Wacker Neuson EZ38 Operator'S Manual Download

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OM EZ38 us 1.1 * ez38b800.fm

8-1

Troubleshooting

NOTICE

Contact a Wacker Neuson service center in case of malfunctions or signs
that are not listed in the following tables

or that persist after maintenance

on or with the machine has been performed correctly.

8.1

Diesel engine malfunctions

Malfunction/sign

Indicator

light

Possible cause

Remedy

See

Engine does not start or is
not easy to start

Empty fuel tank

Refueling

7-27

Malfunctioning or discharged
battery

Replace the battery

7-48

Malfunctioning fuse

Check the fuse

9-4

Control lever base not raised Raise the control lever base

4-19

Engine starts, but does not
run smoothly or faultless

Air in fuel system

Let the engine run

7-30

Water in fuel system

Empty the water separator

7-30

Engine overheats

Engine oil level too low

Add engine oil

7-34

Dirty air filter

Contact a Wacker Neuson
service center.
Replace the air filter

Dirty radiator fins

Clean the radiator

7-37

Coolant level too low

Add coolant

7-36

Malfunctioning or insuffi-
ciently tightened V-belt

Contact a Wacker Neuson
service center

Engine overheats

Torn V-belt

Stop operation immediately,
have the error repaired by a
Wacker Neuson service
center

Engine does not have
enough output

Dirty air filter

Contact a Wacker Neuson
service center
Replace the air filter

Insufficient or no engine oil
pressure

Engine oil level too low

Add engine oil

7-34

Black engine smoke

Dirty air filter

Contact a Wacker Neuson
service center
Replace the air filter

Blue engine smoke

Oil level too high

Contact a Wacker Neuson
service center

The indicator light for the
coolant temperature illumi-
nates (red) and the buzzer
sounds

Coolant temperature is too
high

Let the engine run at idling
speed without any load
Wait until the temperature
drops and the indicator light
goes out
Stop the engine
Check the coolant level

4-37

Troubleshooting

Summary of Contents for EZ38

Page 1: ...Track Excavator EZ38 OPERATOR S MANUAL 5200016122 1 1 0814 www wackerneuson com 5 2 0 0 0 1 6 1 2 2 ...

Page 2: ...ction or translation of this publication in whole or part without the written consent of Wacker Neuson Linz GmbH Violations of legal regulations in particular of the copyright protection will be subject to civil and criminal prosecu tion Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their prod ucts For this reason we may from time to time need to ...

Page 3: ...1 Machine overview 3 1 3 2 Brief description of the machine 3 2 3 3 Notices and regulations on use 3 4 3 4 Labels 3 7 4 Putting into operation 4 1 Cabin control stand 4 1 4 2 Overview of control elements 4 31 4 3 Indicator lights and warning lights overview 4 36 4 4 Preparatory work 4 39 4 5 Starting and stopping the engine 4 43 5 Operation 5 1 Steering system 5 1 5 2 Accelerator actuation 5 1 5 3...

Page 4: ...em 7 50 7 18 Tires Tracks 7 50 7 19 Maintenance of attachments 7 53 7 20 Maintenance of options 7 53 7 21 Exhaust gas treatment 7 54 7 22 Machine preservation 7 54 8 Troubleshooting 8 1 Diesel engine malfunctions 8 1 8 2 Malfunctions of the traveling drive 8 2 8 3 Malfunctions of the hydraulic system 8 2 8 4 Malfunctions of the electrical system 8 3 8 5 Troubleshooting the air conditioning 8 4 8 6...

Page 5: ...pendix XI DGUV Test Prüf und Zertifizierungsstelle Fachbereich Bauwesen Landsberger Str 309 D 80687 Munich Distinguishing EU number 0515 Notified body according to Directive 2000 14 EC appendix VI TÜV SÜD Industrie Service GmbH Westendstr 199 D 80686 Munich Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directi...

Page 6: ...ed sound power level 94 dB A Guaranteed sound power level 95 dB A Directives and standards We hereby declare that this product corresponds to the relevant regulations and requirements of the following Directives and standards 2006 42 EC 2004 108 EC 2002 44 EC 2005 88 EC 2000 14 EC DIN EN ISO 12100 2010 DIN EN 474 1 2006 A1 2009 except 7 3 DIN EN 474 5 2012 DIN EN ISO 3471 2010 DIN EN ISO 3744 2010...

Page 7: ...at new personnel but it also serves as a reference for experienced personnel Furthermore the reliability and the service life of the machine will be increased by following the instructions in the Operator s Manual This is why the Operator s Manual must be kept at hand in the machine The operator must carefully read and understand the Operator s Manual before starting up servicing or repairing the ...

Page 8: ...n alphabetical list B Continuation of an alphabetical list Cross references see page 1 1 page Cross references 7 pos no or table no Cross references Fig 5 fig no 1 Cross references see chapter 5 Operation on page 5 1 see chapter Cross references see Operation on page 5 1 see text Information Identifies an information that when followed provides for a more efficient and economical use of the machin...

Page 9: ...es regarding operation for example TOPS Tip Over Protective Structure ROPS Roll Over Protective Structure without losing contact with the ground FOPS Falling Objects Protective Structure FGPS Front Guard Protective Structure AUX Auxiliary hydraulic circuit B Width NE Nominal width PS Stabilizer blade LS Stick VDS Vertical Digging System HSWS Hydraulic Easy Lock quickhitch s h Service hours Pos Pos...

Page 10: ...me unit 1 cm 0 061 in 1 m 35 31 ft 1 ml 0 034 US fl oz 1 l 0 26 gal 1 l min 0 26 gal min Unit of length 1 mm 0 039 in 1 m 3 28 ft Weight 1 kg 2 2 lbs 1 g 0 035 oz Pressure 1 bar 14 5 psi 1 kg cm 14 22 lbs in Force output 1 kN 224 81 lbf 1 kW 1 34 hp 1 PS 0 986 hp Torque 1 Nm 0 74 ft lbs Speed 1 kph 0 62 mph Acceleration 1 m s 3 28 ft s ...

Page 11: ...age caused by these modifications shall not be applicable The safety of the machine can be negatively affected by performing machine modifications without proper authority and by using spare parts equipment attachments and optional equipment that have not been checked and released by Wacker Neuson GmbH Warranty and product liability for possible damage caused by these modifications shall not be ap...

Page 12: ...1 6 OM EZ38 us 1 1 ez38v100 fm 1 Notes ...

Page 13: ...njury or death WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury Consequences in case of non observance Obey all safety messages that follow this symbol to avoid possible injury or death CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury Consequences in case of non observance Obey ...

Page 14: ...use also includes observing the instructions set forth in this Operator s Manual and observing the maintenance schedule 4 Machine safety can be negatively affected by performing machine modifications without proper authority and by using spare parts equipment attachments and optional equipment which have not been checked and released by Wacker Neuson Wacker Neuson will not be liable for damage res...

Page 15: ...ting or servicing persons to wear protective clothing and safety equipment Operator training and knowledge Always keep this Operator s Manual and other manuals that accompany the machine in their storage compartment provided in the operator station on the machine Immediately replace an incomplete or illegible Operator s Manual All persons working on or with the machine must read and understand the...

Page 16: ...der any circumstances Machines with a maximum authorized lifting capacity of over 1000 kg 2 205 lbs or an overturning moment of over 40 000 Nm 29 500 ft lbs may be used for lifting gear applications if the following conditions are fulfilled Acoustic and optical warning device see chapter 3 20 Safe load indicator option on page 3 72 Load holding control valve see chapter 3 17 Load holding control v...

Page 17: ... only after the machine operator has given his permission The machine operator may give his permission only after the machine is at a standstill and the work attachment no longer moves General instructions Staying under suspended loads in the danger zone or under the machine s attachment is prohibited The machine operator and the person attaching or securing the load must have visual contact Perso...

Page 18: ...ment on the undercarriage and the steering and brake systems can be performed only by skilled individuals who have been specially trained for such work Work on the hydraulic system of the machine must be performed only by a technician with special knowledge and experience in hydraulic equipment 2 6 Safety instructions Regarding Operation Preparing for use The machine must only be used in technical...

Page 19: ...a heater plug intake air pre heating is used at the same time Make sure the control levers the signaling and the light systems are functional before operating the machine and also before restarting after an interruption of work Fold up the control lever base before releasing the seat belt in order to avoid unintentional operation Job site awareness Familiarize yourself with the surroundings and ci...

Page 20: ... sloping terrain adapt your travel speed to the prevailing ground conditions Never get on or off a moving machine and do not jump off the machine The travel control levers require practice before an operator becomes familiar with the control response Therefore adjust the travel speed to your abilities and the surroundings During traveling across a slope with the telescopic undercarriage extended p...

Page 21: ...n Craning applications are procedures involving raising transporting and lowering loads with the help of slings and load securing devices for example ropes and tracks In doing so the help of persons is necessary for securing and detaching the load This applies for example to lifting and lowering pipes shaft rings or containers The excavator may be used for applications with lifting gear ONLY if th...

Page 22: ...y to avoid damage and potential injury Confirm that the attachment has been properly and securely attached to the machine according to the instructions Before using the attachment the operator shall confirm that the attachment performs correctly in response to control actuation Do not attach the attachment with the engine running and the machine moving Before putting the machine attachment into op...

Page 23: ...ed tie down points Confirm that the excavator tie down procedures will prevent sideways forward rearward and upward motion of the excavator in the event the transport vehicle is involved in an incident or sudden avoidance maneuver 2 10 Safety Guidelines for Maintenance General maintenance notes Adhere to prescribed intervals or those specified in this Operator s Manual for routine checks inspectio...

Page 24: ...abel such as Repair work do not start machine to the control elements as a precautionary measure Observe the startup and shutdown procedures set forth in this Operator s Manual This applies to any work concerning the operation conversion or adjustment of the machine and its safety oriented devices or any work related to inspection and maintenance Prior to performing assembly work on the machine st...

Page 25: ...ached and secured to lifting gear Use only suitable lifting gear and suspension systems in a technically perfect state with adequate load bearing capacity Stay clear of suspended loads Clean the machine especially connections and threaded unions of any traces of oil fuel or preservatives before performed maintenance repair work Do not use aggressive detergents Use lint free cleaning rags Before cl...

Page 26: ...reheating is used at the same time risk of explosions Apply special care when working on the fuel system increased risk of fire Tracks Repair work on the tracks must be performed only by trained technical staff or by a Wacker Neuson service center Malfunctioning tracks reduce the machine s operational safety Therefore check the tracks regularly for cracks cuts or other damage Check track tension a...

Page 27: ...tings lengths and quality of the hoses must comply with the technical requirements Noise Close all doors and windows if practical Wear ear protection This is especially important when performing hammer operations or working in enclosed areas MSDS When handling oil grease and other chemical substances such as battery electrolyte or hydraulic fluid observe the product related safety regulations Mate...

Page 28: ...Engine exhaust contains carbon monoxide This is a poison you cannot see or smell Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation through such items as muffler fans or hoses is provided Do not smoke during operating the machine Do not run the engine near open flames Do not touch the engine or muffler during the engine is running or immediately ...

