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Wacker Neuson 38Z3, Service Manual

The Wacker Neuson 38Z3 is a compact excavator known for its versatility and power. Ensure your machine stays in top condition by downloading the free Service Manual from manualshive.com. This manual provides step-by-step instructions for maintenance and troubleshooting, allowing you to maximize the performance of your equipment.

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SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm

Wiring diagram A4 38Z3 (legend) .......................................................................... 6-11
Wiring diagram A4  ................................................................................................. 6-12
Engine wiring harness (legend)  ............................................................................. 6-13
Engine wiring harness A4 ...................................................................................... 6-14
Cab wiring harness A4 (legend)  ............................................................................ 6-15
Cab wiring harness A4 ........................................................................................... 6-16
Roof wiring harness A4 .......................................................................................... 6-17
Revs control wiring harness (option)  ..................................................................... 6-18
Wiring diagram A3 (legend) ................................................................................... 6-20
Wiring diagram A3  ................................................................................................. 6-21
Engine wiring harness A3 (legend) ........................................................................ 6-22
Engine wiring harness A3 ...................................................................................... 6-23
Cab wiring harness A3 (legend)  ............................................................................ 6-24
Cab wiring harness A3 ........................................................................................... 6-25
Roof wiring harness A3 .......................................................................................... 6-26
Revs control wiring harness (option)  ..................................................................... 6-27

 Air conditioning  ........................................................................................................ 7-3

Specific safety instructions ................................................................................ 7-3
Specifications  .................................................................................................... 7-3
Components  ...................................................................................................... 7-5
Compressor  ....................................................................................................... 7-6
Filling up the air conditioning system ................................................................. 7-7
Maintenance  ...................................................................................................... 7-8
Troubleshooting  ................................................................................................. 7-9

Counterweight ........................................................................................................ 7-10

Specifications .................................................................................................. 7-10

Long stick ............................................................................................................... 7-10

Specifications .................................................................................................. 7-10

Control circuit (pipework) connections for grab  ..................................................... 7-11

 Attachments ..................................................................................................... 7-11

3rd control circuit connections  ............................................................................... 7-12

 Auxiliary hydraulics connections  ............................................................................ 7-12

Safe load indicator DE (safety valve for boom)  ..................................................... 7-13

Position  ............................................................................................................ 7-13
Setting the pressure switch  ............................................................................. 7-13
Function  ........................................................................................................... 7-14
Wiring diagram  ................................................................................................ 7-14

Safe load indicator FR (safety valves for boom and stick) ..................................... 7-15

Position  ............................................................................................................ 7-15
Setting the pressure switch  ............................................................................. 7-15
Function  ........................................................................................................... 7-16
Wiring diagram  ................................................................................................ 7-17

3rd control circuit  ................................................................................................... 7-18

Function  ........................................................................................................... 7-18
Diagram  ........................................................................................................... 7-18

Drive interlock (antitheft protection) ....................................................................... 7-19

Position  ............................................................................................................ 7-19
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

I-5

Table of c ontents

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Summary of Contents for 38Z3

Page 1: ...Track excavator Track excavator...

Page 2: ...lectronic No part of this publication may be reproduced translated or used in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage o...

Page 3: ...burst valve burst valve 2 4 2 4 Electric sy Electric system stem 2 5 2 5 Fuse box in instrument panel Fuse box in instrument panel 2 5 2 5 Main fuse box with relays underneath the cab Main fuse box w...

Page 4: ...ng the V belt of the air conditioning system 3 26 3 26 Pressure check Pressure check 3 27 3 27 General General 3 27 3 27 Checking pilot control pressure Checking pilot control pressure 3 27 3 27 Press...

Page 5: ...ng the nozzle jet 4 6 Injection time 4 7 Checking injection time 4 7 Setting injection time 4 8 Replacement of fuel injection pump 4 8 Adjusting engine revs 4 9 Compression 4 9 Checking the coolant th...

