Wacker Neuson 75Z3 Track Excavator Service Manual 1000132821 PDF

Description

Wacker Neuson 75Z3 Track Excavator Service Manual 1000132821 – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson 75Z3 Track Excavator Service Manual 1000132821 – PDF DOWNLOAD 

Language : English
Pages : 329
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Wacker Neuson 75Z3 Track Excavator Service Manual 1000132821 – PDF DOWNLOAD 

Introduction
Important information on this service manual 1-1
Identification of warnings and dangers 1-2
Designated use and exemption from liability 1-3
Type labels and component numbers 1-4
Machine overview 1-6
Cab overview 1-7
Up to serial no : AD07209 1-7
From serial no : AH00646 1-8
Cab (legend) 1-9
Instrument panel overview 1-10
Up to serial no : AD07209 1-10
From serial no : AH00646 1-11
Instrument panel (legend) 1-12
Engine compartment overview up to serial no AD07209 1-13
Engine compartment overview from serial no AH00646 1-14
Chassis overview 1-15
Tilting the cab 1-16
Summer/winter operation 1-18
Preheated fresh air 1-18
Auxiliary hydraulics/boom swivel pedal 1-19
Specifications
Chassis 2-1
Engine 2-1
Fuel injection pump 2-2
Capacities 2-2
Tightening torques 2-2
Hydraulic system 2-3
Auxiliary hydraulics oil flow* 2-3
Screwable hose burst valve 2-4
Undercarriage and swivel unit 2-4
Stabiliser blade 2-4
Electric system 2-5
Fuse box in instrument panel 2-5
Main fuse box with relays up to serial no AD07209 2-5
Relays 2-6
Main fuse box with relays from serial no AH00646 2-6
Noise levels 2-7
Vibration 2-7
Coolant compound table 2-7
Model-specific tightening torques 2-7
General tightening torques 2-8
Tightening torques for hydraulic screw connections (dry assembly) 2-8
Tightening torques for high-resistance screw connections 2-11
Dimensions model 75Z3 2-12
Lift capacity table 75Z3 2-13
Lift capacity table 75Z3 with long stick 2-14
Lift capacity table 75Z3 with counterweight 2-15
Lift capacity table 75Z3 with long stick and counterweight 2-16
Kinematics 2-17
Maintenance
Fluids and lubricants 3-1
Additional oil change and filter replacement (hydraulics) 3-2
table of contents
I-2 SERV-HB 75Z3 EN – Edition 2 0 * 7003s11IVZ fm
table of contents
Maintenance label 3-3
Explanation of symbols on the maintenance label 3-3
Maintenance plan (overview) 3-5
Service package 3-8
Up to serial no AD07209 3-8
From serial no AH00646 3-8
Introduction 3-8
Fuel system 3-9
Specific safety instructions 3-9
Refuelling 3-9
Stationary fuel pumps 3-10
Diesel fuel specification 3-10
Bleeding the fuel system 3-10
Emptying the fuel tank 3-11
Fuel prefilter with water separator 3-11
Replacing the fuel filter 3-12
Engine lubrication system 3-13
Checking the oil level 3-13
Filling up engine oil 3-14
Changing engine oil 3-15
Replacing the engine oil filter cartridge 3-16
Cooling system 3-17
Specific safety instructions 3-17
Checking/filling up coolant 3-18
Draining coolant 3-19
Air filter 3-20
Replacing the filter 3-21
Functional check once a week of the dust valve 3-22
V-belt 3-23
Checking V-belt tension 3-23
Retightening the V-belt 3-24
Checking the V-belt of the air conditioning system 3-25
Tightening the V-belt of the air conditioning system 3-25
Pressure check 3-26
General 3-26
Checking pilot control pressure 3-26
Pressure check of variable displacement pump P1 3-27
Pressure check of variable displacement pump P2 3-28
Pressure check of gear pump P3 3-29
Secondary pressure limiting valve of the gear motor 3-29
Measuring ports: overview 3-31
Primary pressure limiting valves 3-31
Test report 3-32
Hydraulic system 3-35
Specific safety instructions 3-35
Checking the hydraulic oil level 3-36
Checking the hydraulic oil level 3-36
Filling up hydraulic oil 3-37
Changing hydraulic oil 3-38
