Wacker Neuson 28Z3 Service Manual Download

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Service Manual

Track excavator

Machine model

28Z3

Edition

2.0

Language

Article number

1000178347

Summary of Contents for 28Z3

Page 1: ...Service Manual Track excavator Machine model 28Z3 Edition 2 0 Language en Article number 1000178347...

Page 2: ...f this publication may be reproduced translated or used in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage or retrieval systems...

Page 3: ...4 Stabiliser blade 2 4 Electrical system 2 4 Noise levels 2 5 Vibration 2 5 Coolant compound table 2 5 Powertilt 2 5 Model specific tightening torques 2 6 General tightening torques 2 6 Tightening to...

Page 4: ...6 Change cab air filter 3 27 V belt 3 28 Checking V belt tension 3 28 Retightening the V belt 3 29 Pressure check 3 31 General 3 31 Overview of measuring ports up to serial number AG02712 3 31 Overvie...

Page 5: ...and maintenance work at regular intervals 3 61 Instructions concerning specific components 3 61 Alternator 3 61 Battery 3 62 General maintenance work 3 63 Cleaning 3 63 General instructions for all a...

Page 6: ...14 Main valve block diagram 5 15 Pressure limiting valves 5 16 Pump assignment 5 17 Drive counterbalancing system 5 18 Pump assignment for drive counterbalancing 5 18 Regeneration stick section 5 19...

Page 7: ...ignal wiring harness option 6 22 Hydraulic quickhitch wiring harness option 6 23 Battery lead 6 24 Options Counterweight 7 2 Specifications 7 2 Long stick 7 2 Specifications 7 2 Automatic engine speed...

Page 8: ...l service valve 7 29 Function 7 29 PowerTilt PTS06 General instructions 8 2 General safety instructions 8 2 Checking the product 8 3 Internal decompression valve 8 3 Testing the hydraulic system of th...

Page 9: ...decompression valve 8 24 Installing the standard journal coupling 8 24 Lubrication and tests 8 27 Lubrication 8 27 Test for internal leaks 8 27 Testing the internal decompression valve 8 28 Securing...

Page 10: ...I 8 SHB 28Z3 EN Edition 2 0 28Z3s20IVZ fm...

Page 11: ...Operation...

Page 12: ...safety and readiness of your machine and maintains its value We reserve the right to improve the technical standard of our machines without adapting the service manual Modifying Wacker Neuson products...

Page 13: ...or the operator or other persons Measures for avoiding danger Caution Failure to observe the instructions identified by this symbol can result in damage to the machine Measures for avoiding danger for...

Page 14: ...hich have not been checked and released by Wacker Neuson GmbH Wacker Neuson GmbH will not be liable for damage resulting from this Wacker Neuson Linz GmbH shall not be liable for personal injury and o...

Page 15: ...chine type Betriebsgewicht operating weight poids en charge Operating weight Transportgewicht transport weight poids en transport Transport weight G Gew GWR PTAC Gross weight rating admissible Max Nut...

Page 16: ...valve block number The type label arrow is located on the lower side of the main valve block Travelling drive number The type label arrow is located on the travelling drive Swivel unit number The type...

Page 17: ...rt number Serien Nr serial no no de s rie serial number Gewicht weight poids max authorised weight Volumen volume volume max capacity f r Modell for model pour le mod le for equipment model Lieferant...

Page 18: ...ics 4 Stick 5 Handle 6 Stabiliser blade 7 Eye hook for loading tying down the machine 8 Undercarriage 9 Exhaust pipe 10 Engine cover 11 Rotating beacon 12 Boom light 13 Canopy standard cab option 14 T...

Page 19: ...SHB 28Z3 EN Edition 2 0 28z3s110 fm 1 9 Operation 1 6 Cab overview 23 24 21 3 4 5 6 9 10 1 11 13 14 15 16 18 17 28 27 31 32 30 29 33 25 22 20 19 8 34 26 7 12 2...

Page 20: ...ay element 12 Heating 13 Preheating start switch 14 Control lever right 15 Drive interlock status indicator option up to serial number AG00698 16 Control lever base right 17 Stabiliser blade lever 18...

Page 21: ...l overview 35 36 38 39 42 41 Control element on control console Control element on cab wall Control elements for proportional controls version option Control element on control console Control element...

Page 22: ...on indicator light red 38 Engine oil pressure indicator light red 39 Coolant temperature indicator light red 40 Safe load indicator option light red 41 Fuel level indicator 42 Hour meter 43 High speed...

Page 23: ...64 63 Pos Designation For more information see page 53 Water separator 3 15 54 Hydraulic pump 5 2 55 Fuse box 2 5 56 Washer system tank 57 Air filter 3 24 58 Fuel filter 3 16 59 Throttle cable 60 Oil...

Page 24: ...sis overview 70 66 67 69 71 73 68 72 Pos Designation For more information see page 66 Heating control 3 63 67 Swivel joint 5 27 68 Shuttle valve 69 Manifold 70 Swivel unit 5 24 71 Heating 3 63 72 4 2...

Page 25: ...t 74 75 79 77 78 76 Pos Designation For more information see page 74 Fuel filler inlet 3 13 75 Changeover valve for SAE ISO controls option 5 32 76 Return filter 3 46 77 Main valve block 5 6 78 Contro...

Page 26: ...liser blade to the ground Stop the engine Operate the joystick repeatedly to release the pressure in the hydraulic system Remove the ignition key and carry it with you Fold the control lever base up C...

Page 27: ...Specifications...

Page 28: ...d Compression 23 5 1 bar 340 8 14 5 psi at 250 rpm Engine oil pressure at rated speed 2 9 4 4 bar 42 64 psi Pressure switch for engine oil pump 0 5 0 1 bar 7 25 1 45 psi Thermostat opening temperature...

Page 29: ...l 28Z Pump Double variable displacement twin gear pump 11 5 11 5 8 2 7 cm 0 70 0 70 0 48 0 16 cu in Flow rate 30 80 30 80 21 40 7 2 l min at 2500 rpm 8 1 8 1 5 7 1 9 gal min at 2376 rpm Operating pres...

Page 30: ...n 10 30 gal min 27 0 l min 7 13 gal min 150 bar 2175 psi 33 5 l min 8 85 gal min 25 5 l min 6 74 gal min 180 bar 2611 psi 27 0 l min 7 13 gal min 21 5 l min 5 68 gal min 200 bar 2901 psi 12 0 l min 3...

Page 31: ...O 6395 93 dB A Driver perceived sound pressure level LPA 2 2 According to EN ISO 6396 78 dB A Uncertainty KPA 3 3 According to EN ISO 4871 0 9 A Vibration Trigger value Effective acceleration value fo...

Page 32: ...the indication made here Model 28Z3 Thread Tightening torque Nm lbs ft Live ring M12 10 9 120 88 5 Track roller M14 10 9 120 88 5 Drive pinion M12 10 9 120 88 5 Travelling drive M12 10 9 120 88 5 Gear...

