Operator’s Manual Wheel Loader WL 30 www.wackerneuson.
December 10 Edition
You have opted for a Wacker Neuson loader – thank you very much for putting your trust in us. Your Wacker Neuson loader is a powerful product with robust technology and a wide range of applications to aid you in your day-to-day work. In order to familiarize yourself with your loader in a quick, comprehensive manner, please read this Operator’s Manual attentively.
2 CONTENTS TABLE OF CONTENTS PREFACE................................................................................................................................................................ 7 1 2 1.1 1.2 1.3 1.4 BASIC INFORMATION...................................................................................................................................... 8 Notes about this Operator’s Manual....................................................................................................
CONTENTS WL30 2.6 2.7 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7 3 4 5 Final decommissioning / dismantling..................................................................................................... 30 Safety labels used.................................................................................................................................. 31 Safety devices...............................................................................................................................
4 CONTENTS 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 Fueling................................................................................................................................................... 60 Operation............................................................................................................................................... 62 Doors and windows.................
WL30 6 CONTENTS 5.5 Optional equipment...............................................................................................................................110 6.1 6.2 TOWING AND TRANSPORTING...................................................................................................................114 Towing...................................................................................................................................................114 Transporting..................
6 CONTENTS 10.7.7 10.7.8 10.7.9 10.7.10 10.7.11 10.8 10.9 Servicing the axles.............................................................................................................................. 191 Servicing the cab vent filter.................................................................................................................. 195 Servicing the brakes............................................................................................................................
P R E FA C E WL30 7 PREFACE This Operator’s Manual describes how to operate and service the loader. It provides operating and maintenance personnel with the necessary knowledge of the loader‘s functional characteristics in order to allow them to operate, diagnose, maintain and repair the loader safely.
8 B A S I C I N F O R M AT I O N 1 BASIC INFORMATION Each new user must be instructed before using the loader for the first time. Instructions for using the Operator’s Manual: • • • • Read the Operator’s Manual carefully before starting up the loader Observe all the safety instructions Follow the regulations and laws applicable at the place of use Keep the Operator’s Manual in the protected compartment provided in the operator station/cab.
B A S I C I N F O R M AT I O N WL30 1.1 9 Notes about this Operator’s Manual The specifications, illustrations, weight information and technical data are not binding and correspond to the state of the art at the time of printing. We must reserve the right to make changes without prior notice in the area of design, configuration, appearance and technology on account of the ongoing further development of the products.
10 B A S I C I N F O R M AT I O N 1.2 Explanation of the symbols used in this Operator’s Manual To ensure safe operation and maintenance of the wheel loader, it is necessary that you follow all the instructions in this Operator’s Manual. The following symbols and the signal words DANGER, WARNING, CAUTION, NOTICE, and NOTE, and the adjacent text, indicate hazards and instructions. This is the safety alert symbol. It is used to alert you to potential personal hazards.
B A S I C I N F O R M AT I O N WL30 CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. ►► Obey all safety messages that 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. Note: Contains additional information important to a procedure.
12 B A S I C I N F O R M AT I O N 1.3 Warranty and liability The manufacturer/supplier is not liable for damage resulting from unintended use. The operator/user is the sole bearer of this risk. The Operator’s Manual must always be located in the loader or at the place where it is being used. Place the Operator’s Manual in the document pocket at the rear of the operator‘s platform. Observe the following points: • • • • • • • Do not make any changes to the wheel loader.
B A S I C I N F O R M AT I O N WL30 1.4 13 Intended use Unintended use can endanger the lives of operating personnel or other persons and cause injuries or extensive material damage. The loader has been built according to applicable standards and regulations. Operation by inexperienced persons, or in an unintended manner, can result in hazards that can lead to personal risk and subsequent harm to the operator and persons in the operating area of the wheel loader.
14 B A S I C I N F O R M AT I O N Similar uses of the loader with alternative attachments which do not change the safety requirements for the loader but modify the way in which it is used are only acceptable when attachments that have been expressly approved by Wacker Neuson are employed. Special conditions apply if you use optional Wacker Neuson attachments. The wheel loader shall not be employed for any of the following work activities: The intended operation is described in this Operator’s Manual.
