Service Manual Wacker Neuson 28Z3 Track Excavator;
Content:
OPERATION
Notices on this service manual
Identification of warnings and dangers
Designated use and exemption from liability
Type labels and component numbers
Machine overview
Cab overview
Cab (legend)
Instrument panel overview
Instrument panel legend
Overview of open engine and valve compartment
Engine compartment: overview
Chassis overview
Valve compartment
Stop and park the machine
Parking the machine on slopes
SPECIFICATIONS
Chassis
Engine
Fuel injection pump
Engine capacities
Engine tightening torques
Hydraulic system
Work hydraulics
Auxiliary hydraulics oil flow 28Z3
Undercarriage and swivel unit
Stabiliser blade
Electrical system
Noise levels
Vibration
Coolant compound table
Powertilt
Model-specific tightening torques
General tightening torques
Tightening torques for hydraulic screw connections (dry assembly)
Tightening torques for high-resistance screw connections
Dimensions model 28Z3
Dimensions model 28Z3 VDS
Lift capacity table 28Z3 (short stick)
Lift capacity table 28Z3 long stick (option)
Lift capacity table 28Z3 short stick and extra weight (option)
Lift capacity table 28Z3 long stick (option) and extra weight (option)
Lift capacity table 28Z3 VDS (short stick)
Lift capacity table 28Z3 long stick VDS (option)
Kinematics
MAINTENANCE
Fluids and lubricants
Oil grades for the diesel engine, depending on temperature
Additional oil change and filter replacement (hydraulic system)
Oil grades for the hydraulic system, depending on temperature
Maintenance label
Explanation of symbols on the maintenance label
Maintenance plan (overview)
Service package
Introduction
Safety-relevant parts
Fuel system
Refuelling
Emptying the fuel tank
Stationary fuel pumps
Diesel fuel specification
Bleeding the fuel system
Water separator
Replacing the fuel filter
Tank for washer system
Engine lubrication system
Checking the oil level
Filling up engine oil
Changing engine oil
Replacing the engine oil filter cartridge
Engine and hydraulics cooling system
Specific safety instructions
Checking/filling up coolant
Checking the coolant level
Filling up coolant
Draining coolant
Air filter
Replacing air filter elements
Air intake
Change cab air filter
V-belt
Checking V-belt tension
Retightening the V-belt
Pressure check
General
Overview of measuring ports (up to serial number AG02712)
Overview of measuring ports (from serial number AG02713)
Checking pilot control pressure
Pressure check of variable displacement pump P1
Pressure check of variable displacement pump P2
Pressure check of gear pump P3
Secondary pressure limiting valve of the gear motor
Primary pressure limiting valves
Test report
Hydraulic system
Specific safety instructions
Checking the hydraulic oil level
Filling up hydraulic oil
Changing hydraulic oil
Monitoring the hydraulic oil return filter
Replacing the hydraulic oil filter
Draining condensation water from the hydraulic oil tank
Important information for the use of biodegradable oil
Checking hydraulic pressure lines
Pilot valve
Travelling drive
Checking the oil level and filling up oil
Draining oil
Tracks
Checking track tension
Adjusting track tension
Maintenance of attachments
Lubrication points
Parking the machine
Overview of lubrication points
Lubrication points on the stabiliser blade and stabiliser blade ram
Lubrication points on the swivelling console and slewing ram
Lubrication points on the boom, bucket and stick rams
Lubrication points on the boom and stick
Lubrication point on the joint rod
Lubrication point on ball bearing race of live ring
Lubrication point of live ring teeth
Lubrication point of VDS live ring teeth
VDS lubrication points (option)
Powertilt lubrication points (option)
Lubrication points of hydraulic quickhitch (option)
Lubrication points of mechanical quickhitch (option)
Cab
Electrical system
Service and maintenance work at regular intervals
Instructions concerning specific components