Page 6: ...E00854 5 20 Function 5 21 Travelling drive starting no AE00855 5 23 Function 5 24 Swivel unit 5 26 Parking brake multidisc brake function 5 27 Swivel joint 5 30 Sealing 5 30 Breather filter 5 31 Troub...

Page 7: ...lling up the air conditioning system 7 7 Maintenance 7 8 Troubleshooting 7 9 Counterweight 7 10 Specifications 7 10 Long stick 7 10 Specifications 7 10 Control circuit pipework connections for grab 7...

Page 8: ...plug assignment 7 24 Safety features 7 25 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 r...

Page 9: ...10 fm 85 Air filter 3 20 86 Automatic revs setting option 7 30 87 New fuel filter 4 13 88 Oil dipstick 89 Engine oil filter 3 16 90 New air conditioning compressor option 91 Oil filler neck 4 1 92 Exp...

Page 10: ...SERV HB 38Z3 EN Edition 2 1 38z3s110 fm 94 Swivel joint 5 30 95 Leak oil strip 96 Swivel unit 5 26 97 Battery 3 47 98 Main valve block 5 5 99 Pilot valve drive 5 13 100 Jack...

Page 11: ...n key Fold the control lever base left up Unscrew screw Screw cated at the front right in the cab underneath the floor mat Slacken screw suitable tool Screw is located in the cab at the right behind t...

Page 12: ...it pin into guide Use the handle to lower the cab until it is back on the pump Insert tube Slowly turn tube The cab is lowered by its own weight Mount lock screws and rear with suitable tools and the...

Page 13: ...i Revs control Mechanical Lubrication system Engine oil lubrication Fuel tank 44 l 11 6 gal Engine oil 7 1 l 1 9 gal Coolant without radiator 2 l 0 53 gal Radiator 3 5 l 0 9 gal 5 5 l 1 5 gal Expansio...

Page 14: ...ssure limiting valve for pump P3 210 3 bar 3046 44 psi Secondary pressure l imiting valve for main valve block 275 0 0 5 bar 3989 0 7 psi at 20 l min 5 3 gpm Main pressure limiting valve for pilot con...

Page 15: ...mph Hill climbing ability no longer than 3 minutes 30 58 Chain width 300 mm 11 8 No of track rollers on either side 4 Ground clearance 280 mm 11 Ground pressure 0 34 kg cm 4 8 psi Upper carriage swive...

Page 16: ...F3 F4 F8 F9 F10 F5 F6 F7 F3 10 A Indicators engine relay F4 10 A Boom working light F5 15 A Cab working light F6 10 A Valves horn F7 15 A Heating air conditioning F8 10 A Wiper interior light F9 10 A...

Page 17: ...alted surface W 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 Fig 2 Relays K7 K6...

Page 18: ...9 40 30 22 55 44 Live ring M14 10 9 180 133 Track roller M16 10 9 275 203 Drive pinion M14 10 9 180 133 Travelling drive M14 10 9 180 133 Gear motor M16 10 9 275 203 Angled engine bracket M10 8 8 45 3...

Page 19: ...with hot engine parts or the exhaust system there is an increased Never bleed the fuel system if the engine is hot Bleed the fuel system in the following cases After removing and fitting the fuel filt...

Page 20: ...e fuel system see Bleeding the fuel system on page 3 10 Check the fuel prefilter as follows If the red indicator ring rises to position Unscrew thread The water drains Wait until the indicator ring re...

Page 21: ...a commercially available tool Collect the fuel as it drains Clean the sealing surface of the filter carrier if it is dirty Lightly oil the rubber gasket of the new filter cartridge or apply a thin coa...

Page 22: ...wait at least 5 minutes before checking Proceed as follows Park the machine on level ground Switch off the engine Fold the control lever base up Let the engine cool down Open the engine cover Clean t...

