Wacker Neuson 75Z3/75Z32 Track excavators Operator’s Manual – PDF DOWNLOAD
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Wacker Neuson 75Z3/75Z32 Track excavators Operator’s 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 Neuson After-Sales Service will be pleased to answer any further questions regarding the machine or the service manual.
TABLE OF CONTENTS:
Wacker Neuson 75Z3/75Z32 Track excavators Operator’s Manual – PDF DOWNLOAD
Documentation 1-2
Operation
Information on this service manual 1-2
Identification of warnings and dangers 1-3
Designated use and exemption from liability 1-4
Type labels and component numbers 1-5
Machine overview 1-7
Cabin overview 1-8
Up to serial no: AD07209 1-8
From serial no: AH00646 1-9
Cabin (legend) 1-10
Instrument panel overview 1-11
Up to serial no: AD07209 1-11
From serial no: AH00646 1-12
Instrument panel legend 1-13
Engine compartment up to serial no AD07209 (overview) 1-14
Engine compartment from serial no AH00646 (overview) 1-15
Chassis overview 1-16
Raising/lowering the cabin 1-17
Summer/winter operation 1-19
Preheated fresh air 1-19
Auxiliary hydraulics/boom swivel pedal 1-20
Technical data
Chassis 2-2
Engine 2-2
Fuel injection pump 2-3
Capacities 2-3
Tightening torques 2-3
Hydraulic system 2-4
Auxiliary hydraulics oil flow* 2-4
Screwable hose burst valve 2-5
Travel gear and swivel unit 2-5
Stabilizer blade 2-5
Electrical system 2-6
Fuse box in instrument panel 2-6
Main fuse box with relays up to serial no AD07209 2-6
Relays 2-7
Main fuse box with relays (from serial no AH00646) 2-7
Noise levels 2-8
Vibration 2-8
Coolant compound table 2-8
Model-specific tightening torques 2-8
General tightening torques 2-9
Tightening torques for hydraulic threaded fittings (dry assembly) 2-9
Tightening torques for high-resistance threaded fittings 2-11
Dimensions model 75Z3 2-12
Lift capacity table 2-13
Kinematics 2-13
Measuring live ring tolerance 2-14
Maintenance
Fluids and lubricants 3-2
Additional oil change and filter replacement (hydraulic system) 3-3
Maintenance label 3-4
Explanation of symbols on the maintenance label 3-4
Table of contents
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Table of contents
Maintenance plan (overview) 3-6
Introduction 3-11
Fuel system 3-12
Specific safety instructions 3-12
Refueling 3-12
Stationary fuel pumps 3-13
Diesel fuel specification 3-13
Bleeding the fuel system 3-13
Emptying the fuel tank 3-14
Fuel prefilter with water separator 3-14
Replacing the fuel filter 3-15
Engine lubrication system 3-16
Checking the oil level 3-16
Adding engine oil 3-17
Changing engine oil 3-18
Replacing the engine-oil filter cartridge 3-19
Cooling system 3-20
Specific safety instructions 3-20
Checking the coolant level/adding coolant 3-21
Draining coolant 3-23
Air filter 3-24
Replacing the filter 3-25
Functional check once a week of the dust valve 3-26
V-belt 3-27
Checking V-belt tension 3-27
Retensioning the V-belt 3-28
Checking the V-belt of the air conditioning system 3-29
Tensioning the V-belt of the air conditioning system 3-29
Pressure check 3-30
General 3-30
Checking pilot control pressure 3-30
Pressure check of variable displacement pump P1 3-31
Pressure check of variable displacement pump P2 3-32
Pressure check of gear pump P3 3-33
Secondary pressure limiting valve of the gear motor 3-33
Measurement connections (overview) 3-34
Primary pressure limiting valves 3-34
Test report 3-35
Hydraulic system 3-37
Specific safety instructions 3-37
Checking the hydraulic oil level 3-38
Checking the hydraulic oil level 3-38
Adding hydraulic oil 3-39
Changing hydraulic oil 3-40
Monitoring the hydraulic oil return filter 3-40
Checking hydraulic pressure lines 3-41
Traveling drive 3-42
Checking the oil level and adding oil 3-42
Draining oil 3-42
Tracks 3-44
Checking track tension 3-44
Setting the tracks 3-45
Overview of lubrication points 3-46
Parking the machine 3-47
Lubrication points on the boom, bucket and stick cylinders 3-47
Lubrication points on the boom and stick 3-48
Joint rod lubrication point 3-49
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Table of contents
Lubrication points on the stabilizer blade and stabilizer blade cylinder 3-49
Lubrication points on the swiveling cylinder and swiveling console 3-50
Lubrication points on live ring (ball bearing) 3-51
Lubrication points on live ring (teeth) 3-52
Powertilt lubrication points (option) 3-53
Lubrication points of hydraulic quickhitch (option) 3-53
Lubrication points of control lever base (from serial no AJ02793) 3-54