Monitoring the hydraulic oil reflux filter 3-38
Checking hydraulic pressure lines 3-39
Travelling drive 3-39
Checking the oil level and filling up oil 3-40
Draining oil 3-40
Chains 3-41
Checking chain tension 3-41
Setting the chains 3-42
SERV-HB 75Z3 EN – Edition 2 0 * 7003s11IVZ fm I-3
table of contents
Lubrication work 3-43
Stabiliser blade 3-43
Lubrication points on the swivelling console 3-43
Boom lubrication points 3-44
Lubrication points on the stick 3-44
Lubrication strip 3-45
Maintenance of attachments 3-45
Electric system 3-46
Specific safety instructions 3-46
Service and maintenance work at regular intervals 3-46
Instructions concerning specific components 3-47
Alternator 3-47
Battery 3-48
Jump-starting the engine 3-48
Cab 3-49
Replacing the cab filter 3-49
General maintenance work 3-50
Cleaning 3-50
General instructions for all areas of the machine 3-50
Inside the cab 3-51
Exterior of the machine 3-51
Engine compartment 3-51
Screw connections and attachments 3-52
Engine
Engine 4TNV98-VNS (up to serial no AD07209 American Tier 2) 4-1
Fuel system 4-3
Removing the valve cover 4-4
Checking and adjusting valve clearance 4-4
Checking valve clearance 4-4
Setting zero play of the valve bridge 4-5
Setting valve clearance 4-5
Tightening order for cylinder head bolts 4-6
Checking the injection nozzles 4-7
Pressure check 4-7
Checking the nozzle jet 4-7
Injection time 4-8
Checking injection time 4-8
Setting injection time 4-8
Replacement of fuel injection pump 4-9
Adjusting engine revs 4-10
Compression 4-10
Checking the coolant thermostat 4-10
Checking the thermal switch 4-11
Oil pressure switch 4-11
Checking the coolant circuit 4-12
Engine 4TNV98-ZVNS from serial no AH00646 4-13
Fuel system 4-15
Removing the valve cover 4-16
Checking and adjusting valve clearance 4-16
Checking valve clearance 4-16
Setting zero play of the valve bridge 4-17
Setting valve clearance 4-17
Tightening order for cylinder head bolts 4-18
Checking the injection nozzles 4-19
Pressure check 4-19
I-4 SERV-HB 75Z3 EN – Edition 2 0 * 7003s11IVZ fm
table of contents
Checking the nozzle jet 4-19
Injection time 4-20
Checking injection time 4-20
Setting injection time 4-21
Replacement of fuel injection pump 4-22
Compression 4-23
Checking the coolant thermostat 4-23
Checking the thermal switch 4-24
Oil pressure switch 4-24
Checking the coolant circuit 4-24
Engine trouble 4-25
Electronic engine control (E-ECU) 1-2
Features 1-2
Engine error codes 1-3
Error diagnosis 1-7
E-ECU connector assignment 1-7
Important information on the ECU maintenance wiring harness 1-8
Flash code 7 – proportional injection pump solenoid (control rack) 1-9
Related DTC (Diagnostic Trouble Codes) 1-9
Diagnosis description 1-11
Flash code 5 – manual throttle 1-13
Related DTC 1-13
Work description 1-15
Flash code 4-1 ECU internal 1-16
Related DTC 1-16
Work description 1-17
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
1-18
Related DTC 1-18
Work description 1-19
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
1-20
Related DTC 1-20
Work description 1-22
Flash code 2-4 – sensor 5 V 1-24
Related DTC 1-24
Work description 1-25
Flash code 2-3 – power supply voltage 1-27
(1) P0562/1: power supply voltage error (voltage too low) 1-27
DTC detection conditions 1-27
Troubleshooting 1-27
Diagnosis description 1-27
(2) P0563/0: power supply voltage error (voltage too high) 1-28
DTC detection conditions 1-28
Troubleshooting 1-28
Diagnosis description 1-28
Flash code 6 – revs sensor 1-29
Work description 1-31
Flash code 1-1 – backup revs sensor 1-32
Related DTC 1-32
Work description 1-34
Flash code 9 – overspeed error 1-35
(1) P0219/0: overspeed error 1-35
DTC detection conditions 1-35
Troubleshooting 1-35
