Wacker Neuson HPU8 Electro-hydraulic power unit Tracks Excavators Service Manual - PDF DOWNLOAD

Service Manual

Electro-hydraulic power unit

Machine model

A01-01

Edition

1.2

Document order number

1000322998

Language

en

From serial number

WNCA0101VPAL00160

Language

Order no.

Operator’s manual

de

1000280662

Service manual

en

1000322998

Spare parts list HPU8 (A01-01)

de/en/fr

1000315132

Spare parts list HPU8 (A01-01)

de/it/es

1000315133

Documentation

Legend Original service manual Edition Date Document

x 1.2 XX/2014 SHB HPU8 en

Copyright 2014 Wacker Neuson Linz GmbH, Hörsching Printed in Austria All rights reserved, in particular the copyright, the right of reproduction and the right of distribution applicable worldwide.

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.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH. Violations of legal regulations, in particular of the copyright protection, shall be subject to civil and criminal prosecution.

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 figures and descriptions in this documentation which do not reflect products that have already been delivered and that will not be implemented on these machines.

Technical data, dimensions and weights are only given as an indication. Responsibility for errors or omissions not accepted.

The cover features the machine with possible optional equipment.

Photographs and graphics are symbolic representations and may differ from the actual products.

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

Table of contents Bedienung Hinweise zum Servicehandbuch .............................................................................. 1-2 Kennzeichnung von Warn- und Gefahrenhinweisen ............................................... 1-2 Zeichenerklärung und Abkürzungen ........................................................................ 1-3 Zeichenerklärung ............................................................................................... 1-3 Abkürzungen ..................................................................................................... 1-4 Umrechnungstabelle .......................................................................................... 1-5 Gewährleistung und Haftung ................................................................................... 1-6 Gewährleistungs- und Haftungsausschluss ...................................................... 1-6 Beschilderung .......................................................................................................... 1-7 Typenschilder .................................................................................................... 1-7 Gesamtansicht ......................................................................................................... 1-8 Außenansicht Schaltkasten ..................................................................................... 1-9 Bauteilanordnung ................................................................................................... 1-10 Übersicht Kontroll- und Warnleuchten ................................................................... 1-11 Kontrollleuchten ............................................................................................... 1-11 Betriebsstundenzähler ..................................................................................... 1-11 Technische Daten Typen und Handelsbezeichnung ............................................................................. 2-2 Elektromotor ............................................................................................................ 2-2 Bereifung ................................................................................................................. 2-2 Hydrauliksystem ...................................................................................................... 2-3 Hydraulikschlauch-Spezifikationen .................................................................... 2-3 Geräuschemissionen ............................................................................................... 2-3 Vibration ................................................................................................................... 2-3 Gewicht .................................................................................................................... 2-4 Gewicht Aggregat .............................................................................................. 2-4 Anzugsdrehmomente ............................................................................................... 2-4 Typenbezogene Anzugsdrehmomente .............................................................. 2-4 Allgemeine Anzugsdrehmomente ...................................................................... 2-5 Anzugsdrehmomente für hochfeste Schraubverbindungen .............................. 2-7 Abmessungen .......................................................................................................... 2-8 Wartung Hinweise zur Wartung .............................................................................................. 3-2 Zuständigkeiten und Vorraussetzungen ............................................................ 3-2 Wichtige Sicherheitshinweise zu den Pflege- und Wartungsarbeiten ............... 3-2 Betriebs- und Schmierstoffe .................................................................................... 3-3 Hydrauliköltypen (temperaturabhängig) ............................................................ 3-3 Wartungsplan ........................................................................................................... 3-4 Kühlsystem .............................................................................................................. 3-6 Wichtige Hinweise zum Kühlsystem .................................................................. 3-6 Kühler reinigen .................................................................................................. 3-6 Hydrauliksystem ...................................................................................................... 3-7 Wichtige Hinweise zum Hydrauliksystem .......................................................... 3-7 Hydraulikölstand kontrollieren ........................................................................... 3-8 Hydrauliköl nachfüllen ....................................................................................... 3-8 Hydrauliköl wechseln ......................................................................................... 3-9 Hydraulikölfilter wechseln ................................................................................ 3-10 Kondenswasser Hydrauliköltank ablassen ...................................................... 3-11 Hydrauliksystem auf Dichtheit und Zustand kontrollieren ................................ 3-11 Wartung- und Pflege von Anbauwerkzeugen ........................................................ 3-12 Wichtige Hinweise zur Wartung- und Pflege von Anbauwerkzeugen .............. 3-12 Elektrische Anlage ................................................................................................. 3-12 Wichtige Hinweise zur elektrischen Anlage ..................................................... 3-12 SHB HPU8 en - Edition 1.2 * HPU8s10IVZ.fm

I-1

Überprüfen der Kontrollleuchten ...................................................................... 3-12 Bereifung ................................................................................................................ 3-13 Kontrollarbeiten ................................................................................................ 3-13 Reifen-/Räderwechsel ..................................................................................... 3-13 Wartung der Hebeöse ............................................................................................ 3-13 Reinigungs- und Pflegearbeiten ............................................................................. 3-14 Wichtige Hinweise zu Reinigungs- und Pflegearbeiten ................................... 3-14 Einsatz von Lösungsmitteln ............................................................................. 3-14 Reinigung des Aggregats ................................................................................ 3-15 Stilllegung und Wiederinbetriebnahme .................................................................. 3-16 Vorübergehende Stilllegung ............................................................................ 3-16 Wiederinbetriebnahme ..................................................................................... 3-16 Endgültige Stilllegung ............................................................................................ 3-16 Entsorgung ...................................................................................................... 3-16 Motor Übersicht .................................................................................................................. 4-2 Hydraulikanlage Funktionsweise ........................................................................................................ 5-2 Bauteilanordnung ..................................................................................................... 5-3 Hydrauliktankkomponenten ............................................................................... 5-4 Belüftungsfilter (Hydrauliktank) ................................................................................ 5-6 Störungen an der Hydraulikanlage .......................................................................... 5-6 Elektrische Anlage Wichtige Hinweise zur elektrischen Anlage ....................................................... 6-2 Ohm'sches Gesetz (Strom, Spannung, Widerstand); Leistung ................................ 6-2 Messgeräte, Messmethode ...................................................................................... 6-2 Bauteilanordnung ..................................................................................................... 6-4 Schaltkasten mit Sicherheitsschaltgerät ABB .......................................................... 6-5 Schaltkasten mit Sicherheitsschaltgerät Pilz ........................................................... 6-6 Störungen Schaltkasten ........................................................................................... 6-7 Lampe Störung leuchtet ..................................................................................... 6-7 Lampe Störung leuchtet nicht ............................................................................ 6-7 Schaltpläne Hydraulikschaltplan .................................................................................................. 7-2 Legende Stromlaufplan (gültig für Sicherheitsschaltgerät ABB und Pilz) ................ 7-3 Stromlaufplan Teil1 (gültig für Sicherheitsschaltgerät ABB und Pilz) ...................... 7-4 Stromlaufplan Teil2 (gültig für Sicherheitsschaltgerät ABB und Pilz) ...................... 7-5 Stromlaufplan Teil3 (gültig für Sicherheitsschaltgerät ABB) .................................... 7-6 Stromlaufplan Teil3 (gültig für Sicherheitsschaltgerät Pilz) ...................................... 7-7 Spezialwerkzeug PAL

I-2

SHB HPU8 en - Edition 1.2 * HPU8s10IVZ.fm

Operation

Operation

Operation

1

Operation

1.1 Notices on this service manual This service manual contains important notices on how to perform regular maintenance and servicing work on the machine. Therefore, the service manual aims not only at new personnel, but it also serves as a reference for experienced personnel. The service manual helps to avoid hazardous situations and reduce repair costs and downtimes.

