Page 1 5200016122 0814 Track Excavator EZ38 OPERATOR’S MANUAL www.wackerneuson.com...
Page 2 – without prior permission in writing from the manufacturer. No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH.
Page 3: Table Of Contents
5.14 Decommissioning and putting the machine back into operation............5-57 5.15 Final decommissioning of machine..................... 5-59 Transport 6.1 Towing the machine ..........................6-1 6.2 Loading the machine ..........................6-3 6.3 Transporting the machine ........................6-6 OM EZ38 us 1.1 * ez38us1_1IVZ.fm...
Page 4: Table Of Contents
9.6 Steering system ............................ 9-2 9.7 Operating hydraulics..........................9-3 9.8 Electrical system........................... 9-4 9.9 Tightening torques ..........................9-6 9.10 Coolant ..............................9-7 9.11 Noise emissions............................ 9-7 9.12 Vibration..............................9-8 9.13 Weight..............................9-11 9.14 Payload/stability..........................9-13 Index Index ................................S-1 OM EZ38 us 1.1 * ez38us1_1IVZ.fm...
Page 5: Ec Declaration Of Conformity (Tier Iv Interim)
DIN EN ISO 12100:2010, DIN EN 474-1:2006+A1:2009, DIN EN 474-5:2012, DIN EN ISO 3471:2010, DIN EN ISO 3744:2010, DIN EN ISO 3449:2008, DIN EN ISO 13849-2:2012 Responsible for documentation Technical director Hörsching, Place, date EG-1 OM EZ38 us 1.1 * ez38konf.fm...
Page 6 DIN EN ISO 12100:2010, DIN EN 474-1:2006+A1:2009 (except 7.3), DIN EN 474-5:2012, DIN EN ISO 3471:2010, DIN EN ISO 3744:2010, DIN EN ISO 3449:2008, DIN EN ISO 13849-2:2012 Hörsching, Responsible for documentation Technical director Place, date EG-2 OM EZ38 us 1.1 * ez38konf.fm...
Page 7: Operator's Manual
This Operator’s Manual does not include special superstructures. Please contact your dealer if you require more information on the machine or the Operator’s Manual. OM EZ38 us 1.1 * ez38v100.fm...
Page 8 Information Identifies an information that, when followed, provides for a more efficient and economical use of the machine. Environment Failure to observe the instructions identified by this symbol can cause damage to the environment. OM EZ38 us 1.1 * ez38v100.fm...
Page 9 The machine can be equipped with an American Tier IV interim or Tier IV final engine, depending on the destination country. Both engine variants are described separately if there are engine-specific differences (regarding operation, for example). OM EZ38 us 1.1 * ez38v100.fm...
Page 10 (14.5 psi) 1 kg/cm² (14.22 lbs/in²) Force/output 1 kN (224.81 lbf) 1 kW (1.34 hp) 1 PS (0.986 hp) Torque 1 Nm (0.74 ft.lbs.) Speed 1 kph (0.62 mph) Acceleration 1 m/s² (3.28 ft/s²) OM EZ38 us 1.1 * ez38v100.fm...
Page 11: Warranty And Liability
Neuson Linz GmbH. Furthermore, all instructions in this Operator’s Manual must be observed. Have the maintenance on or with the machine, delivery inspection and the entries in the service booklet performed by an Wacker Neuson service center, otherwise warranty claims will not be acknowledged. Liability •...
Page 12 Notes: OM EZ38 us 1.1 * ez38v100.fm...
Page 13: Safety Symbols Found In This Manual
► Obey all safety messages that follow this symbol to avoid possible minor or moderate injury. NOTICE NOTICE indicates a situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 14: Warranty
5. Wacker Neuson shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions on labels and in this Operator’s Manual, and by the negligence of the duty to exercise due care when: •...
Page 15: Preparing To Use The Machine
Before starting up the machine, ALWAYS inspect the machine to make sure that it is ready for safe work and travel operation. • Wear close-fitting work clothes that do not hinder movement. Tie back long hair and remove all jewelry (including rings). OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 16 NEVER make any modifications, additions or conversions to the machine and its superstructures (for example, cab, etc.), or the machine’s attachments, without the approval of Wacker Neuson! Such modifications may affect safety and/or machine performance. This also applies to the installation and adjustment of safety devices and valves, as well as to welding work on load-bearing elements.
Page 17 The machine may be traveled with a raised load only if the path of the machine is level! • The machine operator must not raise loads over persons. • The machine operator may not leave his seat as long as the load is raised. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 18: Operator And Technician Qualifications And Basic Responsibilities
With regard to specific operational features, e.g. those relevant to job organization, work sequences or the persons entrusted with the work, supplement the Operator's Manual by corresponding instructions, including those relevant to supervising and reporting duties. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 19 However, make sure that motorists of public roads will not be temporarily blinded by the work lights. • Provide additional lighting on the job site if the lights of the machine are not sufficient for performing work safely. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 20 Never install a man basket or a working platform to the machine. Mechanical integrity • Take the necessary precautions to make sure the machine is used only when in a safe and serviceable state. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 21: Applications With Lifting Gear
Have loads fastened, and crane operators instructed, by a qualified person competent in raning operation and standard hand signals. The person giving instructions to the operator must be within sight of the operator during load attachment and load disconnection. OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 22: Attachments
• If an optional attachment is installed, make sure that all lights and associated indicator lights are installed and functional. 2-10 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 23: Transport And Towing
Personal safety measures • Brief the technician and the operator before beginning maintenance or repair work. Appoint someone to supervise the activities. 2-11 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 24 Observe the adjustment, maintenance and inspection activities and intervals set forth in this Operator’s Manual, including information on the replacement of parts and partial equipment. These activities must be performed only by qualified personnel. 2-12 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 25 Special Hazards Battery • In case of a frozen battery or of an insufficient electrolyte level, do not try starting the machine with battery jumper cables. The battery can burst or explode. 2-13 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 26 Tracks • Repair work on the tracks must be performed only by trained technical staff or by a Wacker Neuson service center. • Malfunctioning tracks reduce the machine's operational safety. Therefore, check the tracks regularly for cracks, cuts or other damage.
Page 27 • Before performing welding, flame-cutting and grinding work, clean the machine and its surroundings from dust and other flammable substances, and make sure the premises are adequately ventilated – risk of explosions! 2-15 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 28: Safety Guidelines During Using Internal Combustion Engines
Refill the fuel tank in a well-ventilated area. • Replace the fuel tank cap after refueling. • Do not smoke. • Do not refuel a hot or running engine. • Do not refuel the engine near an open flame. 2-16 OM EZ38 us – 1.1* * Sicherheit(us).fm...
Page 29: Machine Overview
Rotating beacon (option) Door arrester Engine cover Fuel tank filler inlet Exhaust pipe Eye hook for tying down the machine Stabilizer blade Travel gear Handle Auxiliary hydraulics Door handle and lock Tank cover Fig. 3 OM EZ38 us 1.1 * ez38e300.fm...
Page 30: Brief Description Of The Machine
E07-02 EZ38 Brief description of the machine The machine model EZ38 is a self-propelled work machine. Get informed on and follow the legal regulations of your country. This machine is a versatile and powerful helper for moving earth, gravel and debris on construction sites and elsewhere. A wide range of attachments accounts for the numerous applications of the machine, among others hammer and grab applications.
Page 31 Protection against heavy falling objects (FOPS) or heavy objects penetrating into the cabin from the front (Front Guard), such as trees, pieces of rock, for machines that are used for clearance work, demolition work and forestry work. OM EZ38 us 1.1 * ez38e300.fm...
Page 32: Notices And Regulations On Use
3-5. - Every other use is regarded as not designated for the use of the machine. Wacker Neuson will not be liable for damage resulting from use other than mentioned above. The operator/machine owner alone will bear the risk.
Page 33 In order to avoid damage to the machine, only the attachments listed below have been certified for installation on the machine. ► Contact a Wacker Neuson service center if you wish to use other attachments. Using attachments of other manufacturers, or attachments which have been released for other machine types, can reduce the machine’s output...
Page 34 EZ38 with hydraulic Easy Lock quickhitch Bucket type Width Weight Capacity Ditch cleaning bucket 1400 mm (55 in) 121 kg (267 lbs) 0.158 m (5.6 ft Offset bucket 1200 mm (47 in) 142 kg (313 lbs) 0.129 m (4.6 ft...
