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Wacker Neuson 38Z3 Service Manual
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Wacker Neuson 38Z3 Service Manual

Wacker Neuson 38Z3 Service Manual

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Summary of Contents for Wacker Neuson 38Z3

  • Page 1 Track excavator  Track excavator ...
  • Page 2 The cover features the machine with possible optional equipment. The cover features the machine with possible optional equipment. Wacker Neuson Linz GmbH Wacker Neuson Linz GmbH Haidfeldstr. 37 Haidfeldstr. 37  A-4060 Linz-Leo...
  • Page 3 Lift capacity table 38Z3 long stick ong stick ............................ 2-14 ....2-14 Lift capacity table 38Z3 with long stick + extra weight ........... 2-15 Lift capacity table 38Z3 with long stick + extra weight ........... 2-15 Kinematics Kinematics ................................
  • Page 4 Lubrication points on the stick Lubrication points on the stick ............................ 3-43 ....3-43 Lubrication strip Lubrication strip ....................................... 3-44 ..3-44 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm...
  • Page 5 Checking the coolant thermostat ................4-21 Checking the thermal switch .................. 4-22 Oil pressure switch ....................4-22 Checking the coolant circuit ................... 4-23 Engine trouble ......................4-23 Hydraulic pump PVD-1B-32BP-11G5-4904A (up to AE02803) SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm...
  • Page 6 Hydraulics diagram 38Z3 A3 .................. 5-35 Option diagram 1 ....................5-36 Option diagram 2 ....................5-37 Main valve block diagram 38Z3 A3 ................ 5-38 Ohm's Law (current, voltage, resistance); power ............. 6-1 Measuring equipment, measuring methods ............. 6-1 Cable colour coding ....................6-3 Relays ........................
  • Page 7 Disabling the drive interlock ................7-19 Enabling the drive interlock ................7-19 Programming ....................7-19 Proportional controls ....................7-21 Function ......................7-21 Ports ........................ 7-21 Overview ......................7-22 Wiring harness ....................7-23 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm...
  • Page 8 Measures to be taken in case of malfunctions ..........7-25 Diagnosis display ..................... 7-25 Fuel-filling pump ..................... 7-27 Connections ..................... 7-28 Service valve ......................7-29 Function ......................7-29  Automatic revs setting (Tier 3A from AG00573) ............ 7-30 Installation ......................7-31 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm...
  • Page 9 Automatic revs setting (option) 7-30  New fuel filter   4-13  Oil dipstick Engine oil filter   3-16  New air conditioning compressor (option) Oil filler neck 4-1  Expansion tank 3-18  Radiator   3-18  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm...
  • Page 10 Swivel joint 5-30  Leak oil strip Swivel unit 5-26  Battery 3-47  Main valve block 5-5  Pilot valve (drive) 5-13  Jack SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm...
  • Page 11  Always close the door. Even if the door is secured in the open position with the door arrester –  Always close the door before tilting the cab  ☞ Should the door be open as you tilt the cab, do not actuate the door opener ☞ unintentionally  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm...
  • Page 12 – see Tightening torques for high-resistance screw connections on page 2-9  Check tilt rod K, the split pin and safety cables H at regular intervals for cracks and cuts. Replace defective parts immediately  ☞ Fig. 10: Tilting the cab SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm...
  • Page 13 44.1 – 49.0 / 32.5 - 36.1 (M9x1) Connecting rod bearing screw 93.2 – 98.1 / 68.7 - 72.4 (M12x1.5) Main bearing screw 83.3 – 88.2 / 61.4 - 65.1 (M10x1.25) Flywheel screw SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 14 29 / 7.7 200 / 2901 16 / 4.2 27 / 7.1 Output indications for auxiliary hydraulics with unpressurised reflux line.  Adjustment – see Flow rate adjustment of auxiliary hydraulics    on page 5-12 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 15 Upper carriage swivel speed 1740/345 mm (68.5"/13.6") Width/height 390/450 mm (15.4"/17.7") Max. lift over/under subgrade 1/2" 1.2 mm (0.05") Stabiliser blade – see chapter 5.17   Hydraulics diagram 38Z3 A3    on page 5-35 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 16 The main fuse box is located in the partition wall to the left of the engine. 40 A Start, preheat, cutoff solenoid 50 A Fuel-filling pump, main fuse, ignition lock Cutoff solenoid switching relay Preheating high current relay SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 17 Effective acceleration value for the < Trigger value body * * Measurements as per 2002/44/EC (excavating, driving and hammering with a Wacker Neuson hammer). Machine and attachment operation and maintenance as per Operator's Manual. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 18 100 (74) M36X2 WS 41 180 (133) M45X2 WS 55 220 (162) Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s210.fm...