Furthermore, the reliability and the service life of the machine will be increased by following the instructions in the service manual.

Careful and prudent working is the best way to avoid accidents!

Operational safety and readiness of the machine do not only depend on your skill, but also on maintenance and servicing of the machine. This is why regular maintenance and servicing is absolutely necessary.

Extensive maintenance and repair work must always be performed by a Wacker Neuson service center. Use only original spare parts for repairs. This ensures operational safety and readiness of your machine, and maintains its value.

• We reserve the right to improve the technical standard of our machines without adapting the service manual.

• Modifying Wacker Neuson products and fitting them with additional equipment and attachments not included in our delivery program requires Wacker Neuson’s written authorization, otherwise warranty and product liability for possible damage caused by these modifications shall not be applicable.

• Subject to modifications and printing errors.

Your Wacker Neuson dealer will be happy to answer any further questions regarding the machine or the service manual.

1.2 Identification of warnings and dangers Important indications regarding the safety of the personnel and the machine are identified in this Service Manual with the following terms and symbols:

Danger!

Failure to observe the instructions identified by this symbol can cause injury or death for the operator or other persons. ☞ Measures for avoiding danger

Caution!

Failure to observe the instructions identified by this symbol can cause damage to the machine. ☞ Measures for avoiding danger for the machine

1-2

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Operation 1.3 Explanation of symbols and abbreviations Explanation of symbols • Identifies a list • Subdivision within lists.

Follow the order of the activity.

☞ Identifies an activity ☞ Subdivision of an activity

Follow the order of the activity.

➥ Identifies a result after a list ➥ Subdivision of a result after a list.

Follow the order of the activity.

Cross reference: see page 1-1 (page) Cross reference: 7 (pos. no. or table no.)

Cross reference: fig. 1 (fig. no. 1) Cross references: – see chapter “5 Operation” on page 5-1 (see chapter) Cross references: – see “Operation” on page 5-1 (– see text)

Notice!

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.

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

1-3

Operation Abbreviations TOPS

=

Tip Over Protective Structure

ROPS

=

Roll Over Protective Structure

FOPS

=

Falling Objects Protective Structure

FGPS

=

Front Guard Protective Structure

AUX

=

Auxiliary-hydraulics circuit

B

=

Width

NE

=

Nominal width

PS

=

Stabilizer blade

LS

=

Stick

HSWS

=

Hydraulic quickhitch

o/h

=

Operating hours

Pos.

=

Position

Fig.

=

Figure

e.g.

=

for example

approx.

=

approximately

=

1-4

max.

=

maximum

min.

=

minimum

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Operation Conversion table The rounded imperial values are indicated in brackets, for example 1060 cm³ (64.7 in³).

Volume unit 1 cm³ 1 m³ 1 ml 1l 1 l/min

(0.061 in³) (35.31 ft³) (0.034 US fl.oz.)

(0.26 gal) (0.26 gal/min)

Unit of length 1 mm 1m

(0.039 in) (3.28 ft)

Weight 1 kg 1g

(2.2 lbs) (0.035 oz)

1 bar 1 kg/cm²

(14.5 psi) (14.22 lbs/in²)

Pressure

Force/output 1 kN 1 kW 1 PS

(224.81 lbf) (1.34 hp) (0.986 hp)

Torque 1 Nm

(0.74 ft.lbs.)

1 kph

(0.62 mph)

Acceleration 1 m/s²

(3.28 ft/s²)

Speed

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

1-5

Operation 1.4 Warranty and liability Exemption from warranty and liability Warranty Warranty claims can be made only if the conditions of warranty have been observed. They are included in the General Conditions of Sales and Delivery for new machines and spare parts sold by the dealers of Wacker Neuson Linz GmbH. Furthermore, all instructions in this Operator’s Manual must be observed.

Have the maintenance, delivery inspection and the entries in the service booklet performed by a Wacker Neuson service center, otherwise warranty claims will not be acknowledged.

Liability • Modifying Wacker Neuson products and fitting them with additional equipment and attachments not included in the delivery program requires Wacker Neuson’s written authorization, otherwise warranty and product liability for possible damage caused by these modifications shall not be applicable.

• The safety of the machine can be negatively affected by performing machine modifications without proper authority and by using spare parts, equipment, attachments and optional equipment that have not been checked and released by Wacker Neuson.

Warranty and product liability for possible damage caused by these modifications shall not be applicable.

• Wacker Neuson Linz GmbH shall not be liable for personal injury and/or damage to property caused by failure to observe the safety instructions and the Operator’s Manual, and by the negligence of the duty to exercise due care when: • handling • operating • servicing and performing maintenance and • repairing the machine. This is also applicable in those cases in which special attention has not been drawn to the duty to exercise due care, in the safety instructions as well as in the Operator’s and maintenance manuals.

• Read and understand the Operator’s Manual before starting up, servicing or repairing the machine. Observe all safety instructions.

1-6

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Operation 1.5 Labels Danger!

Accident hazard! Remove missing or damaged labels immediately.

Can cause serious injury or death. ☞ Check warning and information labels regularly whether they are missing or damaged.

☞ Never remove warning and information labels.

Type labels Serial number The serial number is stamped on the chassis. It is also located on the type label.

Refer to the Operator’s Manual of the machine for more information.

Fig. 1:

Type label (symbolic representation)

Electric motor The type label is located on top of the electric motor.

Fig. 2:

Electric motor type label

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

1-7

Operation 1.6 Overview 2

1 7

6 6 13 5 10 11

8

10

3 9

9

6

13

14

9

9

15 12 4

Position

1-8

Designation

Position Designation

1

Lifting eye

9

Transport handles

2

Lance

10

Supports

3

Control box

11

Storage compartment for battery charger

4

Electric fan

12

Hydraulic oil sight glass

5

Wheels/tires

13

Stabilizer blade hooks

6

Tie-down points (total of 4)

14

Hydraulic connections

7

Ventilation grid of hydraulic oil radiator

15

Three-phase connector

8

Document box

--

--

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Operation 1.7 Outside view of control box

2

3

1 4

6

Pos.

5

Designation

1

Power unit start (green)

2

Power unit stop (red)

3

Emergency off switch

4

Control box lock

5

Hour meter

6

Accessories outlet 230 V

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

1-9

Operation 1.8 Overview of components 1

2

3

4

5

6 7

12

8 7 11 9 10

Pos.

Designation

1

Hydraulic oil radiator

2

Radiator fan

3

Solenoid valve

4

Breather filter

5

Hydraulic oil return filter

6

Hydraulic oil reservoir

7

Hydraulic couplings

8

Pressure limiting valve

9

Hydraulic pump (gear pump)

10

Electric motor

11

Mains supply

12

Electrical cabinet

1-10

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Operation 1.9 Indicator lights and warning lights (overview) Indicator lights The indicator lights provide information on the operating state and possible malfunctions.

Symbol

Color

Designation

Green

Error-free operation

Red

Malfunction

Hour meter Counts the operating hours and shows when the next maintenance interval is due.

