Page 1 Service Manual Track excavator Machine model 28Z3 Edition Language Article number 1000178347...
Page 2 Edition Issued 5/2008 12/2011 Copyright – 2011 Wacker Neuson 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.
Page 3: Table Of Contents
Lift capacity table 28Z3 long stick (option) ............. 2-14 Lift capacity table 28Z3 short stick and extra weight (option) ........ 2-15 Lift capacity table 28Z3 long stick (option) and extra weight (option) ....2-16 Lift capacity table 28Z3 VDS (short stick) .............. 2-17 Lift capacity table 28Z3 long stick VDS (option) ............
Page 4 Important information for the use of biodegradable oil ........3-46 Checking hydraulic pressure lines ..............3-47 Pilot valve ....................... 3-48 Travelling drive ....................... 3-49 Checking the oil level and filling up oil ............. 3-49 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 5 Pressure check ....................4-8 Checking the nozzle jet .................... 4-9 Injection time ......................4-9 Checking injection time ..................4-9 Setting injection time ..................4-11 Removing and installing the injection pump ............4-12 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 6 Auxiliary hydraulics connections ................5-35 Troubleshooting in the hydraulic system ..............5-36 Hydraulics diagram (legend) .................. 5-38 Hydraulics diagram 28Z3 ..................5-39 Hydraulics diagram for options 28Z3 ..............5-40 Main valve block diagram 28Z3 ................5-41 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 7 ......................... 7-13 Safe load indicator FR (up to serial no. AG02443) .......... 7-14 Function ......................7-14 Diagram (from serial no. AG04828) ..............7-15 Diagram (serial nos. AG02444 to AG04827) ........... 7-16 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 8 Trial assembly ......................8-17 Installing the seals (kit A), shaft bearings and pressure discs (kit B) ..... 8-17 Installing the end-cap seals and bearings ............8-18 Installing the piston seals and bearings ............8-19 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 9 Securing the PowerTilt swivel device on the machine ........... 8-29 Fitting a bucket or equipment onto the PowerTilt swivel device ......8-29 Troubleshooting ....................8-30 Adjusting the play on the PowerTilt ............... 8-31 Checking the circumferential play ..............8-31 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 10 SHB 28Z3 EN - Edition 2.0 * 28Z3s20IVZ.fm...
Page 11 Operation...
Page 12: Notices On This Service Manual
This is why regular maintenance and ser- vice work is absolutely necessary. Extensive maintenance and repair work must always be carried out by a Wacker Neuson workshop. Use only original spare parts for repairs. This ensures operational safety and readiness of your machine, and maintains its value.
Page 13: Identification Of Warnings And Dangers
Failure to observe the instructions identified by this symbol can result in dam- age to the environment. The environment is in danger if environmentally haz- ardous material (e.g. waste oil) is not subject to proper use or disposal. SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 14: Designated Use And Exemption From Liability
Neuson GmbH. Wacker Neuson 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: •...
Page 15: Type Labels And Component Numbers
– see chapter 2 Specifications on page 2-2 Cab number The type label (arrow) is located on the chassis of the cab, at the upper left beside the door. Fig. 3: Cab type label SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 16 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 top of the gear motor. Fig. 8: Swivel unit type label SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 17 Baujahr/model year/année fabr.: year of construction Norm/standard/norme: standards the component complies with Not all components require all fields to filled with data. Other information – see chapter 2 Specifications on page 2-2 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 18: Machine Overview
10 Engine cover 11 Rotating beacon 12 Boom light 13 Canopy (standard)/cab (option) 14 Tank filler inlet 15 Valve cover 16 Rubber tracks 17 Lubrication point for track tension Fig. 12: Machine outside views SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 19: Cab Overview
Operation Cab overview SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 20: Cab (Legend)
Radio (option) Drinks/cup holder/storage net Cab bearing Changeover valve for SAE/ISO controls (option) Seat belt (lock) Armrest (left) Throttle Vertical Digging System (VDS) (option) Control lever (left) Control lever base (left) Seat 1-10 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 21: Instrument Panel Overview
Operation Instrument panel overview Control element on control console Control element on cab wall Control elements for proportional controls version (option): Control element on control console Control element on cab wall 1-11 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 22: Instrument Panel Legend
Hydraulic quickhitch switch (option) Proportional controls status indicator (option) Washer system Working light Roof lights (option) Rotating beacon (option) Automatic engine speed setting (option) 1.10 Overview of open engine and valve compartment 1-12 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 23: Engine Compartment: Overview
Hydraulic pump Fuse box Washer system tank 3-24 Air filter 3-16 Fuel filter Throttle cable 3-17 Oil dipstick 3-18 Oil filler opening 3-22 Radiator 3-22 Radiator cap Engine cover 3-22 Expansion tank 1-13 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 24: Chassis Overview
1.12 Chassis overview Pos. Designation For more information see page 3-63 Heating control 5-27 Swivel joint Shuttle valve Manifold 5-24 Swivel unit 3-63 Heating 4/2 way solenoid valve (option) 5-32 Proportional valve (option) 1-14 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 25: Valve Compartment
For more information see page 3-13 Fuel filler inlet 5-32 Changeover valve for SAE/ISO controls (option) 3-46 Return filter Main valve block 7-27 Control valve for proportional controls (option) 3-43 Hydraulic tank cap 1-15 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 26: Stop And Park The Machine
• Lower the bucket into the ground on the downhill side of the machine. • Place the stabiliser blade downhill and lower it to the ground. • Secure the tracks accordingly (e.g. chocks, etc.) so the machine cannot move. Fig. 14: Parking on slopes 1-16 SHB 28Z3 EN – Edition 2.0 * 28z3s110.fm...
Page 27: Specifications
Specifications...
