Wacker Neuson Group WL32 Wheel loader Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Wacker Neuson Group WL32 Wheel loader Service Manual – PDF DOWNLOAD
Use of the service manual
- The purpose of this service manual is to help maintain the constant operation readiness of the machine. This ensures the high value of the machine through careful maintenance and after-sales monitoring.
- The experiences of our factory personnel and service technicians are summarized in this service manual. Every sequence of images shows the procedure of a repair process.
- The provided text contains necessary instructions for adjustment, application of special tools, etc. Major repair procedures are described in such a way that smaller subtasks can also be performed individually following the respective procedures.
- The manual is appended according to further technical development of the machines and therefore is kept up-to-date to serve as a reference. For reasons of safety and security, always compare the specified values and capacities with the latest Operator’s Manual of the respective machine.
- Technical data, dimensions and weights are only given as an indication. Responsibility for errors or omissions not accepted. Deviations of images are possible.
Information
Careful and prudent working is the best way to avoid accidents
TABLE OF CONTENTS:
Wacker Neuson Group WL32 Wheel loader Service Manual – PDF DOWNLOAD
Contents
E Introduction
E1 Notice on this service manual E-1
Use of the service manual E-2
Explanation of symbols and abbreviations E-3
Repair instructions E-4
E2 Technical data E-5
Engine E-5
Permissible inclination E-6
Electrical system E-6
Machine-travel hydraulics E-6
Operating hydraulics E-7
Brakes E-7
Tires E-8
Steering system E-8
Noise emissions E-9
Vibration E-9
Machine weight E-10
Payload/load-carrying capacity/axle load E-10
Dimensions E-11
E3 Tightening torques E-13
General tightening torques E-13
Specific tightening torques E-13
Torque values for metric coarse-pitch thread E-14
Torque values for metric fine-pitch thread E-15
Tightening torques for hydraulic screw connections and air-conditioning screw connections with
sealing cone and O-ring DIN 3865 E-16
Tightening torques for hydraulic screw connections with olive DIN 3861 E-17
Tightening torques for hydraulic system screw-in spud SDS E-18
Tightening torques for hydraulics rotating threaded fittings E-21
Tightening torques for banjo bolts DIN 7643 E-21
Tightening torques for adjustable hydraulics screw-in spuds SDE E-22
Tightening torques for brake line threaded fittings E-24
Tightening torques for worm drive hose clamps E-24
Tightening torques for spring-loaded worm drive hose clamps E-24
E4 Safety instructions E-25
Pay particular attention to the following E-25
Safety symbols and signal words E-25
Safety and Accident Prevention Regulations E-26
Safety instructions for repair work E-27
Safety instructions for work on the engine E-30
Safety instructions for work on the hydraulic system E-31
Safety instructions for work on the air conditioning system E-32
Safety instructions for work on traveling drive and axles E-33
Safety instructions for work on the braking system E-33
Safety instructions for work on the frame E-33
Safety instructions for work on the electrical system E-35
Safety instructions for work on the wheels E-35
E5 Special tools E-36
Claws and extractors E-36
Clamp E-36
Contents
C-2 SHB WL32 * 10
C Contents
B Operation
B1 Overview of control elements B-1
Control and display elements B-2
Indicating instruments (363 kW engine) B-4
Indicating instrument (357 kW and 447 kW engine) B-6
Loader unit control lever B-7
Overview of rotary switches (option) B-8
Overview of switch panels B-8
B2 Indicator lights and warning lights (overview) B-11
Description of indicator lights and warning lights (363 kW engine) B-11
Description of indicator lights and warning lights (357 and 447 kW engine) B-14
1 Maintenance
11 Information on maintenance 1-1
Responsibilities and prerequisites 1-1
Safety instructions 1-1
Battery master switch 1-5
12 Maintenance overview 1-6
Daily/weekly maintenance 1-6
Inspection schedules 1-7
Inspection intervals 1-10
13 Lubrication plan 1-13
14 Fluids and lubricants 1-15
Fluids and lubricants (overview) 1-15
Perkins engine 404D-22 (363 kW) 1-15
Perkins engine 404F-22 (357 kW)/404F-22T (447 kW) 1-16
15 Maintenance accesses 1-17
Maintenance openings 1-17
Raising the control stand sideways 1-17
16 Cleaning and maintenance 1-20
Information on cleaning and maintenance 1-20
Information on cleaning 1-21
General safety check 1-21
17 Lubrication work 1-22
Lubrication 1-22
