38Z3 Service Manual

Service Manual
Track excavator
Machine model 38Z3

Edition 2.1
Language English
Item no. 1000160891
Documentation
Description Order no.
Operator's Manual 1000155267
Service manual 1000160891
Spare parts catalogue:

up to serial no. AE02803 1000154748
from serial no. AG00573 1000180706
Copyright – 2006 Wacker Linz GmbH, Linz-Leonding

Printed in Austria
All rights reserved
No part of this publication may be reproduced, translated or used in any form or by any means – graphic, electronic
or mechanical including photocopying, recording, taping or information storage or retrieval systems – without prior
permission in writing from the manufacturer.
The cover features the machine with possible optional equipment.
Wacker Neuson Linz GmbH

Haidfeldstr. 37
A-4060 Linz-Leonding
Document: SERV-HB 38Z3 EN
Order no.: 1000160891
Edition: 2.1
Table of contents
Table of contents
Table of contents
Operation
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
Cab (legend) ............................................................................................................ 1-8
Instrument panel overview (up to serial no. AE02803) ............................................ 1-9
Instrument panel (legend) ...................................................................................... 1-10
Instrument panel overview (from serial no. AG00573) .......................................... 1-11
Instrument panel (legend) ...................................................................................... 1-12
Engine compartment overview (Tier 2 up to AE02803) ......................................... 1-13
Engine compartment overview (Tier 3A from AG00573) ....................................... 1-14
Chassis overview ................................................................................................... 1-15
Tilting the cab ........................................................................................................ 1-16
Specifications
Chassis .................................................................................................................... 2-1
Engine ...................................................................................................................... 2-1
Fuel injection pump ........................................................................................... 2-2
Engine capacities .............................................................................................. 2-2
Engine tightening torques .................................................................................. 2-2
Hydraulic system ..................................................................................................... 2-3
Auxiliary hydraulics oil flow ................................................................................ 2-3
Undercarriage and swivel unit ................................................................................. 2-4
Stabiliser blade ........................................................................................................ 2-4
Screwable hose burst valve ............................................................................... 2-4
Electric system ......................................................................................................... 2-5
Fuse box in instrument panel ............................................................................ 2-5
Main fuse box with relays underneath the cab .................................................. 2-5
Relays ................................................................................................................ 2-6
Noise levels ............................................................................................................. 2-6
Vibration ................................................................................................................... 2-6
Coolant compound table .......................................................................................... 2-7
Model-specific tightening torques ............................................................................ 2-7
General tightening torques ...................................................................................... 2-7
Tightening torques for hydraulic screw connections (dry assembly) ................. 2-7
Tightening torques for high-resistance screw connections ................................ 2-9
Dimensions model 38Z3 ........................................................................................ 2-11
Lift capacity table 38Z3 .......................................................................................... 2-12
Lift capacity table 38Z3 short stick + extra weight ................................................. 2-13
Lift capacity table 38Z3 long stick .......................................................................... 2-14
Lift capacity table 38Z3 with long stick + extra weight ........................................... 2-15
Kinematics ............................................................................................................. 2-16
Attachments ........................................................................................................... 2-17
Maintenance
Fluids and lubricants ................................................................................................ 3-1
Additional oil change and filter replacement (hydraulics) .................................. 3-2
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. AE02803 ................................................................................... 3-8
From serial no. AG00573 .................................................................................. 3-8
SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm I-1

Table of contents
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
Filling up coolant .............................................................................................. 3-19
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 ........................................ 3-26
Pressure check ...................................................................................................... 3-27
General ............................................................................................................ 3-27
Checking pilot control pressure ....................................................................... 3-27
Pressure check of variable displacement pump P1 ......................................... 3-28
Pressure check of variable displacement pump P2 ......................................... 3-29
Pressure check of gear pump P3 .................................................................... 3-30
Secondary pressure limiting valve of the gear motor ....................................... 3-30
Measuring ports: overview ............................................................................... 3-31
Primary pressure limiting valves ...................................................................... 3-31
Test report .............................................................................................................. 3-32
Hydraulic system .................................................................................................... 3-34
Checking the hydraulic oil level ....................................................................... 3-35
Filling up hydraulic oil ...................................................................................... 3-36
Changing hydraulic oil ..................................................................................... 3-36
Monitoring the hydraulic oil reflux filter ............................................................ 3-37
Checking hydraulic pressure lines ................................................................... 3-38
Travelling drive ....................................................................................................... 3-39
Checking the oil level and filling up oil ............................................................. 3-39
Draining oil ....................................................................................................... 3-39
Chains .................................................................................................................... 3-40
Checking chain tension .................................................................................... 3-40
Setting the chains ............................................................................................ 3-41
Lubrication work ..................................................................................................... 3-42
Stabiliser blade ................................................................................................ 3-42
Lubrication points on the swivelling console .................................................... 3-42
Boom lubrication points ................................................................................... 3-43
Lubrication points on the stick ......................................................................... 3-43
Lubrication strip ............................................................................................... 3-44
I-2 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm

Table of contents
Maintenance of attachments ........................................................................... 3-44

Electric system ....................................................................................................... 3-45
Service and maintenance work at regular intervals ......................................... 3-45
Instructions concerning specific components .................................................. 3-46
Alternator ......................................................................................................... 3-46
Battery ............................................................................................................. 3-47
Cab ........................................................................................................................ 3-48
Replacing the cab filter .................................................................................... 3-48
General maintenance work .................................................................................... 3-49
Cleaning .......................................................................................................... 3-49
General instructions for all areas of the machine ............................................ 3-49
Inside the cab .................................................................................................. 3-50
Exterior of the machine .................................................................................... 3-50
Engine compartment ....................................................................................... 3-50
Screw connections and attachments ............................................................... 3-50
Pivots and hinges ............................................................................................ 3-50
Engine
Engine overview 3TNV88-PNS (Tier 2) ................................................................... 4-1
Fuel system ............................................................................................................. 4-3
Checking and adjusting valve tip clearance ............................................................. 4-4
Tightening order for cylinder head bolts .................................................................. 4-5
Checking the injection nozzles ................................................................................ 4-6
Pressure check .................................................................................................. 4-6
Checking the nozzle jet ............................................................................................ 4-6
Injection time ............................................................................................................ 4-7
Checking injection time ...................................................................................... 4-7
Setting injection time ......................................................................................... 4-8
Replacement of fuel injection pump .................................................................. 4-8
Adjusting engine revs .............................................................................................. 4-9
Compression ............................................................................................................ 4-9
Checking the coolant thermostat ........................................................................... 4-10
Checking the thermal switch .................................................................................. 4-11
Oil pressure switch ................................................................................................ 4-11
Checking the coolant circuit ................................................................................... 4-11
Engine overview 3TNV88-BPNS (Tier 3A) ............................................................ 4-12
Fuel system ........................................................................................................... 4-14
Removing the cylinder-head cover ........................................................................ 4-15
Checking and adjusting valve tip clearance ........................................................... 4-15
Tightening order for cylinder head bolts ................................................................ 4-16
Checking the injection nozzles .............................................................................. 4-17
Pressure check ................................................................................................ 4-17
Checking the nozzle jet .......................................................................................... 4-17
Injection time .......................................................................................................... 4-18
Checking injection time .................................................................................... 4-18
Setting injection time ....................................................................................... 4-19
Replacement of fuel injection pump ................................................................ 4-20
Adjusting engine revs ............................................................................................ 4-21
Compression .......................................................................................................... 4-21
Checking the coolant thermostat ........................................................................... 4-21
Checking the thermal switch .................................................................................. 4-22
Oil pressure switch ................................................................................................ 4-22
Checking the coolant circuit ................................................................................... 4-23
Engine trouble ........................................................................................................ 4-23
Hydraulic system
Hydraulic pump PVD-1B-32BP-11G5-4904A (up to AE02803)

Table of contents
PVD-1B-34BP-10G5 (from AG00573) ..................................................................... 5-1

Pump unit: exploded view .................................................................................. 5-3
Pilot oil supply unit ............................................................................................. 5-4
Main valve block ...................................................................................................... 5-5
Ports .................................................................................................................. 5-5
Legend ............................................................................................................... 5-6
Main valve block diagram .................................................................................. 5-7
Pressure limiting valves ..................................................................................... 5-8
Pump assignment .............................................................................................. 5-9
Drive counterbalancing system .............................................................................. 5-10
Pump assignment for drive counterbalancing .................................................. 5-10
Regeneration – stick section .................................................................................. 5-11
Bucket pre-tension ................................................................................................. 5-11
Flow rate adjustment of auxiliary hydraulics .......................................................... 5-12
Pilot valves ............................................................................................................. 5-13
Joystick ............................................................................................................ 5-13
Pilot valve (driving) .......................................................................................... 5-15
Pilot valve for auxiliary hydraulics .................................................................... 5-17
Valves .................................................................................................................... 5-18
7/2 directional valve (changeover valve) ......................................................... 5-18
Changeover valve for SAE/ISO controls (option) ............................................ 5-19
Travelling drive up to no. AE00854 ........................................................................ 5-20
Function ........................................................................................................... 5-21
Travelling drive starting no. AE00855 .................................................................... 5-23
Function ........................................................................................................... 5-24
Swivel unit .............................................................................................................. 5-26
Parking brake/multidisc brake function ............................................................ 5-27
Swivel joint ............................................................................................................. 5-30
Sealing ............................................................................................................. 5-30
Breather filter ......................................................................................................... 5-31
Troubleshooting in the hydraulic system ................................................................ 5-32
Hydraulics diagram A4 ........................................................................................... 5-33
Hydraulics diagram (legend) .................................................................................. 5-34
Hydraulics diagram 38Z3 A3 .................................................................................. 5-35
Option diagram 1 ................................................................................................... 5-36
Option diagram 2 ................................................................................................... 5-37
Main valve block diagram 38Z3 A3 ........................................................................ 5-38
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 in instrument panel ................................................................................... 6-4
Main fuse box with relays ......................................................................................... 6-4
Relays ...................................................................................................................... 6-5
Socket ...................................................................................................................... 6-5
Joystick tip switches ................................................................................................. 6-6
Joystick (left) ...................................................................................................... 6-6
Joystick (right) .................................................................................................... 6-6
Instrument panel overview ....................................................................................... 6-6
Switch overview (up to serial no. AE02803) ............................................................ 6-7
Switch overview (from serial no. AG00573) ............................................................. 6-8
Alternator ................................................................................................................. 6-9
Starter ...................................................................................................................... 6-9

Table of contents
Wiring diagram A4 38Z3 (legend) .......................................................................... 6-11

Wiring diagram A4 ................................................................................................. 6-12
Engine wiring harness (legend) ............................................................................. 6-13
Engine wiring harness A4 ...................................................................................... 6-14
Cab wiring harness A4 (legend) ............................................................................ 6-15
Cab wiring harness A4 ........................................................................................... 6-16
Roof wiring harness A4 .......................................................................................... 6-17
Revs control wiring harness (option) ..................................................................... 6-18
Wiring diagram A3 (legend) ................................................................................... 6-20
Wiring diagram A3 ................................................................................................. 6-21
Engine wiring harness A3 (legend) ........................................................................ 6-22
Engine wiring harness A3 ...................................................................................... 6-23
Cab wiring harness A3 (legend) ............................................................................ 6-24
Cab wiring harness A3 ........................................................................................... 6-25
Roof wiring harness A3 .......................................................................................... 6-26
Revs control wiring harness (option) ..................................................................... 6-27
Options
Air conditioning ........................................................................................................ 7-3
Specific safety instructions ................................................................................ 7-3
Specifications .................................................................................................... 7-3
Components ...................................................................................................... 7-5
Compressor ....................................................................................................... 7-6
Filling up the air conditioning system ................................................................. 7-7
Maintenance ...................................................................................................... 7-8
Troubleshooting ................................................................................................. 7-9
Counterweight ........................................................................................................ 7-10
Specifications .................................................................................................. 7-10
Long stick ............................................................................................................... 7-10
Specifications .................................................................................................. 7-10
Control circuit (pipework) connections for grab ..................................................... 7-11
Attachments ..................................................................................................... 7-11
3rd control circuit connections ............................................................................... 7-12
Auxiliary hydraulics connections ............................................................................ 7-12
Safe load indicator DE (safety valve for boom) ..................................................... 7-13
Position ............................................................................................................ 7-13
Setting the pressure switch ............................................................................. 7-13
Function ........................................................................................................... 7-14
Wiring diagram ................................................................................................ 7-14
Safe load indicator FR (safety valves for boom and stick) ..................................... 7-15
Position ............................................................................................................ 7-15
Setting the pressure switch ............................................................................. 7-15
Function ........................................................................................................... 7-16
Wiring diagram ................................................................................................ 7-17
3rd control circuit ................................................................................................... 7-18
Function ........................................................................................................... 7-18
Diagram ........................................................................................................... 7-18
Drive interlock (antitheft protection) ....................................................................... 7-19
Position ............................................................................................................ 7-19
Disabling the drive interlock ............................................................................. 7-19
Enabling the drive interlock ............................................................................. 7-19
Programming ................................................................................................... 7-19
Proportional controls .............................................................................................. 7-21
Function ........................................................................................................... 7-21
Ports ................................................................................................................ 7-21
Overview .......................................................................................................... 7-22
Wiring harness ................................................................................................. 7-23

Table of contents
Control valve plug assignment ......................................................................... 7-24

Safety features ................................................................................................. 7-25
Measures to be taken in case of malfunctions ................................................. 7-25
Diagnosis display ............................................................................................. 7-25
Fuel-filling pump ..................................................................................................... 7-27
Connections ..................................................................................................... 7-28
Service valve .......................................................................................................... 7-29
Function ........................................................................................................... 7-29
Automatic revs setting (Tier 3A from AG00573) .................................................... 7-30
Installation ........................................................................................................ 7-31

Operation
Operation
Operation
1 Operation
1.1 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. It helps 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.
Will be pleased to answer any further questions regarding the machine or the service
manual.
Your Wacker Neuson dealer.
Abbreviations/symbols
• This symbol stands for a list
• Subdivision within lists or an activity. Follow the steps in the recommended sequence
☞ This symbol requires you to carry out the activity described
➥ Description of the effects or results of an activity
n. s. = not shown
“Option” = optional equipment
Stated whenever controls or other components of the machine are installed as an option.
A combination of digits, or a combination of digits and letters, e.g. 40/188 or 40/A

A used for
identifying the control elements, means:
Figure no. 40/control element no. 18 or position A in figure no. 40
Figures carry no numbers if they are placed to the left of the text.
SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-1

Operation
1.2 Identification of warnings and dangers

Important indications regarding the safety of the staff and the machine are identified in this
Operator's Manual with the following terms and symbols:
Danger!
Failure to observe the instructions identified by this symbol can result in
personal injury or death for the operator or other persons.
☞ Measures for avoiding danger
Caution!
Failure to observe the instructions identified by this symbol can result in
damage to the machine.
☞ Measures for avoiding danger for the machine
Important!
This symbol identifies instructions for a more efficient and economical use of the
machine.
Environment!
Failure to observe the instructions identified by this symbol can result in damage to the
environment. The environment is in danger if environmentally hazardous material (e.g.
waste oil) is not subject to proper use or disposal.
1-2 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

Operation
1.3 Designated use and exemption from liability

• The machine is intended for:
• moving earth, gravel, coarse gravel or ballast and rubble as well as for
• working with the attachments mentioned in chapter Fields of application
• Every other application is regarded as not designated for the use of the machine.
Wacker Neuson Linz GmbH will not be liable for damage resulting from use other
than mentioned above. The user alone will bear the risk.
Designated use also includes observing the instructions set forth in the Operator's
Manual and observing the maintenance and service conditions.
• The safety of the machine can be negatively affected by carrying out machine
modifications without proper authority and by using spare parts, equipment,
attachments and optional equipment which have not been checked and released by
Wacker Neuson Linz GmbH. Wacker Neuson Linz GmbH will not be liable for damage
resulting from this
• Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to
property caused by failure to observe the safety instructions and the Operator's
Manual, and by the negligence of the duty to exercise due care when:
• handling
• operating
• servicing and carrying out maintenance work and
• repairing the machine. This is also applicable in those cases in which special
attention has not been drawn to the duty to exercise due care, in the safety
instructions, the Operator's Manuals and maintenance manuals (machine/engine).
• Read and understand the Operator's Manual before starting up, servicing or repairing
the machine. Observe the safety instructions!
• The machine may not be used for transport jobs on public roads

Operation
1.4 Type labels and component numbers

Serial number
The serial number is stamped on the machine chassis under the hydraulic pump. It is also
located on the type label.
The type label is located at the front right on the machine chassis (at cab level).
Fig. 1: Type label: location Type label information

Model: 38z3
Year: 2005
PIN: AC 000000
Output: 27.1 kW (36.3 hp)
Mass: 3800 kg (8378 lbs)
Load: ---------------
Max. gross mass: ---------------
Max. axle load: ---------------
---------------
Fig. 2: Type label Other information – see Specifications on page 2-1
Cab number
The type label (arrow) is located in the cab, on the upper rear right chassis member.
Fig. 3: Cab type label
Engine number
The type label (arrow) is located on the cylinder-head cover (engine).
Example:: Yanmar 46557
Fig. 4: Diesel engine number

Operation
Hydraulic pump number

The type label (arrow) is located on the hydraulic pump housing.
Fig. 5: Hydraulic pump type label
Control valve number

The type label (arrow) is located on the lower side of the main valve block.
Fig. 6: Main valve block type label
Travelling drive number

The type label (arrow) is located on the travelling drive.
Fig. 7: Travelling drive type label
Swivel unit number

The type label (arrow) is located on the swivel unit.
Fig. 8: Swivel unit type label

Operation
1.5 Machine: overview
1 Boom light 2
2 Boom
3 Stick
Rubber chains 7
4
Steel chains (option) 3
5 Undercarriage
6 Stabiliser blade 1
7 Cab 8
8 Engine cover
5 6
2
9 Handles
10 Tank filler inlet (oil)
11 Device for counterweight (option)
3 12 Exhaust pipe
10
12 11
9
Fig. 9: Machine outside views

Operation
1.6 Cab overview
25 23 24 26 1
28
22
20
19
8
2
27 3
5
17 15
18
29
21
30 12
16
6 7
10
9
11
14
13

Operation
1.7 Cab (legend)
Pos. Description
1 Hammer pedal
2 Control lever (left)
3 Control lever (right)
4 Control lever base (left)
5 Control lever base (right)
6 Armrest (left)
7 Armrest (right)
8 Lever – horizontal seat adjustment
9 Rear window air vent
10 Radio (option)
11 Seat (backrest adjustment)
12 Seat belt
13 Cup holder
14 Bracket – document storage bin
15 Console switch panel
16 Cab switch panel
17 Throttle
18 Stabiliser blade lever
19 Fuse box
20 Preheating start switch
21 Cigarette lighter
22 Round indicating instrument
23 Drive pedal (left)
24 Drive pedal (right)
25 Drive lever (left)
26 Drive lever (right)
27 Drive interlock status indicator (option)
28 Front air vent
29 Drive interlock emitter/receiver unit
30 Seat

Operation
1.8 Instrument panel overview (up to serial no. AE02803)
35
34 36
33 37
38
32
41
52
39
31
51
40 42
43 44 45 46 47 48 49 50

Operation
1.9 Instrument panel (legend)
Pos. Description For more information see page

31 Air filter telltale (red) 3-21
32 Cold starter telltale (yellow)
33 Hydraulic oil filter telltale (red) 3-39
34 Telltale (red) – hydraulic oil temperature
35 Telltale (red) – alternator charge function
36 Telltale (red) – engine oil pressure
37 Coolant temperature telltale (red)
38 Telltale (yellow) – engine oil temperature
39 Safe load indicator telltale (red) 7-13
40 Hour meter
41 Turn indicators
42 Temperature indicator
43 Wiper
44 Roof lights
45 Rotating beacon
46 High speed
47 Working lights
48 Fan
49 Safe load indicator (option) 7-13
50 Proportional controls telltale 7-21
51 Fuel level indicator (diesel)
52 Lights telltale

Operation
1.10 Instrument panel overview (from serial no. AG00573)
57
56 75
55 58
59
54
76
74
60
53
73
61
Control element on control console Control element on cab wall
62 63 64 65 66 67 68 69 70 71
Control elements for proportional controls version (option):
62 63 64 65 72 67 68 69 70 71

Operation
1.11 Instrument panel (legend)

53 Telltale (red) – air filter 3-20
54 Cold starter telltale (yellow)
55 Telltale (red) – hydraulic oil filter 3-37
56 Telltale (red) – hydraulic oil temperature
57 Telltale (red) – alternator charge function
58 Telltale (red) – engine oil pressure
59 Coolant temperature telltale (red)
60 Telltale (red) – safe load indicator 7-13
61 Hour meter
62 High speed
63 Working light
65 Automatic revs setting (option) 7-30
66 Not assigned
67 Washer system
68 Roof lights
69 Rotating beacon
70 Ventilation
71 Air conditioning (option1) 7-3
72 Proportional control status indicator (option) 7-21
73 Fuel level indicator (diesel)
74 Not assigned
75 Not assigned
76 Not assigned
1.
If equipped with air conditioning and proportional controls, switch assignment is the same as without proportional controls. The status telltale is then installed in the control console on the right.

Operation
1.12 Engine compartment overview (Tier 2 up to AE02803)
77 78 79 83 80 81 82 84

77 Air filter 5-5
78 Throttle cable 3-31
79 Engine oil filter 3-11
80 Oil filler neck 4-1
81 Fan wheel 3-18
82 Expansion tank 3-18
83 Fuel injection pump 4-8
84 Temperature control (thermostat) 4-10

Operation
1.13 Engine compartment overview (Tier 3A from AG00573)
91
85 86 87 88 89 90 91 92 93

85 Air filter 3-20
87 New fuel filter 4-13
88 Oil dipstick
89 Engine oil filter 3-16
90 New air conditioning compressor (option)
91 Oil filler neck 4-1
92 Expansion tank 3-18
93 Radiator 3-18

Operation
1.14 Chassis overview
94 95 96 97 98 99 100

94 Swivel joint 5-30
95 Leak oil strip
96 Swivel unit 5-26
97 Battery 3-47
98 Main valve block 5-5
99 Pilot valve (drive) 5-13
100 Jack

Operation
1.15 Tilting the cab
Danger!
Careful when tilting the cab –
Danger of accidents!
☞ Always tighten screws A , B and C firmly when driving and working with the
machine.
☞ Always close the door
☞ Stay clear from underneath the cab as you tilt it
• Switch off the engine
• Remove the ignition key
• Fold the control lever base (left) up
Slackening the lock screw

Slacken the screws as follows:
☞ Switch off the engine
☞ Remove the ignition key
A
☞ Fold the control lever base (left) up
☞ Unscrew screw A with a suitable tool
➥ Screw A is located at the front right in the cab underneath the floor mat
☞ Slacken screw B with a suitable tool
➥ Screw B is located in the cab at the right behind the seat
Danger!
Always close the door. Even if the door is secured in the open position with the
door arrester –
☞ Always close the door before tilting the cab
B
☞ Should the door be open as you tilt the cab, do not actuate the door opener
unintentionally

Operation
Tilting the cab

Proceed as follows:
E ☞ Insert tube D onto guide pin E and pump as far as it will go
F ➥ (jack function)
➥ The cab is raised as far as the pump will go
☞ Pull the handle until the cab is completely tilted beyond the centre of motion
➥ The cab is secured with safety cable H
D ☞ Remove the split pin from bracket J
➥ Slide tilt rod K into guide L
➥ Secure tilt rod K with the split pin in guide L
Tilting the cab down:
☞ Remove the split pin from guide L
➥ Slide tilt rod K into clasp J
➥ Insert the split pin into guide L
☞ Use the handle to lower the cab until it is back on the pump
☞ Insert tube D on pin F
☞ Slowly turn tube D counterclockwise (to the left)
➥ The cab is lowered by its own weight
H
➥ The lift pump must be opened when driving with the machine (to prevent the
lift piston from touching the cab) !
☞ Mount lock screws A (front) and B (rear) with suitable tools and the specific torque
– see Tightening torques for high-resistance screw connections on page 2-9
Caution!
Check tilt rod K , the split pin and safety cables H at regular intervals for cracks
L and cuts.
☞ Replace defective parts immediately
K
J
Fig. 10: Tilting the cab

Operation

Specifications
Specifications
Specifications
2 Specifications
2.1 Chassis
Sturdy steel sheet chassis, rubber-mounted engine
2.2 Engine
Model 38Z3
Engine type Tier 2 Tier 3A
Product Yanmar diesel engine
Type 3TNV88-PNS 3TNV88-BPNS
Design Water-cooled 4 stroke diesel engine
No. of cylinders 3
Fuel injection system Direct injection
Aspiration Natural aspiration
Cooling system Water-cooled/aspirating fan
Lubrication system Force-feed lubrication with trochoidal pump
Displacement 1642 cm³ (100.2 in3)
Nominal bore and stroke 88 x 90 mm (3.46 x 3.54”)
Output 21,0 kW (28.2 hp) at 2400 rpm
101.5 – 110.5 Nm (74.9 - 106.6 Nm (78.6 lbf ft)
Max. torque
81.5 lbf ft) at 1100 rpm at 1440 rpm
Max. engine speed with- 2500 ± 10 rpm
out load
Idling speed 1100 ± 50 rpm
Valve tip clearance 0.15 – 0.25 mm / 0.0059 - 0.0098” (cold)
(intake = outlet)
34.3 ± 1 bar at 250 rpm 33.3 – 35.3 bar at 250 rpm
Compression
(497.5 ± 14.5 psi at 250 rpm) (483 - 512 psi at 250 rpm)
Engine oil pressure 3 – 4 bar (43.5 - 58 psi) 3.5–5.0 bar (50.8 - 72.5 psi)
Pressure switch for 0.5 ± 0.1 bar (7.25 ± 1.45 psi)
engine oil pump
Thermostat opening 69.5 – 72.5 °C (157.1 - 162.5°F)
temperature
Thermal switch 107 – 113 °C (224.6 - 235.4°F)
Firing order 1–3–2
Counterclockwise
Direction of rotation
(as seen from the flywheel)
Intake manifold preheating Glow elements (preheating
Starting aid
(preheating time 10 – 15 sec) time 10 – 15 seconds)
Max. inclined position 30° in all directions
(engine no longer sup- 35° no longer than 3 minutes!
plied with oil):
Specific fuel consumption 257 g/kWh (0.423 lb/hph) 252 g/kWh (0.414 lb/hph)
Exhaust values accord- 97/68/EC Tier 2 97/68/EC Tier 3A
ing to EPA Tier 2 EPA Tier 4 interim

Specifications
Fuel injection pump

YPD-MP2
Type
Tier 2 Tier 3A
Design Single piston distributor injection pump
216 – 226 bar 196 – 206 bar
Injection pressure
(3133 - 3278 psi) (2843 - 2988 psi)
Revs control Mechanical
Lubrication system Engine oil lubrication
Engine capacities
Model 38Z3
Capacities
Tier 2 Tier 3A
Fuel tank 44 l (11.6 gal)
Engine oil 7,1 l (1.9 gal)
Coolant (without radiator) 2 l (0.53 gal)
Radiator 3,5 l (0.9 gal) 5,5 l (1.5 gal)
Expansion tank 0,84 l (0.22 gal)
Overview of capacities: – see Fluids and lubricants on page 3-1
Engine tightening torques
Tightening torques Nm / lbf ft
Cylinder-head bolt 85.3 – 91.1 / 62.96 - 67.20 (M10x1.25)
Connecting rod bearing screw 44.1 – 49.0 / 32.5 - 36.1 (M9x1)
Main bearing screw 93.2 – 98.1 / 68.7 - 72.4 (M12x1.5)
Flywheel screw 83.3 – 88.2 / 61.4 - 65.1 (M10x1.25)

