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TROUBLESHOOTING A ND E ME RGE NCY M AINTE NA NCE

224

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

TROUBLESHOOTING AND EMERGENCY MAINTENANCE

Содержание WL 50

Страница 1: ...Operator s Manual Wheel Loader WL 50 www wackerneuson com...

Страница 2: ...December 08 Edition...

Страница 3: ...nformation 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 how to operat...

Страница 4: ...17 2 3 Safety instructions for certain operating phases 18 2 3 1 Safety instructions for normal operation 18 2 3 2 Safety instructions for other operating modes 20 2 4 Safety instructions for particu...

Страница 5: ...Battery disconnect switch 37 2 8 7 Loader lift arm locking system 38 3 TECHNICAL DATA 39 3 1 Technical description 39 3 2 Loader data 41 3 3 Product identification number plates 43 3 4 Dimensions 44 4...

Страница 6: ...eadlights and rotating beacon 76 5 2 4 Ventilation and heating of the cab 78 5 2 5 Before starting the engine 80 5 2 6 Starting the engine 81 5 3 Propulsion operation 84 5 3 1 Preparation for travel i...

Страница 7: ...ECTION 138 10 1 Basic safety instructions for servicing and inspection 138 10 2 Servicing and inspection intervals 146 10 3 Lubrication schedule 158 10 4 Cleaning the loader 160 10 5 General safety ch...

Страница 8: ...electrical system 210 10 8 Jump starting emergency starting 218 10 9 Loader storage 221 11 Troubleshooting and emergency maintenance 224 12 Safety instructions for repairs 228 12 1 General safety reg...

Страница 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...

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

Страница 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...

Страница 12: ...or serious injury Obey all safety messages that follow this symbol to avoid injury or death WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury...

Страница 13: ...and protection de vices are intact Observe the monitoring systems during operation Repairs may only be performed by trained profession als Follow the Operator s Manual exactly The manufacturer suppli...

Страница 14: ...and repairing the wheel loader to maintain service and performance levels Intended use 1 4 The loader has been built according to applicable standards and regulations Operation by inexperienced perso...

Страница 15: ...owing work activities lifting or transporting people using it as a working platform using it to lift or transport loads without providing work equipment for it pulling trailer loads operating after th...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ...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...

Страница 19: ...loader 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 reac...

Страница 20: ...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 directe...

Страница 21: ...tability 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 th...

Страница 22: ...of 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...

Страница 23: ...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...

Страница 24: ...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...

Страница 25: ...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 OSHA191...

Страница 26: ...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...

Страница 27: ...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...

Страница 28: ...ers e g poisonous gases corrosive steam poison ous i e containing toxins surroundings etc Hydraulics pneumatics 2 4 6 When detected oil leaks shall be repaired to avoid environmental hazards fire haza...

Страница 29: ...tion Wait until hot surfaces have cooled and can be touched comfortably Smoking and open flames are prohibited during fueling Danger of fire or explosion Tip overs 2 4 7 WARNING Personal injury hazard...

Страница 30: ...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 Fin...

Страница 31: ...fety message labels on the machine in a legible manner If a safety label becomes dam aged or illegible replace it with a new label avail able from your Wacker Neuson dealer or at www wackerneuson com...

Страница 32: ...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...

Страница 33: ...ctivity 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 surfaces ca...

Страница 34: ...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...

Страница 35: ...n der pressure can cause burns Do not open radiator when it is hot Re fer to Operator s Manual Safety label 16 Warning Personal injury hazard Falling attachments can strike people in the danger ous ar...

Страница 36: ...r s seat Fig 4 Rotating beacon 2 8 2 Optional equipment Fig 5 Attaching the rotat ing beacon The receptacle for the rotating beacon can be attached to the operator cab roof in the back Fig 5 To switch...

Страница 37: ...g for any mechani cal or chemical damage and replace if neces sary inspect all seat belt hardware for functional ity and serviceability repairing or replacing if necessary fasten the seat belt and adj...

Страница 38: ...travel is the primary access system to the operator station The right hand access is a secondary opening intended for emergency use only Backup alarm for reverse drive 2 8 5 Optional equipment A back...