Page 33: ...ith thread and screwed plug Non return valve with elastic seal Identification aid outside Sealing washer Elastic seal O ring Nm lbs ft Nm lbs ft Nm lbs ft Nm lbs ft mm M10X1 0 9 7 18 13 15 11 18 13 10...

Page 34: ...33X2 0 150 111 310 229 310 229 210 155 33 1 3 M42X2 0 240 177 450 332 330 243 360 266 42 1 7 M48X2 0 290 214 540 398 420 310 540 398 48 1 9 G1 8A 35 26 55 41 45 33 45 33 13 16 0 52 G1 4A 45 33 80 59 6...

Page 35: ...m lbs ft Nm lbs ft Nm lbs ft Nm lbs ft 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 71 52 83 61 42 31 62 46 M12X1 25 87 64 130 96 150 111 75 55 110 81 M12X...

Page 36: ...1 Max digging height short stick 4170 mm 13 8 Max digging height long stick 4300 mm 14 1 Max dump height short stick 2840 mm 9 4 Max dump height long stick 2970 mm 9 9 Max digging radius short stick...

Page 37: ...SHB 28Z3 EN Edition 2 0 28z3s210 fm 2 11 Specifications 2 14 Dimensions model 28Z3 VDS Fig 2 Machine dimensions model 28Z3 Short stick Long stick...

Page 38: ...300 mm 14 1 Max digging height long stick 4430 mm 14 6 Max dump height short stick 2960 mm 9 9 Max dump height long stick 3090 mm 10 2 Max digging radius short stick 4614 mm 15 2 Max digging radius lo...

Page 39: ...t capacity is exceeded 3 5 m 11 5 ft 3 0 m 9 8 ft 2 5 m 8 2 ft A B Lowered blade Lowered blade Lowered blade Lowered blade 3 0 m 9 8 ft 508 1121 387 854 492 1085 426 939 2 0 m 6 6 ft 489 1078 280 617...

Page 40: ...hydraulic lift capacity is exceeded 3 5 m 11 5 ft 3 0 m 9 8 ft 2 5 m 8 2 ft A B Lowered blade Lowered blade Lowered blade Lowered blade 3 0 m 9 8 ft 458 1009 339 747 423 933 423 933 2 0 m 6 6 ft 447 9...

Page 41: ...draulic lift capacity is exceeded 3 5 m 11 5 ft 3 0 m 9 8 ft 2 5 m 8 2 ft A B Lowered blade Lowered blade Lowered blade Lowered blade 3 0 m 9 8 ft 508 1121 427 941 492 1085 483 1085 2 0 m 6 6 ft 489 1...

Page 42: ...r 87 of the hydraulic lift capacity is exceeded 3 5 m 11 5 ft 3 0 m 9 8 ft 2 5 m 8 2 ft A B Lowered blade Lowered blade Lowered blade Lowered blade 3 0 m 9 8 ft 458 1009 377 832 423 933 423 933 2 0 m...

Page 43: ...lade Raised blade Lowered blade Raised blade Lowered blade Raised blade 3 0 m 9 10 516 1138 403 889 444 979 495 1091 464 1023 495 1091 2 0 m 6 7 501 1105 303 668 333 655 508 1120 348 767 382 842 549 1...

Page 44: ...sed blade Lowered blade Raised blade Lowered blade Raised blade Lowered blade Raised blade 3 0 m 9 10 466 1027 356 785 391 862 430 948 430 948 430 948 2 0 m 6 7 458 1010 275 606 303 668 468 1032 348 7...

Page 45: ...SHB 28Z3 EN Edition 2 0 28z3s210 fm 2 19 Specifications 2 21 Kinematics E Pin diameter 40 mm 1 57 F Stick width 140 mm 5 51 L Pin distance from bucket mount 180 mm 7 09 Bucket Bucket Stick...

Page 46: ...2 20 SHB 28Z3 EN Edition 2 0 28z3s210 fm Specifications...

Page 47: ...Maintenance...

Page 48: ...esters with an iodine value of 10 g mg according to DIN 51524 section 3 HVLP HEES PANOLIN HLP Synth 46 FINA BIOHYDRAN SE 46 BP BIOHYD SE 46 Grease Roller and friction bear ings KPF2 K 206 6 KPF2K 20...

Page 49: ...intervals Notice Please refer to the maintenance plan on page 3 7 for additional maintenance work Engine oil grade Ambient temperature C F C 20 15 10 5 0 5 10 15 20 25 30 35 40 SAE 10W SAE 20W SAE 10...

Page 50: ...grades for the hydraulic system depending on temperature Hydrau lics oil grade Ambient temperature C F HVLP1 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...

Page 51: ...efilter Radiator Check the coolant level Radiator Drain and fill in new coolant Engine Check valve clearance Adjust if necessary Engine Check the engine oil level Engine Change engine oil Engine Repla...

Page 52: ...e the air filter 1000h 500h 500h 1000h D D 1000173185 API CF 1000h 10h 50h 3 2 4 D 1 D 1 1 3 50h 10h 1 3 1 34 C 29 F ASTM D4985 50h 10h 4 6 10h 500h 250h 1000h 1 SAE 10W 40 ASTM D6210 KF2K 25 Li soap...

Page 53: ...r element maintenance display on filter 4 Coolant Hydraulic oil filter insert 5 Hydraulic oil 6 Hydraulic oil tank breather Cab air filter of heating system Drain condensation water from hydraulic oil...

Page 54: ...ew connections of the safety devices e g cab etc for tightness Check screws for tightness Check pin lock Check line fixtures Check indicator lights for correct function Couplings dirt pile up on hydra...

Page 55: ...emblies components Rectify if necessary Lights signalling system acoustic warning system Heating function Hydraulic quickhitch lock Check pedal function Check the Powertilt Leakage check Check for tig...

Page 56: ...acid production facilities steel and aluminium mills chemical plants and other nonferrous metal plants 5 Replace the hydraulic oil filter insert the first time after 50 s h then every 500 s h 6 Drain...

Page 57: ...dirt and debris can be blown into your face Therefore wear protective goggles masks and clothing when using compressed air 3 6 Safety relevant parts Service and maintenance work must be carried out b...

Page 58: ...he risk of fire Notice Do not run the fuel tank completely dry Otherwise air is drawn into the fuel sys tem This requires bleeding the fuel system see Bleeding the fuel system on page 3 14 Notice Fill...

Page 59: ...se air is drawn into the fuel sys tem This requires bleeding the fuel system see Bleeding the fuel system on page 3 14 Notice Fill up the tank with the correct fuel type at the end of each working day...

Page 60: ...g Protect the suction pipe opening of the barrel pump with a fine mesh screen Immerse it down to a max 15 cm 5 9 above the floor of the barrel Only fill the tank using refuelling aids funnels or fille...