Page 28: Chassis
Fuel injection pump Type YPES-3ML In-line pump Design 118 – 128 bar (1711 – 1856 psi) Injection pressure Mechanical Engine speed control Engine oil lubrication Lubrication system SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 29: Engine Capacities
Main pressure restriction for pilot control pres- -0/+4 -0/+58 bar (435 psi) sure Main pressure restriction for swivel drive -4/+2 -58/+29 bar (2901 psi) (hydraulic motor pressure restriction) Return filter Filter SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 30: Auxiliary Hydraulics Oil Flow 28Z3
Max. lift over/under subgrade Electrical system Model 28Z Electrical system Alternator 12 V 40 A Starter 12 V 1.1 kW (1.5 hp) Battery 12 V 44 Ah Socket E.g. for cigarette lighter; 15 A max. SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 31: Noise Levels
2.10 Powertilt Powertilt Model size Piston stroke 525 cm³ (32 cu. in.) Required oil flow 3 – 6 l/min (0.8 – 1.6 gal/min) Connections 1/4" Slewing range 180° Weight 65 kg (143.3 lbs.) SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 32: Model-Specific Tightening Torques
100 (73.75) M36X2 WS 41 180 (132.7) M45X2 WS 55 220 (162.3) Galvanised and dry surface (O-ring slightly oiled). Torque tolerance: -10 % Values determined empirically and to be applied as approximate figures. SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 33 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 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 34: Tightening Torques For High-Resistance Screw Connections
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. SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 35 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. SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 36: Dimensions Model 28Z3
Max. tail end lateral projection (90° rotation of upper car- 0 mm (0'0”) riage) Max. boom displacement to bucket centre (right-hand 533 mm (1'9”) side) Max. boom displacement to bucket centre (left-hand 764 mm (2'6”) side) 2-10 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 37: Dimensions Model 28Z3 Vds
Specifications 2.14 Dimensions model 28Z3 VDS * Short stick ** Long stick Fig. 2: Machine dimensions (model 28Z3) 2-11 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 38 0 mm (0'0”) Max. boom displacement to bucket centre (right-hand side) 533 mm (1'9”) Max. boom displacement to bucket centre (left-hand side) 764 mm (2'6”) Max. tilt angle for VDS 15° 2-12 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 39: Lift Capacity Table 28Z3 (Short Stick)
The machine'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. 2-13 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 40: Lift Capacity Table 28Z3 Long Stick (Option)
Specifications 2.16 Lift capacity table 28Z3 long stick (option) 3.5 m (11.5 ft) 3.0 m (9.8 ft) 2.5 m (8.2 ft) Lowered blade Lowered blade Lowered blade Lowered blade 3.0 m 458* 423* 423* (9.8 ft) (1009*) (747) (933*) (933*) 2.0 m...
Page 41: Lift Capacity Table 28Z3 Short Stick And Extra Weight (Option)
Specifications 2.17 Lift capacity table 28Z3 short stick and extra weight (option) 3.5 m (11.5 ft) 3.0 m (9.8 ft) 2.5 m (8.2 ft) Lowered blade Lowered blade Lowered blade Lowered blade 3.0 m 508* 492* 483* (9.8 ft) (1121*)
Page 42: Lift Capacity Table 28Z3 Long Stick (Option) And Extra Weight (Option)
Specifications 2.18 Lift capacity table 28Z3 long stick (option) and extra weight (option) 3.5 m (11.5 ft) 3.0 m (9.8 ft) 2.5 m (8.2 ft) Lowered blade Lowered blade Lowered blade Lowered blade 3.0 m 458* 423* 423* (9.8 ft)
Page 43: Lift Capacity Table 28Z3 Vds (Short Stick)
Specifications 2.19 Lift capacity table 28Z3 VDS (short stick) 3.5 m (11'6”) 3.0 m (9'10”) 2.5 m (8'2”) 2.0 m (6'7”) Lowered Raised Lowered Raised Lowered Raised Lowered Raised Lowered Raised blade blade blade blade blade blade blade blade blade blade 3.0 m...
Page 44: Lift Capacity Table 28Z3 Long Stick Vds (Option)
Specifications 2.20 Lift capacity table 28Z3 long stick VDS (option) 3.5 m (11'6”) 3.0 m (9'10”) 2.5 m (8'2”) 2.0 m (6'7”) Lowered Raised Lowered Raised Lowered Raised Lowered Raised Lowered Raised blade blade blade blade blade blade blade blade...
Page 45: Kinematics
Specifications 2.21 Kinematics Pin diameter 40 mm (1.57”) Stick width 140 mm (5.51”) Pin distance from bucket mount 180 mm (7.09”) Bucket Stick Bucket 2-19 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 46 Specifications 2-20 SHB 28Z3 EN – Edition 2.0 * 28z3s210.fm...
Page 47: Maintenance
Maintenance...
Page 48: Fluids And Lubricants
Biodegradable hydraulic oil based on saturated synthetic esters with an iodine value of < 10 g/mg, according to DIN 51524, section 3, HVLP, HEES KPF2K-20 according to DIN 51502/DIN ISO 6743-9 lithium-saponified grease KF2K-25 according to DIN 51502 multipurpose lithium grease with MoS² additive Standard acid-proof grease SHB 28Z3 EN – Edition 2.0 * 28z3s310.fm...
Page 49: Oil Grades For The Diesel Engine, Depending On Temperature
Every 400 s/h Percentage of hammer work 60 % Every 300 s/h 100 s/h Over 80 % Every 200 s/h Notice! Please refer to the maintenance plan on page for additional maintenance work. SHB 28Z3 EN – Edition 2.0 * 28z3s310.fm...
Page 50: Oil Grades For The Hydraulic System, Depending On Temperature
Maintenance Oil grades for the hydraulic system, depending on temperature Hydrau- lics oil Ambient temperature (C°/°F) grade °C ISO VG32 ISO VG46 HVLP ISO VG68 °F According to DIN 51524 section 3 SHB 28Z3 EN – Edition 2.0 * 28z3s310.fm...
Page 51: Maintenance Label
Change oil Travelling drive Check oil level Undercarriage Check track tension Hydraulic system Check oil level Hydraulic system Change hydraulic oil Hydraulic system Replace the hydraulic oil filter, replace the breather filter SHB 28Z3 EN – Edition 2.0 * 28z3s310.fm...
Page 52 KF2K - 25 Li - soap 4 / 6 Li - soap API GL5 SAE 80W90 ASTM D4985 -34°C / -29°F ASTM D6210 250h 250h 500h 500h 1000h 1000h API CF SAE 10W-40 1000173185 SHB 28Z3 EN – Edition 2.0 * 28z3s310.fm...
Page 53 Maintenance Authorised workshop Customer Every 2000 s/h Every 1500 s/h Every 1000 s/h once a year Every 500 s/h Every 250 s/h Every 50 s/h Service work (daily) SHB 28Z3 EN – Edition 2.0 * 28z3s311.fm...
Page 54 Maintenance Authorised workshop Customer Every 2000 s/h Every 1500 s/h Every 1000 s/h once a year Every 500 s/h Every 250 s/h Every 50 s/h Service work (daily) SHB 28Z3 EN – Edition 2.0 * 28z3s311.fm...
Page 55 Maintenance Authorised workshop Customer Every 2000 s/h Every 1500 s/h Every 1000 s/h once a year Every 500 s/h Every 250 s/h Every 50 s/h Service work (daily) SHB 28Z3 EN – Edition 2.0 * 28z3s311.fm...
Page 56 Maintenance 3-10 SHB 28Z3 EN – Edition 2.0 * 28z3s311.fm...
Page 57: Maintenance Plan (Overview)
• The Operator's Manuals of the attachments. Carry out the prescribed inspections and rectify any disorders immediately before putting the machine into operation, or have them rectified by a Wacker Neuson workshop. Secure the open engine cover and other open covers appropriately. Do not open the engine cover and other covers on slopes or in strong wind.