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

1-11

Operation

1-12

SHB HPU8 en – Edition 1.2 * HPU8s110.fm

Technical data

Technical data

Technical data

2

Technical data

2.1 Models and trade names Machine model/machine designation

Trade name

A01-01

HPU8

2.2 Electric motor Electric motor Product Type Product Type Design

HPU8 Winter motor (up to serial no. WNCAD101NPAL00139) 2SIEL 132M4 AC motor (from serial number WNCA0101VPAL00160) FCPY 132 M-4/HE 3-phase electric motor

Rated power

7.5 kW (10 hp)

Rated speed

1460 rpm

Rated voltage

400 V

Rated frequency

50 Hz

Rated torque

49.1 Nm (36.2 ft.lbs.)

Rated current

16 A

Output factor (at 100 % load)

0.83

Efficiency (at 100 % load) Inertia Type of cooling Protective system/terminal box Insulation class Direction of rotation

88.7 % 0.030 kg m2 (103 lb in2) IC 411 IP55 F Right/left

2.3 Tires Tires Wheel width Wheel diameter Tire pressure

2-2

HPU8 90 mm (3.5 in) 340 mm (13.4 in) 3 bar (44 psi)

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

Technical data 2.4 Hydraulic system Hydraulic system

HPU8

Type of control

Constant control

Number of pumps

1

Pump type

Gear pump

Flow rate

20 l/min (5.3 gal/min)

Operating pressure for operating hydraulics

210 bar (3,046 psi)

Hydraulic reservoir capacity

9.6 l (2.5 gal)

Hydraulic hose capacity (12 m/39 ft)

4.5 l (1.2 gal)

Hydraulic hose specifications Hydraulic hose Dimension

HPU8 DN16

Operating pressure

210 bar (3,046 psi)

Minimum bursting pressure

840 bar (12,183 psi)

1

12 m (39 ft)

Protective hose on excavator side

Yes

Maximum length 1.

Pressure losses with hose lengths over 12 meters.

2.5 Noise emissions Measured sound power level LwA 1

90.3 dB

Guaranteed sound power level LwA1

93 dB

Uncertainty factor KA22 Operator-perceived sound pressure level LpA (without cabin)3 1.

2.

3.

0.8 -

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)

Notice!

Measurements performed on asphalted surface.

2.6 Vibration The relevant threshold values are observed.

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

2-3

Technical data 2.7 Weight Weight of power unit Weight

HPU8

Transport/operating weight1 1.

192 kg (423 lbs)

Transport weight: basic machine + 10 % fuel capacity.

Notice!

The weight of all the equipment (hydraulic hoses, for example) must be added to the weight of the power unit. Weight indications can vary by +/− 2 %.

2.8 Tightening torques Notice!

Refer to the spare parts catalogue of the power unit for the tightening torques and screws requiring adhesive fastening.

Model-specific tightening torques HPU8

Thread

Angled motor bracket* Pump base* Pump*

M10 8.8 M10 10.9 M10 8.8

Torque Nm (ft.lbs.)

45 (33.2) 65 (48) 45 (33.2)

*) All connections with an * must be glued with Loctite S2420 or VaryBond 12-43.

2-4

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

Technical data General tightening torques Tightening torques for hydraulic threaded fittings (dry assembly) Metric hose fittings for hydraulic applications (light execution, DKOL) Torque Nominal Ø Outer Ø Thread Wrench size Nm (ft.lbs.)

05 06 08 10 12 16 20 25 32

6L 8L 10L 12L 15L 18L 22L 28L 35L

M12X1.5 M14X1.5 M16X1.5 M18X1.5 M22X1.5 M26X1.5 M30X2 M36X2 M45X2

WS 14 WS 17 WS 19 WS 22 WS 27 WS 32 WS 36 WS 41 WS 55

15 (11) 20 (14.7) 40 (29.5) 50 (36.8) 75 (55.3) 85 (62.7) 100 (73.75) 180 (132.7) 220 (162.3)

Galvanized and dry surface (O-ring slightly oiled). Torque tolerance: −10 % Values determined empirically and to be applied as approximate figures.

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

Outer Ø

Thread

Wrench size

05 06 08 10 12 16 20 25 32

8S 10S 12S 14S 16S 20S 25S 30S 38S

M16X1.5 M18X1.5 M20X1.5 M22X1.5 M24X1.5 M30X2 M36X2 M42X2 M52X2

WS 19 WS 22 WS 24 WS 27 WS 30 WS 36 WS 41 WS 50 WS 60

Torque Nm (ft.lbs) 40 (29.5) 50 (36.8) 60 (44.3) 75 (55.3) 90 (66.4) 100 (73.8) 180 (132.8) 270 (199.1) 400 (295)

Galvanized and dry surface (O-ring slightly oiled). Torque tolerance: −10 % Values determined empirically and to be applied as approximate figures.

Threaded fittings with various seals for hydraulic applications (light execution) Straight pipe fitting with thread and screwed plug Thread

M10X1.0 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M22X1.5 M27X2.0 M33X2.0 M42X2.0

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Nm (ft.lbs) 9 (7) 20 (15) 35 (26) 45 (33) 55 (41) 65 (48) 90 (66) 150 (111) 240 (177)

Nm (ft.lbs.)

18 (13) 25 (18) 45 (33) 55 (41) 70 (52) 125 (92) 180 (133) 310 (229) 450 (332)

Nm (ft.lbs.)

15 (11) 25 (18) 35 (26) 40 (30) 45 (33) 60 (44) 100 (74) 160 (118) 210 (155)

Nm (ft.lbs.)

18 (13) 25 (18) 35 (26) 50 (37) 70 (52) 125 (92) 145 (107) 210 (155) 360 (266)

Identification aid outside Ø mm (") 10 (0.4) 12 (0.5) 14 (0.55) 16 (0.6) 18 (0.7) 22 (0.9) 27 (1.0) 33 (1.3) 42 (1.7)

2-5

Technical data Threaded fittings with various seals for hydraulic applications (light execution) M48X2.0 G1/8A G1/4A G3/8A G1/2A G3/4A G1A G1 1/4A G1 1/2A

290 (214) 9 (7) 35 (26) 45 (33) 65 (48) 90 (66) 150 (111) 240 (177) 290 (214)

540 (398) 18 (13) 35 (26) 70 (52) 90 (66) 180 (133) 310 (229) 450 (332) 540 (398)

260 (192) 15 (11) 30 (22) 45 (33) 55 (41) 100(74) 160 (118) 210 (155) 260 (192)

540 (398) 18 (13) 35 (26) 50 (37) 65 (48) 140 (103) 190 (140) 360 (266) 540 (398)

48 (1.9) 9.73 (0.38) 13.16 (0.52) 16.66 (0.66) 20.96 (0.83) 26.44 (1.04) 33.25 (1.31) 41.91 (1.65) 47.80 (1.88)

Torque tolerance: –10 %; countermaterial: steel/aluminum

Threaded fittings with various seals for hydraulic applications (heavy execution) Straight pipe fitting with thread and screwed plug Thread

M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M27X2.0 M33X2.0 M42X2.0 M48X2.0 G1/8A G1/4A G3/8A G1/2A G3/4A G1A G1 1/4A

Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Nm (ft.lbs.)

20 (15) 35 (26) 45 (33) 55 (41) 55 (41) 65 (48) 90 (66) 150 (111) 240 (177) 290 (214) 35 (26) 45 (33) 65 (48) 90 (66) 150 (111) 240 (177) 290 (214)

Nm (ft.lbs.)

35 (26) 55 (41) 70 (52) 90 (66) 125 (92) 135 (100) 180 (133) 310 (229) 450 (332) 540 (398) 55 (41) 80 (59) 115 (85) 180 (133) 310 (229) 450 (332) 540 (398)

Nm (ft.lbs.)

35 (26) 45 (33) 55 (41) 70 (52) 80 (59) 100 (74) 170 (126) 310 (229) 330 (243) 420 (310) 45 (33) 60 (44) 75 (55) 170 (125) 310 (229) 330 (243) 420 (310)

Nm (ft.lbs.)

35 (26) 45 (33) 55 (41) 70 (52) 100 (74) 125 (92) 135 (100) 210 (155) 360 (266) 540 (398) 45 (33) 60 (44) 100 (74) 145 (107) 260 (192) 360 (266) 540 (398)

Identification aid outside Ø mm (") 12 (0.5) 14 (0.55) 16 (0.6) 18 (0.7) 22 (0.9) 27 (1.0) 12 (0.5) 33 (1.3) 42 (1.7) 48 (1.9) 13.16 (0.52) 16.66 (0.66) 20.96 (0.83) 26.44 (1.04) 33.25 (1.31) 41.91 (1.65) 47.80 (1.88)

Torque tolerance: –10 %; countermaterial: steel/aluminum

2-6

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

Technical data Tightening torques for high-resistance threaded fittings With coarse-pitch thread

Thread M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Screws according to DIN 912, DIN 931, DIN 933, etc.