Page 29: ... lights option 3 Lifting eye 4 Rotating beacon option 5 Door arrester 6 Engine cover 7 Fuel tank filler inlet 8 Exhaust pipe 9 Eye hook for tying down the machine 10 Stabilizer blade 11 Travel gear 12 Handle 13 Auxiliary hydraulics 14 Door handle and lock 15 Tank cover 1 6 3 3 8 2 3 4 9 9 10 11 12 13 15 5 14 13 2 7 Introduction ...

Page 30: ...chine are Travel gear Travel gear Stabilizer blade Live ring Upper carriage Cabin Water cooled Diesel engine Hydraulic and electrical components Boom Information The machine can be equipped with the Telematic option for transmitting operating data location etc via satellite The Diesel engine permanently drives a variable displacement pump whose oil flow is sent to the control valve Depending on ac...

Page 31: ...on for canopy protective structure against fragments flying around from the front Definition of FOPS Front Guard categories Level I Protection against small falling objects FOPS or small objects penetrating into the cabin from the front Front Guard such as bricks small pieces of concrete tools for machines that are used for repairing roads landscaping work and for working on other construction sit...

Page 32: ... from use other than mentioned above The operator machine owner alone will bear the risk Designated use also includes observing the instructions set forth in the Operator s Manual and observing the maintenance and service conditions The machine may not be used for transport jobs on public roads In applications with lifting gear the machine is used according to its designated use only if the mandat...

Page 33: ...nual of the attachment manufacturer for using and performing maintenance on attachments such as hammers grabs hydraulic quickhitch etc EZ38 without quickhitch Bucket type Width Weight Capacity Bucket 400 mm 16 in 53 kg 117 lbs 0 069 m3 2 44 ft3 Bucket 600 mm 24 in 70 kg 154 lbs 0 107 m3 3 8 ft3 Bucket 700 mm 28 in 78 kg 172 lbs 0 127 m3 4 5 ft3 Ditch cleaning bucket 1000 mm 39 in 87 kg 192 lbs 0 1...

Page 34: ...7 lbs 0 150 m3 5 3 ft3 EZ38 with hydraulic Easy Lock quickhitch Bucket type Width Weight Capacity EZ38 equipment Attachments Weight Hydraulic Easy Lock quickhitch console HS 03 33 kg 73 lbs Hammer bracket HS 03 NE 16 27 kg 60 lbs Hammer bracket HS 03 NE 22 30 kg 66 lbs Hammer NE 16 150 kg 331 lbs Hammer NE 22 220 kg 485 lbs Hydraulic Easy Lock quickhitch console HS 03 with Powertilt 104 kg 229 lbs...

Page 35: ... 5 Description of attachment HYDRAULIC EXCAVATOR Fahrzeug Seriennummer serial no no de série Machine serial number Fahrzeug Modell model modèle Machine designation Leistung performance Engine output Typ version Machine type Betriebsgewicht operating weight poids en charge Operating weight Transportgewicht transport weight poids en transport Transport weight G Gew GWR PTAC Gross weight rating admis...

Page 36: ...he serial number is located on the type label The type label is located on the hydraulic quickhitch fork Powertilt with hydraulic quickhitch The serial number of the Powertilt is stamped in the housing near the hydraulic connections The serial number of the hydraulic quickhitch is located on the type label The type label is located on the hydraulic quickhitch fork Fig 6 Fig 7 Fig 8 Fig 9 ...

Page 37: ...he middle of the chassis FOPS type label small screen The type label is located at the front left on the chassis Front Guard type label The type label is located at the upper right of the chassis Information Type quantity and position of the labels depend on options country and machine Fig 10 Fig 11 Fig 12 ...

Page 38: ...3 10 OM EZ38 us 1 1 ez38e300 fm 3 Warning labels Fig 13 ...

Page 39: ...ine s danger zone during operation Position At the front of the chassis near the swiveling console Meaning Explosion hazard Connecting jump leads incorrectly can cause explosions and personal injuries with possible death Position Next to the battery Meaning Crushing hazard Stay clear of the machine s swiveling range during operation Position On the rear window Meaning Modifications to the structur...

Page 40: ...d by a Wacker Neuson service center Position In the engine compartment on the cover of the relay box Meaning option This label indicates the emergency exit on machines equipped with the Front Guard option Position On the upper edge of the rear window in the cabin Meaning option Crushing hazard Exceeding the specified load stability can cause serious injuries and even death Can cause serious damage...

Page 41: ...gradient angle and maximum lateral angle of inclination Do not use high speed While operating the machine maintain a safe distance from overhead electric lines Can cause severe injuries due to electric shock Position Canopy on the C pillar on the left in driving direction Cabin on the B pillar on the left in driving direction Meaning option Always switch on the safe load indicator during lifting g...

Page 42: ...e cool down Injury hazard due to fluid escaping under pressure Let the engine cool down Release the pressure in the hydraulic system and open the covers carefully Position On the engine cover Meaning Burn hazard due to hot parts on the boom lines plug and socket connections threaded fittings hydraulic cylinders couplings etc Position On the boom on the left and right Meaning Reflector at the rear ...

Page 43: ...OM EZ38 us 1 1 ez38e300 fm 3 15 3 Labels Fig 29 ...

Page 44: ...3 Other biodegradable hydraulic oil Position Next to the filler inlet of the hydraulic oil reservoir Meaning Indicates the lifting points of the machine Position On either side of the stabilizer blade and on either side of the boom Meaning Indicates the tie down points for tying down the machine Position On either side of the stabilizer blade and on either side of the travel gear Meaning Indicatio...

Page 45: ...hours or daily Position On the upper carriage at the front left in driving direction Meaning option Indicates the lubrication points of the VDS tilt console Position On the roof window on right hand side in driving direction Meaning This label indicates the position in which the control levers are locked Position On the left hand control lever base Meaning Fuses Position At the left under the seat...

Page 46: ...in driving direction Meaning option Indicates the control operations that do not comply with the ISO standard if the SAE controls are selected Position On the roof window on right hand side in driving direction Meaning The coolant must have a thermal stability of at least 30 C 22 F Position In the engine compartment on the expansion tank Fig 39 Wiring diagram Controls A ISO controls Operating Patt...

Page 47: ...of the proportionally controlled auxiliary hydraulics Operating Pattern A ISO controls Check before starting the machine the operating pattern that has been chosen Position On the roof window on right hand side in traveling direction Meaning This label describes the functions of the pedals control levers and 3rd control circuit Powertilt with proportional controls Operating Pattern A ISO controls ...

Page 48: ... on the left in traveling direction Meaning This label describes the functions of the hydraulic Easy Lock quickhitch Position On the roof window on right hand side in traveling direction Meaning This label shows how to refuel with a fuel filling pump Position Near the fuel filling pump Fig 45 Fig 46 Fig 47 ...

Page 49: ...the mandatory climbing aids A clean and use them for entering and exiting Face the machine as you enter and leave it Have damaged climbing aids replaced Entry and exit canopy Stop the machine see chapter Operation stopping the machine Cabin entry and exit option Stop the machine see chapter Operation stopping the machine Information During entering or leaving the cabin the door must be locked in t...

Page 50: ... outside Press door lock A Locking the door 1 Turn the key in door lock A clockwise R 2 The door is locked Unlocking the door 1 Turn the key in door lock A counter clockwise L 2 The door is unlocked Opening the door from the inside Press lever A on the door lock downward Fig 50 A R Fig 51 A ...

Page 51: ... ez38i400 fm 4 3 4 Securing an open door Press bracket A against arrester B until it engages with an audible click Releasing the door arrester Pull button A to release the door out of the arrester Fig 52 B A Fig 53 A ...

Page 52: ... for closing the doors CAUTION Crushing hazard Be careful when opening and closing the front window Can cause minor injuries Hold both handles Duck your head Let both locks lock into place Keep extremities and clothing clear of the window channel Opening the front window 1 Keep levers A pressed on the left and right and pull the front window upward with both handles B Fig 54 Fig 55 A B ...

Page 53: ...s A and let them engage in both locks C Closing the front window 1 Press levers A on the left and right and pull the front window downward with both handles B 2 Press levers A on either side and engage them in the lock Fig 56 C A Fig 57 A B Fig 58 A ...

Page 54: ... pull the front window upward with both handles B 2 Let levers A engage in both locks C Closing the lower front window 1 Keep levers A pressed on the left and right and pull the lower front window downward with handles B 2 Release levers A and let them engage in both locks C Fig 59 Fig 60 B C A Fig 61 A B C ...

Page 55: ...ht and pull the lower front window upward with both handles B 2 Let levers A engage in both locks C 3 Keep levers A pressed on the left and right and pull the entire front window upward with both handles B 4 Release levers A and let them engage in both locks C Fig 62 Fig 63 A B C Fig 64 A B Fig 65 A C ...

Page 56: ...nd pull the front window downward with both handles B 2 Press levers B and make them lock into place on either side 3 Keep levers A pressed on the left and right and pull the lower front window downward with handles B 4 Release levers A and let them engage in both locks C Fig 66 B A Fig 67 A Fig 68 A B C ...

Page 57: ...nt window to the inside 2 Release levers A and let them engage in both locks B Close 1 Press levers A on either side 2 Press the front window forward and let it engage Opening closing the side window Open Press lever D upward and let the side window engage in the required recess Close Press lever D upward and close Fig 69 Fig 70 B A Fig 71 D ...

Page 58: ... protective Front Guard structures option WARNING Personal injury hazard during emergency exit using the right window Can cause severe injury or death The emergency exit through the right window of the machine has neither footholds nor handholds for safely entering or exiting the cabin CAUTION Personal injury hazard due to glass splinters Can cause minor injuries Protect your face and eyes from th...

Page 59: ...ury hazard due to incorrect seat adjustment An incorrect weight adjustment can cause injuries to the spinal cord Ensure that the seat is correctly adjusted to the operator s weight before traveling or operating the machine 1 Sit down on the seat 2 Turn lever A counter clockwise Adjusts a higher weight 3 Turn lever A clockwise Adjusts a lower weight Backrest adjustment 1 Sit down on the seat 2 Pull...

Page 60: ...4 12 OM EZ38 us 1 1 ez38i400 fm 4 Horizontal adjustment 1 Sit down on the seat 2 Pull lever C upward and move the seat forward or backward at the same time Fig 75 C ...

Page 61: ... to damaged or dirty seat belt A damaged or dirty seat belt can cause serious injuries or death Keep the seat belt and buckle clean and check them for damage Have a damaged seat belt and buckle immediately replaced by a Wacker Neuson service center Have the seat belt immediately replaced after every accident and the bearing capacity of the fastening points and seat fixtures checked by a Wacker Neu...

Page 62: ...he red pushbutton switch D on seat belt buckle B until the buckle latch comes out 2 Place seat belt C aside Longer shorter seat belt adjustment Longer seat belt adjustment Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length Shorter seat belt adjustment Pull the free end of the seat belt and shorten it to the required length Fig 76 A B C Fig 77 C B D ...

Page 63: ... hazard due to damaged or dirty seat belt A damaged or dirty seat belt can cause serious injuries or death Keep the seat belt and buckle clean and check them for damage Have a damaged seat belt and buckle immediately replaced by a Wacker Neuson service center Have the seat belt immediately replaced after every accident and the bearing capacity of the fastening points and seat fixtures checked by a...