Alternator
Battery
General maintenance work
Cleaning
General instructions for all areas of the machine
Inside the cab
Cleaning the seat belt
Exterior of the machine
Engine compartment
Shatter protection
Screw connections and attachments
Pivots and hinges
Preparatory work before taking out of service
Maintenance if the machine is out of service for a longer period of time
Putting into operation again
Fire extinguisher
ENGINE
3TNV76-NNS engine overview
Fuel system
Cooling system
Checking and adjusting valve clearance
Lapping the intake and exhaust valves
Tightening order for cylinder head bolts
Order for removing the cylinder-head bolts:
Order for mounting the cylinder-head bolts:
Checking the injection nozzles
Pressure check
Checking the nozzle jet
Injection time
Checking injection time
Setting injection time
Removing and installing the injection pump
Removing the injection pump
Fitting the injection pump
Measuring and adjusting the engine speed
Compression
Checking the coolant thermostat
Checking the thermal switch
Oil pressure switch
Checking the coolant circuit
Cleaning the cooling water channels
Coolant and fuel hoses
Crankcase vent
Replacing the glow plugs
Engine trouble
HYDRAULIC SYSTEM
Hydraulic pump PVD-0B-23BP-8G3-5083A
Pump unit: exploded view
Pilot oil supply unit
Dismantling the hydraulic pump
Assembling the hydraulic pump
Troubleshooting on the hydraulic pump
Main valve block
Ports
Main control lines (legend)
Pump/tank lines
Main valve block diagram
Pressure limiting valves
Pump assignment
Drive counterbalancing system
Pump assignment for drive counterbalancing
Regeneration - stick section
Bucket pre-tension
Auxiliary hydraulics flow rate adjustment
Travelling drive
Function
Swivel unit
Swivel unit brake
Swivel joint
Replace the sealing rings
Swivel joint VDS (option)
Pilot valves
Joystick
Pilot valve (driving)
Changeover valve for SAE/ISO controls (option)
Proportional valve (option)
Changeover valve VDS (option)
3/2 directional valve (option)
Easy Lock valve (option)
Hydraulic oil tank service valve (option)
Breather filter
Auxiliary hydraulics connections
Troubleshooting in the hydraulic system
Hydraulics diagram (legend)
Hydraulics diagram 28Z3
Hydraulics diagram for options 28Z3
Main valve block diagram 28Z3
Electrical system
Ohms Law (current, voltage, resistance); power
Measuring equipment, measuring methods
Cable colour coding
Relays
Use, mode of function
Socket
Electric units
Fuse box
Alternator
Starter
Switches: overview
Switch legend
Cigarette lighter
Radio and mounting/wiring for radio installation (option)
Front working light
Cab lights (option)
Rotating beacon (option)
Driving signal (option)
Wiring diagram (legend)
Wiring diagram
Engine/chassis wiring harness (legend)
Chassis/engine wiring harness
Cab wiring harness
Proportional controls wiring harness (option)
Engine speed control wiring harness (option)
Driving signal wiring harness (option)
Hydraulic quickhitch wiring harness (option)
Battery lead
OPTIONS
Counterweight
Specifications
Long stick
Specifications
Automatic engine speed setting
Installation
Grab pipework
Attachments
3rd control circuit/PowerTilt ports
Safe load indicator
Safe load indicator DE (from serial no. AG04828) (safety valves for boom)
Safe load indicator DE (serial nos. AG02444 to AG04827) (safety valves for boom)
Safe load indicator DE (up to serial no. AG02443)
Function
Wiring diagram
Setting the pressure switch
Safe load indicator FR (from serial no. AG04828) (safety valves for boom, stick and stabiliser
blade)
Safe load indicator FR (serial nos. AG02444 to AG04827) (safety valves for boom,
stick and stabiliser blade)
Safe load indicator FR (up to serial no. AG02443)
Function
Diagram (from serial no. AG04828)
Diagram (serial nos. AG02444 to AG04827)
Diagram (up to serial no. AG02443)
Setting the pressure switch
Hose burst valve safety feature
Mechanical quickhitch
Hydraulic quickhitch (Easy Lock)