Specifications
2.3 Hydraulic system
Hydraulics Model 38Z3

Double variable displacement + twin gear
Tier 2 pump
(up to 2 x 16 + 10.5 + 4.5 cm³
AE02803) (2 x 1.0 + 0.64 + 0.27 in3)
Pump PVD-2B44BP-16G5-4713F
Double variable displacement + gear pump
Tier 3A 2 x 16 + 10.5 + 4.5 cm³
(from
(2 x 1.0 + 0.64 + 0.27 in3)
AG00573)
PVD-1B-34BP-10G5
2 x 40 + 26.3 + 11.3 l/min (2 x 11 + 7 + 3 gpm)
Flow rate
at 2500 rpm
Control valve 11 sections/12 sections (3rd control circuit)
Main pressure limiting valve for pumps 240±3 bar (3481±44 psi)
P1, P2
Main pressure limiting valve for pump 210±3 bar (3046±44 psi)
P3
Secondary pressure l 275-0/+0.5 bar (3989 -0/+7 psi)
imiting valve for main valve block at 20 l/min (5.3 gpm)
Main pressure limiting valve for 35±1 bar (508 ± 14.5 psi)
pilot control pressure
Main pressure limiting valve for swivel 210±3 bar (3046 ±44 psi)
unit engine pressure restriction
Hydraulic oil cooler Standard
Hydraulic tank capacity 45 l (12 gal.US)
2nd speed shift pressure 180 bar (2611 psi)
3.7– 1.2/+1.2 sec at 50 °C / 122°F
Gear motor braking deceleration time
oil temperature
Circulation pressure P1,P2 15.5 bar (224.8 psi) / 12.5 bar (181.3 psi)
Circulation pressure P3 18 bar (261 psi)
Auxiliary hydraulics oil flow
Pressure (bar / psi) P2 + P3 (l/min / gpm) P2 (l/min / gpm)
15 / 218 65.5 / 17.3 40.5 / 10.7
40 / 580 64 / 16.9 40 / 10.6
60 / 870 62.5 / 16.5 39 / 10.3
90 / 1305 56 / 14.8 38.5 / 10.2
120 / 1740 50.5 / 13.3 37.5 / 9.9
150 / 2176 43.7 / 11.5 33.5 / 8.8
180 / 2611 37 / 9.8 29 / 7.7
200 / 2901 16 / 4.2 27 / 7.1
Important!
Output indications for auxiliary hydraulics with unpressurised reflux line.
Adjustment – see Flow rate adjustment of auxiliary hydraulics on page 5-12

Specifications
2.4 Undercarriage and swivel unit
Undercarriage/swivel unit Model 38Z3

2 speed ranges 2.8/4.6 km/h (1.7/2.9 mph)
Hill climbing ability (no longer than 3 30°/58 %
minutes)
Chain width 300 mm (11.8")
No. of track rollers on either side 4
Ground clearance 280 mm (11")
Ground pressure 0.34 kg/cm² (4.8 psi)
Upper carriage swivel speed 8.8 rpm
2.5 Stabiliser blade
Stabiliser blade Model 38Z3

Width/height 1740/345 mm (68.5"/13.6")
Max. lift over/under subgrade 390/450 mm (15.4"/17.7")
Screwable hose burst valve
Location Thread Gap dimension

Stabiliser blade 1/2" 1.2 mm (0.05")
– see chapter 5.17 Hydraulics diagram 38Z3 A3 on page 5-35 item 23

Specifications
2.6 Electric system
Electric system
Alternator 12 V 55 A
Starter 12 V 1.7 kW (2.3 hp)
Battery 12 V 71 Ah
Socket E.g. for cigarette lighter; 15 A max.
Fuse box in instrument panel
Fuse no. Rated current (A) Protected circuit

F3 10 A Indicators, engine relay
F4 10 A Boom working light
F5 15 A Cab working light
F6 10 A Valves, horn
F7 15 A Heating, air conditioning
F3 F4 F5 F6 F7 F8 F9 F10
F8 10 A Wiper, interior light
Fig. 1: Fuse box F9 10 A Rotating beacon, radio, drive interlock
F10 15 A Socket, cigarette lighter
Main fuse box with relays underneath the cab
The main fuse box is located in the partition wall to the left of the engine.

F1 40 A Start, preheat, cutoff solenoid
F2 F1
F2 50 A Fuel-filling pump, main fuse, ignition lock
K5
Relay no.
K9
K9 Cutoff solenoid switching relay
K5 Preheating high current relay

Specifications
Relays
The relays are located in the relay box under the cab, next to the swivelling console.
K6
Switching relay no. Protected circuit
K6 10 s preheating timer (telltale only)
K7 Starting relay
K8 1 s cutoff solenoid timer
K8 V1 Cutoff solenoid recovery diode
K7
V1
Fig. 2: Relays
2.7 Noise levels
Sound power level Model 38Z3

Sound power level (LWA) 95 dB (A)
Sound pressure level (LPA) 75 dB (A)
Important!
Measurement of sound power level according to EC Directive 2000/14 EC. Noise
level at the driver's ear measured according to EC Directives 84/532/EEC, 89/514/
EEC and 95/27/EEC.
Measurements carried out on asphalted surface.
2.8 Vibration
W
Vibration
Effective acceleration value for the < Trigger value
upper extremities of the body *
Effective acceleration value for the < Trigger value
body *
* Measurements as per 2002/44/EC (excavating, driving and hammering with a Wacker Neuson hammer). Machine and
attachment operation and maintenance as per Operator's Manual.

Specifications
2.9 Coolant compound table
Outside tempera- Coolant: Halvoline XLC (based on ethylene glycol)

ture Water Anticorrosion agent Antifreeze agent
% by cm³/l
Up to °C (°F) % by volume % by volume
volume (in3/gal)
4 (39.2) 99 –
-10 (14) 79 20
10
-20 (-4) 65 1 34
(2.6)
-25 (-13) 59 40
-30 (-22) 55 44
2.10 Model-specific tightening torques
38Z3 Nm (lbf ft)

Live ring M14 10.9 180 (133)*
Track roller M16 10.9 275 (203)*
Drive pinion M14 10.9 180 (133)*
Travelling drive M14 10.9 180 (133)*
Gear motor M16 10.9 275 (203)*
Angled engine bracket M10 8.8 45 (33)
Engine bearing M10 8.8 45 (33)
Pump base M10 10.9 70 (52)
Pump M12 10.9 110 (81)
Swivel joint M10 10.9 64 (47)*
Counterweight/additional counterweight M20 8.8 290 (214)*
*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.
2.11 General tightening torques

Tightening torques for hydraulic screw connections (dry assembly)
Metric hose fittings for hydraulic applications (light execution, DKOL)

Wrench size Tightening torque
Nominal ø Outer ø Thread
(WS) Nm(lbf ft)
05 6L M12X1,5 WS 14 15 (11)
06 8L M14X1,5 WS 17 20 (15)
08 10L M16X1,5 WS 19 40 (30)
10 12L M18X1,5 WS 22 50 (37)
12 15L M22X1,5 WS 27 75 (55)
16 18L M26X1,5 WS 32 85 (63)
20 22L M30X2 WS 36 100 (74)
25 28L M36X2 WS 41 180 (133)
32 35L M45X2 WS 55 220 (162)
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 %
Values determined empirically and to be applied as approximate figures.

Specifications
Metric hose fittings for hydraulic applications (heavy execution, DKOL)

Wrench size Tightening torque
Nominal ø Outer ø Thread
WS Nm (lbf ft)
05 8S M16X1,5 WS 19 40 (30)
06 10S M18X1,5 WS 22 50 (37)
08 12S M20X1,5 WS 24 60 (44)
10 14S M22X1,5 WS 27 75 (55)
12 16S M24X1,5 WS 30 90 (66)
16 20S M30X2 WS 36 100 (74)
20 25S M36X2 WS 41 180 (133)
25 30S M42X2 WS 50 270 (199)
32 38S M52X2 WS 60 400 (295)
Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 %
Values determined empirically and to be applied as approximate figures.
Screw connections with various seals for hydraulic applications (light execution)
Straight pipe fitting with thread and screwed
Non-return
plug Identification
valve with
Thread Sealing Elastic aid outside Ø
O-ring elasticseal
washer seal
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) mm ( " )
M10X1,0 9 (7) 18 (13) 15 (11) 18 (13) 10 (0.4)
M12X1,5 20 (15) 25 (18) 25 (18) 25 (18) 12 (0.5)
M14X1,5 35 (26) 45 (33) 35 (26) 35 (26) 14 (0.55)
M16X1,5 45 (33) 55 (41) 40 (30) 50 (37) 16 (0.6)
M18X1,5 55 (41) 70 (52) 45 (33) 70 (52) 18 (0.7)
M22X1,5 65 (48) 125 (92) 60 (44) 125 (92) 22 (0.9)
M27X2,0 90 (66) 180 (133) 100 (74) 145 (107) 27 (1.0)
M33X2,0 150 (111) 310 (229) 160 (118) 210 (155) 33 (1.3)
M42X2,0 240 (177) 450 (332) 210 (155) 360 (266) 42 (1.7)
M48X2,0 290 (214) 540 (398) 260 (192) 540 (398) 48 (1.9)
G1/8A 9 (7) 18 (13) 15 (11) 18 (13) 9,73 (0.38)
G1/4A 35 (26) 35 (26) 30 (22) 35 (26) 13,16 (0.52)
G3/8A 45 (33) 70 (52) 45 (33) 50 (37) 16,66(0.66)
G1/2A 65 (48) 90 (66) 55 (41) 65 (48) 20,96 (0.83)
G3/4A 90 (66) 180 (133) 100(74) 140 (103) 26,44 (1.04)
G1A 150 (111) 310 (229) 160 (118) 190 (140) 33,25 (1.31)
G1 1/4A 240 (177) 450 (332) 210 (155) 360 (266) 41,91 (1.65)
G1 1/2A 290 (214) 540 (398) 260 (192) 540 (398) 47,80 (1.88)
Torque tolerance: – 10 %; countermaterial: steel/aluminium

Specifications
Screw connections with various seals for hydraulic applications (heavy execution)
Straight pipe fitting with thread and
Non-return
screwed plug Identification aid
valve with
Thread Sealing Elastic outside Ø
O-ring elastic seal
washer seal
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) mm ( " )
M12X1,5 20 (15) 35 (26) 35 (26) 35 (26) 12 (0.5)
M14X1,5 35 (26) 55 (41) 45 (33) 45 (33) 14 (0.55)
M16X1,5 45 (33) 70 (52) 55 (41) 55 (41) 16 (0.6)
M18X1,5 55 (41) 90 (66) 70 (52) 70 (52) 18 (0.7)
M20X1,5 55 (41) 125 (92) 80 (59) 100 (74) 22 (0.9)
M22X1,5 65 (48) 135 (100) 100 (74) 125 (92) 27 (1.0)
M27X2,0 90 (66) 180 (133) 170 (126) 135 (100) 12 (0.5)
M33X2,0 150 (111) 310 (229) 310 (229) 210 (155) 33 (1.3)
M42X2,0 240 (177) 450 (332) 330 (243) 360 (266) 42 (1.7)
M48X2,0 290 (214) 540 (398) 420 (310) 540 (398) 48 (1.9)
G1/8A 35 (26) 55(41) 45 (33) 45 (33) 13,16 (0.52)
G1/4A 45 (33) 80 (59) 60 (44) 60 (44) 16,66(0.66)
G3/8A 65 (48) 115 (85) 75 (55) 100 (74) 20,96 (0.83)
G1/2A 90 (66) 180 (133) 170 (125) 145 (107) 26,44 (1.04)
G3/4A 150 (111) 310 (229) 310 (229) 260 (192) 33,25 (1.31)
G1A 240 (177) 450 (332) 330 (243) 360 (266) 41,91 (1.65)
G1 1/4A 290 (214) 540 (398) 420 (310) 540 (398) 47,80 (1.88)
Torque tolerance: – 10 %; countermaterial: steel/aluminium
Tightening torques for high-resistance screw connections
With coarse-pitch thread

Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)
M5 5,5 (4) 8 (6) 10 (7) 5 (4) 7 (5)
M6 10 (7) 14 (10) 17 (13) 8,5 (6) 12 (9)
M8 25 (18) 35 (26) 42 (31) 20 (15) 30 (22)
M10 45 (33) 65 (48) 80 (59) 40 (30) 59 (44)
M12 87 (64) 110 (81) 147 (108) 69 (51) 100 (74)
M14 135 (100) 180 (133) 230 (170) 110 (81) 160 (118)
M16 210 (155) 275 (203) 350 (258) 170 (125) 250 (184)
M18 280 (207) 410 (302) 480 (354) 245 (181) 345 (254)
M20 410 (302) 570 (420) 690 (509) 340 (251) 490 (361)
M22 550 (406) 780 (575) 930 (686) 460 (339) 660 (487)
M24 710 (524) 1000 (738) 1190 (878) 590 (435) 840 (620)
M27 1040 (767) 1480 (1092) 1770 (1305) 870 (642) 1250 (922)
M30 1420 (1047) 2010 (1482) 2400 (1770) 1200 (885) 1700 (1254)
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft;
DIN 7984 – hexagon socket head cap screw with short head
All values subject to a friction coefficient of μ = 0.12 and are to be used as approximate figures.

Specifications
With fine-pitch thread

Screws according to DIN 912, DIN Screws according to
931, DIN 933 etc. DIN 7984
Thread
8.8 10.9 12.9 8.8 10.9
Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)
M8X1,0 25 (18) 37 (28) 43 (32) 22 (16) 32 (24)
M10X1,0 50 (37) 75 (55) 88 (65) 43 (32) 65 (48)
M10X1,25 49 (36) 71 (52) 83 (61) 42 (31) 62 (46)
M12X1,25 87 (64) 130 (96) 150 (111) 75 (55) 110 (81)
M12X1,5 83 (61) 125 (92) 145 (107) 72 (53) 105 (77)
M14X1,5 135 (100) 200 (148) 235 (173) 120 (89) 175 (129)
M16X1,5 210 (155) 310 (229) 360 (266) 180 (133) 265 (195)
M18X1,5 315 (232) 450 (332) 530 (391) 270 (1991) 385 (284)
M20X1,5 440 (325) 630 (465) 730 (538) 375 (277) 530 (391)
M22X1,5 590 (435) 840 (620) 980 (723) 500 (369) 710 (524)
M24X2,0 740 (546) 1070 (789) 1250 (922) 630 (465) 900 (664)
M27X2,0 1100 (811) 1550 (1143) 1800 (1328) 920 (679) 1300 (959)
M30X2,0 1500 (1106) 2150 (1586) 2500 (1844) 1300 (959) 1850 (1364)
DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft;
DIN 7984 – hexagon socket head cap screw with short head
All values subject to a friction coefficient of μ = 0.12 and are to be used as approximate figures.

Specifications
2.12 Dimensions model 38Z3
3158
870
2500
2500
345
300
300
2725 2075 1140
4800 1740
Fig. 3: Machine dimensions (model 38Z3)
Main data Model 38Z3

Service weight 3630 kg (8003 lbs)
Height 2500 mm (8’2")
Width 1740 mm (5’9")
Transport length 4800 mm (15’9")
Max. digging depth 3110 mm (10’2")
Stick length (standard) 1500 mm (4’11")
Stick length (long version) 1750 mm (5’9")
Max. digging depth for long stick (+ 300 mm) 3360 mm (11’0")
Max. vertical digging depth 2430 mm (7’11")
Max. vertical digging depth (long stick) 2670 mm (8’9")
Max. digging height 4530 mm (14’10")
Max. digging height (long stick) 4660 mm (15’3")
Max. dump height 3220 mm (10’7")
Max. dump height (long stick) 3350 mm (11’0")
Max. digging radius 5300 mm (17’5")
Max. digging radius (long stick) 5540 mm (18’2")
Max. reach at ground level 5300 mm (17’5")
Max. reach at ground level (long stick) 5430 mm (17’10")
Max. breakout force at bucket tooth 25,70 kN (5778 lbf)
Max. tearout force (standard stick) 21,90 kN (4923 lbf)
Max. tearout force (long stick) 19,40 kN (4361 lbf)
Min. tail end slewing radius 870 mm (2’10")
Max. tail end lateral projection over chains 0 mm (0’)
Max. boom displacement to bucket centre (right-hand side) 740 mm (2’5")
Max. boom displacement to bucket centre (left-hand side) 590 mm (1’11")

Specifications
2.13 Lift capacity table 38Z3

All table indications in kg (lb) and horizontal position on firm ground without bucket.
4,5 m 3,5 m 2,5 m

A
(14’8”) (11’5”) (8’2”)
3,0 m 660* 660*

(9’8”) (1455*) (1455*)
2,0 m 790* 425 785* 640
(6’6”) (1742*) (937) (1731*) (1411)
1,0 m 825* 395 840* 410 1050* 600 1735* 975
(3’3”) (1819*) (871) (1852*) (904) (2315*) (1323) (3825*) (2150)
Fig. 4: Lift capacity table (model 38Z3) 0,0 m 805* 385 855* 400 1210* 570 2025* 925
(0’0”) (1775*) (849) (1885*) (882) (2668*) (1257) (4464*) (2039)
-1,0 m 1160* 565 1875* 915
(-3’3”) (2557*) (1246) (4134*) (2017)
-2,0 m 1440* 945
(-6’6”) (3175*) (2083)
max Admissible load on extended stick

A Reach from live ring centre
B Load hook height
* Lift capacity limited by hydraulics
With the stabiliser blade in driving direction
Without the stabiliser blade, 90° to driving direction
If equipped with a bucket or other attachments, lift capacity or tilt load is reduced by bucket
or attachment dead weight.
Calculation basis: according to ISO 10567

The track excavator's lift capacity is restricted by the settings of the pressure limiting
valves and the hydraulic system's stabilising features.
Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded.

Specifications
2.14 Lift capacity table 38Z3 short stick + extra weight

4,5 m 3,5 m 2,5 m

A
(14’9") (11’6") (8’2")
3,0 m 660* 660*

(9’10") (1455*) (1455*)
2,0 m 790* 480 785* 715
(6’7") (1742*) (1058) (1731*) (1576)
1,0 m 825* 450 840* 465 1050* 675 1735* 1095
(3’3") (1819*) (992) (1852*) (1025) (2315*) (1488) (3825*) (2414)
(0’0") (1775*) (970) (1885*) (1003) (2668*) (1422) (4464*) (2039)
-1,0 m 1160* 640 1875* 1035
(-3’3") (2557*) (1411) (4134*) (2282)
-2,0 m 1440* 1060
(-6’7") (3175*) (2337)

B Load hook height


Specifications
2.15 Lift capacity table 38Z3 long stick

4,5 m 3,5 m 2,5 m

A
(14’9") (11’6") (8’2")
3,0 m
(9’10")
2,0 m 705* 425 670* 645
(6’7") (1554*) (937) (1477*) (1422)
1,0 m 755* 360 790* 410 965* 600 1520* 985
(3’3") (1664*) (794) (1742*) (904) (2127*) (1323) (3351*) (2172)
(0’0") (1653*) (772) (1863*) (871) (2579*) (1246) (4354*) (2006)
-1,0 m 1175* 550 1920* 895
(-3’3") (2590*) (1213) (4243*) (1973)
-2,0 m 1570* 915
(-6’7") (3461*) (2017)

B Load hook height


Specifications
2.16 Lift capacity table 38Z3 with long stick + extra weight
4,5 m 3,5 m 2,5 m

A
(14’9") (11’6") (8’2")
3,0 m
(9’10")
2,0 m 705* 475 670* 670*
(6’7") (1554*) (1047) (1477*) (1477*)
1,0 m 755* 405 790* 460 965* 670 1520* 1095
(3’3") (1664*) (893) (1742*) (1014) (2127*) (1477) (3351*) (2414)
(0’0") (1653*) (882) (1863*) (981) (2579*) (1400) (4354*) (2249)
-1,0 m 1175* 620 1920* 1005
(-3’3") (2590*) (1367) (4243*) (2216)
-2,0 m 1570* 1025
(-6’7") (3461*) (2260)

B Load hook height


Specifications
2.17 Kinematics
E Pin diameter 40 mm (1.575”)

F Stick width 140 mm (5.5”)
L Pin distance to bucket mount 180 mm (7.087”)
Bucket Stick
Bucket

Specifications
2.18 Attachments
Description Width mm (ft) Capacity l (ft 3) Item No.

Rear excavator bucket 38z3 300 (0’11") 50 (1.8) 1000093755
Offset bucket 38z3 1000 (3’3") 111 (3.9) 1000096569
Offset bucket 38z3 1400 (4’7") 158 (5.6) 1000096570
Ditch cleaning bucket 1000 (3’3") 117 (4.1) 1000096563
Ditch cleaning bucket 1400 (4’7") 166 (5.9) 1000096564

Specifications

Maintenance
Maintenance
Maintenance
3 Maintenance
3.1 Fluids and lubricants
Season/temper-
Component/ application Engine/machine fluid Specification Capacities 1
ature
SAE 10W-40 2; API: CD, CF, CF-4, CI-4 -20°C (-4°F)
Diesel engine Engine oil ACEA: E3, E4, E5 7.1 l (1.8 gal)
+40°C (104°F)
JASO: DH-1
Q8 T 55, SAE 85W-904
About 1.3 l each
Travelling drive Gearbox oil3 Q8 T 55, SAE 80W-905 Year-round
(0.3 gal)
FINA PONTONIC GLS, SAE85W-90
Hydraulic oil HVLP466
PANOLIN HLP Synth 46
Hydraulic oil tank Year-round 45 l (11.9 gal)
7 FINA BIOHYDRAN SE 46
Biodegradable oil
BP BIOHYD SE-46
Roller and friction bearings 8 Year-round As required
(live ring ball bearing race) FINA Energrease L21M
Grease
Open gear Year-round As required
(live ring gears) BP Energrease MP-MG29
Grease nipples Multipurpose grease FINA Energrease L21 M10 Year-round As required
Battery terminals Acid-proof grease11 FINA Marson L2 Year-round As required
2-D ASTM D975 – 94 (USA)
1-D ASTM D975 – 94 (USA)
EN 590 : 96 (EU)
Fuel tank Diesel fuel ISO 8217 DMX (International) 44 l (11.6 gal)
BS 2869 – A1 (GB) Summer or win-
ter diesel depend-
BS 2869 – A2 (GB) ing on outside
temperatures
Soft water + antifreeze ASTM D4985
Radiator Coolant Year-round 5.5 l (1.5 gal)
Distilled water + antifreeze ASTM D4985
Refrigerating agent R134a12 Year-round ~ 950 g (2.1 lbs)
122 cm³ (7.45 in3)
Air conditioning bis AE02803
Compressor oil Sanden SP20 Year-round
90 cm³ (5.5 in3)
ab AG00573
Washer system Cleaning agent Water + antifreeze Year-round 1,2 l (0.32 gal)
1. The capacities indicated are approximative values; the oil level check alone is relevant for the correct oil level
2. According to DIN 51502
3. Hypoid gearbox oil based on basic mineral oil (SAE85W-90 according to DIN 51502), (API GL-4, GL5)
4. The Q8 T55 SAE 85W-90 gearbox oil is no longer produced.
5. The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils!
6. According to DIN 51524 section 3
7. Hydraulic ester oils (HEES)
8. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive
9. KP2N-20 according to DIN 51502 EP multipurpose calcium sulphonate complex grease
10. KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive
11. Standard acid-proof grease
12. According to DIN 8960

Maintenance
Oil grades for the diesel engine, depending on temperature

Engine oil grade Ambient temperature (C°)
°C -20 -15 -10 -5 0 5 10 15 20 25 30 35 40
SAE 10W
SAE 20W
SAE 10W-30
API CD, CF, CF-4, SAE 10W-40

CI-4
SAE 15W-40
ACEA: E3, E4, E5
JASO: DH-1 SAE 20
SAE 30
SAE 40
°F -4 5 14 23 32 41 50 59 68 77 86 95 104
Additional oil change and filter replacement (hydraulics)
Caution!
An additional oil change and filter replacement can be required depending on
how the machine is used. Failure to observe these replacement intervals can
cause damage to hydraulic components.
☞ Observe the following intervals
Application Hydraulic oil Hydraulic oil filter insert

Normal work (excavation work) Every 1000 s/h Replace the first time after 50 s/h, then every 500 s/h
20 % Every 800 s/h
300 s/h
40 % Every 400 s/h
Percentage of hammer work
60 % Every 300 s/h
100 s/h
Over 80 % Every 200 s/h
Important!
Please refer to the maintenance plan on page 3-5 for additional maintenance work.

