Wacker Neuson 8009640011 Operation & Maintenance Manual Download

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OPERATION & MAINTENANCE

MANUAL

Skid Steer

Loader

W10

Item

800964

0011

Revision

101

Date

March 2022

Summary of Contents for 8009640011

Page 1: ...OPERATION MAINTENANCE MANUAL Skid Steer Loader SW10 Item 8009640011 Revision 101 Date March 2022 ...

Page 2: ...cation involved Designs and texts may disagree more or less obviously with some technical characteristics of the machine in this case contact the manufacturer before proceeding In the manual and if necessary on some parts of the machine certain symbols are used followed according to the case by messages inherent to safety For more attentive and easier reading of these follow the warnings as descri...

Page 3: ...OLS P a g e DRIVER S SEAT 16 SAFETY BELTS 16 SAFETY BAR 16 CONTROLANDAUXILIARYINSTRUMENTS 17 MACHINESTARTINGANDSTOPPING 22 MOVEMENTANDDRIVING 23 USEOFTHEMACHINE 27 EQUIPMENT ACCESSORIES P a g e 31 32 32 34 SHOVELREPLACEMENTORREPLACEMENTOFOTHER ACCESSORIES PREPAREDFORQUICKFITTING HYDRAULIC POWER TAKEOFF P T O DRIVING CABIN USEOFLIFTINGFORKS SUPPLIESANDEQUIPMENTS 35 MAINTENANCE P a g e 36 39 40 41 4...

Page 4: ...for heavy duty and or particular use bolt in replacement of the 4 eye bolts MACHINE IDENTIFICATION The machine is fitted with a special plate carrying the identification data of the machine riveted to the left front side of the frame For any queries always quote the type and serial number stated on the plate For further explanations please consult the modes on the Spare Parts Manual attached to th...

Page 5: ...100 Autonomy About hours 8 HYDRAULIC SYSTEM HYDRAULIC SYSTEM Hydrostatic transmission with n 2 variable capacity pumps that each power n 2 fixed cylinder hydrostatic motor reducers Negative command brakes on the motor reducers of the front axle wheels Main variable cylinder axial piston pump Lt min 57 4 x 2 Auxiliary gear pump Lt min 39 x 1 Total capacity Lt min 153 8 Useful capacity for power tak...

Page 6: ... and the key removed from the ignition The body must be level Position the machine at the rear of the truck ensuring that the longitudinal axle coincides with that of the truck Check that the ramps are suitable for the vehicle to be loaded Only use homologated and or certified ramps Check that the ramps are perfectly clean and free of grease and that there is no risk whatsoever of the tyres Check ...

Page 7: ...latform with a truss or other equipment Before ascending or descending check perfect alignment between the tyres and the ramps Do not steer or adjust direction while on the ramps If necessary return to the point of departure repositioning correctly Caution of passage in the connection area between the ramps and the loading platform of the truck the steep slope must be negotiated by moving very slo...

Page 8: ...achine by fixing them to the special seats located on the roof of the cabin If the eyebolts are removed close the four seats with the plastic caps supplied Any infiltration of water could seriously damage the electrical system of the right hand and left hand dashboard Restrict the lifting area prohibiting access to foreign personnel Do not pass over persons or things and ensure that the loading ar...

Page 9: ... be blocked Involuntary lifting of arms is prevented by the hydraulic block inserted on start up of the machine Disconnection and insertion is controlled by a button Fig 1 ref 4 on the right command panel Obligation for approved yellow flashing light This functions even when the use of a lighting device is not obligatory Front loading shovel in max lifting position and blocked to the frame using t...

Page 10: ...the vehicle these signal a potential danger and point out the precautions to take to prevent it If the warning message is not fully understood ask for an explanation from your employer or from your authorised dealer For the entire period of use of the machine be aware of the possible dangers and take care to prevent them Inobservance of the regulations for use and maintenance make the machine dang...

Page 11: ...propriate temperature It is recommended to drive the machine at 60 70 of its power for the first 100 hours Before starting to drive or activate the equipment ensure that there is nobody in the sur rounding working area Should anyone enter into the manoeuvring zone stop the machine On carrying out work on site the overall height and width of the machine must always be taken into consideration The l...

