Repair Manual for Wheel Loader WL 30 - Wacker Neuson

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2 Filling quantities 2-10 1000239425 - WDF-6001-00EN WL 30 - 10/2008-1 (WDF-7020-00EN)
Special tightening torques General tightening torques Screws with coarse-pitch thread WL 30 - 10/2008-1 (WDF-7020-00EN) 1000239425 - WDF-6001-00EN Tightening torques 3 This section summarizes the tightening torques in two groups: Special tightening torques General tightening torques If no special tightening torque is stipulated, the general tightening torques apply (see "General tightening torques"). Assembly Connection Tightening torque (Nm) Engine Cylinder head cover: Bolt Nut Drive and axles Front axle securing 360 Tightening torques for screws with coarse-pitch thread as a function of the quality 14 14 Rear axle securing 360 Wheel Wheel nut 285 Wheel (twin tires) Hooked bolt nut 285 Thread size in mm Tightening torque 1) in Nm Quality 8.8 Quality 10.9 Quality 12.9 M4 3 4 5 M5 5.5 8 10 M6 10 14 16 M8 23 34 40 M10 46 67 79 M12 79 115 135 M14 125 185 220 M16 195 290 340 M18 280 400 470 M20 395 560 660 M22 540 760 890 M24 680 970 1150 M27 1000 1450 1700 M30 1350 1950 2300 1) These values apply to screws with an untreated, unlubricated surface. 3Tightening torques 2-11
Page 1 and 2: © 2008 Wacker Neuson SE - 80809 M
Page 3 and 4: Service address and spare parts WL
Page 5 and 6: VI Violet WH White X Plug connector
Page 7 and 8: Part 1 Safety 1 Repair work (comple
Page 9 and 10: 4.3 Rear axle. . . . . . . . . . .
Page 11 and 12: A Additional weight Replacement . .
Page 13 and 14: Hose book . . . . . . . . . . . . .
Page 15 and 16: Turning the bearing see Engine, cle
Page 19 and 20: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 21 and 22: 1 Repair work (complete vehicle) .
Page 23 and 24: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 25 and 26: Safety instructions for working on
Page 27 and 28: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 29 and 30: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 31 and 32: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 33 and 34: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 35 and 36: WL 30 - 10/2008-1 (WDF-7019-00EN) 1
Page 37 and 38: A Axles Safety instructions . . . .
Page 41 and 42: WL 30 - 10/2008-1 (WDF-7020-00EN) 1
Page 43 and 44: 1 Technical data . . . . . . . . .
Page 45 and 46: Engine Perkins 4-cylinder Diesel e
Page 47: WL 30 - 10/2008-1 (WDF-7020-00EN) 1
Page 51 and 52: Variable displacement pump, driving
Page 53 and 54: The gear pump delivers 19 cm3 per r
Page 55 and 56: Meaning and position of the safety
Page 57 and 58: Sticker Meaning WL 30 - 10/2008-1 (
Page 59 and 60: Fig. 2 Stickers located on the righ
Page 61 and 62: 7.1 Test pressure gauge WL 30 - 10/
Page 63 and 64: 8.1 Insertion tool WL 30 - 10/2008-
Page 65 and 66: 8.5 Electrical contact key WL 30 -
Page 67 and 68: Enter every replaced hydraulic line
Page 69 and 70: D Driving bolts . . . . . . . . . .
Page 73 and 74: Hydraulic system WL 30 - 10/2008-1
Page 75 and 76: 1 Complete vehicle. . . . . . . . .
Page 77 and 78: 1.1 Inspection log Vehicle data Veh
Page 79 and 80: 2.1 Checking and adjusting the valv
Page 81 and 82: Installing the cylinder head cover
Page 83 and 84: If a fault is found: WL 30 - 10/200
Page 85 and 86: Symptom Possible cause Remedy Engin
Page 87 and 88: 3.1 Checking and adjusting the star
Page 89 and 90: Adjusting the pressure cut-off WL 3
Page 91 and 92: WL 30 - 10/2008-1 (WDF-7021-00EN) 1
Page 93 and 94: WL 30 - 10/2008-1 (WDF-7021-00EN) 1
Page 95 and 96: Adjusting the control commencement
Page 97 and 98: Checking the emergency steering cap
Page 99 and 100:
WL 30 - 10/2008-1 (WDF-7021-00EN) 1
Page 101 and 102:
Symptom Possible cause Remedy Suppl
Page 103 and 104:
4.1 Inspecting the differential loc
Page 105 and 106:
4.3 Troubleshooting on the drive Sy
Page 107 and 108:
Checking and adjusting the curling
Page 109 and 110:
6.1 Checking the heater Start the
Page 111 and 112:
7.1 Checking the generator Requirem
Page 113 and 114:
7.4 Testing the fuel level sensor R
Page 115 and 116:
B Belt buckle circuit Testing . . .
Page 117 and 118:
© 2008 Wacker Neuson SE - 80809 M
Page 119 and 120:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
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1 Complete vehicle. . . . . . . . .
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8.2.11 Replacing the fuel level sen
Page 125 and 126:
1.1 Helpful tips WL 30 - 10/2008-1
Page 127 and 128:
2.1 Engine (as supplied) 2.1.1 Engi
Page 129 and 130:
Releasing the engine mounts Fig. 7
Page 131 and 132:
Fig. 15 Connections (left) WL 30 -
Page 133 and 134:
Spare parts and auxiliary equipment
Page 135 and 136:
Fig. 24 Clutch PA flange attachment
Page 137 and 138:
Checking the air supply and oil lev
Page 139 and 140:
Page 141 and 142:
2.3 Air filter system 2.3.1 Replaci
Page 143 and 144:
Checking the position of the air fi
Page 145 and 146:
Removing the main fuel filter Fig.