Page 23: ...nd other nonferrous metal plants steel and aluminium mills chemical plants and other nonferrous metal plants Replace outside filter Replace outside filter hours hours General instructions for air filt...

Page 24: ...e outside filter Carefully remove outside filter Carefully remove inside filter Carefully remove inside filter Cover the air supply at the end of the filter with a clean lint free cloth to prevent dus...

Page 25: ...s follows Proceed as follows Switch off the engine Switch off the engine Apply the parking bra Apply the parking brake ke Squeeze the discharge slot of dust valve Squeeze the discharge slot of dust va...

Page 26: ...lever base up Remove the key and carry it with you Remove the key and carry it with you Disconnect the battery or the battery master switch Disconnect the battery or the battery master switch Let the...

Page 27: ...ve the key and carry it with you Disconnect the battery or the battery master switch Let the engine cool down Open the engine cover Slacken fastening screws Use a suitable tool to push the alternator...

Page 28: ...Disconnect the battery or the battery master switch Let the engine cool down Open the engine cover Carefully check V belt Replace the V belt if it touches the base of the V belt groove or the discs o...

Page 29: ...he battery or the battery master switch Close the engine cover Retighten as follows from serial number AG00573 Switch off the engine Fold the control lever base up Remove the key and carry it with you...

Page 30: ...V at maximum engine revs See chapter Specifications see Hydraulic system on page 2 3 for the pressure settings Connect a pressure gauge to measuring port MP 4 Move the control lever base safety switch...

Page 31: ...op Check and make a note of the pressure value Pressure drop should not exceed the specified value by more than 10 Adjust the pressure at the primary pressure limiting valve PPLV 1 on the main valve b...

Page 32: ...SERV HB 38Z3 EN Edition 2 1 38z3s410 fm...

Page 33: ...SERV HB 38Z3 EN Edition 2 1 38z3s410 fm...

Page 34: ...the cylinder reaches the top dead centre of the compression cycle Valve overlapping Check the valve cap for abnormal wear Check valve tip clearance with a feeler gauge Valve tip clearance 0 15 0 25 mm...

Page 35: ...rry out work on the cylinder head on a cold engine Bear in the mind the order for tightening the cylinder head bolts See figure Apply oil to the threads and contact surfaces before mounting Mount the...

Page 36: ...or drips after it has ejected fuel Create a pressure of about 20 bar 290 psi below injection pressure and check whether fuel escapes from the nozzle Remove the injection lines and the injection nozzle...

Page 37: ...le for drips after it has ejected fuel Create a pressure of about 20 bar 290 psi below injection pressure and check whether fuel escapes from the nozzle Remove the injection lines and the injection no...

Page 38: ...e bore of the piston as shown in Fig 6 Measurement Remove the rubber plug from the flywheel housing Turn the ring gear on the flywheel with a screwdriver until the piston reaches the lowest point in t...

Page 39: ...pump Mark the initial position on the pump and wheel case housing before setting the fuel injection pump see Fig 9 Remove all injection lines on the fuel injection pump and slacken the 4 flange screws...

Page 40: ...uel injection pump Check the marked position of the drive pinion of the fuel injection pump fig 12 Slacken and tighten nut 12 2 tightening torque 23 28 Nm 17 21 lbf ft Check injection time Mount gear...

Page 41: ...d the injection nozzles Set the fuel injection pump to zero delivery remove the plug for the cutoff solenoid Turn the engine Mount the compression gauge on the cylinder you want to measure Turn the en...

Page 42: ...ctivated with right hand side drive and a boom function bucket boom stick or auxiliary hydraulics The drive counterbalancing system is enabled by means of an increased banking up pressure if both pist...

Page 43: ...rod side oil can flow to the base side The regeneration valve is located in the stick segment on the lower side A nozzle is integrated in the pressure line of the bucket segment If the bucket and the...