Maintenance
3.2 Maintenance label

Explanation of symbols on the maintenance label
Symbol Assembly Explanation
General Visual check
General Grease instructions
Fuel system Drain condensation water
Fuel system Replace the fuel filter, clean the fuel prefilter
Radiator Check the coolant level
Radiator Drain and fill in new coolant
Engine Check valve tip clearance. Adjust if necessary
Engine Check the engine oil level
Engine Change engine oil
Engine Replace the oil filter
Engine Check V-belt tension
Travelling drive Change oil
Travelling drive Check oil
Undercarriage Check chain tension
Hydraulic system Check oil level
Hydraulic system Change hydraulic oil
Hydraulic system Replace the hydraulic oil filter, replace the breather filter

Maintenance
Symbol Assembly Explanation
Radiator fins Clean
Heating,
Replace the cabine air filter
air conditioning
KF2K-25 KP2N-20
KF2K-25 KF2K-25

Maintenance
Maintenance plan/service hours (s/h)

3.3 Maintenance plan (overview)
Work description
For service and maintenance work on the attachment, please refer to the operation and maintenance manual of the
Customer
workshop
Authorised
once a year
Every 50 s/h
(once a day)
Every 500 s/h
attachment manufacturer as well.
Every 1000 s/h

Every 1500 s/h
Maintenance work
Fluid and filter changes ( ):
SERV-HB 38Z3 EN – Edition 2.1 * 38Z3s311.fm

Carry out the following oil and filter changes (check oil levels after test run):
• Engine oil1 ● ● ●
• Engine oil filter2 ● ● ●
• Fuel filter3 ● ● ●
• Air filter element as indicated by telltale ●
• Coolant ● ●
• Hydraulic oil filter insert 4 ● ● ●
• Hydraulic oil ● ●
• Hydraulic oil tank breather ● ●
• Gearbox oil5,6 ● ● ●
Inspection work ( ):
Check the following material. Refill if necessary:
• Engine oil ● ●
• Engine coolant ● ●
• Hydraulic oil ● ●
• Gearbox oil ● ●
7 ● ●
Clean water ducts
Check engine/hydraulic oil radiator and air conditioning for contamination. Clean if necessary ● ●
Check cooling systems, heating and hoses for leaks and pressure (visual check) ● ●
Check the joystick/drive valve pilot control filter for dirt, clean it if necessary8 ●
Replace cab filter for heating and air conditioning ● ●
Air filter (damage) ● ●
Prefilter with water separator: drain water ● ●
• Clean ● ●
Check V-belt condition and tension ● ●
Check exhaust system for damage and condition ● ●
Check valve tip clearance. Adjust if necessary ● ●
9 ● ●
Clean and adjust the fuel injection pump
3-5
Maintenance
3-6
Work description
Maintenance
Customer
workshop
Authorised
once a year
Every 50 s/h
(once a day)
Every 500 s/h
Every 1000 s/h

Every 1500 s/h
Maintenance work
Check and adjust the injection pressure of the injection nozzles, clean the injection needles/nozzles ● ●
10 ● ●
Check and adjust injection time
Empty diesel fuel tank ● ●
Check battery electrolyte. Fill up with distilled water if necessary ● ● ●
Check alternator, starter and electric connections, bearing play and function ● ●
Check preheating system and electric connections ● ●
Check correct function of air filter contamination gauge ● ●
Pressure check of primary pressure limiting valves 10 ● ● ●
Check chains for cracks and cuts ● ●
Check chain tension. Retighten if necessary ● ●
Check bearing play of tread rollers, track carrier rollers, front idlers ● ●
Check piston rods for damage ● ●
Check screws for tightness 10 ● ● ●
Check pin lock ● ●
Check line fixtures ● ●
Check telltales for correct function ● ● ●
Check cab tilt lock, cables and cable holders for damage and correct function ● ● ●
Couplings, dirt pile-up on hydraulic system dust caps ● ●
Check insulating mats in the engine compartment for damage/condition ● ●
Ensure grease supply of central lubrication system (option) ● ●
Check labels and Operator's Manual for completeness and condition ● ●
Check function of engine cover gas strut ● ●
Lubrication service ( ):
Lubricate the following assemblies/components – see Wartungsaufkleber on page 5-35:
• Stabiliser blade ● ●
• Swivelling console ● ●
• Boom ● ●
• Stick ● ●

Work description
Customer
workshop
Authorised
once a year
Every 50 s/h
(once a day)
Every 500 s/h
Every 1000 s/h

Every 1500 s/h
Maintenance work
• Attachments ● ●
• Grease strip on chassis – see Wartungsaufkleber on page 5-35 ● ●

Air conditioning ( ):
Carry out the following maintenance and inspection work:
• Function of air conditioning 11 ● ●
Replace cab filter ● ●
Check dehumidifier for corrosion, condensation and air bubbles ● ●
Replace dehumidifier and refrigerating agent 12 ● ●
Compressor oil 11 ● ●
Check the refrigerating agent ● ●
Functional check ( ):
Check the function of the following assemblies/components. Rectify if necessary:
• Lights, signalling system, acoustic warning system 10 ● ● ●
• Heating function 10 ● ● ●
Leakage check ( ):
Check for tightness, leaks and chafing: pipes, flexible lines and screw connections of the following assemblies and components. Rectify if necessary:
• Visual check ● ●
☞ Engine and hydraulic system ● ●
☞ Cooling and heating circuit ● ●
☞ Travelling drive ● ●
1. Drain engine oil the first time after 50 s/h, then every 500 s/h
2. Replace the engine oil filter the first time after 50 s/h, then every 500 s/h
3. Replace the fuel filter the first time after 50 s/h, then every 500 s/h
4. Replace the hydraulic oil filter insert the first time after 50 s/h, then every 500 s/h
5. Drain the gearbox oil the first time after 50 s/h, then every 1000 s/h
6. The Q8 T55 SAE 85W-90 gearbox oil is no longer produced. The Q8 T55 SAE 80W-90 gearbox oil is used from 10/2006 onwards. Do not mix both gearbox oils!
7. Clean the water ducts every other 1000 s/h servicing
8. Coarse dirt causes malfunctions and can even destroy the filter screen!
9. Clean and adjust the fuel injection pump
10. Check and adjust injection time every other 1000 s/h servicing
11. Replace the compressor oil every other 1500 s/h servicing or every 2 years
10 Check the first time at 50 s/h, then every 500 s/h
11 Switch on once every week
12 Replace the dehumidifier and the refrigerating agent every 1500 s/h or every 2 years
3-7
Maintenance
Maintenance
Maintenance
3.4 Service package

Up to serial no. AE02803
1000127612 1 Service package 38Z3 (Tier 2)
1000018587 1 ➥ Engine oil filter
1000178758 1 ➥ Fuel filter
1000106892 1 ➥ Water separator element
1000069998 1 ➥ Seal for diesel fuel filter housing
1000064543 1 ➥ O-ring for oil drain plug
1000012360 1 ➥ Seal
1000004556 1 ➥ Reflux filter insert
1000004567 1 ➥ Air filter insert
1000104765 1 ➥ Cylinder head cover gasket
1000003894 3 ➥ O-ring
1000146380 1 ➥ Cab air filter (with heating)
1000143330 1 ➥ Cab air filter (with air conditioning)
From serial no. AG00573

1000179349 1 Service package 38Z3 (Tier 3A)
1000018587 1 ➥ Engine oil filter
1000180500 1 ➥ Fuel filter
1000106892 1 ➥ Water separator element
1000069998 1 ➥ Seal for diesel fuel filter housing
1000064543 1 ➥ O-ring for oil drain plug
1000012360 1 ➥ Seal
1000004556 1 ➥ Reflux filter insert
1000104765 1 ➥ Cylinder head cover gasket
1000003894 3 ➥ O-ring
1000146380 1 ➥ Cab air filter (with heating)
1000143330 1 ➥ Cab air filter (with air conditioning)
3.5 Introduction
Operational readiness and the service life of machines are heavily dependent on
maintenance.
Before carrying out service and maintenance work, always read, understand and follow
the instructions given in
• Chapter 2 “SAFETY INSTRUCTIONS” in the Operator's Manual
• The Operator's Manuals of the attachments.
Secure open (engine) covers appropriately.
Do not open (engine) covers on slopes or in strong wind.
Dirt can be blown away and cause severe injuries when using compressed air. Always
wear protective goggles, masks and clothing.

Maintenance
Daily service and maintenance work, and maintenance according to maintenance plan
“ A”” must be carried out by a specifically trained driver. All other maintenance work must
be carried out by trained and qualified staff only.
The maintenance plans indicate when the maintenance work mentioned below must be
carried out (– see Maintenance plan (overview) on page 3-5).
3.6 Fuel system

Specific safety instructions
• Extreme caution is essential when handling fuel – high risk of fire!
• Never carry out work on the fuel system in the vicinity of naked flames or sparks!
• Do not smoke when working on the fuel system or when refuelling!
• Before refuelling, switch off the engine and remove the ignition key!
• Do not refuel in closed rooms!
• Wipe away fuel spills immediately!
• Keep the machine clean to reduce the risk of fire!
Refuelling
Filler inlet A for the fuel tank is located in the engine compartment, on the right in driving
direction.
Danger!
All work involving fuel carries an increased
A
Danger of fire and poisoning!
☞ Do not refuel in closed rooms
☞ Never carry out work on the fuel system in the vicinity of naked flames or
sparks
Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
environmentally friendly manner!
Important!
Do not run the fuel tank completely dry. Otherwise, air is drawn into the fuel
system. This requires bleeding the fuel system
– see Bleeding the fuel system on page 3-10.
Important!
Fill up the tank with the correct fuel type at the end of each working day to prevent
the formation of condensation water in the fuel tank (condensation water damages
the injection pump).
Do not fill the tank completely but leave some space for the fuel to expand.

Maintenance
Stationary fuel pumps General

Only refuel from stationary fuel pumps. Fuel from barrels or cans is usually contaminated.
Even the smallest particles of dirt can cause
• Increased engine wear
• Malfunctions in the fuel system and
• Reduced effectiveness of the fuel filters
Refuelling from barrels
If refuelling from barrels cannot be avoided, note the following points (see fig. 2):
wrong • Barrels must neither be rolled nor tilted before refuelling
• Protect the suction pipe opening of the barrel pump with a fine-mesh strainer
• Immerse it down to a max. 15 cm (6") above the floor of the barrel
• Only fill the tank using refuelling aids (funnels or filler pipes) with integral microfilter
right • Keep all refuelling containers clean at all times
Fig. 2: Refuelling from a barrel
Diesel fuel specificationn Use only high-grade fuels
Grade Cetane number Use

• No. 2-D according
to DIN 51601 For normal outside temperatures
• No. 1-D according Min. 45 For outside temperatures below 4 °C
to DIN 51601 (39°F) or for operation above 1500 m
(4921’) altitude
Bleeding the fuel system

Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
☞ Never bleed the fuel system if the engine is hot!
Bleed the fuel system in the following cases:

• After removing and fitting the fuel filter, prefilter or the fuel lines back on again
• After running the fuel tank empty
• After running the engine again, after it has been out of service for a longer period of
time
☞ Bleed the fuel system as follows:
• Fill the fuel tank
• Turn the ignition key to the first position
• Wait about 5 minutes while the fuel system bleeds itself automatically
• Start the engine
If the engine runs smoothly for a while, and then stops; or if it does not run smoothly:
• Bleed the fuel system again as described above
• Have this checked by authorised staff if necessary

Maintenance
Emptying the fuel tank

Due to dirt and the formation condensation water in the fuel tank, empty the fuel tank every
500 service hours as follows:
☞ Place a container (e.g. a barrel) with sufficient capacity
☞ Suck off the diesel fuel
☞ Check the fuel tank for contamination and clean if necessary
☞ Replace the filter according to the maintenance specifications
☞ Refill the fuel tank
☞ Bleed the fuel system – see Bleeding the fuel system on page 3-10
Fuel prefilter with water separator

Old engine type (up to serial number AE02803): Check the fuel prefilter as follows:
☞ If the red indicator ring rises to position C
On
☞ Unscrew thread A
Off ➥ The water drains
➥ Wait until the indicator ring returns to the bottom of the water separator
☞ Screw thread A back on again
B
Interrupt fuel supply as follows:
☞ Turn ball-type cock B to the OFFF mark
C
➥ Fuel supply is interrupted
☞ Turn ball-type cock B to the ON
N mark
➥ Fuel supply is open again
A
Environment!
Fig. 3: Fuel prefilter Thread A is fitted with a hose. Collect the water as it drains with a suitable container and
dispose of it in an environmentally friendly manner.
New eng ine type (from serial nu mb er AG00573):

Maintenance
Replacing the fuel filter

Old en gine typ e (up to serial n umber AE02803):
Danger!
If the fuel, as it drains, comes into contact with hot engine parts or the exhaust
system, there is an increased
Danger of burns!
A
☞ Never change the fuel filter if the engine is hot!
Fig. 4: Fuel filter position

Environment!
Use a suitable container to collect the fuel as it drains and dispose of it in an
New engine type (from serial number AG00573):
☞ Change fuel filter 4/A as follows:

• Close the fuel feed line with the stop cock on the fuel prefilter
• Thoroughly clean the outside surfaces of fuel filter 4/A
• Place a suitable container under the filter
• Slacken and unscrew fuel filter cartridge using a commercially available tool
• Collect the fuel as it drains
Fig. 5: Unscrewing the fuel filter
• Clean the sealing surface of the filter carrier if it is dirty

• Lightly oil the rubber gasket of the new filter cartridge or apply a thin coat of clean diesel
fuel to it
• Screw on the cartridge by hand until the gasket makes contact
Fig. 6: Cleaning the sealing surface and oiling the gasket
• Tighten the fuel filter cartridge by turning it a further half revolution

• Open the stop cock on the water separator again
• Bleed the fuel system – see Bleeding the fuel system on page 3-10
• Make a test run – and check for tightness!
• Dispose of the old fuel filter cartridge by an ecologically safe method
Fig. 7: Tightening the fuel filter

Maintenance
3.7 Engine lubrication system
Caution!
If the engine oil level is too low or if an oil change is overdue, this can cause
Engine damage or loss of output!
☞ Have the oil changed by an authorised workshop
– see Maintenance plan (overview) on page 3-5
Checking the oil level

Important!
Check the oil level once a day.
We recommend checking it before starting the engine. After switching off a warm
engine, wait at least 5 minutes before checking.
Checking the oil level

☞ Proceed as follows:
Old engin e type (up to serial number AE02803): • Park the machine on level ground
• Switch off the engine!
max • Fold the control lever base up
min
• Let the engine cool down
• Open the engine cover
• Clean the area around the oil dipstick with a lint-free cloth
• Oil dipstick A :
☞ Pull it out
A ☞ Wipe it with a lint-free cloth
☞ Push it back in as far as possible
☞ Withdraw it and read off the oil level
Fig. 8: Checking the oil level
☞ However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the
oil dipstick A .
A

Maintenance
Filling up engine oil

Caution!
Too much or incorrect engine oil can result in engine damage! For this reason:
☞ Do not add engine oil above the MAX mark of oil dipstick 9/A
☞ Use only the specified engine oil
☞ Use engine oils of the same brand and grade => never mix different oils!
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
Old eng ine type (up to serial nu mber AE02803): ☞ Proceed as follows:
• Clean the area around oil filler cap B with a lint-free cloth
OIL
• Open filler cap B
B • Raise oil dipstick A slightly to allow any trapped air to escape
• Fill in engine oil
• Wait about 3 minutes until all the oil has run into the oil sump
• Check the oil level
– see Checking the oil level on page 3-13
A
• Fill up if necessary and check the oil level again
• Close filler cap B
• Push oil dipstick A back in as far as possible
Fig. 9: Oil dipstick and oil filler cap
New engin e type (from serial number AG00573):
• Completely remove all oil spills from the engine
B

Maintenance
Changing engine oil
Danger!
Caution when draining hot engine oil –
+ 80 °C Danger of burns!
+176°F ☞ Wear protective gloves
☞ Use suitable tools
OIL
Fig. 10: Optimum engine oil temperature
Environment!
Use a suitable container to collect the engine oil as it drains and dispose of it in an
☞ Change the engine oil as follows:

• Park the machine on level ground
• Let the engine run until reaching service temperature (oil temperature about 80 °C/
176°F)
• Place a container under the opening to collect the oil as it drains
• Unscrew the oil drain plug
• Completely drain the oil
• Screw the oil drain plug back on again
– see Filling up engine oil on page 3-14
• Checking the oil level
• Start the engine and let it run briefly at low revs
• Wait a moment until all the oil has run into the oil sump
• Check the oil level again
• Fill up if necessary and check again

Maintenance
Replacing the engine oil filter cartridge

Old eng ine type (up to serial nu mber AE02803):
Danger!
A
Caution when draining hot engine oil –
Danger of burns!
☞ Wear protective gloves
Fig. 11: Engine oil filter position
Environment!
Collect the drained engine oil in a suitable container. Dispose of used oil and filters in an
A
☞ Change the filter as follows:

• Place a suitable container underneath the oil filter to collect the oil as it drains
• Slowly slacken oil filter cartridge A using a commercially available tool
A • Let the oil drain into the container
• Remove the filter cartridge once the oil is completely drained
• Make sure the thread adapter is correctly placed in the filter head
Fig. 12: Unscrewing the engine oil filter
• Clean the inside of the filter head

• Apply a thin coat of fresh engine oil to rubber seal B of the new oil filter cartridge
• Tighten the new filter cartridge by hand until the gasket makes contact
Fig. 13: Cleaning the filter head and oiling the gasket
• Tighten oil filter cartridge A by hand by about a further half revolution

• Make sure the oil level is correct!
A
• Let the engine run briefly
• Check the seal of oil filter cartridge A and retighten by hand
• Check the oil level and fill in engine oil if necessary
• Dispose of the used oil filter in an environmentally friendly manner
Fig. 14: Tightening the filter cartridge

Maintenance
3.8 Cooling system

The oil and water cooler is located in the engine compartment, on the right side of the
engine.
The expansion tank for the coolant is also located in the engine compartment, in front of
the oil cooler.

• Dirt on the radiator fins reduces the cooler's heat dissipation capacity!
To avoid this:
☞ Clean the outside of the radiator at regular intervals. Use oil-free compressed air
(2 bar / 29 psi max.) to clean. Maintain a certain distance to the radiator to avoid
damage to the radiator fins. Refer to the maintenance plans in the appendix for the
cleaning intervals
☞ In dusty or dirty work conditions, clean more frequently than indicated in the
maintenance plans
• An insufficient coolant level reduces the heat dissipation capacity as well and can lead
to engine damage! Therefore:
☞ Check the coolant level at regular intervals. Refer to the maintenance plans in the
appendix for the intervals
☞ If coolant must be added frequently, check the cooling system for leaks and/or
contact your dealer!
☞ Never fill in cold water/coolant if the engine is warm!
☞ After filling the expansion tank, make a test run with the engine and check the coolant
level again after switching off the engine
• The use of the wrong coolant can destroy the engine and the cooler. Therefore:
☞ Add enough antifreeze compound to the coolant – but never more than 50 %. If
possible use brand-name antifreeze compounds with anticorrosion additives
☞ Observe the coolant compound table
– see Coolant compound table on page 2-7
☞ Do not use cooler cleaning compounds if an antifreeze compound has been added to
the coolant – otherwise this causes sludge to form, which can damage the engine
• Once you have filled the expansion tank:
☞ Test run the engine
☞ Let the engine cool down
☞ Check the coolant level again
Environment!
Use a suitable container to collect the coolant as it drains and dispose of it in an

Maintenance
Checking/filling up coolant
Old eng ine type (up to serial nu mber AE02803):
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure –
B
Danger of burns!
☞ Wait at least 15 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Open filler cap B to the first notch and release the pressure
Fig. 15: Radiator filler cap ☞ Make sure the coolant temperature is sufficiently low so you can touch the
radiator plug with your hands
B
Danger!
Antifreeze is flammable and poisonous –
New eng ine type (from serial nu mb er AG00573): ☞ Keep away from flames
☞ Avoid eye contact with antifreeze
• If antifreeze comes into contact with the eyes
➥ Immediately rinse with clean water and seek medical assistance
Checking the coolant level
A ☞ Proceed as follows:
FULL • Park the machine on level ground
• Switch off the engine!
LOW
• Fold the control lever base up
• Remove the key and carry it with you
• Let the engine and the coolant cool down
• Check the coolant level on the transparent coolant tank A and on the radiator B
Old engin e typ e (up to serial number AE02803): ☞ If the coolant level is below the LOW
W seam or if there is no coolant at the radiator's
Fig. 16: Expansion tank for coolant filler inlet:
• Fill up coolant (use only coolants of the same brand and grade => do not mix different
coolants!)
Important!
Check the coolant level once a day.
We recommend checking it before starting the engine.

Maintenance
Filling up coolant
Old en gine type (u p to serial n umb er AE02803): After the engine has cooled down:
☞ Release overpressure in the radiator
☞ Carefully open the cap to the first notch and fully release the pressure
B ☞ Open filler cap B
☞ Fill up coolant up to the lower edge of the filler inlet (radiator) and of the expansion tank
(use coolants of the same brand and grade => never mix different coolants!)
☞ Close filler cap B
☞ Start the engine and let it warm up for about 5 – 10 minutes
Fig. 17: Filling up coolant ☞ Remove the key and carry it with you
☞ Check the coolant level again
B ➥ The coolant level must be between the LOW W and FULLL tank seams
☞ If necessary, fill up coolant and repeat the procedure until the coolant level remains
constant
Important!
Check the antifreeze every year before the cold season sets in!
New engine typ e (from serial n umber AG00573):
Draining coolant
Old engine type (up to serial number AE02803):
Danger!
Never open the coolant tank and never drain coolant if the engine is warm
since the cooling system is under high pressure –
Danger of burns!
☞ Wait at least 10 minutes after switching off the engine!
☞ Wear protective gloves and clothing
☞ Open filler cap 17/BB to the first notch and release the pressure
Fig. 18: Radiator drain plug
After the engine has cooled down:

☞ Release overpressure in the radiator
☞ Open the cap to the first notch and fully release the pressure
☞ Open filler cap 17/B
☞ Open the drain plug of the radiator and drain the coolant
☞ Close the drain plug again
• From serial number AG00573:
☞ The drain opening is closed with a plug. Open this plug carefully with a suitable tool,
drain the coolant and screw the plug back in.
☞ Fill up the radiator with suitable coolant
– see Fluids and lubricants on page 3-1
☞ Check the coolant level
– see Checking the coolant level on page 3-18

Maintenance
3.9 Air filter
Caution!
The filter cartridge will be damaged if it is washed or brushed out!
Bear in mind the following to avoid premature engine wear!
☞ Do not clean the filter cartridge
☞ Replace the filter cartridge when the telltale comes on
☞ Never reuse a damaged filter cartridge
☞ Ensure cleanliness when replacing the filter cartridge!
Telltale X in the round display element monitors the filter cartridge.

☞ Replace outside filter B and inside filter C:
• If telltale X in the round display element comes on
• According to the maintenance plan
Important!
For applications in especially dusty environmentt , the air filter is fitted with an
extra inside filter C. Do not clean inside filter C.
X Caution!
Filter cartridges degrade prematurely when in service in acidic air for longer
periods of time. This risk is present for example in acid production facilities,
steel and aluminium mills, chemical plants and other nonferrous-metal plants.
☞ Replace outside filter B and inside filter C at the latest after 50 service
hours!
General instructions for air filter maintenance:

• Store filters in their original packaging and in a dry place
• Do not knock the filter against other objects as you install it
B • Check air filter attachments, air intake hoses and air filters for damage, and
immediately repair or replace if necessary
• Check the screws at the induction manifold and the clamps for tightness
• Check the function of the dust valve, replace if necessary
C
Fig. 19: Air filter

Maintenance
Replacing the filter

• Replace outside filter A as follows:
D ☞ Switch off the engine
☞ Remove the key and carry it with you
E ☞ Open the engine cover
☞ Remove dirt and dust from the air filter and the area around the air filter
☞ Fold both bow clips D on lower housing section E to the outside
☞ Remove lower housing section E
Fig. 20: Removing the lower housing section ☞ Carefully remove outside filter B with slightly turning movements
☞ Make sure all dirt (dust) inside the upper and lower housing sections, including the dust
valve, has been removed
B ☞ Clean the parts with a clean lint-free cloth, do not use compressed air
☞ Check the air filter cartridges for damage, only install intact filters
☞ Carefully insert new outside filter B in the upper housing section
☞ Position lower housing section E (make sure it is properly seated)
☞ Close both bow clips D
Fig. 21: Removing the filter element
• Replace inside filter C as follows:

☞ Open the engine cover
☞ Remove dirt and dust from the air filter and the area around the air filter
C ☞ Fold both bow clips D on lower housing section E to the outside
☞ Remove lower housing section E
Fig. 22: Replacing the inside filter ☞ Carefully remove outside filter B with slightly turning movements
☞ Carefully remove inside filter C
☞ Cover the air supply at the end of the filter with a clean lint-free cloth to prevent dust
from entering the engine
☞ Make sure all contamination (dust) inside the upper housing section and dust valve G
has been removed
☞ Clean the parts with a clean lint-free cloth, do not use compressed air
☞ Remove the cloth from the air supply
☞ Check the air filter cartridges for damage, only install intact filters
☞ Carefully insert the new inside filter C
☞ Carefully insert outside filter B in the upper housing section
☞ Position lower housing section E (make sure it is properly seated)
☞ Close both bow clips D
Important!
Make sure dust valve G shows downwards once it is installed!

Maintenance
Functional check once a week of the dust valve

The air filter is located in the engine compartment, on the right-hand side of the machine.
• Apply the parking brake
• Squeeze the discharge slot of dust valve B
• Remove hardened dust by compressing the upper area of the valve
☞ Clean the discharge slot if necessary
Fig. 23: Air filter – dust valve

Maintenance
3.10 V-belt
Danger!
Only check or retighten/replace the V-belt when the engine is switched off –
Danger of personal injury!
☞ Switch off the engine before carrying out inspection work in the engine
compartment!
☞ Disconnect the battery or the battery master switch
Caution!
Cracked and stretched V-belts cause engine damage
☞ Have the V-belt replaced by an authorised workshop
Check the V-belt once a day or every 10 service hours, and retighten if necessary!
Retighten new V-belts after about 15 minutes of running time.
Checking V-belt tension

• Check as follows:
1
☞ Fold the control lever base up
☞ Carefully check V-belt 1 for damage, cracks or cuts
☞ Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley
• If the V-belt is damaged:
Fig. 24: Checking V-belt tension
☞ Have the V-belt replaced by authorised staff
☞ Press with your thumb to check the deflection of the V-belt between the crankshaft
disc and the fan wheel position C. A new V-belt should have a deflection
of 6 to 8 mm (0.2" - 0.3"), a used V-belt (after about 5 minutes running time) should
have a deflection of 7 to 9 mm (0.3" - 0.35").
☞ Retighten the V-belt if necessary.

Maintenance
Retightening the V-belt

Caution!
Overtightening the V-belt can damage the V-belt, the V-belt guide and the
water pump bearing.
Avoid contact of oil, grease or similar substances with the V-belt.
☞ Check V-belt tension – see Checking V-belt tension on page 3-23
• Retighten as follows:
3 ☞ Fold the control lever base up
A ☞ Open the engine cover
☞ Slacken fastening screws 3 of alternator 4
☞ Use a suitable tool to push the alternator in the direction of arrow A until reaching the
correct V-belt tension (fig. Fig. 25)
4
☞ Keep the alternator in this position, and at the same time retighten fastening screws 3
Fig. 25: Retightening the V-belt ☞ Check V-belt tension again and adjust it if necessary
☞ Connect the battery or the battery master switch
☞ Close the engine cover

Maintenance
Checking the V-belt of the air conditioning system

Old en gine type (u p to serial n umb er AE02803):
Caution!
2
Excessive or insufficient tension of the V-belt can cause damage to V-belt 1 or
to compressor 2 of the air conditioning system.
About 9 mm ☞ Always make sure the V-belt has the correct tension
1
☞ Replace V-belts with damage, cracks, cuts etc.
☞ Avoid contact of oil, grease or similar substances with the V-belt
• Check as follows:
Fig. 26: Checking the V-belt tension of the air conditioning
system
2 ☞ Disconnect the battery or the battery master switch
☞ Carefully check V-belt 1 for damage, cracks or cuts
1
☞ Replace the V-belt if it touches the base of the V-belt groove or the discs of the pulley
• If the V-belt is damaged:
New eng ine type (from serial nu mb er AG00573): ☞ Have the V-belt replaced by authorised staff
☞ Press with your thumb to check the deflection of the V-belt. A new V-belt should have
a deflection of 7 to 9 mm (0.3" - 0.35"), a used V-belt (after about 5 minutes running
time) should have a deflection of 9 to 11 mm (0.35" - 0.4")
☞ Retighten the V-belt if necessary.