Page 35: Labels
Maximum payload Front gross axle weight rat- Zul. Achslast vorne/front GAWR/PNBE AV: Rear gross axle weight rat- Zul. Achslast hinten/rear GAWR/PNBE AR: EWG Nr./CEE no.: EEC check number Baujahr/model year/année fabr.: Year of construction OM EZ38 us 1.1 * ez38e300.fm...
Page 36 The serial number of the Powertilt is stamped in the housing near the hydraulic connections. The serial number of the hydraulic quickhitch is located on the type label. The type label is located on the hydraulic quickhitch fork. Fig. 9 OM EZ38 us 1.1 * ez38e300.fm...
Page 37 Fig. 11 Front Guard type label The type label is located at the upper right of the chassis. Fig. 12 Information Type, quantity and position of the labels depend on options, country and machine. OM EZ38 us 1.1 * ez38e300.fm...
Page 38 Warning labels Fig. 13 3-10 OM EZ38 us 1.1 * ez38e300.fm...
Page 39 Modifications to the structure (welding, driling, for example), retrofitting and incorrect repairs affect the protective effect of the cabin/canopy and can cause serious injuries and even death. Position On the rear window. Fig. 19 3-11 OM EZ38 us 1.1 * ez38e300.fm...
Page 40 On the front window. Fig. 20 Meaning Accumulator is under high pressure. Maintenance or repair work may only be performed by a Wacker Neuson service center. Position In the engine compartment on the cover of the relay box. Fig. 21...
Page 41 Failure to observe this can cause the machine to tip over, which in turn can cause serious injuries and even death. Read and understand the Operator’s Manual. Position On the B pillar on the left in traveling direction. Fig. 25 3-13 OM EZ38 us 1.1 * ez38e300.fm...
Page 42 Position On the boom on the left and right. Fig. 27 Meaning Reflector at the rear. Position On either side of the machine at the rear. Fig. 28 3-14 OM EZ38 us 1.1 * ez38e300.fm...
Page 43 Labels Fig. 29 3-15 OM EZ38 us 1.1 * ez38e300.fm...
Page 44 On either side of the stabilizer blade, and on either side of the travel gear Fig. 33 Meaning Indication of sound power level produced by the machine. = sound power level. Position At the front on the chassis. Fig. 34 3-16 OM EZ38 us 1.1 * ez38e300.fm...
Page 45 Meaning This label indicates the position in which the control levers are locked. Position On the left-hand control lever base. Fig. 37 Meaning Fuses. Position At the left under the seat. Fig. 38 3-17 OM EZ38 us 1.1 * ez38e300.fm...
Page 46 On the roof window on right-hand side in driving direction. Fig. 40 Meaning The coolant must have a thermal stability of at least –30 °C (–22 °F). Position In the engine compartment on the expansion tank. Fig. 41 3-18 OM EZ38 us 1.1 * ez38e300.fm...
Page 47 (Operating Pattern A: ISO controls). Check before starting the machine the operating pattern that has been chosen. Position On the roof window on right-hand side in traveling direction. Fig. 44 3-19 OM EZ38 us 1.1 * ez38e300.fm...
Page 48 This label describes the functions of the hydraulic Easy Lock quickhitch. Position On the roof window on right-hand side in traveling direction. Fig. 46 Meaning This label shows how to refuel with a fuel-filling pump. Position Near the fuel-filling pump. Fig. 47 3-20 OM EZ38 us 1.1 * ez38e300.fm...
Page 49: Putting Into Operation 4.1 Cabin/Control Stand
Stop the machine (see chapter “Operation, stopping the machine”). Fig. 48 Cabin entry and exit (option) Stop the machine (see chapter “Operation, stopping the machine”). Information During entering or leaving the cabin, the door must be locked in the arrester. Fig. 49 OM EZ38 us 1.1 * ez38i400.fm...
Page 50 Unlocking the door: 1. Turn the key in door lock A counter-clockwise (L). 2. The door is unlocked. Fig. 50 Opening the door from the inside: Press lever A on the door lock downward. Fig. 51 OM EZ38 us 1.1 * ez38i400.fm...
Page 51 Securing an open door Press bracket A against arrester B until it engages with an audible click. Fig. 52 Releasing the door arrester Pull button A to release the door out of the arrester. Fig. 53 OM EZ38 us 1.1 * ez38i400.fm...
Page 52 ► Keep extremities and clothing clear of the window channel. Opening the front window Fig. 54 1. Keep levers A pressed on the left and right, and pull the front window upward with both handles B. Fig. 55 OM EZ38 us 1.1 * ez38i400.fm...
Page 53 1. Press levers A on the left and right, and pull the front window downward with both handles B. Fig. 57 2. Press levers A on either side and engage them in the lock. Fig. 58 OM EZ38 us 1.1 * ez38i400.fm...
Page 54 1. Keep levers A pressed on the left and right, and pull the lower front window downward with handles B. 2. Release levers A and let them engage in both locks C. Fig. 61 OM EZ38 us 1.1 * ez38i400.fm...
Page 55 3. Keep levers A pressed on the left and right, and pull the entire front window upward with both handles B. Fig. 64 4. Release levers A and let them engage in both locks C. Fig. 65 OM EZ38 us 1.1 * ez38i400.fm...
Page 56 3. Keep levers A pressed on the left and right, and pull the lower front window downward with handles B. 4. Release levers A and let them engage in both locks C. Fig. 68 OM EZ38 us 1.1 * ez38i400.fm...
Page 57 2. Press the front window forward and let it engage. Fig. 70 Opening/closing the side window Open Press lever D upward and let the side window engage in the required recess. Close Press lever D upward and close. Fig. 71 OM EZ38 us 1.1 * ez38i400.fm...
Page 58: Emergency Exit
The rear or right window can be used as an emergency exit if the door is blocked. The rear window is broken with emergency hammer A fastened over the rear window. Fig. 72 4-10 OM EZ38 us 1.1 * ez38i400.fm...
Page 59 1. Sit down on the seat. 2. Pull lever B upward and lean back at the same time to push the backrest into the required position. 3. Let lever B lock into place. Fig. 74 4-11 OM EZ38 us 1.1 * ez38i400.fm...
Page 60 Horizontal adjustment 1. Sit down on the seat. 2. Pull lever C upward and move the seat forward or backward at the same time. Fig. 75 4-12 OM EZ38 us 1.1 * ez38i400.fm...
Page 61 Accident hazard! Do not adjust the seat belt during machine operation! Adjusting the seat belt during machine operation can cause serious injuries or death. ► Adjust the seat belt before machine operation. ► Ensure that the buckle is inserted (pull test). 4-13 OM EZ38 us 1.1 * ez38i400.fm...
Page 62 Hold buckle latch A at a right angle to the seat belt and pull the seat belt to the required length. Shorter seat belt adjustment Pull the free end of the seat belt and shorten it to the required length. Fig. 78 4-14 OM EZ38 us 1.1 * ez38i400.fm...
Page 63 Accident hazard! Do not adjust the seat belt during machine operation! Adjusting the seat belt during machine operation can cause serious injuries or death. ► Adjust the seat belt before machine operation. ► Ensure that the buckle is inserted (pull test). 4-15 OM EZ38 us 1.1 * ez38i400.fm...
Page 64 Fig. 79 Unfastening the retracting seat belt 1. Press the red pushbutton switch D on seat belt buckle B until the buckle latch comes out. Seat belt C is automatically retracted. Fig. 80 4-16 OM EZ38 us 1.1 * ez38i400.fm...
Page 65 Operator’s Manual. The operator must observe the local regulations. • Use safety-oriented ladders and work platforms for adjustment work on the machine. • Never use machine parts or attachments/superstructures as a climbing aid. 4-17 OM EZ38 us 1.1 * ez38i400.fm...
Page 66 We recommend having the mirrors adjusted by a second person. Information Do not make any changes or modifications that impair visibility. Otherwise the machine does not meet the requirements for conformity and licensing. 4-18 OM EZ38 us 1.1 * ez38i400.fm...
Page 67 ➥ The selected elements must not move. ➥ Work may be performed with the machine. 8. The selected elements move: ➥ Stop operation immediately. ➥ Contact a Wacker Neuson service center and have the malfunction rectified. 4-19 OM EZ38 us 1.1 * ez38i400.fm...
Page 68 Information Ensure the firm and safe mounting of the fire extinguisher. Check the fire extinguisher at regular intervals, also ensure that it is safely installed. Fig. 84 Observe the manufacturer’s indications. 4-20 OM EZ38 us 1.1 * ez38i400.fm...
Page 69 ► Replace the complete protective structure if it is damaged, deformed and/or cracked. ► Contact a Wacker Neuson service center in case of doubt. ► Retrofit, assembly and repair work may only be performed by a Wacker Neuson service center.
