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Service Manual
Electro-hydraulic power unit
Machine model A01-01
Edition 1.3
Document order number 1000322998
Language en
From serial number WNCA0101VPAL00160
Copyright 2015 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 includ-
ing 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: [email protected]
www.wackerneuson.com
Documentation
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
Legend
Original service manual
x
Edition
1.3
Date
04/2015
Document
SHB HPU8 en
SHB HPU8 en - Edition 1.3 * HPU8s10IVZ.fm I-1
Table of contents
Operation
Notices on this service manual ................................................................................ 1-2
Identification of warnings and dangers .................................................................... 1-2
Explanation of symbols and abbreviations .............................................................. 1-3
Explanation of symbols ...................................................................................... 1-3
Abbreviations ..................................................................................................... 1-4
Conversion table ................................................................................................ 1-5
Warranty and liability ............................................................................................... 1-6
Exemption from warranty and liability ................................................................ 1-6
Labels ...................................................................................................................... 1-7
Type labels ........................................................................................................ 1-7
Overall view (7.5 kW version) .................................................................................. 1-8
Overall view (9 kW version) ..................................................................................... 1-9
Outside view of control box .................................................................................... 1-10
Overview of components ....................................................................................... 1-11
Indicator lights and warning lights (overview) ........................................................ 1-12
Indicator lights ................................................................................................. 1-12
Hour meter ....................................................................................................... 1-12
Technical data
Models and trade names ......................................................................................... 2-2
Electric motor ........................................................................................................... 2-2
Tires ......................................................................................................................... 2-2
Hydraulic system ..................................................................................................... 2-3
Hydraulic hose specifications ............................................................................ 2-3
Noise emissions ....................................................................................................... 2-3
Vibration ................................................................................................................... 2-3
Weight ...................................................................................................................... 2-4
Weight of power unit .......................................................................................... 2-4
Tightening torques ................................................................................................... 2-5
Model-specific tightening torques ...................................................................... 2-5
General tightening torques ................................................................................ 2-5
Tightening torques for high-resistance threaded fittings .................................... 2-7
Dimensions .............................................................................................................. 2-8
Maintenance
Information on maintenance .................................................................................... 3-2
Responsibilities and prerequisites ..................................................................... 3-2
Important safety instructions on maintenance ................................................... 3-2
Fluids and lubricants ................................................................................................ 3-3
Hydraulic oil types (depending on temperature) ................................................ 3-3
Maintenance plan .................................................................................................... 3-4
Cooling system ........................................................................................................ 3-6
Important information regarding the cooling system .......................................... 3-6
Cleaning the radiator ......................................................................................... 3-6
Hydraulic system ..................................................................................................... 3-7
Important information on the hydraulic system .................................................. 3-7
Checking the hydraulic oil level ......................................................................... 3-8
Adding hydraulic oil ........................................................................................... 3-8
Changing hydraulic oil ....................................................................................... 3-9
Replacing the hydraulic oil filter ....................................................................... 3-10
Draining condensation water from the hydraulic oil reservoir .......................... 3-11
Checking the hydraulic system for leaks and general condition ...................... 3-11
Maintenance of attachments .................................................................................. 3-12
Important information regarding maintenance of attachments ........................ 3-12
Electrical system .................................................................................................... 3-12
Important information regarding the electrical system ..................................... 3-12
Checking the indicator lights ............................................................................ 3-12
Tires ....................................................................................................................... 3-13
Inspection work ................................................................................................ 3-13
I-2 SHB HPU8 en - Edition 1.3 * HPU8s10IVZ.fm
Tire/wheel replacement ................................................................................... 3-13