Page 64: ... belt Insert buckle latch A into seat belt buckle B with an audible click Unfastening the retracting seat belt 1 Press the red pushbutton switch D on seat belt buckle B until the buckle latch comes out Seat belt C is automatically retracted Fig 79 A B Fig 80 D B C ...

Page 65: ...rrors guide for example Additional equipment or attachments must not be installed if they impair visibility WARNING Accident hazard due to incorrect adjustment of visual aids Incorrectly adjusted visual aids can cause serious injuries or death Adjust the visual aids before machine operation Immediately replace damaged or broken visual aids Curved mirrors enlarge reduce or distort the field of view...

Page 66: ...hine in the left hand mirror Ensure visibility of the rear right edge of the machine in the right hand mirror Information Set the machine to travel position before adjusting the mirrors see Travel position on page 5 3 Information We recommend having the mirrors adjusted by a second person Information Do not make any changes or modifications that impair visibility Otherwise the machine does not mee...

Page 67: ...can be rotated The engine cannot be started Functional check of control lever base Perform a functional check of the control lever base every time before you start the machine 1 Start the machine 2 Fold the control lever base down 3 Travel on open terrain 4 Secure the danger zone 5 Stop the machine 6 Raise the control lever base 7 Move all control levers and pedals in all directions The selected e...

Page 68: ...s standard nor optional equipment If necessary a fire extinguisher according to NFPA must be installed by a Wacker Neuson service center A suitable bracket for the cabin or canopy must be fastened on the cabin framework behind the seat Information Ensure the firm and safe mounting of the fire extinguisher Check the fire extinguisher at regular intervals also ensure that it is safely installed Obse...

Page 69: ...in case of doubt Retrofit assembly and repair work may only be performed by a Wacker Neuson service center Replace self locking fasteners Information Machine operation is only allowed with a correctly installed and intact cabin or correctly installed and intact canopy For additional protection only use correctly installed and intact Wacker Neuson protective structures that have been released for t...

Page 70: ...on is prohibited without a protective FOPS structure Information The protective FOPS structure corresponds to level I according to ISO 3449 1992 The machine owner must ensure that the hazard situation is evaluated and that the national regulations are observed The machine owner must ensure that only work is performed that does not require any higher protection Accidents cannot be fully avoided des...

Page 71: ... 2 persons are required for installing removing 4 Install the lock nuts and screws on either side 5 Tighten screws A M10 and lock nuts on the left and right to 45 Nm 33 ft lbs 6 Tighten screws B M12 and lock nuts on the left and right to 87 Nm 64 ft lbs 7 Install the light in position C option 8 Install the mirror in positions D option Fig 85 Fig 86 B A Fig 87 C D ...

Page 72: ...on is prohibited without a protective FOPS structure Information The protective FOPS structure corresponds to level I according to ISO 3449 2008 The machine owner must ensure that the hazard situation is evaluated and that the national regulations are observed The machine owner must ensure that only work is performed that does not require any higher protection Accidents cannot be fully avoided des...

Page 73: ... Remove all lights option 3 A minimum 2 persons are required for installing removing 4 Install the lock nuts and screws on either side 5 Mounting point for protective structure A 6 Tighten screws B and lock nuts on the left and right to 65 Nm 48 ft lbs 7 Mounting point for cabin canopy C Fig 88 Fig 89 A B Fig 90 C C ...

Page 74: ...ccording to ISO 10262 1998 The machine owner must ensure that the hazard situation is evaluated and that the national regulations are observed The machine owner must ensure that only work is performed that does not require any higher protection Accidents cannot be fully avoided despite equipping a machine with protective structures Installing 1 Stop and park the machine Stop the engine See Prepari...

Page 75: ...tective structure B lower 7 Mounting point for cabin canopy C upper D lower 8 Tighten lock nuts and screws E to 65 Nm 48 ft lbs 9 Install the mirror in both positions F option 10 Install the light in position G option Fig 93 B Fig 94 C D Fig 95 F E G Fig 96 E ...

Page 76: ...t hazard in conditions of restricted visibility due to rain snowfall dust etc Restricted visibility can cause minor injuries Stop machine operation immediately Resume work only if visibility is no longer restricted NOTICE Do not use brushes steel wool or other abrasive cleaners for cleaning the polycarbonate disc Do not wipe dust in a dry state Information The shatter protection canopy option prot...

Page 77: ... the height of the job site Installing 1 A minimum 2 persons are required for installing removing 2 Stop and park the machine Stop the engine See Preparing lubrication 3 Install remove shatter protection A from the front and fasten remove it at the fastening points B with the fastening material supplied 4 Tighten screws C at fastening points B to 25 Nm 18 ft lbs Fig 97 A Fig 98 Fig 99 B B A Fig 10...

Page 78: ...side 2 Tighten screw A to 85 Nm 63 ft lbs 3 Raise the floor mat on the outer right side 4 Tighten lock nut B to 85 Nm 63 ft lbs 5 Tighten screw C to 85 Nm 63 ft lbs 6 Tighten screw D to 85 Nm 63 ft lbs 7 Tighten screw E to 85 Nm 63 ft lbs 8 Tighten screw F to 85 Nm 63 ft lbs Fig 101 A Fig 102 B C Fig 103 D E Fig 104 F ...

Page 79: ...n Socket A 12 V socket is located at the front left of the machine chassis 4 2 Overview of control elements This chapter describes the controls and contains information on the function and handling of the indicator lights and controls in the cabin The pages stated in the table refer to the description of the controls Fig 105 ...

Page 80: ...4 32 OM EZ38 us 1 1 ez38i400 fm 4 Cabin 2 1 3 6 12 23 8 9 10 15 17 14 19 18 21 4 6 5 22 13 Fig 106Overview of control elements proportional controls Fig 106 Overview of control elements 16 20 11 7 21 ...

Page 81: ... controls 5 21 11 Starter lock 4 43 12 Right hand switch panel 4 34 13 12 V power outlet cabin option 14 Temperature controller cabin option 5 11 15 Radio option 16 ISO SAE changeover 5 19 17 Seat 4 11 18 Throttle 5 1 19 Oil flow AUX II rotary switch proportional controls 5 21 20 Switch panel on left hand control lever base 4 34 21 Changeover of boom swivel pedal 22 Powertilt AUX II or 3rd control...

Page 82: ...00 fm 4 Display element and switches Fig 107 Switch panel on left hand control lever base Right switch panel cabin 26 27 25 28 29 30 31 32 34 35 39 40 41 42 43 33 36 48 49 50 44 45 46 47 44 47 Right switch panel canopy 38 36 37 ...

Page 83: ... meter 4 38 35 Hour meter maintenance meter changeover 4 37 36 Not assigned 37 Hydraulic oil filter monitoring 4 37 38 Air filter monitoring 4 37 39 Tilting the upper carriage Vertical Digging System option 5 54 40 Working lights 5 8 41 Safe load indicator option 5 48 42 Hydraulic quickhitch option 5 32 43 Wiper wash system cabin 5 10 44 Rotating beacon option 5 9 45 Ventilation heating cabin 5 11...

Page 84: ...nates The electrical system works if the indicator light of the electrical system goes out within one minute Engine oil pressure The indicator light red illuminates and the buzzer sounds Stop the engine immediately and check the oil level If the engine oil level is correct contact a Wacker Neuson service center Note The indicator light illuminates when the starter is turned on and goes out as soon...

Page 85: ...speed and little load Contact a Wacker Neuson service center if the indicator light does not go out Air filter monitoring The indicator light red illuminates if the air filter is dirty and if it has to be replaced Stop and park the machine Contact a Wacker Neuson service center Changeover between hour meter and maintenance counter Fuel level indicator Indicates the remaining amount of fuel in the ...

Page 86: ...ge indicator light goes out The hour meter is used for specifying the maintenance intervals Maintenance meter service hours up to next servicing The maintenance meter starts at 500 0 hours It counts down to 0 0 hours A wrench symbol flashes as soon as the maintenance meter reaches this value The meter keeps on counting down 0 1 hours 0 2 hours etc Symbol Designation ...

Page 87: ...ructions in this Operator s Manual The machine owner must observe the local regulations Perform a functional check of the control lever base Perform a functional check of the safe load indicator option Do not make any changes or modifications that impair visibility Otherwise the machine does not meet the requirements for conformity and licensing Observe the safety instructions in chapter Safety 2 ...

Page 88: ... if necessary 7 31 7 32 3 Correct engine oil level 7 33 4 Coolant level OK 7 35 5 Correct oil level in the hydraulic oil reservoir 7 43 6 Glass cleaner in washer tank OK 7 49 7 Lubrication points greased 7 6 8 Tracks checked for cracks cuts etc 9 Light system signalling warning and indicator lights operational 10 Windows mirrors lights steps all pedals and control levers clean 11 All control lever...

Page 89: ... hydraulic oil filter and air filter do not illuminate 4 37 5 Do the pedals and control levers work correctly 5 13 6 Performed functional check of control lever base 4 19 No Question Page 1 Attachment lowered to the ground 5 34 5 39 2 Stabilizer blade lowered to the ground 5 20 3 Control lever base raised 4 19 4 Cabin locked especially if the machine cannot be supervised 4 2 When parking on public...

Page 90: ...refully during its first 50 operating hours Do not load a cold engine Warm up the machine at low engine speed and little load do not warm it up at a standstill Do not change engine speed abruptly Avoid using the machine under heavy loads and or at high speeds Avoid abrupt acceleration braking and changing traveling direction Do not run the engine at high speed for extended periods Strictly observe...

Page 91: ...interlock Do not run the starter for more than 10 seconds Wait about 1 minute so the battery can recover and the starter does not overheat before trying again Information Ensure that there is sufficient ventilation before operating the machine in enclosed areas Information All controls must be within easy reach You must be able to move the travel levers to their limit positions Starter lock Fig 10...

Page 92: ...he engine starts All indicator lights go out If the engine does not start after 10 seconds Interrupt the start procedure and repeat it after about 1 minute If the engine still does not start after a few tries contact a Wacker Neuson service center for error analysis 6 As soon as the engine runs Release the starting key Information The engine will not start unless the left hand control lever base i...

Page 93: ... hazard due to rotating parts Rotating parts can cause serious injuries or death Open the engine cover only at engine standstill NOTICE Damage to machine due to electrical short circuit or overvoltage The positive terminal of the starting battery must not be brought into contact with electrically conductive vehicle parts NOTICE Damage to machine due to higher battery voltage Only use batteries wit...

Page 94: ... at the rear of battery master switch A 5 First connect one end of the red battery jumper cable to the rear of battery master switch A then connect the other end to the positive terminal of the starting battery 6 Connect one end of the black battery jumper cable to the negative terminal of the starting battery 7 Connect the other end of the black battery jumper cable to metal part B 8 Wait at leas...

Page 95: ...s of low load operation are Increased engine oil consumption Dirt in engine due to engine oil in exhaust system Blue smoke in exhaust gas Stopping the engine NOTICE Engine damage by stopping the engine after full load In order to avoid heat accumulation let the engine run at idling speed with no load for at least 5 minutes and then stop it Turn the starting key to 0 and remove it Fig 112 0 1 2 3 P...

Page 96: ...to engine electronics due to operation of battery master switch Do not operate the battery master switch with a running engine Interrupting power supply Turn the key to position B and remove it Establishing power supply Insert the key and turn it to position A Fig 113 A B ...