Page 70 ► The machine owner must ensure that only work is performed that does not require any higher protection. ► Accidents cannot be fully avoided despite equipping a machine with protective structures. 4-22 OM EZ38 us 1.1 * ez38i400.fm...
Page 71 6. Tighten screws B (M12) and lock nuts on the left and right to 87 Nm (64 ft.lbs). Fig. 86 7. Install the light in position C (option). 8. Install the mirror in positions D (option). Fig. 87 4-23 OM EZ38 us 1.1 * ez38i400.fm...
Page 72 ► The machine owner must ensure that only work is performed that does not require any higher protection. ► Accidents cannot be fully avoided despite equipping a machine with protective structures. 4-24 OM EZ38 us 1.1 * ez38i400.fm...
Page 73 5. Mounting point for protective structure: A. 6. Tighten screws B and lock nuts on the left and right to 65 Nm (48 ft.lbs.). Fig. 89 7. Mounting point for cabin/canopy: C Fig. 90 4-25 OM EZ38 us 1.1 * ez38i400.fm...
Page 74 2. Remove all lights and mirrors (option). 3. A minimum 2 persons are required for installing/removing. 4. Install the lock nuts and screws on either side. Fig. 91 5. Mounting point for protective structure: A (upper). Fig. 92 4-26 OM EZ38 us 1.1 * ez38i400.fm...
Page 75 Fig. 94 8. Tighten lock nuts and screws E to 65 Nm (48 ft.lbs.). 9. Install the mirror in both positions F (option). 10.Install the light in position G (option). Fig. 95 Fig. 96 4-27 OM EZ38 us 1.1 * ez38i400.fm...
Page 76 ► Accidents cannot be fully avoided despite equipping a machine with protective structures. The shatter protection can be combined with a protective Front Guard structure if the machine is equipped with a canopy. 4-28 OM EZ38 us 1.1 * ez38i400.fm...
Page 77 Job site Height of job site A: 120 cm (47 in). Fig. 97 Figures 97 and 98 refer to work with a Wacker Neuson hydraulic hammer. Information Working with another attachment can modify the height of the job site. Fig. 98 Installing 1.
Page 78 Fig. 102 6. Tighten screw D to 85 Nm (63 ft.lbs). 7. Tighten screw E to 85 Nm (63 ft.lbs). Fig. 103 8. Tighten screw F to 85 Nm (63 ft.lbs). Fig. 104 4-30 OM EZ38 us 1.1 * ez38i400.fm...
Page 79: Overview Of Control Elements
This chapter describes the controls, and contains information on the function and handling of the indicator lights and controls in the cabin. The pages stated in the table refer to the description of the controls. 4-31 OM EZ38 us 1.1 * ez38i400.fm...
Page 80 Cabin Fig. 106 Overview of control elements Fig. 106Overview of control elements – proportional controls 4-32 OM EZ38 us 1.1 * ez38i400.fm...
Page 81 22 Powertilt (AUX II) or 3rd control circuit (AUX II) operation (proportional controls option) 5-30, 5-29 23 Boom swivel, auxiliary hydraulics (AUX I) operation (proportional controls option) 5-26, 5-25 24 Boom swivel pedal (proportional controls option) 4-33 OM EZ38 us 1.1 * ez38i400.fm...
Page 82 Display element and switches Right switch panel (cabin) Right switch panel (canopy) Switch panel on left-hand control lever base Fig. 107 4-34 OM EZ38 us 1.1 * ez38i400.fm...
Page 83 43 Wiper/wash system (cabin) 44 Rotating beacon (option) 45 Ventilation/heating (cabin) 5-11 5-12 46 Air conditioning 47 Automatic engine speed setting (option Tier IV interim) 4-38 48 Maintenance meter 4-38 49 Service hours 50 Hours 4-35 OM EZ38 us 1.1 * ez38i400.fm...
Page 84: Indicator Lights And Warning Lights (Overview)
The indicator light (yellow) illuminates if the starting key is in position 2. The indicator light goes out after 4 seconds and the engine can be started. (Air is preheated.) Contact a Wacker Neuson service center if the indicator light does not go out. Safe load indicator light The safe load indicator gives the operator optical (red) and acoustic warnings when the values of the stability table are reached or exceeded.
Page 85 In cold weather the indicator light can illuminate immediately when the engine is started. Warm up the machine at low engine speed and little load. Contact a Wacker Neuson service center if the indicator light does not go out. Air filter monitoring The indicator light (red) illuminates if the air filter is dirty and if it has to be replaced.
Page 86 The maintenance meter starts at 500.0 hours. It counts down to 0.0 hours. A wrench symbol flashes as soon as the maintenance meter reaches this value. The meter keeps on counting down (−0.1 hours, −0.2 hours, etc.). 4-38 OM EZ38 us 1.1 * ez38i400.fm...
Page 87: Preparatory Work
Immediately remove dirt, for example oil, grease, dirt, snow or ice. Always use the mandatory climbing aids during entering and exiting the machine. Never get on a moving machine and never jump off the machine. 4-39 OM EZ38 us 1.1 * ez38i400.fm...
Page 88 Rags, tools and other loose objects removed? Seating position adjusted correctly? 4-11 Are all mirrors functional and adjusted correctly? 4-17 Seat belt fastened? 4-13 Before putting the machine into operation, ensure that no one is in the danger zone. 4-40 OM EZ38 us 1.1 * ez38i400.fm...
Page 89 Machine adequately secured? Machine additionally secured with chocks under the tracks to prevent it from rolling away? When parking on slopes: Machine additionally secured with chocks under the tracks to prevent it from rolling away? 4-41 OM EZ38 us 1.1 * ez38i400.fm...
Page 90 – see chapter “7.2 Maintenance overview” on page 7-2. traveling on public roads Information The machine is not certified for travel on public roads. 4-42 OM EZ38 us 1.1 * ez38i400.fm...
Page 91: Starting And Stopping The Engine
Function Park position Not assigned Stop position Insert or remove the starting key Travel position All electric functions are enabled Preheats the engine Preheater active Starts the engine Starter is actuated Fig. 108 4-43 OM EZ38 us 1.1 * ez38i400.fm...
Page 92: Starting The Engine
During the warm-up phase, check for unusual noise, exhaust color, leaks, malfunctions or damage. In case of malfunctions, damage or leaks, park and secure the machine, and find out the cause for the damage and have it repaired. 4-44 OM EZ38 us 1.1 * ez38i400.fm...
Page 93 Damage to the electrical system of the machine. ► The vehicles must not touch each other during the starting aid. NOTICE Damage to consumers of vehicle with discharged battery due to voltage peaks. ► Switch off all consumers. 4-45 OM EZ38 us 1.1 * ez38i400.fm...
Page 94 Once the engine has started: With the engine running, disconnect both jump leads in exactly the reverse order (first the negative terminal –, then the positive terminal +). ➥ This prevents sparking. Starting battery Fig. 111 4-46 OM EZ38 us 1.1 * ez38i400.fm...
Page 95: Stopping The Engine
► In order to avoid heat accumulation, let the engine run at idling speed with no load for at least 5 minutes, and then stop it. Turn the starting key to “0” and remove it. Fig. 112 4-47 OM EZ38 us 1.1 * ez38i400.fm...
Page 96 ► Do not operate the battery master switch with a running engine. Interrupting power supply: Turn the key to position B and remove it. Establishing power supply: Insert the key and turn it to position A. Fig. 113 4-48 OM EZ38 us 1.1 * ez38i400.fm...
Page 97: Steering System
The machine automatically switches to slow speed if it encounters a higher driving resistance (for example in curves). If the driving resistance is reduced, the machine automatically switches back to high speed. Fig. 116 OM EZ38 us 1.1 * ez38b500.fm...
Page 98: Brakes
Reduce travel speed with the travel levers/travel pedals, and not with the engine speed control of the engine. Mechanical brake The stabilizer blade is used as a parking brake. Press the stabilizer blade against the ground. OM EZ38 us 1.1 * ez38b500.fm...
Page 99: Travel Operation
The following operating conditions must be fulfilled in order to ensure optimal output and a long service life of the machine. Do not operate the machine at ambient temperatures above +45 °C (+104 °F) or below −15 °C (−5 °F). OM EZ38 us 1.1 * ez38b500.fm...
Page 100: Traveling On Slopes
Perform slow and smooth travel movements. • Avoid sudden travel movements. • Reduce the engine speed. The machine can slip even on gentle slopes if it travels across grass, leaves, humid metal surfaces, frozen ground or ice. OM EZ38 us 1.1 * ez38b500.fm...