Страница 39: ...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...

Страница 40: ...et or attachment to en gage the road surface 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 prev...

Страница 41: ...draulics 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 tra...

Страница 42: ...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...

Страница 43: ...change re ceptacle lifting and tipping cylinders and the appropriate attachments The loader is equipped with a rollover protective structure ROPS Loader data 3 2 Engine Manufacturer Deutz Model 4 cyli...

Страница 44: ...6454 psi Working hydraulics Flow rate 64 l min 17 gallons min Working pressure 230 bar 3336 psi Steering hydraulics Flow rate 64 l min 17 gallons min Working pressure 190 bar 2756 psi Noise values Ave...

Страница 45: ...built Vehicle ID Type Engine power Axle loads Operating weight Permissible total weight In addition the vehicle ID is engraved on the right side of the rear end near the entry area Fig 10 1 Furthermor...

Страница 46: ...TECHNICAL DATA 44 Dimensions 3 4 Dimensions Fig 11...

Страница 47: ...m 131 3 inch G Height of seat 1563 mm 61 5 inch H Max dumping height 2569 mm 101 1 inch I Scraping depth 50 mm 1 97 inch K Reach at H 723 mm 28 5 inch L Height to top of cab 2602 mm 102 4 inch Item De...

Страница 48: ...iption of the indicator warning and control elements 46 DESCRIPTION OF THE INDICATOR WARNING AND CONTROL ELEMENTS 4 Operating elements and instruments 4 1 Fig 12 Operating elements 2 3 4 5 6 7 8 10 11...

Страница 49: ...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...

Страница 50: ...e malfunction before operating the machine 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...

Страница 51: ...lter Illuminates if the pressure at the return filter is too high 4 No function Available for optional equipment 1 5 Indicator for fuel display Illuminates when the fuel quantity falls to approx 5 l 1...

Страница 52: ...g 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 actio...

Страница 53: ...Indicator light for parking brake Illuminates when the parking brake is on 12 Air filter indicator light Illuminates when the air filter is contaminated 13 Indicator light for overdrive Illuminates w...

Страница 54: ...n 1 Engine tem perature Shows the diesel engine s temperature 2 Tachometer Shows the diesel engine s rpm 3 Hour meter Adds up the loader s operating time Plan your service work and inspection work acc...

Страница 55: ...itches 4 4 Item Designation Function 1 Combination switch Switches lighting and signal horn ON OFF 2 Rotary switch tem perature control To adjust the temperature of the heater fan 3 Rotary switch heat...

Страница 56: ...Description of the indicator warning and control elements 54 Rocker switches 4 5 1 3 2 1 0 Fig 16 Rocker switches 1 1 2 3 4 5 6 7 8 9 10 Fig 17 Rocker switches 2...

Страница 57: ...to relieve pressure on the optional hydraulics 6 Rocker switch float position emergency lowering of the loader lift arms needed if the loader is equipped with electrically unlockable lowering brake va...

Страница 58: ...Description of the indicator warning and control elements 56 Rocker switches 11 12 13 14 15 16 Fig 18 Rocker switches 3...

Страница 59: ...itch for rear headlights Switches rear headlights on off 13 Rocker switch rear window wiper back washer system second switch level Switches rear window wipers and back washer system on off 14 Rocker s...

Страница 60: ...or inactivity refer to the procedure for preparing to operate the loader Read the Operator s Manual before starting up the loader Lower the loader lift arms and attachment to the ground and stop the...

Страница 61: ...ional 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 release...

Страница 62: ...fuel and coolant leaks Operation 5 1 2 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...

Страница 63: ...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...

Страница 64: ...the door from the inside by pulling the unlocking lever upwards Fig 20 2 CAUTION Possibility of injury or equipment damage from un latched cab doors Close and latch the cab doors during opera tion The...

Страница 65: ...ned and locked in this po sition Open and close the side windows using the lever Fig 21 Arrest the side window by locking it in the holder Fig 22 Activate lever Item 1 to release the window arrest Fig...

Страница 66: ...rs can also be opened together with the side window and locked in this position Arrest the door by locking it in the holder Fig 23 Activate lever Item 1 to release the door arrest Fig 24 Fig 23 Door a...

