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Wacker Neuson WL 30, Operator'S Manual

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Wacker Neuson WL 30 Operator'S Manual Download Page 218

TROUBLESHOOTINg A ND E ME RgE NCY M AINTE NA NCE

216

Fault / malfunction

Possible cause

Remedy

Engine does not start

Handbrake not set, drive direction switched

Set the handbrake, shift to neutral

Fuel reservoir empty

Fill up the reservoir and vent the fuel system if 

necessary

Fuel filter clogged, paraffin separation in winter Change the fuel filter, use winter diesel

Release solenoid on the engine does not at-

tract

Check the fuses

Fuel line is leaky

Retighten all the threaded connections and 

clamps

Starting speed too low

Check and charge the battery, check that bat-

tery terminals fit tightly

Engine is running but loader 

will not drive

Set the handbrake

Release the handbrake

Handbrake switch is defective

Replace the handbrake switch

Inch cartridge is not in neutral position

Check and, if necessary, repair the inch car-

tridge and brake shoe return spring

The solenoids on the transmission pump are 

not getting any power

Check the fuses, and have the multi-function 

lever and the electronics checked at the ga-

rage

11 

TROUBLESHOOTING AND EMERGENCY MAINTENANCE

Summary of Contents for WL 30

Page 1: ...www wackerneuson com Operator s Manual Wheel Loader WL 30...

Page 2: ...December 10 Edition...

Page 3: ...on to the information regarding operation this Operator s Manual also contains important maintenance and op erating instructions for conserving the value of your loader Furthermore we will show you ho...

Page 4: ...19 2 3 Safety instructions for certain operating phases 20 2 3 1 Safety instructions for normal operation 20 2 3 2 Safety instructions for other operating modes 22 2 4 Safety instructions for particu...

Page 5: ...disconnect switch 39 2 8 7 Loader lift arm locking system 40 3 TECHNICAL DATA 41 3 1 Technical description 41 3 2 Loader data 43 3 3 Product identification number plates 45 3 4 Dimensions 46 4 DESCRI...

Page 6: ...ation and heating of the cab 76 5 2 5 Before starting the engine 77 5 2 6 Starting the engine 78 5 3 Propulsion operation 80 5 3 1 Preparation for travel in public traffic 80 5 3 2 Travel speed 81 5 3...

Page 7: ...g and inspection 130 10 2 Servicing and inspection intervals 138 10 3 Lubrication schedule 150 10 4 Cleaning the loader 152 10 5 General safety check 154 10 6 Specifications and filling quantities 155...

Page 8: ...gency starting 210 10 9 Loader storage 213 11 Troubleshooting and emergency maintenance 216 12 Safety instructions for repairs 220 12 1 General safety regulations for repairs 220 12 2 Engine 223 12 3...

Page 9: ...Manual with instructions and regulations regarding environmental protection and national regulations relating to accident prevention All persons involved in work on or with the loader must read and a...

Page 10: ...place of use Keep the Operator s Manual in the protected compart ment provided in the operator station cab 1 BASIC INFORMATION If it is not possible to rule out hazards to persons or material during...

Page 11: ...strictly observe the safety instructions in this Opera tor s Manual and the legal and trade association regulations at the usage location This Manual provides information and procedures to safely oper...

Page 12: ...e hazards and instructions This is the safety alert symbol It is used to alert you to potential personal hazards Obey all safety messages that follow this sym bol DANGER DANGER indicates a hazardous s...

Page 13: ...at follow this symbol to avoid possible minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a situation which if not avoided could result in property damage Important...

Page 14: ...and protection de vices are intact Observe the monitoring systems during operation Repairs may only be perform by trained professionals Follow the Operator s Manual exactly The manufacturer supplier i...

Page 15: ...rial by moving the loader forward taking into account the safety instructions regulations and time periods listed by Wacker Neuson in the Operator s Manual One work cycle consists of picking up liftin...

Page 16: ...anual The instructions describe how to operate main tain inspect and adjust the wheel loader safely The repair manual provides additional instruction for safely diagnosing malfunctions and repairing t...

Page 17: ...BASIC INFORMATION 15 WL30...

Page 18: ...rviceable condition Observe the operating instructions described in this Operator s Manual and all applicable work site safety regulations Observe the permissible payloads Wheel Loaders may only be us...

Page 19: ...ement the Operator s Manual with instructions including supervisory and reporting requirements taking into account differences between various companies e g with regard to the organization of work wor...

Page 20: ...l Loader Repair Manual describes the special tools diagnosis techniques repair sequence proce dures lifting and supporting devices needed to repair this machine To avoid unnecessary hazards and possib...

Page 21: ...oader must be qualified to operate the machine through demonstration of com prehension of the operating instructions No one shall operate the wheel loader if impaired due to intoxication or drug react...

Page 22: ...l loader position the loader bucket or accessories before moving the machine Re confirm that there are no people in the work or travel area before moving the machine The safety instructions are direct...

Page 23: ...ability This also includes the duty to pass on information regarding the approved carrying capacity payload for the relevant loader at tachments carrying capacity approved payload are specified in the...

Page 24: ...f the wheel loader function and attachments Do not attempt to perform maintenance or repair on the wheel loader until the machine and engine is stopped and all attachments are in a stable position Do...

Page 25: ...bing aids Keep all handles steps pedestals platforms and ladders free of dirt snow and ice Clean the entire loader especially the connections and threaded connections with oil fuel or care prod ucts w...

Page 26: ...ting structure base or mounting hardware is damaged consult your Wacker Neuson dealer for assistance Do not attempt to repair straighten or reuse a damaged ROPS or FOPS Responsibly dispose of the unwa...

Page 27: ...objects can strike the operator Do not transport large bales or packaged goods without a FOPS operator canopy or cabin Ensure that large loads are properly secured and supported See ANSI B56 1 OSHA19...

Page 28: ...e occurs Do not leave the loader until the electricity has been disconnected and a qualified technician directs the op erator to leave the machine If feasible drive the loader away from the danger are...