Page 101 Raise the boom about 20 – 30 cm (8 – 12 in) off the ground and position it straight ahead at the center of the machine. Do not exceed a maximum sloping angle of 15°. < 15° Fig. 122 OM EZ38 us 1.1 * ez38b500.fm...
Page 102 < 10° Fig. 123 On lateral inclinations over 10°, pile up material to create a horizontal, firm and level surface that can be used as a platform for the machine. > 10° Fig. 124 OM EZ38 us 1.1 * ez38b500.fm...
Page 103: Parking The Machine
Position the boom on the downhill side of the machine and firmly press the attachment into the ground. • Press the stabilizer blade against the ground. • Secure the tracks accordingly (chocks, blocks, for example) as shown Fig. 126. Fig. 126 OM EZ38 us 1.1 * ez38b500.fm...
Page 104: Differential Lock
If this is yet not enough to illuminate the job site sufficiently, stop work and only take it up again if sufficient illumination can be ensured. Position Designation Working light (standard) Front and rear working lights (option) Fig. 128 OM EZ38 us 1.1 * ez38b500.fm...
Page 105 44 illuminates Rotating beacon switched off, Press switch 44 up the indicator light in switch 44 goes out Fig. 131 Information Observe the legal regulations of your country for operating the rotating beacon. OM EZ38 us 1.1 * ez38b500.fm...
Page 106: Wiper/Wash System
► Do not rely on the traveling signal under any circumstances. ► If the traveling signal does not sound, stop machine operation immediately and get in touch with a Wacker Neuson service center (observe the relevant national regulations). Wiper/wash system Front wiper The switch is located on the right-hand switch panel.
Page 107: Heating, Ventilation And Air Conditioning System
Fig. 135 Temperature setting The temperature controller is located on the right below the seat. Ventilation Turn temperature controller 14 clockwise. Heating Turn temperature controller 14 counter-clockwise. Fig. 136 5-11 OM EZ38 us 1.1 * ez38b500.fm...
Page 108 Let the air conditioning system run once a month for at least 10 – 15 Fig. 137 minutes to ensure its full function and efficiency. Information During machine operation with air conditioning turned on, the machine‘s hydraulic performance is slightly reduced. 5-12 OM EZ38 us 1.1 * ez38b500.fm...
Page 109: Operating Hydraulics
Retract stick Swivel upper carriage to the left Swivel boom to the right Swivel boom to the left Lower boom Dump bucket Raise boom Curl bucket Lower stabilizer blade Raise stabilizer blade ISO controls 5-13 OM EZ38 us 1.1 * ez38b510.fm...
Page 110 Retract stick Swivel upper carriage to the left Swivel boom to the right Swivel boom to the left Lower boom Dump bucket Raise boom Curl bucket Lower stabilizer blade Raise stabilizer blade SAE controls 5-14 OM EZ38 us 1.1 * ez38b510.fm...
Page 111 Move forward Machine moves forward Move forward Move backward Machine moves backward Move backward Move backward Machine turns to the left Move forward Move forward Machine turns to the right Move backward Fig. 138 5-15 OM EZ38 us 1.1 * ez38b510.fm...
Page 112 Bear in mind the extended width of the machine. Rotating the upper carriage to the left Push the left-hand control lever to the left. Fig. 139 5-16 OM EZ38 us 1.1 * ez38b510.fm...
Page 113 1. Park the machine on firm, level and horizontal ground. 2. Raise the machine with the stabilizer blade as far as it will go. Fig. 141 5-17 OM EZ38 us 1.1 * ez38b510.fm...
Page 114 ➥ If the attachment does not move from the piece of wood: ➥ Machine is operational. ➥ If the attachment moves away from the piece of wood: ➥ Stop operation immediately. ➥ Contact a Wacker Neuson service center and have the malfunction rectified. Fig. 145 5-18...
Page 115 ► Always secure the wing nut on the changeover lever of the directional valve. ► Do not operate the machine with a malfunctioning wing nut. Contact a Wacker Neuson service center and replace the malfunctioning wing nut. The changeover valve is located at the front left under the travel gear.
Page 116 Information The stabilizer blade is also used as a parking brake. ► Press the stabilizer blade against the ground. Information In order to ensure maximum stability during operate: ► Lower the stabilizer blade. 5-20 OM EZ38 us 1.1 * ez38b510.fm...
Page 117 If the full oil flow is required, turn the rotary switch to the right (MAX). Fig. 150 (left-hand control lever base) Fig. 151 (right-hand control lever base) 5-21 OM EZ38 us 1.1 * ez38b510.fm...
Page 118 If several sizes of hydraulic hammers are available for the machine, the following applies when using the Powertilt unit: ► Always use the smallest possible hydraulic hammer. ► Contact your dealer for information on the correct equipment. 5-22 OM EZ38 us 1.1 * ez38b510.fm...
Page 119 ► Stop work immediately if a hydraulic hose moves back and forth in an unusual manner. The pressure accumulator could be malfunctioning. Contact a Wacker Neuson service center and have the malfunction rectified immediately. ► Do not use the impact force of the attachment to perform demolition work.
Page 120 Fig. 153 Switching on hammer operation: Push slide switch 23 on the right-hand control lever to the left. Switching off hammer operation: Release slide switch 23 on the right control lever. Fig. 154 5-24 OM EZ38 us 1.1 * ez38b510.fm...
Page 121 Oil flow to left-hand line: Push slide switch 23 on the right-hand control lever to the left. Oil flow to right-hand line: Push slide switch 23 on the right-hand control lever to the right. Fig. 157 5-25 OM EZ38 us 1.1 * ez38b510.fm...
Page 122 Swiveling the boom to the right: Push slide switch 23 on the right-hand control lever to the right. Swiveling the boom to the left: Push slide switch 23 on the right-hand control lever to the left. Fig. 161 5-26 OM EZ38 us 1.1 * ez38b510.fm...
Page 123 ► Never exceed the weight and mass values specified in the stability table. Lifting gear applications are only allowed with both the following Wacker Neuson lifting gear: • Joint rod with lifting eye • Powertilt unit with load hook Fig. 162 (symbolic representation) 5-27 OM EZ38 us 1.1 * ez38b510.fm...
Page 124 Reduce the load until the indicator light goes out and the warning no longer sounds. Suitable OSHA-rated and approved equipment for fastening and securing loads must be available. Fig. 163 – see chapter “ Safe load indicator (option)” on page 5-48 Fig. 164 5-28 OM EZ38 us 1.1 * ez38b510.fm...
Page 125 Oil flow to left-hand line: Push slide switch 22 on the left-hand control lever to the left. Oil flow to right-hand line: Push slide switch 22 on the left-hand control lever to the right. Fig. 166 5-29 OM EZ38 us 1.1 * ez38b510.fm...
Page 126 The Powertilt unit may only be installed and removed by a Wacker Neuson service center! Adjust the required oil flow with the rotary switch on the left-hand control lever base. Fig. 167 Actuating the Powertilt unit Fig. 168 5-30 OM EZ38 us 1.1 * ez38b510.fm...
Page 127 Push slide switch 22 on the left-hand control lever to the left. Rotating the Powertilt unit to the right: Push slide switch 22 on the left-hand control lever to the right. Fig. 169 5-31 OM EZ38 us 1.1 * ez38b510.fm...
Page 128 For operation-specific reasons, only use the function “Raise stabilizer blade” to open or close. Picking up an attachment 1. Unlock and press switch 42. ➥ The buzzer sounds. ➥ The hydraulic quickhitch is enabled and can be operated. Fig. 170 5-32 OM EZ38 us 1.1 * ez38b510.fm...
Page 129 8. Release foot-operated pushbutton switch 3. 9. Pull and hold stabilizer-blade lever 8 as far as it will go. ➥ The quickhitch closes. 10.Release stabilizer-blade lever 8. 11.Switch off switch 42. ➥ The buzzer is silent. Fig. 174 5-33 OM EZ38 us 1.1 * ez38b510.fm...
Page 130 Fig. 176 3. Press and hold foot-operated pushbutton switch 3. 4. Pull and hold stabilizer-blade lever 8 as far as it will go. ➥ The quickhitch opens and unlocks the attachment. Fig. 177 5-34 OM EZ38 us 1.1 * ez38b510.fm...
Page 131 9. Release foot-operated pushbutton switch 3. 10.Pull and hold stabilizer-blade lever 8 as far as it will go. ➥ The quickhitch closes. 11.Release the stabilizer-blade lever. 12.Switch off switch 42. ➥ The buzzer is silent. Fig. 179 5-35 OM EZ38 us 1.1 * ez38b510.fm...