Page 12: ...f the rubber seal and remove the insert it includes Push the glass towards the outside with force ref 2 and exit from the vehicle The rear window safety exit is not suitable for use in environments where polar clothing is required N B In machines equipped with a front door which also becomes an emergency exit act as follows Pull the special peg ref 3 positioned in the upper central part of the gla...

Page 13: ...ovel must always be upstream both in ascent and in descent The empty shovel must always be downstream both in ascent and in descent The load must always be as low as possible Avoid travelling over land where lateral and longitudinal slopes are both present Never pass across slopes Ascent and descent must be carried out by following the slope in a straight line and not at an angle or in an oblique ...

Page 14: ... the machine to keep persons away MAKING THE LIFTING ARMS SAFE MAKING THE LIFTING ARMS SAFE MAKING THE LIFTING ARMS SAFE MAKING THE LIFTING ARMS SAFE MAKING THE LIFTING ARMS SAFE If the machine malfunctions or blocks with the arm raised it is necessary to make them safe by bringing them to the ground This is a very delicate operation that must be carried out by following the indications below 1 Th...

Page 15: ... lubricants Do not weld grind smoke or light flames near to the battery or fuel tank When replacing the battery follow the indications supplied in the relative chapter Always keep the machine clean and check any type of leak that may occur Check efficiency and integrity of the electric plant possible cause of starting a fire Always clean the machine well after use as deposits of inflammable debris...

Page 16: ...e belt from the fixed part plac ing it to the right of the driver SAFETY BAR SAFETY BAR SAFETY BAR SAFETY BAR SAFETY BAR Every machine is equipped with a safety bar that together with the safety belts and cabin in compliance with ROPS and FOPS makes up the operator s safety girdle The machine must always be driven with safety bar lowered and safety belts fas tened FUNCTIONSOFTHESAFETYBAR A SAFETY ...

Page 17: ...R CONTROL OL OL OL OL AND AND AND AND AND A A A A AUXILIAR UXILIAR UXILIAR UXILIAR UXILIARY INSTR Y INSTR Y INSTR Y INSTR Y INSTRUMENTS UMENTS UMENTS UMENTS UMENTS CONTROL PANEL 17 Fig 1 Fig 1 Fig 1 Fig 1 Fig 1 OPERATOR CONTROLS ...

Page 18: ...ED SWITCH FOR POWER TAKE OFF P T O CONTROL INSERTED Deactivates the command on the RIGHT manipulator 4 LIFTING ARM SAFETY ACTIVATION AND DEACTIVATION SWITCH ALWAYS insert with the engine switched on and the safety bar lowered Press it again for deactivation 5 2 POSITION SWITCH WITH MECHANICAL INTERLOCK FOR ACTIVATION OF LIFTING ARM FLUCTUATION FUNCTION ROUND LEVELLING can only be activated with th...

Page 19: ...ing light switches off 7 4 ENGINE COOLING LIQUID TEMPERATURE WARNING LIGHT The warning light signals anomalous functioning of the diesel engine cooling plant 7 5 GENERATOR CHARGE INDICATOR OFF in normal operating position goes off immediately after starting When ON it signals malfunctioning in the battery recharging system 7 6 ENGINE OILPRESSURE INDICATOR When this indicator comes on it signals ma...

Page 20: ...nctioning of the four direction indicators Insert the switch every time a potential danger exists and in EMERGENCY situations 10 FLASHLIGHT DEVICE SWITCH Commands the device positioned above the cabin connected through a plug at the side of the left working light ALWAYS SWITCHED ON DURING CIRCULATION ON ROADS 11 WORKING LIGHT SWITCH Commands the working lights situated on the front part of the cab...

Page 21: ...tion fuse 7 5A F7 Power take off PTO protection fuse 10A F8 Alternator excitement protection fuse 5A F9 Engine shutdown protection fuse 30 15A F10 Radio and emergency lights protection fuse 30 10A F11 Position lights right line protection fuse 5A F12 Position lights right line Position lights right line number plate light protection fuse 5A F13 Headlights protection fuse 10A F14 Protection fuse 15...

Page 22: ...e atmospheric conditions and climatic Start up can only be carried out with the safety bar raised Position A Do not allow unauthorised persons to drive the machine Remember that the responsibility for the machine lies with the person who has received it Do not start using the machine until sure of its functioning It is a good rule to practice in an open and clear area when manoeuvres in which expe...