Page 61: ...ine Fold the control lever base up Remove the ignition key Bleed the fuel system again as described above Check for leaks after starting the engine Water separator Check the water separator as follows...

Page 62: ...r face Open stop cock B ON vertical Bleed the fuel system see Bleeding the fuel system on page 3 14 Check the filter for tightness after a short test run Dispose of the old filter insert in an environ...

Page 63: ...es before checking Park the machine on level and horizontal ground Stop the engine Fold the control lever base up Switch off ignition Remove the ignition key and carry it with you Let the engine cool...

Page 64: ...area around oil filler cap B with a lint free cloth Open filler cap B Raise oil dipstick A slightly to allow any trapped air to escape Fill in engine oil Wait about 3 minutes until all the oil has ru...

Page 65: ...e about 80 C 176 F Stop the engine Switch off ignition and remove the ignition key Fold the control lever base up Place a container under the opening to collect the oil as it drains Unscrew the oil dr...

Page 66: ...thread adapter is correctly placed in the filter head Clean the inside of the filter head Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge Tighten the new filter...

Page 67: ...to engine damage Therefore Check the coolant level at regular intervals Refer to the maintenance plans in the appendix for the intervals If coolant must be added frequently check the cooling system f...

Page 68: ...Keep away from flames Avoid eye contact with antifreeze If antifreeze comes into contact with the eyes Immediately rinse with clean water and seek medical assistance Checking the coolant level Park t...

Page 69: ...d repeat the procedure until the coolant level remains constant Close and lock the engine cover Caution Do not mix the coolant with other coolants Only use the coolant recommended by Wacker Neuson see...

Page 70: ...f necessary General instructions for maintenance of the air filter element Store filters in their original packaging and in a dry place Do not knock the air filter element against other objects as you...

Page 71: ...r AG03215 Close bow clips D on housing section E from serial number AG03216 Press the button at the front to reset dirt indicator A Close and lock the engine cover Notice Ensure that dust valve G show...

Page 72: ...insert the new inside air filter C in the inside housing section F Carefully insert the outside air filter B in the upper housing section F Position lower housing section E ensure that it is properly...

Page 73: ...clothing Carefully clean the filter with compressed air Do not aim the compressed air at the skin or at other people Do not use compressed air for cleaning your clothing The machine is equipped with...

Page 74: ...cool down Open the engine cover Carefully check V belt 1 for damage cracks or cuts Replace the V belt if it touches the base of the V belt groove or if the pulleys are damaged If the V belt is damaged...

Page 75: ...gine cool down Raise the upper front window Remove the lower front window Slacken fastening screws 1 Remove the body bound rivet 2 next to the right hand control lever base Remove the side trim Slacke...

Page 76: ...ing the correct V belt tension see Checking V belt tension on page 3 28 Keep the alternator in this position and at the same time retighten fastening screw 7 Check V belt tension again and adjust it i...

Page 77: ...sure gauges that are connected for checking pressure even the slightest traces of dirt e g a grain of sand can impair tightness and cause leaks Overview of measuring ports up to serial number AG02712...

Page 78: ...the control lever base safety switch to work position Check and make a note of the pressure value Adjusting pressure reducing valve 4 PRV 4 Adjust the pressure at the pressure reducing valve 4 PLV4 39...

Page 79: ...make a note of the pressure value Pressure drop should not be more than 10 of the specified value Setting primary pressure limiting valve 1 PPLV 1 Adjust the pressure at the primary pressure limiting...

Page 80: ...specified value Setting primary pressure limiting valve 2 PPLV 2 Adjust the pressure at the primary pressure limiting valve PPLV 2 43 B on the main valve block Slacken the locknut of the pressure limi...

Page 81: ...more than 10 of the specified value Setting primary pressure limiting valve 3 PPLV 3 Adjust the pressure at the primary pressure limiting valve PPLV 3 45 C on the main valve block Slacken the locknut...

Page 82: ...g valve on the gear motor Slacken the locknut of the pressure limiting valve Unscrew the pressure limiting valve until you can read off a pressure drop on the pressure gauge The valve seat may be stuc...

Page 83: ...ntrol Function Movement Symbol Measuring port Pressure limiting valve Specified values 1st meas urement 2nd meas urement Engine speed Pressure in bar psi Joystick ANY Measuring port MP 4 pump Pressure...

Page 84: ...miting valve PPLV 1 main valve block max 225 3 3263 43 5 min 202 3 2930 43 5 DOWN max 225 3 3263 43 5 min 202 3 2930 43 5 Bucket DUMP OUT max 225 3 3263 43 5 min 202 3 2930 43 5 DUMP IN max 225 3 3263...

Page 85: ...Primary pressure limiting valve PPLV 2 MVB max 225 3 3263 43 5 min 202 3 2930 43 5 RETRACT max 225 3 3263 43 5 min 202 3 2930 43 5 Right hand drive Forwards Measuring port MP 2 pump Primary pressure l...

Page 86: ...2 2988 58 29 min 185 4 2 2683 58 29 B 2 max 206 4 2 2988 58 29 min 185 4 2 2683 58 29 Swivel boom Left max 206 4 2 2988 58 29 min 185 4 2 2683 58 29 Right max 206 4 2 2988 58 29 min 185 4 2 2683 58 2...

Page 87: ...he following problems is detected Damaged or leaky hydraulic seals Worn or torn shells or uncovered reinforcement branches Expanded shells in several positions Entangled or crushed movable parts Forei...

Page 88: ...er Sight glass B is located at the rear left of the machine under the engine cover Check the oil level on sight glass B The oil level must be about 1 cm 0 39 over the centre between positions MIN and...

Page 89: ...rk the machine on level ground Position the boom straight ahead Lower the boom and the attachment to the ground Extend the stabiliser blade ram Lower the stabiliser blade to the ground Stop the engine...

Page 90: ...et the machine run at idling speed without load for some minutes Monitoring the hydraulic oil return filter Pressure switch A activates the red indicator light in the instrument panel which monitors t...

Page 91: ...environmentally friendly manner Draining condensation water from the hydraulic oil tank Check the hydraulic oil tank after a longer standstill or every 500 service hours Drain the condensation water...

Page 92: ...kind of biodegradable oil ensure that the remaining amount of initial biodegradable oil does not exceed the indications of the manufacturer of biodegradable oil Do not fill up with mineral oil the con...

Page 93: ...essure lines and screw connections Replace damaged parts with new ones Never search for leaks with your hands Have damaged flexible lines replaced by authorised workshops only Leaks and damaged pressu...

Page 94: ...de to the ground Set the boom straight Stop the engine Move the control levers in all directions repeatedly Switch off ignition and remove the ignition key Fold up the control lever base Let the engin...

Page 95: ...uantity of oil must flow out of opening B LEVEL If the oil does not flow out of opening B LEVEL fill up oil Fill in oil through opening A until a small quantity of oil flows out of opening B LEVEL Scr...