Страница 67: ...ust the seat in the following ways Fig 26 WARNING Personal injury or property damage hazard Adjusting the operator seat while the wheel loader is in operation can cause inadvertent control move ments...

Страница 68: ...ft the seat out of its lowest position until it engages in the middle position Lift the seat further in order to reach the highest position Lift the seat until it reaches the upper stop at which point...

Страница 69: ...engthwise direction together with the steering console by pushing the locking bar upwards After the adjustment the locking bar must click into place in the desired position The operator s seat should...

Страница 70: ...Adjust the steering column as needed 2 Let go of the adjustment lever 3 WARNING Personal injury or property damage hazard Adjusting the steering column while the wheel load er is in operation can cau...

Страница 71: ...rating with a dam aged seat belt can result in injury to the opera tor Make sure seat belt and buckle stay clean Before operation check function of seat belt and buckle Replace the belt or buckle imme...

Страница 72: ...t over your lap 2 Seat belt must not be twisted 3 Insert the seat belt tab Item 1 into the opening in belt 4 buckle Item 3 until it clicks If necessary adjust the seat belt to your body size 5 See sec...

Страница 73: ...t and then adjust the seat belt Adjusting the seat belt Adjust your seat belt so that it fits snugly Lengthening the seat belt Pull the tongue clasp to draw the seat belt out to the 1 required length...

Страница 74: ...e rocker switches are switched on by moving them to the down position Check the lighting turn signal and forward warning device each time before driving Lighting system and forward warning device 5 2...

Страница 75: ...or 1 The right turn signal is activated Pull the lever towards the operator 2 The left turn signal is activated Push the lever upwards 3 Main beam is switched on Push the lever downwards 4 Low beam is...

Страница 76: ...windshield wiper switches on in level 1 Twist the rotary switch to position II The windshield wiper switches on in level 2 Twist the rotary switch to position J The front windshield wiper switches on...

Страница 77: ...eld wiper switches off 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 loa...

Страница 78: ...g traffic Operate the taillights using the rocker switch Item 12 Fig 33 the same way you would the front headlights The switches for switching on the headlights are located in the cab to the right abo...

Страница 79: ...acon switches on Put the rocker switch Item 15 in position 0 The rotating beacon switches off Rear window heating The loader has a heated rear window With this heater you can keep the rear window free...

Страница 80: ...d 23 Heating Temperature Use the left regulator Item W to adjust the temperature continuously Fig 34 Turn the left regulator Item W to the left The temperature rises Turn the left regulator Item W to...

Страница 81: ...ats the cab in the process Fig 35 Ventilation outlets Air conditioning system The air conditioning system is switched on and off using the rocker switch adjacent to the steering wheel on the right Fig...

Страница 82: ...gine 5 2 5 Before starting the engine Make sure that no one is on or near the load er Keep the operating elements clean and dry Remove or tighten all loose objects in the cab Make sure that the cab wi...

Страница 83: ...w 0 C 32 F until the hydraulic fluid is warm enough to permit smooth responsive operation The lower the outside temperature the longer the warm up phase Observe the hydrofilter s pressure display Do n...

Страница 84: ...g pressure Level II Preheating Turn the key further to the right against spring pressure level III start Let go of the key as soon as the engine starts the key will return to level I and the indicator...

Страница 85: ...mergency maintenance or contact a specialist garage It is absolutely not possible to start the engine by tow starting the loader This could damage the hy draulic system Preheating You can preheat the...

Страница 86: ...with the road 3 surface but not more than necessary for safe transport to avoid visibility restrictions and reduced stability Do not travel with the loader arms completely raised to 4 avoid collision...

Страница 87: ...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...

Страница 88: ...ection 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 with the i...

Страница 89: ...der s gears After start ing the engine overdrive is automatically activated Press the button The loader shifts from overdrive to crawler gear Indicator light 14 Fig 13 page 50 lights up Press the butt...

Страница 90: ...traveling speed by decreasing the engine speed To brake the loader step on the braking inching ped al To stop step on the braking inching pedal until the loader has come to a stop Shift to neutral Pu...