Page 97: ...speeds that can be selected with the stabilizer blade lever 25 Normal speed The high speed symbol green does not illuminate Switch in position 0 High speed The high speed symbol green illuminates Switch in position 1 The machine automatically switches to slow speed if it encounters a higher driving resistance for example in curves If the driving resistance is reduced the machine automatically swit...

Page 98: ...s Hydraulic brake Releasing the travel levers travel pedals brakes the machine During traveling downhill the automatic hydraulic brake valves prevent the machine from traveling faster than the admissible travel speed Information Reduce travel speed with the travel levers travel pedals and not with the engine speed control of the engine Mechanical brake The stabilizer blade is used as a parking bra...

Page 99: ...r starting the engine Indicator lights 28 charge indicator light and 29 engine oil pressure go out Slowly actuate the travel lever Machine starts traveling Information The machine will not start travel unless the control lever bases are folded down Stopping see chapter Hydraulic brake on page 5 2 Operating temperature range The following operating conditions must be fulfilled in order to ensure op...

Page 100: ...g downhill or uphill with a full attachment Traveling diagonally on slopes is prohibited Stones and the humidity in the upper layer of the ground can drastically affect machine traction and stability The machine can slip sideways on gravel or loose rocky soil The stability of the machine can be reduced on rough terrain Newly filled or muddy ground can give away under the weight of the machine or t...

Page 101: ... side must face uphill Set the stabilizer blade uphill Raise the boom about 20 30 cm 8 12 in off the ground and position it straight ahead at the center of the machine Do not exceed a maximum gradient angle of 15 Traveling downhill During traveling downhill the front side must face downhill Set the stabilizer blade downhill Raise the boom about 20 30 cm 8 12 in off the ground and position it strai...

Page 102: ...angle of inclination Do not exceed a maximum lateral angle of inclination of 10 On lateral inclinations over 10 pile up material to create a horizontal firm and level surface that can be used as a platform for the machine Fig 123 10 Fig 124 10 ...

Page 103: ...se the pressure in the hydraulic system 6 Remove the starting key and carry it with you 7 Raise the control lever base 8 Close the windows and doors 9 Close and lock all covers and doors 10 Secure the tracks accordingly chocks blocks for example as shown in Fig 125 Information In order to prevent the formation of condensation water add the fuel tank nearly completely at the end of each working day...

Page 104: ...mination of the job site can be ensured without blinding other motorists Information Switch on the working lights in poor light conditions If illumination still is not sufficient use external lights If this is yet not enough to illuminate the job site sufficiently stop work and only take it up again if sufficient illumination can be ensured Fig 127 40 Position Function ON Press switch 40 down Work...

Page 105: ...ate the horn Rotating beacon option The switch is located on the right hand switch panel Information Observe the legal regulations of your country for operating the rotating beacon Fig 129 Fig 130 5 Fig 131 44 Position Function ON Press switch 44 down Rotating beacon switched on the indicator light in switch 44 illuminates OFF Press switch 44 up Rotating beacon switched off the indicator light in ...

Page 106: ...r observe the relevant national regulations 5 7 Wiper wash system Front wiper The switch is located on the right hand switch panel NOTICE Damage to wiper if the front window is raised Do not actuate the wipers if the front window is raised Washer system NOTICE Damage to electric pump if the tank is empty Do not actuate the washer system if the tank is empty Fig 132 43 Position Function OFF Press s...

Page 107: ...rn temperature controller 14 clockwise Heating Turn temperature controller 14 counter clockwise Fig 134 45 Position Function 1st position Press switch 45 down one step Low fan speed 2nd position Press switch 45 down two steps High fan speed OFF Press switch 45 all the way up Fan is switched off Fig 135 1 2 Position Function 1 Loosen the screw and slide it to the left Ventilation is closed 2 Loosen...

Page 108: ...t 10 15 minutes to ensure its full function and efficiency Information During machine operation with air conditioning turned on the machine s hydraulic performance is slightly reduced Fig 137 46 Position Function ON Press switch 46 down Air conditioning is switched on OFF Press switch 46 up Air conditioning is switched off ...

Page 109: ...ward Right hand track forward Left hand track reverse Right hand track reverse Extend stick Swivel upper carriage to the right Retract stick Swivel upper carriage to the left Swivel boom to the right Swivel boom to the left Lower boom Dump bucket Raise boom Curl bucket Lower stabilizer blade Raise stabilizer blade ISO controls Standard Proportional controls option Operation ...

Page 110: ...ht hand track forward Left hand track reverse Right hand track reverse Extend stick Swivel upper carriage to the right Retract stick Swivel upper carriage to the left Swivel boom to the right Swivel boom to the left Lower boom Dump bucket Raise boom Curl bucket Lower stabilizer blade Raise stabilizer blade SAE controls Standard Proportional controls option ...

Page 111: ...sure that both tracks move as you change direction The stabilizer blade side is the front side main traveling direction Raise the boom and the stabilizer blade Both the travel levers and the travel pedals can be used for traveling The travel speed depends on the position of the travel levers or travel pedals Fig 138 1 2 3 4 1 2 4 3 Position Function 1 2 Move forward Move forward Machine moves forw...

Page 112: ...ersons in the swiveling range of the machine can be seriously injured Ensure that no one is in the swiveling range If the machine is equipped with an extra weight option the upper carriage projects beyond the tracks when it is rotated Bear in mind the extended width of the machine NOTICE Damage to machine when working in the immediate vicinity of walls parts of buildings or other obstacles Ensure ...

Page 113: ...ic swivel unit brake The upper carriage s rotation is sufficiently braked by moving the left hand control lever back to initial position Moving the control lever in the opposite direction brakes the upper carriage with maximum hydraulic output Functional check of swivel unit brake Perform the functional check on a warm machine after work once a day If the machine is put back into operation after a...

Page 114: ...ng key and carry it with you 7 Raise the control lever base 8 Wait 1 minute 9 Put a piece of wood A against the attachment see figure 10 Wait 1 minute If the attachment does not move from the piece of wood Machine is operational If the attachment moves away from the piece of wood Stop operation immediately Contact a Wacker Neuson service center and have the malfunction rectified Fig 142 Fig 143 9 ...

Page 115: ...lever of the directional valve Do not operate the machine with a malfunctioning wing nut Contact a Wacker Neuson service center and replace the malfunctioning wing nut The changeover valve is located at the front left under the travel gear The changeover valve can be switched between Operating Pattern A ISO controls and Operating Pattern B SAE controls The function label for the controls is affixe...

Page 116: ...formation Lowering the stabilizer blade too deeply into the ground can create a high resistance Slightly raise the stabilizer blade The clearance between the stabilizer blade and the ground should be about 1 cm 0 4 in Raise the stabilizer blade before start traveling Information The stabilizer blade is also used as a parking brake Press the stabilizer blade against the ground Information In order ...

Page 117: ...nal operation of the auxiliary hydraulics depending on the position of slide switch A on the control lever If precision work for example with an offset bucket does not require the full oil flow of the auxiliary hydraulics AUX I and AUX II the oil flow can be set progressively with the rotary switch If the full oil flow is required turn the rotary switch to the right MAX A Fig 149 Fig 150 left hand...

Page 118: ...tection If the machine is equipped with a cabin option all windows and doors must be closed WARNING Accident hazard due to tipping over of machine A tipping machine can cause serious injuries or death During operation all persons must stay clear of the work area of the machine Do not perform any demolition work under the machine This could cause the machine to tip over The machine can lose its bal...

Page 119: ... than 15 seconds Do not raise the machine with the boom Working with the hydraulic cylinders or the boom fully extended is prohibited Do not swivel the Powertilt unit beyond 30 during hammer operation otherwise the load on the boom increases enormously Stop work immediately if a hydraulic hose moves back and forth in an unusual manner The pressure accumulator could be malfunctioning Contact a Wack...

Page 120: ... Release pedal 2 Proportionally controlled hammer AUX I option 1 Turn the rotary switch on the right control lever base to maximum oil flow Switching on hammer operation Push slide switch 23 on the right hand control lever to the left Switching off hammer operation Release slide switch 23 on the right control lever Fig 152 2 Fig 153 Fig 154 23 ...

Page 121: ...ard Proportionally controlled additional control circuit AUX I option 1 Turn the rotary switch on the right hand control lever base to the required position Operating the additional control circuit Oil flow to left hand line Push slide switch 23 on the right hand control lever to the left Oil flow to right hand line Push slide switch 23 on the right hand control lever to the right 2 Fig 155 Fig 15...

Page 122: ...e boom proportionally controlled 1 Turn the rotary switch on the right hand control lever base to the required position 2 Press and hold button A on the left hand control lever base Swiveling the boom Swiveling the boom to the right Push slide switch 23 on the right hand control lever to the right Swiveling the boom to the left Push slide switch 23 on the right hand control lever to the left Fig 1...

Page 123: ...g gear applications only if the mandatory lifting gear joint rod for example and safety equipment optical and acoustic warning devices safe load indicator stability table load holding control valves for example is installed functional and enabled NOTICE If the weight or mass value is exceeded there is a risk of damage to property if the machine tips over Never exceed the weight and mass values spe...

Page 124: ...r As soon as indicator light 31 illuminates and the warning sounds Reduce the load until the indicator light goes out and the warning no longer sounds Suitable OSHA rated and approved equipment for fastening and securing loads must be available see chapter Safe load indicator option on page 5 48 Fig 163 41 Fig 164 31 ...

Page 125: ... switch on the left hand control lever base to the required position Operating the additional control circuit Oil flow to left hand line Push slide switch 22 on the left hand control lever to the left Oil flow to right hand line Push slide switch 22 on the left hand control lever to the right Fig 165 Fig 166 22 ...

Page 126: ... Ensure that no one is in the danger zone Information For more information see Easy Lock Powertilt with Easy Lock Operator s Manual Information The Powertilt unit may only be installed and removed by a Wacker Neuson service center Adjust the required oil flow with the rotary switch on the left hand control lever base Actuating the Powertilt unit Fig 167 Fig 168 22 ...

Page 127: ... Powertilt unit to the left Push slide switch 22 on the left hand control lever to the left Rotating the Powertilt unit to the right Push slide switch 22 on the left hand control lever to the right Fig 169 Rotation to the left Rotation to the right ...

Page 128: ...uries or death Ensure that no one is in the danger zone Do not use a damaged attachment After hitching the attachment or before starting machine operation ensure that the lock is correctly connected with the mount The check pin K must be fully retracted Otherwise repeat the lock cycle until check pin K is retracted Ensure correct locking with a short and rapid succession of stick and bucket moveme...

Page 129: ...h claws A on the side of the machine into pins Z of the attachment mount 6 Extend the bucket hydraulic cylinder so that the second pin D of the attachment touches the quickhitch 7 Check whether the attachment touches the quickhitch with the second pin D 8 Release foot operated pushbutton switch 3 9 Pull and hold stabilizer blade lever 8 as far as it will go The quickhitch closes 10 Release stabili...

Page 130: ...rious injuries or death Ensure that no one is in the danger zone Lower the attachment to level and firm ground ensuring stability 1 Lower the attachment to about 5 10 cm 2 4 in above the ground 2 Actuate switch 42 The buzzer sounds 3 Press and hold foot operated pushbutton switch 3 4 Pull and hold stabilizer blade lever 8 as far as it will go The quickhitch opens and unlocks the attachment Fig 175...