Page 96: ...horizontal ground Raise the machine evenly and horizontally Raise the machine by means of the boom and the stabiliser blade Slowly and carefully actuate the control levers The rubber track has a mark...

Page 97: ...valve A Check the tension is correct by starting the engine letting it run at idling speed and slowly moving the machine forwards and reverse and switching it off again Check the tension of the tracks...

Page 98: ...Stop the engine Remove the key and carry it with you Move control levers 1 and 2 in all directions repeatedly Fold the control lever base up Do not allow anyone to stay in the cab and close the doors...

Page 99: ...console Fig 69 D Daily 2 10 Offset ram Fig 67 C and Fig 79 M Daily 2 11 Ball bearing race of live ring see Lubrication point on ball bearing race of live ring on page 3 57 1 12 Teeth of live ring sta...

Page 100: ...liser blade Lubrication points on the swivelling console and slewing ram Apply grease to lubrication points 10 on the offset ram Apply grease to lubrication points 10 of the offset ram Apply grease to...

Page 101: ...pply grease to lubrication points 2 on the stick ram Apply grease to lubrication points 1 on the bucket ram Apply grease to lubrication points 3 on the boom ram Apply grease to lubrication points 1 on...

Page 102: ...boom Apply grease to lubrication points 7 on the stick Apply grease to lubrication points 7 on the stick Lubrication point on the joint rod Apply grease to lubrication point 8 on the joint rod Fig 74...

Page 103: ...Remove ejected grease Turn the machine 90 at a time Stop and park the machine Apply grease to each of lubrication points 11 with one stroke of the grease gun Remove ejected grease Turn the machine 360...

Page 104: ...ring teeth Drive and stop the machine over a pit The lubrication point is located on the right hand side of the undercarriage Apply grease to lubrication point 13 with five strokes of the grease gun R...

Page 105: ...ption Carry out maintenance of the Powertilt unit once a day with the other maintenance work for the machine Carry out visual checks for possible defects damage or cracks Remove all dirt on and around...

Page 106: ...ightly greased Apply grease to the friction surfaces of the lock mechanism via 2 grease nipples 16 on either side of the quickhitch see Fig 87 Before starting work check the acoustic signal You must b...

Page 107: ...he electrical system must always be replaced by an authorised expert Lamps and fuses may be replaced by the customer When carrying out maintenance work on the electrical system pay particular attentio...

Page 108: ...if the battery is frozen or if the acid level is low The battery can rupture or explode Replace the battery immediately Always disconnect the negative terminal from the battery before starting repair...

Page 109: ...leaning with a high pressure cleaner or steam jet Electric components and damping material must be covered and not directly exposed to the jet Cover the vent filter on the hydraulic oil tank and the f...

Page 110: ...sensors causes them to fail and leads to engine damage Shatter protection Clean the window only with water and a mild soap solution Do not use aggressive detergents Do not use brushes steel wool or si...

Page 111: ...rvice for a longer period of time The following measures must be taken if the machine is out of service for more than 30 days Putting into operation again Remove anticorrosion agent from the piston ro...

Page 112: ...Cut 2 threads with the correct diameter in the drilled holes Install the trim Fasten a retaining bracket you have made yourself with corresponding screws and washers Fasten the fire extinguisher onto...

Page 113: ...Engine...

Page 114: ...0 28z3s410 fm Engine 4 Engine 4 1 3TNV76 NNS engine overview Fuel filter Engine oil filter Air intake Oil pressure switch Water pump V belt Fan blade Oil filler neck Fuel injection pump Oil dipstick O...

Page 115: ...SHB 28Z3 EN Edition 2 0 28z3s410 fm 4 3 Engine Alternator Tightening bracket Starter V belt Valve cover Exhaust manifold...

Page 116: ...28Z3 EN Edition 2 0 28z3s410 fm Engine 4 2 Fuel system S i n t e r e d m e t a l f i l t e r Fuel injection pump Fuel filter R e t u r n Feed line Filler inlet Water separator with stop cock Tank Fue...

Page 117: ...SHB 28Z3 EN Edition 2 0 28z3s410 fm 4 5 Engine 4 3 Cooling system Pulley Temperature switch Intermediate flange Water pump seal Thermostat housing Thermostat Water pump...

Page 118: ...the valve clearance if it varies To reduce the number of necessary rotations of the crankshaft for checking the valve clearance the setting of various valves can be adjusted in parallel in accordance...

Page 119: ...to this during adjustment Check the valve clearance again Repeat the procedure for each valve Place the valve cover gasket Mount the valve cover again Lapping the intake and exhaust valves To ensure a...

Page 120: ...s sure gauge If the injection pressure is too low replace the spacer in the nozzle by a thicker one If the pressure is too high replace the spacer by a thinner one Injection pressure 118 128 bar 1713...

Page 121: ...ked Apply current to the cutoff solenoid or remove the cutoff solenoid and the O ring from the injection pump Fuel supply is enabled Set the throttle to the maximum speed Remove the cap on the flywhee...

Page 122: ...r 1 and push to one side The opening of injection pump A must be visible Open all fuel cocks B see Fig 10 Notice Fuel is pumped to the cylinder only every second turn of the crankshaft for this reason...

Page 123: ...ubject to tension once they are mounted Bleed the injection lines once they are installed Setting injection time Variations of the injection time outside the tolerance range can be corrected by turnin...

Page 124: ...o not turn the crankshaft Tighten the screw of the pulley with a long spanner to fix the crankshaft in place Slacken lock nut D of gear C and unscrew until the shaft end of the injection pump Use an e...

Page 125: ...rease for assembly Tighten the screw of the pulley with a long spanner to fix the crankshaft in place Set the injection pump to the original position by means of the marks on the gear casing and injec...

Page 126: ...ad Run the diesel engine until it reaches operating temperature Check idling speed and maximum engine speed with all attachment functions in neutral Idling speed 1300 25 rpm Max engine speed 2375 25 r...

Page 127: ...temperature check with a tem perature gauge Thermostat opening temperature 70 73 C 158 163 F 4 13 Checking the thermal switch Drain the coolant Remove the thermal switch Warm up the thermal switch in...

Page 128: ...e pressure in the cooling system by means of a hand pump to about 1 bar 15 psi Check the lines and the connections for leaks if the pressure drops at the pressure gauge Checking the radiator cap Remov...

Page 129: ...ressure and possible damage Install the parts in reverse order 4 19 Replacing the glow plugs Removing the glow plugs Unscrew the fastening screws of valve cover D see Fig 27 Remove the valve cover and...

Page 130: ...fuse Dirty fuel filter Very dirty air filter Cutoff solenoid does not attract High pressure created immediately in the hydraulic system Air in fuel system Engine starts but does not run smoothly or f...

Page 131: ...Engine oil consumption too high Lube oil level too high Machine inclination too high Wrong SAE grade of engine lubrication oil Worn oil scraper rings Engine smoke Blue Lube oil level too high Machine...