Page 29: ...pair by a qualified technician before resuming operation Replacement fuses shall be of the same type and capac ity as specified by the manufacturer in the Operator s and Repair Manuals Do not attempt...

Page 30: ...rs e g poisonous gases corrosive steam poison ous i e containing toxins surroundings etc 2 4 6 Hydraulics pneumatics When detected oil leaks shall be repaired to avoid environmental hazards fire hazar...

Page 31: ...ion Wait until hot surfaces have cooled and can be touched comfortably Smoking and open flames are prohibited during fueling Danger of fire or explosion 2 4 7 Tip overs WARNING Personal injury hazard...

Page 32: ...apacity and OSHA lifting devices to safely complete the lifting operation Only restart the loader according to the Operator s Manual See Chapter 6 for complete transporting and towing instructions 2 6...

Page 33: ...g 3 Location of the Safety labels 2 7 Safety labels used Maintain all safety message labels on the machine in a legible manner If a safety label becomes dam aged or illegible replace it with a new lab...

Page 34: ...1 Warning Do not stand near the loader during operation Do not go under the loader lift arms when raised Safety label 2 Shearing hazard Shearing hazard from rotating fan Stop the engine before enterin...

Page 35: ...any work activity on the wheel loader Safety label 6 Important Lubricate the center joint daily before beginning work Refer to your Opera tor s Manual for more information Safety label 7 Warning Hot...

Page 36: ...l 11 Warning Pinching crushing hazard Avoid the ar ticulation area while the Wheel Loader is in operation Before working in the articulation area and before transport ing secure the articulation pivot...

Page 37: ...maged they can not serve their protective function Never drill or weld the ROPS FOPS protective structures Refer to Operator s Manual Hot liquids or steam escaping under pressure can cause burns Do no...

Page 38: ...acon on and off see the chapter Switches rocker switches Use the yellow rotating beacon according to local regulations Contact your Wacker Neuson dealer if you want to install a fire extinguisher or a...

Page 39: ...ctional ity and serviceability repairing or replacing if necessary fasten the seat belt and adjust to contact the lower torso firmly When not in use store the seat belt by placing it across the seat p...

Page 40: ...cy exit Fig 7 Emergency exit The cab door on the left side of the machine fac ing the forward direction of travel is the primary access system to the operator station The right hand access is a second...

Page 41: ...y is a means of resisting machine theft Turn the switch lever counter clockwise The battery is disconnected from the electrical system Turn the switch lever clockwise The battery is connected to the e...

Page 42: ...This can result in loss of machine control with possible injury to the operator and other work site persons Always lock the loader lift arm control to prevent inadvertent activation during travel The...

Page 43: ...raulics provide power to the transfer gear box by a directly attached hydraulic motor The rear axle is integral with the transfer gear box The front axle is powered by a driveshaft connecting the tran...

Page 44: ...r capability of the diesel engine Since the input power is limited to the diesel engine output increased demands from traversing a grade or loading the bucket will result in speed reduction which incr...

Page 45: ...eptacle lifting and tipping cylinders and the appropriate attachments The loader is equipped with a rollover protective structure ROPS 3 2 Loader data Engine 4 cylinder Perkins diesel engine Output 35...

Page 46: ...Working pressure 450 bar 6527 psi Working hydraulics Flow rate 49 l min 12 94 gallons min Working pressure 210 bar 3046 psi Steering hydraulics Flow rate 49 l min 12 94 gallons min Working pressure 19...

Page 47: ...n the right side of the rear end near the entry area Fig 10 1 Furthermore the following loader components each have their own rating plate The diesel engine The axial piston variable displacement pump...

Page 48: ...TECHNICAL DATA 46 3 4 Dimensions Fig 11 Dimensions...

Page 49: ...26 33 inch G Height of seat 1254 mm 49 37 inch H Max dumping height 2416 mm 95 12 inch I Scraping depth 26 mm 1 02 inch K Reach at H 334 mm 13 15 inch L Height to top of cab 2251 mm 88 62 inch Item De...

Page 50: ...iption of the indicator warning and control elements 48 4 DESCRIPTION OF THE INDICATOR WARNING AND CONTROL ELEMENTS 4 1 Operating elements and instruments Fig 12 Operating elements 1 2 3 4 5 6 7 8 9 1...

Page 51: ...strument panel 3 Steering wheel 4 Accelerator 5 Operating lever for load arm drive 6 Operating lever for optional hydraulics 7 Operating lever for parking brake 8 Operator s seat 9 Braking inching ped...

Page 52: ...achine If an indicator light illuminates during operation move the machine to a safe place lower the loader arms and stop the engine Do not operate the wheel loader until the reason for the illuminate...

Page 53: ...re Illuminates when engine oil pressure is too low 5 Warning light for generator Illuminates if the battery is not charged 6 Warning light for engine temperature Illuminates when engine temperature 7...

Page 54: ...ring operation move the machine to a safe place lower the loader arms and stop the engine Do not operate the wheel loader until the reason for the illuminated indicator is determined and corrective ac...

Page 55: ...beam is switched on 13 Not used No function 14 Air filter indicator light Illuminates when the air filter is contaminated 15 Turn signal indicator light Illuminates when a turn signal is on 16 Warnin...

Page 56: ...Description of the indicator warning and control elements 54 4 3 Switches rocker switches Fig 14 Switches rocker switches 1 1 2 3 4 5 6 7 8...

Page 57: ...n order to release the hydraulic locking device for attachments 3 Rocker switch for hazard warning lights Switches hazard warning lights on off 4 No function Available for optional equipment Switches...

Page 58: ...Description of the indicator warning and control elements 56 9 10 11 12 13 14 Switches rocker switches Fig 15 Switches rocker switches 2...

Page 59: ...dshield wipers on off 10 Rocker switch for rear windshield wipers Switches rear windshield wipers on off 11 Rocker switch for front headlights Switches front headlights on off 12 Rocker switch for rea...