Page 58: Fuel System
Avoid refuelling with cans in order to avoid dirt in the fuel! ☞ When refuelling the machine without a fuel-filling pump, use safety-oriented ladders and work platforms. ☞ Never use machine parts or attachments/superstructures as a climbing aid! 3-12 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 59: Refuelling
Do not work in closed rooms Fig. 2: Fuel tank ☞ Never carry out work on the fuel system in the vicinity of naked flames or sparks ☞ No smoking, no fire! 3-13 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 60: Stationary Fuel Pumps
Danger of injury due to rotating parts! ☞ Before starting the engine, ensure that no-one is within danger area of the engine/the machine! ☞ Start the engine only if the engine cover is closed! 3-14 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 61: Water Separator
Fuel supply is open again Environment! 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. 3-15 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 62: Replacing The Fuel Filter
In order to restore this valve's function, moisten this non-return valve, dip it briefly in water and then blow Fig. 6: Tank for washer system air through it. 3-16 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 63: Engine Lubrication System
The oil level must be between the MAX and MIN marks. However if necessary, fill up oil at the latest when the oil reaches the MIN mark on the oil dipstick A. 3-17 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 64: Filling Up Engine Oil
Filling in the engine oil too fast via filler inlet B in the valve cover can cause engine damage. ☞ Fill in the engine oil slowly so it can go down without entering the intake system. 3-18 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 65: Changing Engine Oil
• Wait about 3 minutes until all the oil has run into the oil sump • Check the oil level again • Fill up if necessary and check again • Completely remove all oil spills from the engine 3-19 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 66: Replacing The Engine Oil Filter Cartridge
• Check the oil level and fill in engine oil if necessary • Completely remove all oil spills from the engine • Dispose of the used oil filter in an environmentally friendly manner Fig. 13: Tightening the filter cartridge 3-20 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 67: Engine And Hydraulics Cooling System
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 environmentally friendly manner! 3-21 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 68: Checking/Filling Up Coolant
If the coolant level is below the LOW seam or if there is no coolant at the radiator's filler inlet: FULL • Fill up coolant Notice! Check the coolant level once a day. Fig. 15: Expansion tank for coolant We recommend checking it before starting the engine. 3-22 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 69: Filling Up Coolant
Stop the engine ☞ Let the coolant cool down ☞ Unscrew filler inlet B ☞ Pump out the coolant with a suitable pump ➥ Collect the coolant in a suitable container 3-23 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 70: Air Filter
Remove dirt and dust from the air filter element and the area around the air filter ☞ Turn the lower housing section E to the left (up to serial number AG03215) Fig. 19: Removing the housing section (up to serial number AG03215) 3-24 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 71 Fig. 22: Removing the housing section (up to serial number AG03215) ☞ Open bow clips D on housing section E (from serial number AG03216) ☞ Remove lower housing section E Fig. 23: Removing the housing section (from serial number AG03216) 3-25 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 72: Air Intake
Danger of engine damage! ☞ Check once a day for cleaniness before putting the machine into operation! Fig. 26: Engine air intake 3-26 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 73: Change Cab Air Filter
Remove screws A and the cover ☞ Remove the filter and clean or replace it ☞ Install the filter ☞ Mount screws A and the cover Fig. 27: Cab air filter cover 3-27 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 74: V-Belt
Avoid contact of oil, grease or similar substances with the V-belt. ☞ Replace V-belts with damage, cracks, cuts etc. ☞ Avoid contact of oil, grease or similar substances with the V-belt 3-28 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 75: Retightening The V-Belt
Fig. 30: Removing the body-bound rivet ☞ Slacken fastening screws 3 Fig. 31: Slackening the fastening screws ☞ Remove cover 4 • Take care not to bend the hose Fig. 32: Removing the cover 3-29 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 76 Check V-belt tension again and adjust it if necessary ☞ Mount the trims and covers back on that have been removed ☞ Connect the battery ☞ Close the engine cover Fig. 35: Retightening the V-belt 3-30 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 77: Pressure Check
Designation Pump 1 measuring port MP 1 Pump 2 measuring port MP 2 Pump 3 measuring port MP 3 Pilot oil supply unit measuring port MP 4 Fig. 37: Measurement ports 3-31 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 78: Checking Pilot Control Pressure
Adjust the pressure at the pressure reducing valve 4 (PLV4) 39/D at the pilot oil sup- ply unit ☞ Check the pilot control pressure again once adjustment is over Fig. 39: Pressure reducing valve 3-32 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 79: Pressure Check Of Variable Displacement Pump P1
Check the primary pressure limiting valve 1 and the pressure drop once adjustment is over Also check with the extend boom, the extend/retract bucket and with the right-hand side forwards/reverse drive functions! Fig. 41: Primary pressure limiting valve 1 3-33 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 80: Pressure Check Of Variable Displacement Pump P2
Checking the auxiliary hydraulics pressure Notice! Factory indications for auxiliary hydraulics secondary valves are possibly invalid – adapt these values to the attachment! Fig. 43: Primary pressure limiting valve 2 3-34 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 81: Pressure Check Of Gear Pump P3
Checking the auxiliary hydraulics pressure Notice! Factory indications for auxiliary hydraulics secondary valves are possibly invalid – adapt these values to the attachment! Fig. 45: Primary pressure limiting valve 3 3-35 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 82: Secondary Pressure Limiting Valve Of The Gear Motor
Pump primary pressure limiting valve 1 PPLV 1 Pump primary pressure limiting valve 2 PPLV 2 Pump primary pressure limiting valve 3 PPLV 3 Pressure reducing valve of pilot oil supply unit PRV 4 3-36 SHB 28Z3 EN – Edition 2.0 * 28z3s312.fm...
Page 83 3-37 SHB 28Z3 EN – Edition 2.0 * 28z3s313.fm...
Page 84 3-38 SHB 28Z3 EN – Edition 2.0 * 28z3s313.fm...
Page 85 3-39 SHB 28Z3 EN – Edition 2.0 * 28z3s313.fm...
Page 86 3-40 SHB 28Z3 EN – Edition 2.0 * 28z3s313.fm...
Page 87: Hydraulic System
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. 3-41 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 88: Checking The Hydraulic Oil Level
Between 50 and 90 °C MAX mark Normal operation (between 122 and 194 °F) Notice! Measure the oil level of the hydraulic system only after the machine reaches its operating temperature. 3-42 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 89: Filling Up Hydraulic Oil
• Check the hydraulic oil level on sight glass B • Fill up if necessary and check again • Close cap C of the hydraulic tank hand tight again • Install the tank cover Fig. 50: Hydraulic tank cap 3-43 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 90: Changing Hydraulic Oil
This is caused by increased oil viscosity. In this case: ☞ Set engine speed so that indicator light 33 goes out Fig. 52: Hydraulic oil filter indicator light Fig. 53: Return filter pressure switch 3-44 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 91: Replacing The Hydraulic Oil Filter
– see Checking the hydraulic oil level on page 3-42 ☞ Fill in clean hydraulic oil – see Filling up hydraulic oil on page 3-43 Close the hydraulic oil tank correctly 3-45 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 92: Important Information For The Use Of Biodegradable Oil
• Use only the biodegradable hydraulic fluids which have been tested and approved by Wacker Neuson. Always contact Wacker Neuson GmbH for the use of other products which have not been recommended. In addition, ask the oil supplier for a written declaration of guarantee.
