Wacker Neuson Tracked excavator EZ26 Service manual – PDF DOWNLOAD

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Wacker Neuson Tracked excavator EZ26 Service manual – PDF DOWNLOAD

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Wacker Neuson Tracked excavator EZ26 Service manual – PDF DOWNLOAD

1 Operation
1.1 Notices on this service manual

This service manual contains important information on how to work safely,
correctly and economically with the vehicle. Therefore, it aims not only at
new personnel, but it also serves as a reference for experienced
personnel. It helps to avoid hazardous situations and reduce repair costs
and downtimes.
Furthermore, the reliability and the service life of the machine will be
increased.
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. This is
why regular maintenance and servicing is absolutely necessary.
Use only original spare parts for repairs. This ensures operational safety
and readiness of your machine, and maintains its value.
• Modifying Wacker Neuson Linz GmbH products and fitting them with
additional equipment and attachments not included in our delivery
program requires written authorization. If the approval does not take
place, our warranty and product liability for possible damage caused by
these modifications shall not be applicable.
• Subject to modifications and printing errors.
Your Wacker Neuson Linz GmbH technical support will be happy to
answer any further questions regarding the machine or the service
manual
TABLE OF CONTENTS:

Wacker Neuson Tracked excavator EZ26 Service manual – PDF DOWNLOAD

Service manual…………………………………………………………………………………. 1
Table of Contents…………………………………………………………………………… 3
1 Operation………………………………………………………………………………… 7
1.1 Notices on this service manual………………………………………………………… 7
1.2 Identification of warnings and dangers…………………………………………………. 8
1.3 Explanation of symbols and abbreviations……………………………………………….. 9
Abbreviations……………………………………………………………………….. 10
Conversion table…………………………………………………………………….. 11
1.4 Warranty and liability……………………………………………………………….. 12
1.5 Labels……………………………………………………………………………… 13
Type labels…………………………………………………………………………. 13
1.6 Machine overview…………………………………………………………………….. 16
1.7 Engine compartment…………………………………………………………………… 17
1.8 Valve compartment……………………………………………………………………. 18
1.9 Chassis overview…………………………………………………………………….. 19
1.10 Hydraulic connections……………………………………………………………….. 20
1.11 Parking the machine…………………………………………………………………. 21
1.12 Fire extinguisher…………………………………………………………………… 22
1.13 Towing the vehicle………………………………………………………………….. 23
1.14 Loading the vehicle…………………………………………………………………. 25
Tie-down points……………………………………………………………………… 25
Crane-lifting……………………………………………………………………….. 27
Lifting eyes………………………………………………………………………… 28
1.15 Transporting the vehicle…………………………………………………………….. 30
2 Technical data……………………………………………………………………………. 31
2.1 Engine……………………………………………………………………………… 31
2.2 Drive/axles…………………………………………………………………………. 33
2.3 Tracks……………………………………………………………………………… 33
2.4 Fuel injection pump………………………………………………………………….. 33
2.5 Brake/steering system………………………………………………………………… 33
2.6 Hose identification code……………………………………………………………… 33
2.7 Hydraulic system…………………………………………………………………….. 34
Work hydraulics……………………………………………………………………… 34
Auxiliary hydraulics flow rate EZ28……………………………………………………. 35
2.8 Maximum speed……………………………………………………………………….. 36
2.9 Coolant compound table……………………………………………………………….. 36
2.10 Ground clearance/ground pressure……………………………………………………… 36
2.11 Excavator forces……………………………………………………………………. 36
2.12 Vibration………………………………………………………………………….. 36
2.13 Electrical system…………………………………………………………………… 37
Electrical components………………………………………………………………… 37
Fuses/relays………………………………………………………………………… 37
Bulbs………………………………………………………………………………. 38
2.14 Weights……………………………………………………………………………. 39
Determining the loading weight………………………………………………………… 39
2.15 Noise emissions…………………………………………………………………….. 40
2.16 Powertilt (option)………………………………………………………………….. 40
2.17 Engine tightening torques……………………………………………………………. 41
2.18 Model-specific tightening torques…………………………………………………….. 41
2.19 General tightening torques…………………………………………………………… 42
Tightening torques for hydraulic screw connections (dry assembly)…………………………. 42
Tightening torques for high-resistance threaded fittings…………………………………. 45