Page 60: ...s 2 4 3 1 Item Designation Function Symbol 1 Fuel gauge Shows the fuel quantity 2 Tachometer Shows the diesel engine s rpm 3 Hour meter Adds up the loader s operating time Plan your service work and i...

Page 61: ...Description of the indicator warning and control elements 59 WL30...

Page 62: ...before operating the wheel loader After prolonged storage or inactivity refer to the procedure for preparing to operate the loader Lower the loader lift arms and attachment to the ground and stop the...

Page 63: ...nal high grade diesel fuel to operate the loader If at all possible use a fine filter in the filling line ENVIRONMENTAL NOTE Diesel fuel is hazardous to the environment Do not allow it to be released...

Page 64: ...fuel and coolant leaks 5 1 2 Operation WARNING Personal injury hazard Do not operate the loader if it is not in service able condition or responding correctly to control commands Park the machine in a...

Page 65: ...pressure see tire pres sure table Ensure that the engine enclosures and the caps for the fuel reservoir and hydraulic fluid reservoir are present and have been tightened Operator station access WARNIN...

Page 66: ...er Fig 19 Always check that the cab doors and windows are closed before leaving the loader Fig 18 Cab door locking Fig 19 Releasing locked cab doors CAUTION Possibility of injury or equipment damage f...

Page 67: ...20 2 Adjust the steering column as needed 3 Let go of the adjustment lever Fig 20 Adjusting the steer ing column WARNING Personal injury or property damage hazard Adjusting the steering column while t...

Page 68: ...djustment WARNING Personal injury or property damage hazard Adjusting the operator seat while the wheel loader is in operation can cause inadvertent control move ments Do not adjust the operator seat...

Page 69: ...4 Lengthwise adjustment Adjust the length setting by pulling the locking lever up wards After you have made the adjustment the locking lever should lock in the desired position The operator s seat sh...

Page 70: ...elt over your lap 3 Seat belt must not be twisted 4 Insert the seat belt tab Item 1 into the opening in belt buckle Item 3 until it clicks 5 If necessary adjust the seat belt to your body size See sec...

Page 71: ...t and then adjust the seat belt Adjusting the seat belt Adjust your seat belt so that it fits snugly Lengthening the seat belt 1 Pull the tongue clasp to draw the seat belt out to the required length...

Page 72: ...ctions are not working The warning and indicator lights display fault mes sages from the equipment All the rocker switches are switched on by moving them to the down position 5 2 1 Lighting system and...

Page 73: ...ctivated Rotate the lever toward the operator The parking light switches on Continue rotating the lever toward the operator The driving light switches on Push the lever upwards position 3 The low beam...

Page 74: ...es on Put the rocker switch Item 4 in position 2 The front windshield washer system switches on Put the rocker switch Item 4 in position 0 The windshield wipers and windshield washer system switch off...

Page 75: ...sure Fig 26 WARNING Burn and cutting shearing hazards from hot or mov ing engine parts Do not open the engine enclosure until the en gine has stopped Do not attempt to service the wheel loader until t...

Page 76: ...the cab roof on the right next to the operator s seat Item 6 and 7 Fig 27 WARNING Personal injury or property damage hazard Work ing and driving lights can blind passing motorists Do not drive on pub...

Page 77: ...n 1 The rotating beacon switches on Put the rocker switch Item 8 in position 0 The rotating beacon switches off optional equipment Front headlights Put the rocker switch Item 6 in position 1 The headl...

Page 78: ...ing column Temperature Use the left regulator Item W to adjust the temperature continuously Fig 28 Turn the left regulator Item W to the left The temperature rises Turn the left regulator Item W to th...

Page 79: ...Remove or tighten all loose objects in the cab Make sure that the cab windows and exterior mirrors are clean While in the operator s seat position the exterior mirrors so that you have a good view of...

Page 80: ...circumstances tow start the loader to start the engine This could damage the hydraulic system Turn off the engine immediately if the warning lights do not go out when the engine is running Have the ma...

Page 81: ...nst the spring pres sure level II starting 5 Let go of the key as soon as the engine starts the key will return to level I and the indicator lights will go out Check if all the indicator lights have g...

Page 82: ...ion Put the tooth guard on the bucket 2 Check the lighting system and if applicable the function of the rotating beacon Switch on the headlights 3 Adjust the attachment height for clearance with the r...

Page 83: ...k area for obstruc tions vehicles and people to avoid collisions and runover incidents All functions of the multi function lever only works if the operator has attached the seat belt firmly and comfor...

Page 84: ...vel direction switch posi tion when the loader is moving in either forward or reverse Before and after changing direction with the loader stopped confirm that the indicator lights are in agreement wit...

Page 85: ...ader s gears After start ing the engine overdrive is automatically activated Press the button The loader shifts from overdrive to crawler gear Indicator light 9 Fig 13 page 50 lights up Press the butt...

Page 86: ...eling speed by decreasing the engine speed 2 To brake the loader step on the braking inching pedal 3 To stop step on the braking inching pedal until the loader has come to a stop 4 Shift to neutral 5...

Page 87: ...er is moving will cause the moving loader to change direction abruptly Do not change the travel direction switch posi tion when the loader is moving in either forward or reverse It is not necessary to...

Page 88: ...trol response Jerky spongy or delayed control response may indicate that air has entered the hydraulic sys tem Cycle the hydraulic system a few times If the controls become smooth the air has been eli...

Page 89: ...ts prior to each work shift Check the functioning of the operating equipment Check the functioning of the brakes and warning devices Report any defects to the supervisor and when changing shifts to th...

Page 90: ...tact with the ground or surface to be back dragged En gaging float with the lift arms raised will cause rapid descent of the lift arms Do not engage the loader controls unless seated in the operator s...

Page 91: ...float position disengages Loader lift arms Pull the multi function lever Item A rearwards The loader lift arms are raised Pull the multi function lever Item A forwards The loader lift arms are lowered...