Maintenance of attachments 3-54
Electrical system 3-55
Specific safety instructions 3-55
Servicing and maintenance at regular intervals 3-55
Instructions concerning specific components 3-56
Alternator 3-56
Battery 3-57
Battery charge condition 3-57
Charging the battery 3-57
Replacing the battery 3-57
Jump-starting the engine 3-58
Cabin 3-59
Replacing the cabin filter 3-59
General maintenance 3-60
Cleaning 3-60
General instructions for all areas of the machine 3-60
Inside the cabin 3-61
Exterior of the machine 3-61
Engine compartment 3-61
Threaded fittings and attachments 3-62
Engine
Engine 4TNV98-VNS (up to serial no AD07209 Tier 2) 4-2
Fuel system 4-4
Removing the cylinder-head cover 4-5
Checking and adjusting valve clearance 4-5
Checking valve clearance 4-5
Setting zero play of the valve bridge 4-6
Setting valve clearance 4-6
Tightening order for cylinder head bolts 4-7
Checking the injection nozzles 4-8
Pressure check 4-8
Checking the nozzle jet 4-8
Injection time 4-9
Checking injection time 4-9
Setting injection time 4-9
Replacement of fuel injection pump 4-10
Adjusting engine speed 4-11
Compression 4-11
Checking the coolant thermostat 4-11
Checking the thermal switch 4-12
Oil pressure switch 4-12
Checking the coolant circuit 4-13
Engine 4TNV98-ZVNS (from serial no AH00646) 4-14
Fuel system 4-16
Removing the cylinder-head cover 4-17
Checking and adjusting valve clearance 4-17
Checking valve clearance 4-17
Setting zero play of the valve bridge 4-18
Setting valve clearance 4-18
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Tightening order for cylinder head bolts 4-19
Checking the injection nozzles 4-20
Pressure check 4-20
Checking the nozzle jet 4-20
Injection time 4-21
Checking injection time 4-21
Setting injection time 4-22
Replacement of fuel injection pump 4-23
Compression 4-24
Checking the coolant thermostat 4-24
Checking the thermal switch 4-25
Oil pressure switch 4-25
Checking the coolant circuit 4-25
Engine malfunctions 4-26
Electronic engine control unit (E-ECU) 4-28
Features 4-28
Engine error codes 4-29
Error diagnosis 4-33
E-ECU connector assignment 4-33
Important information on the ECU maintenance wiring harness 4-34
Flash code 7 – proportional injection pump solenoid (control rack) 4-35
Related DTC (Diagnostic Trouble Codes) 4-35
Diagnosis description 4-37
Flash code 5 – manual throttle 4-39
Related DTC 4-39
Work description 4-41
Flash code 4-1 ECU internal 4-42
Related DTC 4-42
Work description 4-43
Flash code 4-1 ECU temperature sensor and 2-5 ECU temperature rise alarm
4-44
Related DTC 4-44
Work description 4-45
Flash code 4 coolant temperature sensor and 3-6 coolant temperature rise alarm
4-46
Related DTC 4-46
Work description 4-48
Flash code 2-4 – sensor 5 V 4-50
Related DTC 4-50
Work description 4-51
Flash code 2-3 – power supply voltage 4-53
(1) P0562/1: power supply voltage error (voltage too low) 4-53
DTC detection conditions 4-53
Troubleshooting 4-53
Diagnosis description 4-53
(2) P0563/0: power supply voltage error (voltage too high) 4-54
DTC detection conditions 4-54
Troubleshooting 4-54
Diagnosis description 4-54
Flash code 6 – engine speed sensor 4-55
Work description 4-57
Flash code 1-1 – backup engine speed sensor 4-58
Related DTC 4-58
Work description 4-60
Flash code 9 – overspeed error 4-61
(1) P0219/0: overspeed error 4-61
DTC detection conditions 4-61
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Troubleshooting 4-61
Diagnosis description 4-61
Flash code 1-7 – proportional solenoid relay of the injection pump (control rack)
4-62
Related DTC 4-62
Work description 4-64
Flash code 1-5 – preheating relay 4-66
Related DTC 4-66
Work description 4-67
Flash code 1-4 – CSD (cold start device) solenoid coil 4-70
Related DTC 4-70
Work description 4-71
Flash code 1-3 – EGR (exhaust gas recirculation) valve 4-73
Related DTC 4-73
Work description 4-75
Flash code 2-1 – oil pressure switch and 3-1 – oil pressure drop error 4-77
Related DTC 4-77
Work description 4-79
Flash code 8 – proportional injection pump solenoid (control rack) 4-81
Related DTC 4-81
Work description 4-83
Flash code 1-6 – main relay 4-85
Related DTC 4-85
Work description 4-87
Flash code 1-2 – CAN (Controller Area Network) communication 4-89
Related DTC 4-89
Work description 4-90
Automatic engine speed setting 4-91
How it works 4-91
Hydraulic system
Hydraulic pump AP2D36LV3RS6-875-P 5-2
Pump unit: exploded view 5-4
Pilot oil supply unit 5-5
Main valve block 5-7
Connections 5-7