Maintenance
Tightening the V-belt of the air conditioning system

Old en gine typ e (u p to serial n umber AE02803): • Retighten as follows (up to serial number AE02803):
5
3 1 ☞ Remove the key and carry it with you
☞ Slacken slide nut 3 on tightening bracket 5
☞ Push the tightening bracket in the direction of arrow A by hand until reaching the
A correct V-belt tension (fig. Fig. 27)
☞ Keep the tightening bracket in this position, and at the same time retighten slide nut 3
☞ Check V-belt tension again and adjust it if necessary
Fig. 27: Retightening the V-belt of the air conditioning ☞ Connect the battery or the battery master switch
system
• Retighten as follows (from serial number AG00573):
☞ Slacken nut 3 on tightening bracket 5
☞ Push the tightening bracket in the direction of arrow A by hand until reaching the
correct V-belt tension (fig. Fig. 27)
5
☞ Keep the tightening bracket in this position, and at the same time retighten nut 3
☞ Check V-belt tension again and adjust it if necessary
A ☞ Connect the battery or the battery master switch
3
New eng ine type (from serial nu mb er AG00573):

Maintenance
3.11 Pressure check

General • Run the machine warm before checking the pressure! Hydraulic oil temperature:
50 °C / 122°F min. (operating temperature)
• Pressure drop is checked by reducing revs from maximum to idling speed at constant
load
• Set the primary pressure limiting valves (PPLV) at maximum engine revs.
• See chapter “Specifications”
– see Hydraulic system on page 2-3 for the pressure settings
• Ensure utmost cleanliness of all measuring points and ports, micro measuring
lines and pressure gauges that are connected for checking pressure => even the
slightest traces of dirt, e.g. a grain of sand, can impair tightness and cause leaks!
Checking pilot control pressure

Checking pilot control pressure
☞ Connect a pressure gauge to measuring port MP 4 28/4
☞ Move the control lever base (safety switch) to work position
☞ Check and make a note of the pressure value.
Fig. 28: Pilot control pressure measuring port
Adjusting pressure limiting valve 4 (PLV4)

☞ Adjust the pressure at the pressure limiting valve 4 (PLV4) 29/D at the pilot oil supply
unit
☞ Check the pilot control pressure again once adjustment is over
Fig. 29: Pressure reducing valve

Maintenance
Pressure check of variable displacement pump P1

Hydraulic supply for boom, bucket and left-hand side drive functions
Checking primary pressure limiting valve 1 (PPLV 1)

☞Extend the boom ram or the bucket ram as far as it will go at maximum
engine revs
Checking pressure drop

1 ☞ Extend the boom ram or the bucket ram as far as it will go at maximum engine revs
☞ Swiftly reduce engine revs from maximum to minimum -> pressure drop
Fig. 30: Measuring port P1 ➥ Pressure drop should not exceed the specified value by more than 10 %
Adjusting primary pressure limiting valve 1 (PPLV 1)

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 1) 31/AA on the main
valve block
☞ Slacken the locknut of the pressure limiting valve
☞ Unscrew the pressure limiting valve until you can read off a pressure drop on the
A pressure gauge
➥ The valve seat may be stuck and must be slackened first
☞ Adjust the pressure limiting valve and tighten the locknut
☞ Check the primary pressure limiting valve 1 and the pressure drop once adjustment is
over
Also check with the retract boom, the extend/retract bucket and with the left-hand
side forwards/reverse drive functions!
Fig. 31: Primary pressure limiting valve 1

Maintenance
Pressure check of variable displacement pump P2

Hydraulic supply of stick, right-hand side drive and auxiliary hydraulics functions

☞Extend the stick ram as far as it will go at maximum engine revs
☞Check and make a note of the pressure value.

☞ Extend the stick ram as far as it will go at maximum engine revs
2
➥ Pressure drop should not exceed the specified value by more than 10 %
Fig. 32: Measuring port P2

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 2) 33/BB on the main
valve block
B ☞ Unscrew the pressure limiting valve until you can read off a pressure drop on the
pressure gauge
over
Also check with the retract stick and the right-hand side forwards/reverse drive
functions!
Checking the auxiliary hydraulics pressure

Important!
Factory indications for auxiliary hydraulics secondary valves are possibly invalid –
adapt these values to the attachment!

Maintenance
Pressure check of gear pump P3

Hydraulic supply for stabiliser blade, auxiliary hydraulics/boom swivel, upper carriage
rotation

☞ Extend the stabiliser blade ram as far as it will go at maximum engine revs

☞ Extend the stabiliser blade ram as far as it will go at maximum engine revs
3
➥ Pressure drop should not exceed the specified value by more than 10 %
Fig. 34: Measuring port P3

☞ Adjust the pressure at the primary pressure limiting valve (PPLV 3) 35/C
C on the main
valve block
pressure gauge
C over
Also check with the retract stabiliser blade, boom swivel and upper carriage
rotation functions
Checking the auxiliary hydraulics pressure
Important!
Factory indications for auxiliary hydraulics secondary valves are possibly invalid –
adapt these values to the attachment!
Secondary pressure limiting valve of the gear motor

Check (at idling speed)
1 ☞ Connect a pressure gauge to measuring port MP 3
☞ Place the bucket or the boom against the ground or the stabiliser blade, or drive against
hydraulic resistance
Adjusting the secondary pressure limiting valve on the gear motor (at idling speed)
☞ Set the pressure at the shock anticavitation valves 1 on the gear motor
pressure gauge
Fig. 36: Secondary pressure limiting valve
☞ Check the secondary pressure limiting valve again once adjustment is over

Maintenance
Measuring ports: overview
1
Pos. Description
1 Pump 1 measuring port MP 1
4 Pilot oil supply unit measuring port MP 4
2
4 3
Fig. 37: Measurement ports
Primary pressure limiting valves
1 2
Pos. Description
1 Pump primary pressure limiting valve 1 PPLV 1
4 Pilot oil supply unit pressure limiting valve PLV 4

Maintenance
Maintenance
3-32
3.12 Test report
Pilot control
Specified values
1st measure- 2nd measure-
Maintenance
Function Movement Symbol Measuring port Pressure limiting valve Engine Pressure (bar)
ment ment
speed (psi)
Pressure limiting valve
Measuring port Rated 35+4
Joystick ANY PLV 4
MP 4 (pump) value (507.63±58)
(pilot oil supply unit)
Pump 1
Specified values
ment ment
speed (psi)
max. 240±3(3481±43.5)
UP
min. 216±3(3133±43.5)
Boom
max. 240±3(3481±43.5)
DOWN
min. 216±3(3133±43.5)
max. 240±3(3481±43.5)
EXTEND
min. 216±3(3133±43.5)
Bucket
max. 240±3(3481±43.5)
(pump)
RETRACT
min. 216±3(3133±43.5)
(main valve block) max. 240±3(3481±43.5)
Measuring port MP 1
FORWARDS
Right-hand min. 216±3(3133±43.5)
side drive max. 240±3(3481±43.5)
REVERSE
Primary pressure limiting valve PPLV 1
Min. 216±3(3133±43.5)
Pump 2
Function Movement Symbol Measuring port Pressure limiting valve Specified values
ment ment
max. 240±3(3481±43.5)
EXTEND Measuring port Primary pressure limiting min. 216±3(3133±43.5)
Stick MP 2 valve
max. 240±3(3481±43.5)
RETRACT (pump) PPLV 2 (MVB)
min. 216±3(3133±43.5)
SERV-HB 38Z3 EN – Edition 2.1 * 38z3s313.fm

3.12 Test report
max. 240±3(3481±43.5)
FORWARDS
Left-hand side min. 216±3(3133±43.5)
drive max. 240±3(3481±43.5)
REVERSE Measuring port Primary pressure limiting
min. 216±3(3133±43.5)
MP 2 valve
PPLV 2 (MVB) max. 240±3(3481±43.5)
A (pump)
Auxiliary min. 216±3(3133±43.5)

hydraulics max. 240±3(3481±43.5)
B
min. 216±3(3133±43.5)
Pump 3
Specified values
ment ment
speed (psi)
max. 210±3(3046±43.5)
UP
Stabiliser min. 189±3(2741±43.5)
blade max. 210±3(3046±43.5)
DOWN
min. 189±3(2741±43.5)
max. 210±3(3046±43.5)
A (2)
Auxiliary min. 189±3(2741±43.5)
hydraulics max. 210±3(3046±43.5)
(pump)
B (2)
min. 189±3(2741±43.5)
(main valve block)
max. 210±3(3046±43.5)
Measuring port MP 3
LEFT
min. 189±3(2741±43.5)
Boom swivel
max. 210±3(3046±43.5)
RIGHT
Primary pressure limiting valve PPLV 3
min. 189±3(2741±43.5)
Secondary pressure limiting max. 210±3(3046±43.5)
LEFT
Measuring port valve min. 189±3(2741±43.5)
Rotate
MP 3 SPLV max. 210±3(3046±43.5)
RIGHT (gear motor) min. 189±3(2741±43.5)
3-33
Maintenance
Maintenance
Maintenance
3.13 Hydraulic system

• Release the pressure in all lines carrying hydraulic oil prior to any maintenance and
repair work. To do this:
• Lower all hydraulically controlled attachments to the ground
• Move all control levers of the hydraulic control valves several times
• Hydraulic oil escaping under high pressure can penetrate the skin and cause serious
injuries. Always consult a doctor immediately even if the wound seems insignificant –
otherwise serious infections could set in!
• If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has
penetrated the hydraulic system. This can cause damage to the hydraulic pump!
• Oil or fuel flowing out of high pressure lines can cause fire or malfunctions, and severe
injuries or damage to property. Interrupt work immediately if slack nuts or damaged
hoses and lines are detected.
☞ Contact your Wacker Wacker Neuson dealer immediately.
• Replace the hose or line if one of the problems mentioned below is detected.
☞ Damaged or leaky hydraulic seals.
☞ Worn or torn shells or uncovered reinforcement branches.
☞ Expanded shells in several positions.
☞ Entangled or crushed movable parts.
☞ Foreign bodies jammed or stuck in protective layers.
Caution!
Contaminated hydraulic oil, lack of oil or wrong hydraulic oil –
Danger of severe damage to the hydraulic system!
☞ Take care to avoid contamination when working!
☞ Always fill in hydraulic oil by means of a strainer or the reflux filter!
☞ Only use authorised oils of the same type
☞ Always fill up hydraulic oil before the level gets too low
– see Filling up hydraulic oil on page 3-36
☞ If the hydraulic system is filled with biodegradable oil, then only use
biodegradable oil of the same type for filling up – observe the sticker on the
hydraulic oil tank!
☞ Contact customer service if the hydraulic system filter is contaminated with
metal chippings. Otherwise, follow-on damage can result!
Environment!
Collect drained hydraulic oil and biodegradable oil in a suitable container! Dispose of
drained oil and used filters by an ecologically safe method. Always contact the relevant
authorities or commercial establishments in charge of oil disposal before disposing of
biodegradable oil.

Maintenance
Checking the hydraulic oil level

Caution!
Do not fill up oil if the oil level is above the FULLL mark, otherwise the hydraulic
system can be damaged and escaping oil can cause serious injuries.
☞ Check the hydraulic oil level each time the machine is put into operation or
once a day
• If the attachment is not positioned as shown:

☞ Start the engine and let it run at idling speed
☞ Retract the bucket and boom rams, lower the boom, the bucket teeth and the
stabiliser blade to the ground.
Fig. 38: Parking the excavator ☞ Switch off the engine again.
B
• Sight glass B is located at the rear of the excavator
• Check the oil level on sight glass B
• The oil level should be at the middle of the sight glass
• A yellowish colour of the entire sight glass is a sign that too much oil has been filled
Fig. 39: Oil level indicator on the hydraulic oil tank in
If the oil level is lower
• Fill up hydraulic oil
The oil level varies according to the machine's operating temperature:
Machine condition Temperature Oil level

• Before putting into Between 10 and 30 °C In the lower part of the sight glass
operation (50°F und 86°F)
• Normal operation Between 50 and 90 °C In the upper part of the sight
(122°F und 194°F) glass
Important!
Measure the oil level of the hydraulic system only after the machine reaches its
operating temperature.

Maintenance
Filling up hydraulic oil

Do not fill up the hydraulic oil unless the engine is switched off. Otherwise, hydraulic oil will
overflow at the filler opening on the hydraulic tank.
☞ Fill up as follows:
• Position the machine as shown in Fig. 38
• Clean the area around filler opening with a cloth
• Open the filler opening
• Fill in clean hydraulic oil through the strainer
• Check the hydraulic oil level on sight glass B
• Close the filler opening
Fig. 40: Hydraulic oil filler inlet with strainer
Important!
You can also refill through the reflux filter to avoid contamination of the hydraulic
oil as you fill up.
Changing hydraulic oil

Important!
Only change the hydraulic oil if it is warm (about 50 °C / about 122°F).
Retract all hydraulic rams before changing the oil.
☞ Open the breather filter to release pressure

☞ Take the drain hose (about 40 cm / 15.7" long) from the machine (screwed on the left-
hand side of the hydraulic oil tank)
☞ Drain the oil into a container
☞ Check the hydraulic oil tank for contamination and clean if necessary
☞ Replace the filter according to the maintenance specifications
☞ Close the drain hose correctly again and store it
☞ Fill in clean hydraulic oil through the strainer
B – see Filling up hydraulic oil on page 3-36
☞ Close the hydraulic oil tank correctly
Fig. 41: Hydraulic oil tank drain hose
☞ Let the machine run at idling speed without load for some minutes

Maintenance
Monitoring the hydraulic oil reflux filter

Pressure switch A activates the red telltale X in the instrument panel which monitors the
X reflux filter.
The control pressure is set at 2.5 bar (36 psi) and cannot be modified.
The filter element must be replaced by an authorised workshop:
• If telltale X comes on when the hydraulic oil is at operating temperature
• At the latest after 1000 service hours (once every year)
In cold weather telltale X can come on immediately when the engine is started. This is
caused by increased oil viscosity. In this case:
☞ Set engine speed so that telltale X goes out
Fig. 42: Telltale for reflux filter
Fig. 43: Reflux filter pressure switch

Maintenance
Checking hydraulic pressure lines Specific safety instructions
Danger!
Caution when checking hydraulic lines, especially when searching for leaks.
Hydraulic oil escaping under high pressure can penetrate the skin and cause
serious injuries.
☞ Always consult a doctor immediately, even if the wound seems insignificant
– otherwise serious infections could set in!
☞ Always observe the following instructions:
• Retighten leaking screwed fittings and hose connections only when the
system is not under pressure; i.e. release the pressure before working
on pressurised lines!
• Never weld or solder damaged or leaking pressure lines and screw
connections. Replace damaged parts with new ones!
• Never search for leaks with your bare hands, but wear protective gloves!
• Use paper or wood to check for minor leaks. Never use an unprotected
light or naked flame!
• Have damaged flexible lines replaced by authorised workshops only!
• Leaks and damaged pressure lines must be immediately repaired or replaced by an

authorised workshop or after-sales staff.
This not only increases the operating safety of your machine but also helps to protect
the environment.
• Replace hydraulic hoses every 6 years from the date of manufacture, even if they do
not seem to be damaged
In this respect, we recommend that you observe all the relevant safety regulations for
hydraulic lines, as well as the safety regulations regarding accident prevention and
occupational health and safety in your country. Also observe DIN 20066, part 5.
1 Q/00 The date of manufacture (month or quarter and year) is indicated on the flexible line.
Example:
The indication “ 1 Q/000” means manufactured in the 1st quarter of 2000.

Maintenance
3.14 Travelling drive

Danger!
Immediately after switching off the engine, the engine's components and the
oil are very hot. This can cause burns.
If the inside of the drive gear is under pressure, the oil or the plug can be
squeezed out.
Danger of injury and scalding!
☞ Wait until the engine has cooled down before taking up work.
☞ Slowly open the plug to reduce the pressure inside.
Caution!
The Q8 T55 SAE 85W-90 gearbox oil is no longer produced!
☞ Therefore the Q8 T55 80W-90 gearbox oil is used from 10/2006 onwards!
☞ Do not mix both oils under no circumstances!
Checking the oil level and filling up oil

☞ Park the machine on firm and horizontal ground
A
☞ Place the machine so that filler plug A is at the top
B ☞ Let the engine cool down
☞ Unscrew screws A and B with a suitable tool
Fig. 44: Checking the oil level ☞ A small quantity of oil must flow out of opening B
➥ If the oil does not flow out of opening B , fill up oil:
☞ Fill in oil through opening A ,
➥ until a small quantity of oil flows out of opening B
☞ Screw screws A and B back in again
☞ Move the machine a few metres
☞ Check the oil level again
➥ If the oil level is not correct:
☞ Repeat the procedure
Draining oil
☞ Park the machine on firm and horizontal ground
B
☞ Place the machine so that filler plug B is at the bottom
A ☞ Let the engine cool down
☞ Unscrew screws A and B with a suitable tool
Fig. 45: Draining oil ➥ The oil now flows out of opening A
☞ Use a suitable container to collect the oil as it drains
Environment!
Collect the oil with a suitable container and dispose of it in an environmentally friendly
manner.

Maintenance
3.15 Chains
• Chain wear can vary according to work and ground conditions.
☞ We recommend checking chain wear and tension once a day.
☞ Park the machine on firm and level ground to check and carry out maintenance.
Checking chain tension

Danger!
Working under the machine with the chains off the ground and only supported
by the attachment is extremely dangerous.
Caution, danger!
☞ Firmly support the machine with chocks or suitable brackets
Check chain tension as follows:

☞ Park the machine on firm and level ground
☞ Raise the excavator with the boom and the stick
☞ Slowly and carefully actuate the control levers
Fig. 46: Raising the excavator ☞ Use suitable auxiliary means to support the machine
• Standard play between the sliding block's shoulder and the contact area of the second
support roller of the drive pinion is 25-30 mm (1.0 - 1.2").
☞ If the tension of the steel or rubber chain is not in accordance with the rated value,
adjust the tension as follows.
25 – 30 mm
(1.0 - 1.2" )
Fig. 47: Measuring distance

Maintenance
Setting the chains

Danger!
The lubricating valve can be squeezed out due to the high grease pressure in
the hydraulic ram.
☞ Do not slacken and unscrew the lubricating valve by more than one turn.
☞ Slacken no other component except the lubricating valve.
☞ Keep your face away from the lubricating valve connection.
➥ Contact your Wacker Neuson dealer if this does not reduce the tension
of the rubber sliding block.
Caution!
Excessive tension of the chains causes severe damage to the ram and the
chain.
☞ Tighten the chains only up to the prescribed measuring distance
Tightening the chains

☞ Inject grease with the pump through lubricating valve A
☞ Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again
☞ Check the tension of the track chains again
➥ If it is not correct:
☞ Adjust again
☞ Should the track chain still be slack after injecting more grease, replace the chain or the
seal in the ram. Contact a Wacker Neuson dealer in this case
A
Fig. 48: Tightening the chains Reducing tension
• Draining grease in a way different from the one described below is very dangerous.
Also bear in mind the safety instructions on this page
☞ Slowly open the lubricating valve A by 1 turn to allow the grease to flow out.
☞ Place a suitable container underneath to collect the grease
➥ The grease flows out of the groove of the lubricating valve
☞ Retighten the lubricating valve A
A ☞ Check the tension is correct by starting the engine, letting it run at idling speed and
slowly moving the machine forwards and reverse and switching it off again
Fig. 49: Draining grease
☞ Check the tension of the track chains again
➥ If it is not correct:
☞ Adjust again
Environment!
Use a suitable container to collect the grease as it flows out and dispose of it in an
environmentally friendly manner.

Maintenance
3.16 Lubrication work

Apply multipurpose lithium grease with an MoS² additive to all lubrication points indicated.
Stabiliser blade
☞ Apply grease to lubrication points A on the stabiliser blade ram
☞ Apply grease to lubrication points B on the stabiliser blade
Fig. 50: Lubrication points on the stabiliser blade
Lubrication points on the swivelling console

☞ Apply grease to lubrication points C of the swivelling console
Fig. 51: Lubrication points on the swivelling console

Maintenance
Boom lubrication points

☞ Apply grease to lubrication points D on the boom
Fig. 52: Boom lubrication points
Lubrication points on the stick

☞ Apply grease to lubrication points E on the stick
Fig. 53: Lubrication points on the stick

Maintenance
Lubrication strip
Apply grease to the lubrication strip as follows:
☞ Lubrication point A for live ring ball bearing
➥ Grease: BP Energrease MP-MG2
C
☞ Lubrication point B for the offset ram
Important!
A
Apply grease to lubrication points A and B once a day.
B A portable lamp can be connected to the lubrication strip's 12 V connection C.
Fig. 54: Lubrication strip on the chassis
Maintenance of attachments
Important!
Correct maintenance and service is absolutely necessary for smooth and
continuous operation, and for an increased service life of the attachments. Please
observe the lubrication and maintenance instructions in the Operator's Manuals of
the attachments.

Maintenance
3.17 Electric system

• The battery contains sulphuric acid! This acid must not be allowed to come into contact
with the skin, the eyes, clothing or the machine.
Therefore when recharging or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with plenty of
water and seek medical attention at once!
• Especially when charging batteries, as well as during normal operation of batteries, an
oxyhydrogen mixture is formed in the battery cells – danger of explosion!
• Do not attempt to jump-start the machine if the battery is frozen or if the acid level is
low. The battery can rupture or explode!
☞ Replace the battery immediately
• Avoid naked flames and sparks and do not smoke in the vicinity of open battery cells –
otherwise the gas produced during normal battery operation can ignite!
• Use only 12 V power sources. Higher voltages will damage the electric components
• When connecting the battery leads, make sure the poles +/– are not inverted, otherwise
sensitive electric components will be damaged
• Do not interrupt voltage-carrying circuits at the battery terminals because of the danger
of sparking!
• Never place tools or other conductive articles on the battery – danger of short circuit!
• Disconnect the negative (––) battery terminal from the battery before starting repair work
on the electric system
• Dispose of used batteries properly
Service and maintenance work at regular intervals
Before driving the machine

☞ Check every time before driving the machine:
• Is the light system OK?
• Is the signalling and warning system OK?
Every week
☞ Check once a week:
• Electric fuses
– see Fuse box in instrument panel on page 2-5
• Cable and earth connections
• Battery charge condition
– see Battery on page 3-47
• Condition of battery terminals

Maintenance
Instructions concerning specific components

Cables, bulbs and fuses
Always observe the following instructions:
• Defective components of the electric system must always be replaced by an authorised
expert. Bulbs and fuses may be changed by unqualified persons
• When carrying out maintenance work on the electric system, pay particular attention to
ensuring good contact in leads and fuses
• Blown fuses indicate overloading or short circuits. The electric system must therefore
be checked before installing the new fuse
• Only use fuses with the specified load capacity (amperage)
– see Fuse box in instrument panel on page 2-5
Important!
Always disconnect and remove the battery before carrying out welding work on the
machine, and short-circuit the terminal cables of the machine to avoid damage to
the electronic components.
Alternator
Always observe the following instructions:
• Only test run the engine with the battery connected
• When connecting the battery, make sure the poles (+/–) are not inverted
• Always disconnect the battery before carrying out welding work or connecting a quick
battery charger
• Replace defective charge telltales immediately
– see Telltale (red) – alternator charge function on page 1-12

Maintenance
Battery
Danger!
Battery acid is highly caustic!
Danger of caustic injury!
Therefore when recharging and/or working near the battery:
☞ Always wear goggles and protective clothing with long sleeves
If acid is spilt:
☞ Thoroughly rinse all affected surfaces immediately with plenty of water
☞ Thoroughly wash any part of the body touched by the acid immediately with
plenty of water and seek medical attention at once!
Especially when charging batteries, as well as during normal operation of
batteries, an oxyhydrogen mixture is formed in the battery cells –
Danger of explosion!
☞ Avoid naked lights and sparks in the vicinity of the battery and do not
smoke!
☞ Do not attempt to jump-start the machine if the battery is frozen or if the
acid level is low. The battery can rupture or explode!
• Replace the battery immediately
☞ Always disconnect the negative terminal (–) from the battery before starting
repair work on the electric system!
Battery A is located in the engine compartment, on the right in driving direction. The
battery is “maintenance-free”. However have the battery checked at regular intervals to
make sure the electrolyte level is between the MIN and MAX marks.
Checking the battery requires it to be removed and must be carried out by an authorised
workshop.
A
Always follow the specific battery safety instructions!
+ - Important!
Do not disconnect the battery while the engine is running.
Fig. 55: Battery
• Jump-starting the engine:

☞ Connect the plus lead of the starting aid to the positive terminal of the flat battery
☞ Connect the earthing lead of the starting aid to a bare part of the chassis of the machine
with the flat battery
☞ Charge the flat battery for a few minutes
➥ Start the engine
☞ Remove the earthing lead of the starting aid from the chassis
☞ Remove the plus lead of the starting aid from the positive terminal of the battery on the
jump-started machine

Maintenance
3.18 Cab
☞ Check cab bearings B for damage
Important!
B Check the cab fastening screws for tightness, retighten with a suitable tool if
necessary
– see Tightening torques for high-resistance screw connections on page 2-9
Fig. 56: Cab bearing
Replacing the cab filter
Fresh/recirculated air filter

Remove the ventilation grill in the cab to replace the filter. Make sure not to overstretch the
cables of the fuse box as you tilt the grill. You can now see the filter mat.
Replacing the filter:

☞ Slacken the ventilation grill in the cab
Fig. 57: Cab filter ☞ You can now access the cab filter
☞ Remove the cab filter (lever out the clips with a screw driver)
☞ Insert a new cab filter
☞ Mount the cover of the ventilation in the cab back on again

Maintenance
3.19 General maintenance work

Cleaning
Cleaning the machine is divided into 3 separate areas:
• Inside the cab
• Exterior of the machine
• Engine compartment
The wrong choice of cleaning equipment and agents can impair the operating safety of the
machine on the one hand, and on the other undermine the health of the persons in charge
of cleaning the machine. It is therefore essential to observe the following instructions.
General instructions for all areas of the machine
When using washing solvents

• Ensure adequate room ventilation
• Wear suitable protective clothing
• Do not use flammable liquids, such as petrol or diesel
When using compressed air
• Work carefully
• Wear goggles and protective clothing
• Do not aim the compressed air at the skin or at other people
• Do not use compressed air for cleaning your clothing
When using a high-pressure cleaner or steam jet

• Electric components and damping material must be covered and not directly exposed
to the jet
• Cover the vent filter on the hydraulic oil tank and the filler caps for fuel, hydraulic oil etc.
• Protect the following components from moisture:
• Engine
• Electric components such as the alternator etc.
• Control devices and seals
• Air intake filters etc.
When using volatile and easily flammable anticorrosion agents and sprays:
• Ensure adequate room ventilation
• Do not use unprotected lights or naked flames
• Do not smoke!

Maintenance
Inside the cab

Caution!
Never use high-pressure cleaners, steam jets or high-pressure water to clean
inside the cab. Water under high pressure can
• penetrate into the electric system and cause short circuits and
• damage seals and disable the controls!
We recommend using the following aids to clean the cab:
• Broom
• Vacuum cleaner
• Damp cloth
• Bristle brush
• Water with mild soap solution
Cleaning the seat belt:

• Clean the seat belt (which remains fitted in the machine) only with a mild soap solution;
do not use chemical agents as they can destroy the fabric!
Exterior of the machinee The following articles are generally suitable:

• High-pressure cleaner
• Steam jet
Engine compartment
Danger!
Clean the engine at engine standstill only –
☞ Switch off the engine before cleaning
Caution!
When cleaning the engine with a water or steam jet
☞ The engine must be cold
☞ and do not point the jet directly at electric sensors such as the oil pressure
switch.
The humidity penetrating any such sensors causes them to fail and leads to
engine damage!
Screw connections and attachments

All screw connections must be checked regularly for tightness, even if they are not listed in
the maintenance schedules.
Retighten loose connections immediately. Contact an authorised workshop if necessary.
Pivots and hinges

All mechanical pivot points on the machine (e.g. door hinges, joints) and fittings (e.g. door
arresters) must be lubricated regularly, even if they are not listed in the lubrication plan.