Page 92: ...onnection is for the pressure side the left hand is for the return line 5 4 2 Activating the optional hydraulics Activating the optional hydraulics using the control lever Place the optional hydraulic...

Page 93: ...s use e g broom Then you do not have to constantly hold the control lever for the optional hydraulics Move the control lever for the optional hydraulics to the left L past normal operation The lever w...

Page 94: ...l hydraulics Item 1 The left hand connection is for the pressure side the right hand is for the return line Activate the button for optional hydraulics Item 2 The right hand connection is for the pres...

Page 95: ...some attachments a depressurized return line is re quired The connection for the depressurized return line is located on the front left of the load arm Fig 36 The connection is designed in such a way...

Page 96: ...after selecting the height for the travel arms for the travel segment Do not release the loader lift arm lock until start ing the work cycle or after parking the loader and prior to lowering the lift...

Page 97: ...ease the button item 1 Fig 38 The differential lock switches off Avoid damage to the transmission Only switch on the differential lock if the wheels are not moving Only use the differential lock for l...

Page 98: ...Neuson is not liable in the event of other attachments being used Do not exceed the rated load capacity of the wheel loader as stated in the specifications Exceeding the rated capacity can create uni...

Page 99: ...ic fluid enters the eye seek immediate treatment in an emergency room Do not use an attachment unless it is in service able condition Before attempting to uncouple an attachment read the instructions...

Page 100: ...il can penetrate the skin causing infections If this occurs seek immediate emergency room treatment Oil entering the eyes must also be treated im mediately in an emergency room Coupling of attachments...

Page 101: ...raulic pres sure in the lines to enable coupling the attachment hy draulic lines 7 Insert the attachment s quick couplers in the appropriate connections for the attachment hydraulic lines on the loade...

Page 102: ...ower the attachment 2 Stop the engine and actuate the control lever for the attachment hydraulics several times in both directions to release residual hydraulic pressure 3 Disconnect the hydraulic cou...

Page 103: ...n 5 4 5 page 96 Operating element Operate the bucket using the control lever for the loader lift arms Read the chapter Operating lever for Loader lift arms Section 5 4 1 page 88 NOTICE Avoid overloadi...

Page 104: ...lever Fig 40 0 Neutral position 1 Lift 2 Lower 2a Float position 3 Tilt in 4 Tilt out 4a Float position The float position facilitates stripping during resurfacing work To do so lower the bucket with...

Page 105: ...ss more effectively the curl position of the attachment from the op erator s seat With the attachment in a horizontal position mark the place on the tipping cylinder on which the lev el indicator is l...

Page 106: ...with the bucket as close as practical to the working surface or ground to reduce the risk of tipping the wheel loader To reduce the risk of tipping the wheel loader do not raise the loader lift arms a...

Page 107: ...in this position to the location or truck where the material in the bucket is to be deposited Carry the loaded bucket low until necessary to lift it to the necessary loading height If material is to b...

Page 108: ...to avoid a large amount of wheel slip Fig 45 Resistant material Lower the bucket to the ground to lift out resistant material and tilt the bucket forwards until you have a digging angle When you driv...

Page 109: ...amage from lubrication starvation Do not operate the engine or machine after an incident until a technician has inspected and cor rected any damage resulting from the incident ENVIRONMENTAL NOTE Right...

Page 110: ...he condition and tension of the fan pulley Use engine lubricating oil of the proper viscosity class Regularly check the engine air filter Do not use starting aids such as ether The manifold heating sy...

Page 111: ...ove Hydraulic and lubricating fluids are more viscous when cold When ambient temperatures are at or near the freezing point of 0 C 32 F permit the engine drivetrain and hydraulic system to warm up at...

Page 112: ...12 to compensate for the vertical movement of the bucket or attachment as the feature moves Loader lift arm damping The loader lift arm damping is engaged by means of the pull switch adjacent to the...

Page 113: ...tivation Pull the switch Fig 47 upwards The red indicator light in the switch is illuminated Damping is engaged Do not actuate the loader lift arm bucket or attachment control Push the switch Fig 47 d...

Page 114: ...hydraulic connections do not suffice for certain attachments This feature is activated by moving the control lever adjacent to the right side of the operator s seat Fig 48 Move the control lever to th...

Page 115: ...g 49 by means of the switch Item 2 Fig 50 on the control lever The electrical connector on the loader lift arms is used to connect attachments for which certain functions must be activated electricall...

Page 116: ...ains must be of sufficient capac ity to withstand the energy imparted to the towed machine by the towing source Inspect the towing device to confirm that it is serviceable and will perform to OSHA rat...

Page 117: ...ditions are met Do not tow the wheel loader more than 500 meters 0 3 miles Do not exceed 2 km h 1 2 mph during the towing operation Transporting the wheel loader farther than 500 me ters 0 3 miles re...

Page 118: ...nal injury or equipment dam age An unsecured operator station can move or tip unexpectedly during a towing operation Do not attempt towing the wheel loader until the operator cab platform has been sec...

Page 119: ...ScrewinthestudItem1 Fig 52 untilitislevelwiththehexnut Note Turn the studs Item 1 Fig 52 no further than described otherwise parts of the valve become dam aged 4 Return the operator cab platform to o...

Page 120: ...ulation frame lock down and fit over the front locking pin Secure with spring pin An articulation frame lock is provided as illustrated in Fig 53 for preventing unintended frame articula tion during t...

Page 121: ...Towing and transporting 119 WL30 Articulation frame lock installed Fig 53 Articulation frame lock Articulation frame lock storage posi tion 1...

Page 122: ...ion lock Secure the wheel loader to the transport per the instructions in Section 9 Securing the Loader on page 129 WARNING Possibility of equipment damage or personal injury from improper lifting Con...

Page 123: ...ed with labels Fig 54 indicating the lifting points Rotate the eyelets on the rear attachment points by loosening the mounting screws Retighten the mounting screws after rotating the eyelets into lift...