Maintenance of the lifting point .............................................................................. 3-13
Cleaning and maintenance .................................................................................... 3-14
Important information on cleaning and maintenance ....................................... 3-14
Use of solvents ................................................................................................ 3-14
Cleaning the power unit ................................................................................... 3-15
Putting out of operation/back into operation .......................................................... 3-16
Putting out of operation temporarily ................................................................. 3-16
Putting back into operation .............................................................................. 3-16
Permanently putting out of operation ..................................................................... 3-16
Disposal ........................................................................................................... 3-16
Engine
Overview .................................................................................................................. 4-2
Hydraulic system
How it works ............................................................................................................. 5-2
Overview of components ......................................................................................... 5-3
Hydraulic reservoir components ........................................................................ 5-4
Breather filter (hydraulic oil reservoir) ...................................................................... 5-6
Troubleshooting the hydraulic system ..................................................................... 5-6
Electrical system
Important information regarding the electrical system ....................................... 6-2
Ohm’s Law (current, voltage, resistance); power ..................................................... 6-2
Measuring equipment, measuring methods ............................................................. 6-2
Overview of components ......................................................................................... 6-4
Switch box with protective switching device ABB .................................................... 6-5
Switch box with protective switching device Pilz ...................................................... 6-6
Control box (option 9kW) ......................................................................................... 6-7
Control box malfunctions ......................................................................................... 6-9
Malfunction indicator light illuminates ................................................................ 6-9
Malfunction indicator light does not illuminate ................................................... 6-9
Diagrams
Hydraulics diagram (7,5 kW and Option 9 kW) ........................................................ 7-2
Wiring diagram legend (applies to protective switching device ABB and Pilz) ........ 7-3
Wiring diagram part 1 (applies to protective switching device ABB and Pilz) .......... 7-4
Wiring diagram part 2 (applies to protective switching device ABB and Pilz) .......... 7-5
Wiring diagram part 3 (applies to protective switching device ABB) ........................ 7-6
Wiring diagram part 3 (applies to protective switching device Pilz) ......................... 7-7
Panel overview (Option 9 kW) ................................................................................. 7-8
Panel layout (Option 9 kW) ...................................................................................... 7-9
Cable overview (Option 9 kW) ............................................................................... 7-10
Power supply (Option 9 kW) .................................................................................. 7-11
Control voltage 115VAC (Option 9 kW) ................................................................. 7-12
Control voltage 24VDC CLASS2 (Option 9 kW) .................................................... 7-13
Emergency stop (Option 9 kW) .............................................................................. 7-14
Hydraulic pump (Option 9 kW) ............................................................................... 7-15
Hydraulic pump (Option 9 kW) ............................................................................... 7-16
Hydraulic pump shutdown (Option 9 kW) .............................................................. 7-17
Solenoid valve load relieving (Option 9 kW) .......................................................... 7-18
Oil cooling fan (Option 9 kW) ................................................................................. 7-19
Terminal diagram (Option 9 kW) ............................................................................ 7-20
Terminal diagram (Option 9 kW) ............................................................................ 7-21
Cable overview (Option 9 kW) ............................................................................... 7-22
Parts list (Option 9 kW) .......................................................................................... 7-23
Special tools PAL
1-2 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
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 man-
ual 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 follow-
ing 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 ser-
vicing 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
Operation
SHB HPU8 en – Edition 1.3 * HPU8s110.fm 1-3
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 eco-
nomical use of the machine.
Environment!
Failure to observe the instructions identified by this symbol can cause damage
to the environment.
1-4 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
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
=
max. = maximum
min. = minimum
SHB HPU8 en – Edition 1.3 * HPU8s110.fm 1-5
Operation
Conversion table
The rounded imperial values are indicated in brackets, for example 1060 cm³ (64.7 in³).
Volume unit
1 cm³ (0.061 in³)
1 m³ (35.31 ft³)
1 ml (0.034 US fl.oz.)
1 l (0.26 gal)
1 l/min (0.26 gal/min)
Unit of length
1 mm (0.039 in)
1 m (3.28 ft)
Weight
1 kg (2.2 lbs)
1 g (0.035 oz)
Pressure
1 bar (14.5 psi)
1 kg/cm² (14.22 lbs/in²)
Force/output
1 kN (224.81 lbf)
1 kW (1.34 hp)
1 PS (0.986 hp)
Torque
1 Nm (0.74 ft.lbs.)
Speed
1 kph (0.62 mph)
Acceleration
1 m/s² (3.28 ft/s²)
1-6 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
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 per-
formed 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 modifica-
tions 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 instruc-
tions 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.
SHB HPU8 en – Edition 1.3 * HPU8s110.fm 1-7
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.
Electric motor
The type label is located on top of the electric motor.
