96
Establishing Power Supply96
Operation97
Accelerator Actuation97
Manual Throttle97
High Speed97
Steering System97
Automatic Engine Speed Setting (Option Tier IV Interim)98
Hydraulic Brake98
Mechanical Brake98
Travel Operation99
Travel Position99
Start Traveling and Stopping99
Operating Temperature Range99
Traveling on Slopes100
Preparations for Traveling on Slopes101
Traveling Uphill101
Traveling Downhill101
Lateral Angle of Inclination102
Parking the Machine103
Parking the Machine on Slopes103
Differential Lock104
Lights/Signalling System104
Working Lights104
Interior Light105
Horn105
Rotating Beacon (Option)105
Traveling Signal (Option)106
Wiper/Wash System106
Front Wiper106
Washer System106
Heating, Ventilation and Air Conditioning System107
Ventilation/Heating (Option)107
Temperature Setting107
Air Conditioning108
Operating Hydraulics109
Overview of Pedals and Control Levers (Operating Pattern A)109
Overview of Pedals and Control Levers (Operating Pattern B)110
Travel Levers/Travel Pedals111
Rotating the Upper Carriage112
Rotating the Upper Carriage to the Left112
Functional Check of Swivel Unit Brake113
Automatic Swivel Unit Brake113
Hydraulic Swivel Unit Brake113
ISO/SAE Controls (Option)115
Stabilizer Blade116
Proportional Controls (Option)117
Hammer Operation (Option)118
Information Regarding Hammer Operation118
Working with a Hydraulic Hammer119
Hammer Pedal – AUX I (Option)120
Proportionally Controlled Hammer AUX I (Option)120
Additional Control Circuit – AUX I (Option)121
Proportionally Controlled Additional Control Circuit – AUX I121
Operating the Additional Control Circuit121
Swiveling the Boom122
Swiveling the Boom (Proportionally Controlled)122
Lifting Gear Applications123
Additional Control Circuits125
3Rd Control Circuit – AUX II (Option)125
Powertilt – AUX II (Option)126
Actuating the Powertilt Unit126
Rotating the Powertilt Unit to the Left127
Rotating the Powertilt Unit to the Right127
Hydraulic Quickhitch - Easy Lock (Option)128
Picking up an Attachment128
Grab Control Circuit (Option)132
Stopping Grab Operation132
Stopping Bucket Operation132
Connecting and Disconnecting Hydraulic Couplings133
Hydraulic Connections133
Picking up134
Attachments134
Setting down135
Releasing the Pressure in the Operating Hydraulics136
Retrofitting a Bucket137
If Pin C Is Stuck137
Work Operation138
Inadmissible Work Procedures138
Working with the Swivel Force138
Working with the Travel Force138
Fully Lowering the Stabilizer Blade139
Protecting the Stabilizer Blade against Shocks139
Working on Slopes139
General Notices Regarding Work Operation140
Travel Operation in High Speed140
Operation in Water140
Working with the Bucket141
Bucket Position When Digging141
Working Alongside Trenches141
Loading Material142
Grading142
Emergency Lowering143
Safe Load Indicator (Option)144
Switching on the Safe Load Indicator145
Switching off the Safe Load Indicator145
Load Holding Control Valve (Option)146
Stabilizer Blade Hydraulic Cylinder146
Load Holding Control Valve “Basic” (Option)146
Load Holding Control Valve “Advanced” (Option)146
Travel Interlock (Option)148
Coding a New Key148
Deleting Coded Keys148
Travel Interlock with Keypad (Option)149
User Code149
Starting the Machine149
Stopping the Machine with the Keypad149
Tilting the Upper Carriage (Vertical Digging System) (Option)150
Shovel Bucket Operation152
Tilting the Upper Carriage152
Lowering the Upper Carriage152
Decommissioning the Machine Temporarily153
Decommissioning and Putting the Machine Back into Operation153
Putting the Machine Back into Operation154
Final Decommissioning of Machine155
Disposal155
Information Regarding Towing157
Transport 6.1 Towing the Machine157
Loading the Machine159
Driving Onto Transport Vehicles159
Traveling Onto Transport Vehicles159
Lifting the Machine160
Transporting the Machine162
Information Regarding Transport162
Tying down162
Important Information on Maintenance163
Responsibilities and Prerequisites163
Important Safety Instructions on Maintenance on or with the Machine163
Maintenance Overview164
Maintenance Plan164
Daily Maintenance (Operator)165
Weekly Maintenance (Every 50 Service Hours) (Operator)165
Every 1000 Service Hours (Operator)165
Every 250 Service Hours (Wacker Neuson Service Center)165
Every 500 Service Hours or Once a Year (Wacker Neuson Service Center)166
Every 1000 Service Hours (Wacker Neuson Service Center)166