Page 93: Checking Hydraulic Pressure Lines
Also observe DIN 20 066. The article number is marked on the clamping section, and the date of manufacture is indicated on the hose of each hose connection. 3-47 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 94: Pilot Valve
Remove pilot control filter B from the joystick ☞ Check pilot control filter screen C for dirt and clean it if necessary. Replace it by a new filter if it is damaged! Assemble in the reverse order. 3-48 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 95: Travelling Drive
The oil now flows out of opening C (DRAIN) ☞ 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. 3-49 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 96: Tracks
20 – 25 mm (0.78 – 0.98”). ☞ If the tension of the steel or rubber track is not in accordance with the rated value, adjust the tension as follows. Fig. 61: Measuring distance 3-50 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 97: Adjusting Track Tension
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 track ten- sion. ☞ Release grease only as described below. ➥...
Page 98: Maintenance Of Attachments
Lubricate all mechanical pivots on the machine (such as door hinges, joints) and Fig. 65: Lubrication recommendation fittings (such as door arresters) at regular intervals even if they are not listed in the lubrication plan. 3-52 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 99: Overview Of Lubrication Points
Powertilt lubrication points (option) on page 3-59 Hydraulic quickhitch (option) – see Lubrication points of hydraulic quickhitch (option) on page 3-60 Quickhitch option – see Lubrication points of mechanical quickhitch (option) on page 3-60 3-53 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 100: Lubrication Points On The Stabiliser Blade And Stabiliser Blade Ram
Apply grease to lubrication points 10 of the offset ram Fig. 68: Lubrication point on offset ram ☞ Apply grease to lubrication points 9 of the swivelling console Fig. 69: Lubrication points on the swivelling console 3-54 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 101: Lubrication Points On The Boom, Bucket And Stick Rams
Apply grease to lubrication points 3 on the boom ram Fig. 72: Lubrication points on the boom ram ☞ Apply grease to lubrication points 1 on the bucket ram Fig. 73: Lubrication points on the bucket ram 3-55 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 102: Lubrication Points On The Boom And Stick
Fig. 77: Lubrication points on the stick Lubrication point on the joint rod ☞ Apply grease to lubrication point 8 on the joint rod Fig. 78: Lubrication point on the joint rod 3-56 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 103: Lubrication Point On Ball Bearing Race Of Live Ring
Danger of severe crushing that can cause death or severe injury! ☞ – see chapter Parking the machine on page 3-52 Caution! Lubrication can be carried out over a pit only. 3-57 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 104: Lubrication Point Of Vds Live Ring Teeth
Turn the machine 90° at a time and apply grease to lubrication point 13 with five strokes of the grease gun in the following three positions. ☞ Remove ejected grease. ☞ Turn the machine 360° twice. Fig. 84: Turn the machine 90° at a time 3-58 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 105: Vds Lubrication Points (Option)
Carry out visual checks for possible defects, damage or cracks. Remove all dirt on and around moving parts. Apply grease by means of grease nipples 15. – see PowerTilt PTS06 on page 8-1 Fig. 86: Powertilt lubrication points 3-59 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 106: Lubrication Points Of Hydraulic Quickhitch (Option)
Check cab bearings B for damage Notice! Check the cab fastening screws for tightness, retighten with a suitable tool if necessary – see Tightening torques for high-resistance screw connections on page 2-8 Fig. 89: Cab bearing 3-60 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 107: Electrical System
• Always disconnect the battery before carrying out welding work or connecting a quick battery charger. • Replace defective charge indicator lights immediately – see Alternator charge function indicator light (red) on page 1-12 3-61 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 108: Battery
• Never place tools or other conductive articles on the battery – danger of short circuit! • Dispose of used batteries properly. Danger! Do not disconnect the battery while the engine is running! 3-62 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 109: General Maintenance Work
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! 3-63 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 110: Exterior Of The Machine
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. 3-64 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 111: Preparatory Work Before Taking Out Of Service
• Check the oil levels in all units and fill up oil if necessary. Start the machine and ensure that each function and all warnings work correctly before putting the machine back into operation. 3-65 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 112: Fire Extinguisher
➥ Fasten the fire extinguisher according to the manufacturer's indications Notice! Check the fire extinguisher at regular intervals, also ensure that it is safely mounted. Fig. 92: Fire extinguisher in canopy 3-66 SHB 28Z3 EN – Edition 2.0 * 28z3s314.fm...
Page 113: Engine
Engine...
Page 114: 3Tnv76-Nns Engine Overview
Engine Engine Engine 3TNV76-NNS engine overview Oil filler neck Water pump V-belt Air intake Fuel filter Fan blade Oil pressure switch Engine oil filter Oil dipstick Oil filler neck Fuel injection pump SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 115 Engine Tightening bracket Valve cover V-belt Exhaust manifold Alternator Starter SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 116: Fuel System
Engine Fuel system SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 117: Cooling System
Engine Cooling system SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 118: Checking And Adjusting Valve Clearance
Slacken locknut C and set screw B on the rocker arm. ☞ Check the valve cap for abnormal wear – see Fig. ☞ For the correct valve clearance insert feeler gauge A. SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 119: Lapping The Intake And Exhaust Valves
Order for mounting the cylinder-head bolts: V-belt side Tightening torques for cylinder-head bolts 1st position 26.9 – 28.9 Nm 19.8 – 21.3 lbs/ft 2nd position 53.9 – 57.9 Nm 39.8 – 42.7 lbs/ft SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 120: Checking The Injection Nozzles
• Open the ball-type cock on the fuel filter again Leak oil line Spacers Compression Nozzle needle spring seat Pressure spring centring Lower nozzle screw fitting Upper nozzle screw fitting Compression Nozzle body spring SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 121: Checking The Nozzle Jet
➥ Top dead centre can be assigned to the correct cylinder with the number B stamped Fig. 5: Top dead centre mark next to it SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 122 Or turn the ring gear on the flywheel with a screwdriver ☞ Slowly turn clockwise until fuel is discharged from the opening of injection pump A Fig. 10: Turning the fuel cocks to flow 4-10 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 123: Setting Injection Time
Checking injection time on page 4-9 Notice! Bend the injection lines as you mount them so they are not subject to tension once they are mounted. Bleed the injection lines once they are installed. 4-11 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 124: Removing And Installing The Injection Pump
Remove the fuel injection pump ➥ To this purpose unscrew the three fastening screws of the injection pump Notice! Fig. 15: Gear screws After removing the injection pump, do not turn the crankshaft anymore 4-12 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 125: Fitting The Injection Pump
Fit the cover of the injection pump on the gear casing and tighten the screws ➥ Apply sealing compound to the sealing surface ☞ Fit the fuel injection lines back on again 4-13 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 126: Measuring And Adjusting The Engine Speed
➥ Specified value: 34.3 +/- 1 bar (498 psi +/- 15) at 250 rpm ➥ Threshold value: 27.5 +/- 1 bar (399 psi +/- 15) at 250 rpm 4-14 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 127: Checking The Coolant Thermostat
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 (225 – 235 °F) Thermal switch Fig. 23: Checking the thermal switch 4-15 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 128: Oil Pressure Switch
4.17 Coolant and fuel hoses ☞ Check the coolant and fuel hoses regularly to ensure that they are not kinked, cracked or damaged ➥ Renew coolant and fuel hoses every 2 years 4-16 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 129: Crankcase Vent
Fig. 28: Replacing the glow plugs ☞ Refit the wiring harness and tighten the nuts ☞ Lightly grease and fit the new valve cover gasket ☞ Fit the valve cover and tighten the fastening screws 4-17 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 130: Engine Trouble
Defective fan, torn or loose V-belt Engine overheats. Temperature warning system responds Resistance in cooling system too high, flow capacity too low Defective fuel injector Not enough coolant Defective coolant pump Cooling system leaks 4-18 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 131 Coolant combustion (defective cylinder-head gasket) Dirty air filter Defective air filter maintenance switch or gauge Defective fuel injector (drips) Black Wrong fuel injection pump setting Wrong valve clearance Dirty injection nozzle 4-19 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 132 Engine 4-20 SHB 28Z3 EN – Edition 2.0 * 28z3s410.fm...