2.20 Payload/lift capacity……………………………………………………………….. 45
2.21 Dimensions EZ26…………………………………………………………………….. 46
EZ26 VDS……………………………………………………………………………. 48
2.22 Kinematics…………………………………………………………………………. 50
2.23 Measuring live ring tolerance………………………………………………………… 51
3 Maintenance………………………………………………………………………………. 53
3.1 Information on maintenance……………………………………………………………. 53
Responsibilities and prerequisites…………………………………………………….. 53
Important safety instructions on maintenance……………………………………………. 54
3.2 Special tools……………………………………………………………………….. 54
3.3 Fluids and lubricants………………………………………………………………… 55
Hydraulic oil types………………………………………………………………….. 56
Additional oil change and filter replacement (hydraulic system)…………………………… 56
3.4 Important information regarding operation with biodegradable oil………………………….. 57
Engine oil………………………………………………………………………….. 57
3.5 Maintenance label……………………………………………………………………. 58
Explanation of symbols on the maintenance label…………………………………………. 59
3.6 Maintenance plan…………………………………………………………………….. 61
3.7 Overview of maintenance areas…………………………………………………………. 66
3.8 Maintenance accesses…………………………………………………………………. 67
Engine cover………………………………………………………………………… 67
Reservoir cover……………………………………………………………………… 68
Fuse box……………………………………………………………………………. 68
3.9 Fuel system…………………………………………………………………………. 69
Important information regarding the fuel system…………………………………………. 69
Diesel fuel specification…………………………………………………………….. 69
Refueling…………………………………………………………………………… 69
Emptying the fuel tank……………………………………………………………….. 71
Bleeding the fuel system……………………………………………………………… 72
Checking the water separator………………………………………………………….. 72
Emptying the water separator………………………………………………………….. 73
Fuel filter with water separator………………………………………………………. 74
Checking the water separator on fuel filter…………………………………………….. 74
Emptying the water separator on the fuel filter…………………………………………. 75
Replacing the fuel filter…………………………………………………………….. 76
3.10 Washer system………………………………………………………………………. 77
Important information regarding the washer system……………………………………….. 77
Checking the fluid level and adding fluid………………………………………………. 77
3.11 Engine lubrication system……………………………………………………………. 78
Important information regarding the engine lubrication system…………………………….. 78
Checking the engine oil level…………………………………………………………. 78
Adding engine oil……………………………………………………………………. 79
Changing engine oil………………………………………………………………….. 80
Replacing the engine-oil filter cartridge………………………………………………. 81
3.12 Cooling system……………………………………………………………………… 83
Important information regarding the cooling system………………………………………. 83
Checking the coolant level……………………………………………………………. 83
Adding coolant………………………………………………………………………. 84
Draining coolant…………………………………………………………………….. 85
Cleaning the radiator………………………………………………………………… 86
3.13 Air filter…………………………………………………………………………. 87
Important information regarding the air filter………………………………………….. 87
Dirt indicator………………………………………………………………………. 88
Replacing the air filter……………………………………………………………… 88
Checking the air intake………………………………………………………………. 89
3.14 Heating, ventilation and air conditioning system (option)……………………………….. 90
Checking/replacing the fresh-air filter………………………………………………… 90
3.15 V-belt…………………………………………………………………………….. 91
Checking V-belt condition and tension………………………………………………….. 91
Replacing/retensioning the V-belt……………………………………………………… 92
3.16 Emergency lowering………………………………………………………………….. 95
Important information regarding emergency lowering………………………………………. 95
3.17 Releasing the pressure in the work hydraulics………………………………………….. 95
3.18 Connecting and disconnecting hydraulic couplings……………………………………….. 96
3.19 Pressure check……………………………………………………………………… 97
General…………………………………………………………………………….. 97
Measurement connections (overview)…………………………………………………….. 97
Checking pilot control pressure……………………………………………………….. 97
Pressure check of variable displacement pump P1…………………………………………. 98
Pressure check of variable displacement pump P2…………………………………………. 99
Pressure check of gear pump P3…………………………………………………………100
Secondary pressure limiting valve for swivel unit………………………………………..101
Primary pressure limiting valves……………………………………………………….101
3.20 Test report…………………………………………………………………………102
3.21 Hydraulic system…………………………………………………………………….106
Important information on the hydraulic system……………………………………………106