Page 131: ...ade lever 6 Retract the bucket hydraulic cylinder 7 Set down the attachment 8 Raise the boom 9 Release foot operated pushbutton switch 3 10 Pull and hold stabilizer blade lever 8 as far as it will go The quickhitch closes 11 Release the stabilizer blade lever 12 Switch off switch 42 The buzzer is silent Fig 178 K Fig 179 ...

Page 132: ...is performed on either side of the stick Stopping grab operation 1 Move both levers A on the ball type cock to position B Notch C indicates the flow direction Stopping bucket operation 1 Move both levers A on the ball type cock to position C Fig 180 Fig 181 B A C Fig 182 C A ...

Page 133: ...hydraulic circuit in all directions repeatedly 6 Remove the starting key and carry it with you The grab hose couplings can now be coupled and uncoupled from the couplings Hydraulic connections Information Follow the instructions in the Operator s Manual of the attachment manufacturer for connecting the hydraulics to the attachment Fig 183 Stick left A B C Connection Stick left right A Grab control...

Page 134: ...azard when hitching attachments Can cause severe injuries or death Always wear protective equipment when installing the connecting pins Ensure that no one is in the danger zone Only use attachments that are in perfect condition Set and adjust the boom to the correct position with the control levers Align the fastening bores in the attachment with a mandrel to make it easier to insert the pin in th...

Page 135: ...ment to the ground without too much pressure otherwise the resistance when removing the pins is too high Re equipping the attachments is described below for a bucket If you are fitting or removing attachments with their own hydraulic functions offset bucket for example you must follow the special information given in the Operator s Manual of the attachment Information The hydraulic system of the m...

Page 136: ...ing key to position 1 6 Lower the control lever base 7 Move the control lever the slide switch of the proportional controls or the pedal of the relevant hydraulic circuit in all directions repeatedly The pressure in the system sections that have been actuated is released This can be seen by the brief movement the hoses make as the pressure is released Uncouple the attachment immediately after the ...

Page 137: ...th you Information Place the bucket only with minimum pressure on the ground as you remove the pins The higher the pressure on the ground the higher the resistance and the more difficult it is to remove the pins Assembly 1 Install a bucket only if it is positioned on level ground with the flat side facing downward 2 Stop and park the machine Stop the engine See Preparing lubrication 3 Apply grease...

Page 138: ...tachment Working with the travel force Never ram the attachment into the ground to dig when traveling This can damage the machine or the attachment Retracting the attachment During retracting the attachment ensure that it does not touch the stabilizer blade Avoid impact during operation to avoid damage to the excavator bucket and machine components Do not use the falling force of the attachment as...

Page 139: ...of the machine over the entire width of the stabi lizer blade when using it for stabilization Protecting the stabilizer blade against shocks The stabilizer blade or stabilizer blade hydraulic cylinder can be damaged when hitting it against rocks etc Working on slopes During performing deep excavations with the stabilizer blade at the front ensure that the boom hydraulic cylinder or attachment do n...

Page 140: ...void start traveling and stopping abruptly as well as changing direction suddenly The stabilizer blade must be at the front when traveling in high speed Operation in water Do not immerse the rear end of the machine in water Bear this in mind in particular when leaving water in order not to damage the machine Operation in salt water is prohibited Water must not reach any further than the upper edge...

Page 141: ...excavation force is achieved at an angle of 80 to 120 between the boom and the stick 1 Penetrate into the ground with the bucket 2 Lower the stick and at the same time position the bucket so that the flat lower side of the bucket is parallel with the ground 3 Move the stick toward the machine and curl the bucket at the same time Working alongside trenches For more efficient work Install a suitable...

Page 142: ...r end Work is performed with the smallest possible swivel angle Grading Use the stabilizer blade to Fill in trenches Grade surfaces Lower the stabilizer blade to the ground for grading work Set the depth of the layer you want to remove with the stabilizer blade lever The machine must not be raised by lowering the stabilizer blade The clearance between the stabilizer blade and the ground should be ...

Page 143: ...r zone Stop all work movements immediately if someone enters the danger zone Observe the following during emergency lowering 1 Turn the starting key to position 1 2 Lower the control lever base 3 Push the right hand control lever forward until the boom is fully lowered 4 Return the control lever to neutral Information Lower the boom immediately after stopping the engine ...

Page 144: ...r is prohibited Have the error repaired by a Wacker Neuson service center Functional check of the pressure switch of the safe load indicator Always perform a functional check of the safe load indicator before performing lifting gear applications 1 Start the machine 2 Travel on open terrain 3 Secure the danger zone 4 Stop the machine 5 Switch on the safe load indicator 6 Raise the boom as far as it...

Page 145: ...1 Press switch 41 on the instrument panel down Indicator light 31 in the display element is used for monitoring As soon as the admissible values are reached or exceeded indicator light 31 illuminates and an acoustic signal sounds Switching off the safe load indicator 1 Press switch 41 on the instrument panel forward Fig 203 41 Fig 204 31 Fig 205 41 ...

Page 146: ...l valve Basic option The boom and stick are equipped with a load holding control valve that keeps them in the last position if a hydraulic hose bursts The load holding control valve is adjusted and sealed at the factory The correct functioning is no longer ensured and warranty is void if the seal is removed or if the load holding control valve is tampered with Load holding control valve Advanced o...

Page 147: ... 12 Emergency lowering on page 5 47 4 Raise the control lever base 5 Remove the starting key and lock the cabin 6 Secure the machine and the attachment 7 Contact a Wacker Neuson service center and have the malfunction rectified Environment Use a suitable container to collect engine machine fluids as they flow out and dispose of them in an environmentally friendly manner ...

Page 148: ...0 and remove master key B 4 Now insert the new key or the key requiring coding in the starter lock and turn it to position 1 within 15 seconds 5 This action registers the key The procedure is automatically cancelled if no key requiring coding is detected by the system within 15 seconds Several keys requiring coding can be inserted one after another in the starter lock Each key must then remain at ...

Page 149: ...tes green if the code is correct Stopping the machine with the keypad The machine can be stopped with the keypad shortcut V00V Information If the starter is not actuated within 60 seconds after entering the code the drive interlock is switched off again and the indication flashes red Humidity or dust can penetrate into housing if the surface of the keys is damaged Contact a Wacker Neuson service c...

Page 150: ... machine only if it is at a standstill and if the attachment is empty Never turn lower or set down the attachments abruptly Do not extend or retract the boom abruptly Do not exceed a maximum lateral angle of inclination of 10 on a slope Do not exceed a maximum angle of 15 on an uphill or downhill slope see chapter Traveling on slopes on page 5 4 WARNING Crushing hazard due to tilting the machine i...

Page 151: ...ments abruptly Do not extend or retract the boom abruptly Do not exceed a maximum lateral angle of inclination of 10 on a slope Do not exceed a maximum angle of 15 on an uphill slope Do not exceed a maximum angle of 15 on a downhill slope On a slope position the machine so that the upper carriage is tilted toward the slope see chapter Traveling on slopes on page 5 4 NOTICE Walls or parts of buildi...

Page 152: ...wering the upper carriage 1 Press and hold switch 1 backward 2 Press the right hand control lever 2 to the left The upper carriage is lowered 3 If the required tilt angle is reached return control lever 2 to the neutral position and release button 1 Shovel bucket operation NOTICE The stick is damaged if it is hit by the bucket base Do not dump the bucket completely if it is used as a shovel bucket...

Page 153: ...ssure cleaner in a suitable place see chapter 7 5 Cleaning and maintenance on or with the machine on page 7 19 3 Check the machine for leaks and loose nuts screws and connections 4 Carefully clean and dry the entire machine 5 Spray an anticorrosion agent onto bare metal parts of the machine piston rods of hydraulic cylinders for example 6 Apply grease to all lubrication points 7 Fill the fuel tank...

Page 154: ...on plan 10 Check all engine machine fluids in the units or tanks and add fluids if necessary 11 If the machine was out of service for over 6 months change the oil in the gearbox engine hydraulic oil reservoir and other units 12 Replace the hydraulic oil filters return and breather filters if the machine was out of service for over 6 months 13 Remove and keep the starting key and fuse F3 in a safe ...

Page 155: ...l guidelines regarding disposal Environment Avoid damage to the environment Do not allow the oil and oily wastes to get into the ground or stretches of water and dispose of them in an environmentally friendly manner If the machine is no longer used according to its designated use ensure that it is decommissioned or put out of operation and disposed of according to applicable regulations Observe al...

Page 156: ...5 60 OM EZ38 us 1 1 ez38b510 fm 5 Notes ...

Page 157: ...g facilities such as a towing coupling hooks and eyes The maximum permissible load of the towing eye hook is equal to 1 5 times the maximum weight of the machine A tractor vehicle of the same weight category must be used as a minimum In addition the tractor vehicle must be equipped with a safe brake system and sufficient tractive power Tow away the machine only if the engine is running and if the ...

Page 158: ...8 us 1 1 ez38t600 fm 6 Information The manufacturer s warranty shall not apply to accidents or damage caused by towing the machine Using towing eye hook A to pull other machines or to tow equipment is prohibited ...

Page 159: ...he ramps at the smallest possible angle Ensure that the grade does not exceed 15 27 4 Use access ramps with an antiskid surface only 5 Ensure that the loading area is clear and access to it is not obstructed due to superstructures for example Traveling onto transport vehicles 1 Start the engine of the machine 2 Raise the attachment and the stabilizer blade to avoid touching the ramps 3 Carefully t...

Page 160: ...he weight of the machine Use suitable slings for raising the machine Information Use OSHA rated and approved lifting devices capable lifting the excavator attachments options and accumulated debris Refer to the general weight guidelines in the specification section of this manual Do not attempt to lift the excavator with any type of crane including wheel loaders unless the crane operator is qualif...

Page 161: ...s inside the machine 14 Leave the cabin close and lock all doors windows and covers 15 Install suitable slings at the points provided for lifting the machine 16 Slowly raise the machine until there is no more contact with the ground 17 Wait until the machine does not swing any more 18 If the balance and the condition and position of the slings is correct slowly raise the machine to the required he...

Page 162: ...osition the boom straight ahead at the center of the machine 4 Lower the boom and the stabilizer blade 5 Firmly fasten the machine on the loading area with tie down points A with slings of adequate size observe the legal regulations 6 Before transporting the machine through heavy rain close the outlet of the exhaust pipe with a simple cap or suitable adhesive tape 7 Ensure that the operator of the...

Page 163: ... center Use only original spare parts for repairs The manufacturer shall not be liable for damage to the machine or injury caused by failure to observe the specific notices and descriptions Important safety instructions on maintenance on or with the machine Follow all safety instructions given in this Operator s Manual Follow the instructions given in chapter Safety safety instructions on maintena...

Page 164: ...r dirt Check the threaded fittings of the protective structures cabin for example for tightness Clean the lights light system signalling system Option Check the safe load indicator 5 48 Check the hydraulic quickhitch Easy Lock acoustic warning system 5 32 Lubricate the Powertilt according to the lubrication plan 7 6 Adjust the mirrors correctly clean them and check them for damage check the fasten...