Page 124: ...r and attachment Clean the wheel loader to reduce the hazard of dirt and debris falling from the machine during transport Clean the wheel loader tires loading ramp and transport vehicle load deck to r...

Page 125: ...nt points to which to tie down the loader use the towing equipment and the attachment points marked with labels Fig 56 which are located on the steps on the right and the left Fig 57 Fig 56 Tie down p...

Page 126: ...Towing and transporting 124 Fig 58 Tying down the loader...

Page 127: ...nd attachment as quickly and safely as possible If a hydraulic hose fails Avoid contact with the oil stream Working hy draulic oil can exceed 93 C 200 F causing severe burns High pressure oil streams...

Page 128: ...ening the filler neck illustration 1 Fig 59 5 Remove the preload from the drive s system by opening the return filter illustration 2 Fig 59 WARNING Personal injury hazard A fine jet of hydraulic fluid...

Page 129: ...r high pressure can pierce the skin Seek medical assistance immediately if you get hydraulic fluid in your eyes or on your skin Only trained personnel may open the load holding control valves After ma...

Page 130: ...on or insufficient mass you will have to augment the process using a control cable or ratchet straps 3 Screw the screw Item 2 back in as soon as the loader lift arms is completely lowered and retighte...

Page 131: ...the controls after the engine has stopped Secure the loader with the wheel chock Clean dirt off the loader Perform a visual inspection to make sure there are no leaks in the hydraulic system in the c...

Page 132: ...However the descriptions of work processes provide the necessary instructions only for experienced specialized technicians Keep the Operator s Manual with the loader at all times Personnel Maintenanc...

Page 133: ...rmation is provided in the separate Repair Manual Position the attachments on the ground so that no movements can occur when mechanical or hydraulic con nections are released Do not attempt any servic...

Page 134: ...id any contact with electrical or rubber prod ucts when using water or steam High pressure washers are not recommended for cleaning the inside of the cab or the opera tor station Wear appropriate prot...

Page 135: ...arms completely lowered and engine turned off there can still be considerable residual pressure in parts of the hydraulic system Residual pressure reduces gradually at first If a hydraulic system is...

Page 136: ...moisture pen etration is visible Burn hazard The operating temperature of the engine and hydraulic system fluids exceeds 93 C 200 F Contact with human skin will cause severe burns Do not touch hot flu...

Page 137: ...les of the battery This will generate extreme heat and potentially ignite explosive battery gases Personal injury hazard Battery acid is corrosive to metallic surfaces and harmful to human skin Wear p...

Page 138: ...the battery before working on the electrical system if tools spare parts etc with electrical components or contacts could touch it Always disconnect the battery before welding Diesel engine exhaust f...

Page 139: ...on work al ways reattach all the safety devices Do not start the engine until the loader is no longer be ing worked on and everyone has left the danger area Only start the engine from the operator s s...

Page 140: ...d the tire pressure Make sure all fasteners are tight Check the wheel bolts Check that the brake system is functional Check the windshield washer system Check the seat belt Check the instruments indic...

Page 141: ...eck the tension and condition of the fan belt Check the acid level of the battery Check the attachments Check the piston rods for the hydraulic cylinders Check the routing of the hoses and pipes Check...

Page 142: ...raulic cylinders for damage or dirt Check the routing of the bowden cables and electrical wiring Retighten all the fasteners Observe in particular the engine suspension axle mounting and drive shaft C...

Page 143: ...nce adjust if necessary only Perkins 1004 4 Check the functioning of the door and engine enclosure mechanisms Check ROPS cab Check the condition of the tires Change the engine oil and filter Clean the...

Page 144: ...rs Check the air filter hose Check routing of bowden cables and electrical wiring Retighten all the fasteners Observe in particular the engine suspension axle mounting and drive shaft Check the engine...

Page 145: ...ering Check the lighting system if present Check the exhaust system Check the hinge pins and joint bushings Check the center pivot bolts and bearings Check the idle speed Check the functioning of the...

Page 146: ...dro return filter Change the hydro pressure filter Change the oil in the transfer case Change the oil in the axles Are all the grease nipples lubricated Lubricate if necessary Lubricate the drive shaf...

Page 147: ...anual for the engine Perform the maintenance work listed in the inspec tion schedule depending on which interval has been reached first that is if either the number of operat ing hours have been reach...

Page 148: ...heck the routing of hoses and pipes X X Check the piston rods for the hydraulic cylinders X X Check the air filter hose X X X X Check routing of bowden cables and electrical wiring X X Retighten all s...

Page 149: ...in the hydraulic system X X Check the idle speed X X X X Check max speed when loaded and unloaded X X Check the starter and alternator engine manual X X Check the heater plugs and fuel injectors engin...

Page 150: ...n the pre filter X X Clean the fuel feed pump for Deutz engines X X Clean the air filter replace if necessary X X X X Change the hydraulic fluid X X Change the hydro return filter X X Pressure filter...

Page 151: ...ce on Industrial Safety and Health X X Required if there is a damage in the hydraulic system which is supposed to be caused by strong abrasive wear Valve clearance for Perkins 400 series 0 2 mm 0 008...

Page 152: ...he points of lubrication daily with water resistant multi purpose grease Lubricate all other moving parts such as the handbrake lever foot pedals cables etc using the oil can Fig 61 Points of lubricat...

Page 153: ...front 1 22 Large tie rod rear 1 23 Bearing for small reversing lever 1 24 Pivot point of tool attachment 2 25 Tool locking bolts 2 Item Point of lubrication Nipples 1 Engine enclosure hinges 2 2 Door...

Page 154: ...Make sure that the radiator is thoroughly clean all over Do not damage the radiator fins when cleaning the radiator with a high pressure cleaner Always cover up the suction connection of the air filte...

Page 155: ...he loader is new in the first three months only clean it with a sponge As the paintwork on the underside is not fully hard ened the paintwork can be damaged if cleaned with a high pressure cleaner Ple...