Diagnosis description 1-35
Flash code 1-7 – proportional solenoid relay of the injection pump (control rack)
SERV-HB 75Z3 EN – Edition 2 0 * 7003s11IVZ fm I-5
table of contents
1-36
Related DTC 1-36
Work description 1-38
Flash code 1-5 – preheating relay 1-40
Related DTC 1-40
Work description 1-41
Flash code 1-4 – CSD (cold start device) solenoid coil 1-44
Related DTC 1-44
Work description 1-45
Flash code 1-3 – EGR (exhaust gas recirculation) valve 1-47
Related DTC 1-47
Work description 1-49
Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error 1-51
Related DTC 1-51
Work description 1-53
Flash code 8 – proportional injection pump solenoid (control rack) 1-55
Related DTC 1-55
Work description 1-57
Flash code 1-6 – main relay 1-59
Related DTC 1-59
Work description 1-61
Flash code 1-2 – CAN (Controller Area Network) communication 1-63
Related DTC 1-63
Work description 1-64
Automatic revs setting 1-65
How it works 1-65
Hydraulic system
Hydraulic pump AP2D36LV3RS6-875-P 5-1
Pump unit: exploded view 5-3
Pilot oil supply unit 5-4
Main valve block 5-6
Ports 5-6
Legend 5-7
Main valve block diagram 5-8
Pressure limiting valves 5-9
Pump assignment 5-10
Drive counterbalancing system 5-11
Pump assignment for drive counterbalancing 5-11
Drive counterbalancing system, actuation of hydraulic motors and auxiliary
hydraulics 5-12
Bucket pre-tension 5-13
Boom summation – raise 5-14
Check valve (load retaining valve) 5-15
Stick ram summation – extend 5-16
Pilot valves 5-17
Joystick 5-17
Pilot valve (driving) 5-19
Pilot valve for auxiliary hydraulics 5-21
Pilot valve for stabiliser blade 5-22
Valves 5-23
7/2 directional valve (changeover valve) 5-23
4/3 directional valve 5-24
Shuttle valve block 5-25
Changeover valve for SAE/ISO controls (option) 5-26
Drive up to serial number: AC 02793 5-27
Function 5-28
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table of contents
2nd speed range function 5-28
Travelling drive Auto2Speed from serial no AC 02794 5-29
Function 5-30
2nd speed range function 5-30
Swivel unit 5-32
Parking brake/multidisc brake function 5-33
Anti Swing Back (ASB) valve 5-34
Swivel joint 5-39
Breather filter 5-40
Troubleshooting in the hydraulic system 5-41
Hydraulics diagram 5-42
Hydraulics diagram (legend) 5-43
Hydraulics diagram 5-44
Options diagram 1 5-45
Options diagram 2 5-46
Main valve block diagram 5-47
Electric system
Ohm’s Law (current, voltage, resistance); power 6-1
Measuring equipment, measuring methods 6-1
Cable colour coding 6-3
Relays 6-3
Use, mode of function 6-3
Electric units 6-4
Fuse box on the instrument panel up to serial no AD07209 6-4
Main fuse box with relays up to serial no AD07209 6-4
Relays up to serial no AD07209 6-5
Fuse box on the instrument panel from serial no AH00646 6-6
Main fuse box with relays from serial no AH00646 6-6
ECU from serial no AH00646 6-7
Socket 6-7
Joystick tip switches 6-8
Joystick (left) 6-8
Joystick (right) 6-8
Instrument panel overview 6-9
Switches up to serial no AD07209 (overview) 6-10
Switches from serial no AH00646 (overview) 6-10
Alternator 6-11
Starter 6-11
Wiring diagram A4 up to serial no AD07209 (legend) 6-13
Wiring diagram A4 up to serial no AD07209 6-14
Wiring diagram A4 from serial no AH00646 (legend) 6-15
Wiring diagram A4 (1) from serial no AH00646 6-16
Wiring diagram A4 (2) from serial no AH00646 6-17
Engine – chassis A4 wiring harness 1000116497 up to serial no AD07209 (legend)
6-18
Engine – chassis A4 wiring harness 1000116497 up to serial no AD07209 6-19
Engine – chassis A4 wiring harness 1000173970 from serial no AH00646 (legend)
SERV-HB 75Z3 EN – Edition 2 0 * 7003s11IVZ fm I-7
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6-20
Engine – chassis A4 wiring harness 1000173970 from serial no AH00646 6-21