Page 165: ...ll steps for previous maintenance intervals 1 Rinse the system to remove dirt Repeat the procedure in the opposite flow direction Daily maintenance operator Only once after the first 50 service hours Wacker Neuson service center Engine oil replacement Yanmar 3TNV88 BPNS and 3TNV88F EPNS Engine oil filter replacement Yanmar 3TNV88 BPNS and 3TNV88F EPNS Hydraulic oil filter insert replacement Drive ...

Page 166: ...al check Check Powertilt for axial play must not be over 0 38 mm 0 015 in All steps for maintenance once a day and once a week Every 1000 service hours Wacker Neuson service center Coolant replacement Hydraulic oil replacement Replacement of hydraulic oil reservoir breather filter Drive gearbox oil replacement Replacement of air filter element 1 Check valve clearance adjust if necessary Change cab...

Page 167: ...ather All steps for maintenance once a day and once a week and all steps for maintenance at 500 service hours Every 2000 service hours or every 2 years Wacker Neuson service center Check the bladder type accumulator Option Replace the dehumidifier of the air conditioning system Replace the air conditioning refrigerant Replace the air conditioning compressor oil All steps for maintenance once a day...

Page 168: ...7 6 OM EZ38 us 1 1 ez38w700 fm 7 Lubrication plan 14 14 15 15 Powertilt with hydraulic Easy Lock quickhitch option VDS vertical digging system option 13 9 4 5 8 1 1 2 2 3 6 8 10 12 3 6 7 11 Fig 217 ...

Page 169: ...nder Daily 2 9 Stabilizer blade hydraulic cylinder Daily 4 10 Live ring ball bearing Every week 1 11 Live ring gears 1000 service hours 1 12 Live ring gear VDS option Every week 1 13 Vertical Digging System VDS option Every week 2 14 Hydraulic quickhitch option Daily 21 Hydraulic quickhitch claw Every week 15 Powertilt option Daily 4 16 Door hinges cabin option Every week 2 17 Pin lock notch and l...

Page 170: ...enance label Some maintenance on or with the machine may only be performed by a Wacker Neuson service center see maintenance plan Fig 219 Oil oil filter replacement interval Yanmar 3TNV88F EPNS first change at 50 o h then at 250 500 750 etc ...

Page 171: ...he engine oil Engine Replace the engine oil filter Engine Check the V belt tension Engine Replacing the V belt Engine Replacing the air filter element Engine Checking valve clearance Traveling drive Check the gearbox oil of the drive Traveling drive Replace the gearbox oil of the drive Travel gear Checking track tension Hydraulic system Check the oil level of the hydraulic system Hydraulic system ...

Page 172: ...d grease 7 ISO L X BCEB 2 according to DIN ISO 6743 9 lithium saponified grease Year round As required Open transmissions live ring ball bearing Live ring gears Grease nipples Battery terminals Acid proof grease8 8 Standard acid proof grease NGLI category 2 FINA Marson L2 Year round As required Fuel9 9 Sulphur content below 0 05 cetane number over 45 Diesel fuel10 10 Countries with exhaust emissio...

Page 173: ...to hydraulic components Observe the following intervals Engine oil grade Ambient temperature C API CF CF 4 CI 4 ACEA E3 E4 E5 JASO DH 1 C 20 15 10 5 0 5 10 15 20 25 30 35 40 SAE 10W SAE 20W SAE 10W 40 SAE 15W 40 SAE 20 SAE 30 SAE 40 F 4 5 14 23 32 41 50 59 68 77 86 95 104 Application Hydraulic oil Hydraulic oil filter insert Normal work Every 1000 s h Replace the first time after 50 s h then every...

Page 174: ...ydraulic system depending on temperature Hydraulics oil grade Ambient temperature C HVLP 46 1 1 According to DIN 51524 section 3 ISO VG 46 C 20 15 10 5 0 5 10 15 20 25 30 35 40 50 ISO VG32 ISO VG46 ISO VG68 F 4 5 14 23 32 41 50 59 68 77 86 95 104 122 ...

Page 175: ...erefore ensure that the remaining amount of initial hydraulic fluid in the hydraulic system does not exceed 8 when changing biodegradable oil observe the manufacturer indications Do not add mineral oil the content of mineral oil should not exceed 2 in order to avoid foaming problems and to ensure biological degra dability When running the machine with biodegradable oil the same oil and filter repl...

Page 176: ...nal injury hazard due to open engine cover Can cause minor injuries Take care not to knock your head on the open engine cover Opening 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Open the engine cover by pressing button A The engine cover is supported by a gas strut Closing Firmly press down the engine cover Locking and unlocking The engine cover is locked with the start...

Page 177: ...ing or lowering the cabin Raising or lowering the cabin can cause serious injury or death All persons must stay clear of the cabin as you raise and lower it Safely store all loose objects inside the machine Always close and lock the door and windows before raising the cabin NOTICE Damage to lift pump due to unclosed valve Turn the lift pump valve clockwise 1 Stop and park the machine Stop the engi...

Page 178: ...rod C clockwise 7 Insert tilt rod C onto guide E and pump as far as it will go The cabin is raised as far as the pump will go 8 Place yourself beside the machine and pull the handhold of the cabin until the cabin is completely tilted beyond the center of motion The cabin is secured with a safety cable Fig 223 B Fig 224 C D Fig 225 C E Fig 226 ...

Page 179: ... Neuson service center Lowering the cabin 1 Ensure that the piston of the lift pump is fully extended 2 Turn valve D clockwise 3 Remove the split pin from guide H 4 Press tilt rod F into bracket G 5 Use the handhold to lower the cabin until it is back on the pump 6 Fit tilt rod C onto valve D 7 Slowly turn tilt rod C counter clockwise The cabin is lowered by its own weight NOTICE Damage to cabin b...

Page 180: ... 1 ez38w700 fm 7 Information Replace self locking fasteners self locking nuts for example by new ones after removing them 8 Tighten lock nut A to 85 Nm 63 ft lbs 9 Tighten screw B to 85 Nm 63 ft lbs Fig 231 A Fig 232 B ...

Page 181: ...ith compressed air Work carefully Wear safety glasses and protective clothing Do not aim the compressed air at the skin or at other people Do not use compressed air for cleaning your clothing Cleaning with a high pressure cleaner or steam jet Cover electric parts Do not directly expose electrical components and damping material to the jet Cover the vent filter on the hydraulic oil reservoir and th...

Page 182: ... and damage seals and disable the controls We recommend using the following aids to clean the cabin Broom Vacuum cleaner Damp cloth Brush Water with mild soap solution Cleaning outside the machine We recommend using the following aids to clean the machine High pressure cleaner Steam jet Cleaning the engine compartment WARNING Burn hazard due to hot engine parts Can cause severe injuries or death S...

Page 183: ...p the seat belt clean as coarse dirt can impair the proper functioning of the seat belt buckle Clean the seat belt which remains fitted in the machine with a mild soap solution only Do not use chemical agents as they can destroy the fabric Cleaning the shatter protection Clean the polycarbonate disc only with water and a mild soap solution Do not use aggressive detergents Do not use brushes steel ...

Page 184: ...4 Stop the engine 5 Operate the control lever repeatedly to release the pressure in the hydraulic system 6 Raise the control lever base 7 Remove the starting key and carry it with you 8 Safely store all loose objects inside the machine 9 Close the windows and doors 10 Close and lock all covers 11 Attach a warning label to the control elements for example Machine being serviced do not start 12 Wait...

Page 185: ... boom and the stabilizer blade to the ground 3 Stop the engine remove the starting key and carry it with you 4 Apply grease to lubrication point 10 with two strokes of the grease gun 5 Start the engine raise the boom and the stabilizer blade 6 Rotate the upper carriage by 90 7 Repeat steps 2 6 three times until the upper carriage is back in its initial position 8 Rotate the upper carriage several ...

Page 186: ...2 Lower the stabilizer blade to the ground 3 Lower and support the boom to prevent it from lowering into the pit 4 Stop the engine remove the starting key and carry it with you Remove cover A by means of six screws B on the lower side 5 Apply grease to lubrication point 11 with five strokes of the grease gun 6 Start the engine raise the boom and the stabilizer blade 7 Rotate the upper carriage by ...

Page 187: ...on the console 1 Park the machine on firm level and horizontal ground 2 Lower the stabilizer blade to the ground 3 Lower the boom and the stabilizer blade to the ground 4 Stop the engine remove the starting key and carry it with you 5 Apply grease to lubrication point 12 with five strokes of the grease gun 6 Start the engine raise the boom and the stabilizer blade 7 Rotate the upper carriage by 90...

Page 188: ...he control lever base 3 Spray fluid grease onto guide lever A 4 Spray fluid grease on both sides of the double spring B 5 Raise and lower the control lever base several times Information Keep the lubrication points clean and remove ejected grease Powertilt Powertilt with Easy Lock option when used in water Apply grease to the lubrication points before using the Powertilt unit in water After using ...

Page 189: ...em Diesel fuel specification NOTICE Engine damage due to incorrect or dirty Diesel fuel Only use clean Diesel fuel according to the engine machine fluids and lubricants Do not use Diesel fuel with additives see Fluids and lubricants on page 7 10 Refueling WARNING Burn hazard due to deflagrations Fuels develop explosive and flammable mixtures with air that can cause severe injuries or death Fire op...

Page 190: ...hine Stop the engine See Preparing lubrication 2 Open the engine cover 3 Remove filler cap A 4 Refuel 5 Close filler cap A 6 Close and lock the engine cover Stationary fuel pumps Even the smallest particles of dirt can cause increased engine wear malfunctions in the fuel system and reduced effectiveness of the fuel filters Refueling from barrels If refueling from barrels cannot be avoided note the...

Page 191: ... 2 Open the engine cover 3 Remove filler cap A 4 Unwind hose B of the fuel filling pump The lance is located on the right in the engine compartment 5 Put the lance in the container with the fuel 6 Switch on the fuel filling pump with switch C 7 The red LED D illuminates when the tank is full 8 Switch off the fuel filling pump with switch C 9 Close filler cap A 10 Close and lock the engine cover Fi...

Page 192: ...osition 5 Wait about 5 minutes during the fuel system bleeds itself automatically 6 Start the engine If the engine runs smoothly for a while and then stops or if it does not run smoothly 1 Stop the engine 2 Raise the control lever base 3 Remove the starting key and carry it with you 4 Bleed the fuel system again as described above 5 Check for leaks after starting the engine 6 Have a Wacker Neuson ...

Page 193: ...er on the ground 5 Turn ball type cock D to the OFF mark Fuel supply is interrupted 6 Unscrew connection C Wait until indicator ring A returns to the bottom of the water separator 7 Screw connection C back on again 8 Turn ball type cock D to the ON mark Fuel supply is open 9 Remove the hose 10 Close and lock the engine cover Environment Use a suitable container to collect engine machine fluids as ...

Page 194: ...ing the fuel water mixture 3 Open the engine cover 4 Connect a drain hose to port A Place the hose into a container on the ground 5 Open screw B 6 Collect the fuel water mixture in a suitable container 7 Close screw B 8 Remove the hose 9 Close and lock the engine cover Information Use a suitable container to collect engine machine fluids as they flow out and dispose of them in an environmentally f...

Page 195: ... the intake system Information Check the oil level once a day We recommend checking it before starting the engine After stopping a warm engine wait at least 5 minutes before checking Checking the engine oil level 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Open the engine cover 3 Clean the area around the oil dipstick with a lint free cloth 4 Pull out oil dipstick A 5 W...