Page 132: ...4 20 SHB 28Z3 EN Edition 2 0 28z3s410 fm Engine...

Page 133: ...Hydraulic system...

Page 134: ...ulic system is governed by a throttle 5 1 Hydraulic pump PVD 0B 23BP 8G3 5083A Double variable displacement pump 2 gear pumps 4 3 2 1 6 5 Gear pump unit Variable displacement pump unit Pilot oil suppl...

Page 135: ...on 2 0 28z3s510 fm 5 3 Hydraulic system 8 10 9 Variable displacement pump unit Gear pump unit 7 Pos Designation 7 Suction line Port 8 Port PB1 gear motor supply 9 Port PA 2nd speed range 10 Port PB2 p...

Page 136: ...9 Pos Designation Pos Designation 1 Drive unit 11 O ring 2 Swash plate 12 O ring 3 Ball 13 O ring 4 Stop stud 14 Pilot oil supply unit 5 Stop pin 15 Solenoid switch 6 Spring 16 Solenoid switch 7 Stop...

Page 137: ...7 5 7 Both valves can be interchanged 3 30 bar Pos Designation Port 1 Gear motor supply PB1 2 Pilot valve supply PB2 3 Solenoid valve for safety valve 4 Drives 2nd speed range supply PA 5 2nd speed r...

Page 138: ...Unscrew the hexagon head screws 2 x and remove the gear pump and coupling with the ring The coupling and ring are located either on the gear pump or variable displacement pump Mark or measure the set...

Page 139: ...s from the pump The length of the stop studs varies note the correct position Also note the number and position of the spring seats Remove the circlip with circlip pliers Knock the shaft out of the ho...

Page 140: ...accumulating in the parts and to provide lubrication during assembly Apply a thin layer of grease to the O ring surface to secure it in the grooves provided Assemble the pump in the reverse order of d...

Page 141: ...2 x and then insert them into the pump housing Ensure that the stop studs and spring seats are correctly positioned The stop studs have various lengths and must be fitted in the original position othe...

Page 142: ...g sections Use new O rings Position the guides correctly Fit the seal and align with the parallel pin of the housing Use a new seal Place both housing sections together Insert two screws M10x65 on the...

Page 143: ...O rings Fit the coupling and ring into the housing Fit the gear pump and screw tight with the two fastening screws and washers Tightening torque 19 6 23 5 Nm 14 5 17 3 lbs ft Fit the O rings on the h...

Page 144: ...f pump Damaged parts in the pump Insufficient flow or pressure Speed of the diesel engine too low Damaged parts in the pump Wrong coupling was fitted Abnormal noises or vibrations Air in the hydraulic...

Page 145: ...ck Auxiliary hydraulics Stabiliser blade Upper carriage rotation Straight ahead drive counter balancing system Boom Right hand drive Input P1 P2 B1 A1 B3 A3 A2 T1 P1 P2 A4 B4 A5 B5 A6 B6 A7 B7 A8 B8 P...

Page 146: ...right via swivel joint A4 B4 Drive left via swivel joint A5 B5 Stick ram A6 B6 Auxiliary hydraulics A7 B7 3rd control circuit option A8 B8 Swivel boom A9 B9 Stabiliser blade A10 B10 Upper carriage rot...

Page 147: ...5 Hydraulic system Main valve block diagram Drive counterbalancing system P3 Input P1 Input P2 Bucket Boom Right hand drive Left hand drive Stick Auxiliary hydraulics 3rd control circuit Stabiliser bl...

Page 148: ...Secondary pressure limiting valve stick rod side 4 Secondary pressure limiting valve bucket rod side 5 Secondary pressure limiting valve boom rod side 6 Secondary pressure limiting valve boom base sid...

Page 149: ...ydraulics section Auxiliary hydraulics flow rate adjustment segment 3rd control circuit option Boom swivel Stabiliser blade section Upper carriage rotation section Drive counterbalancing system sectio...

Page 150: ...nd side drive and a boom function bucket boom stick or auxiliary hydraulics Function The drive counterbalancing system is enabled by means of an increased banking up pressure if both piston valves for...

Page 151: ...segment so the rod side oil can flow to the base side Location The regeneration valve is located in the stick segment on the lower side 5 5 Bucket pre tension A nozzle is integrated in the pressure l...

Page 152: ...ibed below There are two possible positions Set screw against hydraulic resistance The valve seat is closed in this position P2 P3 supply the auxiliary hydraulics section with oil Factory setting Open...

Page 153: ...ched via 2 capacity positions 1 2 3 5 6 1 2 3 5 4 7 8 Pos Designation 1 Drive port swivel joint right 4 left 3 2 Drive port swivel joint right 2 left 5 3 2nd speed range port swivel joint 8 4 Directio...

Page 154: ...an abrupt standstill With the brake piston in neu tral position the ports are no longer connected to the motor which can no longer turn 2 speed range functions Speed range 1 High speed switch switche...

Page 155: ...fm 5 23 Hydraulic system Pos Designation 1 Travelling drive 2 Screw connection 3 Screw connection 4 O ring set 5 Brake cartridge 6 Hydraulic motor 7 Lifetime seal 8 Bearing 9 Plug 10 Plug 11 Snap rin...

Page 156: ...ned for smooth braking X X X 2 1 2 8 1 2 9 7 3 6 5 4 7 5 1 2 6 4 7 8 10 Pos Designation 1 SH brake release port shuttle valve 2 Pilot control pressure port pilot oil supply unit 3 Brake release valve...

Page 157: ...h maximum hydraulic output Mechanical stop brake A multidisc brake integrated in the rotation drive has an additional mechanical brake effect with time delay This negative effect brake is used as a st...

Page 158: ...5 22 13 lbs ft 20 42 Nm 31 lbs ft 25 Nm 18 4 lbs ft Pos Designation Pos Designation 1 Pinion shaft 11 O ring 2 Spacer washer 12 Ring gear 3 Bearing seal ring 13 Gear reduction 4 Bearing 14 Gear reduct...

Page 159: ...side Pull the swivel joint apart Replace the sealing rings Push the swivel joint together again Insert circlip 11 again a a a a a a a a a a a a a a a a 13 12 11 Pos Port Pos Designation 1a Pilot contr...

Page 160: ...he swivel joint ensures the oil flow between the upper carriage and the undercarriage 1 3 5 7 9 2 4 6 8 10 11 12 13 Pos Port Pos Designation 1 High speed 8 Tilt ram 2 Stabiliser blade ram 9 Tilt ram 3...

Page 161: ...B 35 507 6 30 0 2 5 435 1 0 36 6 0 7 0 87 10 0 0 2 1 18 25 1 35 20 10 1 Pos Designation Pos Description left hand joystick Description right hand joystick A Control lever 1 Stick extension control Boo...

