The Wacker Neuson EZ38 service manual PDF takes this track excavator apart on paper: 266 factory pages, OEM document 1000333445, running from track chain and final drive to the cabin roof harness. Full wiring harness diagrams cover both Yanmar engines fitted to the EZ38, the 3TNV88-BPNS and the Tier IV 3TNV88F-EPNS, with legends and cable color coding so you trace a dead circuit to one connector instead of the whole loom. Hydraulics run just as deep: exploded views of the PVD-1B-32 pump unit, the main valve block diagram with its pressure limiting valves, and pressure check procedures for both variable displacement pumps. Set track tension play at 20 to 25 mm, and pull cylinder-head bolts to 85.3 to 91.1 Nm in the printed tightening order. An excavator that sits all morning bills nothing. Bookmarked and text-searchable, the file jumps straight to the page you want; download it before the next fault does.
What's Inside This Wacker Neuson EZ38 Manual
| System | Pages | Key Topics |
|---|---|---|
| Operation | 9-24 | Information on This Service Manual, Identification of Warnings and Dangers, Explanation of Symbols and Abbreviations (Conversion Table) |
| Engine | 109-150 | Engine 3TNV88-Bpns, Fuel System, Removing the Cylinder-Head Cover, Checking and Adjusting Valve Clearance, Tightening Order for Cylinder Head Bolts |
| Hydraulic System | 151-182 | Hydraulic Pump Pvd-1B-32BP-11G5-4904A / Pvd-1B-32BCP-11G5-5596Z (Pump Unit: Exploded View, Diagram, Pilot Oil Supply Unit) |
| Electrical System | 183-214 | Ohm’s Law; Power, Measuring Equipment, Measuring Methods, Cable Color Coding, Relays (Use, Mode of Function), Socket, Alternator, Starter |
| Diagrams | 215-236 | Hydraulics Diagram, Main Valve Block, Electrical Diagrams, Electrical Diagram Tier Iv Eco |
| Options | 237-256 | Air Conditioning (Specific Safety Instructions, Technical Data, Components, Compressor, Filling Up the Air Conditioning System, Maintenance, Troubleshooting) |
| Special Tools | 257-266 | Infrared Thermometer, Hand-Held Infrared Tachometer, Wacker Neuson Measuring Kit, Proportional Controls Configuration Kit, Dial Gage, Vacuum Pump |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder-head bolt | 85.3 – 91.1 Nm (62.9 – 67.2 ft.lbs.) | p. 32 |
| Connecting rod bearing screw | 44.1 – 49.0 Nm (32.5 – 36.1 ft.lbs.) | p. 32 |
| Check bearing play of tread rollers, track carrier rollers, front idlers | Every 500 operating hours | p. 55 |
| track tension play | 20 – 25 mm (0.8 – 1 in) | p. 103 |
| Switch operating point of valve pos. 6 | 180 bar (2610.68 psi) | p. 172 |
| Engine Oil Capacity | 7.1L | p. 45 |
| Hydraulic Oil Reservoir Capacity | 36.5L | p. 45 |
| Fuel Tank Capacity | 44L | p. 45 |
| Engine Cooling System Capacity | 5L | p. 45 |
| Engine Idling Speed (3TNV88-BPNS) | 1100 rpm | p. 26 |
| Engine Max Speed (3TNV88-BPNS) | 2500 rpm | p. 26 |
| Operating Pressure (Hydraulics) | 240 bar | p. 27 |
Wacker Neuson EZ38 Common Problems This Manual Covers
Wacker Neuson EZ38 rubber track sags, derails on turns, or walks off the front idler
Check track tension play: 20 to 25 mm (0.8 to 1 in) of sag per the spec on page 103. Lift the track with the boom and add grease through the tension cylinder valve. If tension will not hold, inspect the track adjuster and recoil spring, and check roller and idler bearing play, a 500 hour check on page 55.
Manual Section: Track Tension Maintenance p. 103Engine cranks but will not start, or runs rough and lacks power under load
Drain the water separator and bleed the fuel system first; air in the lines is the usual culprit after a filter change. Then work through the engine troubleshooting steps starting on page 122. If power is still down, test compression: readings below the 26.5 to 28.5 bar threshold on page 119 point to internal wear.
Manual Section: Engine Malfunctions p. 122Weak digging power, slow cylinders, or bucket stalls under load with engine running fine
Test main relief pressure before condemning the engine. Connect a gauge per the pressure check procedure and verify the pump reaches the 240 bar operating pressure listed on page 27. If it tops out low, adjust the main relief valve and recheck; a pump that still will not build pressure needs the teardown covered from page 151.
Manual Section: Hydraulic System p. 151Engine overheats and coolant temperature climbs steadily when digging hard in warm weather
Clean the radiator and oil cooler fins with compressed air, blowing from the fan side outward. Check coolant level with the engine cold; the system holds only 5 l, listed in the fluids and capacities table starting on page 45, so a slow loss shows up fast. Test the cap and thermostat next, working through the cooling system section on page 73, and check fan belt tension before pulling anything major apart.
Manual Section: Cooling System Maintenance p. 73Air conditioning blows warm or compressor cycles on and off in the cab
Verify compressor clutch engagement and belt condition before touching the charge. Weigh the refrigerant in: the system takes 950 g of R134a, listed on page 238. An undercharged system from a slow leak blows warm and short-cycles the compressor; dye-test the condenser and hose fittings, then pull vacuum and recharge to the full 950 g.
Manual Section: Air Conditioning Troubleshooting p. 238Frequently Asked Questions
What are the torque specifications for cylinder-head bolts on the EZ38?
The tightening torque for the cylinder-head bolts on the EZ38 is 85.3 – 91.1 Nm (62.9 – 67.2 ft.lbs.) for the second pass, following an initial pass of 42.6 – 45.5 Nm (31.4 – 33.6 ft.lbs.). p. 114
What are the replacement specifications for rubber tracks on a Wacker Neuson EZ38?
When replacing rubber tracks, you must pay attention to the direction of rotation from serial number WNCE0702PAL00937 onwards. The track width is 300 mm (12 in) and there are 4 tread rollers. p. 27
What is the engine oil capacity for the EZ38?
The engine oil capacity for the Yanmar diesel engine in the EZ38 is approximately 7.1 liters (1.9 gallons). p. 45
What is the valve clearance for the EZ38 engine?
The valve clearance (intake and outlet) for the EZ38 engine when cold is 0.15 – 0.25 mm (0.006 – 0.01 inches). p. 26
What is the injection pressure for the injection nozzles on the Wacker Neuson EZ38?
The injection pressure for the injection nozzles is 196 – 206 bar (2843 – 2988 psi). p. 115
Do I get instant access to this Wacker Neuson EZ38 Service Manual?
All 266 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print just the pages I need from this Wacker Neuson EZ38 manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Reviews
There are no reviews yet.