Wacker Neuson WL34 Wheel loader Operator’s Manual – PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Wacker Neuson WL34 Wheel loader Operator’s Manual – PDF
Introduction
Notice on this service manual
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.
TABLE OF CONTENTS:
Wacker Neuson WL34 Wheel loader Operator’s Manual – PDF
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-5
Traveling drive/axles E-6
Machine-travel hydraulics E-6
Brakes E-6
Tyres E-7
Steering system E-7
Operating hydraulics E-8
Coolant E-8
Vibration E-9
Weights E-10
Payload/load-carrying capacity/lift capacity 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 climate screw fixtures with taper
connections and O-rings DIN 3865 E-16
Tightening torques for hydraulic screw connections with cutting ring DIN 3861 E-17
Tightening torques for hydraulic screw struts SDS E-18
Tightening torques for hydraulics rotating screw connections E-21
Tightening torques for hollow screws DIN 7643 E-21
Tightening torques for adjustable hydraulic screw struts SDE E-22
Tightening torques for brake line screw connections 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
I-2 SHB WL34 * 20 * [en]
I
B Operation
Overview of control elements B-1
Indicating instruments B-3
Loader unit control lever B-4
Overview of rotary switches (option) B-5
Overview of switch panels B-5
B1 Indicator lights and warning lights (overview) B-7
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
Lubrication plan 1-13
13 Fluids and lubricants 1-15
Fluids and lubricants (overview) 1-15
Perkins engine 404D-22 (357 kW) 1-15
Perkins engine 404F-22 (357 kW) 1-16
Deutz engine TD2011L04w (551 kW) 1-16
14 Maintenance accesses 1-17
Opening the engine cover 1-17
Removing/installing the operator seat 1-18
Removing/installing the footwell cover panel 1-18
Removing/installing cover for rear wall cladding 1-19
Removing/installing filler cap for the control console 1-19
15 Cleaning and maintenance 1-20
Information on cleaning and maintenance 1-20
Information on cleaning 1-21
General safety check 1-21
16 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
17 Fuel system 1-30
Information on the fuel system 1-30
Fuel system 1-31
Refueling with diesel fuel 1-31
Water separator maintenance 1-33
Replace the filter element of the fuel filter (Perkins Motor) 1-34
Replace the fuel filter (Perkins Motor) 1-36
Bleeding the fuel system 1-37
18 Engine lubrication system 1-39
Replace the engine oil and engine oil filter 1-39
19 Cooling system 1-41
Information on the cooling system 1-41
Information on the coolant 1-41
Checking/adding/changing coolant 1-42
Checking the antifreeze mixture 1-43
Cleaning the cooling system 1-44
SHB WL34 * 20 * [en] I-3
I
110 Air filter 1-45
Information on the engine air filter system 1-45
Engine air filter dust valve 1-46
Engine air filter 1-46
111 V-belt/toothed belt 1-48
Information on the V-belt 1-48
Checking the V-belt tension/tensioning the V-belt 1-49
Note on toothed belts 1-49
112 Hydraulic system 1-50
Information on the hydraulic system 1-50
Change the ventilation filter 1-51
Information on hydraulic oil 1-52
Checking the hydraulic oil level 1-52
Adding hydraulic oil 1-53
Changing hydraulic oil 1-53
Replacing the hydraulic oil filter insert 1-54
Replacing filter insert of high-pressure filter 1-54
Bleeding the hydraulic system 1-55
113 Electrical system 1-56
Information on the electrical system 1-56
Fuses 1-56
Information on the battery 1-57
Removing the battery 1-57
Battery maintenance 1-58
Starting aid and jump-starting 1-59
114 Heating and ventilation 1-61
Heating maintenance 1-61
Maintenance of cabin breather filter 1-61
115 Washer system 1-62
Filling up the washer system reservoir 1-62
116 Axles/travel drive 1-63
Checking and replacing the axle oil 1-63
117 Braking system 1-65
Information on the braking system 1-65