Engine
4
4.1
Air intake
incl. preheater
Engine

Engine
Oil filler neck

Engine overview 3TNV88-PNS (Tier 2)
Fuel injection pump
Fuel filter
Engine oil filter
Oil dipstick
Oil pressure switch

Engine
4-1
4-2
Engine
Cylinder-head cover
Exhaust manifold
Water pump
Starter
Tightening bracket
Fan blade Alternator
V-belt

4.2
Filler inlet Sintered metal filter
Reflux
Fuel system

Tank
Feed line
Water separator
with stop cock
Fuel injection
pump
Fuel filter
Fuel pump
Engine
4-3
Engine
4.3 Checking and adjusting valve tip clearance

☞ Standard setting of valve tip clearance is possible:
➥ On a cold engine
☞ Remove the cylinder-head cover

☞ Turn the engine with a screwdriver (as in 4.7) until the cylinder reaches the top dead
normal abnormal centre of the compression cycle.
➥ Valve overlapping
Fig. 1: Valve cap wear
☞ Check the valve cap for abnormal wear
☞ Check valve tip clearance 2/AA with a feeler gauge
➥ Valve tip clearance:0.15 – 0.25 mm (0.006 - 0.01")
☞ Repeat the procedure for each cylinder

A
☞ Place the cylinder head cover gasket
☞ Mount the cylinder-head cover
Fig. 2: Checking valve tip clearance

Engine
4.4 Tightening order for cylinder head bolts

☞ Order for removing the cylinder-head bolts
V-belt side
Important!
Always carry out work on the cylinder head on a cold engine!
Caution!
Bear in the mind the order for tightening the cylinder-head bolts!
☞ See figure
V-belt side
Important!
Apply oil to the threads and contact surfaces before mounting.
☞ Mount the cylinder-head bolts

➥ Tightening torques:
• 1st pass 41,1 - 46,9 Nm (30.31 - 34.59 lbf ft)
• 2nd pass 85,3 - 91,1 Nm (62.91 - 67.19 lbf ft)

Engine
4.5 Checking the injection nozzles

Pressure check
☞ Remove the injection line and the injection nozzle
☞ Connect the injection nozzle with the high pressure line of the nozzle tester
☞ Slowly increase pressure until the nozzle ejects fuel and read the pressure off the
pressure gauge
☞ If the injection pressure is too low, replace the spacer in the nozzle by a thicker one.
If the pressure is too high, replace the spacer by a thinner one.
➥ Injection pressure: 216 - 226 bar (3133 - 3278 psi)
• Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar
Fig. 3: Nozzle tester (276 psi)
• Check the injection nozzle for drips after it has ejected fuel
☞ Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel escapes from the nozzle
Upper nozzle screw fitting Pressure spring centring Lower nozzle screw fitting
Leak oil line Spacers Compression Nozzle needle
spring seat
Compression Nozzle body
spring
4.6 Checking the nozzle jet

☞ Remove the injection lines and the injection nozzles
☞ Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times)
☞ Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle
eject fuel
☞ The nozzle jet must create a shape on the paper as shown in Fig. 4/1
optimal --------------variation--------------
Fig. 4: Shape of nozzle jet

Engine
4.7 Injection time

Checking injection time
• Preparatory work:
☞ Remove the high pressure injection lines first.
☞ Unscrew plug 5/1 of the piston.
☞ Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
1 ☞ Screw the dial gauge into the bore of the piston as shown in Fig. 5.
• Measurement:
☞ Remove the rubber plug from the flywheel housing
☞ Turn the ring gear on the flywheel with a screwdriver until the piston reaches the lowest
point in the fuel injection pump (proceed by comparing with the first cylinder)
☞ Set the measuring equipment to “0”
☞ Continue turning the ring gear upwards on the flywheel with the screwdriver until the
piston in the fuel injection pump reaches a stroke of 2.5 mm (0.1").
Fig. 5: Measuring equipment

Engine
☞ Read the degrees before top dead centre by means of the indentations on the flywheel
• Mark the “1/4” and “2/3” indents (top dead centre)
• In front of each of these indents, there are 3 more indents without numbers. These
indents stand for 10°, 15° and 20° before top dead centre
➥ Rated value: 14.5° + 1° before top dead centre (~ second indentation)
Fig. 7: Top dead centre indentation and 10° before top

dead centre
Setting injection time

• Variations outside the tolerance range can be corrected by turning the fuel injection
pump.
☞ Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump – see Fig. 8
☞ Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
about ½ a revolution (do not unscrew completely)
☞ Rotate the pump in the required direction, and tighten one of the screws before you
check the setting
Label for setting
➥ Rotated towards the engine: earlier injection time
➥ Rotated away from the engine: later injection time
☞ Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted
Fig. 8: Mark on housing
☞ Check injection time again
☞ Adhesive label number 1000158808
Replacement of fuel injection pump
Mark on pump housing ☞ Mark the initial position on the pump and wheel case housing before removing the fuel
Labels injection pump – see fig. 9
☞ Remove gear casing cover 10/1 of the fuel injection pump
☞ Mark the position of the gear of the fuel injection pump 11/AA with respect to gear 11/B
– see fig. 11
☞ Completely slacken lock nut 11/2 of the drive pinion
Example: +1° Example: +0.25°
Fig. 9: Correction of injection angle
☞ Remove the fuel injection pump

☞ Read off the injection angle on the pump
☞ Read off the injection angle on the new pump
➥ Read off the imprint on the engine side of the fuel injection pump
Fig. 10: Gear casing

Engine
☞ Difference of “Angle of new pump” – “Angle of old pump” gives you the mounting angle
2 of the new fuel injection pump
➥ Positive value: later injection time (away from the engine)
A ➥ Negative value: earlier injection time (towards the engine)
☞ Install the new fuel injection pump

☞ Check the marked position of the drive pinion of the fuel injection pump (fig. 11)
B ☞ Screw on and tighten nut 11/2
Fig. 11: Gear casing ☞ Check injection time
☞ Mount gear casing cover 10/1 of the fuel injection pump
Important!
Do not slacken screws 12/33 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
A manufacturer!
3 B
4.8 Adjusting engine revs
Important!
The maximum engine revs are set and sealed by the manufacturer without the
pump and may not be modified!
Adjust engine revs without load!

☞ Run the diesel engine until it reaches operating temperature
A
☞ Check idling speed A and maximum revs B with all attachment functions in neutral
➥ Idling speed 1100 ± 50 rpm
➥ Max. revs: 2500 ± 10 rpm
☞ Adjust as shown if values differ.
Fig. 13: Adjusting engine revs
4.9 Compression
☞ Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid)
☞ Turn the engine
☞ Mount the compression gauge on the cylinder you want to measure
☞ Turn the engine with the starter and read the pressure off the pressure gauge
➥ Specified value: 34,3 ± 1 bar bei 250U/min (497.5 ± 14.5 psi at 250 rpm)
➥ Threshold value: 28 ± 1 bar bei 250U/min (406 ± 14.5 psi at 250 rpm)
Fig. 14: Compression

Engine
4.10 Checking the coolant thermostat

☞ Remove the thermostat
➥ The thermostat is located on the water pump
– see Engine overview 3TNV88-PNS (Tier 2) on page 4-1
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 15: Coolant thermostat
☞ Warm up the thermostat in a container with water

Thermometer
☞ Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge)
➥ Thermostat opening temperature: 69.5 – 72.5 °C (157.1 - 162.5°F)

Engine
4.11 Checking the thermal switch

☞ Remove the thermal switch
Thermometer
☞ Warm up the thermal switch in a container with antifreeze or oil
☞ Measure the resistance of the thermal switch as shown by means of an ohmmeter.
➥ The switch must allow the coolant to pass at a temperature of 107 – 113 °C
(224.6 - 235.4°F)).
Test prods
Fig. 16: Checking the thermal switch
4.12 Oil pressure switch

☞ Remove the cable connection from the oil pressure switch (in the area of the cutoff
Measurement solenoid)
prod ☞ Start the engine, check for correct idling speed
☞ Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
➥ Oil pressure switch OK: infinite resistance
➥ The oil pressure switch is defective if the oil can pass
Fig. 17: Oil pressure switch
4.13 Checking the coolant circuit

Leakage check
☞ Fill up the radiator completely
☞ Mount an adapter on the radiator as shown
☞ Increase the pressure in the cooling system by means of a hand pump to about 1 bar
(15 psi )
➥ Check the lines and the connections for leaks if the pressure drops at the pressure
Fig. 18: Checking the radiator for leaks
gauge
Checking the radiator cap
☞ Remove the radiator cap and mount it onto the adapter as shown
☞ Increase the pressure to about 1 bar / 15 psi (stamped onto the radiator cap) with the
hand pump
➥ The radiator cap must open
Radiator cap
Fig. 19: Checking the radiator cap

4-12
Air intake 4.1
Engine
Engine
Sheathed-element
heater plugs
Oil filler neck

Engine overview 3TNV88-BPNS (Tier 3A)
Fuel injection pump
Fuel filter
Engine oil filter
Oil dipstick
Oil pressure switch
SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm

Cylinder-head cover
Exhaust manifold

Water pump
Starter
Fan blade Tightening bracket
Alternator
V-belt
Engine
4-13
4-14
4.2
Sintered metal filter
Engine
Fuel radiator
Filler inlet
Fuel system
Tank Reflux
Feed line
Water separator
with stop cock
Fuel injection pump
Fuel filter
Fuel pump

Engine
4.3 Removing the cylinder-head cover
Important!
In order to avoid damage to the glow elements, remove them before removing the
cylinder head.
How to remove:
☞ Remove all dirt on the engine with a lint-free cloth

☞ Unscrew all hoses and fuel injection lines from the valve cover
☞ Remove the air intake and the exhaust manifold
☞ Unscrew and remove the valve cover
Fig. 1: Removing the valve cover
4.4 Checking and adjusting valve tip clearance

☞ Standard setting of valve tip clearance is possible:
➥ On a cold engine
☞ Turn the engine with a screwdriver (as in 4.7) until the cylinder reaches the top dead
centre of the compression cycle.
normal abnormal ➥ Valve overlapping
☞ Check the valve cap for abnormal wear
Fig. 2: Valve cap wear
☞ Check valve tip clearance 2/AA with a feeler gauge
➥ Valve tip clearance:0.15 – 0.25 mm (0.006 - 0.01")
☞ Repeat the procedure for each cylinder

A
☞ Put the cylinder head cover gasket in place
☞ Mount the cylinder-head cover
Fig. 3: Checking valve tip clearance
SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm 4-15

Engine
4.5 Tightening order for cylinder head bolts

☞ Order for removing the cylinder-head bolts
V-belt side
☞ Mount the cylinder-head bolts
➥ Tightening torques:
• 1st pass 42,6 - 45,5 Nm (31.4 - 33.6 lbf ft)
• 2nd pass 85,3 - 91,1 Nm (62.9 - 67.2 lbf ft)
Caution!
Bear in the mind the order for tightening the cylinder-head bolts!
☞ See figure
V-belt side
Important!
Apply oil to the threads and contact surfaces before mounting.
Important!
Always carry out work on the cylinder head on a cold engine!
4-16 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s420_Tier 3.fm

Engine
4.6 Checking the injection nozzles

Pressure check
☞ Remove the injection line and the injection nozzle
☞ Slowly increase pressure until the nozzle ejects fuel and read the pressure off the
pressure gauge
☞ If the injection pressure is too low, replace the spacer in the nozzle by a thicker one.
If the pressure is too high, replace the spacer by a thinner one.
➥ Injection pressure: 196 - 206 bar (2843 - 2988 psi)
• Spacer thickness of 0.1 mm (0.004") corresponds to modification by 19 bar (276 psi)
Fig. 4: Nozzle tester
• Check the injection nozzle for drips after it has ejected fuel
☞ Create a pressure of about 20 bar (290 psi) below injection pressure and check
whether fuel escapes from the nozzle
Upper nozzle screw fitting Pressure spring centring Lower nozzle screw fitting
Leak oil line Spacers Compression Nozzle needle
spring seat
Compression Nozzle body
spring
4.7 Checking the nozzle jet

☞ Quickly create pressure until the nozzle ejects fuel (ejection 3 – 4 times)
☞ Hold a white sheet of paper about 30 cm (12") away from the nozzle and let the nozzle
eject fuel
☞ The nozzle jet must create a shape on the paper as shown in Fig. 5/1
optimal Variation
Fig. 5: Shape of nozzle jet

Engine
4.8 Injection time

Checking injection time
• Preparatory work:
☞ Remove all dirt on the engine with a lint-free cloth
☞ Remove the high pressure fuel injection lines
☞ Unscrew plug Fig. 6/1 of the piston.
☞ Mount the sleeve (no. 1000158805) and the extension (no. 1000158806) onto the dial
1 gauge (no. 1000158807) and fasten them with a clamp (no. 1000083308).
☞ Screw the dial gauge into the bore of the piston as shown in Fig. 6.
• Measurement:
☞ Remove the rubber plug from the flywheel housing
☞ Turn the ring gear on the flywheel with a screwdriver until the piston reaches the lowest
point in the fuel injection pump (proceed by comparing with the first cylinder), or turn at
the front on the crankshaft disc with a key (WAF 19)
☞ Set the measuring equipment to “0”
☞ Continue turning the ring gear upwards on the flywheel with the screwdriver until the
piston in the fuel injection pump reaches a stroke of 2.5 mm (0.1").

Engine
☞ Read the degrees before top dead centre by means of the indentations on the flywheel
• Mark the “1/4” and “2/3” indents (top dead centre)
• In front of each of these indents, there are 3 more indents without numbers. These
indents stand for 10°, 15° and 20° before top dead centre
Fig. 8: Top dead centre indentation and 10° before top

dead centre
➥ Rated value: calculation according to Yanmar manual:

value on injection pump (in this case: 6.8 see Fig. 11 ) x 2 + FIR
(FIR for 38Z3 = 4.5)
Setting injection time

• Variations outside the tolerance range can be corrected by turning the fuel injection
pump.
☞ Mark the initial position on the pump and wheel case housing before setting the fuel
injection pump – see Fig. 9
☞ Remove all injection lines on the fuel injection pump and slacken the 4 flange screws by
Label for setting about ½ a revolution (do not unscrew completely)
☞ Rotate the pump in the required direction, and tighten one of the screws before you
check the setting
➥ Rotated towards the engine: later injection time
➥ Rotated away from the engine: earlier injection time
☞ Bend each of the injection lines before you mount them so they are not subject to
tension once they are mounted
Fig. 9: Mark on housing
☞ Check injection time again

Engine
Replacement of fuel injection pump

Mark on pump housing ☞ Mark the initial position on the pump and wheel case housing before removing the fuel
Labels injection pump – see Fig. 10
☞ Remove gear casing cover 11/1 of the fuel injection pump
☞ Turn the engine until the indents on the gears coincide
☞ Completely slacken lock nut 122/2 of the drive pinion
Example: +1° Example: +0.25°
Fig. 10: Correction of injection angle
☞ Remove the fuel injection pump

☞ Read off the injection angle on the pump
☞ Read off the injection angle on the new pump
➥ Read off the imprint on the engine side of the fuel injection pump
1
• Tightening torque: 23 – 28 Nm (17 - 21 lbf ft)

Fig. 11: Gear casing imprint
☞ Difference of “Angle of new pump” – “Angle of old pump” gives you the mounting angle
2 of the new fuel injection pump
➥ Positive value: earlier injection time (towards the engine)
A ➥ Negative value: later injection time (away from the engine)
☞ Install the new fuel injection pump
☞ Check the marked position of the drive pinion of the fuel injection pump (fig. 12)
B ☞ Slacken and tighten nut 12/2 (tightening torque: 23 – 28 Nm / 17 - 21 lbf ft)
☞ Check injection time
☞ Mount gear casing cover 11/1 of the fuel injection pump
• Tightening torque: 78 – 88 Nm (58 - 65 lbf ft)
• If a front housing cover is installed, the drive wheel of the injection pump is adapted to
the impeller by means of marks A,B,C (see Fig. 12):
• 1...Injection pump drive wheel 2...Camshaft drive wheel
3...Auxiliary drive wheel (option) 4...Crankshaft drive wheel
5...Direction of rotation 6...Fuel pump drive wheel (4TNV only)
7...Impeller
Important!
A Do not slacken screws 13/33 of the drive pinion of the fuel injection pump. These
screws specify the precision setting of the fuel injection pump set by the
manufacturer!
3 B

Engine
4.9 Adjusting engine revs
Important!
The maximum engine revs are set and sealed by the manufacturer without the
pump and may not be modified!
Adjust engine revs without load!

☞ Run the diesel engine until it reaches operating temperature
A
☞ Check idling speed A and maximum revs B with all attachment functions in neutral
➥ Idling speed 1100 ± 50 rpm
B
➥ Max. revs: 2500 ± 10 rpm
☞ Adjust as shown if values differ.
Fig. 14: Adjusting engine revs
4.10 Compression
☞ Set the fuel injection pump to zero delivery (remove the plug for the cutoff solenoid)
☞ Turn the engine
☞ Mount the compression gauge on the cylinder you want to measure
☞ Turn the engine with the starter and read the pressure off the pressure gauge
➥ Specified value: 33,3 - 35,3 bar bei 250U/min (483 - 512 psi at 250 rpm)
➥ Threshold value: 26,5 - 28,5 bar bei 250U/min (384 - 413 psi at 250 rpm)
Fig. 15: Compression
4.11 Checking the coolant thermostat

☞ Remove the thermostat
➥ The thermostat is located on the water pump
– see on page 4-13
Housing cover
Thermostat
Seal
Housing
Thermal switch
Fig. 16: Coolant thermostat

Engine
☞ Warm up the thermostat in a container with water

Thermometer
☞ Check whether the thermostat opens at the specified temperature (check with a
Thermal switch temperature gauge)
➥ Thermostat opening temperature: 69,5 - 72,5 °C (157.1 - 162.5°F)
4.12 Checking the thermal switch

☞ Remove the thermal switch
Thermometer
☞ Warm up the thermal switch in a container with antifreeze or oil
☞ Measure the resistance of the thermal switch as shown by means of an ohmmeter.
➥ The switch must allow the coolant to pass at a temperature of 107 - 113°C
(224.6 - 235.4°F)).
Test prods
Fig. 17: Checking the thermal switch
4.13 Oil pressure switch

☞ Remove the cable connection from the oil pressure switch (in the area of the cutoff
Measurement solenoid)
prod ☞ Start the engine, check for correct idling speed
☞ Measure the resistance of the oil pressure switch as shown by means of an ohmmeter.
➥ Oil pressure switch OK: infinite resistance
➥ The oil pressure switch is defective if the oil can pass
Fig. 18: Oil pressure switch

Engine
4.14 Checking the coolant circuit

Leakage check
☞ Fill up the radiator completely
☞ Mount an adapter on the radiator as shown
☞ Increase the pressure in the cooling system by means of a hand pump to about 1 bar
(15 psi )
➥ Check the lines and the connections for leaks if the pressure drops at the pressure
Fig. 19: Checking the radiator for leaks
gauge
Checking the radiator cap
☞ Remove the radiator cap and mount it onto the adapter as shown
☞ Increase the pressure to about 1 bar / 15 psi (stamped onto the radiator cap) with the
hand pump
➥ The radiator cap must open
Radiator cap
Fig. 20: Checking the radiator cap
4.15 Engine trouble
Problem Possible causes

No fuel
Air in fuel system
Wrong SAE grade of engine lubrication oil
Fuel grade does not comply with specifications
Defective or flat battery
Loose or oxidised cable connections in starter circuit
Defective starter, or pinion does not engage
Engine does not start or is not easy to start Wrong valve tip clearance
Defective fuel injector
Defective starting relay
Defective glow plug
Defective solenoid switch
Cutoff solenoid does not attract
Cutoff solenoid without current
High pressure created immediately in the hydraulic system
Wrong valve tip clearance
Engine starts, but does not run smoothly or faultless Injection line leaks
Air in fuel system

Engine

Oil level too low
Damaged water pump
Oil level too high
Dirty air filter
Engine overheats. Temperature warning system responds Dirty cooler fins
Defective fan, torn or loose V-belt
Defective thermostat
Resistance in cooling system too high, flow capacity too low
Oil level too high
Dirty air filter
Insufficient engine output Wrong valve tip clearance
Air in fuel system
Injection line leaks
Injection line leaks
Engine does not run on all cylinders
Oil level too low
Defective engine oil pump
Insufficient or no engine oil pressure Machine inclination too high
Clogged engine oil intake filter
Wrong SAE grade of engine lubrication oil
Oil level too high
Engine oil consumption too high
Machine inclination too high
Oil level too high
Blue Machine inclination too high
Engine oil combustion (defective cylinder-head gasket)
Engine starting temperature too low
White
Engine smoke Wrong valve tip clearance
Coolant combustion (defective cylinder-head gasket)
Exteme misalignment of injection time
Dirty air filter
Wrong valve tip clearance
Black
Defective fuel injector (drips)
Wrong fuel injection pump setting

Hydraulic system
Hydraulic system
Hydraulic system
5 Hydraulic system
The hydraulic system is governed by a throttle
5.1 Hydraulic pump PVD-1B-32BP-11G5-4904A (up to AE02803)

PVD-1B-34BP-10G5 (from AG00573)
Double variable displacement pump + 2 gear pumps
Pilot oil supply unit
7 6
4
3
Gear pump unit Variable displacement pump unit
Pos. Description
1 Port P4
2 Pressure limiting valve
3 Bleed screw
4 Port P1
5 Control initiation set screw
6 Port P2
7 Port P3

Hydraulic system
4 5
Variable displacement pump unit Gear pump unit
Pos. Description
1 Control initiation set screw
2 Suction line Port
3 Port PR (2nd speed range)
4 Port PV (gear motor brake release supply)
5 Pilot valve supply

Hydraulic system
Pump unit: exploded view
2
4
1 5
6
10
3
11 7
12 6
13
18
17 16
15
14
Pos. Description Pos. Description

1 Drive unit 10 Gear pump
2 Swash plate 11 O-ring
3 Ball 12 O-ring
4 Stop stud 13 O-ring
5 Stop pin 14 Pilot oil supply unit
6 Spring 15 Solenoid switch
7 Stop pin 16 Solenoid switch
8 Grooved ball bearing 17 Fastening screw
Variable displacement
9 Rotary shaft lip seal 18
pump sealing kit

Hydraulic system
Pilot oil supply unit
1 2 3 4 5
BAR
9 8 7
Both valves can be interchanged
3 5 7
Pos. Description Port

1 Gear motor brake release supply PR
2 Pilot valve supply BV
3 Solenoid valve for safety valve
4 Drives/2nd speed range supply PV
5 2nd speed range solenoid valve
6 Pump 4 supply Internal to P4
7 Pressure limiting valve
8 Tank line
9 Accumulator

Hydraulic system
5.2 Main valve block

Ports
Bucket B1 A1
Boom T1 A2
B2
Right-hand side drive B3 A3
Input P1 P2 P1 P2
Left-hand side drive B4 A4
Stick B5 A5
Auxiliary hydraulics/swivel boom B6 A6
Auxiliary hydraulics flow rate

adjustment segment
3rd control circuit (option) B7 A7
Stabiliser blade B8 A8
Rotating the upper carriage

B9 A9
Straight ahead
T2 P3

Hydraulic system
Legend
Main control lines
Port Legend
A1, B1 Bucket ram
A2, B2 Boom ram
A3, B3 Drive (left) via swivel joint
A4, B4 Drive (right) via swivel joint
A5, B5 Stick ram
A6, B6 Auxiliary hydraulics/boom swivel
A7, B7 3rd control circuit (option)
A8, B8 Stabiliser blade
A9, B9 Upper carriage rotation
T2 , P3 Straight ahead
Pump/tank lines
Port Legend
P1 Pump 1 port
P2 Pump 2 port
P3 Pump 3 port
T1 Tank line via non-return valve and filter in tank
T2 Tank line via oil cooler and filter in tank
S: bucket pre-tension
– see Bucket pre-tension on page 5-11

Hydraulic system
Main valve block diagram
Bucket
Boom
Right-hand side drive
Input P1
Input P2
Left-hand side drive
Stick
Auxiliary hydraulics/
swivel boom
3rd control circuit
Stabiliser blade
Rotating the upper

carriage
Drive counterbalancing
system P3

Hydraulic system
Pressure limiting valves
1 4
7
2
3 8
11 9
10
Pos. Description
1 Secondary pressure limiting valve (bucket base side)
2 Primary pressure limiting valve P1
3 Secondary pressure limiting valve (stick rod side)
4 Secondary pressure limiting valve (bucket rod side)
5 Secondary pressure limiting valve (boom rod side)
6 Secondary pressure limiting valve (boom base side)
8 Secondary pressure limiting valve (stick base side)
9 Secondary pressure limiting valve (stabiliser blade base side)
11 Anticavitation valve

Hydraulic system
Pump assignment
Hydraulic supply by pump 1
• Bucket section
• Boom section
• Right-hand side drive section
• Left-hand side drive section
• Stick section
• Auxiliary hydraulics/boom swivel section
• 3rd control circuit section (option)
• Stabiliser blade section
• Upper carriage rotation section
• Drive counterbalancing system section
Bucket
Pump 1
Boom
Right-hand
side drive
Input P1 P2
Left-hand side
drive
Stick
Pump 2
Auxiliary hydraulics/swivel boom
Auxiliary hydraulics flow

rate adjustment segment
3rd control circuit
(option)
Pump 3
Stabiliser blade
Rotating the upper
carriage
Input P3 Drive
output T2 counterbalancing
system

Hydraulic system
5.3 Drive counterbalancing system

Without drive counterbalancing system
Actuating the boom as you drive causes the machine to leave its track!
(P1, P2 each supply a drive, and the boom function is also governed by P1 or P2)
With drive counterbalancing system
If the boom is actuated as you drive straight ahead, the machine stays in its track, but drive
speed does not remain constant.
The drive counterbalancing system is activated with right-hand side drive and a boom
function (bucket, boom, stick or auxiliary hydraulics).
Function
☞ The drive counterbalancing system is enabled by means of an increased banking-up
pressure if both piston valves for driving and a boom function are activated.
➥ P3 takes over all boom functions
Pump assignment for drive counterbalancing

• Right-hand side drive section
• Left-hand side drive section
• Bucket section
• Boom section
• Stick section
• Auxiliary hydraulics/boom swivel section
• 3rd control circuit section (option)
• Stabiliser blade section
• Swivel unit section
• Drive counterbalancing system section

Hydraulic system
5.4 Regeneration – stick section

Problem
High loads on the stick can cause the stick ram to be “emptied” on the base side, which
can cause the stick to stop in vertical position.
Solution
A non-return valve is integrated in the stick segment so the rod-side oil can flow to the
base side.
Location
The regeneration valve is located in the stick segment on the lower side.
5.5 Bucket pre-tension

A nozzle is integrated in the pressure line of the bucket segment. If the bucket and the
boom (both supplied with oil by the same pump) are actuated at the same time, both move
simultaneously, and not the bucket (with its smaller mass) first, and then the boom with its
larger mass – see Main valve block diagram on page 5-7.
Location

Hydraulic system
5.6 Flow rate adjustment of auxiliary hydraulics

The available oil quantity at the auxiliary hydraulics ports can be modified by means of set
screws A or B on the main valve block.
Set screw – see Pressure limiting valves on page 5-8
Important!
The effect described below is achieved by simply opening one of the set screws.
There are two possible positions: – see Auxiliary hydraulics oil flow on page 2-3
Set screw “ against hydraulic resistance”

The valve seat is closed in this position
• P2 + P3 supply the auxiliary hydraulics section with oil
• Factory setting
“ Open” set screw
Unscrew the valve seat by at least 2 revolutions, but no more than 3, to open the valve
seat completely.
• P2 supplies the auxiliary hydraulics section with oil
• The oil supplied by P3 flows to the tank via the open valve seat.
Important!
Intermediate positions of the set screws cause the hydraulic oil to warm up –
danger of overheating!
A B

Hydraulic system
5.7 Pilot valves

Joystick • Pilot valve for bucket, boom, stick and rotation
• Consists of a lever and four pressure reducing valves
Numbering for right-hand side joystick.