Страница 91: ...e starting key before leaving the op erator seat WARNING Personal injury and machine damage hazards from abrupt directional changes Actuating the direction switch when the loader is moving will cause...

Страница 92: ...rol 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 elim...

Страница 93: ...s prior to each work shift Check the functioning of the operating equipment Check the functioning of the brakes and warning de vices Report any defects to the supervisor and when changing shifts to th...

Страница 94: ...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...

Страница 95: ...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...

Страница 96: ...means of a locking mecha nism If you have switched on the locking mechanism the loader lift arms will not move if the loader con trols are moved When the locking mechanism is switched on the control...

Страница 97: ...hydraulics using the control lever Fig 41 Operating lever for the optional hydraulics R Z L Place the optional hydraulic control in neutral when the system is not required This is necessary to avoid...

Страница 98: ...achment is unlocked If the valve lever is set to Hydraulic locking mechanism you can actuate the loader lift arms s hydraulic connections Fig 43 via the control lever for the optional hydraulics Item...

Страница 99: ...continuous 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 for wards past normal operation posit...

Страница 100: ...button If the lever of the valve is set to Hydraulic locking mecha nism you can activate the hydraulic locking mechanism via the buttons for the optional hydraulics Item 1 and Item 2 Fig 44 Activate t...

Страница 101: ...tachments 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 45 The connection is designed in such a way that it...

Страница 102: ...lock switches on Release the button item 1 Fig 46 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 dif...

Страница 103: ...Operating and operation 101 WL50 Fig 46 Switch for differen tial lock 1 12V 1...

Страница 104: ...r 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 un...

Страница 105: ...ent of pressurized leakage In the event high pressure fluid comes in contact with skin or if hydraulic fluid enters the eye seek immediate treatment in an emergency room Do not use an attachment unles...

Страница 106: ...ig 48 to avoid unintentional disconnection of the attach ment Confirm that the hydraulic couplings are correctly matched to operate the attachment Pressurized hydraulic oil can penetrate the skin caus...

Страница 107: ...n 105 WL50 Fig 47 Switching the three way valve Hydraulic connection Hydraulic locking mecha nism NICHT UNTER LAST schalten Do not operate under load Ne pas changer de vitesse sous charge Quitar la pr...

Страница 108: ...re working correctly and the couplers and hydraulic lines are not leaking Drive the loader up to the attachment Fig 48 1 Bring the locating pins Item 1 under the mounting hook 2 Item 2 Raise the loade...

Страница 109: ...components such as clamshells Actuate the attachment controls through the full range of motion to release residual hydraulic pressure If the attachment is equipped with integral sup ports extend them...

Страница 110: ...lves Activate the bucket curl rotating the lower portion of the loader frame cou pler away from the attachment coupler Back the loader away from the attachment if the recep 8 tacle frame is free WARNI...

Страница 111: ...5 4 5 page 102 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 92 NOTICE Avoid overloadi...

Страница 112: ...he control lever Fig 49 0 Neutral position 1 Lift 2 Lower 2a Float position 3 Tilt in 4 Tilt out The float position facilitates stripping during resurfacing work To do so lower the bucket with the tip...

Страница 113: ...ess 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 level indicator is l...

Страница 114: ...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...

Страница 115: ...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...

Страница 116: ...to avoid a large amount of wheel slip Fig 54 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...

Страница 117: ...amage from lubrication starvation Do not operate the engine or machine after an incident until a technician has inspected and corrected any damage resulting from the in cident ENVIRONMENTAL NOTE Right...

Страница 118: ...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...

Страница 119: ...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...

Страница 120: ...ately 30 cm 12 to compensate for the vertical movement of the bucket or attachment as the feature moves Loader lift arm damping Engaging the feature reduces the effect of uneven ground on the attitude...

Страница 121: ...ndicator light in the switch is illuminated Damping is engaged Do not actuate the loader lift arm bucket or attachment control Move the rocker switch Item 2 into position 0 The indicator light in the...

Страница 122: ...s Fig 57 by depressing the switch 2 designated in Fig 58 The electrical connector on the loader lift arm is used to connect attachments for which certain functions must be activated electrically 12V 2...

Страница 123: ...Operating and operation 121 WL50...

