Wacker Neuson SW24 ST35 SW28 ST45 Compact loaders Service Manual – PDF DOWNLOAD
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DESCRIPTION:
Wacker Neuson SW24 ST35 SW28 ST45 Compact loaders Service Manual – PDF DOWNLOAD
- 1 Operation
1.1 Information on this service manual - This service manual contains important information on how to work safely, correctly and economically with the machine. Therefore, it aims not only at new personnel, but it also serves as a reference for experienced personnel.
- It 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 Operator’s 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.
TABLE OF CONTENTS:
Wacker Neuson SW24 ST35 SW28 ST45 Compact loaders Service Manual – PDF DOWNLOAD
Operation
Information on this service manual 1-2
Identification of warnings and dangers 1-3
Explanation of symbols and abbreviations 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
Machine overview 1-9
Engine compartment (overview) 1-10
Chassis overview 1-11
Hydraulic connections 1-12
Releasing the pressure in the hydraulic system 1-12
Connecting and disconnecting hydraulic couplings 1-12
Releasing the pressure in the auxiliary hydraulics 1-12
Preparations for releasing the pressure (loader unit/load stabilizer): 1-13
Emergency lowering 1-14
Opening the high-pressure circuit (SW24/28 only) 1-15
Transportation 1-15
Technical data
Engine 2-2
Traveling drive/axles 2-3
Brakes 2-3
Tires/tracks 2-4
Tires 2-4
Tracks 2-4
Steering system 2-4
Operating hydraulics 2-4
Speed 2-4
High Flow (option) 2-5
Coolant 2-5
Compound table 2-5
Noise emissions 2-5
Vibration 2-5
Weight 2-6
Machine weights 2-6
Weight of attachments 2-6
Breakout forces 2-6
Ground clearance/ground pressure 2-7
Payload/stability 2-7
Electrical system 2-8
Fuse box 2-8
Main fuse box 2-9
Bulbs 2-10
Tightening torques 2-10
Model-specific tightening torques 2-10
General tightening torques 2-11
Tightening torques for hydraulic threaded fittings (dry assembly) 2-12
Tightening torques for high-resistance threaded fittings 2-14
Dimensions 2-15
SW24/28 (overview) 2-15
ST35/ST45 (overview) 2-17
Table of contents
I-2 SHB S04 en – Edition 10 * * S04sIVZfm
Table of contents
Maintenance
Fluids and lubricants 3-2
Engine-oil types (temperature-dependent) 3-3
Hydraulic oil types (depending on temperature) 3-3
Important information regarding operation with biodegradable hydraulic oil 3-3
Maintenance overview 3-5
Maintenance label 3-5
Lubrication work 3-7
Preparing lubrication 3-7
Lubrication plan 3-8
Maintenance plan 3-9
Information on maintenance 3-14
Responsibilities and prerequisites 3-14
Important safety instructions on maintenance 3-14
Maintenance accesses 3-14
Radiator cover 3-14
Engine cover 3-16
Tilting the radiator 3-17
Raising/lowering the cabin 3-19
Side cover 3-23
Underbody maintenance access 3-24
Cabin fuse box 3-24
Main fuse box in engine compartment 3-24
Fuel system 3-25
Important information regarding the fuel system 3-25
Diesel fuel specification 3-25
Refueling 3-25
Water separator 3-27
Position 3-27
Emptying the water separator 3-27
Replacing the prefilter element of the water separator 3-28
Replacing the fuel filter 3-28
Bleeding the fuel system 3-29
Engine lubrication system 3-31
Important information regarding the engine lubrication system 3-31
Checking the engine oil level 3-31
Adding engine oil 3-32
Changing engine oil 3-33
Replacing the engine-oil filter cartridge 3-34
Cooling system 3-36
Important information regarding the cooling system 3-36
Checking the coolant level 3-37
Adding coolant 3-37
Draining coolant 3-38
Air filter 3-39
Important information regarding the air filter 3-39
Air filter monitoring 3-39
Replacing the air filter 3-39
Checking the air intake 3-40
Replacing the cabin air filter 3-41
Washer system 3-41
Important information regarding the washer system 3-41
Checking the fluid level and adding fluid 3-41
V-belts 3-42
Checking V-belt tension 3-42
Replacing the V-belt 3-43
Checking the V-belt tension of the air conditioning system (option) 3-44
SHB S04 en – Edition 10 * S04sIVZfm I-3
Table of contents
Tightening the V-belt of the air conditioning system (option) 3-44
Replacing the V-belt of the air conditioning system (option) 3-45
Replacing the crankcase breather filter (Tier IV) 3-46
Pressure check 3-47
General 3-47
Prerequisites for pressure check 3-47
Preparations 3-47
Measurement connections 3-48
Checking the main pressure (P1 & P2) 3-49
Checking the pilot control pressure of the operating and travel hydraulics (constant
pressure) 3-50
Checking the operating hydraulics pressure 3-50