118 Tires 1-66
Information on tires 1-66
Inflating the tires 1-67
Wheel change 1-68
Checking the liquid level of the tires 1-69
Ballasting wheels with liquid 1-69
119 Maintenance and servicing work on attachments 1-70
120 Maintenance of options 1-71
Automatic trailer coupling 1-71
121 Exhaust gas treatment 1-72
Information on exhaust-gas treatment 1-72
Regeneration of diesel particulate filter 1-73
2 Engine
21 Perkins engine 404D-22 (357 kW) 2-1
Overview 2-2
Adjust idle speed 2-5
Removing/installing the engine 2-5
Removing/installing the starter 2-9
Alternator 2-10
22 Perkins engine 404F-22 (357 KW) 2-11
Overview 2-12
I-4 SHB WL34 * 20 * [en]
I
23 Deutz engine TD2011 L04w (551 kW) 2-15
Overview 2-15
Lube oil system 2-18
24 Removing/installing the fuel tank 2-20
3 Cooling
31 Removing/installing the radiator 3-1
32 Removing/installing fan blades 3-3
4 Travel drive
41 Traveling drive hose routing 4-1
42 M-Drive hose routing 4-2
43 Variable displacement pump 4-3
Overview 4-3
Pressures 4-4
Checking/adjusting the pressure cutoff 4-5
Checking/adjusting the inching 4-6
Checking/adjusting the starting speed 4-6
Checking low pressure (supply pressure) 4-7
Checking the high pressure of the variable displacement pump 4-7
Checking the setting pressure of the variable displacement pump 4-8
Checking/adjusting the mechanical zero position 4-9
Removing/installing the variable displacement pump 4-10
44 Variable displacement motor 4-12
Overview 4-12
Checking and adjusting the control initiation of the variable displacement motor 4-13
Removing/installing the variable displacement motor 4-14
45 Hydraulic oil reservoir 4-16
Removing/installing the hydraulic oil reservoir 4-16
Removing/installing the return filter 4-17
Removing/installing the temperature switch 4-18
46 Removing/installing the cardan shaft 4-19
47 M-Drive (Option) 4-21
Pressure values 4-21
48 Troubleshooting 4-22
No forward or reverse travel 4-22
Machine travel starts too early 4-23
Machine travel starts too late 4-24
Severe engine droop 4-25
Not enough traction force 4-26
Travel speed is not reached 4-27
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
SHB WL34 * 20 * [en] I-5
I
6 Braking system
61 Overview 6-1
62 Service/parking brake 6-2
Overview 6-2
Drum brake setup 6-3
Change brake jaws/wire rope adapter 6-4
Exchange the spring-loaded cylinder 6-8
Removing/installing parking brake 6-10
Removing/installing the Bowden cable for the fixed brakes 6-11
63 Master brake cylinder 6-12
Overview 6-12
Removing/installing the master brake cylinder 6-13
7 Steering system
71 Hose routing 7-1
72 Removing/installing the steering wheel 7-2
73 Removing/installing the steering column 7-4
74 Removing/installing the steering column gas strut 7-5
75 Remove/install steering cylinder 7-7
76 Steering orbitrol S1 7-9
Overview 7-9
Removing/installing the steering orbitrol 7-10
77 Checking the steering hydraulics 7-12
8 Work hydraulics
81 Overview 8-1
82 Vehicles with a serial number < 3025887 8-2
83 Vehicles with a serial number > 3025887 8-3
Hose routing with hydraulic lock 8-3
Hose routing with mechanical lock 8-4
Hose routing with counterbalance valve 8-5
Hose routing with 3rd control circuit comfort 8-6
84 Gear pump P37 8-7
Overview 8-7
Checking the gear pump 8-7
Removing/installing the gear pump 8-9
85 Removing/installing lock cylinder A4 8-10
86 Removing/installing the lock pin 8-11
87 Removing/installing the tilt cylinder 8-12
88 Removing/installing the loader unit 8-14
89 Removing/installing the lift cylinder 8-17
810 Removing/installing the reversing lever 8-19
Removing/installing the rear reversing lever 8-19
Removing/installing the front reversing lever 8-21
811 Removing/installing solenoid valve V30 8-22
812 Removing/installing the quickhitch 8-23
813 Removing/installing operation lever for additional hydraulic system (control lever) 8-24