Страница 124: ...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...

Страница 125: ...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...

Страница 126: ...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...

Страница 127: ...crewinthestudItem1 Fig 60 untilitislevelwiththehexnut 3 Note Turn the studs Item 1 Fig 60 no further than described otherwise parts of the valve become dam aged Return the operator cab platform to ope...

Страница 128: ...iculation frame lock down and fit over the rear locking pin Secure with spring pin An articulation frame lock is provided as illustrated in Fig 61 for preventing unintended frame articula tion during...

Страница 129: ...Towing and transporting 127 WL50 Articulation frame lock installed Fig 61 Articulation frame lock Articulation frame lock storage posi tion 1...

Страница 130: ...ion lock Secure the wheel loader to the transport per the instructions in Section 9 Securing the Loader on page 137 WARNING Possibility of equipment damage or personal injury from improper lifting Con...

Страница 131: ...ed with labels Fig 62 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...

Страница 132: ...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...

Страница 133: ...Towing and transporting 131 WL50 Use the attachment points Fig 65 marked with labels Fig 64 to tie down the loader Fig 64 Tie down point label rear Fig 65 Tie down points front...

Страница 134: ...Towing and transporting 132 Fig 66 Tying down the loader...

Страница 135: ...rk surface The same procedure shall be used if the hydrostatic propulsion system stops responding In the event of a working hydraulic system failure Lower the loader lift arms and attachment as quickl...

Страница 136: ...onal injury hazard A fine jet of hydraulic fluid under high pressure can pierce the skin Seek medical assistance im mediately if you get hydraulic fluid in your eyes or on your skin Open only unpressu...

Страница 137: ...ARNING Personal injury hazard A fine jet of hydraulic fluid under high pressure can pierce the skin Seek medical assistance immediately if you get hydraulic fluid in your eyes or on your skin Only tra...

Страница 138: ...on or insufficient mass you will have to augment the process using a control cable or ratchet straps Screw the screw Item 2 back in as soon as the loader 3 lift arms is completely lowered and retighte...

Страница 139: ...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...

Страница 140: ...d 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 Maintenan...

Страница 141: ...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...

Страница 142: ...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...

Страница 143: ...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...

Страница 144: ...oisture 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 flui...

Страница 145: ...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...

Страница 146: ...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...

Страница 147: ...ion work al ways reattach all the safety devices Do not start the engine until the loader is no longer being worked on and everyone has left the danger area Only start the engine from the operator s s...

Страница 148: ...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...

Страница 149: ...heck 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 Chec...

Страница 150: ...draulic 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...

Страница 151: ...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...

Страница 152: ...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...

Страница 153: ...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...

Страница 154: ...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...

Страница 155: ...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...

Страница 156: ...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...

Страница 157: ...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...

Страница 158: ...ilter 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 first chang...

Страница 159: ...Check all the oil levels X X Inspect according to the accident prevention regulations X X Valve clearance for Perkins 400 series 0 2 mm 0 008 inlet and outlet for a cold engine Valve clearance for Per...

Страница 160: ...SERVICING AND INSPECTION 158 Lubrication schedule 10 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Fig 70 Points of lubrication...

Страница 161: ...achment 2 24 Tool locking bolts 2 Item Point of lubrication Nipples 1 Engine enclosure hinges 2 2 Cab tilting hinge rear 1 3 Door hinges 4 4 Brake pedal bearing in the cab 1 Brake lever bearing under...

Страница 162: ...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...

Страница 163: ...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...

Страница 164: ...vices 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 d...

Страница 165: ...al Cooling system contents 10 2 64 Water with conventional HD coolant antifreeze HD coolant antifreeze ASTN D4985 Front axle Rear axle 4 2 4 9 1 11 1 29 Transmission oil SAE 90 GL 5 Complete hydraulic...

Страница 166: ...1 pages 164 168 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...

Страница 167: ...nclosure lock automatically engages when the engine enclosure is closed If the engine stops and can not be restarted from the opera tor position check to determine if there is fuel in the fuel reservo...

Страница 168: ...til the cab has been rigidly bolted to the main frame Tilt the cab slowly and keep hands and arms clear of pinch points NOTICE Avoid damage to the cab doors Either close the doors or remove them Remov...