3rd control circuit
Function
Diagram
Drive interlock (antitheft protection)
Position
Disabling the drive interlock
Enabling the drive interlock
Programming
Proportional controls
Function
Ports
Measures to be taken in case of malfunctions
Left-hand control lever
Boom swivel controls
Auxiliary hydraulics
Hammer operation
Adjusting control response
Characteristic curves - status indicator
Wiring harness
Control unit connector assignment
Measures to be taken in case of malfunctions
Diagnosis display
Engine oil service valve
Function
POWERTILT PTS06
General instructions
General safety instructions
Checking the product
Internal decompression valve
Testing the hydraulic system of the machine
Specifications/requirements
Tools
Making a tool VI for removing the seals
Separating the bucket or equipment from the PowerTilt swivel device
Separating the PowerTilt swivel device from the machine
Exploded views PTS06
PTS06 components
Sealing kit A and bearing kit B PTS06 (overview)
Assembly drawing
Removing the standard journal coupling
Removing the end cap, securing ring and internal decompression valve
Removing the shaft
Removing the piston tube body
Removing the seals (kit A), shaft bearings and pressure discs (kit B)
Checking components and dead centre marks
Trial assembly
Installing the seals (kit A), shaft bearings and pressure discs (kit B)
Installing the end-cap seals and bearings
Installing the piston seals and bearings
Fitting the shaft seal and the bearing
Installing the piston tube
Installing the shaft
Installing the end cap and the securing ring
Installing the internal decompression valve
Installing the standard journal coupling
Lubrication and tests
Lubrication
Test for internal leaks
Testing the internal decompression valve
Securing the PowerTilt swivel device on the machine
Fitting a bucket or equipment onto the PowerTilt swivel device
Troubleshooting
Adjusting the play on the PowerTilt
Checking the circumferential play
Service Manual Wacker Neuson 28Z3 Track Excavator;
Content:
OPERATION
Notices on this service manual
Identification of warnings and dangers
Designated use and exemption from liability
Type labels and component numbers
Machine overview
Cab overview
Cab (legend)
Instrument panel overview
Instrument panel legend
Overview of open engine and valve compartment
Engine compartment: overview
Chassis overview
Valve compartment
Stop and park the machine
Parking the machine on slopes
SPECIFICATIONS
Chassis
Engine
Fuel injection pump
Engine capacities
Engine tightening torques
Hydraulic system
Work hydraulics
Auxiliary hydraulics oil flow 28Z3
Undercarriage and swivel unit
Stabiliser blade
Electrical system
Noise levels
Vibration
Coolant compound table
Powertilt
Model-specific tightening torques
General tightening torques
Tightening torques for hydraulic screw connections (dry assembly)
Tightening torques for high-resistance screw connections
Dimensions model 28Z3
Dimensions model 28Z3 VDS
Lift capacity table 28Z3 (short stick)
Lift capacity table 28Z3 long stick (option)
Lift capacity table 28Z3 short stick and extra weight (option)
Lift capacity table 28Z3 long stick (option) and extra weight (option)
Lift capacity table 28Z3 VDS (short stick)
Lift capacity table 28Z3 long stick VDS (option)
Kinematics
MAINTENANCE
Fluids and lubricants
Oil grades for the diesel engine, depending on temperature
Additional oil change and filter replacement (hydraulic system)
Oil grades for the hydraulic system, depending on temperature
Maintenance label
Explanation of symbols on the maintenance label
Maintenance plan (overview)
Service package
Introduction
Safety-relevant parts
Fuel system
Refuelling
Emptying the fuel tank
Stationary fuel pumps
Diesel fuel specification
Bleeding the fuel system
Water separator
Replacing the fuel filter
Tank for washer system
Engine lubrication system
Checking the oil level
Filling up engine oil
Changing engine oil