Checking the hydraulic oil level……………………………………………………….107
Adding hydraulic oil………………………………………………………………….107
Changing hydraulic oil………………………………………………………………..109
Monitoring the hydraulic oil return filter………………………………………………109
Replacing the hydraulic oil filter……………………………………………………..110
Draining condensation water from the hydraulic oil reservoir………………………………111
Checking the hydraulic system for leaks…………………………………………………112
Checking the condition and age of hydraulic hoses………………………………………..113
3.22 Checking the pilot control filter……………………………………………………..114
3.23 Travel drive………………………………………………………………………..115
Checking the oil level and adding oil…………………………………………………..115
Draining oil…………………………………………………………………………116
3.24 Tires/tracks………………………………………………………………………..117
Important information on the tracks…………………………………………………….117
Checking track tension………………………………………………………………..117
Correcting track tension………………………………………………………………118
Replacing the tracks………………………………………………………………….119
3.25 Maintenance of attachments……………………………………………………………120
Important information regarding maintenance of attachments………………………………..120
3.26 Maintenance of options……………………………………………………………….120
Joint rod (lifting eye) and load hook…………………………………………………..120
3.27 Lubrication work…………………………………………………………………….121
Preparing lubrication…………………………………………………………………121
Lubrication schedule………………………………………………………………….122
Live ring (ball bearing)………………………………………………………………124
Live ring gears………………………………………………………………………125
Live ring gear VDS (option)……………………………………………………………126
Control lever base……………………………………………………………………127
Using the quickhitches in water………………………………………………………..127
3.28 Electrical system……………………………………………………………………128
Important information regarding the electrical system…………………………………….128
Fuses and relays……………………………………………………………………..129
Check the battery state of charge………………………………………………………130
Charging the battery………………………………………………………………….130
Replacing the battery…………………………………………………………………131
Check battery degassing hose…………………………………………………………..131
3.29 Cleaning and maintenance……………………………………………………………..133
Important information on cleaning and maintenance………………………………………..133
Use of solvents………………………………………………………………………134
Cleaning inside the cabin……………………………………………………………..134
Cleaning the exterior of the machine……………………………………………………134
Cleaning the engine compartment………………………………………………………..134
Cleaning the seat belt………………………………………………………………..135
Cleaning the shatter protection………………………………………………………..135
Threaded fittings and attachments………………………………………………………135
3.30 Resetting the maintenance meter……………………………………………………….136
4 Engine……………………………………………………………………………………138
4.1 Overview of engine 3TNV76-NNS (Tier IV final up to 2012)………………………………….138
4.2 Fuel system………………………………………………………………………….140
4.3 Cooling system……………………………………………………………………….141
4.4 Checking and adjusting valve clearance………………………………………………….142
4.5 Tightening order for cylinder head bolts………………………………………………..144
Order for removing the cylinder-head bolts:……………………………………………..144
Order for installing the cylinder-head bolts:……………………………………………144
4.6 Checking the injection nozzles…………………………………………………………145
Pressure check……………………………………………………………………….145
4.7 Checking the nozzle jet……………………………………………………………….146
4.8 Injection time……………………………………………………………………….146
Checking injection time……………………………………………………………….146
Setting injection time………………………………………………………………..149
4.9 Removing and installing the injection pump………………………………………………150
Removing the injection pump……………………………………………………………150
Fitting the fuel injection pump………………………………………………………..151
4.10 Measuring and adjusting the engine speed……………………………………………….153
4.11 Compression…………………………………………………………………………153
4.12 Checking the coolant thermostat……………………………………………………….154
4.13 Checking the temperature sensor……………………………………………………….154
4.14 Oil pressure switch………………………………………………………………….155
4.15 Checking the coolant circuit………………………………………………………….155
4.16 Cleaning the cooling water channels……………………………………………………155
4.17 Coolant and fuel hoses……………………………………………………………….155
4.18 Crankcase vent………………………………………………………………………156
4.19 Replacing the glow plugs……………………………………………………………..156
4.20 Engine malfunctions………………………………………………………………….157
4.21 Overview of engine 3TNV80F-SNNS (Tier IV final from 2012)………………………………..160