8.8 Nm (ft.lbs.)

5.5 (4) 10 (7) 25 (18) 45 (33) 87 (64) 135 (100) 210 (155) 280 (207) 410 (302) 550 (406) 710 (524) 1040 (767) 1420 (1047)

10.9 Nm (ft.lbs.)

8 (6) 14 (10) 35 (26) 65 (48) 110 (81) 180 (133) 275 (203) 410 (302) 570 (420) 780 (575) 1000 (738) 1480 (1092) 2010 (1482)

Screws according to DIN 7984

12.9 8.8 Nm (ft.lbs.) Nm (ft.lbs.)

10 (7) 5 (4) 17 (13) 8.5 (6) 42 (31) 20 (15) 80 (59) 40 (30) 147 (108) 69 (51) 230 (170) 110 (81) 350 (258) 170 (125) 480 (354) 245 (181) 690 (509) 340 (251) 930 (686) 460 (339) 1190 (878) 590 (435) 1770 (1305) 870 (642) 2400 (1770) 1200 (885)

10.9 Nm (ft.lbs.)

7 (5) 12 (9) 30 (22) 59 (44) 100 (74) 160 (118) 250 (184) 345 (254) 490 (361) 660 (487) 840 (620) 1250 (922) 1700 (1254)

DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.

With fine-pitch thread

Thread M8X1.0 M10X1.0 M10X1.25 M12X1.25 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M24X2.0 M27X2.0 M30X2.0

Screws according to DIN 912, DIN 931, DIN 933, etc.

8.8 Nm (ft.lbs.)

25 (18) 50 (37) 49 (36) 87 (64) 83 (61) 135 (100) 210 (155) 315 (232) 440 (325) 590 (435) 740 (546) 1100 (811) 1500 (1106)

10.9 Nm (ft.lbs.)

37 (28) 75 (55) 71 (52) 130 (96) 125 (92) 200 (148) 310 (229) 450 (332) 630 (465) 840 (620) 1070 (789) 1550 (1143) 2150 (1586)

Screws according to DIN 7984

12.9 8.8 Nm (ft.lbs.) Nm (ft.lbs.)

43 (32) 22 (16) 88 (65) 43 (32) 83 (61) 42 (31) 150 (111) 75 (55) 145 (107) 72 (53) 235 (173) 120 (89) 360 (266) 180 (133) 530 (391) 270 (199) 730 (538) 375 (277) 980 (723) 500 (369) 1250 (922) 630 (465) 1800 (1328) 920 (679) 2500 (1844) 1300 (959)

10.9 Nm (ft.lbs.)

32 (24) 65 (48) 62 (46) 110 (81) 105 (77) 175 (129) 265 (195) 385 (284) 530 (391) 710 (524) 900 (664) 1300 (959) 1850 (1364)

DIN 912 – hexagon socket head cap screw; DIN 931/DIN 933 – hexagon head screw with/without shaft; DIN 7984 – hexagon socket head cap screw with short head All values subject to a friction coefficient of µ = 0.12 and are to be used as approximate figures.

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

2-7

Technical data 2.9 Dimensions

HPU8

2-8

Dimension

A

Height

1000 mm (39 in)

B

Width

720 mm (28 in)

C

Transport length

930 mm (37 in)

D

Ground clearance

150 mm (6 in)

E

Distance between stabilizer blade hooks

603 mm (24 in)

F

Distance between center of wheel hub and stabilizer blade hooks

593 mm (23 in)

SHB HPU8 en – Edition 1.2 * HPU8s210.fm

Maintenance

Maintenance

Maintenance

3 3.1

Maintenance Information on maintenance

Responsibilities and prerequisites The working order and the service life of machines are heavily dependent on maintenance.

Daily and weekly servicing and maintenance must be performed by specifically trained personnel.

Have the maintenance, 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/operating company to perform the mandatory maintenance.

This ensures optimal machine operation. Immediately repair or replace parts that are already damaged or not working properly before they are due for replacement.

Repair or replacement of safety-relevant parts may only be performed by a Wacker Neuson service center.

Use only original spare parts for repairs.

The manufacturer shall not be liable for damage to the power unit or injury caused by failure to observe the specific notices and descriptions Important safety instructions on maintenance • Follow all safety instructions given in this Operator’s Manual.

• Follow the instructions given in chapter Safety, safety instructions on maintenance and qualification of the operating and maintenance personnel in this Operator’s Manual.

• Follow the maintenance and safety instructions given in the Operator’s Manuals of the attachments.

• Wear protective gloves and clothing.

• Observe the danger indications and safety instructions during maintenance.

• In order to avoid injury hazard, do not perform any work on hot components.

• Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

• Attach a warning label to the control elements (for example “Power unit being serviced, do not start”).

• Stop the power unit.

• Do not re-use self-locking fasteners.

3-2

SHB HPU8 en – Edition 1.2 * HPU8s310.fm

Maintenance 3.2

Fluids and lubricants

Power unit

Fluid/lubricant

Specification

Season/temperature

Hydraulic oil

Eurolub HVLP 462

Year-round3

Hydraulic oil reservoir Hydraulic oil hose 1.

2.

3.

Capacities 1 9.6 l (2.5 gal) 4.6 l (1.2 gal)

The capacities indicated are approximate values; the sight glass or the dipstick alone is relevant for the correct level.

Capacities indicated are no system fills According to DIN 51524 section 3, ISO-VG 46.

Depending on local conditions

Hydraulic oil types (depending on temperature) Hydraulic oil types Hydraulic oil grade

SHB HPU8 en – Edition 1.2 * HPU8s310.fm

Ambient temperature min.

max.

ISO VG32

−20 °C (−4 °F)

30 °C (86 °F)

ISO VG46

−5 °C (23 °F)

40 °C (104 °F)

ISO VG68

+5 °C (41 °F)

50 °C (122 °F)

3-3

Maintenance

Maintenance 3.3 Maintenance plan Daily maintenance (operator) Inspection work (Check the following fluids and lubricants, check the oil levels after a test run and add oil if necessary) Check the fluids and lubricants (engine oil, engine coolant, hydraulic oil)

--

Check the hydraulic oil radiator for dirt, clean it if necessary

--

Check and if necessary clean the electric fan once a day

--

Check pin lock

--

Check the indicator lights

--

Check the hydraulic couplings for dirt

--

Check the threaded fittings for tightness

--

Leakage check Check for tightness, leaks and chafing: pipes, flexible lines and threaded fittings of the following assemblies and components. Repair if necessary -Hydraulic system Hoses (visual check)

--

Visual check Correct function, deformation, damage, superficial cracks, wear and corrosion Check the wheels for damage

--

Check the travel gear for damage

--

Check the tire pressure and correct the pressure as required

--

Check the hydraulic hose for damage

--

Check the lifting point

--

Weekly maintenance (every 50 operating hours) (user) Check the wheel nuts

3-4

--

SHB HPU8 en – Edition 1.2 * HPU8s311.fm

Maintenance Only once after the first 50 operating hours (Wacker Neuson service center)

Page

Hydraulic oil filter insert replacement

--

Check the threaded fittings for tightness

--

Check labels and Operator’s Manual for completeness and condition

--

Pressure check of primary pressure limiting valves (operating hydraulics)

--

All steps for maintenance once a day and once a week

--

Every 250 operating hours (Wacker Neuson service center)

Page

Hydraulic oil replacement

--

Hydraulic oil filter insert replacement

--

Check the hydraulic oil radiator for dirt and clean it if necessary

--

Check the electric fan for dirt and clean it if necessary

--

All steps for maintenance once a day and once a week

--

Every 500 operating hours (Wacker Neuson service center)

Page

Drain the condensation water from the hydraulic oil reservoir

--

Check the electric cables and connectors (cable and grounding connections, etc.)