Page 147 and 148:
Removing the fuel feed pump Fig. 44
Page 149 and 150:
2.5 Exhaust system 2.5.1 Replacing
Page 151 and 152:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 153 and 154:
Depressurizing the hydraulic system
Page 155 and 156:
Requirements Ensure the following:
Page 157 and 158:
Cleaning the guide bush Remove the
Page 159 and 160:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 161 and 162:
3.2.3 Replacing the annular shaft s
Page 163 and 164:
Removing the variable displacement
Page 165 and 166:
Fig. 76 Steering cover Fig. 77 Prio
Page 167 and 168:
Page 169 and 170:
Page 171 and 172:
Installing the steering cylinder at
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
3.5.2 Sealing the gear pump Require
Page 179 and 180:
3.5.3 Removing the control valve Re
Page 181 and 182:
Inserting the control valve Instal
Page 183 and 184:
Removing the coils Unscrew 1 nut (
Page 185 and 186:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 187 and 188:
Removing the cross controller Insta
Page 189 and 190:
Installing the lifting cylinder, ro
Page 191 and 192:
Page 193 and 194:
Installing the tipping cylinder, ro
Page 195 and 196:
Page 197 and 198:
Detaching the lines Remove the plu
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WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 201 and 202:
4.1 Replacing the drive shaft Requi
Page 203 and 204:
Removing the hydraulic lines Reliev
Page 205 and 206:
Fig. 174 Front axle support WL 30 -
Page 207 and 208:
4.3 Rear axle 4.3.1 Removing the re
Page 209 and 210:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 211 and 212:
Connecting the hydraulic lines on t
Page 213 and 214:
5.1 Service brake 5.1.1 Replacing t
Page 215 and 216:
Page 217 and 218:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 219 and 220:
Page 221 and 222:
Page 223 and 224:
6.2.4 Replacing the engine hood Req
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6.2.6 Emergency release of the engi
Page 227 and 228:
Preparing the self-aligning bearing
Page 229 and 230:
Installing the self-aligning bearin
Page 231 and 232:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 233 and 234:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 235 and 236:
Disconnecting electrical cables Un
Page 237 and 238:
Securing the operator's platform Co
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WL 30 - 10/2008-1 (WDF-7022-00EN) 1
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6.5 Load arm 6.5.1 Replacing the co
Page 243 and 244:
Connecting the hydraulic lines Spar
Page 245 and 246:
Drive in a new bearing from the out
Page 247 and 248:
Page 249 and 250:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
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Page 253 and 254:
7.1 Seat 7.1.1 Replacing the driver
Page 255 and 256:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 257 and 258:
Installing the driver's canopy WL 3
Page 259 and 260:
Removing the document compartment I
Page 261 and 262:
Removing the Bowden cables Unscrew
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WL 30 - 10/2008-1 (WDF-7022-00EN) 1
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WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 267 and 268:
Removing the windshield washer cont
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Page 271 and 272:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 273 and 274:
Preparation for bonding Place the
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WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 277 and 278:
Installing the instrument steering
Page 279 and 280:
8.1 Generator, battery and motors 8
Page 281 and 282:
8.1.3 Replacing the rear windshield
Page 283 and 284:
Installing the windshield wiper mot
Page 285 and 286:
Page 287 and 288:
Replacing the ignition lock Unscre
Page 289 and 290:
Remove the plug (Fig. 387,3). Unsc
Page 291 and 292:
WL 30 - 10/2008-1 (WDF-7022-00EN) 1
Page 293 and 294:
8.3 Relays, coils and fuses 8.3.1 R
Page 295 and 296:
Removing the solenoid valve Mark t
Page 297 and 298:
Replacing the indicator lamp WL 30
Page 299 and 300:
8.4.4 Replacing the audible warning
Page 301 and 302:
Page 303 and 304:
Fig. 409 Rear headlight Removing th
Page 305 and 306:
Page 307 and 308:
A Additional weight Replacement . .
Page 309 and 310:
O Operator's platform Installing .
Page 311 and 312:
Page 313 and 314:
WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 315 and 316:
1 Hydraulic circuit diagram . . . .
Page 317 and 318:
WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 319 and 320:
WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 321 and 322:
Component list WL 30 Date: 06.08.08
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WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 325 and 326:
WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 327 and 328:
WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 329 and 330:
Plug assignment, multi-function lev
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WL 30 - 10/2008-1 (WDF-7023-00EN) 1
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WL 30 - 10/2008-1 (WDF-7023-00EN) 1
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WL 30 - 10/2008-1 (WDF-7023-00EN) 1
Page 337 and 338:
A Assignment Combination switch . .
Page 339 and 340:
Page 341 and 342:
WL 30 - 10/2008-1 (WDF-7024-00EN) 1
Page 343 and 344:
1 Engine workshop manual (example)
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WL 30 - 10/2008-1 (WDF-7024-00EN) 1
Page 347 and 348:
Electric Drives and Controls Hydrau
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Electric Drives and Controls Hydrau
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WL 30 - 10/2008-1 (WDF-7024-00EN) 1
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WL 30 - 10/2008-1 (WDF-7024-00EN) 1
Page 355 and 356:
E Engine Workshop manual (example)
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Repair Manual for Wheel Loader WL 30 - Wacker Neuson

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