4.22 Fuel system…………………………………………………………………………162
4.23 Cooling system………………………………………………………………………163
4.24 Altitude-dependent output reduction……………………………………………………164
4.25 Checking and adjusting valve clearance…………………………………………………165
4.26 Tightening order for cylinder head bolts……………………………………………….167
Order for removing the cylinder-head bolts:……………………………………………..167
Order for installing the cylinder-head bolts:……………………………………………167
4.27 Checking the injection nozzles………………………………………………………..168
Pressure check……………………………………………………………………….168
4.28 Checking the nozzle jet………………………………………………………………169
4.29 Injection time………………………………………………………………………169
Checking injection time……………………………………………………………….169
Setting injection time………………………………………………………………..172
4.30 Removing and installing the injection pump……………………………………………..173
Removing the injection pump……………………………………………………………173
Fitting the fuel injection pump………………………………………………………..175
4.31 Measuring and adjusting the engine speed……………………………………………….177
4.32 Compression…………………………………………………………………………177
4.33 Checking the coolant thermostat……………………………………………………….178
4.34 Checking the temperature sensor……………………………………………………….178
4.35 Oil pressure switch………………………………………………………………….179
4.36 Checking the coolant circuit………………………………………………………….179
4.37 Cleaning the cooling water channels……………………………………………………180
4.38 Coolant and fuel hoses……………………………………………………………….180
4.39 Crankcase vent………………………………………………………………………181
4.40 Replacing the glow plugs……………………………………………………………..181
4.41 Engine malfunctions………………………………………………………………….182
5 Hydraulic system…………………………………………………………………………..186
5.1 Hydraulic pump……………………………………………………………………….187
Pump unit: exploded view………………………………………………………………189
Double variable displacement und twin gear pump PVD-0B-23BCP-8G3-5498Z (Yanmar 3TNV80F-SNNS)….191
Assembling the hydraulic pump………………………………………………………….195
Malfunctions of the hydraulic pump……………………………………………………..198
5.2 Main valve block……………………………………………………………………..200
Connections………………………………………………………………………….200
Main control lines……………………………………………………………………204
Pressure limiting and other valves……………………………………………………..205
5.3 Drive counterbalancing system………………………………………………………….206
Pump assignment for drive counterbalancing………………………………………………206
5.4 Regeneration – stick segment…………………………………………………………..207
5.5 Bucket pre-tension……………………………………………………………………208
5.6 Power train………………………………………………………………………….209
Function…………………………………………………………………………….210
5.7 Swivel unit………………………………………………………………………….212
Swivel unit brake…………………………………………………………………….213
5.8 Swivel joint…………………………………………………………………………215
5.9 Swivel joint VDS (option)……………………………………………………………..216
5.10 Pilot valves………………………………………………………………………..217
Joystick…………………………………………………………………………….217
Pilot valve (machine travel)…………………………………………………………..218
5.11 Valves……………………………………………………………………………..219
Proportional valve (option)……………………………………………………………219
Changeover valve VDS (option)………………………………………………………….219
3/2 directional valve (option)…………………………………………………………219
8/2 directional valve (option)…………………………………………………………220
Hydraulic quickhitch valve (option)…………………………………………………….220
Hydraulic oil reservoir service valve…………………………………………………..220
5.12 Breather filter……………………………………………………………………..221
5.13 Malfunctions of the hydraulic system…………………………………………………..222
6 Electrical system………………………………………………………………………….224
6.1 Ohmic law (current, voltage, resistance); Power………………………………………….224
6.2 Measuring equipment, measuring methods………………………………………………….224
6.3 Cable color coding……………………………………………………………………225
6.4 Relays………………………………………………………………………………225
Use, mode of function…………………………………………………………………225
Fuses/relays…………………………………………………………………………226
Bulbs……………………………………………………………………………….227
6.5 Electric units……………………………………………………………………….228
6.6 Alternator…………………………………………………………………………..228
6.7 Starter……………………………………………………………………………..228
6.8 Engine/chassis wiring harness (legend)………………………………………………….231
6.9 Chassis/engine wiring harness………………………………………………………….234
6.10 Cabin wiring harness…………………………………………………………………235
6.11 Cab headlight wiring harness………………………………………………………….236
6.12 Canopy lights wiring harness (option)………………………………………………….237
6.13 Canopy rotating lights wiring harness (option)………………………………………….238
6.14 Proportional controls wiring harness (option)…………………………………………..239