WL30 B A S I C I N F O R M AT I O N 15
16 BASIC SAFET Y INSTRUCTIONS 2 BASIC SAFETY INSTRUCTIONS This Wheel Loader is equipped with a Starter Lock / Drive Lock which must be kept operational. • • • • Use the loader and attachments only as intended and in serviceable 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 used on suitable terrain.
BASIC SAFET Y INSTRUCTIONS WL30 2.1 Organizational measures The following safety instructions are directed at the operator / user of the loader. • • • • 17 Always keep the Operator’s Manual in the compartment provided for it. As a supplement to the Operator’s Manual, universally valid legal and other binding regulations relating to road traffic, compulsory coverage, accident prevention and environmental protection must be observed, and users must be instructed to observe them.
18 BASIC SAFET Y INSTRUCTIONS • • • • If worn or damaged parts need replacement, use only Wacker Neuson replacement parts to ensure optimum performance and safety. Inspect hydraulic hoses and fittings prior to the start of each work shift. Correct any observed leaks or abrasion issues before operating the machine. Extended environmental exposure can cause undetectable damage. Replace hose assemblies periodically as advised in the maintenance schedule.
BASIC SAFET Y INSTRUCTIONS WL30 2.2 • • • • 19 Selection and qualification of personnel / basic duties The operator of the wheel loader must be qualified to operate the machine through demonstration of comprehension of the operating instructions. No one shall operate the wheel loader if impaired due to intoxication or drug reaction. Diagnosis and repair of the wheel loader shall be performed by trained competent technicians unimpaired by intoxication or drug reaction.
20 BASIC SAFET Y INSTRUCTIONS 2.3 Safety instructions for certain operating phases The safety instructions are directed at all persons involved in work on or with the loader. 2.3.1 • • • • • Safety instructions for normal operation Refrain from any measures that could put safety into question. Before starting work, familiarize yourself with the working environment in which you will be using the loader.
BASIC SAFET Y INSTRUCTIONS WL30 • • • • • When driving on public roads, lanes and squares, observe the valid road traffic regulations and put the loader into a condition permissible for the road beforehand. As a matter of principle, turn on the lights when traveling on public roads to increase awareness for road traffic.. When driving through underpasses, gates, bridges, tunnels, overhead lines, etc., always make sure that you have enough clearance above and on both sides and a sufficient safety margin.
22 BASIC SAFET Y INSTRUCTIONS 2.3.2 Safety instructions for other operating modes These safety instructions refer to special tasks relating to the use of the loader and servicing tasks - as well as emergency maintenance during operation or work concerning disposal of the auxiliary and operating materials. • • • The Operator’s Manual provides adjustment, maintenance and inspection information and schedules in subsequent sections.
BASIC SAFET Y INSTRUCTIONS WL30 • • • Use lifting devices to raise and support parts and assemblies exceeding 10 kg (22 lbs) weight during repair and replacement activity. Use only OSHA approved devices to perform the lifting operation and verify that the lifting devices are in serviceable condition. The use of a crane to lift heavy assemblies or components requires that the operator is certified by OSHA.
24 BASIC SAFET Y INSTRUCTIONS • • • Should it be necessary to remove safety devices during setup, servicing or repairs, reinstall and check the safety devices immediately after finishing the work and verify that the devices perform correctly. Replace the ROPS (Roll Over Protective Structure) or FOPS structure if it is permanently deflected, a member is deformed, it has become corroded, and/or it has been modified.
BASIC SAFET Y INSTRUCTIONS WL30 2.4 Safety instructions for particular hazards 2.4.1 Forklift attachment WARNING Personal injury hazard. Falling 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, OSHA1910 and OSHA1926 for regulations on carrying material. ►► Do not stack load higher than fork restraint. Fig.
26 BASIC SAFET Y INSTRUCTIONS 2.4.2 Working near overhead power lines WARNING Electric shock hazard. The operator of the Wheel Loader can be killed if the Wheel Loader comes in contact with electrical wires. ►► Keep the loader and attachment tools at a sufficient distance from overhead power lines and other electrical lines of more than 50 V (see table below). Nominal voltage Clearance distance up to 1000 V 1m 3.3 ft over 1 kV up to 110 kV 3m 9.