Adjusting the operating hydraulics pressure 3-51
Checking the 3rd control circuit pressure (High Flow option) 3-51
Test report 3-52
Hydraulic system 3-54
Important information on the hydraulic system 3-54
Checking the hydraulic oil level 3-55
Adding hydraulic oil 3-55
Replacing hydraulic oil 3-56
Changing the hydraulic oil filter element 3-57
Draining condensation water from the hydraulic oil reservoir 3-58
Replacing the boost-pressure filter 3-59
Checking the hydraulic system for leaks 3-59
Checking the condition and age of hydraulic hoses 3-60
Tires/tracks 3-61
Inspection work 3-61
Tires 3-61
Wheel change 3-62
Checking track tension (ST35/ST45) 3-63
Correcting track tension (ST35/ST45) 3-63
Checking drive-chain tension (SW24/SW28) 3-65
Correcting drive-chain tension (SW24/SW28) 3-66
Replacing the drive-chain oil (SW24/SW28) 3-67
Axles/traveling drive 3-68
Checking the oil level and adding oil 3-68
Changing the oil 3-69
Electrical system 3-70
Important information regarding the electrical system 3-70
Fuses and relays 3-70
Battery charge condition 3-71
Charging the battery 3-71
Replacing the battery 3-71
Cleaning and maintenance 3-72
Information on cleaning and maintenance 3-72
Use of solvents 3-72
Cleaning inside the cabin 3-73
Cleaning the outside of the machine 3-73
Cleaning the engine compartment 3-73
Cleaning the seat belt 3-74
Threaded fittings and attachments 3-74
Maintenance of attachments 3-74
Important information regarding maintenance of attachments 3-74
Exhaust gas treatment 3-74
Maintenance of options 3-74
I-4 SHB S04 en – Edition 10 * * S04sIVZfm
Table of contents
Engine
Perkins 854F-E34TTF engine (overview) 4-2
Auxiliary flow aftertreatment system 4-7
Representation with auxiliary-flow diesel particulate filter 4-8
Engine block overview 4-9
Representation with separate intake-manifold pressure sensor and temperature
sensor 4-10
Turbocharger 4-11
Replacing the oxygen sensor 4-11
Fuel system 4-12
Engine malfunctions 4-13
Hydraulic system
Hydraulic pump 5-2
Hydraulic pump 5-3
Diagram 5-5
Standard operating pump 5-6
High Flow operating pump (option) 5-7
Fan motor 5-8
Pilot oil supply unit 5-9
Main valve block 5-10
Connections 5-10
Main valve block diagram 5-11
Pressure limiting valve 5-12
Pilot valves 5-13
2nd speed valve 5-13
High Flow valve (option) 5-14
Proportional valve 5-15
Emergency lowering valve 5-16
Single parallel lift valve (option) 5-17
Load stabilizer (option) 5-18
Hose burst valve (option) 5-19
Easy Lock valve (option) 5-20
Hydraulic control 5-21
Float position 5-21
Joystick on left (ISO controls) 5-22
Joystick on right (ISO controls) 5-23
Joystick on left (H controls) 5-24
Joystick on right (H controls) 5-25
Traveling drive 5-26
Function 5-26
Traveling drive ST35-45 5-27
Diagram 5-28
Drive diagram ST35-45 5-29
Traveling drive SW24-28 5-30
Diagram 5-31
Chain drive SW24-28 5-32
Drive diagram SW28-38 5-33
Malfunctions in the hydraulic system 5-34
Electrical system
Ohm’s Law (current, voltage, resistance); power 6-2
Measuring equipment, measuring methods 6-2
Cable color coding 6-3
Relays 6-4
Use, mode of function 6-4
Electrical system 6-4
Alternator 6-4
SHB S04 en – Edition 10 * S04sIVZfm I-5
Table of contents
Starter 6-4
Engine cover wiring harness 6-6
Wiring harness legend: chassis/engine Tier IV V1 6-7
Wiring harness for chassis/engine Tier IV V1 6-10
Wiring harness legend: chassis/engine Tier IV V2 6-11
Wiring harness for chassis/engine Tier IV V2 6-14
STVO (Austrian road traffic regulations) wiring harness 6-15
Legend for cabin wiring harness V1 6-16
Cabin wiring harness V1 6-21
Legend for cabin wiring harness V2 6-22
Cabin wiring harness V2 6-27
Cabin roof wiring harness 6-28
Air-conditioning wiring harness 6-29
Wiring harness for attachments 6-30
Diagrams
Legend for hydraulic diagram for SW24/SW28/ST35/ST45 7-2
Hydraulics diagram SW24/SW28 7-3
Hydraulics diagram ST35/ST45 7-4
Wiring diagram (legend) 7-5
Wiring diagram SW24/SW28/ST35/ST45 7-6
Power supply, start 7-8
Controller supply 7-9
ECU 12 V 15 7-10
Diesel engine T4 7-11
Diesel engine T4 7-12
CAN 7-16
MVCU inputs 7-17
MVCU inputs 7-18
MVCU inputs 7-19
Joystick (left) 7-20
Joystick (right) 7-21
MVCU inputs 7-22
MVCU outputs 7-23
MVCU outputs 7-24
Attachment controls 7-25
Working light 7-26
Lights according to STVO Austrian road traffic regulations 7-27
Heating, air conditioning 7-28
Wiper, radio 7-29
Options
Drive interlock (option) 8-2
Winter package (option) 8-3
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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