Page 196: ...htly to allow any trapped air to escape 6 Add engine oil 7 Wait about 5 minutes until all the oil has run into the oil sump 8 Check the oil level 9 Add oil if necessary and check the oil level again 10 Close filler cap B 11 Push oil dipstick A back in as far as possible 12 Close and lock the engine cover Environment Use a suitable container to collect engine machine fluids as they flow out and dis...

Page 197: ...amage due to wrong coolant Observe the fluids and lubricants table and the coolant compound table Do not mix the filled in coolant with other coolants NOTICE Engine damage due to low coolant level Check the coolant level once a day Checking the coolant level 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Open the engine cover 3 Check the coolant level on expansion tank A a...

Page 198: ...the MAX mark 6 Close filler cap B 7 Start the engine and let it warm up for about 5 10 minutes 8 Stop the engine 9 Remove the starting key and carry it with you 10 Let the engine cool down 11 Check the coolant level again 12 If necessary add coolant and repeat the procedure until the coolant level remains constant 13 Close and lock the engine cover Environment Dispose of used coolant through appro...

Page 199: ...k conditions clean more frequently than indicated in the maintenance plans NOTICE Damage to radiator fins during cleaning Keep a safe distance from the radiator during cleaning Use oil free compressed air 2 bar 29 psi max to clean Radiator A hydraulic oil cooler B and fuel cooler C are located in the engine compartment 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Open th...

Page 200: ... replace them if necessary Check the screws at the induction manifold and the clamps for tightness Air filter monitoring NOTICE Damage to Diesel engine due to dirty air filter Replace the air filter elements when the red air filter indicator light illuminates Do not clean air filter elements replace them Do not use any damaged air filter elements Replace the air filter elements when the red air fi...

Page 201: ...er 4 Remove dirt and dust from the air filter housing and the area around it 5 Fold bow clips A on lower housing section B to the outside 6 Remove the lower housing section B 7 Carefully remove outside filter C with slightly turning movements 8 Remove all dirt dust inside the upper and lower housing sections including the dust valve 9 Clean the parts with a clean lint free cloth do not use compres...

Page 202: ...ce a day for cleanliness before putting the machine into operation 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Remove the starting key and carry it with you 3 Open the engine cover 4 Check and if necessary clean air intake A 5 Close and lock the engine cover Fig 259 A Fig 260 A ...

Page 203: ...OM EZ38 us 1 1 ez38w710 fm 7 41 7 7 11 V belt toothed belt V belt tension may be checked and the V belt retightened by a Wacker Neuson service center only ...

Page 204: ...omponents Open the breather filter carefully to slowly release the pressure inside the tank Wear protective equipment If oil contacts the eye flush immediately with clean water and seek medical treatment Malfunctioning or leaking threaded fittings hose connections and pressure lines must be immediately repaired by a Wacker Neuson service center search for hydraulic leaks with a piece of cardboard ...

Page 205: ...draulic oil level 1 Park the machine on firm level and horizontal ground 2 Position the boom straight ahead at the center of the machine see figure 3 Lower the boom and the stabilizer blade to the ground 4 Stop the engine 5 Operate the control lever repeatedly to release the pressure in the hydraulic system 6 Remove the starting key and carry it with you 7 Sight glass A is located on the left of t...

Page 206: ...up to the corresponding mark 5 Check the hydraulic oil level on sight glass A 6 Add if necessary and check again 7 Firmly screw filler plug C and tighten tank ventilation B by hand 8 Close and lock the engine cover Environment Use a suitable container to collect engine machine fluids as they flow out and dispose of them in an environmentally friendly manner Fig 263 B Fig 264 C ...

Page 207: ...ely repaired or replaced by a Wacker Neuson service center Have hydraulic hoses replaced every 6 years from the date of manufacture even if they do not seem to be damaged Do not operate the machine with leaking or damaged hydraulic system components Retighten leaking screwed fittings and hose connections only when the system is not under pressure Release the pressure before working on pressurized ...

Page 208: ...f they do not seem to be damaged In this respect we recommend that you observe all the relevant safety regulations for hydraulic lines as well as the safety regulations regarding accident prevention and occupational health and safety in your country Also observe DIN 20 066 part 5 The article number is marked on the clamping section and the date of manufacture is indicated on the hose of each hose ...

Page 209: ... severe injuries or death Fire open flames and smoking is prohibited Do not place any tools on the battery Wear protective gloves and safety glasses Do not attempt to jump start the machine if the battery is frozen or if the acid level is low The battery can rupture or explode Replace the battery immediately Disconnect the earthing lead of the battery before starting repair work on the electrical ...

Page 210: ...formed by a Wacker Neuson service center Replacing the battery Tilt the cabin to access the battery see chapter Raising or lowering the cabin on page 7 15 The battery is maintenance free However have the battery checked at regular intervals to ensure that the electrolyte level is between the MIN and MAX marks Checking the battery requires it to be removed and must be performed by a Wacker Neuson s...

Page 211: ...ormation regarding the washer system Only use glass cleaner with antifreeze if necessary for refilling Checking the fluid level and adding fluid The tank s filler inlet is located on the left in the engine compartment 1 Stop and park the machine Stop the engine See Preparing lubrication 2 Open the engine cover 3 Check the fluid level in tank A and add fluid if necessary 4 Close and lock the engine...

Page 212: ...sion WARNING Crushing hazard when working under the machine Can cause severe injuries or death Ensure that no one is in the danger zone 1 Park the machine on firm level and horizontal ground 2 Raise the machine evenly and horizontally by means of the boom and the stabilizer blade 3 Place the tracks so that mark A is in the middle between travel pinion B and track tension roller C 4 Stop the engine...

Page 213: ... hydraulic cylinder and the track Tighten the tracks only up to the mandatory measuring distance Tightening the tracks 1 Park the machine on firm level and horizontal ground 2 Raise the machine evenly and horizontally by means of the boom and the stabilizer blade 3 Stop the engine 4 Operate the control lever repeatedly to release the pressure in the hydraulic system 5 Pump grease with a grease gun...

Page 214: ...A 4 Check the tension is correct by Lowering the machine to the ground starting the engine letting it run at idling speed without any load and slowly moving the machine forward and reverse and switching it off again Raise the machine again by means of the boom and the stabilizer blade 5 Check the track tension again If it is not correct 6 Adjust again Environment Use a suitable container to collec...

Page 215: ...prohibited Load hook wear Have load hooks Powertilt Powertilt for Easy Lock with inadmissible wear beyond the tolerance for example damage deformations surface cracks and corrosion immediately replaced by a Wacker Neuson service center The nominal size must not be worn more than 10 max tolerance Measurement can be performed with the accuracy of a slide gauge Welding is prohibited If the spring mec...

Page 216: ...m 7 7 21 Exhaust gas treatment Not available 7 22 Machine preservation Machines are partly preserved at the factory for example in the engine compartment Operation in an aggressive environment for example salt deposits is prohibited ...

Page 217: ... Contact a Wacker Neuson service center Replace the air filter Dirty radiator fins Clean the radiator 7 37 Coolant level too low Add coolant 7 36 Malfunctioning or insuffi ciently tightened V belt Contact a Wacker Neuson service center Engine overheats Torn V belt Stop operation immediately have the error repaired by a Wacker Neuson service center Engine does not have enough output Dirty air filte...

Page 218: ...medy See Hydraulic system overheats Dirty hydraulic oil radiator Clean the hydraulic oil radiator 7 37 Hydraulic oil level too low Add hydraulic oil 7 44 Malfunctioning or insuffi ciently tightened V belt Contact a Wacker Neu son service center The display element emits a continuous buzzing sound Malfunctioning pressure switch of safe load indicator Stop work immediately have the error repaired by...

Page 219: ...uns Malfunctioning starter lock Malfunctioning display ele ment Indicator light for engine oil pres sure red illuminates and the buzzer sounds when the engine runs Pressure drop in engine oil circuit The indicator light for the coolant temperature red illuminates and the buzzer sounds Coolant temperature is too high Let the engine run at idling speed without any load Wait until the temperature dro...

Page 220: ...r insuffi ciently tightened V belt Dirty condenser Clean the condenser 7 37 Temperature controller set to heating Set temperature controller to ventilation 5 11 No or insufficient heating output Very dirty condenser Have the error repaired by a Wacker Neuson service center Malfunctioning thermostat Temperature controller set to ventilation Set temperature controller to heating 5 11 Loss of refrige...

Page 221: ... cylinders 3 Displacement 1642 cm3 100 2 in3 Nominal bore and stroke 88 x 90 mm 3 5 x 3 5 in Output 21 4 kW at 2400 rpm 28 7 hp at 2400 rpm Max torque 106 6 Nm at 1440 rpm 78 6 ft lbs at 1440 rpm Max engine speed without load 2500 25 rpm Idling speed 1100 25 rpm Fuel injection system Direct injection Starting aid Glow plugs preheating time 15 seconds Fuel tank 44 l 11 6 gal Exhaust values accordin...

Page 222: ...minal bore and stroke 88 x 90 mm 3 5 x 3 5 in Output 18 2 kW at 2400 rpm 24 4 hp at 2 400 rpm Max torque 94 5 Nm at 1440 rpm 69 7 ft lbs at 1 440 rpm Max engine speed without load 2500 25 rpm Idling speed 1 200 25 rpm Fuel injection system Direct injection Starting aid Glow plugs preheating time 15 seconds Fuel tank 44 l 11 6 gal Exhaust values according to EPA Tier IV final Traveling drive EZ38 V...

Page 223: ... Number type of pumps 4 Oil flows of variable displacement pumps P1 P2 40 l min 10 6 gal min Oil flow of gear pump 1 P3 3rd control circuit or Powertilt 26 3 l min 6 9 gal min Oil flow of gear pump 2 P4 11 3 l min 3 gal min Operating pressure for operate and travel hydraulics 240 bar 3263 psi Swivel unit operating pressure 210 bar 3046 psi Hydraulic tank capacity 38 5 l 10 2 gal Hydraulic oil quan...

Page 224: ...Ah F1 Fig 274 F2 Fuses Rated current A EZ38 F1 40 A Start preheat cutoff solenoid F2 50 A Starter lock fuel filling pump Fig 275 F5 F3 F4 F7 F8 F10 F9 F6 Fuses Rated current A EZ38 F3 10 A Display cutoff solenoid relays F4 10 A Boom working light F5 10 A Cabin working light F6 10 A Valves horn proportional auxiliary hydraulics AUX I proportional 3rd control circuit AUX II F7 15 A Heating air condi...

Page 225: ...olenoid relay K17 Hydraulic quickhitch relay K58 High speed relay V1 Blocking diode EZ38 Working lights roof lights Halogen lamp 12 V 55 W H3 Interior light Festoon lamp 10x38 12 V 5 W Rotating beacon Halogen lamp 12 V 55 W H1 EZ38 Model size 6 Required oil flow 3 6 l min 0 8 1 6 gal min Swiveling range 180 1 1 The actual angle can vary slightly from the indication made here Weight 65 kg 143 3 lbs...