Page 156: ...evices that the step and handles are in good condition clean and fit well cab windows for cracks and fractures the condition of the reflectors and the lighting including the work lights the tires for...

Page 157: ...4 API CH 4 See engine manual Cooling system contents 11 5 3 04 Water with conventional HD coolant antifreeze HD coolant antifreeze ASTN D4985 Front axle Rear axle 3 2 3 9 0 85 1 03 Transmission oil S...

Page 158: ...1 pages 158 161 for detailed instructions on how to tilt the operator cab platform WARNING Crushing shearing hazard Moving engine parts can crush and cut Do not open the engine enclosure unless the en...

Page 159: ...arted from the opera tor position check to determine if there is fuel in the fuel reservoir If fuel is not the problem notify the supervisor and wait for a qualified technician to diagnose and repair...

Page 160: ...k by using the safety support Do not remove the bearing plate from the loader rear frame member Do not operate the wheel loader until the cab has been rigidly bolted to the main frame Tilt the cab slo...

Page 161: ...SERVICING AND INSPECTION 159 WL30 2 1 Fig 63 Cab tilt lever...

Page 162: ...ator s platform Fig 64 Note Do not remove the bolts that hold the support bracket to the rear frame 6 Remove the lever item 1 Fig 63 from the retaining clips and insert it into the holder item 2 Fig 6...

Page 163: ...erneath the operator s platform 2 Lower the operator s platform by hand Ensure that the upper sections of the bearing for the operator s platform lie precisely on the lower sections 3 Re install in th...

Page 164: ...and wait until the engine com partment components are cool enough to touch before performing service work The engine lubricating oil dipstick is located on the left side of the engine facing the dire...

Page 165: ...p the engine 4 Wait until the engine has cooled and the dipstick is com fortable to touch 5 Open the engine enclosure 6 Pull out the dip stick left side of the engine Item 1 Fig 66 7 Wipe the dip stic...

Page 166: ...r to avoid spillage and dispose of it in an ecologically sound manner Refer to Section 10 6 page 155 Specifications and filling quantities for replacing the drained engine lubricating oil Adding engin...

Page 167: ...touch 2 Stop the loader on a horizontal surface and set the park ing brake 3 Lower the loader lift arm and attachment to the ground or working surface 4 Stop the engine 5 Place a container with suffic...

Page 168: ...he engine oil filter contains a bypass valve that opens when the filter is clogged Once the engine oil has been drained 1 Change the engine oil filter see the section Changing the engine oil filter 2...

Page 169: ...lter holder Item 2 Fig 69 4 Lightly oil the rubber seal of the new engine oil filter item 3 Fig 69 5 Screw on the new engine oil filter until it stops against the rubber seal 6 Tighten the new engine...

Page 170: ...ush or cut Hot engine components can cause serious burns Do not open the engine enclosure until the en gine stops Do not touch engine components until they have cooled Fire explosion hazard Fuel and f...

Page 171: ...lug from the inspection glass Item a Fig 70 3 The collected water now runs out 4 Retighten the drain plug when the collected water has run out Check the filter screen in the water separator If require...

Page 172: ...re filter Item 2 Fig 71 can only be re placed in conjunction with the entire housing 1 Place a receptacle under the fuel pre filter 2 Remove the hose clamps from the fuel pre filter 3 Disconnect the f...

Page 173: ...el filter Item 3 Fig 72 4 Clean the sealing surfaces of the filter base and the filter cover Item c Fig 72 5 Replace the gaskets Item b Fig 72 Moisten the new gaskets with diesel fuel and make sure th...

Page 174: ...1 Fill the fuel reservoir 2 Switch the starting key to position I operation so that the electrical fuel feed pump is working 3 Wait 1 minute the system will vent itself automatically 4 The engine can...

Page 175: ...ts cooling fan and drive belts for the fan and alternator Burn hazard Engine components can get very hot during op eration Do not touch the engine mass exhaust system or cooling system immediately aft...

Page 176: ...k main air filter element clean replace Clean or replace the main filter element item 1 Fig 75 during the inspection or if the red cover is visible between inspection intervals in the in spection glas...

Page 177: ...ing a new or cleaned main filter element reset the maintenance display After the engine has been allowed to run the red cover should no longer be visible in the inspection glass in the maintenance dis...

Page 178: ...tor Burn hazard Engine components can get very hot during op eration Do not touch the engine mass exhaust system or cooling system immediately after stopping the engine Wait until the stopped engine h...

Page 179: ...the engine or hydraulic oil or both have become too hot disconnect the cable on one of the two temperature sensors In the event of cooling system overheating check the fol lowing Is there enough cool...

Page 180: ...mage Do not allow antifreeze and coolant to be released uncontrollably into the environment Collect antifreeze and coolant and dispose of it in an ecologically sound manner The coolant must consist of...

Page 181: ...rnal corrosion of the radiator and the engine Checking the antifreeze mix Antifreeze prevents the coolant from freezing at tempera tures below zero and protects the engine block and the radiator from...

Page 182: ...se The coolant must consist of equal parts of water and antifreeze This mix guarantees an optimal ratio of cooling performance and corrosion protection Do not exceed a refill rate of 5 l min 1 3 gpm t...

Page 183: ...age Clean the loader only in a suitable place where the waste water can be collected in an ecologically sound manner Collect contaminated waste water and dispose of it in an ecologically sound manner...

Page 184: ...a piece of cardboard or heavy paper to search for hydraulic system leaks Service the hydraulic system according to the inspection intervals specified in this Operator s Manual Exercise extreme cleanl...

Page 185: ...ked Ventilation filter hydraulic fluid filler neck The ventilation filter is located on the hydraulic fluid reser voir item 1 Fig 83 It ensures that the hydraulic reservoir is ventilated and exhausted...

Page 186: ...the fault has been eliminated 1 Stop the loader on a horizontal surface and set the park ing brake 2 Lower the loader lift arms and attachment to the ground or work surface 3 Stop the engine 4 Remove...