--

Check the threaded fittings for tightness

--

All steps for maintenance once a day and once a week

--

Every 1000 operating hours or once a year (Wacker Neuson service center)

Page

Option --

Lifting eye wear (check at least once a year)

Notice!

Maintenance with the note Wacker Neuson service center must only be performed by the trained and qualified personnel of a Wacker Neuson service center.

SHB HPU8 en – Edition 1.2 * HPU8s311.fm

3-5

Maintenance

Maintenance 3.4 Cooling system Important information regarding the cooling system The hydraulic oil radiator is located behind the ventilation grid.

Cleaning the radiator

Caution!

Burn hazard when performing maintenance on the radiator!

The hot radiator can cause burns. ☞ Stop the power unit and let the hydraulic oil cool down. ☞ Wear protective equipment.

Notice!

Possible damage to the hydraulic system due to dirty hydraulic oil radiator.

• Check and if necessary clean the radiator once a day.

Notice!

Possible damage to radiator fins during cleaning.

• Keep a safe distance from the radiator during cleaning.

• Use oil-free compressed air (2 bar/29 psi max.) to clean.

The hydraulic oil radiator is located in the engine compartment.

☞ Stop the power unit. ☞ Remove dust and other foreign bodies from the fins with compressed air.

Fig. 3:

3-6

Hydraulic oil radiator

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Maintenance 3.5 Hydraulic system Important information on the hydraulic system

Danger!

Burn hazard due to hot hydraulic oil!

Hot hydraulic oil can cause burning to the skin, serious injury or death.

• Allow the hydraulic oil to cool down.

• Wear protective equipment.

Danger!

Injury hazard due to fluid escaping under pressure!

Hydraulic oil escaping under pressure can penetrate the skin and cause serious injury or death.

• Do not operate the power unit with leaking or damaged hydraulic components.

• Open the breather filter slowly to release the pressure inside the reservoir slowly.

• Wear protective equipment. If oil contacts the eye flush immediately with clean water and seek medical treatment.

• Malfunctioning or leaking threaded fittings, hose connections and pressure lines must be immediately repaired (search for hydraulic leaks with a piece of cardboard).

Notice!

Possible damage due to wrong hydraulic oil.

• Neither the power unit nor the excavator must be filled with biodegradable hydraulic oil.

• Only use hydraulic oil according to the Fluids and lubricants table.

• The power unit and the excavator must be filled with hydraulic oil of the same grade.

Notice!

Possible damage to hydraulic system due to incorrect hydraulic oil level.

• The hydraulic oil level must be in the middle between the MIN and MAX marks.

• Check the hydraulic oil level once a day.

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

3-7

Maintenance Notice!

Possible damage to hydraulic system due to dirty hydraulic oil.

• If the hydraulic oil in the sight glass is cloudy, this indicates that there is water or air in the hydraulic system.

• Replace the hydraulic oil filter immediately if it is dirty.

Checking the hydraulic oil level

☞ Put the power unit on firm, level and horizontal ground. ☞ Check the oil level on sight glass A. ➥ After the operating temperature is reached, the oil level must be in the middle between the MIN and MAX marks.

➥ Add oil if the oil level is lower.

A

Fig. 4:

Oil level indicator on the hydraulic oil reservoir

Adding hydraulic oil

☞ Unscrew breather filter B slowly to release the pressure inside the reservoir slowly.

B

Fig. 5:

Breather filter

☞ Add hydraulic oil. ☞ Close the filler opening with breather filter B.

Environment!

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Fig. 6:

3-8

Adding hydraulic oil

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Maintenance Changing hydraulic oil

Notice!

Only change the hydraulic oil if it is warm (about 50 °C/122 °F).

C

Fig. 7:

☞ Put the power unit on firm, level and horizontal ground. ☞ Unscrew breather filter B slowly to release the pressure inside the reservoir slowly. ☞ Remove breather filter B. ☞ Place a suitable container under the power unit to collect the hydraulic oil as it flows out. ☞ Remove oil drain plug C with a suitable tool. ☞ Completely drain the oil. ☞ Check the hydraulic oil reservoir for dirt and clean if necessary. ☞ Install oil drain plug C with a suitable tool.

Oil drain plug

D

☞ Add clean hydraulic oil through filler plug D until reaching the relevant mark. ☞ Check the hydraulic oil level and add oil if necessary. ☞ Completely remove all oil spills. ☞ Install breather filter B.

Environment!

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Fig. 8:

Adding hydraulic oil

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

3-9

Maintenance Replacing the hydraulic oil filter F

☞ Put the power unit on firm, level and horizontal ground. ☞ Remove trim E with a suitable tool. ☞ Unscrew breather filter B slowly to release the pressure inside the reservoir slowly. ☞ Thoroughly clean the outside of hydraulic oil filter F. ☞ Place a suitable container under the power unit to collect the hydraulic oil as it flows out.

B E

Fig. 9:

Breather filter

G H

J

K Fig. 10: Replacing the hydraulic oil filter

☞ Unscrew cover G of the hydraulic oil filter. ☞ Collect the hydraulic oil as it drains. ☞ Remove spring H if it is not seated on cover G. ☞ Remove the old filter element J by means of the bracket and replace with a new element. ☞ Check the surface of the element for dirt residues and coarse particles. ➥ These can be a sign of damage to the components. ➥ Clean the drip and dirt collector K. ☞ Carefully place a new filter element J onto the mount in the filter housing. ☞ Remove dirt from the housing and the sealing surface of cover G if necessary. ☞ Screw on cover G with spring H and tighten by hand. ☞ Install and tighten breather filter B. ☞ Make a test run – and check for tightness. ☞ Install trim E with a suitable tool. ☞ Dispose of the replaced filter element in an environmentally friendly manner.

Environment!

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

3-10

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Maintenance Draining condensation water from the hydraulic oil reservoir Check the hydraulic oil reservoir after a longer standstill or every 500 o/h. Drain the condensation water if there is any.

The hydraulic oil replacement interval must be shortened if the condensation water is not drained regularly.

C

Fig. 11: Drain condensation water

Draining the condensation water from the hydraulic oil reservoir:

☞ Put the power unit on firm, level and horizontal ground. ☞ Unscrew breather filter B slowly to release the pressure inside the reservoir slowly. ☞ Remove breather filter B. ☞ Place a suitable container under the power unit to collect the hydraulic oil as it flows out. ☞ Remove oil drain plug C with a suitable tool. ☞ Drain the condensation water (mixed with hydraulic oil) until only pure hydraulic oil flows out.

☞ Install oil drain plug C with a suitable tool. ☞ Check the hydraulic oil level – see Checking the hydraulic oil level on page 3-8. ☞ Add clean hydraulic oil.– see Adding hydraulic oil on page 3-8 ☞ Install and tighten breather filter B.

Environment!

Use a suitable container to collect fluids and lubricants as they flow out and dispose of them in an environmentally friendly manner.

Checking the hydraulic system for leaks and general condition

Notice!

Leaks and damaged pressure lines must be immediately repaired or replaced.

This not only increases the operating safety of the power unit but also helps to protect the environment.

• Have hydraulic hoses replaced every 6 years from the date of manufacture, even if they do not seem to be damaged.

• Do not remove protective hoses from the hydraulic hose.

In this respect, we recommend that you observe all the relevant safety regulations for hydraulic lines, as well as the safety regulations regarding accident prevention and occupational health and safety in your country. Also observe DIN 20 066, part 5.

The article number is on each hose connection.

The date of manufacture of the flexible line is on the hose.