Page 132 1. Move both levers A on the ball-type cock to position B. ➥ Notch C indicates the flow direction. Fig. 181 Stopping bucket operation: 1. Move both levers A on the ball-type cock to position C. Fig. 182 5-36 OM EZ38 us 1.1 * ez38b510.fm...
Page 133 3rd control circuit or Powertilt (option) Auxiliary hydraulics Hammer return line Fig. 183 Stick (left) Information Follow the instructions in the Operator’s Manual of the attachment manufacturer for connecting the hydraulics to the attachment. Fig. 184 Stick (right) 5-37 OM EZ38 us 1.1 * ez38b510.fm...
Page 134 ► After hitching the attachment or before starting work, ensure that the lock or the pins are correctly connected with the mount. ► Ensure correct locking with a short and rapid succession of stick and bucket movements as close as possible to the ground. 5-38 OM EZ38 us 1.1 * ez38b510.fm...
Page 135 The hydraulic system of the machine is still pressurized even when the engine is not running. Due to the residual pressure, the hydraulic quick couplers can be removed but not installed back on again. ► Release the pressure. 5-39 OM EZ38 us 1.1 * ez38b510.fm...
Page 136 This can be seen by the brief movement the hoses make as the pressure is released. ➥ Uncouple the attachment immediately after the pressure has been released, otherwise pressure can be created again! 5-40 OM EZ38 us 1.1 * ez38b510.fm...
Page 137 7. Insert pin F. 8. Actuate the stick hydraulic cylinder until bores H and I are flush. 9. Stop the engine. Raise the control lever base. Fig. 186 10.Insert pin J. Install linch pins K. 5-41 OM EZ38 us 1.1 * ez38b510.fm...
Page 138: Work Operation
• Do not use the falling force of the attachment as a hoe, hammer or pile- driver. ➥ Working this way can greatly reduce the machine’s service life. Fig. 190 5-42 OM EZ38 us 1.1 * ez38b510.fm...
Page 139 During performing deep excavations with the stabilizer blade at the front, ensure that the boom hydraulic cylinder or attachment do not touch the stabilizer blade. • Position the stabilizer blade at the rear if possible. Fig. 194 5-43 OM EZ38 us 1.1 * ez38b510.fm...
Page 140 Lubricate lubrication points again that were immersed in water for a longer time in order to expel the old grease. Never immerse the live ring or the upper carriage in water. Fig. 197 5-44 OM EZ38 us 1.1 * ez38b510.fm...
Page 141 Fig. 199 • The machine can be used in tight spaces for excavating laterally. - To do this: rotate the upper carriage and swivel the boom at the same time. Fig. 200 5-45 OM EZ38 us 1.1 * ez38b510.fm...
Page 142 Set the depth of the layer you want to remove with the stabilizer-blade lever. ➥ The machine must not be raised by lowering the stabilizer blade. The clearance between the stabilizer blade and the ground should be about 1 cm (0.4 in). Fig. 202 5-46 OM EZ38 us 1.1 * ez38b510.fm...
Page 143: Emergency Lowering
2. Lower the control lever base. 3. Push the right-hand control lever forward until the boom is fully lowered. 4. Return the control lever to neutral. Information Lower the boom immediately after stopping the engine. 5-47 OM EZ38 us 1.1 * ez38b510.fm...
Page 144: Options
7. The acoustic signal does not sound, or the indicator light does not illuminate. ➥ The machine may not be used for lifting gear applications. ➥ Contact a Wacker Neuson service center and have the malfunction rectified. Perform a functional check of the control lever base.
Page 145 31 illuminates and an acoustic signal sounds. Fig. 204 Switching off the safe load indicator 1. Press switch 41 on the instrument panel forward. Fig. 205 5-49 OM EZ38 us 1.1 * ez38b510.fm...
Page 146 The load holding control valve (boom and stick) is adjusted and sealed at the factory. The correct functioning is no longer ensured and warranty is void if the seal is removed or if the load holding control valve is tampered with. 5-50 OM EZ38 us 1.1 * ez38b510.fm...
Page 147 4. Raise the control lever base. 5. Remove the starting key and lock the cabin. 6. Secure the machine and the attachment. 7. Contact a Wacker Neuson service center and have the malfunction rectified. Environment Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner.
Page 148 1. Insert master key B in the starter lock. 2. Turn the starting key to position 1 for a minimum 20 seconds. 3. All coded keys are deleted after 20 seconds, and all existing keys can be re-coded. 5-52 OM EZ38 us 1.1 * ez38b510.fm...
Page 149 If the starter is not actuated within 60 seconds after entering the code, the drive interlock is switched off again and the indication flashes red. Humidity or dust can penetrate into housing if the surface of the keys is damaged. Contact a Wacker Neuson service center. 5-53 OM EZ38 us 1.1 * ez38b510.fm...
Page 150 ► Ensure that no parts of the body protrude outside the machine. ► All persons must stay clear of the danger zone when tilting the machine. ► Neither access nor leave the machine when it is tilted. 5-54 OM EZ38 us 1.1 * ez38b510.fm...
Page 151 Walls or parts of building possibly touched by machine. ► During working in the immediate vicinity of a wall or parts of a building, ensure that the upper carriage does not touch anything when it is tilted. 5-55 OM EZ38 us 1.1 * ez38b510.fm...
Page 152 The stick is damaged if it is hit by the bucket base. ► Do not dump the bucket completely if it is used as a shovel bucket. Fig. 210 Trailer operation The machine is not certified for trailer operation! 5-56 OM EZ38 us 1.1 * ez38b510.fm...
Page 153: Decommissioning And Putting The Machine Back Into Operation
10.Remove the battery and store it in a safe place. Charge the battery and perform battery maintenance at regular intervals. 11.Set the fuel cock to OFF. 12.Close the air-intake openings of the air filter system and exhaust pipe. 5-57 OM EZ38 us 1.1 * ez38b510.fm...
Page 154 Putting the machine back into operation Information If the machine was decommissioned over a longer period of time without performing the specified steps, contact a Wacker Neuson service center before putting the machine back into operation. 1. Remove anticorrosion agents from bare metal parts.
Page 155: Final Decommissioning Of Machine
All fluids, lubricants, material, etc., used on the machine are subject to specific regulations. Dispose of different materials and consumables separately and in an environmentally friendly manner. Disposal may only be performed by a Wacker Neuson service center. Observe the corresponding national guidelines regarding disposal. Environment Avoid damage to the environment.
Page 156 Notes: 5-60 OM EZ38 us 1.1 * ez38b510.fm...
Page 157: Transport 6.1 Towing The Machine
► Tow away the machine only if the engine is running and if the traveling drive is functional. A a malfunctioning machine must be loaded with a crane (ask a recovery service or a Wacker Neuson service center to do this).
Page 158 Information The manufacturer’s warranty shall not apply to accidents or damage caused by towing the machine. Using towing eye hook A to pull other machines or to tow equipment is prohibited. OM EZ38 us 1.1 * ez38t600.fm...
Page 159: Loading The Machine
6. Raise the control lever base. 7. Remove the starting key and carry it with you. 8. Leave the cabin, close and lock all doors, windows and covers. 9. Secure and tie down the machine. Fig. 213 OM EZ38 us 1.1 * ez38t600.fm...
Page 160 Do not attempt to lift the excavator with any type of crane including wheel loaders unless the crane operator is qualified to lift loads in craning operations. The crane operator shall be knowledgable of OSHA 1910 craning regulations. OM EZ38 us 1.1 * ez38t600.fm...
Page 161 Force Boom lifting eye 40 kN (8992 lbs) Stabilizer blade lifting eye 40 kN (8992 lbs) Information The manufacturer’s warranty shall not apply to accidents or damage caused by loading or transporting the machine. OM EZ38 us 1.1 * ez38t600.fm...
Page 162: Transporting The Machine
7. Ensure that the operator of the transport vehicle knows the overall height, width and weight of his transport vehicle (including the machine) before start traveling, and the legal transport regulations of the countries where transport is taking place. Fig. 216 OM EZ38 us 1.1 * ez38t600.fm...
Page 163: Important Information On Maintenance
Have the maintenance on or with the machine, delivery inspection and the entries in the service booklet performed by a Wacker Neuson service center, otherwise warranty claims will not be acknowledged. It is therefore in the interest of the machine owner to perform the mandatory maintenance on or with the machine.