Page 187: ...uid 3 Check the hydraulic fluid level 4 Add hydraulic fluid until the fluid level is at the Maxi mum mark 5 Close the hydraulic oil filler neck cap Item 1 Fig 83 Use the correct oil grade reference Se...

Page 188: ...cologically sound manner Refer to Section 10 6 page 155 Specifications and filling quantities to determine the necessary container volume to avoid spillage 1 Stop the loader on a horizontal surface an...

Page 189: ...section Changing the return filter element 4 Install the plug Fig 85 5 Add hydraulic oil into the hydraulic oil filler neck Item 1 Fig 83 until the oil level has reached the Maximum mark 6 Close the h...

Page 190: ...Item a Fig 87 Otherwise hydraulic fluid will be forced out of the filter housing and could get into the environment Dispose of the old filter element and any leaking hydraulic fluid in an ecologically...

Page 191: ...ure described in Section 8 page 126 5 Remove the cover of the filter housing Item 1 Fig 87 6 Remove the filter element item b Fig 87 7 Insert a new filter element 8 Check the gasket Item c Fig 87 Repl...

Page 192: ...urn the steering wheel to its maximum angle of turn in both directions until the steer ing can be actuated faultlessly and without any noises 5 Check the oil level in the hydraulic fluid reservoir af...

Page 193: ...eduction gears on each axle Service the transmission and the axles according to the inspection intervals specified in this Opera tor s Manual Checking filling and draining screws can be found in the s...

Page 194: ...round or work surface 3 Stop the engine 4 Remove the hex socket screws items a c e Fig 88 89 90 For the wheel reduction gears raise the wheel with a jack first and turn it so that the hex socket screw...

Page 195: ...ies of water Collect leaking transmission oil and dispose of it in an ecologically sound manner The complete axle transfer case differential axle tube wheel drives shares a common oil supply If some o...

Page 196: ...in 8 Check the axle oil level once again after half an hour of operation on the transfer case housing the differential housing and the wheel reduction gears and add trans mission oil if necessary 1 St...

Page 197: ...ntake air for cab ventilation The filter is located on the front of the cab above the middle joint of the loader Fig 91 1 Remove the lid of the filter housing 2 Remove the filter 3 Insert a new filter...

Page 198: ...ard Brake fluid can be absorbed into the skin or cause infections Avoid contact with skin and eyes Wear protective gloves and eye protection Using the wrong brake fluid damages the brake system Only u...

Page 199: ...n the brake fluid container falls below the MIN mark fill with prescribed brake fluid up to the MAX mark and have the brake system checked by a trained specialist ENVIRONMENTAL NOTE Avoid environmenta...

Page 200: ...l or tire sizes can result in damage to the loader s differentials Install only wheels or tires from the same manufac turer which are the same size and have the same wear Inflating the tires WARNING E...

Page 201: ...ic chuck of the filling device from the tire valve 8 Replace the valve stem cap back on the tire valve Air pressure table for tires Tires PR Air pressure 7 00 12 AS 6 3 2 bar 47 psi 27x8 50 15 EM 8 4...

Page 202: ...use a lifting device rated for the mass You will find the tightening torque in the table below Front wheels Rear wheels Wheel bolts M18 x1 5 285 Nm 285 Nm 210 ft lbs 210 ft lbs Observe the direction o...

Page 203: ...he jack under the axle next to the wheel to be changed Make sure that the loader cannot slip off the jack 5 Loosen the wheel bolts 6 Raise the jack just high enough so that the wheel does not touch th...

Page 204: ...e allocation The electrical circuits of the wheel loader are fused to pre vent damage from short circuits and malfunctions The fuses are located in box 1 and 2 near the starting key receptacle on the...

Page 205: ...SERVICING AND INSPECTION 203 WL30 A 40 ampere capacity master fuse is located below the operator s platform Fig 93 Fig 93 Master fuse Fig 94 Fuse boxes Box 1 Box 2...

Page 206: ...ield wipers 10 F024 Rear tail lights 15 F025 Rotating beacon radio 10 F026 Cab courtesy light radio 10 Fig 95 Fuse allocation 1 Box 1 F021 F022 F023 F024 F025 F026 Fuse allocation 2 FR Reserve fuses F...

Page 207: ...10 F006 Optional equipment 10 F007 Optional equipment locking device for attach ments 10 F008 Instrument lighting switch illumination 5 F009 Headlights 15 F010 Available 7 5 Item Fused function for B...

Page 208: ...object such as a wrench contacts both the positive and negative post on the battery it will cause a direct short and a possible explosion Severe burns can result Cover the battery with protective ins...

Page 209: ...e connecting cables clean and lubricate them with anti corrosion grease Make sure that the protective cover of the positive ter minal is always in place and closed item 3 Fig 97 Note the battery indic...

Page 210: ...erator cab platform if the engine is running Follow the instructions in Section 10 7 1 pages 156 161 for opening the engine enclosure and tilting the cab Always follow the correct sequence when discon...

Page 211: ...each pole and provides a means to remove the battery Install the battery following the steps in the reverse order Removing the battery 1 Stop the loader on a horizontal surface and set the park ing br...

Page 212: ...r remove the battery entirely if service work is to be conducted near the battery If a second machine or vehicle is used as the jump start battery source ensure that the vehicles machines do not touch...

Page 213: ...the loader s electrical controls 2 Switch the starting key to position 1 operation The warning lights must light up now 3 If the warning lights do not light up the battery is defec tive In that case...

Page 214: ...ngines continue to idle with the jumper cables connected for about an other two minutes Detach the jumper cables The correct sequence must be adhered to 1 Connect the red jumper cable Item r Fig 99 to...

Page 215: ...e the loader so that the tires no longer touch the ground 4 Release the parking brake 5 Lower the loader lift arms and attachment to the ground 6 Relieve residual hydraulic pressure ref Section 8 page...

Page 216: ...servoir 7 Let the engine idle for 10 minutes before turning it off 8 To preserve the cylinders and combustion chamber crank the engine by hand several times 9 Remove the fan belt and pack it for stora...