Fig. 1: Type label (symbolic representation)
Fig. 2: Electric motor type label
1-8 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
Operation
1.6 Overall view (7.5 kW version)
Position
Designation
Position
Designation
1
Lifting eye
9
Transport handles
2
Lance
10
Supports
3
Control box – see chapter 1.8 Outside view of con-
trol box on page 1-10
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
--
--
9
5
7
4
6
1
6
3
2
8
6
13
13
10
10
9
9
9
15
12
14
11
SHB HPU8 en – Edition 1.3 * HPU8s110.fm 1-9
Operation
1.7 Overall view (9 kW version)
Position Designation Position
Designation
1
Lifting eye
9
Transport handles
2
Lance
10
Supports
3
Control box – see chapter 1.8 Outside view of con-
trol box on page 1-10
11
Storage compartment for battery charger (laterally)
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
16
Main switch
9
5
7
4
6
1
6
3
2
8
6
13
13
10
10
9
9
9
15
12
14
11
16
1-10 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
Operation
1.8 Outside view of control box
1
3
56
2
4
7.5 kW version
9 kW version
453
1 2
7
Pos. 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 (7.5 kW version only)
7
Main switch (9 kW version only)
SHB HPU8 en – Edition 1.3 * HPU8s110.fm 1-11
Operation
1.9 Overview of components
10
12
1 2 4
8
9
5
6
11
7
7
3
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
1-12 SHB HPU8 en – Edition 1.3 * HPU8s110.fm
Operation
1.10 Indicator lights and warning lights (overview)
Indicator lights
The indicator lights provide information on the operating state and possible malfunctions.
Hour meter
Counts the operating hours and shows when the next maintenance interval is due.
Symbol Color Designation
Green Error-free operation
Red Malfunction
2-2 SHB HPU8 en – Edition 1.3 * HPU8s210.fm
Technical data
2 Technical data
2.1 Models and trade names
2.2 Electric motor
2.3 Tires
Machine model/machine designation Trade name
A01-01 HPU8
Electric motor
HPU8 (7.5 kW) HPU8 (9 kW)
Product
Winter motor
(up to serial no. WNCAD101NPAL00139)
--
Type
2SIEL 132M4 --
Product
AC motor
(from serial number WNCA0101VPAL00160)
AC motor
Type
FCPY 132 M-4/HE JL 132 M-4/HE
Design
3-phase electric motor
Engine output according to ISO
7.5 kW 9 kW
Rated speed
1,460 rpm 1,728 rpm
Rated voltage
400 V 480 V
Rated frequency
50 Hz 60 Hz
Rated torque
49.1 Nm (36.2 ft.lbs.) 49.23 Nm (36.3 ft.lbs.)
Rated current
16 A
Output factor (at 100 % load)
0.83 0.84
Efficiency (at 100 % load)
88.7 %
Inertia
0.030 kg m
2
(103 lb in
2
)
Type of cooling
IC 411
Protective system/terminal box
IP55
Insulation class
F
Direction of rotation
Right/left
Maximum power output of acces-
sories outlet
1
1000 W No equipment power outlet
1. Consumers may only be connected to the accessories outlet if the power unit is stopped
Tires
HPU8
Wheel width
90 mm (3.5 in)
Wheel diameter
340 mm (13.4 in)
Tire pressure
3 bar (44 psi)
Technical data
SHB HPU8 en – Edition 1.3 * HPU8s210.fm 2-3
Technical data
2.4 Hydraulic system
Hydraulic hose specifications
2.5 Noise emissions
Notice!
Measurements performed on asphalted surface.
2.6 Vibration
The relevant threshold values are observed.
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 HPU8
Dimension DN16
Operating pressure 210 bar (3,046 psi)
Minimum bursting pressure 840 bar (12,183 psi)
Maximum length
1
1. Pressure losses with hose lengths over 12 meters.
12 m (39 ft)
Protective hose on excavator side Yes
Measured sound power level LwA
1
1. According to ISO 6395 (EC Directives 2000/14/EC and 2005/88/EC)
90.3 dB
Guaranteed sound power level LwA
1
93 dB
Uncertainty factor K
A2
2
2. According to EN ISO 4871 (EC Directives 2000/14/EC and 2005/88/EC)
0.8
Operator-perceived sound pressure level LpA (without cabin)
3
3. According to ISO 6394 (EC Directives 84/532/EEC, 89/514/EEC, 95/27/EEC)
-
2-4 SHB HPU8 en – Edition 1.3 * HPU8s210.fm
Technical data
2.7 Weight
Weight of power unit
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%.
Weight HPU8
Transport/operating weight
1
1. Transport weight: basic machine + 10 % fuel capacity.
192 kg (423 lbs)
/