Page 164: Maintenance Overview
Correct function; deformations, damage, surface cracks, wear and corrosion Page Check the exhaust system for damage Check the insulating mats in the engine compartment for damage Check the cabin and protective structures for damage (Front Guard, FOPS, for example) OM EZ38 us 1.1 * ez38w700.fm...
Page 165 All steps for previous maintenance intervals Rinse the system to remove dirt. Repeat the procedure in the opposite flow direction. Only once after the first 50 service hours (Wacker Neuson service center) Engine oil replacement (Yanmar 3TNV88-BPNS and 3TNV88F-EPNS) Engine oil filter replacement (Yanmar 3TNV88-BPNS and 3TNV88F-EPNS)
Page 166 Every 500 service hours or once a year (Wacker Neuson service center) Engine oil replacement Engine oil filter replacement Fuel filter replacement Clean the water separator (prefilter element) Hydraulic oil filter insert replacement Replace the V-belt Drain the condensation water from the hydraulic oil reservoir...
Page 167 Check the crankcase breather All steps for maintenance once a day and once a week (and all steps for maintenance at 500 service hours) Every 2000 service hours or every 2 years (Wacker Neuson service center) Check the bladder type accumulator Option...
Page 168 Lubrication plan VDS vertical digging system (option) Powertilt with hydraulic Easy Lock quickhitch (option) Fig. 217 OM EZ38 us 1.1 * ez38w700.fm...
Page 169 Apply grease to grease nipples twice daily after operation in water to remove all traces of water. Green means: lubrication every 50 hours or once a week. Blue means: lubrication every 10 hours or daily. OM EZ38 us 1.1 * ez38w700.fm...
Page 170 Maintenance label Some maintenance on or with the machine may only be performed by a Wacker Neuson service center (see maintenance plan). * Oil/oil filter replacement interval Yanmar 3TNV88F-EPNS: first change at 50 o/h; then at 250/500/750 etc. Fig. 219...
Page 171 Hydraulic system Change the hydraulic oil Hydraulic system Replace the hydraulic oil filter insert Hydraulic system Replace the breather filter of the hydraulic oil reservoir Cabin Check the indicator lights Cabin Resetting the maintenance meter OM EZ38 us 1.1 * ez38w700.fm...
Page 172: Fluids And Lubricants
10. Countries with exhaust emission regulations level IIIA, III, Tier IV interim or Tier IV final require using Diesel fuels with a maximum sulphur content of 0.0015 % (= 15 mg/kg).. 11. Up to serial number WNCE0702HPAL00399 12. From serial number WNCE0702CPAL00400 7-10 OM EZ38 us 1.1 * ez38w700.fm...
Page 173 Normal work Every 1000 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 7-11 OM EZ38 us 1.1 * ez38w700.fm...
Page 174 Oil types for hydraulic system (depending on temperature) Hydraulics Ambient temperature (°C) oil grade ° ISO VG32 HVLP 46 ISO VG46 ISO VG68 °F According to DIN 51524 section 3, ISO-VG 46. 7-12 OM EZ38 us 1.1 * ez38w700.fm...
Page 175 • Use only the biodegradable oils that have been tested and released by Wacker Neuson. Contact a Wacker Neuson dealer for the use of other products that have not been released. In addition, ask the oil supplier for a written declaration of guarantee. This guarantee is applicable to damage occurring on the hydraulic components that can be proved to be due to the hydraulic oil.
Page 176: Maintenance Accesses
The engine cover is locked with the starting key. Fig. 220 Turn the starting key in lock A clockwise to R. ➥ Engine cover locked. Turn the starting key in lock A counter-clockwise to L. ➥ Engine cover unlocked. 7-14 OM EZ38 us 1.1 * ez38w700.fm...
Page 177: Fuse Box
► Turn the lift pump valve clockwise. 1. Stop and park the machine. Stop the engine. See “Preparing lubrication”. 2. Raise the floor mat on the right side in the cabin. 3. Loosen lock nut A. Fig. 222 7-15 OM EZ38 us 1.1 * ez38w700.fm...
Page 178 8. Place yourself beside the machine and pull the handhold of the cabin until the cabin is completely tilted beyond the center of motion. ➥ The cabin is secured with a safety cable. Fig. 226 7-16 OM EZ38 us 1.1 * ez38w700.fm...
Page 179 11.Secure tilt rod F with the split pin in guide H. Information Check the tilt rod, split pin, safety cable and the fastening of the safety cable for cracks and cuts. Have malfunctioning parts immediately replaced by a Wacker Neuson service center. Fig. 227 Lowering the cabin 1.
Page 180 Replace self-locking fasteners (self-locking nuts, for example) by new ones after removing them. 8. Tighten lock nut A to 85 Nm (63 ft.lbs). Fig. 231 9. Tighten screw B to 85 Nm (63 ft.lbs). Fig. 232 7-18 OM EZ38 us 1.1 * ez38w700.fm...
Page 181: Cleaning And Maintenance On Or With The Machine
Ensure adequate room ventilation. • Fire, open flames and smoking is prohibited. Environment In order to avoid damage to the environment, clean the machine only in wash bays and places provided to this effect. 7-19 OM EZ38 us 1.1 * ez38w700.fm...
Page 182 ► Stop the engine and let it cool down. ► Wear protective equipment. WARNING Personal injury hazard due to rotating parts! Rotating parts can cause severe injuries or death. ► Open the engine cover only at engine standstill. 7-20 OM EZ38 us 1.1 * ez38w700.fm...
Page 183 Fastening screws on the hydraulic system • Bucket teeth, line and pin fastenings on the attachment Retighten loose connections immediately, and have them immediately replaced by a Wacker Neuson service center if necessary. 7-21 OM EZ38 us 1.1 * ez38w700.fm...
Page 184: Lubrication Work
9. Close the windows and doors. 10.Close and lock all covers. Fig. 233 11.Attach a warning label to the control elements (for example “Machine being serviced, do not start”). 12.Wait at least 10 minutes after stopping the engine! 7-22 OM EZ38 us 1.1 * ez38w700.fm...
Page 185 7. Repeat steps 2 – 6 three times until the upper carriage is back in its initial position. 8. Rotate the upper carriage several times by 360°. Information Keep the lubrication points clean and remove ejected grease. Fig. 235 7-23 OM EZ38 us 1.1 * ez38w700.fm...
Page 186 6. Start the engine, raise the boom and the stabilizer blade. 7. Rotate the upper carriage by 90°. 8. Repeat steps 2 – 7 three times until the upper carriage is back in its initial position. 9. Install cover A. Fig. 238 7-24 OM EZ38 us 1.1 * ez38w700.fm...
Page 187 6. Start the engine, raise the boom and the stabilizer blade. Fig. 239 7. Rotate the upper carriage by 90°. 8. Repeat steps 2 – 7 three times until the upper carriage is back in its initial position. Fig. 240 7-25 OM EZ38 us 1.1 * ez38w700.fm...
Page 188 Powertilt/Powertilt with Easy Lock (option) when used in water • Apply grease to the lubrication points before using the Powertilt unit in water. • After using the Powertilt unit in water, apply grease to the lubrication points to remove all water. 7-26 OM EZ38 us 1.1 * ez38w700.fm...
Page 189: Fuel System
► Fire, open flames and smoking is prohibited. ► Keep the maintenance area clean. ► Do not refuel in closed rooms. ► Do not add gas to the Diesel fuel. ► Let the engine cool down. 7-27 OM EZ38 us 1.1 * ez38w700.fm...
Page 190 Immerse the suction pipe opening down to a max. 15 cm (5.85 in) above the floor of the barrel. • Only fill the tank using refueling aids (funnels or filler pipes) with integral microfilter. • Keep all refueling containers clean. 7-28 OM EZ38 us 1.1 * ez38w700.fm...
Page 191 7. The red LED D illuminates when the tank is full. 8. Switch off the fuel-filling pump with switch C. 9. Close filler cap A. 10.Close and lock the engine cover. Fig. 245 7-29 OM EZ38 us 1.1 * ez38w700.fm...
Page 192 4. Bleed the fuel system again as described above. 5. Check for leaks after starting the engine. 6. Have a Wacker Neuson service center perform a check if necessary. Information The fuel system can be bled automatically even if the engine is at operating temperature.
Page 193 ➥ Fuel supply is open. 9. Remove the hose. 10.Close and lock the engine cover. Environment Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner. 7-31 OM EZ38 us 1.1 * ez38w700.fm...
Page 194 8. Remove the hose. 9. Close and lock the engine cover. Fig. 248 Information Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner. 7-32 OM EZ38 us 1.1 * ez38w700.fm...
