Wacker Neuson 4070 CX80 4070 CX100 Weidemann Wheel Loader Repair Manual- PDF DOWNLOAD
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FILE DETAILS:
Wacker Neuson 4070 CX80 4070 CX100 Weidemann Wheel Loader Repair Manual- PDF DOWNLOAD
Language : English
Pages :522
Downloadable : Yes
File Type : PDF
Size:115 MB
TABLE OF CONTENTS:
Wacker Neuson 4070 CX80 4070 CX100 Weidemann Wheel Loader Repair Manual- PDF DOWNLOAD
Repair Manual 3
Before you continue reading 3
Safety 21
Repair work (complete vehicle) 25
Safety instructions for repair work (complete vehicle) 25
Engine 27
Safety instructions for working on the engine 27
Hydraulic system 29
Safety instructions for working on the hydraulic system 29
Drive and axles 31
Safety instructions for working on the drive and axles 31
Brake system 33
Safety instructions for working on the brake system 33
Vehicle frame and load arm 35
Safety instructions for working on the vehicle frame and load arm 35
Operator’s platform and cab 37
Safety instructions for working on the operator’s platform and cab 37
Electrical system 39
Safety instructions for working on the electrical system 39
Technical data 45
Technical data 49
11 Technical data for Deutz engine 49
12 Technical data for Perkins engine 49
Filling quantities 51
Tightening torques 53
Pressure values 55
41 Pressure values for Deutz engine 55
42 Pressure values for Perkins engine 56
Flow rates 57
Safety stickers 59
Meaning and position of the safety stickers 59
Testing equipment 65
71 Test pump 65
72 Flow meter 65
73 Generator tester 65
74 Magnetic field tester 67
75 Test pressure gauge 67
76 Fuel line with pressure gauge 68
Special tools 69
81 Expulsion and driving sleeves 69
82 Sealing plate (2 x) 70
83 Insertion tool 70
84 Driving bolts 71
85 Electrical contact key 71
86 Half-shells and pull-off fixture 72
87 Assembly tool 72
88 Hose clamp 73
89 Tool for contact removal 73
Hose book 75
Inspections 81
Complete vehicle 85
11 Inspection log for Deutz engine 85
12 Inspection log for Perkins engine 86
13 Telescopic arm inspection log 87
Engine 89
21 Checking and adjusting the valve play (Deutz) 89
22 Checking and adjusting the valve play (Perkins) 91
23 Checking the pressure of the fuel feed pump (Perkins) 95
24 Inspecting the exhaust system for leaks 97
25 Inspecting the radiator for leaks 98
26 Checking the radiator installation 98
27 Troubleshooting on the engine100
Hydraulic system103
31 Driving hydraulics103
311 Checking and adjusting the starting speed103
312 Checking and adjusting the pressure cut-off103
313 Checking the variable displacement pump high pressure105
314 Checking the variable displacement pump supply pressure106
315 Checking the variable displacement pump positioning pressure107
316 Adjusting the driving speed108
317 Checking and adjusting the control commencement of the variable displacement motor109
32 Testing the steering hydraulics111
33 Checking and adjusting the inching112
34 Working hydraulics113
341 Checking the gear pump113
342 Checking the function of the pilot control116
343 Checking the control valve function118
35 Troubleshooting on the hydraulic system119
Drive and axles123
41 Inspecting the differential lock123
42 Checking the water filling of the wheels124
43 Troubleshooting on the drive125
Vehicle frame and load arm127
51 Checking and adjusting the curling to load and dumping stops127
52 Troubleshooting on the telescopic arm128
Cab129
61 Checking the heater and the air-conditioning unit129
62 Troubleshooting in the cab130
Electrical system131
71 Checking the generator131
72 Checking the starter131
73 Checking the temperature sensors132
74 Testing the fuel level sensor133
75 Checking and adjusting the tilt switch134
76 Troubleshooting on the electrical system135
Replacement141
Complete vehicle147
11 Helpful tips147
12 Replacing protective stickers147
Engine149
21 Engine (Deutz)149
211 Engine removal149
212 Preparations for engine installation154
213 Engine installation156
214 Replacing the front rubber buffers161
215 Replacing the rear rubber buffers162
216 Replacing the spacer at the rear163
217 Replacing the clutch PA flange164
218 Cleaning the engine (after toppling the loader)165
22 Engine (Perkins)166
221 Engine removal166
222 Preparations for engine installation170
223 Engine installation171
224 Replacing the front rubber buffers176
225 Replacing the rear rubber buffers177
226 Replacing the clutch PA flange178
227 Cleaning the engine (after toppling the loader)178
23 Radiator180
231 Removing the radiator180