  • Page 19 If the engine runs smoothly for a while, and then stops; or if it does not run smoothly: Switch off the engine • Bleed the fuel system again as described above • Have this checked by authorised staff if necessary • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 20 ➥ Thread  A is fitted with a h ose. Collect the water as it drains with a suitable container and Fig. 3: Fuel prefilter  dispose of it in an environmentally friendly manner. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 21 Bleed the fuel system – see Bleeding the fuel system    on page 3-10 • Make a test run – and check for tightness! • Dispose of the old fuel filter cartridge by an ecologically safe method • Fig. 7: Tightening the fuel filter  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 22 Withdraw it and read off the oil level ☞ Fig. 8: Checking the oil level However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the ☞ oil dipstick   A. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 23 Check the function of the dust valve, replace if necessary Check the function of the dust valve, replace if necessary • • Fi Fig. Ai Air f fil ilter  ter  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 24 ☞ ☞ Make sure dust valve Make sure dust valve G shows downwards once it is installed! G shows downwards once it is installed! SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 25 Clean the discharge slot if necessary  Clean the discharge slot if necessary  ☞ ☞ Fig. Fig. fil filter – dus – dust va valve SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 26 7 to 9 mm (0.3" - 0.35"). have a deflection of 7 to 9 mm (0.3" - 0.35"). Retighten the V-belt if necessary. Retighten the V-belt if necessary. ☞ ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 27 Keep the alternator in this position, and at the same time retighten fastening screws ☞ Check V-belt tension again and adjust it if necessary ☞ Fig. 25: Retightening the V-belt Connect the battery or the battery master switch ☞ Close the engine cover  ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 28 7 to 9 mm (0.3" - 0.35"), a used V-belt (after about 5 minutes running time) should have a deflection of 9 to 11 mm (0.35" - 0.4") Retighten the V-belt if necessary. ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 29 Keep the tightening bracket in this position, and at the same time retighten nut ☞ Check V-belt tension again and adjust it if necessary ☞ Connect the battery or the battery master switch ☞ Close the engine cover  ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 30  Adjust the pressure at the pressure limiting valve 4 (PLV4 ) at the pilot oil supply ☞ unit Check the pilot control pressure again once adjustment is over  ☞ Fig. 29: Pressure reducing valve SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 31  Adjust the pressure limiting valve and tighten the locknut ☞ Check the primary pressure limiting valve 1 and the pressure drop once adjustment is ☞ over  Fig. 31: Primary pressure limiting valve 1 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s312.fm...
  • Page 32 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s410.fm...
  • Page 33 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s410.fm...
  • Page 34 Valve tip clearance:0.15 – 0.25 mm (0.006 - 0.01") ➥ Repeat the procedure for each cylinder  ☞ Place the cylinder head cover gasket  ☞ Mount the cylinder-head cover  ☞ Fig. 2: Checking valve tip clearance SERV-HB 38Z3 EN – Edition 2.1 * 38z3s410.fm...
  • Page 35     i    s     t     l    e     b   -     V  Apply oil to the threads and contact surfaces before mounting. Mount the cylinder-head bolts  ☞ Tightening torques: ➥ 1st pass • 2nd pass • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s410.fm...
  • Page 36 Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle eject fuel  The nozzle jet must create a shape on the paper as shown in Fig. 4  ☞ optimal --------------variation-------------- Fig. 4: Shape of nozzle jet SERV-HB 38Z3 EN – Edition 2.1 * 38z3s410.fm...
  • Page 37 Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle ☞ eject fuel  The nozzle jet must create a shape on the paper as shown in Fig. 5  ☞ optimal Variation Fig. 5: Shape of nozzle j e t SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm...