6.15 Engine speed control wiring harness (option)……………………………………………240
6.16 Travel signal wiring harness (option)………………………………………………….241
6.17 Hydraulic quickhitch wiring harness (option)……………………………………………242
6.18 Battery lead………………………………………………………………………..243
7 Diagrams………………………………………………………………………………….245
7.1 Hydraulics diagram (legend)……………………………………………………………245
7.2 Hydraulics diagram……………………………………………………………………246
7.3 Hydraulics diagram (options)…………………………………………………………..247
7.4 Wiring diagram (legend)……………………………………………………………….248
7.5 Wiring diagram……………………………………………………………………….249
8 Options…………………………………………………………………………………..252
8.1 Counterweight………………………………………………………………………..252
Technical data……………………………………………………………………….252
8.2 Long stick…………………………………………………………………………..252
Technical data……………………………………………………………………….252
8.3 Automatic engine speed setting…………………………………………………………253
8.4 Grab control circuit………………………………………………………………….254
Setting grab operation………………………………………………………………..254
Stopping bucket operation……………………………………………………………..254
8.5 Safe load indicator…………………………………………………………………..255
Functional check of safe load indicator…………………………………………………256
Perform a functional check of the control lever base……………………………………..256
Switching on the safe load indicator……………………………………………………256
Switching off the safe load indicator…………………………………………………..257
Setting the pressure switch……………………………………………………………257
8.6 Hose burst valve……………………………………………………………………..258
8.7 Hydraulic quickhitch valve…………………………………………………………….259
Hydraulic quickhitch pressure variants………………………………………………….260
Easy Lock emergency unlocking (hydraulic quickhitch from serial no. 2200)…………………..262
8.8 Tilting the upper carriage (Vertical Digging System)……………………………………..263
8.9 3rd control circuit…………………………………………………………………..264
Diagram……………………………………………………………………………..264
8.10 Proportional controls………………………………………………………………..265
8.11 Hammer operation…………………………………………………………………….266
Important information regarding hammer operation…………………………………………266
8.12 Additional control circuit – AUX I…………………………………………………….267
8.13 Proportionally controlled additional control circuit – AUX I……………………………..267
8.14 Swiveling the boom…………………………………………………………………..269
8.15 Swiveling the boom (proportionally controlled)………………………………………….269
8.16 Powertilt – AUX II…………………………………………………………………..270
8.17 ISO/SAE controls…………………………………………………………………….271
8.18 Travel signal……………………………………………………………………….272
8.19 Drive interlock……………………………………………………………………..272
8.20 Telematic…………………………………………………………………………..274
Connections………………………………………………………………………….274
Functional check/diode………………………………………………………………..274
9 PowerTilt PTS06……………………………………………………………………………276
9.1 General instructions………………………………………………………………….276
General safety instructions……………………………………………………………276
Checking the product………………………………………………………………….277
Internal decompression valve…………………………………………………………..277
Testing the hydraulic system of the machine……………………………………………..277
Specifications/requirements……………………………………………………………278
9.2 Tools……………………………………………………………………………….279
Making a tool VI for removing the seals…………………………………………………280
9.3 Separating the bucket or equipment from the PowerTilt swivel device………………………..280
9.4 Separating the PowerTilt swivel device from the machine…………………………………..280
9.5 Exploded drawings of PTS06…………………………………………………………….281
Sealing kit A and bearing kit B PTS06 (overview)…………………………………………282
9.6 Assembly drawing……………………………………………………………………..283
9.7 Checking components and dead center marks……………………………………………….284
9.8 Lubrication and tests…………………………………………………………………285
Lubrication………………………………………………………………………….285
Test for internal leaks……………………………………………………………….286
Testing the internal decompression valve………………………………………………..287
9.9 Securing the PowerTilt swivel device on the machine………………………………………288
9.10 Fitting a bucket or equipment onto the PowerTilt swivel device……………………………288
9.11 Adjusting the play on the PowerTilt……………………………………………………288
Checking the circumferential play………………………………………………………288
9.12 Troubleshooting……………………………………………………………………..291
Leere Seite……………………………………………………………………………………. 60

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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.
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S.MWacker Neuson Tracked excavator EZ26 Service manual (1)