232 Installing the radiator183
24 Air filter system186
241 Replacing the suction hose186
242 Replacing the complete air filter187
243 Replacing the air filter housing188
25 Fuel system190
251 Replacing the fuel pre-filter (Deutz)190
252 Replacing the sieve filter of the fuel feed pump (Deutz)191
253 Replacing the complete main fuel filter (Perkins)192
254 Replacing the fuel line193
255 Replacing the Bowden cable of the accelerator194
256 Replacing the fuel tank195
26 Exhaust system196
261 Replacing the muffler and tail pipe196
262 Replacing the flue or flexi-pipe197
Hydraulic system201
31 Complete vehicle201
311 Depressurizing the hydraulic system201
312 Sealing the hydraulic cylinder201
313 Replacing the pivot bearing on the hydraulic cylinder204
32 Driving hydraulics206
321 Replacing the variable displacement pump206
322 Replacing the clutch hub208
323 Replacing the annular shaft seal of the variable displacement pump208
324 Replacing the variable displacement motor209
33 Steering hydraulics211
331 Cleaning the priority valve211
332 Replacing the priority valve212
333 Replacing the orbital steering valve213
334 Removing the steering cylinder214
335 Installing the steering cylinder215
34 Brake hydraulics217
341 Replacing the main brake cylinder217
342 Replacing the brake hydraulics tank218
343 Venting the brake hydraulics219
344 Replacing the brake fluid220
345 Replacing the 3/2-way valve222
35 Working hydraulics (gear pump, valves)223
351 Replacing the gear pump223
352 Sealing the gear pump224
353 Removing the control valve226
354 Installing the control valve226
355 Sealing the control valve227
356 Replacing the 2/2-way valve (curl stop)232
357 Replacing the valve of the vibration damping unit233
358 Replacing the diaphragm accumulator of the vibration damping unit235
36 Working hydraulics (hydraulic cylinder)236
361 Replacing the lifting cylinder236
362 Replacing the lifting cylinder (telescopic arm)238
363 Removing the tipping cylinder240
364 Removing the tipping cylinder (telescopic arm)241
365 Installing the tipping cylinder243
366 Installing the tipping cylinder (telescopic arm)245
367 Replacing the telescopic cylinder247
368 Replacing the counterbalance cylinder (telescopic arm)249
369 Replacing components of the load holding control valve250
37 Control hydraulic252
371 Depressurizing the control hydraulic252
372 Replacing the pilot control252
373 Adjusting the resting strength and play of the pilot control255
374 Replacing the pulsation damper256
375 Replacing the diaphragm accumulator257
38 Auxiliary hydraulics and hydraulic lock257
381 Replacing the locking cylinder257
39 Tank, filter and hydraulic lines259
391 Replacing the hydraulic fluid tank259
392 Replacing the complete return filter260
393 Replacing the pressure filter262
394 Cleaning the pressure filter263
395 Replacing the hydraulic line264
396 Replacing the hydraulic line (telescopic arm)265
Drive and axles267
41 Replacing the drive shaft267
42 Front axle268
421 Removing the front axle268
422 Removing the front axle (telescopic arm)270
423 Installing the front axle272
424 Installing the front axle (telescopic arm)275
43 Rear axle277
431 Removing the rear axle277
432 Installing the rear axle280
Brake system (mechanical section)283
51 Service brake283
511 Replacing the brake shoes283
512 Replacing the brake drum284
52 Parking brake285
521 Replacing the Bowden cable of the parking brake285
Vehicle frame and load arm287
61 Front carriage287
611 Replacing the front fender287
612 Replacing the front weight287
62 Rear carriage and engine hood288
621 Replacing the rear fender288
622 Replacing the base plate289
623 Replacing the rear weight290
624 Replacing the engine hood292
625 Emergency release of the engine hood293
626 Replacing the lock of the engine hood293
63 Center joint295
631 Detaching the center joint295
632 Detaching the center joint (telescopic arm)298
633 Connecting the center joint300
634 Connecting the center joint (telescopic arm)303
635 Replacing the bearing in the self-aligning bearing305
636 Replacing the lower bearing307
64 Insulation mats308
641 Replacing an insulation mat308
65 Load arms309
651 Replacing the complete load arm309
652 Replacing the bearing of the drawbar311
653 Replacing the bearing of the tipping lever312
654 Replacing the front bearing of the load arm313
655 Replacing the rear bearing of the load arm314
66 Telescopic arm 986315
661 Replacing the complete telescopic arm315
662 Removing the inner cylinder318
663 Installing the inner cylinder321