Страница 169: ...SERVICING AND INSPECTION 167 WL50 Fig 72 Position of the cab mounting bolts Fig 73 Tilting the cab 1 2 3...

Страница 170: ...p lever Item 1 Fig 73 into the intended 2 opening in the hand pump Item 2 Fig 73 Release the locking of the operator s platform safety 3 supports by pulling the loop Item 1 Fig 74 Now pump in order to...

Страница 171: ...ne 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 di...

Страница 172: ...dipstick is com 4 fortable to touch Open the engine enclosure 5 Pull out the dip stick left side of the engine Item 1 Fig 6 75 Wipe the dip stick with a clean lint free cleaning rag 7 Put the dip stic...

Страница 173: ...iner to avoid spillage and dispose of it in an ecologically sound manner Refer to Section 10 6 page 163 Specifications and filling quantities for replacing the drained engine lubricating oil Adding en...

Страница 174: ...et the park 2 ing brake Lower the loader lift arm and attachment to the ground 3 or working surface Stop the engine 4 Place a container with sufficient volume to avoid spillage 5 under the drain openi...

Страница 175: ...r The engine oil filter contains a bypass valve that opens when the filter is clogged Once the engine oil has been drained Change the engine oil filter see the section Changing 1 the engine oil filter...

Страница 176: ...f the filter holder Item 2 Fig 3 77 Lightly oil the rubber seal of the new engine oil filter 4 item 3 Fig 77 Screw on the new engine oil filter until it stops against 5 the rubber seal Tighten the new...

Страница 177: ...or catch fire Do not smoke or change the fuel filter near an open flame Do not mix gasoline with diesel fuel ENVIRONMENTAL NOTE Avoid environmental damage Collect leaking fuel and dispose of it in an...

Страница 178: ...en the drain plug when the collected water has 4 run out Venting the fuel system 5 Fig 79 Water separator 1 a Fuel system The fuel filtration system consists of a pre filter 2 and a main filter 3 The...

Страница 179: ...Replace the fuel pre filter 4 Connect the fuel hoses 5 Attach the hose clamps for the fuel pre filter 6 Venting the fuel system 7 Changing the main fuel filter Place a receptacle under the main fuel...

Страница 180: ...Venting the fuel system Fill the fuel reservoir 1 Open the engine enclosure 2 Pump with the hand feed pump Fig 81 until you feel 3 resistance Then pump 3 or 4 more times The engine can now be started...

Страница 181: ...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...

Страница 182: ...pinching the valve Check main air filter element clean replace Clean or replace the main filter element Item 1 Fig 83 during inspections or if the indicator light for the air filter on the instrument...

Страница 183: ...e order After a new or a cleaned main filter element has been in stalled the indicator light in the instrument panel Item 12 Fig 13 should no longer light when the engine is running Should this nevert...

Страница 184: ...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 has coole...

Страница 185: ...in whether 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 e...

Страница 186: ...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...

Страница 187: ...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...

Страница 188: ...e 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 to...

Страница 189: ...NMENTAL NOTE Avoid environmental damage 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...

Страница 190: ...e 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 clean...

Страница 191: ...e Fig 89 One part cools the hydraulic fluid while the other part cools the engine Should the loader get too hot during long drives on the road or at high outside temperatures check whether the fan s V...

Страница 192: ...alized personnel to eliminate the fault Do not drive the loader until the fault has been eliminated Ventilation filter hydraulic fluid filler neck The ventilation filter is located on the hydraulic fl...

Страница 193: ...90 slight 4 ly so that the pressure can escape from the reservoir before removing the cap completely The dip stick is located on the underside of the air filter 5 Remove the dip stick Fig 91 Wipe the...

Страница 194: ...d filling quantities to determine the necessary container volume to avoid spillage Adding hydraulic fluid If the fluid level is under the Maximum mark add hydraulic fluid until the maximum level is re...

Страница 195: ...filler neck cap 6 Vent the hydraulic system see the section Venting the 7 hydraulic system Check the hydraulic fluid level and add hydraulic fluid 8 if necessary Dispose of the old hydraulic fluid in...