Page 195: Engine Lubrication System
NOTICE Damage due to wrong engine oil. ► Use engine oil according to the engine/machine fluids and lubricants. ► Have the oil changed only by a Wacker Neuson service center. NOTICE Damage due to adding engine oil too quickly. ► Add the engine oil slowly so it can go down without entering the intake system.
Page 196 11.Push oil dipstick A back in as far as possible. 12.Close and lock the engine cover. Environment Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner. 7-34 OM EZ38 us 1.1 * ez38w700.fm...
Page 197: Cooling System
4. If the coolant level is below the MIN mark or if there is no coolant at the radiator’s filler inlet: ➥ Add coolant. 5. Close and lock the engine cover. Information Fig. 251 Check the coolant level once a day before starting the engine. 7-35 OM EZ38 us 1.1 * ez38w700.fm...
Page 198 11.Check the coolant level again. 12.If necessary, add coolant and repeat the procedure until the coolant level remains constant. 13.Close and lock the engine cover. Environment Dispose of used coolant through approved methods for recycling. 7-36 OM EZ38 us 1.1 * ez38w700.fm...
Page 199 2. Open the engine cover. 3. Remove dust and other foreign bodies from the fins with compressed air. 4. Close and lock the engine cover. Fig. 253 5. Condenser D (option). Fig. 254 7-37 OM EZ38 us 1.1 * ez38w700.fm...
Page 200: Air Filter
► Do not clean air filter elements, replace them. ► Do not use any damaged air filter elements. Replace the air-filter elements when the red air filter indicator light 38 illuminates. Fig. 255 7-38 OM EZ38 us 1.1 * ez38w710.fm...
Page 201 12.Position the lower housing section B. 13.Close bow clips A. 14.Reset the dirt indicator. 15.Close and lock the engine cover. Information Ensure that dust valve E shows downward once it is installed. Fig. 258 7-39 OM EZ38 us 1.1 * ez38w710.fm...
Page 202 2. Remove the starting key and carry it with you. 3. Open the engine cover. Fig. 259 4. Check and, if necessary, clean air intake A. 5. Close and lock the engine cover. Fig. 260 7-40 OM EZ38 us 1.1 * ez38w710.fm...
Page 203: V-Belt/Toothed Belt
7.11 V-belt/toothed belt V-belt tension may be checked and the V-belt retightened by a Wacker Neuson service center only. 7-41 OM EZ38 us 1.1 * ez38w710.fm...
Page 204: Hydraulic System
Damage due to wrong hydraulic oil. ► Use hydraulic oil according to the engine/machine fluids and lubricants. ► Have the hydraulic oil only changed by a Wacker Neuson service center. NOTICE Damage to hydraulic system due to incorrect hydraulic oil level.
Page 205 ► If the hydraulic oil in the sight glass is cloudy, this indicates that water or air has penetrated the hydraulic system. Contact a Wacker Neuson service center. ► Contact a Wacker Neuson service center if the filter of the hydraulic system is dirty. Checking the hydraulic oil level 1.
Page 206 7. Firmly screw filler plug C, and tighten tank ventilation B by hand. 8. Close and lock the engine cover. Environment Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner. Fig. 264 7-44 OM EZ38 us 1.1 * ez38w710.fm...
Page 207 Checking the hydraulic system for leaks NOTICE Leaks and damaged pressure lines must be immediately repaired or replaced by a Wacker Neuson service center. This not only increases the operating safety of the machine but also helps to protect the environment.
Page 208 NOTICE Leaks and damaged pressure lines must be immediately repaired or replaced by a Wacker Neuson service center. This not only increases the operating safety of the machine but also helps to protect the environment. ► Leaks and damaged pressure lines must be immediately repaired or replaced by a Wacker Neuson service center.
Page 209: Electrical System
7.13 Electrical system Information regarding the electrical system Maintenance and repair work on the electrical system may be performed only by trained technical personnel or Wacker Neuson service centers. • Malfunctioning components of the electrical system must be replaced by a Wacker Neuson service center.
Page 210 – see chapter “ Relays” on page 9-5 – see chapter “ Fuses” on page 9-4 Battery charge condition May only be checked by a Wacker Neuson service center. Charging the battery May only be performed by a Wacker Neuson service center.
Page 211 7.14 Heating, ventilation and air conditioning system Checking/changing the cabin air filter Have maintenance only performed by a Wacker Neuson service center. 7.15 Washer system Information regarding the washer system Only use glass cleaner (with antifreeze if necessary) for refilling.
Page 212: Axles/Traveling Drive
7.16 Axles/Traveling drive Have maintenance only performed by a Wacker Neuson service center. 7.17 Brake system Have maintenance only performed by a Wacker Neuson service center. 7.18 Tires/Tracks Information regarding the tracks Track wear can vary according to work and ground conditions.
Page 213 - slowly moving the machine forward and reverse and switching it off again. 8. Check the track tension again. ➥ If it is not correct: 9. Repeat steps 2 – 8. Contact a Wacker Neuson service center if track tension still is too low after pumping in more grease. 7-51...
Page 214 Fig. 271 ➥ If it is not correct: 6. Adjust again. Environment Use a suitable container to collect engine/machine fluids as they flow out and dispose of them in an environmentally friendly manner. 7-52 OM EZ38 us 1.1 * ez38w710.fm...
Page 215: Maintenance Of Attachments
Have load hooks (Powertilt, Powertilt for Easy Lock) with inadmissible wear (beyond the tolerance, for example), damage, deformations, surface cracks and corrosion immediately replaced by a Wacker Neuson service center. The nominal size must not be worn more than 10 % (max. tolerance).
Page 216: Exhaust Gas Treatment
7.21 Exhaust gas treatment Not available 7.22 Machine preservation Machines are partly preserved at the factory (for example in the engine compartment). Operation in an aggressive environment (for example salt deposits) is prohibited. 7-54 OM EZ38 us 1.1 * ez38w710.fm...
Page 217: Diesel Engine Malfunctions
Troubleshooting Troubleshooting NOTICE Contact a Wacker Neuson service center in case of malfunctions or signs that are not listed in the following tables or that persist after maintenance on or with the machine has been performed correctly. Diesel engine malfunctions...
Page 218: Malfunctions Of The Traveling Drive
Lower the control lever Control lever base raised 4-19 base Controls have no function Malfunctioning fuse Check the fuse Contact a Wacker Neu- Replacing the hydraulic oil filter Fouled hydraulic oil filter son service center OM EZ38 us 1.1 * ez38b800.fm...
Page 219: Malfunctions Of The Electrical System
(red) and/or the immediately charge indicator light (red) do Malfunctioning indicator Have the indicator light not illuminate when the engine light replaced by a Wacker stops and starter is switched on Neuson service center (position 1). OM EZ38 us 1.1 * ez38b800.fm...
Page 220: Troubleshooting The Air Conditioning
Leak in system Malfunctioning or insuffi- ciently tightened V-belt Have the error repaired by a Very loud system Damaged air conditioning Wacker Neuson service center compressor Damaged fan motor Malfunctions of attachments No malfunctions specified. OM EZ38 us 1.1 * ez38b800.fm...
Page 221: Models And Trade Names
1100 +/− 25 rpm Fuel injection system Direct injection Starting aid Glow plugs (preheating time 15 seconds) Fuel tank 44 l (11.6 gal) Exhaust values 97/68/EC stage 3A, EPA – Tier IV interim according to OM EZ38 us 1.1 * ez38t900.fm...
Page 222: Traveling Drive/Axles
Traveling drive/axles Traveling drive EZ38 Version Axial piston motor Brakes See travel lever Tracks Rubber track EZ38 Track width 300 mm (12 in) Number of tread rollers Steering system See travel lever OM EZ38 us 1.1 * ez38t900.fm...
Page 223 Swivel unit operating pressure 210 bar (3046 psi) Hydraulic tank capacity 38.5 l (10.2 gal) Hydraulic oil quantity (system fill) 63 l (16.6 gal) Speed EZ38 2 travel speeds 2.8 / 4.6 kph (1.7 / 2.9 mph) OM EZ38 us 1.1 * ez38t900.fm...
Page 224 (AUX I) 10 A proportional 3rd control circuit (AUX Heating, air conditioning, traveling 15 A Fig. 275 signal 10 A Wiper, interior light Rotating beacon, radio, 12 V power 10 A outlet 15 A Socket OM EZ38 us 1.1 * ez38t900.fm...
Page 225 Drive torque – at 210 bar 2990 Nm (2205 ft.lbs.) (3045 psi) Holding torque – at 225 7270 Nm (5362 ft.lbs.) bar (3263 psi) The actual angle can vary slightly from the indication made here. OM EZ38 us 1.1 * ez38t900.fm...