Page 226: ...1480 1092 1770 1305 870 642 1250 922 M30 1420 1047 2010 1482 2400 1770 1200 885 1700 1254 Tightening torques fine pitch thread Property class 8 8 10 9 12 9 8 8 10 9 Screw dimen sions Screws according to DIN 912 DIN 931 DIN 933 etc Screws according to DIN 7984 Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs Nm ft lbs M8X1 0 25 18 37 28 43 32 22 16 32 24 M10X1 0 50 37 75 55 88 65 43 32 65 48 M10X1 25 49 36 ...

Page 227: ...lant with other coolants Up to C F by vol ume by volume 37 34 6 50 50 EZ38 Measured sound power level LwA 1 1 According to ISO 6395 EC Directives 2000 14 EC and 2005 88 EC 94 dB A Guaranteed sound power level LwA 1 95 dB A Uncertainty factor KpA 2 2 According to EN ISO 4871 EC Directives 2000 14 EC and 2005 88 EC 0 8 Operator perceived sound pressure level LpA without cabin 3 3 According to ISO 63...

Page 228: ...ions use the average vibration values measured In order to obtain the estimated vibration value for an experienced operator on level ground subtract the factors from the average vibration value In case of an aggressive working method or difficult terrain add the environmental factors to the average vibration level in order to obtain the estimated vibration level Note For further vibration indicati...

Page 229: ...Move attachments without any jerks Adapt your speed and the itinerary to minimize vibration Travel around obstacles and uneven ground Reduce your speed when traveling across rough terrain Reduce vibration to a minimum during long work cycles or when traveling over long distances Use a machine with a suspension system seat for example Enable the hydraulic oscillation damping if the machine is equip...

Page 230: ... original guidelines This chapter summarizes part of the legal regulations However its aim is not to replace the original references Other parts of this document are based on information of the United Kingdom Health and Safety Executive For more information on vibration refer to Directive 2002 44 EC of European Parliament and Coucil on minimum health and safety requirements regarding exposure of w...

Page 231: ...ght of attachments see Fields of application and use of attachments on page 3 5 Weight EZ38 Transport weight1 1 Transport weight basic machine 10 fuel capacity Canopy 3594 kg 7 923 lbs Canopy VDS 3818 kg 8 417 lbs Cabin 3711 kg 8 181 lbs Cabin VDS 3935 kg 8 675 lbs Operating weight2 2 Operating weight basic machine full fuel tank backhoe bucket 400 mm 16 in operator 75 kg 165 lbs Canopy 3765 kg 8 ...

Page 232: ...nd pressure EZ 38 Max tearout force short stick 17 8 kN 4 002 lbf Max tearout force long stick 15 8 kN 3 552 lbf Max breakout force at bucket tooth 32 kN 7 194 lbf EZ38 EZ38 VDS Ground clearance 280 mm 11 in 225 mm 9 in Ground pressure 0 34 kg cm 4 8 lbs in Upper carriage rotation speed 8 8 rpm ...

Page 233: ...es specified in the table Load density must also be taken into account Never exceed the weight and mass values specified in the table NOTICE If the weight or mass value is exceeded there is a risk of damage to property if the machine tips over Never exceed the weight and mass values specified in the table Information In the case of 360 rotations the lowest value in a column and the corresponding p...

Page 234: ...raulic output and the hydraulic system s stabilizing features Neither 75 of the static tilt load nor 87 of the hydraulic lift capacity is exceeded Designation Explanation A Reach from live ring center B Load hook height max Authorized lift capacity with horizontal boom With the stabilizer blade in traveling direction With or without the stabilizer blade 90 to traveling direc tion Lowered stabilize...

Page 235: ...ng pressure on boom hydraulic cylinder 22500 kPa 3263 psi The lift capacity applies to machines under the following conditions Lubricants and engine machine fluids at the mandatory levels Full fuel tank Cabin or canopy Machine at operating temperature Operator weight 75 kg 165 lbs ...

Page 236: ... 442 974 362 798 1472 3 245 656 1 446 544 1 99 2623 5 783 1238 2 729 1052 2 319 2 0 m 79 in 950 2 094 640 1 411 535 1 179 1104 2 434 680 1 499 568 1 252 1938 4 273 1279 2 820 1094 2 412 4 0 m 13 1 3 0 m 9 10 2 0 m 79 in 3 0 m 9 10 688 1 517 443 977 363 800 637 1 404 509 1 122 424 935 2 0 m 79 in 712 1 570 370 816 297 655 699 1 541 495 1 091 409 902 1 0 m 39 in 750 1 653 343 756 272 600 841 1 854 4...

Page 237: ...7 958 2 112 501 1 105 423 933 1472 3 245 741 1 634 632 1 393 2623 5 783 1391 3 067 1215 2 679 2 0 m 79 in 950 2 094 720 1 587 618 1 362 1104 2 434 765 1 687 657 1 448 1938 4 273 1432 3 157 1257 2 771 4 0 m 13 1 3 0 m 9 10 2 0 m 79 in 3 0 m 9 10 688 1 517 496 1 093 425 937 637 1 404 567 1 250 490 1 080 2 0 m 79 in 712 1 570 418 922 353 778 699 1 541 553 1 219 476 1 049 1 0 m 39 in 750 1 653 389 858...

Page 238: ... 413 911 1460 3 219 724 1 596 616 1 358 2588 5 706 1361 3 000 1186 2 615 2 0 m 79 in 998 2 200 737 1 625 632 1 393 1033 2 277 752 1 658 645 1 422 1848 4 074 1405 3 097 1232 2 716 4 0 m 13 1 3 0 m 9 10 2 0 m 79 in 3 0 m 9 10 672 1 482 473 1 043 403 888 631 1 391 549 1 210 473 1 043 2 0 m 79 in 701 1 545 399 880 336 741 702 1 548 533 1 175 457 1 008 1 0 m 39 in 742 1 636 372 820 311 686 845 1 863 50...

Page 239: ...40 2 072 548 1 208 474 1 045 1460 3 219 808 1 781 705 1 554 2588 5 706 1514 3 338 1349 2 974 2 0 m 79 in 998 2 200 820 1 808 719 1 585 1033 2 277 837 1 845 734 1 618 1848 4 074 1558 3 435 1395 3 075 4 0 m 13 1 3 0 m 9 10 2 0 m 79 in 3 0 m 9 10 672 1 482 525 1 157 458 1 010 631 1 391 608 1 340 534 1 177 2 0 m 79 in 701 1 545 447 985 385 849 702 1 548 591 1 303 517 1 140 1 0 m 39 in 742 1 636 419 92...

Page 240: ...le Use the machine for lifting gear applications only if the mandatory lifting gear joint rod for example and safety equipment optical and acoustic warning devices safe load indicator stability table load holding control valves for example is installed functional and enabled NOTICE If the weight or mass value is exceeded there is a risk of damage to property if the machine tips over Never exceed t...

Page 241: ...ither 75 of the static tilt load nor 87 of the hydraulic lift capacity is exceeded Calculation basis according to ISO 10567 Setting pressure on boom hydraulic cylinder 22500 kPa 3263 psi Lift capacities apply to machines under the following conditions Lubricants and engine machine fluids at the mandatory levels Full fuel tank Cabin or canopy Machine at operating temperature Operator weight 75 kg 1...

Page 242: ...9 22 OM EZ38 us 1 1 ez38t900 fm 9 Cabin or canopy without extra weight Cabin or canopy with extra weight ...

Page 243: ...OM EZ38 us 1 1 ez38t900 fm 9 23 9 VDS cabin or canopy without extra weight VDS cabin or canopy with extra weight ...

Page 244: ...9 24 OM EZ38 us 1 1 ez38t900 fm 9 Dimensions Overview EZ38 ...

Page 245: ...ing radius short stick 5300 mm 17 5 K2 Max digging radius long stick 5535 mm 18 2 M Max boom displacement to bucket center right side 740 mm 29 in N Max boom displacement to bucket center left side 590 mm 23 in O Max lift height of stabilizer blade over ground 380 mm 15 in P Max scraping depth of stabilizer blade below ground surface 460 mm 18 in Q1 Distance between bucket and stabilizer blade sho...

Page 246: ...9 26 OM EZ38 us 1 1 ez38t900 fm 9 Overview EZ38 VDS ...

Page 247: ...s short stick 5300 mm 17 5 K2 Max digging radius long stick 5535 mm 18 2 M Max boom displacement to bucket center right side 740 mm 29 in N Max boom displacement to bucket center left side 590 mm 23 in O Max lift height of stabilizer blade over ground 380 mm 15 in P Max scraping depth of stabilizer blade below ground surface 460 mm 18 in Q1 Distance between bucket and stabilizer blade short stick ...

Page 248: ...9 28 OM EZ38 us 1 1 ez38t900 fm 9 Notes ...

Page 249: ...9 Charge indicator light 4 36 Check lists 4 40 Checking hydraulic hoses 7 46 Checking the coolant level 7 35 Checking the engine oil level 7 33 Checking the fluid level 7 49 Checking the fuel filter 7 32 Checking the hydraulic oil level 7 43 Checking the hydraulic system for leaks 7 45 Checking the water separator 7 30 Checking track tension 7 50 Cleaning and maintenance work 7 19 Cleaning inside ...

Page 250: ...r pedal 5 22 Hammer pedal AUX I 5 24 Heating 5 11 7 49 High speed 5 1 High speed 2nd speed 4 36 Horizontal seat adjustment 4 12 Horn 5 9 Hour meter maintenance meter 4 38 Hydraulic brake 5 2 Hydraulic connections 5 37 Hydraulic oil filter monitoring 4 37 Hydraulic quickhitch 5 32 Picking up an attachment 5 32 Setting down an attachment 5 34 Hydraulic swivel unit brake 5 17 Hydraulic system 7 42 8 ...

Page 251: ...tions for starting the engine 4 43 Preparatory work for putting into operation 4 39 Preparing lubrication 7 22 Proportional controls 5 21 5 47 Proportionally controlled additional control circuit AUX I 5 25 Proportionally controlled hammer 5 24 Protective FOPS screen 4 24 Protective structures 4 21 Putting into operation 4 1 Putting the machine back into operation 5 58 Putting the machine into ope...

Page 252: ...raveling signal 5 10 Troubleshooting 8 1 Troubleshooting the air conditioning 8 4 Tying down 6 6 Type label 3 7 Type label hydraulic quickhitch 3 8 Type labels 3 7 U Use of solvents 7 20 V V belt 7 41 VDS live ring gear 7 25 Ventilation 5 11 7 49 Vertical Digging System 5 54 Vibration 9 8 W Warm up phase of machine 4 44 Warning labels 3 10 Warranty and liability 1 5 Washer system 5 10 7 49 Weight ...

Page 253: ...hich have already been delivered and which will not be implemented on these machines Technical data dimensions and weights are given as an indication only Responsibility for errors or omissions not accepted No reproduction or translation of this publication in whole or part without the written consent of Wacker Neuson Linz GmbH All rights under the provision of the Copyright Act are reserved Wacke...

Page 254: ...lephone 262 255 0500 Fax 262 255 0550 Telephone 800 770 0957 www wackerneuson com Wacker Neuson Linz GmbH Flughafenstr 7 A 4063 Hörsching Phone 43 0 7221 63000 Fax 43 0 7221 63000 2200 E mail office linz wackerneuson com www wackerneuson com Order no 5200016122 Language us ...

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