Страница 196: ...94 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 sound mann...

Страница 197: ...er of the filter housing Item a Fig 5 94 Remove the filter element item b Fig 94 6 Insert a new filter element 7 Check the gasket Item c Fig 94 Replace the gasket 8 if it is damaged Screw on the cover...

Страница 198: ...rn the steering wheel to 4 its maximum angle of turn in both directions until the steering can be actuated faultlessly and without any noises Check the oil level in the hydraulic fluid reservoir af 5...

Страница 199: ...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...

Страница 200: ...und 2 or work surface Stop the engine 3 Remove the hex socket screws items a c e Fig 4 95 96 97 For the wheel reduction gears raise the wheel with a jack first and turn it so that the hex socket screw...

Страница 201: ...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...

Страница 202: ...in Check the axle oil level once again after half an hour of 8 operation on the transfer case housing the differential housing and the wheel reduction gears and add trans mission oil if necessary Stop...

Страница 203: ...ke cylinders by means of the braking inching pedal WARNING Personal injury hazard The service and parking brakes are essential for safe operation of the wheel loader Loss of control is hazardous to th...

Страница 204: ...nd waste containing oil to spill on the ground or get into bodies of water Collect leaking transmission oil and dispose of it in an ecologically sound manner Using the wrong brake fluid damages the br...

Страница 205: ...engine enclosure Fig 98 The control marks MAX and MIN are on the side of the container If the brake oil level in the brake fluid container falls below the MIN mark fill with prescribed brake fluid up...

Страница 206: ...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 Ex...

Страница 207: ...ar 66 psi 15 5 55 18 EM 14 4 0 bar 60 psi 405 70 R18 EM 4 0 bar 60 psi 15 0 55 17 AS 10 3 5 bar 50 psi 405 70 R20 AS 3 5 bar 50 psi Stop the loader on a horizontal surface and set the park 1 ing brake...

Страница 208: ...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...

Страница 209: ...jack under the axle next to the wheel to 4 be changed Make sure that the loader cannot slip off the jack Loosen the wheel bolts 5 Raise the jack just high enough so that the wheel does 6 not touch th...

Страница 210: ...7 10 The loader is equipped with a dry air filter for filtering the engine intake air for cab ventilation The filter is located on the front of the cab above the middle joint of the loader Fig 99 Remo...

Страница 211: ...k on components of the coolant circuit or in their immediate vicinity WARNING Burn hazard Coolant can contain alkali which may cause chemi cal burns Poison hazard Coolant can be harmful or fatal if sw...

Страница 212: ...onnel Fuse 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 receptacl...

Страница 213: ...is the main fuse for the lights and con trols For loaders with Deutz engine there are also two 50 ampere fuses that protect the preheating sys tem If one of these fuses is burnt through there is majo...

Страница 214: ...ing A 1 Available 7 5 2 Turn signal 7 5 3 Warning flasher 7 5 4 Brake light 15 5 Side lamp left 10 6 Side lamp right 7 5 7 Low beam light 7 5 8 Main beam 7 5 Fuse allocation Fig 102 Box 1 Box 2 Box 3...

Страница 215: ...ability indicator 3 15 Available 10 16 Available 7 5 Item Fused function for Box 3 Rating A 17 Pressure relief Loader lift arms locking system 15 18 Control unit electrical connection 15 19 Front head...

Страница 216: ...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 insulation or remove...

Страница 217: ...ricity when the wheel loader is not in operation Check the acid level of the battery on a weekly basis Add distilled water to the battery manufacturer s speci fied level if the level is low A cover is...

Страница 218: ...he ground 2 or work surface Stop the engine 3 Open the engine enclosure 4 Ref section 10 7 1 page 164 The acid level is visible through the battery housing 5 MIN MAX marks have been affixed on the out...

Страница 219: ...ve pole and then the negative pole Open the engine enclosure 5 Ref section 10 7 1 page 164 Loosen the negative battery cable clamp and remove the 6 clamp from the post Position the cable so it is not...

Страница 220: ...or 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 touc...

Страница 221: ...e loader s electrical controls 1 Switch the starting key to position 1 operation The 2 warning lights must light up now If the warning lights do not light up the battery is defec 3 tive In that case t...