Page 133: Hydraulic System
Hydraulic system...
Page 134: Hydraulic Pump Pvd-0B-23Bp-8G3-5083A
Double variable displacement pump + 2 gear pumps Pilot oil supply unit Variable displacement pump unit Gear pump unit Pos. Designation Port P4 Pressure reducing valve Bleed screw Port P2 Port P1 Port P3 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 135 Hydraulic system Variable displacement pump unit Gear pump unit Pos. Designation Suction line Port Port PB1 (gear motor supply) Port PA (2nd speed range) Port PB2 (pilot valve supply) SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 136: Pump Unit: Exploded View
O-ring Stop stud Pilot oil supply unit Stop pin Solenoid switch Spring Solenoid switch Stop pin Fastening screw Grooved ball bearing Variable displacement pump sealing kit Rotary shaft lip seal Gear pump SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 137: Pilot Oil Supply Unit
Gear motor supply Pilot valve supply Solenoid valve for safety valve Drives/2nd speed range supply 2nd speed range solenoid valve Pump 4 supply Internal to P4 Pressure reducing valve Tank line Accumulator SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 138: Dismantling The Hydraulic Pump
The housing can be separated more easily by tapping the housing with the inside spring lightly by means of a rubber hammer ☞ Remove the intermediate seal Fig. 4: Separating the housing SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 139 Knock the shaft out of the housing by tapping lightly with a rubber hammer ➥ The rotary shaft lip seal and the grooved ball bearing are also loosened at the same time and can be removed Fig. 9: Removing the shaft SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 140: Assembling The Hydraulic Pump
Insert the pins into the cylinder housing on the opposite side, see Fig. 12 and place the centring mechanism on it ☞ Insert the mounting plate with the piston shoes and cylinders into the cylinder housing Fig. 13: Assembling the drive unit SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 141 Place the balls into the corresponding holes in the cradle ➥ Use grease if the balls do not remain in position in the cradle ☞ Insert the cradle with the two balls into the pump housing Fig. 18: Inserting the piston SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 142 ☞ Replace the two upper screws (M10x65) with the two remaining original screws and tighten ➥ Tightening torque 51.0 – 64.7 Nm (37.6 – 47.7 lbs/ft) Fig. 23: Mounting the housing 5-10 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 143 Tightening torque 20.6 – 25.5 Nm (15.2 – 18.8 lbs/ft) After completing assembly, ensure that the shaft of the hydraulic pump can be turned smoothly by hand. Fig. 28: Fitting the pilot oil supply unit 5-11 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 144: Troubleshooting On The Hydraulic Pump
Abnormal noises or vibrations Intake line restricted or obstructed Defective piston shoe Wrong coupling was fitted Damaged O-ring or seal Oil leakage Plug or screw connection loose Leaking rotary shaft lip seal 5-12 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 145: Main Valve Block
Right-hand drive Input P1 P2 Left-hand drive Stick Auxiliary hydraulics Auxiliary hydraulics flow rate adjustment segment 3rd control circuit (option) Swivel boom Stabiliser blade Upper carriage rotation Straight-ahead/drive counter- balancing system 5-13 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 146: Main Control Lines (Legend)
Pump 3 port Tank line via non-return valve and filter in tank Tank line via oil cooler and filter in tank S: bucket pre-tension – see Bucket pre-tension on page 5-19 5-14 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 147: Main Valve Block Diagram
Main valve block diagram Bucket Boom Right-hand drive Input P1 Input P2 Left-hand drive Stick Auxiliary hydraulics 3rd control circuit Boom swivel Stabiliser blade Upper carriage rotation Drive counterbalancing system P3 5-15 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 148: Pressure Limiting Valves
Secondary pressure limiting valve (boom base side) Primary pressure limiting valve P2 Secondary pressure limiting valve (stick base side) Secondary pressure limiting valve (stabiliser blade base side) Primary pressure limiting valve P3 Anticavitation valve 5-16 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 149: Pump Assignment
Pump 2 Auxiliary hydraulics Auxiliary hydraulics flow rate adjustment segment 3rd control circuit (option) Boom swivel Pump 3 Stabiliser blade Upper carriage rotation Input P3 Drive counterbal- output T2 ancing system 5-17 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 150: Drive Counterbalancing System
• Auxiliary hydraulics section • Auxiliary hydraulics flow rate adjustment segment • 3rd control circuit section (option) • Boom swivel • Stabiliser blade section • Swivel unit section • Drive counterbalancing system section 5-18 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 151: Regeneration - Stick Section
(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 5-15. Location: 5-19 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 152: Auxiliary Hydraulics Flow Rate Adjustment
• The oil supplied by P3 flows to the tank via the open valve seat. Notice! Intermediate positions of the set screws cause the hydraulic oil to warm up – dan- ger of overheating! 5-20 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 153: Travelling Drive
Drive port (-> swivel joint right 2/left 5) 2nd speed range port (-> swivel joint 8) Directional valve forwards/reverse = brake piston Leak oil port (-> swivel joint 1) 2nd drive speed valve Pressure limiting valves Shuttle valve 5-21 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 154: Function
The solenoid valve is energised, and the swash plate of the hydraulic motor returns to base position, i.e. the motor is at minimum capacity. ➥ The engine runs at high speed but at low tractive power. 5-22 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 155 Hydraulic system Pos. Designation Travelling drive Screw connection Screw connection O-ring set Brake cartridge Hydraulic motor Lifetime seal Bearing Plug Plug Snap ring Hydraulic motor sealing kit 5-23 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 156: Swivel Unit
Right-hand rotation port (-> main valve block) Anticavitation line port (-> main valve block/tank) Left-hand rotation port (-> main valve block) Pressure limiting valves Leak oil port (-> tank) Brake piston Shock anticavitation valves 5-24 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 157: Swivel Unit Brake
Do not use the brake as a service brake but only as a stop brake and parking brake for the swivel unit. Pos. Designation Shock valve Gear motor valve set Engine brake set Timer valve 5-25 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 158 Spacer washer Ring gear Bearing seal ring Gear reduction Bearing Gear reduction Gear housing Sun gear Sealing ring Motor flange Bearing Hydraulic motor Round nut Screw Complete drive Screw Spacer washer Plug 5-26 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 159: Swivel Joint