Replacing the engine oil filter cartridge
Engine and hydraulics cooling system
Specific safety instructions
Checking/filling up coolant
Checking the coolant level
Filling up coolant
Draining coolant
Air filter
Replacing air filter elements
Air intake
Change cab air filter
V-belt
Checking V-belt tension
Retightening the V-belt
Pressure check
General
Overview of measuring ports (up to serial number AG02712)
Overview of measuring ports (from serial number AG02713)
Checking pilot control pressure
Pressure check of variable displacement pump P1
Pressure check of variable displacement pump P2
Pressure check of gear pump P3
Secondary pressure limiting valve of the gear motor
Primary pressure limiting valves
Test report
Hydraulic system
Specific safety instructions
Checking the hydraulic oil level
Filling up hydraulic oil
Changing hydraulic oil
Monitoring the hydraulic oil return filter
Replacing the hydraulic oil filter
Draining condensation water from the hydraulic oil tank
Important information for the use of biodegradable oil
Checking hydraulic pressure lines
Pilot valve
Travelling drive
Checking the oil level and filling up oil
Draining oil
Tracks
Checking track tension
Adjusting track tension
Maintenance of attachments
Lubrication points
Parking the machine
Overview of lubrication points
Lubrication points on the stabiliser blade and stabiliser blade ram
Lubrication points on the swivelling console and slewing ram
Lubrication points on the boom, bucket and stick rams
Lubrication points on the boom and stick
Lubrication point on the joint rod
Lubrication point on ball bearing race of live ring
Lubrication point of live ring teeth
Lubrication point of VDS live ring teeth
VDS lubrication points (option)
Powertilt lubrication points (option)
Lubrication points of hydraulic quickhitch (option)
Lubrication points of mechanical quickhitch (option)
Cab
Electrical system
Service and maintenance work at regular intervals
Instructions concerning specific components
Alternator
Battery
General maintenance work
Cleaning
General instructions for all areas of the machine
Inside the cab
Cleaning the seat belt
Exterior of the machine
Engine compartment
Shatter protection
Screw connections and attachments
Pivots and hinges
Preparatory work before taking out of service
Maintenance if the machine is out of service for a longer period of time
Putting into operation again
Fire extinguisher
ENGINE
3TNV76-NNS engine overview
Fuel system
Cooling system
Checking and adjusting valve clearance
Lapping the intake and exhaust valves
Tightening order for cylinder head bolts
Order for removing the cylinder-head bolts:
Order for mounting the cylinder-head bolts:
Checking the injection nozzles
Pressure check
Checking the nozzle jet
Injection time
Checking injection time
Setting injection time
Removing and installing the injection pump
Removing the injection pump
Fitting the injection pump
Measuring and adjusting the engine speed
Compression
Checking the coolant thermostat
Checking the thermal switch
Oil pressure switch
Checking the coolant circuit
Cleaning the cooling water channels
Coolant and fuel hoses
Crankcase vent
Replacing the glow plugs
Engine trouble
HYDRAULIC SYSTEM
Hydraulic pump PVD-0B-23BP-8G3-5083A
Pump unit: exploded view
Pilot oil supply unit
Dismantling the hydraulic pump
Assembling the hydraulic pump
Troubleshooting on the hydraulic pump
Main valve block
Ports
Main control lines (legend)
Pump/tank lines
Main valve block diagram
Pressure limiting valves
Pump assignment
Drive counterbalancing system
Pump assignment for drive counterbalancing
Regeneration - stick section
Bucket pre-tension
Auxiliary hydraulics flow rate adjustment
Travelling drive
Function
Swivel unit
Swivel unit brake
Swivel joint
Replace the sealing rings
Swivel joint VDS (option)
Pilot valves
Joystick
Pilot valve (driving)
Changeover valve for SAE/ISO controls (option)
Proportional valve (option)
Changeover valve VDS (option)