Legend 5-8
Main valve block diagram 5-9
Pressure limiting valves 5-10
Pump assignment 5-11
Drive counterbalancing system 5-12
Pump assignment for drive counterbalancing 5-12
Drive counterbalancing system, actuation of hydraulic motors and auxiliary
hydraulics 5-13
Bucket pre-tension 5-14
Boom raise summation 5-15
Check valve (load retaining valve) 5-16
Stick cylinder summation – extend 5-17
Pilot valves 5-18
Joystick 5-18
Pilot valve (machine travel) 5-20
Pilot valve for auxiliary hydraulics 5-22
Stabilizer blade pilot valve 5-23
Valves 5-24
7/2 directional valve (changeover valve) 5-24
4/3 directional valve 5-25
Shuttle valve block 5-26
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Changeover valve for SAE/ISO controls (option) 5-27
Hydraulic quickhitch valve 5-28
Traveling drive up to serial no AC02793 5-29
Function 5-30
2nd speed range function 5-30
Traveling drive Auto2Speed from serial no AC02794 5-31
Function 5-32
2nd speed range function 5-32
Swivel unit 5-34
Parking brake/multidisk brake function 5-35
Anti Swing Back (ASB) valve 5-36
Swivel joint 5-41
Breather filter 5-42
Malfunctions in the hydraulic system 5-43
Hydraulics diagram 5-44
Hydraulics diagram (legend) 5-45
Hydraulics diagram (up to serial no WNCE0604CPAL00602) 5-47
Hydraulics diagram (from serial no WNCE0604JPAL00603) 5-48
Options diagram 1 5-49
Options diagram 2 5-50
Main valve block diagram 5-51
Electrical system
Ohm’s Law (current, voltage, resistance); power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-4
Relays 6-4
Use, mode of function 6-4
Electric units 6-5
Fuse box on the instrument panel up to serial no AD07209 6-5
Main fuse box with relays up to serial no AD07209 6-5
Relays up to serial no AD07209 6-6
Fuse box on the instrument panel (from serial no AH00646) 6-6
Main fuse box with relays (from serial no AH00646) 6-7
ECU (from serial no AH00646) 6-7
Socket 6-8
Control lever push button 6-8
Control lever on the left 6-8
Control lever on the right
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
Engine/chassis wiring harness (up to serial no AD07209) (legend) 6-14
Engine/chassis wiring harness (up to serial no AD07209) 6-15
Engine/chassis wiring harness (from serial no AH00646) (legend) 6-16
Engine/chassis wiring harness (from serial no AH00646) 6-17
Switch wiring harness (legend) 6-18
Switches wiring harness up to serial no AH02749 6-19
Switches wiring harness from serial no AJ02793 6-20
Cabin roof wiring harness 6-21
Armrest wiring harness 6-22
Boom working light wiring harness 6-23
Proportional controls wiring harness 6-24
Wiring diagram up to serial no AD07209 (legend) 6-26
Wiring diagram A3 up to serial no AD07209 6-27
Wiring diagram A4 from serial no AH00646 (legend) 6-28
Wiring diagram A4 (1) from serial no AH00646 6-29
Wiring diagram A4 (2) from serial no AH00646 6-30
Options
Air conditioning 7-2
Specific safety instructions 7-2
Technical data 7-2
Installation overview 7-3
Components 7-4
Filling up the air conditioning system 7-6
Maintenance 7-7
Troubleshooting 7-8
Air-suspension seat 7-10
Connections 7-10
Counterweight 7-10
Technical data 7-10
Long stick 7-10
Technical data 7-10
Control circuit (pipework) connections for grab 7-11
3rd control circuit connections 7-11
Auxiliary hydraulics connections 7-12
Quickhitch couplings 7-12
Attachments 7-13
Fuel-filling pump 7-14
Connections up to serial no AD07209 7-15
Central lubrication system 7-16
Position 7-16
Connections 7-16
Function 7-17
Adjusting breaks and lubrication times 7-18
Repair in case of clogging 7-18
Service valve 7-20
Function 7-20
Safe load indicator D (safety valve for boom) 7-21
Position 7-21
Function 7-22
Diagram 7-23
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Safe load indicator F (safety valves for boom and stick) 7-24
Position 7-24
Function 7-25
Diagram 7-25
3rd control circuit 7-27
Function 7-27
Diagram 7-27
Electric auxiliary hydraulics 7-28
Function 7-28
Auxiliary hydraulics shock cartridge 7-29
3rd control circuit shock cartridge 7-30
Immobilizer (antitheft protection) 7-31
Position 7-31
Disabling the immobilizer 7-31
Enabling the immobilizer 7-31
Programming 7-31
Quickhitch 7-33
Proportional controls 7-34
Function 7-34
Connections 7-34
Overview 7-35
Wiring harness 7-36
Control unit 7-36
Control unit connector assignment 7-37
Safety features 7-38
Measures to be taken in case of malfunctions 7-38
Diagnosis display 7-38
Telematic 7-40
Connections 7-40
Functional check/diode 7-40
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