Page 23: ...IVING Traversing of the machine is controlled by the left joy stick The various joy stick positions depending on the manoeuvre to be carried out are represented below STRAIGHT LINE MOVEMENT Position A FORWARD movement Position B REVERSE movement an acoustic safety device is activated ...

Page 24: ...24 OPERATOR CONTROLS Position H PROGRESSIVE RIGHT TURN IN FORWARD MOVEMENT Position G PROGRESSIVE LEFT TURN IN REVERSE MOVEMENT an acoustic safety device is activated Position E 90 LEFT TURN ...

Page 25: ...ESSIVE LEFT TURN IN FORWARD MOVEMENT Position D PROGRESSIVE RIGHT TURN IN REVERSE MOVEMENT an acoustic safety device is activated CONTROL OF THE LIFTING ARM Position I ARMS DESCENT Position L ARMS ASCENT OPERATOR CONTROLS ...

Page 26: ...26 OPERATOR CONTROLS SHOVEL CONTROL Position M SHOVEL CLOSURE Position N SHOVEL OPENING COMMANDS ON RIGHT AND LEFT JOY STICK GRIP O HORN control button P Q Power take off P T O control button ...

Page 27: ...ile and at the same time turn the shovel backwards until it is completely filled 4 Raise the lifting arms to just above the stock pile 5 Pull back lower the lifting arms and move with the shovel low towards the place of unloading EMPTYING During transfer to the unloading area the shovel must be positioned as low as possible and in maximum collection position Transfer must be carried out at a moder...

Page 28: ...ND The machine is equipped with a floating valve which renders the lifting arms idle This function is very important for levelling the ground as the arms and the bucket always follow the course of the ground and with repeated op erations it is possible flatten and level material of the desired thickness parallel to the ground Raise the lifting arms inclining the shovel forward until obtaining an a...

Page 29: ...cavator therefore dig ging is only allowed on loose ground without stones and masses and which is generally easy to penetrate with the shovel To start digging turn the shovel downward until it slightly touches the ground after which ad vance slowly continuing to turn the shovel downwards until it penetrates the ground Advance turning the shovel slightly backwards until it is filled When the shovel...

Page 30: ... and turn the shovel com pletely forward to unload all of the previously accumulated material Pull back and repeat the operation until the ground has been levelled Regarding loading capacity of the shovel refer to the data supplied in the TECHNICAL FEATURES AND DATA chapter Do not overload the shovel An excessive load could cause loss of control or overturning of the machine with serious risks for...

Page 31: ...achment lever to the outside 2 When the shovel has been attached raise the lifting arms so that the shovel moves away from the ground and turn the attachment device backwards allowing the shovel to rest on its base 3 Turn the levers inwards to block the shovel on the attachment base SHOVEL RELEASE To release the shovel proceed as follows 1 Rest the shovel on the ground 2 Open the attachment lever ...

Page 32: ...SE Release is obtained by pulling back the female coupling brace and pulling out the male coupling DRIVING CABIN DRIVING CABIN DRIVING CABIN DRIVING CABIN DRIVING CABIN The standard machine is equipped with an open cabin which on request can be completed with a front lockable door windscreen wipers and a heating system with n 2 orientable vents for the emission of hot air inside the cabin These ve...

Page 33: ...e for functioning of the plant open tap R posi tioned above the diesel engine corresponding to the alternator POSITION A CLOSED POSITIONB OPEN The cabin and driver s position are adequate for use in normal climates it is prohibited to use the machine with polar clothing POSITION A POSITION B 13 EQUIPMENT AND ACCESSORIES ...

Page 34: ...eding with unloading as well as checking the compatibility of the load with the maximum load admitted it is necessary to alternate in tracts descent with a backward rotation of the forks at least 4 5 times to maintain the load in a horizontal position or slightly orientated towards the cabin Always block the forks to the fork support plate and the latter to the machine s quick fitting in a way tha...

Page 35: ...QUIPMENT SUPPLIES AND EQUIPMENT STANDARD EQUIPMENT ROPS and FOPS 1st level open cabin Power take off PTO with quick fitting with electric control for use of optionals Floating valve to ad just the shovel to the ground Quick fit for bucket Front working lights Reverse gear alarm OPTIONAL EQUIPMENT Cabin door Lateral window Heating plant 2nd level FOPS Self levelling valve for parallel lifting of sh...