☞ Slacken circlip 11 on the lower side ☞ Pull the swivel joint apart ☞ Replace the sealing rings ☞ Push the swivel joint together again ☞ Insert circlip 11 again 5-27 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 160: Swivel Joint Vds (Option)
The swivel joint ensures the oil flow between the upper carriage and the undercarriage. Pos. Port Pos. Designation High speed Tilt ram Stabiliser blade ram Tilt ram Stabiliser blade ram Leak oil Driving Rod seal Driving Rotor seal Driving V-ring Driving 5-28 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 161: Pilot Valves
Boom ram retraction control Universal joint Right-hand rotation control Bucket ram retraction control Guide plate Supply from pilot oil supply unit Supply from pilot oil supply unit Tappet Tank line Tank line 5-29 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 162: Pilot Valve (Driving)
11°30' à 2°30' 11° 12° 30' Joystick position (degrees) Pos. Designation Right-hand drive segment control Right-hand drive segment control Left-hand drive segment control Left-hand drive segment control Pilot control pressure Tank line 5-30 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 163 Hydraulic system Pos. Designation Bellows Shift unit Plates Tappet Non-return valve (also used for bleeding pedal damping) Damping 5-31 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 164: Changeover Valve For Sae/Iso Controls (Option)
Fig. 30: Directional valve 5.13 Proportional valve (option) A proportional valve ensures a modifiable control signal (an electric signal) is steplessly transformed into a proportional output signal. Function and settings in the Operator's Manual. 5-32 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 165: Changeover Valve Vds (Option)
Volumetric flow: Q max = 15 l/min (3.9 gal/min) Refer to the Operator's Manual of the component for more information, or see chapter “7.11 Hydraulic Quickhitch (Easy Lock)” on page 7-20. Fig. 33: Easy Lock valve 5-33 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 166: Hydraulic Oil Tank Service Valve (Option)
Replace the filter as indicated in the maintenance plan! Fig. 35: Breather filter – see Maintenance plan (overview) on page 3-7 Pos. Designation Filter fabric Bleeder valve Fig. 36: Breather filter 5-34 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 167: Auxiliary Hydraulics Connections
Standard ports: Port Stick (left) Stick (right) Pressure line Pressure line Large return line Fig. 37: Connections for auxiliary hydraulics Fig. 38: Connections for auxiliary hydraulics 5-35 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 168: Troubleshooting In The Hydraulic System
Contaminated solenoid valve on pilot oil supply unit Machine 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 5-36 SHB 28Z3 EN – Edition 2.0 * 28z3s510.fm...
Page 175: Electrical System
Electrical system...
Page 176: Ohm's Law (Current, Voltage, Resistance); Power
• connect in parallel to consumer. • Measuring resistance (ignition switched off): • Black cable in COM socket (earth), • red cable in socket; • connect in parallel to consumer (see measuring voltage). SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 177: Cable Colour Coding
85 = End of coil (earth) 30 = Input (load line) 87 = Make-contact switch output (load line) 87 a= Break-contact switch output (load line) 87 87a Fig. 1: Terminal description on relay SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 178: Socket
Boom working light, heating Fig. 3: Fuse box 15 A Valves, horn 10 A Cab working light 15 A Wiper, interior light Proportional controls 10 A Rotating beacon, radio 15 A Socket, cigarette lighter SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 179: Alternator
Connection IG indicator light (12 V) Port L indicator light (during service 12 V, otherwise earth) Fig. 6: Alternator Starter Pos. Description Connection S starting relay Connection B battery Fig. 7: Starter SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 180: Switches: Overview
Control element on control console Switch legend Pos. Designation High speed Ventilation Safe load indicator (option) Hydraulic quickhitch switch (option) Proportional controls status indicator (option) Washer system Working light Roof lights (option) Rotating beacon (option) SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 181: Cigarette Lighter
The loudspeakers and the aerial, but not the radio, are installed at the factory with this option. Notice! The cab is prewired up to these components at the factory as a standard SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 182: Front Working Light
Fig. 12: Rear cab light Front and rear cab lights This option includes front cab lights and one rear cab light, see Fig. Fig. 12 Fig. 13. Fig. 13: Front/rear cab lights SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 183: Rotating Beacon (Option)
The pressure switch for the driving signal is located directly on the underside of the drive valve. Fig. 15: Driving signal Driving signal wiring harness Plug Description Wiring harness connector S21 high-speed cable (not equipped) Pressure switch connector Driving signal connector Fig. 16: Driving signal wiring harness SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 184 Electrical system 6-10 SHB 28Z3 EN – Edition 2.0 * 28z3s610.fm...
Page 189 Electrical sys- Electrical system 6-15 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 190 Electrical system 6-16 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 191 Electrical system 6-17 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 192 Electrical system 6-18 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 193 Electrical system 6-19 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 194 Electrical system 6-20 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 195 Electrical system Pressure switch Valve 6-21 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 196 Electrical system 6-22 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 197 Electrical system 6-23 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 198 Electrical system 6-24 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 199 Electrical system 6-25 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 200 Electrical system 6-26 SHB 28Z3 EN – Edition 2.0 * 28z3s612.fm...
Page 201 Options...
Page 202: Counterweight
Options Options Options • Article numbers for options and retrofit kits: please refer to the 28Z3 spare parts list. Counterweight Specifications Lock the screw connection with Loctite S2420 or VaryBond 12-43 Counterweight Weight 112 kg (246.9 lbs.) Tightening torque for screws 290 Nm (214 lbs/ft) Max.