  • Page 38 Continue turning the ring gear upwards on the flywheel with the screwdriver until the ☞  piston in the fuel injection pump reaches a stroke of 2.5 mm (0.1"). Fig. 6: Measuring equipment Fig. 7: Measuring equipment SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm...
  • Page 39 Bend each of the injection lines before you mount them so they are not subject to ☞ tension once they are mounted  Fig. 9: Mark on housing Check injection time again  ☞  Adhesive label number 1000158808  ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm...
  • Page 40 Do not slacken screws 3 of the drive pinion of the fuel injection pump. These screws specify the precision setting of the fuel injection pump set by the manufacturer! Fig. 13: Gear casing SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm...
  • Page 41 Remove the thermostat  ☞ The thermostat is located on the water pump ➥ – see on page 4-13 Housing cover  Thermostat Seal Housing Thermal switch Fig. 16: Cool a nt thermostat SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm...
  • Page 42 Bucket section • Boom section • Stick section •  Auxiliary hydraulics/boom swivel section • 3rd control circuit section (option) • Stabiliser blade section • Swivel unit section • Drive counterbalancing system section • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 43 (both supplied with oil by the same pump) are actuated at the same time, both move simultaneously, and not the bucket (with its smaller mass) first, and then the boom with its larger mass – see Main valve block diagram    on page 5-7. Location SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 44 The oil supplied by P3 flows to the tank via the open valve seat. • Intermediate positions of the set screws cause the hydraulic oil to warm up – danger of overheating! SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 45 Offset ram retraction control Universal joint Right-hand side rotation control Bucket ram retraction control Guide plate Supply from pilot oil supply unit Supply from pilot oil supply unit Tappet Tank line Tank line SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 46 V is inserted in the pump line instead of the GE screw fitting. Check the pilot control filter screen for dirt and clean or replace if necessary. Coarse dirt causes joystick and drive valve malfunctions and can even destroy the filter insert. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 47 Joystick position (degrees) Left-hand side drive segment control Left-hand side drive segment control Right-hand side drive segment control Right-hand side drive segment control Non-return valve Pilot control pressure Tank line Pilot control filter  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 48    p     0    a     0     t     0     f     1    o    :     t  .    e    o     S    n Bellows Shift unit (kit) Plate (kit) Tappet Non-return valve (also used for bleeding pedal damping) Damping SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 49 SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1 * 38z3s510.fm * 38z3s510.fm...
  • Page 50  A2  A2 Main valve block Main valve block il ilia iar hy hydr drau auli lic il ilia iar hy hydr drau auli lic SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 51 Main va valv lve bl bloc ock, st stic ick ra ram re retr trac acti tion co cont ntro rol SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1 * 38z3s510.fm * 38z3s510.fm...
  • Page 52 Drive port (-> swivel joint 2/7) Drive port (-> swivel joint 6/5) Leak oil port (-> swivel joint 1) Forwards/reverse directional valve 2nd speed range port (-> swivel joint 8) 2nd speed range directional valve Brake piston SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 53 2nd speed range switch: switched on • The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash plate is in minimum capacity position. The motor runs at high speed. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 54 Screw connection Cover   Hydraulic motor sealing kit Hydraulic motor   Lifetime seal Travelling drive brake Valve set Piston valve for speed range Brake valve Bearing O-ring Screw connection Washer   Snap ring SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 55 Drive port (-> swivel joint 2/7) Drive port (-> swivel joint 6/5) Leak oil port (-> swivel joint 1) Forwards/reverse directional valve 2nd speed range port (-> swivel joint 8) 2nd speed range directional valve Brake piston SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 56 The motor now runs at low speed. ➥ The directional valve returns to 2nd speed range as soon as the pressure in the travelling drive drops again. The motor runs at high speed again. ➥ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 57 The piston of the brake release valve moves to home position • No more pilot control pressure on the brake piston • The oil in the brake piston flows to the tank via a throttle orifice • The brake is enabled • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 58    n    e    o    o     i    p    e    e    e    e    p     P     S     B     B     G     S     B     R     C     S     0     1     2     3     4     5     6     7     8     9     1 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 59 Shock anticavitation valves Gear motor valve set Timer valve Engine brake set SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 60 Travelling drive tank line Outside part Slacken the circlip on the lower side  ☞ Pull the swivel joint apart  ☞ Replace the sealing rings  ☞ Push together again  ☞ Insert the circlip again  ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 61 Replace the breather filter according to the instructions in the maintenance plan! – see Maintenance plan (overview)    on page 3-5 The breather filter must be replaced at 1000 h under all circumstances! Filter fabric Bleeder valve Fig. 5: Breather filter  SERV-HB 38Z3 EN – Edition 2.1 * 38z3s510.fm...