Page 44: ...are two possible positions see Auxiliary hydraulics oil flow on page 2 3 The valve seat is closed in this position P2 P3 supply the auxiliary hydraulics section with oil Factory setting Unscrew the v...

Page 45: ...e joystick Left hand side joystick 3 1 2 4 A Control lever 1 Stick extension control Offset ram extension control B Rubber collar 2 Left hand side rotation control Bucket ram extension control C Linka...

Page 46: ...rol filter 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 inser...

Page 47: ...ing valves Pressure bar Joystick position degrees Pilot valve piston stroke mm 1 Left hand side drive segment control 2 Left hand side drive segment control 3 Right hand side drive segment control 4 R...

Page 48: ...3 EN Edition 2 1 38z3s510 fm S e t o f t a p p e t s s e a l i n g k i t n o 1 0 0 0 0 6 9 3 3 0 1 Bellows 2 Shift unit kit 3 Plate kit 4 Tappet 5 Non return valve also used for bleeding pedal damping...

Page 49: ...liar ary hy y hydr drau auli lics c cs con ontr trol ol o off ffse set ra t ram ex m exte tens nsio ion co n cont ntro roll B B P Pe ed da all f fiix xt tu ur re e 2 2 Aux Auxili iliary ary hyd hydrau...

Page 50: ...valve energised valve energised Electric control via push button on left hand side joystick Electric control via push button on left hand side joystick A1 A1 Main valve block Main valve block A2 A2 M...

Page 51: ...work work Always secure win Always secure wing nut g nut Fig Fig 1 1 Dir Direc ecti tiona onal val l valve po ve posi siti tion on Fi Fig 2 g 2 Di Dire rect ctio iona nal va l valv lve e A A ISO contr...

Page 52: ...38z3s510 fm 1 Drive port swivel joint 2 7 2 Drive port swivel joint 6 5 3 Leak oil port swivel joint 1 4 Forwards reverse directional valve 5 2nd speed range port swivel joint 8 6 2nd speed range dire...

Page 53: ...The slow drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill With the brake piston in neutral position the ports are no longer connected to the motor which can no...

Page 54: ...onnection 3 Screw connection 4 Screw connection 5 Cover 6 Hydraulic motor sealing kit 7 Hydraulic motor 8 Lifetime seal 9 Travelling drive brake 10 Valve set 11 Piston valve for speed range 12 Brake v...

Page 55: ...peed if the switch for 2nd speed range is switched on high speed 1st speed is automatically engaged if more power is required 1 Drive port swivel joint 2 7 2 Drive port swivel joint 6 5 3 Leak oil por...

Page 56: ...to the motor which can no longer turn The brake release pressure is reduced via both throttles shortly afterwards 2nd speed range switch switched off The directional valve for the 2nd speed range rem...

Page 57: ...ressure to drop and the SH input is unpressurised upon termination of upper carriage rotation boom swivel or stick retraction The piston in the brake release valve switches to home position brake if t...

Page 58: ...s h e r 1 2 R i n g g e a r 3 B e a r i n g s e a l r i n g 1 3 G e a r r e d u c t i o n 4 B e a r i n g 1 4 G e a r r e d u c t i o n S u n g e a r 6 S e a l i n g r i n g 1 6 M o t o r f l a n g e...

Page 59: ...SERV HB 38Z3 EN Edition 2 1 38z3s510 fm 1 Shock anticavitation valves 2 Gear motor valve set 3 Timer valve 4 Engine brake set...

Page 60: ...sealing rings Push together again Insert the circlip again 1a Pilot control pressure PV pilot oil supply unit 1 8 Sealing rings 2a Stabiliser blade 9 PU prop ring 3a Stabiliser blade 10 V sealing rin...

Page 61: ...pressure supports the variable displacement pump s suction Filtering the intake air Opens at 0 4 bar 5 8 psi The breather filter is located at the rear of the machine next to the hydraulic oil filler...