BASIC SAFET Y INSTRUCTIONS WL30 2.4.3 • • • Electrical power Regularly check the loader‘s electrical equipment. Defects, such as loose plug connections or cables with burnt insulation, shall be replaced before resuming operation. If an electrical malfunction is discovered, stop the wheel loader in a safe location, lower the loader arms and attachment to the ground and stop the engine. Contact the supervisor for diagnosis and repair by a qualified technician before resuming operation.
28 BASIC SAFET Y INSTRUCTIONS 2.4.5 • • • Gas, dust, steam, smoke Diesel engine exhaust emissions are toxic in concentrated amounts. Do not operate the wheel loader in enclosed spaces or inadequately ventilated spaces. Determine and follow regulations regarding safe operation at the specific work site. --Do not operate the wheel loader near open flames. --Do not perform welding repairs in explosive atmospheres. --Do not weld fuel reservoirs or fuel system components.
BASIC SAFET Y INSTRUCTIONS WL30 2.4.7 Tip-overs 2.4.8 WARNING Personal injury hazard. Falling Loader can strike or crush the operator. ►► Do not operate the wheel loader without fastening the seat belt. ►► Keep the loader lift arms and attachment as low as practical when traveling. • If the machine tips over, or in the event of an extreme slope condition, take the following steps to avoid engine damage: ►► Stop the engine as quickly as practical to avoid damage from lubrication starvation.
30 BASIC SAFET Y INSTRUCTIONS 2.5 • • • • • Transporting and towing / restarting Instructions are provided in this Operator’s Manual for towing, loading and transporting the wheel loader safely without machine damage. The towing machine shall be capable of towing the wheel loader. The loading and transport equipment shall be appropriate to safely complete the sequence of operation.
BASIC SAFET Y INSTRUCTIONS WL30 2.7 Safety labels used Maintain all safety message labels on the machine in a legible manner. If a safety label becomes damaged or illegible, replace it with a new label available from your Wacker Neuson dealer or at www. wackerneuson.com. 6 13 8 1 9 5 2 7 12 11 15 3 14 10 Fig.
32 BASIC SAFET Y INSTRUCTIONS Safety label 1 Safety label 3 Warning Warning Do not stand near the loader during operation. Do not go under the loader lift arms when raised. Personal injury hazard from falling equipment. Never stand in the unsecured danger area. Use the safety supports. Safety label 2 Safety label 4 Shearing hazard Warning Shearing hazard from rotating fan. Stop the engine before entering the area. Personal injury hazard.
BASIC SAFET Y INSTRUCTIONS WL30 Safety label 5 Safety label 7 Important Warning Remove the starting key and read the Repair Manual before proceeding with any work activity on the wheel loader. Hot surfaces can cause burns. Do not touch hot surfaces. Safety label 6 Safety label 8 Important Warning Lubricate the center joint daily before beginning work. Refer to your Operator’s Manual for more information. Never lift or transport people with the lifting attachment.
34 BASIC SAFET Y INSTRUCTIONS Safety label 9 Safety label 11 Warning Warning Personal injury hazard. Always wear the seat belt while operating the wheel loader. Pinching/crushing hazard. Avoid the articulation area while the Wheel Loader is in operation. Before working in the articulation area and before transporting, secure the articulation pivot. Refer to Operator’s Manual. Safety label 10 Safety label 12 Warning Warning Personal injury hazard. Never transport passengers on the Wheel Loader.
BASIC SAFET Y INSTRUCTIONS WL30 Safety label 13 Warning If the ROPS / FOPS protective structures are damaged, they can not serve their protective function. Never drill or weld the ROPS / FOPS protective structures. Refer to Operator’s Manual. Safety label 14 Warning 15 PSI 1 BAR Hot liquids or steam escaping under pressure can cause burns. Do not open radiator when it is hot. Refer to Operator’s Manual. 35 Label 15 Possibility of equipment damage Close both doors before tilting the cab.