Left-hand side joystick: 3-1-2-4
2 4 3 1
A
Set of tappets = sealing kit

Article no.: 1000021259
E
F P
T
Pressure (bar)
Joystick characteristic curve
Joystick
position
(degrees)
Pos. Description Pos. Description (left-hand side joystick) Description (right-hand side joystick)
A Control lever 1 Stick extension control Offset ram extension control
B Rubber collar 2 Left-hand side rotation control Bucket ram extension control
C Linkage 3 Stick retraction control Offset ram retraction control
D Universal joint 4 Right-hand side rotation control Bucket ram retraction control
E Guide plate P Supply from pilot oil supply unit Supply from pilot oil supply unit
F Tappet T Tank line Tank line

Hydraulic system
Joystick up to model: AD05131 Joystick from model: AD05132
Pilot control filter V is inserted in the pump line instead of the GE

screw fitting.
Important!
Check the pilot control filter screen for dirt and clean or
replace if necessary.
Coarse dirt causes joystick and drive valve malfunctions and
can even destroy the filter insert.

Hydraulic system
Pilot valve (driving)

• Pedal with hydraulic damping
• Consists of two pedals and four pressure reducing valves
3 7

Characteristic curve for

Pressure (bar) drive pilot valve

¼
¼
7

3
3
Pilot valve piston stroke (mm)

²gÌ ²gÌ ²gÌ

²g ² ²g
Joystick position (degrees)
V
Pos. Description
1 Left-hand side drive segment control
2 Left-hand side drive segment control
3 Right-hand side drive segment control
4 Right-hand side drive segment control
5 Non-return valve
P Pilot control pressure
T Tank line
V Pilot control filter

Hydraulic system
3
E
5
4

no.: 1000069330
6
Pos. Description
1 Bellows
2 Shift unit (kit)
3 Plate (kit)
4 Tappet
5 Non-return valve (also used for bleeding pedal damping)
6 Damping

Hydraulic system
Pilot valve for auxiliary hydraulics

• Pilot control unit with pedals for remote control of directional valves
• Consists of a pedal and two pressure reducing valves
1 2
0$ 1P
B
0 1P
$
C
D
Article no.: 1000012382
4
3
Characteristic curve for
Pressure (bar) drive pilot valve

F

Pilot valve piston stroke (mm)

j
j
j

Joystick position (degrees)

A Pedal 1 Auxiliary hydraulics control/offset ram extension control
B Pedal fixture 2 Auxiliary hydraulics control/offset ram retraction control
C Protective caps 3 Tank line
D Mounting plate 4 Supply from pilot oil supply unit
E Tappet
F Spring

Hydraulic system
5.8 Valves
7/2 directional valve (changeover valve)
Switches from auxiliary hydraulics (valve de-energised) to boom swivel and vice versa
(valve energised).
Electric control via push button on left-hand side joystick.
C1 C2
Pos. Port
A1 Main valve block
A2 Main valve block
B1 Boom swivel
B2 Boom swivel
C1 Auxiliary hydraulics
C2 Auxiliary hydraulics
L Leak oil

Hydraulic system
Changeover valve for SAE/ISO controls (option)

The directional valve is located under cover I in the floor panel of the cab.
☞ Open the cover in the base plate (4 screws)
☞ You can now see the lever of the changeover valve
I
☞ Change over
☞ Screw the cover back on again
Fig. 1: Directional valve position
Switching from ISO to SAE controls and vice versa with the directional valve
1 5
Position Function
• A ➥ ISO controls
2 6 • B ➥ SAE controls
☞ Tighten wing nut J after changing control mode

3 7
Danger!
4 8
Changing the directional valve over modifies the controls (control levers) –
☞ Make sure you know which control mode has been selected before starting
work
☞ Always secure wing nut J on the changeover lever of the directional valve
J
A B
Directional valve ports
1 Joystick (right) port 1
Fig. 2: Directional valve
2 Offset ram retraction control
3 Joystick (right) port 3
4 Main valve block, offset ram extension control
5 Main valve block, stick ram extension control
6 Joystick (left) port 1
7 Main valve block, stick ram retraction control
8 Joystick (left) port 3

Hydraulic system
5.9 Travelling drive up to no. AE00854
1 2 3
Pos. Description
1 Drive port (-> swivel joint 2/7)
3 Leak oil port (-> swivel joint 1)
4 Forwards/reverse directional valve
5 2nd speed range port (-> swivel joint 8)
6 2nd speed range directional valve
7 Brake piston

Hydraulic system
Function
Driving:
If high pressure is applied to one of the drives, the brake release piston is actuated first
and passes high pressure on to the brake cylinder, which releases the brake. The throttle
slowly actuates the brake piston at the same time. Brake piston control causes high
pressure to be applied to the motor, which starts turning.
Stopping:
The oil flows from both ports to the tank upon releasing the joystick. The brake piston
slowly returns to home position by means of the throttle orifices. The slow drop of the
brake piston prevents the hydraulic motor from coming to an abrupt standstill. With the
brake piston in neutral position, the ports are no longer connected to the motor, which can
no longer turn. The brake release pressure is reduced via both throttles shortly afterwards.
2 speed range functions

Speed range 1
• 2nd speed range switch: switched off
The directional valve for the 2nd speed range remains in home position (position as shown
in diagram), and the hydraulic motor's swash plate is in maximum capacity position.
➥ The motor runs at low speed.
Speed range 2
• 2nd speed range switch: switched on
The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash
plate is in minimum capacity position.
The motor runs at high speed.

Hydraulic system
Pos. Description
1 Travelling drive
2 Screw connection
3 Screw connection
4 Screw connection
5 Cover
6 Hydraulic motor sealing kit
7 Hydraulic motor
8 Lifetime seal
9 Travelling drive brake
10 Valve set
11 Piston valve for speed range
12 Brake valve
13 Bearing
14 O-ring
15 Screw connection
16 Washer
17 Snap ring

Hydraulic system
5.10 Travelling drive starting no. AE00855

The travelling drive now has an “automatic powershift” gearbox.
The travelling drive is basically in 2nd speed if the switch for 2nd speed range is switched
on (high speed). 1st speed is automatically engaged if more power is required.
.
2'
7
1 2 3
Pos. Description
3 Leak oil port (-> swivel joint 1)
4 Forwards/reverse directional valve
5 2nd speed range port (-> swivel joint 8)
6 2nd speed range directional valve
7 Brake piston

Hydraulic system
Function
Driving:
If high pressure is applied to one of the drives, the brake release piston is actuated first
and passes high pressure on to the brake cylinder, which releases the brake. The throttle
slowly actuates the brake piston at the same time. Brake piston control causes high
pressure to be applied to the motor, which starts turning.
Stopping:
The oil flows from both ports to the tank upon releasing the joystick. The brake release
piston and the brake piston slowly return to their base positions (via the throttle). The slow
drop of the brake piston prevents the hydraulic motor from coming to an abrupt standstill.
With the brake piston in neutral position, the ports are no longer connected to the motor,
which can no longer turn. The brake release pressure is reduced via both throttles shortly
afterwards.
2 speed range functions

Speed range 1
• 2nd speed range switch: switched off
The directional valve for the 2nd speed range remains in home position (position as shown
in diagram), and the hydraulic motor's swash plate is in maximum capacity position.
➥ The motor runs at low speed.
Speed range 2
• 2nd speed range switch: switched on
The directional valve for the 2nd speed range is enabled, and the hydraulic motor's swash
plate is in minimum capacity position.
➥ The motor runs at high speed.
If the pressure rises in the travelling drive, the directional valve for the 2nd speed range is
forced back to home position and and hydraulic motor's swash plate returns to maximum
capacity.
➥ The motor now runs at low speed.
The directional valve returns to 2nd speed range as soon as the pressure in the travelling
drive drops again.
➥ The motor runs at high speed again.
Switch operating point of valve pos. 6: 180 bar (2611 psi)

Hydraulic system
Pos. Description
1 Travelling drive
2 Screw connection
3 Screw connection
4 Screw connection
5 Hydraulic motor
6 Hydraulic motor sealing kit
7 Lifetime seal
8 Bearing
9 Cover
10 O-ring
11 Snap ring
12 Anticavitation valve
13 Piston valve for speed range
14 Brake valve
15 Travelling drive brake

Hydraulic system
5.11 Swivel unit

Hydraulically controlled swash-plate piston motor with maintenance-free swivel gearbox
and mechanical motor brake
2'
X
9
3
X
X
1 2 4 5 6
Pos. Description
1 SH brake release port (-> shuttle valve)
2 Pilot control pressure port (-> pilot oil supply unit)
3 Brake release valve
4 Right-hand side upper carriage rotation port (-> main valve block)
5 Anticavitation line port (-> main valve block/tank)
6 Left-hand side upper carriage rotation port (-> main valve block)
7 Shock anticavitation valves
8 Leak oil port (-> tank)
9 Brake piston
The shock anticavitation valves are dampened for smooth braking.

Hydraulic system
Parking brake/multidisc brake function

Opening the brake
The shuttle valvee (Fig. 3) directs the pilot control pressure to the SH input if upper
carriage rotation, boom swivel or stick retraction is carried out.
The pilot control pressure at the SH input causes the piston in the brake release valve to
shift to active state (brake release). This directs the pilot control pressure at the PG input
to the brake cylinder and releases the brake.
• Movement: upper carriage rotation, boom swivel or stick retraction

• Pilot control pressure is present at the SH input
• The piston of the brake release valve moves to work position
Fig. 3: Shuttle valve
• Pilot control pressure is directed to the brake piston
• Brake is released
Closing the brake

The shuttle valve causes the pilot control pressure to drop and the SH input is
unpressurised upon termination of upper carriage rotation, boom swivel or stick retraction.
The piston in the brake release valve switches to home position (brake) if there is no
pressure at the SH input. The pressure in the brake cylinder escapes via the brake release
valve to the leak oil system. This enables the brake with some delay (depending on oil
viscosity and brake valve leakage).
• End of movement: upper carriage rotation, boom swivel or stick retraction

• The pilot control pressure at the SH input drops
• The piston of the brake release valve moves to home position
• No more pilot control pressure on the brake piston
• The oil in the brake piston flows to the tank via a throttle orifice
• The brake is enabled
Time for releasing the brake: 3.7 sec ± 1.2 at 50 °C (122°F) oil temperature

5-28
Hydraulic system

1 Pinion shaft 11 O-ring
2 Spacer washer 12 Ring gear
3 Bearing seal ring 13 Gear reduction
4 Bearing 14 Gear reduction
5 Gear housing 15 Sun gear
6 Sealing ring 16 Motor flange
7 Bearing 17 Hydraulic motor
8 Round nut 18 Screw
9 Complete drive 19 Screw
10 Spacer washer 20 Plug

Hydraulic system
Pos. Description
1 Shock anticavitation valves
2 Gear motor valve set
3 Timer valve
4 Engine brake set

Hydraulic system
5.12 Swivel joint

8-port swivel joint
12
13
11
Pos. Port Pos. Description

1a Pilot control pressure (PV) pilot oil supply unit 1-8 Sealing rings
2a Stabiliser blade 9 PU prop ring
3a Stabiliser blade 10 V sealing ring
4a and 6a Left-hand side drive 11 Circlip
5a and 7a Right-hand side drive 12 Inside part
8a Travelling drive tank line 13 Outside part
Sealing ☞ Slacken the circlip on the lower side

☞ Pull the swivel joint apart
☞ Replace the sealing rings
☞ Push together again
☞ Insert the circlip again

Hydraulic system
5.13 Breather filter

The breather filter is in charge of:
• Air intake and outlet for pressure compensation in the hydraulic oil tank (varying oil
level) – prevents the oil tank from inflating.
• Pre-tension of the oil tank to the specified overpressure -> supports the variable
displacement pump's suction
• Filtering the intake air
• Opens at 0.4 bar (5.8 psi)
The breather filter is located at the rear of the machine next to the hydraulic oil filler inlet.
Replace the breather filter according to the instructions in the maintenance plan!
Important!
The breather filter must be replaced at 1000 h under all circumstances!
Pos. Description
1 Filter fabric
2 Bleeder valve
Fig. 5: Breather filter

Hydraulic system
5.14 Troubleshooting in the hydraulic system

Defective safety switch on control lever base
Wrong setting of safety switch on control lever base
Defective solenoid valve on pilot oil supply unit
Hydraulic system without function Contaminated solenoid valve on pilot oil supply unit
Hydraulic oil level too low
Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Quickhitch couplings not connected correctly
Hydraulic hammer does not work correctly Hydraulic oil quantity too high/too low
Hydraulic oil pressure too high/too low
Defective switch for 2nd speed range
Defective solenoid valve on pilot oil supply unit
Contaminated solenoid valve on pilot oil supply unit
Excavator runs in 1st speed only
Defective valve fuses
Defective/interrupted plug and socket connection towards solenoid valve
Counterpressure in travelling drive does not drop below control pressure

Hydraulic system
5.15 Hydraulics diagram A4
Stick ram Auxiliary Stabiliser

Bucket Boom Travelling Travelling hydraulics blade ram Gear motor
ram ram drive (right) drive (left) Offset 3rd control
ram circuit (option)
boom swivel
Right-hand
side drive
side drive
Left-hand
Bucket
Boom
Joystick (right)
Joystick (left)

Hydraulic system
5.16 Hydraulics diagram (legend)
Pos. Description
1 Diesel engine
2 Variable displacement pump + gear pump
3 Pilot oil supply unit
4 Left-hand side joystick pilot valve
5 Right-hand side joystick pilot valve
6 Main valve block
7 Left-hand side drive pilot valve
8 Right-hand side drive pilot valve
9 Pressure accumulator
10 Non-return valve
11 Changeover valve: boom swivel/auxiliary hydraulics
12 Overcentre valve
13 Oil filter
14 Oil cooler
15 Swivel unit
16 Travelling drive (left)
17 Travelling drive (right)
18 Offset ram
19 Stick ram
20 Boom ram
21 Bucket ram
22 Stabiliser blade ram
23 Hose burst valve
24 Pilot control filter
25 Throttle non-return valve
26 Breather filter
27 Shuttle valve
28 Swivel joint
29 Auxiliary hydraulics
30 3rd control circuit (option)
31 Measuring ports
Pressure Spring-loaded Pressure Fixed displacement Variable Fixed Double variable

accumulator solenoid valve limiting valve motor displacement displacement displacement pump
motor pump
Tank line Measuring Stop cock Non-return valve Throttle Oil Filter Double-acting ram
port orifice cooler

m
cs
boom swivel
Joystick (right)
Right-hand side drive
Left-hand side drive
Boom
Bucket
If option 3. hydraulic circuit does not exist, section 7 drops out!!!
Option
Main control lines Pump/tank lines
Controlled via Port Legend Port Legend

Joystick (right) A1, B1 Bucket ram P1 Pump 1 port
Joystick (right) A2, B2 Boom ram P2 Pump 2 port
Drive pedal (left) A3, B3 Drive unit (left) via swivel joint P3 Pump 3 port
Drive pedal (right) A4, B4 Drive unit (right) via swivel joint P4 Pump 4 port
Joystick (left) A5, B5 Stick ram T1 Tank line via non-return valve and filter in t
wivel control Switch on joystick + pedal A6, B6 Auxiliary hydraulics/offset ram T2 Tank line via oil cooler and filter in tank
Switch on joystick A7, B7 3rd control circuit
Electric system
Electric system
Electric system
6 Electric system
6.1 Ohm's Law (current, voltage, resistance); power
It describes the interrelation between current, voltage and resistance.
Current “II” – Ampere (A)

Voltage “U
U” – Volt (V)
R” – Ohm (:)
Resistance “R
Mnemonic: U
R I
Output
Power “P” – Watt (W)
P = U x I = R x I² = U²/R
6.2 Measuring equipment, measuring methods

Multifunction measuring device
• Measurements of values (U, R, I, f)
• Continuity test
• Diode test
Calculate the measuring range using known data (P, U, R, I) and set before measuring!
Observe AC/DC basic setting.
➥ AC = alternating current/voltage;
➥ DC = direct current/voltage
Test device with acoustic and optical signal output

• Continuity test in de-energised machine electric system and of wiring harnesses

Electric system
Measuring methods – multifunction measuring device

• Measuring current (ignition switched on):
• Black cable in COM socket (earth)
• red cable in A socket or mA socket; connect in series to consumer
• Measuring voltage (ignition switched on):
• red cable in V socket
• connect in parallel to consumer
• Measuring resistance (ignition switched off):
• red cable in : socket
• connect in parallel to consumer (see measuring voltage)
Test lamp
The test lamp is used to test lines and functions with the ignition switched on.
• Line test (testing voltage):
Connect test lamp between test point (live cable) and machine earth or between test point
(earth line) and a live cable.
• Functional check (testing current):
Connect test lamp between a connection on the consumer to be tested and the connection
line.

Electric system
6.3 Cable colour coding
Colour Code
Black blk
Brown brn
Red red
Orange org
Yellow yel
Green grn
Blue blu
Violet vio
Grey gry
White wht
Pink pnk
6.4 Relays
Use, mode of functionn Relays are used for switching electric loads (high currents) whereby the control power of
the relay coil is relatively low. Relays can therefore be controlled by microelectronics or
microswitches (e.g. touchpad keyboards, sensors).
The switch contacts can be make-contact, break-contact or changeover switches. These
undertake the actual switching function.
Zero-centre relay
86 30 86 = Start of coil (control line)
85 = End of coil (earth)
30 = Input (load line)
87 = Make-contact switch output (load line)
85 87 87a 87 a= Break-contact switch output (load line)
Fig. 1: Terminal description on relay

Electric system
6.5 Electric units
Units
Alternator 12 V 55 A
Starter 12 V 1.7 kW (2.3 hp)
Battery 12 V 71 Ah
Socket E.g. for cigarette lighter; 15 A max.
6.6 Fuse box in instrument panel

F3 10 A Indicators, cutoff solenoid, relays
F4 10 A Boom working light
F5 15 A Roof lights
F6 10 A Valves, horn
F7 15 A Heating, air conditioning
F8 10 A Wipers, lights
F9 10 A Rotating beacon, radio
F10 15 A Socket, cigarette lighter
F3 F4 F5 F6 F7 F8 F9 F10
Fig. 2: Fuse box
6.7 Main fuse box with relays

The main fuse box is located in the partition wall to the left of the engine.
F1 Rated current
F2 Fuse no. Protected circuit
(A)
F1 40 A Start, preheat, cutoff solenoid
K5
F2 50 A Fuel-filling pump, main fuse, ignition lock
K9
Relay no.
Fig. 3: Relays in the engine compartment K9 Cutoff solenoid switching relay
K5 Preheating high current relay

Electric system
6.8 Relays
The relays are located in the relay box on the partition wall to the left of the engine
Switching relay no. Protected circuit

K6
K6 10 s preheating timer (telltale only); black plug
K7 Starting relay
K8 1s cutoff solenoid timer; white plug
V1 Cutoff solenoid recovery diode
K81
K7
V1
Fig. 4: Relays
6.9 Socket
The socket A is located above the lubrication strip B .
Fig. 5: Lubrication strip on the chassis

Electric system
6.10 Joystick tip switches

Joystick (left)
Pos. Description
2 3
1 Switch on auxiliary hydraulics/boom swivel
2 Slide to the left = low throughput (slow movement)
3 Slide to the right = high throughput (fast movement)
1
Two characteristic curves can be selected if the slide switch is moved to the left or right for
2 seconds as you switch on ignition.
If you want to change the characteristic curve again, switch off the ignition to repeat the
procedure described above.
Fig. 6: Left-hand side joystick (standard and option)
Joystick (right)
Pos. Description
2 3
1 Switch on auxiliary hydraulics/boom swivel
2 Slide to the left = low throughput (slow movement)
3 Slide to the right = high throughput (fast movement)
1
Fig. 7: Right-hand side joystick (standard and option)
6.11 Instrument panel overview
1 2 3 4 7
5 6
Pos. Description
1 Wipers
2 Roof lights
3 Rotating beacon
4 Radio ON button (option)
5 Volume
6 Radio station memory
7 Frequency selection

Electric system
6.12 Switch overview (up to serial no. AE02803)
Control elements on control console Control elements on cab wall

8 9 10 11 12 13 14 15 16 17
Control elements for proportional controls version (option)

Control elements on control console Control elements on cab wall
13 14 15 16 17
8 9 10 12 18

8 High speed
9 Working light
10 Ventilation
12 Safe load indicator (option) 7-13, 7-15
13 Washer system
14 Roof lights
15 Rotating beacon
16 Not assigned
17 Not assigned
1. If equipped with air conditioning and proportional controls, switch assignment is the same as without proportional controls.
The status telltale is then installed in the control console on the right.

Electric system
6.13 Switch overview (from serial no. AG00573)
19 20 21 22 23 24 25 26 27 28
Control elements for proportional controls version (option):

19 20 21 22 29 24 25 26 27 28

19 High speed
20 Working light
23 Not assigned
24 Washer system
25 Roof lights
26 Rotating beacon
27 Ventilation
1.
If equipped with air conditioning and proportional controls, switch assignment is the same as without proportional controls. The status telltale is then installed in the control console on the right.

Electric system
6.14 Alternator
The alternator charges the battery and supplies direct current to electric consumers.
Pos. Description
1 Connection B (battery)
Connection P starting relay
2 Connection IG telltale (12V)
Port L telltale (during service 12V, otherwise earth)
1 2
Fig. 8: Alternator
6.15 Starter
2
Pos. Description
1 Connection S starting relay
1
2 Connection B battery
Fig. 9: Starter

Electric system
6-10
Electric system
Wiring diagrams and wiring harnesses include all

options.

6.16 Wiring diagram A4 38Z3 (legend)
No. Description Section Loc. No. Description Section Loc. No. Description Section Loc.
A1 Radio E14 Opt M4 Fan C12 Opt X15 1 pole connection – drive alarm D7
B1 Fuel indicator F7 M5 Washer pump F8 Opt X16 3 pole connection – drive alarm D2-3
B2 Horn E7 M9 Fuel pump F3 X19 1 pole connection – socket F7
B11 Loudspeaker E15 Opt P1 Hour meter B1 XE11 2 pole connection – boom working light F9
B12 Loudspeaker E15 Opt P2 Fuel level indication B1 XS41 2 pole connection – safe load indicator F8
B14 Warning buzzer C2 R1 Glow plug F4 Y1 Cutoff solenoid F3
E7 Rear roof light F14 Opt S1 Preheating start switch A1 Y3 High-speed solenoid valve F9
E9 Front roof light F13 Opt S2 Engine oil pressure switch F5 Y13 Solenoid valve for safety valve F10

E11 Boom light F8/9 S3 Engine temperature switch E5 Y15 Auxiliary hydraulics/boom swivel solenoid F10
valve
E14 Interior light F13 S4 Air filter pressure switch F6
Y16 Auxiliary hydraulics solenoid valve F11 Opt
E15 Cigarette lighter D15 S5 Hydraulic oil pressure switch F5
Y17 Auxiliary hydraulics solenoid valve F11 Opt
F1 Main fuse: starter, preheating E2 S16 Boom working light switch B8
Y31 Air conditioning clutch F7 Opt
F2 Main fuse + fuel-filling pump E1 S17 Cab working light switch C14 Opt
F3 Indicators, engine relay A5 S18 Rotating beacon switch C13 Opt
F4 Boom working light A7 S15 Heating switch B11
F5 Cab working lights A13 S20 Wiper/washer switch C12 Opt
F6 Valves, horn A9 S21 High speed switch B9
F7 Fan, air conditioning A11 S21.1 High-speed tip switch (prepared) E9 Opt
F8 Wiper, interior light A12 S27 Additional hydraulics/boom swivel tip switch D10
F9 Rotating beacon, radio, drive interlock A14 S28 Safety switch D7
F10 Socket, cigarette lighter A8 S30 Additional control circuit tip switch E10 Opt
G1 Alternator F2 S31 Additional control circuit tip switch E11 Opt
G2 Battery F1 S41 Safe load indicator pressure switch E8 Opt
H2 Preheating telltale B/C1 S42 Safe load indicator switch B7 Opt
H3 Engine temperature telltale B/C1 S48 Automatic idling speed tip switch C9 Opt
H4 Engine oil pressure telltale B/C1 S51 Air conditioning switch B10 Opt
H5 Alternator charge function telltale B/C1 S52 Air conditioning pressure switch E7 Opt
H6 Air filter telltale B/C1 S54 Air conditioning thermostat C10 Opt
H7 Hydraulic oil filter telltale B/C1 S55 Horn tip switch C6
H9 Safe load indicator telltale B/C1 Opt V1 Recovery diode F4
H28 Rotating beacon F13 Opt X1 13 pole connection – engine/chassis D4-6
K5 Preheating high current relay E4 X2 11 pole connection – engine/chassis D7-9
K6 Preheating time lag relay E5 X3 2 pole main connection D0
K7 Start high current relay E2 X4 9 pole connection – drive interlock C/D3
K8 Cutoff solenoid time lag relay E3 X8 6 pole connection – joystick (left) D10
K9 Cutoff solenoid switching relay E3 X10 15 pole connection – instrument panel B/C1
M1 Starter F2 X12 9 pole connection – cab D13/14
M2 Wiper motor F12 Opt X13 5 pole connection – engine temperature A3
Electric system
6-11
Electric system
6.17 Wiring diagram A4

6.18 Engine wiring harness (legend)
No. Up to To Colour mm² No. Up to To Colour mm²

1 G1/B alternator M1 starter red 10 38 GND X16/2 drive alarm connection blk 1
2 G1/B alternator F1 main fuse red 6 38A B1 fuel level indicator X16/2 drive alarm connection blk 1
3 M1 starter F2 main fuse red 6 39 B1 fuel level indicator S5 preheating start switch blk 1
4 F1 main fuse K5/30 preheating relay red 4 40 S5 preheating start switch X2/1 engine/chassis connection org/wht 1
5 K5/30 preheating relay K9/30 cutoff solenoid relay red 4 41 X16/1 drive alarm connection X1/1 engine/chassis connection blu 1
6 F1 main fuse K7/A start high current relay red 4 44 S21.1 high-speed tip switch (prepared) X2/2 engine/chassis connection gry 1
7 F2 main fuse X3/A main connection red 6 45 S21.1 high-speed tip switch (prepared) B2 horn gry 1