Page 62: ......

Page 63: ...l j o i n t A 4 B 4 D r i v e u n i t r i g h t v i a s w i v e l j o i n t A 5 B 5 S t i c k r a m A 6 B 6 A u x i l i a r y h y d r a u l i c s o f f s e t r a m A 7 B 7 3 r d c o n t r o l c i r c...

Page 64: ......

Page 65: ......

Page 66: ...x I R x I U R Measurements of values U R I f Continuity test Diode test Calculate the measuring range using known data P U R I and set before measuring Observe AC DC basic setting AC alternating curre...

Page 67: ...E n g i n e s p e e S w i t c h S y m b o l T i m e l a g r e l a y B a s e I n s u l a t i n g s l e e v e S o c k e t h o u s i n g H o u s i n g d w i r i n g h a r n e s s...

Page 68: ......

Page 69: ...e fan at a standstill only Have maintenance and repair work carried out by specialised staff only Make sure the cooling system does not come into contact with chlorine choric substances oil grease or...

Page 70: ...SERV HB 38Z3 EN Edition 2 1 38z3s710 fm...

Page 71: ...supply off at 1 1 C 0 8 C 30 34 F and on again at 2 2 C 0 8 C 36 34 F as required temperature microfuse 1 Compressor 2 Condenser 3 Dehumidifier 4 Air conditioning unit this is where the liquid refrig...

Page 72: ...to confirm deletion The system is deleted once the LED comes on slowly three times Deletion deletes all normal transponders and the master Reason once a key is lost you can no longer delete it Theref...

Page 73: ...ng control response on page 7 22 The slide switch is not pressed fully in this position and you can move the machine more smoothly flat characteristic curve If you require the full throughput then cha...

Page 74: ...ide switch The status display acknowledges by flashing twice Displays the characteristic curve that has been selected for the control valve Telltale in the status display flashes once after switching...

Page 75: ...alve tip switch F14 Blade type fuse K17 Relay changeover valve X14 Joystick right H10 Proportional circuit 1 telltale H11 Proportional circuit 2 telltale X8 Power supply Y16 Connector 1 for auxiliary...

Page 76: ...R_POT1 GND joystick 8 R_POT2 GND potentiometer 9 A_POT3 Potentiometer signal 10 SW3 Auto 11 SW1 Pressure switch 12 RX Serial interface 1 M_ECU Earth 2 MVH1 channel 1 3 MVH2 channel 2 4 MVL1A Pulse mo...

Page 77: ...tches off automatically if a critical error is detected Activating the control The system switches off automatically if a critical error is detected Activating the control unit is only possible by rep...

Page 78: ...ach of the pulse modulation lse modulation outputs outputs The error code ends at the last output stage by displaying an error The error code ends at the last output stage by displaying an error Examp...

Page 79: ...ton Switch off the fuel filling pump as soon as telltale Switch off the fuel filling pump as soon as telltale tank may overflow and can be damaged tank may overflow and can be damaged Bear in min Bear...

Page 80: ...sis wiring harness by The telltale has its own wiring harness connected to the engine chassis wiring harness by means of plug X16 means of plug X16 3 38 8 X XE E1 16 6 2 2 d dr riiv ve e a alla ar rm...

Page 81: ...oil drip tray hose is in oil drip tray Oil drain valve Oil drain valve Completely drain the oil Completely drain the oil Unscrew drain coupling Unscrew drain coupling Screw on cap Screw on cap Fill i...

Page 82: ...of the movements for about 5 seconds the diesel engine is set to idling speed by means of the hydraulic ram and the controls directional valve and time lag relay As soon as a work hydraulic ram and th...

Page 83: ...SERV HB 38Z3 EN SERV HB 38Z3 EN Edition 2 1 Edition 2 1 38z3s710 fm 38z3s710 fm 1 1 Revs control retrofit kit 1 Revs control retrofit kit 1...

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