Every 1500 Service Hours (Wacker Neuson Service Center)167
Every 2000 Service Hours or Every 2 Years167
Every 3000 Service Hours or Every 3 Years167
Lubrication Plan168
Powertilt with Hydraulic Easy Lock Quickhitch (Option)168
VDS Vertical Digging System (Option)168
Maintenance Label170
Explanation of Symbols on the Maintenance Label171
Fluids and Lubricants172
Oil Types for Diesel Engine (Depending on Temperature)173
Additional Oil Change and Filter Replacement (Hydraulic System)173
Oil Types for Hydraulic System (Depending on Temperature)174
Information Regarding Operation with Biodegradable Oil175
Maintenance Accesses176
Engine Cover176
Fuse Box177
Raising or Lowering the Cabin177
Lowering the Cabin179
Cleaning and Maintenance on or with the Machine181
Cleaning with Washing Solvents181
Cleaning with Compressed Air181
Cleaning with a High-Pressure Cleaner or Steam Jet181
Use of Solvents182
Cleaning Inside the Cabin182
Cleaning Outside the Machine182
Cleaning the Engine Compartment182
Cleaning the Seat Belt183
Cleaning the Shatter Protection183
Threaded Fittings and Attachments183
Lubrication Work184
Preparing Lubrication184
Live Ring (Ball Bearing)185
Live Ring Gears186
Vertical Digging System Live Ring Gear (Option)187
Powertilt/Powertilt with Easy Lock (Option) When Used in Water188
Fuel System189
Information Regarding the Fuel System189
Diesel Fuel Specification189
Refueling189
Stationary Fuel Pumps190
Refueling from Barrels190
Refueling with a Fuel-Filling Pump (Option)191
Bleeding the Fuel System192
Checking the Water Separator192
Water Separator192
Emptying the Water Separator193
Emptying the Fuel Filter194
Engine Lubrication System195
Information Regarding the Engine Lubrication System195
Checking the Engine Oil Level195
Adding Engine Oil196
Information Regarding the Cooling System197
Checking the Coolant Level197
Adding Coolant198
Cleaning the Radiator199
Information Regarding the Air Filter200
Replacing the Air Filter201
Checking the Air Intake202
V-Belt/Toothed Belt203
Information Regarding the Hydraulic System204
Checking the Hydraulic Oil Level205
Adding Hydraulic Oil206
Checking the Hydraulic System for Leaks207
Checking the Condition and Age of Hydraulic Hoses208
Electrical System209
Information Regarding the Electrical System209
Fuses and Relays210
Battery Charge Condition210
Charging the Battery210
Replacing the Battery210
Checking/Changing the Cabin Air Filter211
Information Regarding the Washer System211
Checking the Fluid Level and Adding Fluid211
Heating, Ventilation and Air Conditioning System211
Tires/Tracks212
Checking Track Tension212
Axles/Traveling Drive212
Correcting Track Tension213
Tightening the Tracks213
Reducing Tension214
Maintenance of Attachments215
Maintenance of Options215
Joint Rod (Lifting Eye) and Load Hook215
Load Hook Wear215
Machine Preservation216
Exhaust Gas Treatment216
Troubleshooting217
Diesel Engine Malfunctions217
Malfunctions of the Traveling Drive218
Malfunctions of the Hydraulic System218
Malfunctions of the Electrical System219
Troubleshooting the Air Conditioning220
Models and Trade Names221
Engine221
Traveling Drive/Axles222
Operating Hydraulics223
Electrical Components224
Fuses224
Electrical System224
Relays225
Bulbs225
Powertilt (Option)225
General Tightening Torques226
Tightening Torques/Fine-Pitch Thread226
Coolant227
Noise Emissions227
Compound Table227
Vibration228
Indications on Whole-Body Vibration228
Machine Weight231
Weight of Attachments231
Excavator Forces232
Ground Clearance/Ground Pressure232
Payload/Stability233
Safety Instructions – Lift Capacity Table233
Lift Capacity Table EZ38236
Lift Capacity Table EZ38 (Short Stick)236
Lift Capacity Table EZ38 Long Stick (Option)236
Lift Capacity Table EZ38 Short Stick and Extra Weight (Option)237
Lift Capacity Table EZ38 Long Stick (Option) and Extra Weight (Option)237
Lift Capacity Table EZ38 VDS (Short Stick)238
Lift Capacity Table EZ38 Long Stick VDS (Option)238
Lift Capacity Table EZ38 VDS and Extra Weight (Short Stick)239
Lift Capacity Table EZ38 Long Stick VDS and Extra Weight (Option)239
Safety Instructions – Stability Table240
Cabin or Canopy, Without Extra Weight242
Cabin or Canopy, with Extra Weight242
VDS Cabin or Canopy, Without Extra Weight243
VDS Cabin or Canopy, with Extra Weight243
Dimensions244
Overview EZ38244
Overview EZ38 VDS246
Index249

Wacker Neuson EZ38 - Page 12

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