814 Control valve 8-25
Checking and adjusting working pressure 8-25
Removing/installing the control valve 8-25
815 Designation of hydraulic components 8-27
816 Hydraulic circuit diagram HDM19/3 with HDS15/1 8-29
817 Hydraulic circuit diagram – HDM19/4 8-31
818 Hydraulic circuit diagram HDM19/4 M-Drive 8-33
I-6 SHB WL34 * 20 * [en]
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9 Electrical system
91 Fuses 9-1
92 Fuse assignment 9-2
93 Removing/installing the machine control unit 9-5
Disassemble 9-5
Install 9-5
94 Joystick 9-9
Overview 9-9
Removing/installing the joystick 9-10
95 Removing/installing the battery master switch 9-11
96 Malfunctions of the machine electronics 9-12
Error message on display with symbol 9-12
Error codes 9-13
97 Electrical diagram – Electronics, power supply (FG01-01) 9-14
98 Electrical diagram – Electronics CAN Bus (FG01-02) 9-15
99 Electrical diagram – Perkins engine 404D-22 (FG02-01) 9-16
910 Electrical diagram – Perkins engine 404F-22 (FG02-02) 9-17
911 Electrical diagram – Perkins engine 404F-22 (FG02-03) 9-18
912 Electrical diagram – Deutz engine TD2011 (FG02-04) 9-19
913 Electrical diagram – Instrument (FG03-01) 9-20
914 Electrical diagram – Drive function (FG04-01) 9-21
915 Electrical diagram – Manual throttle (FG04-02) 9-22
916 Electrical diagram – Working lights; Rotating beacon; Horn (FG05-01) 9-23
917 Electrical diagram – Light StVZO (German traffic regulations) (turn indicator system, horn)
(FG06-01) 9-24
918 Electrical diagram – Light StVZO (German traffic regulations) (front headlight) (FG06-02) 9-25
919 Electrical diagram – Brake light lighting (FG06-03) 9-26
920 Electrical diagram – Washer system (FG07-01) 9-27
921 Electrical diagram – Radio, cigarette lighter, interior light (FG08-01) 9-28
922 Electrical diagram – Heating; Seat (FG09-01) 9-29
923 Electrical diagram – Hydraulic control circuits, E-connection 12 V (FG10-01) 9-30
924 Electrical diagram – Roll-in stop; Overload display (FG11-01) 9-31
925 Electrical diagram – Loader unit stabilizer, counterbalance valve (FG11-02) 9-32
926 Electrical diagram – 3rd/4th control circuit comfort control (FG11-03) 9-33
927 Designation of electrical components 9-34
Component list 9-34
Cable colors 9-39
10 Trim
101 Removing/installing the engine cover 10-1
102 Removing/installing the base plate 10-2
103 Remove/install the battery cover 10-3
104 Installing / removing rear weight 10-5
11 Cabin
111 Removing/installing the indicating instrument 11-1
112 Removing/installing the starter 11-3
113 Removing/installing the 12 V connector 11-5
114 Heating 11-7
Removing/installing the heating blower 11-7
Removing/installing the heater box 11-10
115 Removing/installing the wiper motor 11-11
SHB WL34 * 20 * [en] I-7
12 Malfunctions
121 Towing a machine 12-1
Preparations for towing 12-1
Towing the vehicle 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
13 Installation position
131 Hydraulic system 13-1
V05 – Priority valve 13-1
V15 / V22 – Control valve 13-1
V30 – 2/2-directional valve lock cylinder 13-2
V72 – Solenoid valve differential lock 13-2
V75 – Damping valve 13-3
V123 – Drive valve TH7 M-Drive 13-3
132 Electrical system 13-4
B006 – Temperature sensor engine 13-4
K001 – High current relay 13-4
K002 – High current relay F026 13-5
K006 – Pre-heat relay 13-5
K007 – Start high current relay 13-6
K010 – Turn indicator relay 13-7
K042 – Switching relay of the engine electronics 13-7
K058 – Switching relay of 1st/2nd speed range 13-8
K088 – Switching relay of the diesel feed pump 13-8
K089 – Switching relay of the DPF pump 13-9
K090 – Switching relay of the DPF glow plug 13-9
K109 – Roll-in stop relay 13-10
S002 – Engine oil pressure switch 13-10
S005 – Hydraulic oil filter clogging pressure switch 13-11
S006 – Hydraulic oil temperature switch
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M