Wacker Neuson EZ53 Track excavator Service manual – PDF DOWNLOAD

Description

Wacker Neuson EZ53 Track excavator Service manual – PDF DOWNLOAD

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DESCRIPTION:

Wacker Neuson EZ53 Track excavator Service manual – PDF DOWNLOAD

1 Operation
1.1 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 hazardous 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 performing 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.

TABLE OF CONTENTS:

Wacker Neuson EZ53 Track excavator Service manual – PDF DOWNLOAD

Operation
Information on this service manual 1-2
Identification of warnings and dangers 1-3
Designated use and exemption from liability 1-4
Labels 1-5
Machine overview 1-7
Engine compartment (overview) 1-8
Chassis overview 1-9
Raising the cabin 1-10
Towing the machine 1-12
Fire extinguisher 1-12
Technical data
Chassis 2-2
Engine 2-2
Fuel injection pump 2-2
Engine capacities 2-3
Hydraulic system 2-3
Auxiliary hydraulics/3rd control circuit flow rate 2-3
Screwable hose burst valve 2-4
Travel gear and swivel unit 2-4
Maximum speed 2-4
Traveling drive 2-4
Tracks 2-4
Stabilizer blade 2-4
Electrical system 2-5
Main fuse box 2-5
Cabin fuse box 2-6
Noise levels 2-6
Vibration 2-6
Coolant compound table 2-6
Compound table 2-6
Weight indications 2-7
Hose identification code 2-7
Tightening torques 2-8
Model-specific tightening torques 2-8
Tightening torques for hydraulic threaded fittings (dry assembly) 2-8
Tightening torques for high-resistance threaded fittings 2-10
Model EZ53 dimensions 2-11
Model EZ53 dimensions VDS 2-13
Lift capacity tables 2-15
Kinematics 2-15
Measuring live ring tolerance 2-16
Maintenance
Fluids and lubricants 3-2
Engine oil types (Tier III) 3-3
Engine oil types (Tier IV) 3-3
Additional oil change and filter replacement (hydraulic system) 3-3
Hydraulic oil types 3-3
Important information regarding operation with biodegradable hydraulic oil 3-4
Maintenance overview 3-5
Maintenance label 3-5
Maintenance plan 3-6
Table of contents
I-2 SHB EZ53 en – Edition 12 * EZ53s11IVZfm
Table of contents
Introduction 3-12
Safety-relevant parts 3-12
Fuel system 3-13
Specific safety instructions 3-13
Refueling 3-14
Stationary fuel pumps 3-14
Bleeding the fuel system 3-15
Emptying the fuel tank 3-16
Fuel prefilter with water separator 3-17
Emptying the water separator on the fuel prefilter 3-17
Replacing the fuel filter 3-17
Engine lubrication system 3-19
Checking the oil level 3-19
Adding engine oil 3-20
Changing engine oil 3-21
Replacing the engine oil filter 3-22
Cooling system 3-24
Specific safety instructions 3-24
Checking the coolant level 3-25
Adding coolant 3-26
Draining coolant 3-27
Cleaning the radiator 3-28
Air filter 3-29
Replacing the air filter 3-30
Checking the air intake 3-30
Washer system 3-31
Checking the fluid level and adding fluid 3-31
V-belt 3-32
Check the V-belt tension of the alternator 3-32
Replacing the alternator V-belt 3-33
Replacing the compressor V-belt 3-34
Retensioning the compressor V-belt 3-34
Checking the V-belt tension of the air conditioning system (option) 3-35
Tensioning the V-belt of the air conditioning system (option) 3-35
Replacing the V-belt of the air conditioning system (option) 3-36
Air conditioning 3-37
Specific safety instructions 3-37
Adding coolant to the air conditioning system 3-37
Replacing the fresh/recirculated-air filter of the air conditioning 3-38
Replace the crankcase breather filter 3-39
Replace the fuel-burner glow plug 3-40
Pressure check 3-41
General 3-41
Checking pilot control pressure 3-41