Page 162: ...95 11 12 30 11 30 4 95 9 35 5 8 377 17 1 82 5 0 04 0 2 0 23 P T 3 1 4 2 P 1 2 3 4 P T T Pressure bar psi Characteristic curve for drive pilot valve Pilot valve piston stroke in mm in Joystick positio...

Page 163: ...Edition 2 0 28z3s510 fm 5 31 Hydraulic system E 1 2 3 5 4 6 Set of tappets sealing kit Pos Designation 1 Bellows 2 Shift unit 3 Plates 4 Tappet 5 Non return valve also used for bleeding pedal damping...

Page 164: ...al valve Tighten wing nut J after changing the control mode 5 13 Proportional valve option A proportional valve ensures a modifiable control signal an electric signal is steplessly transformed into a...

Page 165: ...eed setting option and is installed on the main valve block in the valve compartment at the rear of the machine See also Chapter 7 3 Automatic engine speed setting 5 16 Easy Lock valve option The work...

Page 166: ...he oil tank to the specified overpressure supports the variable displacement pump s suction Filtering the intake air Opens at 0 4 bar 5 8 psi The breather filter is located in the machine at the rear...

Page 167: ...instructions in the Operator s Manual of the attachment manufacturer for connecting the auxiliary hydraulics to attachments Standard ports Fig 37 Connections for auxiliary hydraulics Port Stick left...

Page 168: ...fuses Defective interrupted plug and socket connection towards solenoid valve Hydraulic hammer does not work correctly Quickhitch couplings not connected correctly Hydraulic oil quantity too high too...

Page 169: ...bersicht der Hydraulikpl...

Page 170: ...31 Schockpatrone 3 Steuerkreis 32 Schockpatrone Zusatzhydraulik 33 SAE Ventil 34 3 2 Wegeventil VDS 35 Zylinder Drehzahlregelung 36 Entsperrbares R ckschlagventil 37 Kippzylinder 38 7 2 Wegeventil VD...

Page 171: ...bar 275bar 225bar 225bar 30bar 250 m 250 m tor schildzylinder kzylinder ydraulik tielzylinder trieb trieb zylinder ylinder L ffel Hubarm Fahren links Fahren rechts Joystick links rkreis Opt Dieselmoto...

Page 172: ...ter Joystick satzhydraulik eis Greifer L ffel berlastwarneinrichtung DE Hubarm Schockpatrone ZH Hubarm L ffelstiel euerkreis ertilt Powertilt VDS L ffelstiel Planierschild berlastwarneinrichtung FR be...

Page 173: ...ungen Anschluss Legende A1 B1 L ffelzylinder A2 B2 Hubarmzylinder A3 B3 Fahreinheit rechts ber Drehdurchf hrung A4 B4 Fahreinheit links ber Drehdurchf hrung A5 B5 L ffelstielzylinder A6 B6 Zusatzhydra...

Page 174: ......

Page 175: ...Electrical system...

Page 176: ...ing Observe AC DC basic setting AC alternating current voltage DC direct current voltage Test device with acoustic and optical signal output Continuity test in de energised machine electrical system a...

Page 177: ...e used for switching electric loads high currents whereby the control power of the relay coil is relatively low Relays can therefore be controlled by microelectronics or microswitches e g touchpad key...

Page 178: ...arter 12 V 1 1 kW 1 47 hp Battery 12 V 44 Ah Socket E g for cigarette lighter 15 A max Fig 3 Fuse box F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Fuse no Rated current A Protected circuit F1 40 A Start preheat cut...

Page 179: ...cking diode K6 Preheating time lag relay K7 Starting relay K8 Cutoff solenoid time lag relay K9 Pick up contact cutoff solenoid relay Fig 5 Starting relay K7 Fig 6 Alternator 1 2 Pos Description 1 Con...

Page 180: ...s for proportional controls version option Control element on control console Control element on cab wall 2 1 3 6 7 8 9 1 2 3 4 5 6 7 8 9 Pos Designation 1 High speed 2 Ventilation 3 Safe load indicat...

Page 181: ...option The loudspeakers and the aerial but not the radio are installed at the factory with this option Notice The cab is prewired up to these components at the factory as a standard Fig 8 Cigarette li...

Page 182: ...ear cab lights This option includes front cab lights and one rear cab light see Fig 11 Fig 12 and Fig 13 A B Fig 10 Front working light Pos Description A Front working light B Halogen lamp 12 V 55 W H...

Page 183: ...ight of the engine compartment The pressure switch for the driving signal is located directly on the underside of the drive valve Driving signal wiring harness Fig 14 Rotating beacon E Pos Description...

Page 184: ...6 10 SHB 28Z3 EN Edition 2 0 28z3s610 fm Electrical system...

Page 185: ...Die Stromlaufpl ne und K Optionen...

Page 186: ...halter Motor l E F5 S3 Temperaturschalter Motor F5 S5 Druckschalter Hydraulik l E F6 S16 Schalter Arbeitsscheinwerfer Hubarm B11 S17 Schalter Arbeitsscheinwerfer Kabine B14 Opt S18 Schalter Rundumkenn...

Page 187: ......

Page 188: ......

Page 189: ...SHB 28Z3 EN Edition 2 0 28z3s612 fm 6 15 Electricalsystem Electrical sys tem Wiring harnesses overview...

Page 190: ...ghts fan S16 1 yel 1 41 S16 10 12 V lights fan S16 1 yel 1 42 F4 2 12 V lights fan S15 1 yel 1 43 S15 2 12 V lights fan S15 1 yel 1 44 S15 2 12 V lights fan S15 10 yel 1 45 S16 5 boom working light E1...

Page 191: ...07 K6 earth K8 blk 1 108 V1 earth K8 blk 1 109 X14 2 earth GND blk 1 110 X14 2 earth S5 blk 1 111 M4 2 earth GND blk 1 112 M4 2 earth B1 2 blk 1 113 X19 earth GND blk 1 114 X19 earth E11 2 blk 1 115 Y...

Page 192: ...ad Quickhitch Fan 2nd speed Horn Oil filter Proportional controls Indicator Ignition lock Quickhitch tip switch Quickhitch pressure switch VDS VDS Length indications include connectors adapter sockets...

Page 193: ...F Insulating hose B no fabric soft PVC DIN 40621 temperature range 25 C to 90 C 13 F to 194 F Shrink hose Strand From Up to mm Colour Strand From Up to mm Colour 5 X12 1 E9 1 grn red 12 X12 7 B12 0 5...

Page 194: ...H10 1 12 V H11 1 blu 1 18 X10 6 5 V joystick X12 1 red 1 6 X11 2 valve earth GND V1 brn 1 19 X13 1 5 V joystick X12 1 red 1 7 Y16 2 valve earth GND V1 brn 1 20 X10 7 joystick earth X12 4 blk wht 1 8 Y...

Page 195: ...arness option No Up to To Colour No Up to To Colour 1 X14 S90 1 blu 1 6 Y59 1 K51 87a grn 1 2 S90 10 S90 1 blu 1 7 X14 S88 9 blk 1 3 S90 5 K51 30 gry 1 8 K51 85 S88 9 blk 1 4 S89 K51 30 gry 1 9 K51 85...