8 GND X3/B earth blk 4 46 B2 horn X5/5 armrest/chassis connection org 1
10 K7/B start high current relay M1 starter wht/red 4 47 X19 socket X2/4 engine/chassis connection red/blk 1.5
11 K5/87 preheating relay R1 glow plug brn 6 48 X19 socket GND blk 1.5
12 K9/87 cutoff solenoid switching relay Y1/1 cutoff solenoid wht 4 49 M5 washer pump X2/5 engine/chassis connection blk/wht 1
13 M9/1 fuel pump X1/2 cutoff solenoid blu 1 50 M5 washer pump GND blk 1
13A M9 fuel feed pump Y1/2 cutoff solenoid blu 1 51 XS41/1 safe load indicator X2/6 engine/chassis connection vio/blu 1
14 GND Y1/3 cutoff solenoid blk 2.5 52 XS41/2 safe load indicator GND blk 1
15 K8 cutoff solenoid time lag relay X1/2 engine/chassis connection blu 1 53 XE11/1 boom working light X2/7 engine/chassis connection grn/yel 1
16 K8 cutoff solenoid time lag relay V1 blocking diode blu 1 54 XE11/2 boom working light GND blk 1
16 V1 blocking diode K7/1 start high current relay blu 1 55 S21.1/1 high-speed tip switch (prepared) X2/8 engine/chassis connection brn/blk 1
A 56 Y3 high-speed solenoid valve X2/8 engine/chassis connection brn/blk 1
18 G1/2 alternator X1/1 engine/chassis connection blu 1 57 Y3 high-speed solenoid valve GND blk 1
19 K6 preheating time lag relay X1/3 engine/chassis connection brn 1 58 Y13 solenoid valve for safety valve X5/4 armrest/chassis connection brn/wht 1
20 K6 preheating time lag relay K5/86 preheating relay brn 1 60 GND Y13 solenoid valve for safety valve blk 1
21 K6 preheating time lag relay X1/4 engine/chassis connection wht/blk 1 62 Y15/1 auxiliary hydraulics/boom swivel X5/1 armrest/chassis connection blu/yel 1
22 K6 preheating time lag relay K7/3 start high current relay wht/blk 1 solenoid valve
23 K6 preheating time lag relay X1/5 engine/chassis connection gry/red 1 63 Y15/2 auxiliary hydraulics/boom swivel GND blk 1
24 K8 cutoff solenoid time lag relay K9/86 cutoff solenoid switching relay blu/blk 1 solenoid valve
25 K8 cutoff solenoid time lag relay K9/85 cutoff solenoid switching relay pnk/blk 1 64 Y16/1 electr. auxiliary hydraulics solenoid X5/2 armrest/chassis connection gry/yel 1
26 K7/6 start high current relay G1/3 alternator blk/blu 1 valve
27 GND K5/85 preheating relay blk 1 65 Y16/2 electr. auxiliary hydraulics solenoid GND blk 1
28 K5/85 preheating relay K6 preheating time lag relay blk 1 valve
29 K6 preheating time lag relay K8 cutoff solenoid time lag relay blk 1 66 Y17/1 electr. auxiliary hydraulics solenoid X5/3 armrest/chassis connection gry/grn 1
30 K8 cutoff solenoid time lag relay V1 blocking diode blk 1 valve
30 V1 blocking diode K7/5 start high current relay blk 1 67 Y17/2 electr. auxiliary hydraulics solenoid GND blk 1
A valve
31 G1/1 alternator X1/6 engine/chassis connection pnk 1 68 S52 air conditioning pressure switch X5/7 armrest/chassis connection yel/red 1
32 S2 engine oil pressure switch X1/7 engine/chassis connection wht/grn 1 69 S52 air conditioning pressure switch X2/11 engine/chassis connection yel/red 1
33 S3 engine temperature switch X1/8 engine/chassis connection blk/grn 1 70 X2/11 engine/chassis connection Y31 air conditioning solenoid valve yel/red 1
35 S4 air filter pressure switch X1/10 engine/chassis connection gry/blu 1 71 Y14/1 changeover valve solenoid valve X2/9 engine/chassis connection brn/grn 1
36 S4 air filter pressure switch GND blk 1
37 B1 fuel level indicator X1/11 engine/chassis connection vio/blk 1
Electric system
6-13
Electric system
6.19 Engine wiring harness A4

6.20 Cab wiring harness A4 (legend)
No. Up to To Colour No. Up to To Colour
7 X3/A main connection S1/1 preheating start switch red 6 81 S16/10 boom light switch S16/5 boom light switch grn 1
7A S1/1 preheating start switch F10 socket and cigarette lighter fuse red 4 82 S51/5 air conditioning switch S54 air conditioning thermostat yel/red 1
15 X1/2 engine/chassis connection X4/9 drive interlock connection blu 1 83 S15/6 ventilation switch M4/1 heater fan connection yel/blk 1
15A X4.1/9 drive interlock connection X4.1/5 drive interlock connection blu 1 84 S15/3 heater switch M4/3 heater fan connection yel/blu 1
17 F3 ignition lock fuse X10/1 instrument panel connection blu 1 85 S15/6 ventilation switch S51/1 air conditioning switch yel/blk 1
19 X1/3 engine/chassis connection S1/8 preheating start switch brn 1 86 F7 air conditioning fuse S15/2 heater switch yel 1.5
19A S1/3 preheating start switch S1/6 preheating start switch brn 1 87 S15/1 heater switch S15/2 heater switch yel 1
21 X1/4 engine/chassis connection X4/8 drive interlock connection wht/blk 1 88 S15/1 heater switch S15/10 heater switch yel 1
21A X4.1/4 drive interlock connection X4.1/8 drive interlock connection wht/blk 1 89 S51/10 air conditioning switch S15/10 heater switch yel 1

23 X1/5 engine/chassis connection X10/10 instrument panel connection gry/red 1 90 F5 lights fuse X12/1 cab connector grn 1
31 X1/6 engine/chassis connection X10/8 instrument panel connection pnk 1 91 F8 wiper fuse X12/2 cab connection blu 1
32 X1/7 engine/chassis connection B14/5 warning buzzer connection wht/grn 1 92 F9 radio fuse X12/2 cab connection red 1
32A X10/10 instrument panel connection B14/5 warning buzzer connection wht/grn 1 93 S16/1 boom working light switch X10/2 instrument panel connection grn 1
33 X1/8 engine/chassis connection B14/6 warning buzzer connection blk/grn 1 94 X4/4 drive interlock S1/7 ignition switch wht/blk 1
33A X10/14 instrument panel connection B14/6 warning buzzer connection blk/grn 1 95 S1/5 ignition switch F4 fuse 10A working light blu 2.5
34 X1/9 engine/chassis connection X13 engine temperature connection grn/wht 1 96 S1/6 ignition switch F7 air conditioning fuse blu 2.5
35 X1/10 engine/chassis connection X10/3 instrument panel connection gry/blu 1 97 S42/1 switch for safe load indicator (France) B14/8 warning buzzer vio/blu 1
37 X1/11 engine/chassis connection X10/4 instrument panel connection vio/blk 1 98 X10/13 instrument panel connection B14/2 warning buzzer vio/blu 1
40 X2/1 engine/chassis connection X10/6 instrument panel connection org/wht 1 99 X3/B main connector X10/5 instrument panel connection blk 1
41 X1/1 engine/chassis connection F3 indicators and engine relay fuse blu 1 100 X3/B main connector X4/3 drive interlock blk 1
42 X1/1 engine/chassis connection X4/5 drive interlock connection blu 1 101 S21/9 high-speed switch X4/3 drive interlock blk 1
42 A X4/7 drive interlock connection X4/5 drive interlock connection blu 1 102 S21/9 high-speed switch S16/9 boom light switch blk 1
43 X4/5 drive interlock connection F9 rotating beacon, radio and drive interlock fuse red 1 103 S15/9 heater switch S16/9 boom light switch blk 1
44 X2/2 engine/chassis connection F6 valves and horn fuse gry 1 104 S15/9 heater switch S51/9 air conditioning switch blk 1
46 X1/12 horn connection S55/1 horn switch org 1 105 S42/9 safe load indicator switch S51/9 air conditioning switch blk 1
47 X2/4 engine/chassis connection F10 socket and cigarette lighter fuse red/blk 1.5 106 S42/9 safe load indicator switch S55/2 horn push button blk 1
49 X2/5 engine/chassis connection S20/3 wiper/washer switch blk/wht 1
51 X2/6 engine/chassis connection S42/5 safe load indicator switch vio/blu 1
53 X2/7 engine/chassis connection S16/1 boom working light switch grn/yel 1
55 X2/8 engine/chassis connection S21/1 high-speed switch brn/blk 1
58 X2/9 engine/chassis connection S28 horn switch brn/wht 1
59 X4.1/1 drive interlock connection X4.1/6 drive interlock connection brn/wht 1
62 X2/11 engine/chassis connection X8/2 joystick connection gry 1
64 X2/12 engine/chassis connection X8/3 joystick connection gry/yel 1
66 X2/13 engine/chassis connection X8/6 joystick connection yel/grn 1
69 X2/1 engine/chassis connection S54 horn switch yel/red 1
73 X3/B main connection X8/4 joystick connection blk 1
74 X3/B main connection M4/2 heater fan blk 1
75 X3/B main connection X12/3 fuel gauge blk 1
76 F6 valves and horn fuse X8/1 joystick connection gry 1
77 F6 valves and horn fuse X4/6 drive interlock connection gry 1
78 S21/5 high-speed switch X4/6 drive interlock connection gry 1
79 S21/5 high-speed switch S21/10 high-speed switch gry 1
80 F4 fuse 10A working light S16/5 boom light switch grn 1
Electric system
6-15
Electric system
6.21 Cab wiring harness A4

6.22 Roof wiring harness A4
No. Up to To Colour mm²
49 X12 (7) 9 pole plug and socket connector S20/3 wiper switch blk/wht 1
– cab
75 X12 (3) 9 pole plug and socket connector GND1 blk 1
– cab
90 X12 (1) 9 pole plug and socket connector S17/1 cab lights switch grn 1.5
– cab
90 A S17/2 cab lights switch S17/1 cab lights switch grn 1.5
90B S17/2 cab lights switch S17/10 cab lights switch grn 1
90C E15 cigarette lighter S17/10 cab lights switch grn 1

90D X12 (1) 9 pole plug and socket connector X13/7 cab connection grn 1
3/ – cab
91 X12 (2) 9 pole plug and socket connector S20/2 wiper switch blu 1.5
– cab
91 A S20/10 wiper switch S20/2 wiper switch blu 1
91B S20/10 wiper switch S18/10 rotating beacon switch blu 1
91C X12 (2) 9 pole plug and socket connector X13/6 cab connection blu 1
– cab
92 X12 (4) 9 pole plug and socket connector E15 cigarette lighter red 1.5
– cab
92 A X12 (4) 9 pole plug and socket connector S18/1 rotating beacon switch red 1
– cab
92B X13/8 cab connection S18/1 rotating beacon switch red 1
107 S20/6 wiper switch X13/4 cab connection blu/wht 1
108 S20/6 wiper switch S20/7 wiper switch blu/wht 1
109 S20/5 wiper switch X13/1 cab connection blu/red 1
110 S17/6 cab lights switch X13/5 cab connection grn/red 1
111 S17/3 cab lights switch X13/9 cab connection grn/blu 1
112 S18/5 rotating beacon switch X13/2 cab connection vio 1
Electric system
6-17
6.23 Revs control wiring harness (option)
6-18
Electric system
Pos. Description
1 Engine speed wiring harness
2 Switch
3 Symbol
4 Time lag relay
K51 Base
S89 Insulating sleeve
S90 Socket housing
Y59 Housing

Wiring diagrams and wir
options.
on Section Loc. No. Description Section Loc. No. Description
E14 Opt M1 Starter F2 X4 9 pole connection – drive interlock
F7 M2 Wiper motor F12 Opt X8 6 pole connection – joystick (left)
E7 M4 Fan C12 Opt X10 15 pole connection – instrument
E15 Opt M5 Washer pump F8 Opt panel
E15 Opt M9 Fuel pump F3 X12 9 pole connection – cab
C2 P1 Hour meter B1 X13 5 pole connection – engine tempe
F14 Opt P2 Fuel level indication B1 ture
F13 Opt R1 Glow plug F4 X15 1 pole connection – drive alarm
F8/9 S1 Preheating start switch A1 X16 3 pole connection – drive alarm
F13 S2 Engine oil pressure switch F5 X19 1 pole connection – socket
D15 S3 Engine temperature switch E5 XE11 2 pole connection – boom working
eating E2 S4 Air filter pressure switch F6 light
pump E1 S5 Hydraulic oil pressure switch F5 XS41 2 pole connection – safe load indi
y A5 S16 Boom working light switch B8 tor
A7 S17 Cab working light switch C14 Opt Y1 Cutoff solenoid
A13 S18 Rotating beacon switch C13 Opt Y3 High-speed solenoid valve
A9 S15 Heating switch B11 Y13 Solenoid valve for safety valve
A11 S20 Wiper/washer switch C12 Opt Y15 Auxiliary hydraulics/boom swivel
A12 S21 High speed switch B9 solenoid valve
, drive interlock A14 S21.1 High-speed tip switch (prepared) E9 Opt Y16 Auxiliary hydraulics solenoid valve
r A8 S27 Additional hydraulics/boom swivel tip D10 Y17 Auxiliary hydraulics solenoid valve
F2 switch Y31 Air conditioning clutch
F1 S28 Safety switch D7
B/C1 S30 Additional control circuit tip switch E10 Opt
lltale B/C1 S31 Additional control circuit tip switch E11 Opt
ltale B/C1 S41 Safe load indicator pressure switch E8 Opt
tion telltale B/C1 S42 Safe load indicator switch B7 Opt
B/C1 S48 Automatic idling speed tip switch C9 Opt
le B/C1 S51 Air conditioning switch B10 Opt
tale B/C1 Opt S52 Air conditioning pressure switch E7 Opt
F13 Opt S54 Air conditioning thermostat C10 Opt
t relay E4 S55 Horn tip switch C6
ay E5 V1 Recovery diode F4
E2 X1 13 pole connection – engine/chassis D4-6
g relay E3 X2 11 pole connection – engine/chassis D7-9
To Colour mm² No. Up to To Colour mm² No. Up to To
starter red 10 29 K6 preheating time lag K8 cutoff solenoid time lag blk 1 54 XE11/2 boom working GND
main fuse red 6 relay relay light
main fuse red 6 30 K8 cutoff solenoid time lag V1 blocking diode blk 1 55 S21.1/1 high-speed tip X2/8 engine/chassi
30 preheating relay red 4 relay switch (prepared) tion
30 cutoff solenoid relay red 4 30 V1 blocking diode K7/5 start high current relay blk 1 56 Y3 high-speed solenoid X2/8 engine/chassi
A start high current relay red 4 A valve tion
A main connection red 6 31 G1/1 alternator X1/6 engine/chassis connec- pnk 1 57 Y3 high-speed solenoid GND
B earth blk 4 tion valve
starter wht/ 4 32 S2 engine oil pressure X1/7 engine/chassis connec- wht/ 1 58 Y13 solenoid valve for X5/4 armrest/chass
red switch tion grn safety valve tion
glow plug brn 6 33 S3 engine temperature X1/8 engine/chassis connec- blk/grn 1 60 GND Y13 solenoid valve
1 cutoff solenoid wht 4 switch tion valve
35 S4 air filter pressure X1/10 engine/chassis connec- gry/blu 1 62 Y15/1 auxiliary hydraulics/ X5/1 armrest/chass
2 cutoff solenoid blu 1 switch tion boom swivel solenoid tion
2 cutoff solenoid blu 1 36 S4 air filter pressure GND blk 1 valve
3 cutoff solenoid blk 2.5 switch 63 Y15/2 auxiliary hydraulics/ GND
2 engine/chassis connec- blu 1 37 B1 fuel level indicator X1/11 engine/chassis connec- vio/blk 1 boom swivel solenoid
tion valve
blocking diode blu 1 38 GND X16/2 drive alarm connection blk 1 64 Y16/1 electr. auxiliary X5/2 armrest/chass
38A B1 fuel level indicator X16/2 drive alarm connection blk 1 hydraulics solenoid valve tion
1 start high current relay blu 1 39 B1 fuel level indicator S5 preheating start switch blk 1 65 Y16/2 electr. auxiliary GND
40 S5 preheating start switch X2/1 engine/chassis connec- org/ 1 hydraulics solenoid valve
1 engine/chassis connec- blu 1 tion wht 66 Y17/1 electr. auxiliary X5/3 armrest/chass
41 X16/1 drive alarm connec- X1/1 engine/chassis connec- blu 1 hydraulics solenoid valve tion
3 engine/chassis connec- brn 1 tion tion 67 Y17/2 electr. auxiliary GND
44 S21.1 high-speed tip X2/2 engine/chassis connec- gry 1 hydraulics solenoid valve
86 preheating relay brn 1 switch (prepared) tion 68 S52 air conditioning pres- X5/7 armrest/chass
45 S21.1 high-speed tip B2 horn gry 1 sure switch tion
4 engine/chassis connec- wht/blk 1 switch (prepared) 69 S52 air conditioning pres- X2/11 engine/chass
46 B2 horn X5/5 armrest/chassis connec- org 1 sure switch tion
3 start high current relay wht/blk 1 tion 70 X2/11 engine/chassis con- Y31 air conditioning
47 X19 socket X2/4 engine/chassis connec- red/blk 1.5 nection valve
5 engine/chassis connec- gry/red 1 tion 71 Y14/1 changeover valve X2/9 engine/chassi
48 X19 socket GND blk 1.5 solenoid valve tion
86 cutoff solenoid switching blu/blk 1 49 M5 washer pump X2/5 engine/chassis connec- blk/wht 1
y tion
85 cutoff solenoid switching pnk/blk 1 50 M5 washer pump GND blk 1
y 51 XS41/1 safe load indicator X2/6 engine/chassis connec- vio/blu 1
3 alternator blk/blu 1 tion
52 XS41/2 safe load indicator GND blk 1
85 preheating relay blk 1 53 XE11/1 boom working X2/7 engine/chassis connec- grn/yel 1
preheating time lag relay blk 1 light tion
Horn Socket solenoid Preheat
Overload Preheat- Cutoff sole-
ing timer noid timer
Boom light
Air conditioning
pressure switch
Swivel
Engine oil Cutoff sole-

lic oil Preheat
Air condition- pressure noid
ing clutch
Fuel pump
Air filter
Fuel sensor Engine temperature

speed
afety
switch
Col- Col-
To No. Up to To No. Up to To
our our
/1 preheating start switch red 6 43 X4/5 drive interlock connec- F9 rotating beacon, radio and red 1 88 S15/1 heater switch S15/10 heater s
0 socket and cigarette lighter red 4 tion drive interlock fuse 89 S51/10 air conditioning S15/10 heater s
e 44 X2/2 engine/chassis connec- F6 valves and horn fuse gry 1 switch
/9 drive interlock connection blu 1 tion 90 F5 lights fuse X12/1 cab conne
46 X1/12 horn connection S55/1 horn switch org 1 91 F8 wiper fuse X12/2 cab conne
.1/5 drive interlock connec- blu 1 47 X2/4 engine/chassis connec- F10 socket and cigarette lighter red/ 1.5 92 F9 radio fuse X12/2 cab conne
n tion fuse blk 93 S16/1 boom working light X10/2 instrument
0/1 instrument panel connec- blu 1 49 X2/5 engine/chassis connec- S20/3 wiper/washer switch blk/ 1 switch tion
n tion wht 94 X4/4 drive interlock S1/7 ignition swit
/8 preheating start switch brn 1 51 X2/6 engine/chassis connec- S42/5 safe load indicator switch vio/blu 1
tion 95 S1/5 ignition switch F4 fuse 10A wor
/6 preheating start switch brn 1 53 X2/7 engine/chassis connec- S16/1 boom working light switch grn/ 1 96 S1/6 ignition switch F7 air conditionin
/8 drive interlock connection wht/ 1 tion yel 97 S42/1 switch for safe load B14/8 warning b
blk 55 X2/8 engine/chassis connec- S21/1 high-speed switch brn/ 1 indicator (France)
.1/8 drive interlock connec- wht/ 1 tion blk 98 X10/13 instrument panel B14/2 warning b
n blk 58 X2/9 engine/chassis connec- S28 horn switch brn/ 1 connection
0/10 instrument panel con- gry/ 1 tion wht 99 X3/B main connector X10/5 instrument
ction red 59 X4.1/1 drive interlock con- X4.1/6 drive interlock connec- brn/ 1 tion
0/8 instrument panel connec- pnk 1 nection tion wht 100 X3/B main connector X4/3 drive interlo
n 62 X2/11 engine/chassis con- X8/2 joystick connection gry 1 101 S21/9 high-speed switch X4/3 drive interlo
4/5 warning buzzer connec- wht/ 1 nection 102 S21/9 high-speed switch S16/9 boom light
n grn 64 X2/12 engine/chassis con- X8/3 joystick connection gry/ 1 103 S15/9 heater switch S16/9 boom light
4/5 warning buzzer connec- wht/ 1 nection yel 104 S15/9 heater switch S51/9 air conditio
n grn 66 X2/13 engine/chassis con- X8/6 joystick connection yel/ 1 105 S42/9 safe load indicator S51/9 air conditio
4/6 warning buzzer connec- blk/ 1 nection grn switch
n grn 69 X2/1 engine/chassis connec- S54 horn switch yel/ 1 106 S42/9 safe load indicator S55/2 horn push
4/6 warning buzzer connec- blk/ 1 tion red switch
n grn 73 X3/B main connection X8/4 joystick connection blk 1
3 engine temperature con- grn/ 1 74 X3/B main connection M4/2 heater fan blk 1
ction wht 75 X3/B main connection X12/3 fuel gauge blk 1
0/3 instrument panel connec- gry/ 1 76 F6 valves and horn fuse X8/1 joystick connection gry 1
n blu 77 F6 valves and horn fuse X4/6 drive interlock connection gry 1
0/4 instrument panel connec- vio/blk 1 78 S21/5 high-speed switch X4/6 drive interlock connection gry 1
n 79 S21/5 high-speed switch S21/10 high-speed switch gry 1
0/6 instrument panel connec- org/ 1 80 F4 fuse 10A working light S16/5 boom light switch grn 1
n wht 81 S16/10 boom light switch S16/5 boom light switch grn 1
indicators and engine relay blu 1 82 S51/5 air conditioning switch S54 air conditioning thermostat yel/ 1
e red
/5 drive interlock connection blu 1 83 S15/6 ventilation switch M4/1 heater fan connection yel/blk 1
84 S15/3 heater switch M4/3 heater fan connection yel/blu 1
/5 drive interlock connection blu 1 85 S15/6 ventilation switch S51/1 air conditioning switch yel/blk 1 Switch wi
86 F7 air conditioning fuse S15/2 heater switch yel 1.5 legend
Boom
Overload Air condi- Fan working light High speed
tioning
Horn tip
switch
Air conditioning
thermostat
Safety switch Heating

To Colour mm²
– cab S20/3 wiper switch blk/wht 1
Rotating Roof working Wiper
– cab GND1 blk 1
– cab S17/1 cab lights switch grn 1.5
beacon lights
S17/1 cab lights switch grn 1.5
S17/10 cab lights switch grn 1
S17/10 cab lights switch grn 1
– cab X13/7 cab connection grn 1
– cab S20/2 wiper switch blu 1.5
S20/2 wiper switch blu 1
S18/10 rotating beacon switch blu 1
– cab X13/6 cab connection blu 1
– cab E15 cigarette lighter red 1.5
– cab S18/1 rotating beacon switch red 1
S18/1 rotating beacon switch red 1
X13/4 cab connection blu/wht 1
S20/7 wiper switch blu/wht 1
X13/1 cab connection blu/red 1
X13/5 cab connection grn/red 1
X13/9 cab connection grn/blu 1
X13/2 cab connection vio 1
E15 cigarette lighter blk 1.5
S18/9 rotating beacon switch blk 1
S18/9 rotating beacon switch blk 1
S20/9 wiper switch blk 1
X13/3 cab connection blk 1
. Description
Engine speed wiring harness
Switch
Symbol
Time lag relay
1 Base
9 Insulating sleeve
0 Socket housing
9 Housing
Options
Options
7 Options
• Article numbers for options and retrofit kits: please refer to the 38Z3 spare parts list
7.1 Air conditioning
Danger!
Avoid contact with the heat exchanger or the condenser and the supply lines.
Lines and hoses carrying refrigerating agents or coolants can be pressurised
and hot.
Danger of burns!
☞ Always observe the following instructions:
• Always empty the system before carrying out maintenance work on the
cooling circuit.
• Avoid contact with parts carrying coolant.
• Carry out maintenance work with the fan at a standstill only.
• Have maintenance and repair work carried out by specialised staff only.
Important!
Make sure the cooling system does not come into contact with chlorine, choric
substances, oil, grease or humidity. Use drain and fill systems for R134a only.
Important!
The air conditioning system runs best by taking in “outside” air.
Specifications
Air conditioning Model 38Z3
Refrigerating agent R134a ~ 950 g (2.1 lbs)
Control pressure high pressure on 19±2 bar (276±29 psi)
Control pressure high pressure off 25±2 bar (363±29 psi)
Control pressure low pressure on 2.4 bar (34.8 psi)
Control pressure low pressure on 1.2±0.3 bar (17.4±4.4 psi)
Thermostat switch-on temperature + 2.2 °C (36°F)
Thermostat switch-off temperature –1.1 °C (+30°F)
Compressor oil 116.5 ml (7.1 in3)

Options
Installation overview
Condenser
Dehumidifier
Compressor
Air conditioning unit
Diesel engine

Options
Components
Heater/air conditioning unit
The air conditioning unit consists of:
• Evaporator:: this is where the liquid refrigerating agent evaporates, and the air taken in
by the fan is cooled
• Expansion valve:: installed in the evaporator and controls the quantity of liquid
refrigerating agent injected.
• Ice guard:: a fixed-setting thermostat with sensors placed between the evaporator fins
prevents them from icing up due to freezing condensation water. The thermostat
switches the evaporator's refrigerating agent supply off at –1.1 °C ± 0.8 °C (30 ±34°F)
and on again at +2.2 °C ± 0.8 °C (36 ±34°F) as required.
• Heat exchanger
• Twin radial fan:: can be controlled in steps and is overload-protected by means of a
temperature microfuse.
Pos. Description
1 Compressor
2 Condenser
3 Dehumidifier
4 Air conditioning unit

Options
Compressor
Old eng ine type (up to serial nu mber AE02803): The compressor takes in the gaseous refrigerating agent from the evaporator, compresses
it and presses the refrigerating agent into the condenser. The diesel engine drives the
compressor via a V-belt and an electro-magnetic clutch.
Condenser
The condenser condenses the compressed refrigerating agent, i.e. it is delivered to the
condenser in gaseous state and emerges at the lowest position of the condenser in liquid
form.
Fig. 1: Compressor
Dehumidifier with pressure switch

The dehumidifier consists of a collector with integrated dryer, a sight glass and a pressure
switch.
The dehumidifier serves as an expansion receptacle and tank for the refrigerating agent. It
can bind a small quantity of water chemically, thereby withdrawing it from the circuit.
A sight glass on the dehumidifier enables to check the level of the circuit.
Important!
The cooling system is not working properly if gas bubbles appear in the sight
glass.
Replace the dehumidifier if the sight glass is cloudy or shows traces of corrosion.
Caution!
Always keep the dehumidifier closed otherwise the dryer is saturated by the
Fig. 2: Dehumidifier with pressure switch
humidity in the air and is no longer serviceable.