664 Replacing the energy chain325
665 Replacing a slide bar of the outer cylinder326
666 Replacing a slide bar of the inner cylinder326
667 Removing and installing the tilt mechanism327
668 Replacing the right-hand tipping lever with drawbar330
669 Replacing the left-hand tipping lever with drawbar333
67 Tool attachment335
671 Replacing the tool attachment335
672 Replacing the tool attachment (telescopic arm)336
673 Replacing the locking pin339
Operator’s platform and cab341
71 Seat341
711 Replacing the driver’s seat341
712 Replacing the complete seat belt342
72 Frame342
721 Removing the complete cab342
722 Installing the complete cab346
723 Replacing the front rubber buffers of the cab349
724 Replacing the rear rubber buffers of the cab350
725 Replacing the roof grille of the cab351
726 Replacing the floor mats352
727 Replacing the radio console354
728 Replacing the sun visor355
73 Windows/windshield and doors355
731 Replacing the windshield wiper arms355
732 Replacing the windshield washer container357
733 Replacing a bonded-in window357
734 Replacing the door359
735 Replacing the door lock361
736 Replacing the door stay362
737 Replacing the window stop363
74 Steering column363
741 Replacing the steering column363
742 Replacing the cladding of the steering column364
743 Replacing the steering wheel365
75 Heater and air-conditioning unit366
751 Replacing the Bowden cable of the temperature sensor366
752 Removing and installing the vaporizer of the air- conditioning unit368
753 Removing and installing the air-conditioning compressor369
754 Removing and installing the dryer370
755 Removing and installing the air-conditioning unit condenser371
76 Cab lift hydraulic372
761 Replacing the hand pump372
762 Replacing the hydraulic cylinder373
763 Replacing the Bowden cable of the cab lift hydraulic374
Electrical system377
81 Generator, battery and motors377
811 Replacing the generator (Deutz)377
812 Replacing the generator (Perkins)378
813 Replacing the starter (Deutz)380
814 Replacing the starter (Perkins)382
815 Replacing the rear windshield wiper motor384
816 Replacing the front windshield wiper motor385
817 Replacing the heater blower386
82 Switches387
821 Replacing the battery disconnect switch387
822 Replacing the ignition lock388
823 Replacing the engine temperature sensor389
824 Replacing the temperature sensor of the hydraulic fluid tank390
825 Replacing the return filter overpressure switch391
826 Replacing the parking brake switch392
827 Replacing the switch of the service brake392
828 Replacing the steering column switch393
829 Replacing the switches in the cab394
83 Sensors395
831 Replacing the electronic gas pedal (Perkins)395
832 Replacing the fuel level sensor396
833 Replacing the vacuum gauge397
834 Replacing the tilt switch397
84 Relays, coils and fuses398
841 Replacing a relay398
842 Replacing the solenoid valve of the variable displacement pump399
843 Replacing the coil and core on the variable displacement pump400
844 Replacing the solenoid valve core on the variable displacement motor401
845 Replacing the control unit401
85 Indicator lamps, audible reverse warning device and instruments402
851 Replacing the engine-hour indicator402
852 Replacing the fuel tank gauge404
853 Replacing the instrument lighting405
854 Replacing the horn407
855 Replacing the audible reverse warning device407
86 Lighting system408
861 Replacing a complete headlamp with indicator408
862 Replacing a complete tail lamp409
863 Replacing the headlight410
Attachments411
91 Replacing the earth bucket digging tooth411
92 Replacing the prongs of the fork & grab411
93 Replacing the hydraulic cylinder of the fork & grab412
94 Replacing the hydraulic cylinder of the multi-purpose bucket413
95 Replacing the valve of the multi-purpose bucket414
Circuit diagrams and descriptions423
Hydraulic circuit diagram427
Electrical circuit diagram429
Plug assignments / contact assignments457
31 Plug assignments457
311 Main plug connections fitting & cab458
312 Plug connections instrument steering column464
313 Plug connections – cab467
314 Plug connections – machine471
315 Plug connections – lighting474
32 Contact assignments476
321 Components of the instrument steering column477
322 Components of the cab478
Technical description481
Supplier documentation491
Engine workshop manual (example)495
Variable displ pump repair instructions (example)499
Planetary axle workshop manual (example)501
Electrical components505
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