Page 36: ...ning operations must be carried out with the engine cold using where possible a jet of pressurised water Do not use solvents or similar substances to prevent damaging the guards gaskets etc and the paintwork Do not dispose of the oil and other liquids leaked during the maintenance operation in the environment Collect it and send it to an authorised waste disposal It is advisable to equip an area d...

Page 37: ...3 7 MAINTENANCE Analogue safety system ref 3 fixed inside of the engine hood which must be installed every time the shovel lifting arms are raised to prevent uncontrolled descent ...

Page 38: ...ated in the Manufacturer s Use and Maintenance booklet for the engine installed on the machine The RE FUELLING TABLE states the quantity of liquids lubricant and supplies for the necessities of all individual machine parts The oils and lubricants used to supply the machine on delivery are AGIP PETROLI do not top up with oils or liquids that are different from those recommended Complete replacement...

Page 39: ...TS GREASE POINTS GREASE POINTS GREASE POINTS GREASE POINTS In the scheme beside are indicated the principal greasing points they must be supplied every 8 hours except for those with a different indication MAINTENANCE ...

Page 40: ...f the lubricant When the operation has been completed and before switching off the engine lower the machine arms laying the bucket on the ground and inserting a piece of wood Then again fill the fuel tank with diesel fuel Completely change the oil of the diesel engine hydraulic system and wheel reduction gears taking care to replace the various filters Dismantle the battery checking the level top ...

Page 41: ...eriodically check and clean the air filter Check and clean the terminal board of the alternator and the starter Clean the water oil radiator Rocky terrain Use the machine with caution carry out manoeuvres and movements gently to prevent damaging of the tires or the rubber tracks If possible use reinforced buckets Before starting the operating phases check the articulations joints pins and fastenin...

Page 42: ...e total could be a sign of leakage of the reducer The first oil change must be carried out after 100 hours of functioning The following changes after 1000 hours or at least once a year Per capacity and type refer to the LUBRICANT TABLE The reducer must be emptied immediately after functioning with the oil still hot to prevent impurities from depositing Pay particular attention during emptying as t...

Page 43: ... made easier by dismounting the tyre after having fixed the machine opportunely SER SER SER SER SERVICE VICE VICE VICE VICE EMER EMER EMER EMER EMERGENCY GENCY GENCY GENCY GENCY AND P AND P AND P AND P AND PARKING BRAKE DEVICE ARKING BRAKE DEVICE ARKING BRAKE DEVICE ARKING BRAKE DEVICE ARKING BRAKE DEVICE The braking device is only mounted on the front reducers A HYDRAULIC POWERATTACHMENT B OIL CH...

Page 44: ...TENED CORRECTLY IN PARTICULAR ON THE FRONT REDUCERS IT DOES NOT ALLOW THE MACHINE TO SHUTDOWN TOWING THE MACHINE TOWING THE MACHINE TOWING THE MACHINE TOWING THE MACHINE TOWING THE MACHINE In emergencies it is possible to tow the ma chine by acting on screw F positioned at the centre of every motor reducer Unscrew the screws of the four wheels until complete mechanical disconnection of the transmi...

Page 45: ...ap E is on the left tank and is accessible by opening the engine hood A special indicator Fig 1 ref 1 on the dashboard signals when it goes into reserve Avoid emptying the tank completely since due to the air entering the system the diesel engine would fail to start once refilled if the circuit is not drained beforehand When filling the tank with fuel use a funnel fitted with a very fine metallic ...

Page 46: ...engine is cold If the cap of the expansion tank A of the cooling liquid positioned at the side of the radiator is still hot use a protective glove or rags soaked in cold water Never place the face over the cap when opening DANGEROFBURNS DANGER OF SCALDING The engine cooling liquid is maintained at a service temperature using a fan positioned beneath the radiator and is activated by a hydraulic eng...

Page 47: ...oil use supplied funnel 2 To drain off used oil use the relative discharge pipe 3 prepared on the engine and orientated in a way to discharge through the opening in the floor of the frame into a container with adequate capac ity Never dispose of used oil in the environ ment it must always be disposed of through Authorised Companies ENGINE AIR SUCTION PLANT The air filter A is positioned in the rea...