Страница 222: ...nes continue 4 to idle with the jumper cables connected for about an other two minutes Detach the jumper cables The correct sequence must be adhered to Connect the red jumper cable Item r Fig 104 to t...

Страница 223: ...he loader so that the tires no longer touch the 3 ground Release the parking brake 4 Lower the loader lift arms and attachment to the 5 ground Relieve residual hydraulic pressure ref 6 Section 8 page...

Страница 224: ...servoir Let the engine idle for 10 minutes before turning it off 7 To preserve the cylinders and combustion chamber 8 crank the engine by hand several times Remove the fan belt and pack it for storage...

Страница 225: ...ine oil 4 Start up the engine 5 Check the V belt tension after the first two operating 6 hours Restarting the loader Remove the engine preservative 1 Install the battery 2 Check the air pressure of th...

Страница 226: ...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...

Страница 227: ...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...

Страница 228: ...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...

Страница 229: ...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...

Страница 230: ...ience in repairing this or comparable loaders Should knowledge be lacking training by experienced repair e g Wacker Neuson Service should be per formed General safety regulations for repairs 12 1 Oper...

Страница 231: ...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...

Страница 232: ...label 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 ma...

Страница 233: ...ay 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 S...

Страница 234: ...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...

Страница 235: ...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 138 Brakes 12 5 Repair work on br...

Страница 236: ...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...

Страница 237: ...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...

Страница 238: ...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...

Страница 239: ...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...

Страница 240: ...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 Inspection verifica...

Страница 241: ...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...

Страница 242: ...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...

Страница 243: ...Appendix 241 WL50 For personal notes...

Страница 244: ...ning system 79 Air filter dust valve 180 Air pressure table for tires 205 Articulation frame lock 126 Battery 214 Braking and stopping 88 Changing attachments 102 Changing speeds 87 Changing the axle...

Страница 245: ...ck main air filter element clean replace 180 Cleaning the cooling system 187 Coupling of attachments 104 Daily servicing 146 Depressurized return line 99 Description of the indicator warning and contr...

Страница 246: ...mp starting emergency starting 218 Lighting system and forward warning device 72 Loader data 41 Loader lift arm damping 118 Loader lift arms locking system 94 Loader Tie Down 130 Loader travel 88 Load...

Страница 247: ...Starting the engine 81 Technical descriptions 39 The rotating beacon 77 Tilting the operator s platform 166 Tip overs 115 Towing equipment 123 Troubleshooting and emergency maintenance 224 Troubleshoo...

Страница 248: ...onnect switch 37 Fig 9 Switch for loader lift arms lock 38 Fig 10 Vehicle ID 43 Fig 11 Dimensions 44 Fig 12 Operating elements 46 Fig 13 Control and warning lights 48 Fig 14 Indicator devices 52 Fig 1...

Страница 249: ...Heating controller 78 Fig 35 Ventilation jets 79 Fig 36 Rocker switch for air conditioning system 79 Fig 37 Starting switch 82 Fig 38 Changing direction 87 Fig 39 Operating lever for loader lift arms...

Страница 250: ...trical connector on the loader lift arms 120 Fig 59 Towing equipment 123 Fig 60 Disconnecting the drive 124 Fig 61 Articulation frame lock 127 Fig 62 Attachment point label 129 Fig 63 Attachment point...

Страница 251: ...uel hand feed pump 178 Fig 82 Location of the air filter 180 Fig 83 Air filter elements 180 Fig 84 Engine temperature sensor 183 Fig 85 Hydraulic oil temperature sensor 183 Fig 86 Radiator opening 185...

Страница 252: ...el reduction 198 Fig 98 Brake fluid container 203 Fig 99 Cab vent filter 208 Fig 100 Master fuses 211 Fig 101 Fuse boxes 211 Fig 102 Fuse allocation 212 Fig 103 Location of the battery 215 Fig 104 Con...

Страница 253: ...List of figures 251 WL50...

Страница 254: ...49 89 35402 390 Wacker 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 Machinery HK Ltd Skyline Tower Suite 2303 23 F 39 Wan...

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