Page 196: ...tion 2 0 28z3s612 fm Electrical system 6 24 Driving signal wiring harness option Plug Description X1 Wiring harness connector X2 S21 high speed cable not equipped X3 Pressure switch connector X4 Drivi...

Page 197: ...7 K058 86 K058 1 1 gry yel Quickhitch valve 8 K058 85 B19 1 blk Earth Cable side indication of connector assigment unless otherwise specified Cable type FLRY B DIN 72551 Line and connector labelling w...

Page 198: ...lectrical system 6 26 Battery lead Shrink hose Corrugated pipe Battery lead Battery lead Plus lead red Minus lead black Red Red L L L L L L L Black Black Position 1 Position 2 Position 2 Position 1 Po...

Page 199: ...SHB 28Z3 EN Edition 2 0 28z3s612 fm 6 25 Electricalsystem...

Page 200: ...6 26 SHB 28Z3 EN Edition 2 0 28z3s612 fm Electrical system...

Page 201: ...Options...

Page 202: ...th Loctite S2420 or VaryBond 12 43 Notice Bear in mind the lift capacity table when using a counterweight 7 2 Long stick Specifications Notice Bear in mind the lift capacity table when using a long st...

Page 203: ...func tions are carried out and if the automatic engine speed setting switch A is enabled As soon as a hydraulic function is carried out with the control levers diesel engine speed is automatically inc...

Page 204: ...7 4 SHB 28Z3 EN Edition 2 0 28z3s710 fm Options Installation...

Page 205: ...rds The coupling opens Connecting the coupling Connect the coupling onto the stick ram connection making sure it is straight Wait until you hear a hissing sound of the connection Fully connect the cou...

Page 206: ...al of the attachment manufacturer for connecting the 3rd control circuit to attachments Standard ports Fig 3 3rd control circuit PowerTilt ports Port Bushing Standard Bulkhead coupling 1 2 Quick coupl...

Page 207: ...or as follows Press switch 42 on the instrument panel Indicator light 37 on the round indicating instrument comes on in case of overload The safe load indicator light comes on and an acoustic warning...

Page 208: ...indicator DE from serial no AG04828 safety valves for boom Pos Designation 1 Safe load indicator cable 2 Pilot control segment port 3 Pressure switch 4 Directional valve 5 Hose burst valve 6 Switch 7...

Page 209: ...indicator DE serial nos AG02444 to AG04827 safety valves for boom Pos Designation 1 Safe load indicator cable 2 Pilot control segment port 3 Pressure switch 4 Set screw 5 Hose burst valve 6 Switch 7...

Page 210: ...w towards the ram In the event of a hose rupture the load is safely held in base position by means of the non return valve Retracting the boom ram Pilot control pressure moves valve 2 to work position...

Page 211: ...r legal reasons Wiring diagram Setting the pressure switch Adjust the pressure switch see Setting the pressure switch on page 7 17 Boom up to serial number AG02443 1 2 3 4 5 6 2 6 2 3 6 4 1 2 3 4 5 6...

Page 212: ...s for boom stick and stabiliser blade Pos Designation 1 Boom segment pilot control port 2 Joystick stick port 3 Joystick boom port 4 Stick pressure line port 5 Leak oil strip port 6 Pressure switch 7...

Page 213: ...alves for boom stick and stabiliser blade Pos Designation 1 Boom segment pilot control port 2 Joystick stick port 3 Joystick boom port 4 Stick pressure line port 5 Leak oil strip port 6 Pressure switc...

Page 214: ...rds the ram In the event of a hose rupture the load is safely held in base position by means of the non return valve Retracting the boom ram Pilot control pressure moves valve 2 to work position free...

Page 215: ...re drops In addition safety valve 1 protects the hydraulic rams from overload Overload actuates pressure switch 4 the warning device comes on and the buzzer sounds Notice The valve settings are sealed...

Page 216: ...7 2 5 1 Stabiliser blade 8 1 2 3 4 5 6 5 3 6 1 2 3 4 5 6 5 3 6 6 7 8 1 2 3 4 5 6 Boom Stick Stabiliser blade 6 3 1 2 3 4 5 6 6 3 8 Pos Designation Port Pos Designation Port 1 Safety valve CT1 5 Tank l...

Page 217: ...alues indicated in the lift capacity table for reach and load hook height Remove connector A of cable 1 Pressure switch 3 is located under connector A Set screw 4 is located on the upper side of press...

Page 218: ...e itself immediately repaired and checked by technical staff with suitable training Proceed as follows in case of damage Immediately stop the machine Move the boom to transport position Fold up the le...

Page 219: ...ows Approach the machine to the attachment Pick up the bucket with coupling bar M and coupling claws L of the quickhitch Engage lock mechanism N into mounting bore O Place the bucket on level ground L...

Page 220: ...e Auxiliary hydraulics Boom swivel and Rotate upper carriage For reasons of safety only use the function Raise stabiliser blade to open or close 7 12 3rd control circuit Function The 3rd control circu...

Page 221: ...an ignition key with different coding for the drive interlock Disable the drive interlock with the master key and in addition keep it close to the tran sponder receiver surface for 30 45 seconds see...

Page 222: ...The system is deleted once the LED comes on slowly three times Caution Deletion deletes all normal transponders and the master Reason once an ignition key is lost you can no longer delete it Therefor...

Page 223: ...we recommend setting the controls to the low characteristic curve 1 slow move ments see Adjusting control response on page 7 26 The slide switch is not pressed fully in this position and you can move...

Page 224: ...crushing Stay clear of areas between moving hydraulic components and fixed obsta cles Danger of crushing The operator of the machine or hydraulic system must be aware of possible machine or system err...

Page 225: ...aulics Actuating the auxiliary hydraulics Oil flow in 1st direction Move hammer pedal 8 to the left Oil flow in 2nd direction Move hammer pedal 8 to the right Hammer operation Switching on hammer oper...

Page 226: ...witch on ignition at the same time Then release slide switch B Status indicator 44 acknowledges by flashing twice Characteristic curves status indicator Displays the characteristic curve that has been...

Page 227: ...al circuit 1 indicator light Y16 Auxiliary hydraulics solenoid valve Y17 Auxiliary hydraulics solenoid valve Y18 Connector 1 proportional circuit 2 Y19 Connector 2 proportional circuit 2 Fig 19 Contro...

Page 228: ...nnel 1 magnet 1 5 LSW2 Indicator light 6 LSW3 Indicator light 7 MVL2A Pulse modulation channel 2 magnet 1 8 MVL2B Pulse modulation channel 2 magnet 2 9 MVL1B Pulse modulation M channel 1 magnet 2 10 M...

Page 229: ...til it reaches its operating temperature oil temperature about 80 C 176 F Stop the engine Place a container under the opening to collect the oil as it drains Unscrew cap A of oil drain valve B Screw i...