36 BASIC SAFET Y INSTRUCTIONS 2.8 Safety devices 2.8.1 Fire extinguisher Contact your Wacker Neuson dealer if you want to install a fire extinguisher or a rotating beacon. Your Wacker Neuson dealer has the trained technicians to perform such work safely and effectively. Fig. 4 Fire extinguisher A fire extinguisher can be installed to operator cab rail to the right of the operator ‘s seat. (Fig. 4). 2.8.
BASIC SAFET Y INSTRUCTIONS WL30 2.8.3 37 Seat belt Before starting the engine: • adjust the seat to provide comfortable access to all control ranges. • examine the seat belt webbing for any mechanical or chemical damage and replace if necessary. • inspect all seat belt hardware for functionality 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 pad.
38 BASIC SAFET Y INSTRUCTIONS 2.8.5 Emergency exit The cab door on the left side of the machine facing the forward direction of travel is the primary access system to the operator station. The right hand access is a secondary opening intended for emergency use only. Fig.
BASIC SAFET Y INSTRUCTIONS WL30 2.8.6 Battery disconnect switch After removing the disconnect switch key, place the attached cover over the key opening to prevent dirt and water from entering the switch. To connect the battery to the electrical system, remove the cover, insert the key and rotate the key clockwise. To avoid inadvertent control behavior, do not disconnect the battery from the electrical system with the engine running or any electrical systems activated.
40 BASIC SAFET Y INSTRUCTIONS 2.8.7 Loader lift arm locking system CAUTION Possibility of inadvertent loader lift arm activation. Inadvertent activation can result in the loader arms dropping causing the bucket or attachment to engage 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 prevent inadvertent activation during travel.
TECHNICAL DATA WL30 3 TECHNICAL DATA 3.1 Technical description The loader consists of the vehicle frame, the drive and the axles. The vehicle frame contains all the drive and control units for the standard configuration. The vehicle frame consists of the front carriage with the loader lift arms, and the rear carriage, in which the drive unit is situated. They are connected by an articulated swivel joint.
42 TECHNICAL DATA Hydraulics The loader has two hydraulic systems supplied by a hydraulic fluid reservoir: - hydrostatic drive - steering and working hydraulics The hydrostatic drive consists of an axial piston variable displacement pump, which drives an axial piston motor. The axial piston variable displacement pump is rigid coupled directly to the diesel engine, while the axial piston motor is directly coupled to the transfer case. Displacement is automatic and continuous, but depends on speed and load.
TECHNICAL DATA WL30 Electrical system The electrical system operates at 12 volts and the electrical circuits are protected by fuses to prevent overload damage to the system and its components. Equipment The loading equipment consists of the loader lift arms with an integrated mechanical or hydraulic quick-change receptacle, lifting and tipping cylinders and the appropriate attachments. The loader is equipped with a rollover protective structure (ROPS). 3.
44 TECHNICAL DATA Hydraulics Vibrations (weighted effective value) Driving hydraulics Upper extremities no more than 2.50 m/s² 8.19 ft/s² Feet or seat surface no more than 0.80 m/s² 2.64 ft/s² Flow rate 78 l/min 20.61 gallons/min Working pressure 450 bar 6527 psi Noise values Working hydraulics Flow rate 49 l/min 12.94 gallons/min Average LwA measured at the operator‘s ear 98.
3.3 45 TECHNICAL DATA WL30 Product identification number plates A product identification number plate is attached to the loader on the right side of the front carriage (Fig. 10). Fig. 10 Vehicle ID It lists the following information: Manufacturer Vehicle ID Type Engine power Axle loads Operating weight Permissible total weight Wacker Neuson SE Preußenstraße 41 80809 Munich/Germany Radlader Art.-Nr. Fahrzeug-Ident-Nr. 1 Typ Motorleistung kW zul. Achslast vorn kg Betriebsgewicht kg zul.