Lubricating with the central lubrication system (option) 1-22
Central lubrication system diagram 1-25
Installing the high-pressure hoses on the central lubrication system 1-26
Instructions for troubleshooting in case of central lubrication system blocking 1-27
Repairing a blocking distributor of the central lubrication system 1-28
Troubleshooting table for central lubrication system 1-29
18 Fuel system 1-30
Information on the fuel system 1-30
Fuel system 1-31
Refueling with diesel fuel 1-31
Performing fuel filter maintenance 1-33
Replacing the fuel filter element 1-34
Replacing the fuel filter 1-36
Bleeding the fuel system 1-37
19 Engine lubrication system 1-38
Replace the engine oil and engine oil filter 1-38
110 Cooling system 1-39
Information on the cooling system 1-39
Information on the coolant 1-39
Checking/adding coolant 1-40
Checking the antifreeze mixture 1-41
SHB WL32 * 10 C-3
Contents C
Cleaning the cooling system 1-41
111 Air filter 1-43
Information on the engine air filter system 1-43
Engine air filter dust valve 1-43
Engine air filter 1-44
112 V-belt/toothed belt 1-46
Information on the V-belt 1-46
Checking the V-belt tension/tensioning the V-belt 1-47
113 Hydraulic system 1-48
Information on the hydraulic system 1-48
Replace the breather filter 1-49
Information on hydraulic oil 1-50
Checking the hydraulic oil level 1-50
Adding hydraulic oil 1-51
Changing hydraulic oil 1-51
Replacing the hydraulic oil filter element 1-51
Replacing filter insert of high-pressure filter Z3 1-52
Bleeding the hydraulic system 1-53
114 Electrical system 1-54
Information on the electrical system 1-54
Fuses 1-54
Information on the battery 1-54
Removing the battery 1-55
Starting aid and jump-starting 1-57
115 Heating, ventilation and air conditioning system (option) 1-59
Heating (option) maintenance 1-59
Maintenance of cabin breather filter 1-59
Maintenance of air conditioning (option) 1-59
116 Washer system 1-60
Filling up the washer system reservoir 1-60
117 Axles/traveling drive 1-61
Checking and replacing the axle oil 1-61
118 Braking system 1-63
Information on the braking system 1-63
119 Tires 1-64
Information on tires 1-64
Inflating the tires 1-65
Wheel change 1-66
Checking the liquid level of the tires 1-67
Ballasting wheels with liquid 1-67
120 Maintenance and servicing work on attachments 1-68
Information on attachments 1-68
121 Maintenance of options 1-69
Automatic trailer coupling 1-69
122 Exhaust gas treatment 1-70
Information on exhaust-gas treatment 1-70
Regeneration of diesel particulate filter 1-71
2 Engine
21 Complete component (363 kW engine) 2-1
Overview 2-2
22 Complete component (447 kW engine) 2-5
Overview 2-5
Removing/installing the engine 2-7
23 Alternator (447 kW) 2-13
Removing the alternator V-belt 2-13
C-4 SHB WL32 * 10
C Contents
Removing the alternator 2-13
24 Starter M001 (447 kW) 2-14
Removing/installing the starter 2-14
25 Diesel particulate filter (447 kW engine) 2-16
26 Removing/installing the fuel tank 2-17
3 Cooling
31 Removing/installing the coolant reservoir 3-1
32 Removing/installing the radiator 3-2
33 Removing/installing fan blades 3-4
4 Traveling drive
41 Traveling drive hose routing 4-1
42 Variable displacement pump P35 4-2
Overview 4-2
Pressures 4-3
Checking/adjusting the pressure cutoff 4-4
Checking/adjusting the inching 4-5
Checking/adjusting the starting speed 4-5
Checking low pressure (supply pressure) 4-6
Checking the high pressure of the variable displacement pump 4-6
Checking the setting pressure of the variable displacement pump 4-7
Checking/adjusting the mechanical zero position 4-8
Removing/installing the variable displacement pump 4-9
43 Variable displacement motor M20 4-12
Variable displacement motor screw connection (overview) 4-12
Checking and adjusting the control initiation of the variable displacement motor 4-13
Removing/installing the variable displacement motor 4-14
44 Manifold 4-16
Overview 4-16
Removing/installing the manifold 4-17
45 Hydraulic oil tank Z57 4-18
Removing/installing the hydraulic oil reservoir 4-18
Removing/installing the return filter 4-20
Removing/installing the temperature switch 4-20
46 Removing/installing the cardan shaft 4-21
47 Removing/installing check valve V72 4-23
48 Troubleshooting 4-25
No forward or reverse travel 4-25
Machine travel starts too early 4-26
Machine travel starts too late 4-27
Severe engine droop 4-28
Not enough traction force 4-29
Travel speed is not reached 4-30
5 Axles
51 Front axle 5-1
Overview 5-1
Removing/installing the front axle 5-2
52 Rear axle 5-5
Overview 5-5
Removing/installing the rear axle 5-5
53 Type label – front/rear axle 5-9
6 Brake
61 Removing/installing the brake pedal 6-1