Page 217: ...ngine oil 5 Start up the engine 6 Check the V belt tension after the first two operating hours Restarting the loader 1 Remove the engine preservative 2 Install the battery 3 Check the air pressure of...

Page 218: ...l line is leaky Retighten all the threaded connections and clamps Starting speed too low Check and charge the battery check that bat tery terminals fit tightly Engine is running but loader will not dr...

Page 219: ...loosened from the fan blade Tighten the V belt Oil level is too low or too high Adjust the oil level The hydraulic system is get ting too hot Hydraulic oil cooler is dirty Clean it V belt loosened fr...

Page 220: ...point Measuring point Measuring point Cause Cause Cause Cause Suction pressure Supply pressure Control pressure Suction pressure Supply pressure Filter System Accessories Brake accumulator Cooler Wea...

Page 221: ...Cause Choke Drive direction switch High pressure valves Commencement of control Transposition Control pressure Tire diameter Gear ratio Commencement of control Commencement of control Solenoid Pivotin...

Page 222: ...ience in repairing this or comparable loaders Should knowledge be lacking training by experienced repair e g Wacker Neuson Service should be perform 12 1 General safety regulations for repairs Operato...

Page 223: ...nts Relieve hydraulic pressure in hydraulic lines and hose assemblies cylinders coolers the hydraulic reservoir pressure reservoirs and other systems or accumulators before beginning work Replace defe...

Page 224: ...abel replace the label with the replacement part Your Wacker Neuson dealer can help you to get replace ment labels for your machine After completing the repair Put protective paint on all uncoated mac...

Page 225: ...y weld containers which contain or have contained substances that are com bustible promote combustion are explosive or can during welding produce vapor gas mist or dust that are hazardous to health Sh...

Page 226: ...t switch if present Protect bare terminals and connections against short circuiting Attach the welding grounding terminal in the immedi ate vicinity of the welding site Do not allow the welding curren...

Page 227: ...ars of use Dispose of any leaking oil and waste containing oil in an ecologically sound manner Observe the Basic safety instructions for servicing and inspection page 130 12 5 Brakes Repair work on br...

Page 228: ...el escape and that the machine poses no other dangers in the place where it is standing Protect the loader against unauthorized use Close all openings doors windows engine enclosure and secure the loa...

Page 229: ...ce with the current state of the art at the time of recycling taking into account the accident prevention regulations Dispose of all parts at the sites provided for them de pending on the material Tak...

Page 230: ...ques tions Customer number if available Name of the orderer We reserve the right to change the replacement parts list Always provide the following data for ordering re placement parts This is the onl...

Page 231: ...type Engine no Delivery date Importer name address Service garage name address Enter the most important data for your loader on this page In this way you can quickly access the vehicle ID no and othe...

Page 232: ...rs Stamp signature of the garage 2nd Inspection Performed on Operating hours Stamp signature of the garage 3rd Inspection Performed on Operating hours Stamp signature of the garage 14 2 Inspection ver...

Page 233: ...ours Stamp signature of the garage 6th Inspection Performed on Operating hours Stamp signature of the garage 5th Inspection Performed on Operating hours Stamp signature of the garage 7th Inspection Pe...

Page 234: ...s Stamp signature of the garage 10th Inspection Performed on Operating hours Stamp signature of the garage 9th Inspection Performed on Operating hours Stamp signature of the garage 11th Inspection Per...

Page 235: ...Appendix 233 WL30 For personal notes...

Page 236: ...5 Air filter dust valve 174 Air pressure table for tires 199 Articulation frame lock 118 Battery 206 Braking and stopping 84 Changing attachments 96 Changing speeds 83 Changing the axle oil 193 Changi...

Page 237: ...element clean replace 174 Cleaning the cooling system 181 Coupling of attachments 98 Daily servicing 138 Depressurized return line 93 Description of the indicator warning and control elements 48 Deten...

Page 238: ...ting 210 Lighting system and forward warning device 70 Loader data 43 Loader lift arm damping 110 Loader lift arms locking system 94 Loader Tie Down 122 Loader travel 84 Loading on a transport vehicle...

Page 239: ...quantities 155 Starting the engine 78 Technical descriptions 41 Tilting the operator s platform 158 Tip overs 107 Towing equipment 115 Troubleshooting and emergency maintenance 216 Troubleshooting for...

Page 240: ...ver for the locking mechanism of the Loader lift arm 40 Fig 10 Vehicle ID 45 Fig 11 Dimensions 46 Fig 12 Operating elements 48 Fig 13 Control and warning lights 50 Fig 14 Switches rocker switches 1 54...

Page 241: ...ng lever for loader lift arms 89 Fig 33 Operating lever for the optional hydraulics 91 Fig 34 Hydraulic connections 91 Fig 35 Button for optional hydraulics 92 Fig 36 Depressurized return line 93 Fig...

Page 242: ...hment point label 121 Fig 55 Attachment points 121 Fig 56 Tie down point label 123 Fig 57 Tie down points 123 Fig 58 Tying down the loader 124 Fig 59 Reducing residual pressure 127 Fig 60 Load holding...

Page 243: ...sensor 177 Fig 78 Hydraulic oil temperature sensor 177 Fig 79 Radiator opening 179 Fig 80 Checking the antifreeze mix 179 Fig 81 Cleaning the cooling system 181 Fig 82 Hydraulic fluid cooler 183 Fig 8...

Page 244: ...242 Fig 93 Master fuse 203 Fig 94 Fuse boxes 203 Fig 95 Fuse allocation 204 Fig 96 Location of the battery 207 Fig 97 Servicing the battery 207 Fig 98 Removing the battery 208 Fig 99 Connecting the ju...

Page 245: ...List of figures 243 WL30...

Page 246: ...Neuson Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 1 262 255 0500 Fax 1 262 255 0550 Tel 800 770 0957 Wacker Neuson Machinery HK Ltd Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kwo...

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