Options
Filling up the air conditioning system
Important!
Always have the air conditioning system filled up by an authorised workshop with
specialised staff.
• Only use refrigerating agent R134a according to DIN 8960!
• Fill up the system in accordance with the Operator's Manual of the manufacturer
of the fill station.
• Fill up the system with enough refrigerating agent. Make sure no bubbles appear
in the sight glass.
Start evacuation
20 minutes min. < 20 mbar
(0.29 psi)
Interrupt evacuation Check connections

Check for stabile vacuum Pressure gauge or rectify
Wait 5 minutes min. rises
System is tight
Evacuate for a further 25

minutes min.
Fill in gaseous
refrigerating agent to a
pressure of 3 bar (43.5 psi)
Pressure gauge
rises
Check for leaks
System is tight
Fill in required quantity of

refrigerating agent
Caution!
Do not overfill the system.
☞ Overfilling reduces the system's cooling capacity and can cause damage to
the system.

Options
Maintenance
Important!
Important information for maintenance and repair work:
• There may be residual pressure in the system even if it is empty. Release this
pressure with extreme care as you remove the connections.
• When working on the cooling circuit, close all openings tightly to prevent
humidity from penetrating into the system.
• Do not open the cooling circuit outdoors in humid weather or rain.
Checking the compressor oil

Old eng ine type (up to serial nu mber AE02803): Check the oil level if:
• a system component has been replaced
• the system leaks oil
• the maintenance interval is due
• the system leaks oil
• Replace the compressor oil in this case.
☞ Slacken the screw underneath the compressor and drain the oil.
☞ Retighten the screw again
☞ Open the oil filler opening
Fig. 3: Oil filler inlet for the air conditioning compressor
☞ Fill in fresh oil
☞ Push the oil dipstick into the oil filler opening
➥ Article number for oil dipstick: 1000136739
☞ Withdraw the oil dipstick from the compressor and read off the oil level at the grooves
on the oil dipstick.
➥ The oil level must reach 5 – 7 grooves
☞ Fill in oil of the same grade if the oil level is lower
☞ Close the oil filler opening again
New engin e type (from serial number AG00573): ➥ Tightening torque 15 – 20 Nm (11 - 15 lbf ft)
Fresh/recirculated air filter

Remove the ventilation grill in the cab to replace the filter. Make sure not to overstretch the
cables of the fuse box as you tilt the grill. You can now see the filter mat.
Important!
Fig. 4: Cab filter

The filter mat has other dimensions in the case of the air conditioning option
(no.1000143330 instead of 1000146380 for heating).
Replacing the filter:

☞ Slacken the ventilation cover in the cab
☞ You can now access the cab filter
☞ Remove the cab filter (lever out the clips with a screw driver)
☞ Insert a new cab filter
☞ Mount the cover of the ventilation in the cab back on again

Options
Troubleshooting
Problem Possible causes Troubleshooting
Check the fuse's seat, insert correctly if nec-

essary. Replace a defective fuse. Trouble
Defective or loose fuse occurring again within short time indicates
there is a short circuit or obstruction in the
system. Check the fan for obstruction or a
Fan does not work defect and rectify the cause.
Line interruption Check the line for loose contacts or ruptures
Defective fan motor Replace the fan
Defective fan switch Check or replace the switch
Fan cannot be switched off Short circuit in cable or fan switch Eliminate the short circuit. Install a new cable
and/or switch if necessary
Contaminated contacts Clean the pins. Proceed with extreme care to

avoid short circuits.
Reduced fan output
Heat exchanger heavily contaminated Clean carefully and avoid damage that could
cause leaks.
Flow temperature too low Wait for the engine to warm up
Defective thermostat Replace the thermostat
No or insufficient heating output Heat exchanger fins contaminated Check and/or clean the heat exchanger
Folded or pinched line Eliminate the cause for the error and reroute
the hoses
Loose hose connection Check the seat of the flexible lines and
tighten the clamps
Coolant leaks from the unit
Damaged hose Mount and connect a new hose
Damaged heat exchanger Replace the heat exchanger
Loose or torn V-belt Adjust V-belt tension, replace the V-belt
Interruption in the compressor's solenoid
Check the current to the clutch
coil
Compressor does not work
V-belt pulley does not turn even though
Check and/or replace the compressor
electro-magnetic clutch is applied
Compressor clutch slips Repair the clutch or replace the compressor
Expansion valve is blocked or stuck in open
Condenser overflow Replace the expansion valve
position
Thermostat sensor in wrong position Place the sensor in new position
Iced condenser
Defective expansion valve or thermostat Replace the expansion valve or thermostat
Interruption of refrigerating agent line Check all lines for external damage or chaf-
Loss of refrigerating agent ing
System leak Evacuate, fill up, check for leaks and repair

Options
Problem Possible causes Troubleshooting
Fan duct obstructed Check air intake and outlet for obstruction.
Eliminate the cause for trouble
Refrigerating agent level too low Fill up refrigerating agent
Insufficient cooling output Humidity in system Empty the air conditioning system, replace
the dehumidifier, evacuate and fill up
Dehumidifier saturated or clogged Replace the dehumidifier
Condenser fins contaminated Clean the fins

Important: no use of high-pressure cleaner
Line interruption Check, repair and/or replace the lines
System cools with interruptions
Defective fan motor Replace the fan
Loose or excessively worn V-belt Retighten or replace the V-belt
Loose compressor bracket or worn inside
Repair the bracket, replace the compressor
parts of the compressor
System runs very loudly Excessive wear of fan motor Replace the fan
System too full Suck off refrigerating agent
Not enough refrigerating agent in the system Check for leaks

Fill up the system
7.2 Counterweight
Specificationss Lock the screw connection with Loctite S2420 or VaryBond 12-43
Counterweight Model 38Z3

Weight 152.5 kg (336 lbs)
Tightening torque for screws 290 Nm (214 psi)
Max. tail end lateral projection over chains 60 mm (2.4")
Important!
Bear in mind the lift capacity table when using a counterweight!
7.3 Long stick

Specifications
Long stick Model 38Z3
Short stick 1400 mm (55")
Long stick 1650 mm (65")
Important!
Bear in mind the lift capacity table when using a long stick!

Options
7.4 Control circuit (pipework) connections for grab

Connect and disconnect the grab couplings as follows:
Removing the coupling:
☞ Park the machine on firm and level ground
☞ Extend stick ram A halfway through
☞ Release the pressure on stick ram A by moving the right-hand side control lever to the
left and right
A
☞ Turn lock sleeve C towards lock ball B
☞ Pull lock sleeve C upwards
☞ The coupling opens
Connecting the coupling:

☞ Connect the coupling onto the stick ram connection making sure it is straight
☞ Wait until you hear a hissing sound of the connection
B ☞ Fully connect the coupling on the connection
☞ Turn back the lock again (away from lock ball B )
C
Flat-seal couplings (can be coupled under residual pressure)
ISO designation Thread

Fig. 5: Grab couplings Plug 12.5 1/2 BSP
Sleeve 12.5 1/2 BSP
Couplings according to ISO 16028
Changing over the ball-type cock:
Bucket operation:
A ☞ Set the ball-type cocks to position A
Grab operation:
B ☞ Set the ball-type cocks to position B
B
Fig. 6: Grab ball-type cock
Attachments
Important!
Please refer to the Operator's and maintenance manual of the attachment
manufacturer for using and carrying out maintenance on attachments such as
hammers, grabs etc.

Options
7.5 3rd control circuit connections
Important!
Follow the instructions in the Operator's Manual of the attachment manufacturer
for connecting the 3rd control circuit to attachments.
Standard connections:
Port Bush
Standard Bulkhead coupling 1/2”
Quick coupler option Quick coupler ISO De 12.5 1/2”
Couplings cannot be coupled under pressure!
7.6 Auxiliary hydraulics connections
Important!
for connecting the auxiliary hydraulics to attachments.
Standard connections:
Port Stick (left) Stick (right)

T Pressure line
U V T
bulkhead coupling 1/2”
Fig. 7: Connections for auxiliary hydraulics Pressure line
V
Unpressurised reflux line (hammer)
U
Quick coupler options:
Port Stick (left) Stick (right)

Pressure line
T
quick coupler 12.5 1/2”
Pressure line
V
quick coupler ISO De 12.5 1/2”
Unpressurised reflux line (hammer)
U
quick coupler 1/2”
Couplings according to ISO 16028
Couplings cannot be coupled under pressure!
Important!
for connecting the auxiliary hydraulics to attachments.

Options
7.7 Safe load indicator DE (safety valve for boom)

Position
3
4
Pos. Description
1 Safe load indicator cable
2 Pilot control segment port
3 Pressure switch
4 Set screw
5 Hose burst valve
6 Switch
Setting the pressure switch ☞ A set screw is located at the rear of the pressure switch (no. 3).
☞ Mount a test weight according to the lift capacity table (turned by 90° to the driving
direction).
☞ Set the values specified in the lift capacity table
– see chapter 2.13 Lift capacity table 38Z3 on page 2-12.
• Unscrew the screw = earlier response
• Tighten the screw = later response
☞ Check again and fit the protective cap back on again.

Options
Functionn The valve is mounted direct on the base-side port of the boom ram.
“ Extend ram” function:
• Ram can be extended as usual (always “free flow” towards the ram)
In the event of a hose rupture, the load is safely held in base position by means of
the non-return valve.
“ Retract ram” function:

• Pilot control pressure moves valve (1) to work position (free oil reflux from the base
side)
• The valve moves back to home position if the pilot control pressure drops
In addition, a safety valve (2) protects the hydraulic ram from overload. Overload actuates
the pressure switch (M), the warning device lights up and the buzzer sounds.
Important!
The valve settings are sealed, no modifications for legal reasons!
Wiring diagram
%
2
3E
$
1
$
0 7
1 2
C2 V2

Options
7.8 Safe load indicator FR (safety valves for boom and stick)
Position
5
2
6
3
Pos. Description
1 Boom segment pilot control port
2 Joystick connection
3 Joystick connection
4 Stick pressure line port
5 Leak oil strip port
6 Pressure switch
7 Hose burst valve
8 Boom pressure line port
Setting the pressure switch ☞ A set screw is located at the rear of the pressure switch (no. 6).
☞ Mount a test weight according to the lift capacity table (turned by 90° to the driving
direction).
☞ Set the values specified in the lift capacity table
– see chapter 2.13 Lift capacity table 38Z3 on page 2-12.
• Unscrew the screw = earlier response
• Tighten the screw = later response
☞ Check again and fit the protective cap back on again.

Options
Function
One valve is mounted direct on the base-side port of the boom ram, the other valve is
mounted on the rod-side port of the stick ram.
“ Extend boom ram” function:

• Ram can be extended as usual (always “free flow” towards the ram)
In the event of a hose rupture, the load is safely held in base position by means of
the non-return valve.
“ Retract boom ram” function:

• Pilot control pressure moves valve (1) to work position (free oil reflux from the base
side)
“ Retract stick ram” function:
• Ram can be retracted as usual (always “free flow” from the ram)
The built-in non-return valve safely holds the load in rest position.
“ Extend stick ram” function:

• Pilot control pressure moves valve (1) to work position (free oil flow to the base side)
In addition, a safety valve (2) protects the hydraulic ram from overload. Overload actuates
the pressure switch (M), the warning device lights up and the buzzer sounds.
Important!
The valve settings are sealed, no modifications for legal reasons!

Options
Wiring diagram
%
% $
$
2 0 2
1 1
7 7
$ 3E % 3E
C2 V2

Options
7.9 3rd control circuit

Functionn The 3rd control circuit allows you to operate a range of attachments with up to 3 hydraulic
circuits.
• The 3rd control circuit is actuated proportionally via the slide switch on the right-hand
side joystick.
➥ If the machine is equipped with a 3rd control circuit option, a control valve with an
additional segment for the 3rd control circuit is installed.
Fig. 8: 3rd control circuit
Diagram

Options
7.10 Drive interlock (antitheft protection)

Position
Pos. Description
2 1 Transponder receiver surface
2 Red LED
1
Fig. 9: Drive interlock
Disabling the drive interlock ☞ Approach the transponder to 2 cm (0.8") to the transponder receiver surface
➥ The red LED goes out
☞ Insert the ignition key into the ignition lock within 30 seconds and turn it at least to
position 1
➥ The drive interlock remains disabled
Enabling the drive interlock ☞ Remove or turn the ignition key to position 0
➥ The drive interlock is enabled after 30 seconds
➥ The blinking red LED indicates the drive interlock is enabled
Programming Coding transponder keys

The so-called main or master key is required for coding a new or uncoded key, or a key
with different coding, for the drive interlock.
☞ Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 – 45 seconds
– see Disabling the drive interlock on page 7-19
➥ The LED changes to a steady green light
➥ The system is in programming mode now (coding mode)!
☞ Remove the master key from the transponder receiver surface
➥ The LED changes to a rapidly blinking green light
☞ Hold the key to be programmed against the transponder receiver surface
➥ The key is coded once the LED comes on slowly three times
☞ Hold further keys next to the transponder receiver surface to code them as mentioned
above
The drive interlock is enabled as soon as there is no key contact for 30 seconds.
➥ Blinking red light

Options
Deleting programming/coding
☞ Disable the drive interlock with the master key and in addition, keep it close to the
transponder receiver surface for 30 – 45 seconds
– see Disabling the drive interlock on page 7-19
➥ The LED changes to a steady green light
➥ The system is in programming mode now (coding mode)!
☞ Hold the master key against the transponder receiver surface for a further 30 seconds
➥ The LED changes to a steady red light
➥ The system is in delete mode now (coding mode)!
☞ Remove the master key
➥ The LED changes to a rapidly blinking red light
☞ You have 30 seconds to hold the master key again to the transponder receiver surface
to confirm deletion.
➥ The system is deleted once the LED comes on slowly three times
Caution!
Deletion deletes all “normal“ transponders and the master!
• Reason: once a key is lost, you can no longer delete it!
• Therefore, the entire system is deleted for safety reasons and can be
completely recoded with the remaining (or newly ordered) keys.
Configuration of the deleted system

Once deletion is over, the system recognises any TREBE transponder key, i.e. the system
can be disabled with any key.
The first transponder key to be recoded for the system is automatically the new master and
can be used for coding the “normal” transponder keys – see Programming on page 7-19.
Important!
The following applies both to the coding and programming mode: the system
leaves the coding and programming modes and is disabled as soon as the ignition
key is inserted in the ignition lock and turned to the first position.

Options
7.11 Proportional controls

Functionn This control mode offers proportional operation of the auxiliary hydraulics circuit depending
on the position of switch B on the joystick.
You can also modify the properties of the characterisitic curve. Precision work, for instance
with the offset bucket, does not require the full throughput of the auxiliary hydraulics.
Therefore we recommend setting the controls to the low characteristic curve 1
(slow movements) – see Adjusting control response on page 7-22.
The slide switch is not pressed fully in this position and you can move the machine more
smoothly (flat characteristic curve).
If you require the full throughput then characteristic curve 2 will be the choice to make
(slide switch pressed as far as it will go).
Caution!
Always use button B (– see Hammer operation on page 7-22) on the joystick
for hammer operation.
☞ Do not operate the hammer with characteristic curve 1 too often since the
slide switch described above does not ensure full throughput, causing
power loss and system overheating.
Ports
Connections Hose designation

H T line
I P line
J Auxiliary hydraulics (left)
K Auxiliary hydraulics (right)

Options
Overview
Auxiliary hydraulics control/3rd control circuit control
☞ Move slide switch A to the left or right
☞ Slide switch A ensures proportional control of the auxiliary hydraulics circuit/of
the 3rd control circuit
A ☞ Button C ensures permanent changeover between auxiliary hydraulics and boom
swivelling
C
Hammer operation
Switching on hammer operation

☞ Press button B permanently on the control lever
B
Adjusting control response
Characteristic curve 1 (slow movements)

☞ Switch off ignition, hold slide switch A to the left and switch on ignition at the same time.
A Then wait 2 seconds and release the slide switch. The status display acknowledges by
flashing once.
Characteristic curve 2 (fast movements):

☞ Switch off ignition, hold slide switch A to the right and switch on ignition at the same
time. Then wait 2 seconds and release the slide switch. The status display
acknowledges by flashing twice.
Characteristic curves – status display
Displays the characteristic curve that has been selected for the control valve.
Characteristic curve 1 (slow movements)
☞ Telltale 1 in the status display flashes once after switching on ignition
Characteristic curve 2 (fast movements – max. throughput )
☞ Telltale 1 in the status display flashes twice after switching on ignition

Options
Wiring harness
Ports Hose designation

X10 Connector 1 control unit
X11 Connector 2 control unit
X12 Joystick (left)
X13 Changeover valve tip switch
F14 Blade-type fuse
K17 Relay changeover valve
X14 Joystick (right)
H10 Proportional circuit 1 telltale
H11 Proportional circuit 2 telltale
X8 Power supply
Y16 Connector 1 for auxiliary hydraulics
Y17 Connector 2 for auxiliary hydraulics
Y18 Connector 1 for 3rd control circuit
Y19 Connector 2 for 3rd control circuit

Options
Control valve plug assignment

X10 digital/analog inputs
PIN Description Connections

1 TX Serial interface
2 SW2 Hammer operation
3 SW4 Power
4 A_POT2 Joystick signal channel 2
5 A_POT1 Joystick signal channel 1
Control unit 6 U-analog Analogous supply +5V
7 R_POT1 GND joystick
8 R_POT2 GND potentiometer
9 A_POT3 Potentiometer signal
10 SW3 Auto
11 SW1 Pressure switch
12 RX Serial interface
X11 supply outputs
PIN Description Connections

1 M_ECU Earth
2 MVH1 + channel 1
3 MVH2 + channel 2
4 MVL1A Pulse modulation channel 1/magnet 1
5 LSW2 Telltale
6 LSW3 Telltale
7 MVL2A Pulse modulation channel 2/magnet 1
8 MVL2B Pulse modulation channel 2/magnet 2
9 MVL1B Pulse modulation M channel 1/magnet 2
10 MOT2 Engine
11 MOT1 Engine
12 U_ECU +12 V supply

Options
Safety features
☞ Microcontroller ... diagnoses errors supplied by the output stage.
☞ Monitor...disables the output stage if the microcontroller breaks down.
☞ Output stage...controls the status of the supply lines from the pressure regulating
valves
☞ Watchdog...disables the microcontroller in case the microcontroller breaks down
☞ Switch for valve supply...disables the power supply to the valves if a critical error is
detected.
Measures to be taken in case of malfunctions
Caution!
System breakdowns can never be excluded, therefore:
• Disconnect the electronic controls from the power supply before carrying out repair
work or maintenance on the hydraulic system
• Stay clear of areas and parts with danger of crushing
• Stay clear of in-between moving hydraulic components and fixed obstacles!
DANGER OF CRUSHING!
• The operator of the machine or hydraulic system must be aware of possible machine or
system errors
Diagnosis display
The control valve status is displayed to the user by means of a flashing code.
The following errors are identified by the number of flash pulses:
Critical
No. Pin no. Description Error Troubleshooting
error
0 - - No error - -
Check voltage,
1 B5 Channel 1 input (left) Defective input voltage home position: 2.5 V -
deflected: 0.7 V – 4.3 V
2 A4, A9 Channel 1 output; Y16/Y17 Overload or overheating (output stage) Check magnet on valve -
Short circuit on earth or operating volt-
3 A4, A9 Channel 1 output; Y16/Y17 Check wiring x
age
Check voltage,
4 B4 Channel 2 input (right) Defective input voltage home position: 2.5 V, -
deflected: 0.7 V – 4.3 V
5 A7, A8 Channel 2 output; Y18/Y19 Overload or overheating (output stage) Check magnet on valve -
Short circuit on earth or operating volt-
6 A7, A8 Channel 2 output; Y18/Y19 Check wiring x
age
7 - System start - x
8 A10, A11 Motor output Overheating (output stage) Check motor x
9 - - EEProm data error - x
10 B6 +5V joystick Defective 5V supply - x
The system switches off automatically if a critical error is detected. Activating the control
unit is only possible by repeatedly switching on the supply voltage.

Options
Only the error occurring last is issued if several errors occur at the same time. We
therefore recommend troubleshooting one error after another until the diagnosis telltale no
longer flashes.
In order to obtain a detailed status of the output stage for channels no. 1 and 2, the
hammer operation input must be activated during system start. The system flashes only
briefly if there are no errors.
In case of an error, the error code is issued in the following order of the pulse modulation
outputs:
☞ Channel 1/Magnet 1 > Pause > Channel 1/Magnet 2 > Pause > Channel 2/Magnet 1 >
Pause > Channel 2/Magnet 2
An error code (number of flash pulses) is assigned to each of the pulse modulation
outputs:
Error code Error
1 No error
2 overload, overtemp
3 open load
4 Short circuit on earth
The error code ends at the last output stage by displaying an error.
Examples:
➥ A : channel 2/magnet 1 has an “open load” interruption. The following flash sequence is
then issued:
1 > Pause > 1 > Pause > 3
Cause of error: interruption of coil from solenoid valve (Y19), wiring
interrupted, contact error on plug (Y16; X11)
➥ B: channel 1/magnet 1 has an “Overtemp” error and channel 2 has a “Short circuit to
earth” error, the following flash sequence is issued:
2 > Pause > 1 > Pause > 1 > Pause > 4
Cause of error:
• Channel 1: output stage overload; short circuit of coil from solenoid valve, short circuit
of valve wiring (not to earth or operating voltage)
• Channel 2: wiring, earth contact in valve

Options
7.12 Fuel-filling pump

Refuel with the fuel-filling pump A as follows:
☞ Place the machine on level ground
B ☞ Switch off the engine
A ☞ Insert the hose of fuel-filling pump A into the container with the fuel
– see Stationary fuel pumps on page 3-10
☞ Press button B to switch on fuel-filling pump A
➥ The fuel tank is full as soon as telltale C comes on
☞ Press button B to switch off fuel-filling pump A
Fig. 10: Fuel-filling pump
C Important!
Switch off the fuel-filling pump as soon as telltale C comes on, otherwise the fuel
tank may overflow and can be damaged.
• Bear in mind the fuel tank's maximum capacity
Fig. 11: Fuel-filling pump telltale
The float switch screwed into the fuel tank triggers the telltale.
Fig. 12: Float switch

Options
Connectionss The electric connection for the fuel-filling pump is already installed.
The telltale has its own wiring harness, connected to the engine/chassis wiring harness by
means of plug X16.

;
; 8

6
No. Up to To Colour mm²
38 XE16/2 drive alarm connection X17 float switch blk 1
41 XE16/1 drive alarm connection S60/1 telltale blu 1
100 X17 float switch S60/2 telltale vio 1

Options
7.13 Service valve

Functionn The service valve replaces the conventional oil drain plug by a quick coupler for draining
the engine oil more easily.
B • Let the engine run until reaching service temperature
C (oil temperature about 80 °C / 176°F)
• Place a container under the opening to collect the oil as it drains
• Unscrew cap A of oil drain valve B
• Screw in the drain coupling with a sufficiently long hose D, making sure the end of the
hose is in oil drip tray E
A ➥ Oil drain valve B opens and the engine oil drains
Fig. 13: Drain coupling with hose
• Completely drain the oil

• Unscrew drain coupling C
B
• Screw on cap A of the oil drain valve
C – see chapter Filling up engine oil on page 3-14
• Start the engine and let it run briefly at low revs
D
E • Switch off the engine
• Wait a moment until all the oil has run into the oil sump
• Check the oil level again
Fig. 14: Drain coupling with hose

Options
7.14 Automatic revs setting (Tier 3A from AG00573)
Function
The required diesel engine revs are mechanically adjusted by means of a cable pull, and
the manual throttle. The automatic revs setting is enabled via switch A in the cab.
If the automatic revs setting is enabled and the machine does not carry out any work
movements for about 5 seconds, the diesel engine is set to idling speed by means of the
hydraulic ram and the controls (= directional valve and time lag relay). As soon as a work
operation is carried out again, the engine is reset to the engine speed that has been set
A previously.
If the automatic revs setting is not enabled, engine speed is not lowered automatically.
This is then carried out mechanically with the cable pull and the manual throttle lever.

Options
Installation
Revs control retrofit kit 1 1

Wacker Neuson Linz GmbH
Haidfeldstraße 37
A-4060 Linz / Leonding
Telefon +43 (0) 732 / 90590-0
Fax +43 (0) 732 / 90590-200
E-Mail: [email protected]
www.wackerneuson.com
Kramer-Werke GmbH
Wacker Neuson Straße 1
D-88630 Pfullendorf
Tel. +49 (0 7552 9288-0
Fax +49 (0) 7552 9288-49-0
Wacker Neuson .
Crown Business Park
Dukestown, Tredegar
Gwent South Wales NP22 4EF
United Kingdom
Phone +44 (0) 1495 723083
Fax +44 (0) 1495 713941

38Z3 Service Manual

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Service Manual

Machine model 38Z3

Description Order no.

Operator's Manual 1000155267

Service manual 1000160891

Spare parts catalogue:

Copyright – 2006 Wacker Linz GmbH, Linz-Leonding

Wacker Neuson Linz GmbH

SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm I-1

Introduction .............................................................................................................. 3-8

I-2 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm

Maintenance of attachments ........................................................................... 3-44

SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm I-3

PVD-1B-34BP-10G5 (from AG00573) ..................................................................... 5-1

I-4 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm

Wiring diagram A4 38Z3 (legend) .......................................................................... 6-11

SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm I-5

Control valve plug assignment ......................................................................... 7-24

I-6 SERV-HB 38Z3 EN - Edition 2.1 * 38z3s2_1IVZ.fm

A combination of digits, or a combination of digits and letters, e.g. 40/188 or 40/A

SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-1

1.2 Identification of warnings and dangers

1-2 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

1.3 Designated use and exemption from liability

SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-3

1.4 Type labels and component numbers

Fig. 1: Type label: location Type label information

Fig. 3: Cab type label

Example:: Yanmar 46557

Fig. 4: Diesel engine number

1-4 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

Hydraulic pump number

Fig. 5: Hydraulic pump type label

Control valve number

Fig. 6: Main valve block type label

Travelling drive number

Fig. 7: Travelling drive type label

Swivel unit number

Fig. 8: Swivel unit type label

SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-5

1.5 Machine: overview

Fig. 9: Machine outside views

1-6 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

1.6 Cab overview

SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-7

1.7 Cab (legend)

1-8 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

1.8 Instrument panel overview (up to serial no. AE02803)

SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm 1-9

1.9 Instrument panel (legend)

Pos. Description For more information see page

1-10 SERV-HB 38Z3 EN – Edition 2.1 * 38z3s110.fm

1.10 Instrument panel overview (from serial no. AG00573)

Control elements for proportional controls version (option):

Control element on control console Control element on cab wall