3/2 directional valve (option)
Easy Lock valve (option)
Hydraulic oil tank service valve (option)
Breather filter
Auxiliary hydraulics connections
Troubleshooting in the hydraulic system
Hydraulics diagram (legend)
Hydraulics diagram 28Z3
Hydraulics diagram for options 28Z3
Main valve block diagram 28Z3
Electrical system
Ohms Law (current, voltage, resistance); power
Measuring equipment, measuring methods
Cable colour coding
Relays
Use, mode of function
Socket
Electric units
Fuse box
Alternator
Starter
Switches: overview
Switch legend
Cigarette lighter
Radio and mounting/wiring for radio installation (option)
Front working light
Cab lights (option)
Rotating beacon (option)
Driving signal (option)
Wiring diagram (legend)
Wiring diagram
Engine/chassis wiring harness (legend)
Chassis/engine wiring harness
Cab wiring harness
Proportional controls wiring harness (option)
Engine speed control wiring harness (option)
Driving signal wiring harness (option)
Hydraulic quickhitch wiring harness (option)
Battery lead
OPTIONS
Counterweight
Specifications
Long stick
Specifications
Automatic engine speed setting
Installation
Grab pipework
Attachments
3rd control circuit/PowerTilt ports
Safe load indicator
Safe load indicator DE (from serial no. AG04828) (safety valves for boom)
Safe load indicator DE (serial nos. AG02444 to AG04827) (safety valves for boom)
Safe load indicator DE (up to serial no. AG02443)
Function
Wiring diagram
Setting the pressure switch
Safe load indicator FR (from serial no. AG04828) (safety valves for boom, stick and stabiliser
blade)
Safe load indicator FR (serial nos. AG02444 to AG04827) (safety valves for boom,
stick and stabiliser blade)
Safe load indicator FR (up to serial no. AG02443)
Function
Diagram (from serial no. AG04828)
Diagram (serial nos. AG02444 to AG04827)
Diagram (up to serial no. AG02443)
Setting the pressure switch
Hose burst valve safety feature
Mechanical quickhitch
Hydraulic quickhitch (Easy Lock)
3rd control circuit
Function
Diagram
Drive interlock (antitheft protection)
Position
Disabling the drive interlock
Enabling the drive interlock
Programming
Proportional controls
Function
Ports
Measures to be taken in case of malfunctions
Left-hand control lever
Boom swivel controls
Auxiliary hydraulics
Hammer operation
Adjusting control response
Characteristic curves - status indicator
Wiring harness
Control unit connector assignment
Measures to be taken in case of malfunctions
Diagnosis display
Engine oil service valve
Function
POWERTILT PTS06
General instructions
General safety instructions
Checking the product
Internal decompression valve
Testing the hydraulic system of the machine
Specifications/requirements
Tools
Making a tool VI for removing the seals
Separating the bucket or equipment from the PowerTilt swivel device
Separating the PowerTilt swivel device from the machine
Exploded views PTS06
PTS06 components
Sealing kit A and bearing kit B PTS06 (overview)
Assembly drawing
Removing the standard journal coupling
Removing the end cap, securing ring and internal decompression valve
Removing the shaft
Removing the piston tube body
Removing the seals (kit A), shaft bearings and pressure discs (kit B)
Checking components and dead centre marks
Trial assembly
Installing the seals (kit A), shaft bearings and pressure discs (kit B)
Installing the end-cap seals and bearings
Installing the piston seals and bearings
Fitting the shaft seal and the bearing
Installing the piston tube
Installing the shaft
Installing the end cap and the securing ring
Installing the internal decompression valve
Installing the standard journal coupling
Lubrication and tests
Lubrication
Test for internal leaks
Testing the internal decompression valve
Securing the PowerTilt swivel device on the machine
Fitting a bucket or equipment onto the PowerTilt swivel device
Troubleshooting
Adjusting the play on the PowerTilt
Checking the circumferential play