Pressure check of variable displacement pump P1 3-42
Pressure check of variable displacement pump P2 3-43
Pressure check of gear pump P3 3-44
Secondary pressure limiting valve of the gear motor 3-44
Measurement connections (overview) 3-45
Primary pressure limiting valves 3-45
Test report 3-47
Hydraulic system 3-49
Specific safety instructions 3-49
Checking the hydraulic oil level 3-50
Adding hydraulic oil 3-51
Changing hydraulic oil 3-51
Checking hydraulic pressure lines 3-52
SHB EZ53 en – Edition 12 * EZ53s11IVZfm I-3
Table of contents
Traveling drive 3-53
Checking the oil level and adding oil 3-53
Draining oil 3-53
Tracks 3-54
Checking the track tension of the rubber tracks 3-54
Checking steel track tension (option) 3-55
Adjusting track tension 3-55
Overview of lubrication points 3-57
Parking the machine 3-58
Lubrication points on the boom, bucket and stick cylinders 3-58
Lubrication points on the boom and stick 3-59
Joint rod lubrication point 3-60
Lubrication points on the stabilizer blade and stabilizer blade cylinder 3-61
Lubrication points on the swiveling cylinder and swiveling console 3-61
Lubrication points on ball bearing race of live ring 3-62
Lubrication points of live ring (teeth) 3-63
Powertilt lubrication points (option) 3-64
Lubrication points of hydraulic quickhitch (option) 3-64
Control lever base lubrication points 3-65
VDS lubrication points (option) 3-65
Maintenance of attachments 3-65
Electrical system 3-66
Servicing and maintenance at regular intervals 3-66
Instructions concerning specific components 3-66
Alternator 3-66
Battery 3-67
Battery state of charge 3-67
Charging the battery 3-67
Replacing the battery 3-67
Cabin 3-68
Replacing the cabin filter 3-68
General maintenance 3-69
Cleaning 3-69
General instructions for all areas of the machine 3-69
Inside the cabin 3-69
Cleaning the seat belt 3-70
Exterior of the machine 3-70
Engine compartment 3-70
Threaded fittings and attachments 3-70
Pivots and hinges 3-70
Engine
Perkins 404F-22T Tier IV/404D-22T Tier III 4-2
Sensors and electric components 4-5
Turbocharger 4-8
Setting the valve clearance 4-9
Clean the diesel particulate filter 4-9
Check the water pump (visual check) 4-9
Engine malfunctions 4-10
Hydraulic system
Hydraulic pump PVD-3B-56BCP-21G5-5688A 5-2
Pilot oil supply unit 5-4
Main valve block 5-5
Connections 5-5
Legend 5-6
Main valve block diagram 5-7
Pressure limiting valves 5-8
I-4 SHB EZ53 en – Edition 12 * EZ53s11IVZfm
Table of contents
Pump assignment 5-9
Drive counterbalancing system 5-10
Pump assignment for drive counterbalancing 5-10
Drive counterbalancing system with boom and machine travel (right) activation
5-11
Regeneration – stick section 5-12
Bucket pre-tension 5-12
Flow rate adjustment of auxiliary hydraulics 5-13
Pilot valves 5-14
Control lever 5-14
Pilot valve (machine travel) 5-16
Pilot valve for auxiliary hydraulics 5-17
Stabilizer blade pilot valve 5-18
Valves 5-19
7/2 directional valve (changeover valve) 5-19
4/3 directional valve 5-20
Shuttle valve block 5-21
Changeover valve for SAE/ISO controls (option) 5-22
Traveling drive 5-23
Trasmital drive 5-23
Function 5-24
2nd speed range function 5-24
Swivel unit 5-27
Parking brake/multidisk brake function 5-28
Swivel joint 5-33
Breather filter 5-34
Malfunctions of the hydraulic system 5-35
Electrical system
Ohmic law (current, voltage, resistance); Power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-3
Relays 6-4
Use, mode of function 6-4
Electric units 6-4
Alternator 6-4
Starter 6-4
Engine wiring harness legend Tier IV (up to serial no WNCE0510CPAL00181) 6-6