Have a line replaced if one of the following problems is detected: • Damaged or leaky hydraulic seals.

• Worn or torn shells or uncovered reinforcement branches.

• Expanded shells in several positions.

• Entangled or crushed movable parts.

• Foreign bodies jammed or stuck in protective layers.

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

3-11

Maintenance 3.6 Maintenance of attachments Important information regarding maintenance of attachments Correct maintenance and service is absolutely necessary for smooth and continuous operation, and for an increased service life of the attachments. Please observe the lubrication and maintenance instructions in the Operator’s Manuals of the attachments.

3.7 Electrical system Important information regarding the electrical system

Danger!

Death hazard due to electric shock!

The electrical system is energized and can cause serious injury or death. ☞ The control box may only be opened by the certified electricians of a Wacker Neuson service center.

☞ Keep the control box key in a place that is not accessible by the operator.

Checking the indicator lights Check the indicator lights once a day.

Green indicator light:

☞ Starting the power unit ➥ The green indicator light must illuminate.

Red indicator light:

☞ Press the emergency off button. ➥ The red indicator light must illuminate.

Notice!

Do not put the power unit into operation if one or more indicator lights are malfunctioning. Replace malfunctioning indicator lights immediately.

3-12

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Maintenance 3.8 Tires Inspection work Perform the following maintenance once a day:

☞ Visual check of the tire condition,. ☞ Check the tire pressure. ☞ Check the outside and inside of the tires and rims for damage. ☞ Remove foreign bodies from the tire tread.

Tire/wheel replacement May only be performed by a Wacker Neuson service center.

3.9 Maintenance of the lifting point A

• Do not perform any crane-lifting if the material thickness B of lifting point A is less than 23 mm (0.9 in).

Fig. 12:

A

☞ Rectify the malfunction.

B

Fig. 13:

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

3-13

Maintenance 3.10 Cleaning and maintenance Important information on cleaning and maintenance The wrong choice of cleaning equipment and agents can impair the operating safety of the power unit and undermine the health of the persons in charge of cleaning the power unit.

Follow the information below.

Cleaning with washing solvents

☞ Ensure adequate room ventilation. ☞ Wear suitable protective clothing. ☞ Do not use flammable liquids, such as gasoline or diesel.

Cleaning with compressed air

☞ Work carefully. ☞ Wear safety glasses and protective clothing. ☞ Do not aim the compressed air at the skin or at other people. ☞ Do not use compressed air for cleaning your clothing.

Cleaning with a high-pressure cleaner or steam jet

☞ Cover electric parts. ☞ Do not directly expose electrical components and damping material to the jet. ☞ Cover the vent filter on the hydraulic oil reservoir and the filler caps for fuel, hydraulic oil, etc.

☞ Protect the following components from moisture: ☞ Electrical components such as the electric motor. ☞ Control devices and seals. ☞ Fans, etc.

Cleaning with volatile and easily flammable anticorrosion agents and sprays:

☞ Ensure adequate room ventilation. ☞ Do not use unprotected lights or open flames. ☞ Do not smoke.

Environment!

In order to avoid damage to the environment, clean the power unit only in wash bays and places provided to this effect.

Use of solvents

Notice!

Damage to rubber and electrical parts when cleaning with solvents.

• Do not use solvents, benzine or other aggressive chemicals.

3-14

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Maintenance Cleaning the power unit

Caution!

Burn hazard due to hot components!

Can cause serious burns. ☞ Remove the electric cable from the three-phase connector before performing maintenance on the power unit.

☞ Stop the electric motor and let it cool down. ☞ Wear protective equipment.

Notice!

Possible damage to the electrical/electronic system due to water or steam jet.

• Do not point the water jet directly at the electric sensors such as temperature and oil pressure switches or control valves, etc.

• Protect all electric parts against humidity.

• If water contacts electrical components, dry them with compressed air and apply contact spray to them.

We recommend using the following aids to clean the power unit: • High-pressure cleaner • Steam jet Clean as follows:

☞ Put and shut down the power unit in a wash bay or place. ☞ Clean the power unit. ☞ Allow it to dry (with compressed air) before putting it into operation again.

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

3-15

Maintenance 3.11 Putting out of operation/back into operation The specified measures refer to putting the power unit out of operation and back into operation after more than 30 days.

Putting out of operation temporarily Store the power unit indoors if possible.

If the power unit has to be stored outdoors, place it on a wooden base (if possible) and cover it with a watertight tarp to protect it against humidity.

☞ Stop the power unit. ☞ Check the power unit for leaks and loose threaded fittings. ☞ Carefully clean and dry the power unit. ☞ Spray an anticorrosion agent onto bare metal parts. ☞ Check the hydraulic oil level and if necessary, add oil until the oil level is between the MIN and MAX marks.

Putting back into operation

☞ Remove anticorrosion agents from bare metal parts. ☞ Check the power unit for leaks and loose threaded fittings. ☞ Replace the hydraulic oil and hydraulic oil filters after 6 months.

3.12 Permanently putting out of operation Disposal All fluids, lubricants, material, etc., used on the power unit 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. Follow the relevant national and regional regulations.

If the power unit is no longer used according to its designated use, ensure that it is put out of operation and disposed of according to applicable regulations.

• Observe all applicable safety regulations during power unit disposal.

• Power unit disposal must be performed in accordance with state-of-the-art standards that apply at the time of disposal.

Environment!

Avoid damage to the environment. Do not allow environmentally damaging wastes to get into the ground or stretches of water and dispose of them in an environmentally friendly manner.

3-16

SHB HPU8 en – Edition 1.2 * HPU8s312.fm

Engine

Engine

Engine

4

Engine

4.1 Overview

5

4

1

2

3

45 Nm (33.19 ft.lbs.)

Fig. 14: Symbolic representation

4-2

Pos.

Designation

1

Electric motor

2

Hydraulic pump support

3

Hydraulic pump clutch

4

Electric connection for electric motor

5

Lifting eye

SHB HPU8 en – Edition 1.2 * HPU8s410.fm

Hydraulic system

Hydraulic system

Hydraulic system

5

Hydraulic system

5.1 How it works Depending on the operating state, the oil supply is automatically regulated toward the excavator • Start protection

➥ When the HPU is switched on, the oil circulates without pressure for 10 seconds (control via time-lag relay)

• Warm-up function

➥ At low temperatures, the oil circulates without pressure until it reaches 5 °C/41 °F • Heat protection

➥ The fan is switched on at an oil temperature of 60 °C/140 °F or higher. It is switched off again after the oil cools down to about 45 °C/113 °F.

➥ The power unit is stopped at an oil temperature of 95 °C/203 °F or higher (protection of hydraulic HPU and excavator components)

Circuits • RED: system pressure (feed) • BLUE: return pressure (return) Circuit without pressure • The pump pumps the oil to solenoid valve A. Then from solenoid valve A directly back to the reservoir.

A Fig. 15: Circuit without pressure

Normal circuit B

• The pump pumps the oil to solenoid valve A. Then from solenoid valve A directly to connection coupling B.

A Fig. 16: Normal circuit

5-2

SHB HPU8 en – Edition 1.2 * HPU8s510.fm

Hydraulic system 5.2 Overview of components

1

2

3

7

6

Pos. 1

2 3 4 5 6 7

SHB HPU8 en – Edition 1.2 * HPU8s510.fm

5

4

Designation Hydraulic oil radiator Oil radiator fan Hydraulic oil reservoir Hydraulic couplings Hydraulic pump (gear pump) Pressure limiting valve Solenoid valve for return without pressure

5-3

Hydraulic system Hydraulic reservoir components

1

2

3

4

Pos. 1

2 3 4

5-4

Designation Breather filter Oil level sensor Sight glass Suction filter

SHB HPU8 en – Edition 1.2 * HPU8s510.fm

Hydraulic system

1

3

2

4

Pos. 1

2 3 4

SHB HPU8 en – Edition 1.2 * HPU8s510.fm

Designation Return filter Temperature sensor 95 °C (203 °F) Temperature sensor 60 °C (140 °F) Temperature sensor 5 °C (41 °F)

5-5

Hydraulic system 5.3

Breather filter (hydraulic oil reservoir) • The breather filter is located in the power unit on the hydraulic oil tank.