Page 48: ...s 8 8 To facilitate the fastening operations the table on the side lists the driving torques according to the relevant dimension and class of resistance 3 Turn cartridge D alternately forwards and backwards pulling it towards the back to release it from its seat 4 Clean cartridge D by blowing dry air at a pressure not higher than 3 bar from the inside towards the outside at a distance of 3 4 cm fr...

Page 49: ...ir maxi mum extension In these conditions the oil level should not be below the minimum mark The engine must be off The oil must be at operating temperature around 60ºC For top ups unscrew the cap and use a funnel in order to introduce the oil and this should be car ried out very slowly The capacity of the tank alone at max level is 30 litres EXAUST FILTER REPLACING Positioned on the right interna...

Page 50: ...etection of pressures for traversing are positioned on the left side of the transmission pump visible with the cabin raised points 1 2 3 4 POINT 1 FORWARD movement left wheel POINT 2 REVERSE movement left wheel POINT 3 FORWARD movement right wheel POINT 4 REVERSE movement right wheel The attachment for detection of plant service pressures point 5 must be positioned at the end of the flanged connec...

Page 51: ... bar SERVICES detection point 5 arms and bucket 180 bar SERVO CONTROLS detection point 6 joy stick 24 bar Do not arbitrary modify the valves calibration values because they could the reason of malfunctionings or damages which could compromise the machine safety MAINTENANCE ...

Page 52: ...ious burns Always ensure perfect closure of the filler plugs Do not completely discharge the battery In case of fast discharge check the voltage regulator In the negative case recharge the battery or replace it The liquid contained in the battery is highly corrosive Protect the eyes and hands during the inspection and top up phase Maintain the cable terminals well fastened and protected with greas...

Page 53: ...ot and sheltered place REMOVE THE PROTECTION BEFORE START UP DANGEROFFIRE The machine is fitted with a switch located in the engine compartment which allows disconnecting the battery for any EMERGENCY and in case of extended stops more than 4 hours Always contact authorised workshops for battery recharging MAINTENANCE ...

Page 54: ... 21 W base BA 15S 3 WORKINGLIGHTS BULB 12 V 50 W base GE 886 4 FLASHING LIGHT BULB 12 V 55 W base H1 5 NUMBERPLATELIGHT BULB 12 V 5 W base SV 8 5 8 6 REARDIRECTIONINDICATORS BULB 12 V 21 W base BA 15S 7 REAR STOP LIGHTS BULB 12 V 21 W base BA 15S 8 REARPOSITIONLIGHTS BULB 12 V 4 W base BA 9S 9 REARREFLECTORS MAINTENANCE ...

Page 55: ...YPE BRAND and TYPE Q Q Q Q Q ty ty ty ty ty FUEL TANK HYDROSTATIC AND HYDRAULIC SYSTEM TRAVERSINGMOTOR REDUCERS DIESEL ENGINE ENGINERADIATOR ARTICULATIONS PINSAND BUSH INGS FIFTHWHEEL DIESELFUEL OIL AGIPARNICA46 AGIP ROTRA MP 80W90 OIL AGIP SIGMA S SAE 30 OIL AGIPANTIFREEZE COOLINGLIQUID GREASE AGIP GR SM 42 lt 30 lt 0 7 lt cad 6 0 Kg 9 0 lt S E TYPE OF TYRE 27X8 50 15 27X8 50 15 27X8 50 15 27X8 5...

Page 56: ...EL FILTER CUP DIESEL FUEL TANK HYDRAULIC OIL TANK ENGINE OIL LEVEL COOLANT LEVEL BATTERY LEVEL HYDRAULIC OIL LEVEL AIR FILTER Stoppage spy WHEEL REDUCTION GEAR OIL LEVEL TIGHTNESS NUTS AND SCREWS ALTERNATOR BELT FIFTH WHEEL PINS AND ARTICULATED JOINTS ELECTRICAL AND HYDRAULIC CIRCUIT ENGINE OIL ENGINE OIL FILTER CARTRIDGE DIESEL FUEL FILTER CARTRIDGE DIESEL PRE FILTER HYDRAULIC OIL AND IN TANK FIL...