Page 226: Tightening Torques
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) OM EZ38 us 1.1 * ez38t900.fm...
Page 227: Coolant
According to ISO 6395 (EC Directives 2000/14/EC and 2005/88/EC) According to EN ISO 4871 (EC Directives 2000/14/EC and 2005/88/EC) According to ISO 6394 (EC Directives 84/532/EEC, 89/514/EEC, 95/27/EEC) Information Measurements performed on asphalted surface. OM EZ38 us 1.1 * ez38t900.fm...
Page 228: Vibration
Directive 2002/44/EC of European Parliament and Coucil on minimum health and safety requirements regarding exposure of workers to risks arising from physical agents (vibration). It explains the values for vertical vibration under heavy operating conditions. OM EZ38 us 1.1 * ez38t900.fm...
Page 229 - Picking up and raising loads repeatedly must be limited to a minimum. Reference: The vibration values and calculations are based on the indications made in ISO/TR 25398 Mechanical Vibrations – Guidelines for assessment of exposure to whole-body vibration when operating earth moving machines. OM EZ38 us 1.1 * ez38t900.fm...
Page 230 European Parliament and Coucil on minimum health and safety requirements regarding exposure of workers to risks arising from physical agents (vibration). Your Wacker Neuson dealer provides information on other machine functions reducing vibration and on safe operation. 9-10 OM EZ38 us 1.1 * ez38t900.fm...
Page 231: Weight
Add the weight of all subsequently installed equipment to the weight of the machine. Weight indications can vary by +/− 2 %. Weight of attachments – see “Fields of application and use of attachments” on page 3-5 9-11 OM EZ38 us 1.1 * ez38t900.fm...
Page 232 32 kN (7,194 lbf) at bucket tooth Ground clearance/ground pressure EZ38 EZ38 VDS Ground clearance 280 mm (11 in) 225 mm (9 in) Ground pressure > 0.34 kg/cm² (4.8 lbs/in²) Upper carriage rotation 8.8 rpm speed 9-12 OM EZ38 us 1.1 * ez38t900.fm...
Page 233: Payload/Stability
The indications are only approximate values. Attachments, uneven ground and soft or bad ground conditions affect stability, and the weight and mass values. The operator must take these influences into account. Fig. 277 (symbolic representation) 9-13 OM EZ38 us 1.1 * ez38t900.fm...
Page 234 The machine’s lift capacity is restricted by the hydraulic output and the hydraulic system’s stabilizing features. Neither 75 % of the static tilt load nor 87 % of the hydraulic lift capacity is exceeded. 9-14 OM EZ38 us 1.1 * ez38t900.fm...
Page 235 The lift capacity applies to machines under the following conditions: • Lubricants and engine/machine fluids at the mandatory levels. • Full fuel tank. • Cabin or canopy. • Machine at operating temperature. • Operator weight 75 kg (165 lbs). 9-15 OM EZ38 us 1.1 * ez38t900.fm...
Page 236 1279 1094 (−79 in) (2,094) (1,411) (1,179) (2,434) (1,499) (1,252) (4,273) (2,820) (2,412) Lift capacity table EZ38 long stick (option) 4.0 m (13'-1″) 3.0 m (9'-10") 2.0 m (79 in) 3.0 m (9'-10") (1,517) (977) (800) (1,404) (1,122) (935) 2.0 m...
Page 237 (−79 in) (2,094) (1,587) (1,362) (2,434) (1,687) (1,448) (4,273) (3,157) (2,771) Lift capacity table EZ38 long stick (option) and extra weight (option) 4.0 m (13'-1″) 3.0 m (9'-10") 2.0 m (79 in) 3.0 m (9'-10") (1,517) (1,093) (937) (1,404) (1,250) (1,080) 2.0 m...
Page 238 1405 1232 (−79 in) (2,200) (1,625) (1,393) (2,277) (1,658) (1,422) (4,074) (3,097) (2,716) Lift capacity table EZ38 long stick VDS (option) 4.0 m (13'-1″) 3.0 m (9'-10") 2.0 m (79 in) 3.0 m (9'-10") (1,482) (1,043) (888) (1,391) (1,210) (1,043) 2.0 m...
Page 239 (−79 in) (2,200) (1,808) (1,585) (2,277) (1,845) (1,618) (4,074) (3,435) (3,075) Lift capacity table EZ38 long stick VDS and extra weight (option) 4.0 m (13'-1″) 3.0 m (9'-10") 2.0 m (79 in) 3.0 m (9'-10") (1,482) (1,157) (1,010) (1,391) (1,340) (1,177) 2.0 m...
Page 240 Information The indications are only approximate values. Attachments, uneven ground and soft or bad ground conditions affect stability, and the weight and mass values. The operator must take these influences into account. 9-20 OM EZ38 us 1.1 * ez38t900.fm...
Page 241 Lift capacities apply to machines under the following conditions: • Lubricants and engine/machine fluids at the mandatory levels • Full fuel tank • Cabin or canopy • Machine at operating temperature • Operator weight 75 kg (165 lbs) 9-21 OM EZ38 us 1.1 * ez38t900.fm...
Page 242 Cabin or canopy, without extra weight Cabin or canopy, with extra weight 9-22 OM EZ38 us 1.1 * ez38t900.fm...
Page 243 VDS cabin or canopy, without extra weight VDS cabin or canopy, with extra weight 9-23 OM EZ38 us 1.1 * ez38t900.fm...
Page 244 Dimensions Overview EZ38 9-24 OM EZ38 us 1.1 * ez38t900.fm...
Page 245 Max. tilting angle of boom to the right 55° Max. tilting angle of boom to the left 70° Track width 300 mm (12 in) Stabilizer blade width 1740 mm (69 in) Stabilizer blade height 355 mm (14 in) 9-25 OM EZ38 us 1.1 * ez38t900.fm...
Page 246 Overview EZ38 VDS 9-26 OM EZ38 us 1.1 * ez38t900.fm...
Page 247 Max. tilting angle of boom to the right 55° Max. tilting angle of boom to the left 70° Track width 300 mm (12 in) Stabilizer blade width 1740 mm (69 in) Stabilizer blade height 355 mm (14 in) 9-27 OM EZ38 us 1.1 * ez38t900.fm...
Page 248 Notes: 9-28 OM EZ38 us 1.1 * ez38t900.fm...
Page 249 Bulbs ..............9-5 Diesel engine malfunctions ........8-1 Diesel fuel specification ........7-27 Differential lock ............5-8 Dimensions ............9-24 Display element ........... 4-34, 4-36 Disposal ..............5-59 Document box ............4-31 Drive levers ............5-1 OM EZ38 us 1.1 * ez38us1_1SIX.fm...
Page 250 Load holding control valve “Advanced” ....5-50 Ground pressure ..........9-12 Load holding control valve “Basic” ......5-50 Loading material ........... 5-46 Loading the machine ..........6-3 Low-load operation ..........4-47 Lubrication ............7-22 Lubrication plan ............7-6 OM EZ38 us 1.1 * ez38us1_1SIX.fm...
Page 251 Swivelling the boom ..........5-26 Preparatory work for putting into operation ..4-39 Swivelling the boom (proportionally controlled) ..5-26 Preparing lubrication ..........7-22 Proportional controls ........5-21, 5-47 Proportionally controlled additional control circuit – OM EZ38 us 1.1 * ez38us1_1SIX.fm...
Page 252 Wiper/wash system ..........5-10 Work operation ............. 5-42 Working alongside trenches ......5-45, 5-46 Working lights ............5-8 Working on slopes ..........5-43 Working with a hammer ........5-23 Working with a lowered stabilizer blade ....5-46 OM EZ38 us 1.1 * ez38us1_1SIX.fm...
Page 253 Wacker Neuson Linz GmbH keep abreast of the latest technical developments and constantly improve their products. For this reason, we may from time to time need to make changes to diagrams and descriptions in this documentation which do not reflect products which have already been delivered and which will not be implemented on these machines.
Page 254 Wacker Neuson Corporation P. O. Box 9007 Menomonee Falls, WI 53052-9007 Telephone: (262) 255-0500 Fax: (262) 255-0550 Telephone: (800) 770-0957 www.wackerneuson.com Wacker Neuson Linz GmbH Flughafenstr. 7 A-4063 Hörsching Phone: +43 (0) 7221 63000 Fax: +43 (0) 7221 63000-2200 E-mail: office.linz@wackerneuson.com www.wackerneuson.com Order no.

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