• Opening pressure: 0.2 bar +/− 0.08 bar (2.9 psi +/− 1.16 psi).

• Tightening torque: 10 Nm (7.4 ft.lbs.) max.

(2.9 psi)

(0.72 psi)

2

3

3

Pos.

Designation

1

Hydraulic oil reservoir connecting line

2

Filter fabric

3

O-ring 21.5 mm x 3 mm (0.85 in x 0.11 in)

5.4 Troubleshooting the hydraulic system Problem Error indicator light illuminates (red)

5-6

Possible causes Oil temperature too high (95 °C/203 °F) Hydraulic oil level too low

SHB HPU8 en – Edition 1.2 * HPU8s510.fm

Electrical system

Electrical system

6

Electrical system

Important information regarding the electrical system Maintenance and repair work on the electrical system may be performed only by authorized personnel!

Danger!

Death hazard due to electric shock!

The electrical system is energized and can cause serious injury or death.

• The control box may only be opened by certified electricians.

• Keep the control box key in a place that is not accessible by the operator.

6.1 Ohm’s Law (current, voltage, resistance); power It describes the interrelation between current, voltage and resistance.

Current “I” – Ampere (A) Voltage “U” – Volt (V) Resistance “R” – Ohm ()

Mnemonic:

U R

I

Power Power “P” – Watt (W) P = U x I = R x I² = U²/R

6.2 Measuring equipment, measuring methods Multifunction measuring device • Measurements of values (U, R, I, f) • Continuity test • Diode test Calculate the measuring range using known data (P, U, R, I) and set before measuring!

Observe AC/DC basic setting

➥ AC = alternating current/voltage; ➥ DC = direct current/voltage Test device with acoustic and optical signal output • Continuity test in de-energized machine electrical system and of wiring harnesses

6-2

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

Electrical system Measuring methods – multifunction measuring device • Measuring current (starter switched on): • Black cable in COM socket (ground), • red cable in A socket or mA socket; connect in series to consumer.

• Measuring voltage (starter switched on): • Black cable in COM socket (ground), • red cable in V socket; • connect in parallel to consumer.

• Measuring resistance (starter switched off): • Black cable in COM socket (ground), • red cable in socket; • connect in parallel to consumer (see measuring voltage).

Test lamp The test lamp is used for testing lines and functions with the starter switched on.

• Line test (testing voltage): Connect test lamp between test point (live cable) and machine ground or between test point (grounding line) and a live cable.

• Functional check (testing current): Connect test lamp between a connection on the consumer to be tested and the connection line.

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

6-3

Electrical system 6.3 Overview of components 1

2

4

5

Pos. 1

2 3 4 5 6

6-4

3

6

Designation Emergency OFF switch (S1) Stop/malfunction (SH2) Start/operation (SH1) Hour meter (P1) Accessories outlet (XS2) Grounding connection

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

Electrical system 6.4 Switch box with protective switching device ABB 1

2

3

4

5

6

7

8

9

10

11

Pos. 1

2 3 4 5 6 7 8 9 10 11

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

Designation FI/LS C13 30mA (Q3) Protective motor switch 10-16A (Q1) Contactor 7.5 kW (K3) Contactor 7.5 kW (K4) Softstarter PSR16 (Q2) Three-phase monitoring relay (K1) Protective motor relay (D1) Protective switching device (K5) Time-lag relay (KT1) Fuse 6 A (F1) Coupling relay (K2)

6-5

Electrical system 6.5 Switch box with protective switching device Pilz 1

2

3

4

5

6

7

8

9

10

11

Pos. 1

2 3 4 5 6 7 8 9 10 11

6-6

Designation FI/LS C13 30mA (Q3) Protective motor switch 10-16A (Q1) Contactor 7.5 kW (K3) Contactor 7.5 kW (K4) Softstarter PSR16 (Q2) Three-phase monitoring relay (K1) Protective motor relay (D1) Protective switching device (K5) Time-lag relay (KT1) Fuse 6 A (F1) Coupling relay (K2)

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

Electrical system 6.6 Control box malfunctions Malfunction indicator light illuminates Problem

Indication

Cause/solution

Motor temperature monitoring device D1 (PTC) has triggered Diodes F & U on switching device illu- Automatic reset after motor cools (motor too hot) minate down Protective motor switch Q1 has triggered

With protective switching device ABB: EMERGENCY OFF monitoring device K5 has triggered

With protective switching device Pilz:

Switch in position TRIP

For a reset, turn the switch to position 0 and then back to position 1

Diode DEVICE illuminates, diode OUT does not illuminate

EMERGENCY OFF switch pressed

Level switch or overheating switch have triggered (difference only Diodes DEVICE & OUT do not illuminate possible with measurement or oil level indicator!)

LED lamps POWER & CH1 & CH2 do Temperature switch 95° has trignot illuminate gered Level switch has triggered, has to be confirmed by pressing the EMERGENCY OFF switch!

EMERGENCY OFF monitoring device K5 has triggered

LED lamps POWER & CH1 illuminate, CH2 does not illuminate

Three-phase monitoring relay K1 has triggered

Diodes R/T & F1 illuminate, F2 flashes Phase failure in a feed line

Malfunction indicator light does not illuminate Problem Unit still does not work

Indication

Cause/solution

FI switch Q3 has triggered

Push lever up again

Control fuse F1 has triggered (red LED on fuse illuminates)

Replace the fuse

Three-phase monitoring relay K1 has triggered (if control phase fails, the malfunction indicator light at the front still does Diodes R/T & F1 illuminate, F2 flashes Phase failure in a feed line not illuminate)

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

6-7

Electrical system

6-8

SHB HPU8 en – Edition 1.2 * HPU8s610.fm

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

Diagrams

7-1

Diagrams

Diagrams

Diagrams

7-2

Electric motor 7.5 kW at 1500 rpm (10 hp at 1500 rpm)

Gear pump

Pressure limiting valve

Start valve

Clutch

Hydraulic oil radiator

Return filter

Breather filter

Suction filter

2

3

4

5

6

7

8

9

Designation

1

Pos.

7.1 Hydraulics diagram

7

Diagrams

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

Protective motor relay CM-MSS (2)

Fuse 5 x 20 mm (0.19 x 0.78 in)/6A/T

Three-phase monitoring relay

Coupling relay

Contactor 7.5 kW (10 hp)

Contactor 7.5 kW (10 hp)

Protective switching device

Time lag relay

Hydraulic motor 7.5 kW (10 hp)

Fan motor 0.120 kW (0.16 hp)

Hour meter

Protective motor switch 10-16A

Softstarter PSR16

FI/LS C13/30 mA

Emergency OFF switch

Temperature switch 60 °C/140 °F

Level switch

Temperature switch 95 °C/203 °F

Temperature switch 5 °C/41 °F

Start/operation

Stop/malfunction

Wall power connector 16 A

Outlet

D1

F1

K1

K2

K3

K4

K5

KT1

M1

M2

P1

Q1

Q2

Q3

S1

S2

S3

S4

S5

SH1

SH2

XS1

XS2

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

Valves

Y

Frequency converter

U

Clamps, connectors, connections

Transformer, energy conversion

T

Cables, energy transportation

Switch, push button, command devices

S

X

Choke, diode, resistors

R

Electrostatic filter

Motor protection, softstarter, energy switch

Q

V

Information display of measuring instruments

W

Motors, drives

Contactor, contactor relay, relay

K

P

Indicator lights, signaling unit

Coils, inductance

Alternator, energy supply

H

L

Grounding conductor (yellow-green)