Page 203: Automatic Engine Speed Setting
As soon as a hydraulic function is carried out with the control levers, diesel engine speed is automatically increased again to the engine speed adjusted with the throttle. Pos. Designation Cylinder Bracket Fuel filter bracket Shackle Fork head Plate SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 204: Installation
Options Installation SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 205: Grab Pipework
Fig. 2: Grab ball-type cock Attachments Notice! Please refer to the Operator's and maintenance manual of the attachment manu- facturer for using and carrying out maintenance on attachments such as hammers, grabs etc. SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 206: 3Rd Control Circuit/Powertilt Ports
Follow the instructions in the Operator's Manual of the attachment manufacturer for connecting the 3rd control circuit to attachments. Standard ports: Port Stick (left) Stick (right) 3rd control circuit/PowerTilt 3rd control circuit/PowerTilt Fig. 4: 3rd control circuit/PowerTilt ports Grab Grab SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 207: Safe Load Indicator
Therefore the driver must immediately reduce the load moment as follows: ☞ Reduce reach until both the acoustic signal and the indicator light in the round display element go out Fig. 5: Safe load indicator light SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 208: Safe Load Indicator De (From Serial No. Ag04828) (Safety Valves For Boom)
7.7 Safe load indicator DE (from serial no. AG04828) (safety valves for boom) XS41 376-2102 1000264916 Pos. Designation Safe load indicator cable Pilot control segment port Pressure switch Directional valve Hose burst valve Switch Protective plate SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 209 Safe load indicator DE (serial nos. AG02444 to AG04827) (safety valves for boom) Pos. Designation Safe load indicator cable Pilot control segment port Pressure switch Set screw Hose burst valve Switch Protective plate (from serial number AG03069) SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 210: Safe Load Indicator De (Up To Serial No. Ag02443)
• Pilot control pressure moves valve (2) to work position (free oil return from the base side). • The valve moves back to home position if the pilot control pressure drops. 7-10 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 211: Setting The Pressure Switch
Safety valve Tank line Directional valve Raise/lower boom Pilot control port PILOT Pressure switch Setting the pressure switch Adjust the pressure switch – see Setting the pressure switch on page 7-17 7-11 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 212: Safe Load Indicator Fr (From Serial No. Ag04828) (Safety Valves For Boom, Stick And Stabiliser Blade)
Designation Boom segment pilot control port Joystick stick port Joystick boom port Stick pressure line port Leak oil strip port Pressure switch Hose burst valve Boom pressure line port Protective plate 7-12 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 213: Safe Load Indicator Fr (Serial Nos. Ag02444 To Ag04827) (Safety Valves For Boom, Stick And Stabiliser Blade)
Boom segment pilot control port Joystick stick port Joystick boom port Stick pressure line port Leak oil strip port Pressure switch Hose burst valve Boom pressure line port Protective plate (from serial number AG03069) 7-13 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 214: Safe Load Indicator Fr (Up To Serial No. Ag02443)
• Pilot control pressure moves valve (2) to work position (free oil return from the base side). • The valve moves back to home position if the pilot control pressure drops. 7-14 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 215: Diagram (From Serial No. Ag04828)
Retracting the stabiliser blade ram Check valve (8) is controlled in parallel by the operating pressure (free oil flow to the base side). Diagram (from serial no. AG04828) Boom Stick Stabiliser blade 7-15 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 216: Diagram (Serial Nos. Ag02444 To Ag04827)
Diagram (up to serial no. AG02443) Stick Boom Stabiliser blade Pos. Designation Port Pos. Designation Port Safety valve Tank line Directional valve Raise/lower boom PILOT Pilot control port Extend/retract stick Pressure switch Non-return valve 7-16 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 217: Setting The Pressure Switch
Adjust pressure switch 3 with set screw 4 and a screwdriver. ➥ Unscrew the screw = earlier response ➥ Tighten the screw = later response ☞ Check again and reconnect the connector. Fig. 6: Pressure switch with cable connector 7-17 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 218: Hose Burst Valve Safety Feature
Collect the drained hydraulic oil in a suitable container. ☞ Dispose of drained hydraulic oil by an ecologically safe method ☞ Always contact the relevant authorities or commercial establishments in charge of oil disposal before disposing of biodegradable oil 7-18 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 219: Mechanical Quickhitch
• Insert tube P (included in scope of delivery) in clamping sleeve Q • Press the tube upwards • The lock pins must be in position S Fig. 9: Bucket with quickhitch 7-19 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 220: Hydraulic Quickhitch (Easy Lock)
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. 11: 3rd control circuit Diagram OPTION 3rd control circuit Joystick (right) 7-20 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 221: Drive Interlock (Antitheft Protection)
Hold further keys next to the transmitter/receiver surface to code them as mentioned above The drive interlock is enabled as soon as there is no ignition key contact for 30 seconds. ➥ Blinking red light 7-21 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 222 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. 7-22 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 223: Proportional Controls
Pressing button C ensures full throughput irrespective of the characteristic curve that has been selected! 7-23 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 224: Ports
Upper carriage rotates to the right Backwards Stick is retracted To the left Upper carriage rotates to the left Notice! Always carry out smooth control movements. Fig. 13: Left-hand control lever 7-24 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 225: Boom Swivel Controls
Hammer operation Switching on hammer operation: ☞ Press and hold button C on the control lever Switching off hammer operation: ☞ Release button C on the control lever Fig. 16: Hammer operation 7-25 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 226: Adjusting Control Response
Indicator light 1 in status indicator 2 flashes twice after switching on ignition Notice! The characteristic curve that has been set last is active after the machine is started Fig. 18: Characteristic curves – status indicator again. 7-26 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 227: Wiring Harness
Joystick signal channel 2 A_POT1 Joystick signal channel 1 U-analog Analogous supply +5 V R_POT1 GND joystick Fig. 19: Control unit R_POT2 GND potentiometer A_POT3 Potentiometer signal Auto Pressure switch Serial interface 7-27 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 228: Measures To Be Taken In Case Of Malfunctions
Short circuit on earth or operating volt- A7, A8 Channel 2 output; Y18/Y19 Check wiring System start A10, A11 Motor output Overheating (output stage) Check motor EEProm data error +5 V joystick Defective 5 V supply 7-28 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 229: Engine Oil Service Valve
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 Fig. 22: Drain coupling with hose • Completely remove all oil spills from the engine 7-29 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 230 Options 7-30 SHB 28Z3 EN – Edition 2.0 * 28z3s710.fm...
Page 231 PowerTilt PTS06...