Page 57: ... INCORRECT ENGINE OIL LACK OF FUEL FUEL FILTER CARTRIDGE BLOCKED FUEL SUPPLY PIPES DAMAGED SAFETY BAR LOWERED CONNECT RECHARGE REPLACE CLEAN CONNECT TIGHTEN REPLACE FUSE INSPECT AND REPLACE IF NECESSARY CLEAN OR REPLACE THE FAULTY COMPONENT RELEASE AIR DRAINING CLEAN TANK REPLACE USE RECOMMENDED OIL CHECK AND TOP UP REPLACE INSPECT AND REPLACE IF NECESSARY RAISE AIR OUTLET CLOGGED DIRTY OR FAULTY ...

Page 58: ...GINE COOLING FAN TOP UP INSPECT CALL AN AUTHORISED WORKSHOP INSPECT CLEAN OR REPLACE CLEAN REPLACE INSPECT REPLACE INSPECT AND IF NECESSARY REPLACE THE COMPONENT CONCERNED CHECK TOP UP INSPECT REPLACE INSPECT REPLACE INSPECT REPLACE INSPECT REPLACE ENGINE OVERHEATING STOP IMMEDIATELY CAUSE REMEDY FAULTY INJECTORS ACCELERATOR BROKEN POOR COMPRESSION INSUFFICIENT POWER SUPPLY continues IRREGULAR FUN...

Page 59: ...E LINEARLY WITHOUT FORCING THE CONTROLS IN PARTICULAR WITH CYLINDERS AT END OF TRAVEL HYDRAULIC OIL OVERHEATING COOL FOR THE APPROPRIATE TIME SLOW MOVEMENT OF HYDRAULICALLY CONTROLLEDPARTS insufficient performance follows CAUSE REMEDY ALTERNATOR DOES NOT RECHARGE ELECTROLYTE LEVEL LOW TERMINALS LOOSE OR OXIDISED ALTERNATOR BELT FAULTY CHECK BELT TENSION EFFICIENCY RE PLACE ALTERNATOR CALL AN AUTHO...

Page 60: ...ORISED WORKSHOP continues SLOWMOVEMENT OF HYDRAULICALLY CONTROLLED PARTS insufficient performance FAULT INCORRECT HYDRAULIC OIL HYDRAULIC OIL LEVEL LOW CYLINDER SEALS WORN MAX PRESSURE VALVES FAULTY REPLACE USE RECOMMENDED OIL CHECK AND RESTORE IF NECESSARY INSPECT AND REPLACE IF NECESSARY CHECK CALIBRATE AND REPLACE IF NEEDED LOW OR NO PRESSURE IN THE PLANT INSPECT AND REPLACE IF NECESSARY CALL A...

Page 61: ...NECESSARY CALL AN AUTHORISED WORKSHOP INSPECT AND REPLACE IF NECESSARY ONE OF THE SERVOCONTROLS DOES NOT FUNCTION SEALS WORN OR DAMAGED OIL LEAK PIPES CONNECTORS DAMAGED DISTRIBUTOR VALVE DAMAGED ONE OF THE CYLINDERS DOES NOT FUNCTION OR FUNCTIONS SLOWLY INSPECT AND REPLACE IF NECESSARY CHECK RESTORE INSPECT AND REPLACE THE COMPO NENT CONCERNED IF NECESSARY INSPECT AND REPLACE IF NECESSARY CALL AN...

Page 62: ...DOES NOT FUNCTION HYDRAULIC MOTOR DAMAGED FEED VALVE DAMAGED PIPES CONNECTORS DAMAGED TRANSMISSION DISENGAGEMENT SCREW LOOSENED INSPECT AND REPLACE IF NECESSARY CALL AN AUTHORISED WORKSHOP INSPECT AND REPLACE IF NECESSARY CALL AN AUTHORISED WORKSHOP INSPECT AND REPLACE THE COMPO NENT CONCERNED IF NECESSARY CHECK AND EVENTUALLY TIGHTEN CORRECTLY PUMP FAULTY OR BROKEN MOTOR REDUCER FAULTY OR BROKEN ...

Page 63: ...6 3 MAINTENANCE NOTES PARTS CONCERNED D A T E WORK DONE HOURS WORKED ...

Page 64: ...64 PARTS CONCERNED D A T E WORK DONE HOURS WORKED MAINTENANCE NOTES ...

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