PE

Fuses, safety devices

F

G

M

Neutral conductor (light blue)

N

Digital control

Current-carrying conductor (black)

D

Solenoid valve

L1, L2, L3

Condenser, storage

Y1

Sensors

Description

Designation

C

Description

B

Designation

7.7 Wiring diagram legend (applies to protective switching device ABB and Pilz)

7-3

Diagrams

7-4

7.8 Wiring diagram part 1 (applies to protective switching device ABB and Pilz)

Diagrams

Fan motor 120 W

Temperature switch 60 °C/140 °F

Metal-frame grounding

Hydraulic motor 7.5 kW (10 hp)

Power connector CEE 16A

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

7.9 Wiring diagram part 2 (applies to protective switching device ABB and Pilz)

Hour meter

7-5

Diagrams

7-6

Temperature switch 95 °C/203 °F

7.10 Wiring diagram part 3 (applies to protective switching device ABB)

Diagrams

Level switch

Temperature switch 5 °C/41 °F

Solenoid valve 20 W

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

Temperature switch 95 °C/203 °F

Level switch

7.11 Wiring diagram part 3 (applies to protective switching device Pilz)

Temperature switch 5 °C/41 °F

Solenoid valve 20 W

7-7

Diagrams

7-8

Diagrams

SHB HPU8 en – Edition 1.2 * HPU8s710.fm

Special tools

Special tools PAL

Special tools PAL

8

Special tools PAL 1000161424 Infrared thermometer For checking the temperature development on the machine.

1000159048 Hand-held infrared tachometer Correct troubleshooting on the hydraulic system often requires reading engine speed values, quickly and easily measured with the hand-held infrared tachometer.

1000297321 Spare reflector strip for hand-held tachometer Spare reflector strip for DT1-L, DT-10L 60 cm (23.6 in).

1000183413 Solenoid coil tester For checking relays.

8-2

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

Special tools PAL 1000175777 Wacker Neuson measuring kit with 6 pressure gages • 6 pressure gages (2 x 60 bar/2 x 870 psi, 2 x 400 bar/2 x 5801 psi, 2 x 600 bar/2 x 8702 psi) • Color-coded measuring lines • The pressure gage panel is fitted with magnets at the rear and can be easily positioned on machine • Stabile plastic case

➥ Sealing prevents oil from escaping ➥ Can be secured with a padlock • Extra storage room for test screw connections, etc.

1000171779 Proportional controls configuration kit Laptop connection to proportional control valve of hydraulic system (option).

Specific characteristic curves of the proportional controls can be fine-tuned with the configuration software.

1000158807 Dial gage Measuring range: 10 mm (0.4 in) Measuring accuracy: 0.01 mm (0.0003936 in)

1000158806 Dial gage extension Extension: 30 mm (1.18 in)

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

8-3

Special tools PAL 1000188305 Wiring harness for maintenance of ECU Yanmar EPA TIER 3 Ideal tool for detection of errors in the electronic controls of YANMAR EPA TIER III engines.

Connected in between the control valve and the machine’s main wiring harness, this wiring harness ensures access to the measuring points for troubleshooting. The YANMAR diagnosis tool can also be connected to the ECU with this wiring harness.

In addition, flashing error codes are displayed directly at the test connectors.

1000165847 Yanmar adapter (51851) Yanmar adapter for checking the injection time of the MP-4 pump • Machines: 6003 – 8003 (Tier 2 –> up to injection pump Nov 2013) 1000158805 Yanmar adapter (51841) Yanmar adapter for checking the injection time of the MP-4 pump • Machines: 6003 – 8003 (Tier 2 + Tier 3) 1000165849 Yanmar adapter (51831) Yanmar adapter for checking the injection time of the MP-2 pump Fig. 17: Symbolic representation

• Machines: 2503 – 50z3; except 28z3 (Tier 2 + Tier 3) 1000176831 Hand turning gear for Deutz engine Special Deutz tool for turning the diesel engine more easily.

1000176832 Rotation angle gage for Deutz engine Special Deutz tool for measuring the valve clearance.

8-4

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

Special tools PAL 1000282723 Spur gear extractor H.B. Yanmar engine Suitable for most Yanmar engines, • 4TNE106T • 4TNE98 • 4TNV98 • 4TNV88

1000239099 Wacker Neuson electronics case The Wacker Neuson electronics case includes the following tools and material: • Ejection tools • Various adapters for crimp tongs • Contact bushings, pin and socket contacts, etc.

1000309551 Adjustment pin for Deutz engine Special Deutz tool for blocking the camshaft and crankshaft when replacing the toothed belt.

1000309552 Deutz engine retainer Special Deutz tool for loosening the toothed belt wheel.

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

8-5

Special tools PAL PowerTilt® end cap Special tool for removing and installing the swivel drive • Powertilt PTS10® 1000256985 • Powertilt PTS08® 1000255605 • Powertilt PTS07® 1000255604 • Powertilt PTS06® 1000255603 • Powertilt PTS4.5® 1000255602

1000081593 Wacker Neuson Regular Grade Anti Seize High-temperature lubricant for extremely high loads. Applied to the limit stops of the oscillating-axle cylinder pistons of the wheeled excavators (for example 6503, 9503). Prevents corrosion and seizing of metallic connections up to 1,100 °C (2012 °F).

Also protects seals, flanges, screws, valve bushings and pins. Anti Seize Regular Grade also protects against frictional corrosion of shrink and interference fits, and is resistant against salt water (for example de-icing salt), alkaline solutions, acids and many other chemicals.

1000294213 Wacker Neuson medium-strength flexible surface seal Medium-strength, flexible, anaerobic adhesive for gluing and sealing flange connections on pumps, gearbox housings, engine flanges, etc.

This product features high resistance against water, gas, LPG, oil and technical chemicals.

Suitable as a replacement for solid-matter seals.

Seals reliably in a temperature range of −55 °C to +180 °C (−67 °F – 356 °F), and is impact and vibration resistant. Does not drip, and seals immediately against low pressures.

1000294211 Medium-strength Wacker Neuson screw lock Medium-strength, anaerobic adhesive for securing and sealing screw connections requiring subsequent removal with tools.

Suitable for use on slightly oily surfaces. High resistance against corrosion, vibration, water, gases, various oils, hydrocarbons and many other chemicals.

Excellent thermal resistance from −55 °C to +200 °C (−67 °F – 392 °F), temporary sealing properties up to +250 °C (482 °F). Hardens quickly when removing oxygen, including on stainless steel and passivated surfaces.

Certified according to NSF, DVGW, TZW, GAZ and EN 751-1

8-6

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

Special tools PAL 1000136739 Oil dipstick for air-conditioning compressor Oil dipstick for checking the oil level in the air-conditioning compressor.

1000132690 Set of measurement connections Includes all usual measurement connections with the required screw connections for easy checks of the hydraulic system.

1000061717 Vacuum pump Prevents the hydraulic oil from being completely drained from the reservoir when performing repairs on the hydraulic system.

1000081563 Oil sample receptacle 250 ml (0.066 gal)

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

8-7

Special tools PAL

8-8

SHB HPU8 en – Edition 1.2 * HPU8s810.fm

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 figures and descriptions in this documentation which do not reflect products that have already been delivered and that will not be implemented on these machines.

Technical data, dimensions and weights are only given as an indication. Responsibility for errors or omissions not accepted.

No reproduction or translation of this publication, in whole or part, without the written consent of Wacker Neuson Linz GmbH. All rights under the provision of the Copyright Act are reserved.

Wacker Neuson Linz GmbH Flughafenstr. 7 A-4063 Hörsching Austria

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

9-2

Order no. 1000322998

SHB HPU8Language en – Edition en 1.2 * HPU8schlussbl.fm