62 Removing/installing the parking brake 6-2
63 Removing/installing the parking brake Bowden cable 6-3
64 Master brake cylinder 6-4
SHB WL32 * 10 C-5
Contents C
Overview 6-4
Removing/installing the master brake cylinder 6-5
7 Steering system
71 Steering orbitrol S4 7-1
Overview 7-1
Removing/installing the steering orbitrol 7-3
72 Removing/installing the steering wheel 7-5
73 Removing/installing the steering column 7-7
74 Removing/installing the steering column gas strut 7-8
75 Removing/installing steering cylinder A21 7-10
76 Checking the steering hydraulics 7-12
8 Operating hydraulics
81 Overview 8-1
82 Hose routing 8-2
Standard hose routing (rear machine section) 8-2
Hoses of lift, tilt and lock cylinders 8-3
Hoses of lift and tilt cylinders with counterbalance valve 8-4
High Flow hose routing 8-5
83 Gear pump P32 8-6
Overview 8-6
Checking the gear pump 8-6
Removing/installing the gear pump 8-8
84 Removing/installing lock cylinder A4 8-10
85 Removing/installing the lock pin 8-13
86 Removing/installing the tilt cylinder 8-14
87 Removing/installing the loader unit 8-17
88 Removing/installing the lift cylinder 8-20
89 Removing/installing the reversing lever 8-23
Removing/installing the rear reversing lever 8-23
Removing/installing the front reversing lever 8-25
810 Removing/installing solenoid valve V30 8-26
811 Removing/installing pressure relief valve V60 8-28
812 Removing/installing the quickhitch 8-30
813 Removing/installing the control valve 8-31
814 Designation of hydraulic components 8-33
815 Hydraulics diagram – HDS21/4 with HDS21/1 or 6/2 directional valve 8-35
816 Hydraulics diagram – HDS21/4 with HDS21/2 8-37
817 Hydraulics diagram – HDS21/3 with HDS21/1 or 6/2 directional valve 8-39
818 Hydraulics diagram – HDS21/3 with HDS21/2 8-41
819 Hydraulics diagram – HDS21/4 High Flow 8-43
9 Electrical system
91 Fuses 9-1
Fuse boxes 9-1
Fuse assignment 9-1
92 Removing/installing the machine control unit 9-5
Removal 9-5
Installation 9-5
93 Joystick 9-8
Overview 9-8
Removing/installing the joystick 9-9
94 Removing/installing the battery master switch 9-10
95 Malfunctions of the machine electronics 9-11
363 kW engine 9-11
C-6 SHB WL32 * 10
C Contents
Engine 357 and 447 kW 9-11
96 Electrical diagram – power supply 9-13
97 Electrical diagram – control electronics power supply; joystick lighting 9-14
98 Electrical diagram – Perkins engine 404D-22 9-15
99 Electrical diagram – Perkins engine 404D-22 9-16
910 Electrical diagram – Perkins engine 404F-22 9-17
911 Electrical diagram – Perkins engine 404F-22 9-18
912 Electrical diagram – Ciam instrument 9-19
913 Electrical diagram – Bauser LED instrument 9-20
914 Electrical diagram – travel function 9-21
915 Electrical diagram – turn indicator system; horn 9-22
916 Electrical diagram – lights according to StVZO (German road traffic licensing regulations) 9-23
917 Electrical diagram – lights according to StVZO (German road traffic licensing regulations) 9-24
918 Electrical diagram – working lights; rotating beacon 9-25
919 Electrical diagram – air conditioning; seat 9-26
920 Electrical diagram – wiper/wash system 9-27
921 Electrical diagram – E connection (front & rear); Hydro Comfort; continuous operation of the
3rd control circuit 9-28
922 Electrical diagram – hydraulic system 1 9-29
923 Electrical diagram – hydraulic system 2 9-30
924 Electrical diagram – hydraulic system 3 9-31
925 Electrical diagram – radio; power outlet; interior lighting 9-32
926 Designation of electrical components 9-33
Component list 9-33
Cable colours 9-38
10 Trim
101 Removing/installing the engine cover 10-1
102 Removing/installing the floor panels 10-3
103 Removing/installing the trailer power outlet 10-4
104 Removing/installing the trailer coupling/chassis cover 10-6
105 Removing/installing the counterweight 10-8
11 Cabin
111 Removing/installing the operator seat 11-1
112 Removing/installing the indicating instrument 11-2
113 Removing/installing the starter 11-4
114 Removing/installing the 12 V connector 11-6
115 Removing/installing the control lever console 11-8
116 Radio 11-9
Removing/installing the radio 11-9
Removing/installing the radio console 11-10
Removing/installing the loudspeakers 11-11
117 Removing/installing the armrest 11-12
118 Removing/installing the heating 11-13
119 Removing/installing the cabin 11-14
1110Removing/installing the base plate 11-16
12 Malfunctions
121 Towing a machine 12-1
Preparations for towing 12-1
Towing the machine 12-2
After towing 12-2
122 Error code lists 12-3
Engine control unit Perkins 404F 12-3
Machine control unit TTC77 12-7
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M