Engine wiring harness Tier IV (up to serial no WNCE0510CPAL00181) 6-8
Legend of wiring harness for engine tier IV (from serial number WNCE0510TPAL00182
to serial number WNCE0510LPAL00225) 6-9
Wiring harness of engine tier IV (from serial numberWNCE0510TPAL00182 to serial
number WNCE0510LPAL00225) 6-11
Legend of wiring harness of engine tier IV (from serial number WNCE0510HPAL00226)
6-12
Wiring harness of engine tier IV (from serial number WNCE0510HPAL00226) 6-14
Legend of wiring harness of engine tier III (to serial number WNCE0510KPAL00220)
SHB EZ53 en – Edition 12 * EZ53s11IVZfm I-5
Table of contents
6-15
Wiring harness of engine tier III (to serial number WNCE0510KPAL00220) 6-17
Engine wiring harness legend Tier III (from serial no WNCE0510JPAL00221) 6-18
Engine wiring harness Tier III (from serial no WNCE0510JPAL00221) 6-19
Switch wiring harness legend 6-20
Switch wiring harness 6-21
Switch wiring harness legend (from serial number WNCE0510APAL00238) 6-22
Switch wiring harness (from serial no WNCE0510APAL00238) 6-23
Cabin roof wiring harness 6-24
Armrest wiring harness legend 6-25
Armrest wiring harness 6-26
Armrest wiring harness legend (from serial no WNCE0510APAL00238) 6-27
Armrest wiring harness (from serial no WNCE0510APAL00238) 6-28
Wiring harness for proportional controls 4th control circuit (legend) 6-29
Wiring harness for proportional controls 4th control circuit 6-30
Telematik wiring harness 6-31
Fuel-filling pump wiring harness 6-32
Boom working light cable 6-33
Immobilizer cable 6-34
Cable for 4th control circuit valve 6-35
Rotating beacon cable 6-36
Machine travel signal adapter cable 6-37
Hydraulics diagram 7-2
Hydraulics diagram (legend) 7-2
Hydraulics diagram 7-3
Hydraulics diagram (options) 7-4
Hydraulics diagram – proportional controls 7-5
Main valve block diagram 7-6
Electrical diagram 7-7
Electrical diagram legend 7-7
Electrical diagram Tier III 7-8
Electrical diagram Tier IV 7-9
Options
Air conditioning 8-2
Specific safety instructions 8-2
Technical data 8-2
Installation overview 8-3
Components 8-4
Filling up the air conditioning system 8-6
Troubleshooting 8-7
Air-suspension seat 8-9
Connections 8-9
Counterweight 8-9
Technical data 8-9
Long stick 8-9
Technical data 8-9
Control circuit (pipework) connections for grab 8-10
3rd control circuit connections 8-10
Connections for auxiliary hydraulics 8-11
Quickhitch couplings 8-11
Vantage fuel-filling pump 8-12
Technical data 8-12
Components 8-13
System design 8-14
User interface 8-14
Functions 8-14
I-6 SHB EZ53 en – Edition 12 * EZ53s11IVZfm
Table of contents
Status indicator 8-15
Access to board for electrical connections: 8-15
Main supply 8-15
Secondary supply with key 8-16
Level contact 8-17
Malfunctions 8-18
Maintenance 8-19
Service valve 8-20
Function 8-20
Safe load indicator Basic 8-21
Position 8-21
Function 8-22
Wiring diagram 8-22
Safe load indicator “Advanced” 8-23
Position 8-23
Function 8-24
Wiring diagram 8-25
Safe load indicator pressure switch 8-26
Setting the pressure switch 8-27
3rd control circuit 8-29
Function 8-29
Diagram 8-29
Electric auxiliary hydraulics 8-30
Function 8-30
Auxiliary hydraulics shock cartridge 8-31
3rd control circuit shock cartridge 8-32
Immobilizer 8-33
Proportional controls 8-34
Function 8-34
Connections 8-34
Overview 8-35
Control valve 8-36
Control unit connector assignment 8-36
Safety features 8-37
Measures to be taken in case of malfunctions 8-38
Diagnosis display 8-38
Telematic 8-40
Connections 8-40
Functional check/diode

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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