  • Page 63     t    n     i    r     k    e    n     t     l     i    a     f     t     d    n     i    n    r    a    e     t     l    e     i    v     f     l    a     d    v    n    a    n    r    r    u    e     t     l    e    o    r    o...
  • Page 66 Calculate the measuring range using known data (P, U, R, I) and set before measuring! Observe AC/DC basic setting.  AC = alternating current/voltage; ➥ DC = direct current/voltage ➥ Continuity test in de-energised machine electric system and of wiring harnesses • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s610.fm...
  • Page 67    s    s    e    n    r    a     h    g    n     i    r     i    e    w    v    g    e    y    n     d     i    e    a     l    e     l    s    s    e    e    u    r    p    o    g    s     h    g    n    g     l     i     t...
  • Page 69  Article numbers for options and retrofit kits: please refer to the 38Z3 spare parts list •  Avoid contact with the heat exchanger or the condenser and the supply lines. Lines and hoses carrying refrigerating agents or coolants can be pressurised and hot.
  • Page 70 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 71 +2.2 °C ± 0.8 °C (36 ±34°F) as required. • : can be controlled in steps and is overload-protected by means of a • temperature microfuse. Compressor   Condenser   Dehumidifier   Air conditioning unit SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 72 The following applies both to the coding and programming mode: the system leaves the coding and programming modes and is disabled as soon as the ignition key is inserted in the ignition lock and turned to the first position. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 73 Do not operate the hammer with characteristic curve 1 too often since the ☞ slide switch described above does not ensure full throughput, causing  power loss and system overheating. Connections Hose designation T line P line Auxiliary hydraulics (left) Auxiliary hydraulics (right) SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 74 Displays the characteristic curve that has been selected for the control valve. Telltale  in the status display flashes once after switching on ignition  ☞ Telltale  in the status display flashes twice after switching on ignition  ☞ SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 75 Proportional circuit 1 telltale Proportional circuit 2 telltale Power supply Connector 1 for auxiliary hydraulics Connector 2 for auxiliary hydraulics Connector 1 for 3rd control circuit Connector 2 for 3rd control circuit SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 76 Pulse modulation channel 1/magnet 1 LSW2 Telltale LSW3 Telltale MVL2A Pulse modulation channel 2/magnet 1 MVL2B Pulse modulation channel 2/magnet 2 MVL1B Pulse modulation M channel 1/magnet 2 MOT2 Engine MOT1 Engine U_ECU +12 V supply SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 77 The system switches off automatically if a critical error is detected. Activating the control unit is only possible by repeatedly switching on the supply voltage. unit is only possible by repeatedly switching on the supply voltage. SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1...
  • Page 78 (not to earth or operating voltage) Channel 2: wiring, earth contact in valve Channel 2: wiring, earth contact in valve • • SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 79 The float switch screwed into the fuel tank triggers the telltale. The float switch screwed into the fuel tank triggers the telltale. Fi Fig. 1 Float s swi witc tch SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1 * 38z3s710.fm...
  • Page 80                         SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 81 Fill up if necessary and check again • • Completely remove all oil spills from the engine Completely remove all oil spills from the engine • • SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1 * 38z3s710.fm * 38z3s710.fm...
  • Page 82 This is then carried out mechanically with the cable pull and the manual throttle lever. This is then carried out mechanically with the cable pull and the manual throttle lever. SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm SERV-HB 38Z3 EN – Edition 2.1 * 38z3s710.fm...
  • Page 83 Revs control retrofit kit 1 Revs control retrofit kit 1 SERV-HB 38Z3 EN – SERV-HB 38Z3 EN – Edition 2.1 Edition 2.1 * 38z3s710.fm * 38z3s710.fm...