Switches A4 wiring harness 1000125106 (legend) 6-22
Switches A4 wiring harness 1000125106 6-23
Wiring harness 1000109629: cab roof 6-24
Wiring harness 1000109628: armrest 6-25
Wiring harness 1000116138: boom working light 6-26
Wiring diagram A3 up to serial no AD07209 (legend) 6-29
Wiring diagram A3 up to serial no AD07209 6-30
Wiring diagram A4 from serial no AH00646 (legend) 6-31
Wiring diagram A4 (1) from serial no AH00646 6-32
Wiring diagram A4 (2) from serial no AH00646 6-33
Engine – chassis A3 wiring harness 1000109624 up to serial no AD07209 (legend)
6-34
Engine – chassis A3 wiring harness 1000109624 up to serial no AD07209 6-35
Engine – chassis A3 wiring harness 1000173970 from serial no AH00646 (legend)
6-36
Engine – chassis A3 wiring harness 1000173970 from serial no AH00646 6-37
Wiring harness 1000125106 switches A3 (legend) 6-38
Wiring harness 1000125106 switches A3 6-39
Wiring harness 1000109629: cab roof A3 6-40
Wiring harness 1000109628: armrest A3 6-41
Wiring harness 1000116138: boom working light A3 6-42
Options
Air conditioning 7-1
Specific safety instructions 7-1
Specifications 7-1
Installation: overview 7-2
Components 7-3
Filling up the air conditioning system 7-5
Maintenance 7-6
Troubleshooting 7-7
Air-suspension seat 7-9
Connections 7-9
Counterweight 7-9
Specifications 7-9
Long stick 7-9
Specifications 7-9
Control circuit (pipework) connections for grab 7-10
3rd control circuit connections 7-10
Auxiliary hydraulics connections 7-11
Quickhitch couplings 7-11
Attachments 7-12
Fuel-filling pump 7-13
Connections up to serial no AD07209 7-14
Central lubrication system 7-15
Position 7-15
Ports 7-15
Function 7-16
Adjusting breaks and lubrication times 7-17
Repair in case of clogging 7-17
Service valve 7-19
Function 7-19
Safe load indicator D (safety valve for boom) 7-20
Position 7-20
Function 7-21
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Diagram 7-22
Safe load indicator F (safety valves for boom and stick) 7-23
Position 7-23
Function 7-24
Diagram 7-24
3rd control circuit 7-26
Function 7-26
Diagram 7-26
Electric auxiliary hydraulics 7-27
Function 7-27
Auxiliary hydraulics shock cartridge 7-28
3rd control circuit shock cartridge 7-29
Drive interlock (antitheft protection) 7-30
Position 7-30
Disabling the drive interlock 7-30
Enabling the drive interlock 7-30
Programming 7-30
Quickhitch 7-32
Proportional controls 7-33
Function 7-33
Ports 7-33
Overview 7-34
Wiring harness 7-35
Control unit 7-35
Control valve plug assignment 7-36
Safety features 7-37
Measures to be taken in case of malfunctions 7-37
Diagnosis display 7-37

DESCRIPTION:

Wacker Neuson 75Z3 Track Excavator Service Manual 1000132821 – PDF DOWNLOAD 

Important information on this service manual:

• This service manual contains important information on how to service your machine safely,
  correctly and economically. Therefore, it aims not only at new operators, but it also serves
  as a reference for experienced ones. Your knowledge and skills will help to avoid
  dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability
  and the service life of the machine will be increased by following the instructions in the
  service manual.
• Careful and prudent working is the best way to avoid accidents!
• Operational safety and readiness of the machine do not only depend on your skill, but also
  on maintenance and servicing of the machine.
• Insist on using original spare parts when carrying out maintenance and repair work. This
  ensures operational safety and readiness of your machine, and maintains its value.
• Your Wacker Neuson After-Sales Service will be pleased to answer any further questions
  regarding the machine or the service manual.

S.V 31/12/24