Page 232: Powertilt Pts06 General Instructions
To prevent damage to seals and other internal parts: ☞ Never perform any welding work on the PowerTilt when it is fully mounted. Any modifications can result in loss of the product guarantee. SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 233: Checking The Product
The maintenance technician is responsible for ensuring that the machine and hydraulic system are in correct working order. Since the hydraulic system of the machine supplies the PowerTilt swivel device with oil, checking the system for correct function is essential. SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 234: Specifications/Requirements
Most PowerTilt models have four hydraulic connections: 2 connections with the designation “P1” and 2 with the designation “P2”. Most PowerTilt swivel device supplied in the USA have SAE connections. Customers outside North America are normally supplied with BSPP connections. PowerTilt swivel devices are equipped with external decompression valves at the factory. SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 235: Tools
Making a tool VI for removing the seals on page 8-6 Plastic pusher VIII Permanent marker pen Torque wrench Mounting lever or similar Large socket spanner Allen keys 1 set XIII Rubber or plastic hammer Protective goggles Loctite 242 Loctite 545 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 236: Making A Tool Vi For Removing The Seals
8.4 Separating the PowerTilt swivel device from the machine Carefully lower the PowerTilt swivel device to the ground. Remove the necessary securing parts and pins from the bucket. Remove the pivot pins. Fig. 3: Removing the PowerTilt SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 237: Exploded Views Pts06
Base block on end cap side Integrated Grease nipples Internal decompression valve Cover of grease decompression valve Load hook (option) Lubrication system decompression valve Hydraulic connection P1 Hydraulic connection P2 Pressure screw (coupling) Lock nut (coupling) SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 238: Sealing Kit A And Bearing Kit B Pts06 (Overview)
End cap O-ring Additional ring for end cap Shaft bearing Additional ring for piston Piston bearing Piston seal Pressure disc Piston seal (PTS06 – PTS08) Plug seal Pressure seal A10 O-ring for securing ring SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 239: Assembly Drawing
PowerTilt PTS06 8.6 Assembly drawing A1 A2 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 240: Removing The Standard Journal Coupling
Tighten both set screws e on securing ring 5. Turn the screws alternately to remove the securing ring from end cap 4 and base block 6.2 on the end-cap side. Fig. 8: Tightening the set screws 8-10 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 241 6.1, 6.2. Fig. 10: Removing the standard journal coupling Notice! Parallel pin f between the shaft and the drive-side base block 6.1 prevents the components from shifting. Fig. 11: Shaft parallel pin 8-11 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 242: Removing The End Cap, Securing Ring And Internal Decompression Valve
Remove end cap 4 with two pins and a long mounting lever from the shaft. Fig. 15: Removing the end cap from the shaft ☞ Remove pressure disc B5 from end cap 4 or the housing collar. Fig. 16: Removing the pressure disc 8-12 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 243: Removing The Shaft
Turn the shaft to release the teeth of the shaft from the teeth of the piston tube. Caution! Secure the shaft (heavy)! ☞ Avoid damage to the teeth. Fig. 19: Supporting the shaft 8-13 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 244: Removing The Piston Tube Body
Fig. 21: Removing the piston tube with a hammer and drift Caution! Remove the piston tube carefully! ☞ Avoid damage to the teeth. Fig. 22: Removing the piston tube 8-14 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 245: Removing The Seals (Kit A), Shaft Bearings And Pressure Discs (Kit B)
Fig. 25: Removing the seals and bearings ☞ Remove grease nipple h, grease decompression valve covers i and grease decom- pression valves j. Fig. 26: Removing the grease nipple, etc. Fig. 27: Removing the grease nipple, etc. 8-15 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 246: Checking Components And Dead Centre Marks
Fig. 28: Retightening the dead centre marks of the shaft Fig. 29: Redrawing the dead centre mark of the piston tube Fig. 30: Redrawing the dead centre mark of the ring gear 8-16 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 247: Trial Assembly
• Coat the seals and treated surfaces with high-quality hydraulic oil (in accordance with DIN51524/T3 (HVLP)) before installation. Notice! Fig. 32: Coat the seals and surfaces with oil The exact position and number of seals or bearings depends on the PowerTilt model. 8-17 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 248: Installing The End-Cap Seals And Bearings
Fig. 36: Coat the seals and surfaces with oil ☞ Place O-ring A1 and additional ring A2 in the groove of the inside seal on the end cap. Fig. 37: Coat the seals and surfaces with oil 8-18 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 249: Installing The Piston Seals And Bearings
A5, A6 of the piston tube body. On models with U-cup seals, the lips show away from each other. Fig. 39: Fitting the U-cup seals ☞ If wear indicators are used, install them on the outside and/or inside diameters B4. Fig. 40: Fitting the wear indicators 8-19 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 250: Fitting The Shaft Seal And The Bearing
Install the second pressure seal A9 with the lip showing inside. Fig. 44: Applying grease to the pressure disc of the shaft ☞ Install wear indicator B2. Fig. 45: Shaft wear indicators 8-20 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 251: Installing The Piston Tube
Fig. 49: Pay attention to the marks ☞ With a plastic/rubber hammer and plastic drift, put the teeth of the piston in the ring gear. Fig. 50: Fitting the piston tube 8-21 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 252: Installing The Shaft
Fig. 54: Checking the dead centre marks of the shaft ☞ Ensure the firm seating of the seal with slight blows and turn the shaft into the housing with a mounting lever. Fig. 55: Fastening the shaft 8-22 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 253: Installing The End Cap And The Securing Ring
Fig. 59: Installing the securing ring ☞ Before removing the securing ring, mark the orientation of the teeth of the securing ring and the shaft. Fig. 60: Mark on shaft and securing ring 8-23 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 254: Installing The Internal Decompression Valve
Turn the shaft with a mounting lever until the mounting surface of base block 6.1 on the drive-shaft side is horizontal. Fig. 64: Aligning the base block ☞ Remove threaded bolts IV. Fig. 65: Removing the bolts 8-24 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 255 Fig. 68: Fitting the standard journal coupling on the shaft ☞ Apply a waterproof lubricant to the end of shaft 2, securing ring 5 and the outside surfaces of end cap 4. Fig. 69: Waterproof lubricant Fig. 70: Waterproof lubricant 8-25 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 256 Fig. 74: Fastening screws of shaft Torque specifications for fastening screws in Nm (lbs/ft) Model Size Hexagon socket screw PTS06 M16 x 2.00 258 +/- 7 (190 +/- 5) Fig. 75: Fastening the shaft screws 8-26 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 257: Lubrication And Tests
☞ Connect a hydraulic line to P2 and create pressure as in step 1. ☞ Check for leaks at P1 and near the main shaft and end-cap seals (see step 2). 8-27 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 258: Testing The Internal Decompression Valve
Oil escapes at 210 – 230 bar (3046 – 3336 psi). ☞ Check P2 in the same way. ☞ Replace the valve if the test pressure does not correspond to the specifications. 8-28 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 259: Securing The Powertilt Swivel Device On The Machine
Slacken the lock nut and turn the screw until it touches the pin. ☞ Secure the screw by tightening the locknut. Notice! The mounting pins can be aligned more easily by adjusting correctly when the bucket is replaced. 8-29 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 260: Troubleshooting
Defective grease decompression valve of lubrication system, Clean or replace the grease decompression valves of lubricant through or grease decompression valve has been replaced by a the lubrication system. the grease nip- grease nipple or plug. ples 8-30 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 261: Adjusting The Play On The Powertilt
Press the securing screw out of the oscillating-flange clearance by screwing in the set screws. Notice! To remove/mount the securing ring, slacken the fastening screws of the shaft on the other side. Fig. 84: Adjusting the set screws 8-31 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 262 475 – 680 (350 – 502) Caution! Fit the securing ring before operating the PowerTilt again! Fig. 86: Tightening the blind flange ☞ The shaft turns against the blind flange and the adjusted torque is modified. 8-32 SHB 28Z3 EN – Edition 2.0 * 28z3s810.fm...
Page 263 Wacker Neuson Linz GmbH keep abreast of the latest technical developments and con- stantly 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 264 Wacker Neuson Linz GmbH Haidfeldstr. 37 A-4060 Linz-Leonding Austria Phone: +43 (0) 732 90 5 90-0 Fax: +43 (0) 732 90 5 90-200 E-mail: office.linz@wackerneuson.com www.wackerneuson.com Order no. 1000178347 Language en SHB 28Z3 EN – Edition 2.0 * 28z3schlussbl.fm...

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