Page 230: ...7 30 SHB 28Z3 EN Edition 2 0 28z3s710 fm Options...

Page 231: ...PowerTilt PTS06...

Page 232: ...m and or work range of the user especially when is completely swivelled in No staff should be in the slewing range of the attachment The PowerTilt swivel device increases the slewing radius of buckets...

Page 233: ...e apply penetrant oil to the screws several hours before dismantling Internal decompression valve Notice Remove and replace the internal decompression valve only if there is reason to suspect leakage...

Page 234: ...dels have four hydraulic connections 2 connections with the designation P1 and 2 with the designation P2 Most PowerTilt swivel device supplied in the USA have SAE connections Customers outside North A...

Page 235: ...tool for end cap article number 1000255603 1 IV Threaded bolts PTS06 M12x45 2 V Brush 1 VI Tools for removing seals see chapter Making a tool VI for removing the seals on page 8 6 1 2 VII Plastic pus...

Page 236: ...bucket or equipment from the PowerTilt swivel device 1 Gently lower the bucket or equipment onto the ground and position it so that it can not move or tip over 2 Remove the coupling pin 3 Move the Po...

Page 237: ...necting plug 4 4 End cap 1 d Screw for securing ring 6 5 Circlip 1 e Set screw for securing ring 2 6 Standard journal coupling 1 f Shaft parallel pin 1 6 1 Base block on drive shaft side Integrated g...

Page 238: ...8 Parts list SEALING KIT A Parts list BEARING KIT B No Description Qty No Description Qty A1 End cap O ring 1 A2 Additional ring for end cap 2 B2 Shaft bearing 2 A4 Additional ring for piston 0 B4 Pis...

Page 239: ...SHB 28Z3 EN Edition 2 0 28z3s810 fm 8 9 PowerTilt PTS06 8 6 Assembly drawing P1 P2 a b 2 f B5 m n 3 A9 6 A8 4 11 g 5 1 B B A A A A B B i j e h d A1 A2 A10 A5 A6...

Page 240: ...ide 6 2 base block Caution In order to avoid personal injury and damage to the equipment Before removing the screws from securing ring d secure the standard journal coupling with lifting gear or simil...

Page 241: ...g With lifting gear or similar equipment raise the standard journal coupling 6 or the base blocks 6 1 6 2 Notice Parallel pin f between the shaft and the drive side base block 6 1 prevents the compone...

Page 242: ...Remove the O ring of securing ring A10 from shaft 2 Remove end cap 4 with two pins and a long mounting lever from the shaft Remove pressure disc B5 from end cap 4 or the housing collar Fig 12 Removin...

Page 243: ...ing 1 piston tube body 3 and shaft 2 has dead centre marks As a rule there are small marks at the front of the teeth and on the ring gear The dead centre marks of the shaft are possibly at the very bo...

Page 244: ...released from the ring gear of the housing Notice The piston tube is pulled out of the housing more easily with a plastic rubber hammer and a plastic drift The outer gearing is then released from the...

Page 245: ...damage to parts Use only tools with rounded edges to remove seals Notice Some models may possibly not have wear indicators on the inside and outside diameters of the piston tube body Remove grease ni...

Page 246: ...damage sealing grooves wear indicator grooves pressure disc surfaces shaft surfaces housing bores and gear teeth Search for the dead centre marks on shaft 2 piston tube body 3 and housing ring gear 1...

Page 247: ...a trial assembly However wear indicators and pressure discs must be installed 8 14 Installing the seals kit A shaft bearings and pressure discs kit B Caution Bear the following in mind when installin...

Page 248: ...ter seal Apply a little lithium grease to either side of pressure disc B5 and place the pressure disc on the pressure surfaces of end cap 4 Install the first pressure seal A9 with the lip showing insi...

Page 249: ...followed The seal can wear out prematurely and there is a risk of pressure building up that cannot escape On models with so called U cup or T seals fit the seals on the outside and inside diam eters...

Page 250: ...e of pressure disc B5 and place the pressure disc on shaft 2 Install the second pressure seal A9 with the lip showing inside Install wear indicator B2 Fig 41 Plug seal of shaft A8 Fig 42 Applying grea...

Page 251: ...piston tube into the housing until it makes contact with the ring gear Turn the piston body until the dead centre marks of the piston and the housing are aligned With a plastic rubber hammer and plas...

Page 252: ...the inside seal A6 of the piston Caution Ensure correct alignment of the dead centre marks on shaft 2 and piston tube 3 Do not separate the piston tube from the gearbox Check the dead centre marks an...

Page 253: ...e teeth of the securing ring and the openings of end cap 4 have the best possible alignment by trying out different positions If the openings cannot be aligned turn the end cap by a maximum one tooth...

Page 254: ...curing ring 5 again Align the dead centre marks of the securing ring and the shaft Turn and tighten both screws on the securing ring Fasten end cap 4 on shaft 2 Turn the shaft with a mounting lever un...

Page 255: ...2 with suitable lifting gear Align the parallel pin of the shaft with the base block 6 1 on the drive shaft side Apply a waterproof lubricant to the end of shaft 2 securing ring 5 and the outside sur...

Page 256: ...ctite 242 XV to the threads of the fastening screws of shaft a and tighten the screws Fig 71 O ring for securing ring A10 Fig 72 Loctite 242 on securing ring screws Torque specifications for securing...

Page 257: ...ves j Slowly put the PowerTilt swivel device into operation and lubricate again as required Let the device carry out 20 30 cycles during the test to test the machine for leaks and correct rotation Tes...

Page 258: ...t bracket or the base block on the drive shaft side touches the housing or the bracket Remove the hydraulic hose from port P2 and close it port side to excavator Connect the other hydraulic hose to P2...

Page 259: ...or equipment onto the PowerTilt swivel device Notice Fit a bucket or equipment onto the PowerTilt swivel device only when the hydraulic circuit is installed and functions correctly Fit the bucket moun...

Page 260: ...ed the air from the hydraulic system and determine the cause Hose pipe diameter length is larger longer than recom mended Install new pipe flexible lines with the recommended diameter Install the remo...

Page 261: ...sary Bearing wear can cause the shaft to have axial play in the housing Possibility 2 axial play 0 5 mm 0 02 adjust the PowerTilt If adjusting requires more than half a revolution or if play cannot be...

Page 262: ...ol and tighten the end cap with a torque wrench Caution Fit the securing ring before operating the PowerTilt again The shaft turns against the blind flange and the adjusted torque is modified Fig 85 B...

Page 263: ...h 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 accep...

Page 264: ...0 28z3schlussbl fm Wacker Neuson Linz GmbH Haidfeldstr 37 A 4060 Linz Leonding Austria Phone 43 0 732 90 5 90 0 Fax 43 0 732 90 5 90 200 E mail office linz wackerneuson com www wackerneuson com Order...

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