46 TECHNICAL DATA 3.4 Fig.
TECHNICAL DATA WL30 Dimensions with 31x15,5-15EM tires Item Designation Value A Overall length with standard shovel 4554 mm 179.29 inch A‘ Overall length without shovel 3748 mm 147.56 inch B Axle center to shovel pivotpoint 722 mm 28.43 inch C Wheelbase 1732 mm 68.19 inch D Rear overhang 1179 mm 46.42 inch E Overhead loading height* 2990 mm 117.72 inch F Max. height of shovel pivot point* 3209 mm 126.33 inch G Height of seat* 1254 mm 49.37 inch H Max.
48 Description of the indicator , warning and control elements 4 DESCRIPTION OF THE INDICATOR, WARNING AND CONTROL ELEMENTS 4.1 Operating elements and instruments Fig.
Description of the indicator , warning and control elements WL30 Item Designation 1 Steering wheel turning knob 2 Instrument 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 pedal 10 Operating lever for adjusting the steering column 11 Operating lever for lighting, turn signals and signal horn 49
50 Description of the indicator , warning and control elements 4.2 Control and warning indicator lights • • • If the indicator lights do not illuminate properly at the starting sequence, repair the 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 until the reason for the illuminated indicator is determined and corrective action has been completed.
Description of the indicator , warning and control elements WL30 Item Designation Function 1 Not used No function 2 Heater indicator light Illuminates during preheating 3 Not used No function 4* Warning light for engine oil pressure 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 Indicator light for forward drive Illuminates when gear
52 Description of the indicator , warning and control elements Control and warning indicator lights • • • If the indicator lights do not illuminate properly at the starting sequence, repair the 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 until the reason for the illuminated indicator is determined and corrective action has been completed.
Description of the indicator , warning and control elements WL30 Item Designation Function 10 Indicator light for parking brake Illuminates when the parking brake is on 11 Not used No function 12 Indicator light for main beam Illuminates when the main 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 Warning light for return filter Illuminates
54 Description of the indicator , warning and control elements 4.3 1 Fig.
Description of the indicator , warning and control elements WL30 Item Designation Function 1 Combination switch Switches lighting and signal horn on/off 2 No function Available for optional equipment Switches the optional hydraulics in 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 electrical connector on the lift arms on/off 5 No function A
56 Description of the indicator , warning and control elements Switches / rocker switches Fig.
Description of the indicator , warning and control elements WL30 Item Designation Function 9 Rocker switch for front windshield wipers Switches front windshield 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 rear headlights Switches rear headlights on/off 13 Rocker switch for rotating beacon Switches rotating beacon on/off 14 No function Available
58 Description of the indicator , warning and control elements 4.4 Indicator devices 1 Fig. 16 2 Indicator devices 3 4 Item Designation Function 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.
WL30 Description of the indicator , warning and control elements 59
60 O peratin g and operation 5 OPERATING AND OPERATION 5.1 Before starting up Read the Operator’s Manual before starting up the loader. • • • • • Only operate the loader from the operator’s seat. Observe OSHA safety regulations. Arrange for training with an experienced operator. Practice operating the wheel loader in a remote flat area to become familiar with control response. Using this Manual as a reference, conduct an inspection before operating the wheel loader.
O peratin g and operation WL30 NOTICE Use only clean, conventional 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 uncontrollably into the environment. Immediately soak up with binding material any fuel that has leaked, overflowed or been spilled, and dispose of it in an ecologically sound manner.
62 O peratin g and operation 5.1.2 Operation Before entering the cab WARNING Personal injury hazard. ►► Do not operate the loader if it is not in serviceable condition or responding correctly to control commands. ►► Park the machine in a safe place, lower the loader arms and attachment, stop the engine and notify your supervisor. ►► Do not operate the machine until the problem has been corrected. ►► Check that the safety devices are present and operative each time before you start up the loader.
O peratin g and operation WL30 Operator station access Check: • • • • • • Engine oil level Hydraulic fluid level Coolant level Fuel level Check the condition of the tires, looking for abrasion, cuts or wear. Check the tire pressure! Ensure that the tires are inflated to the proper pressure (see tire pressure table). Ensure that the engine enclosures and the caps for the fuel reservoir and hydraulic fluid reservoir are present and have been tightened. WARNING Slipping hazard.
64 O peratin g and operation 5.1.3 Doors and windows CAUTION Possibility of injury or equipment damage from unlatched cab doors. ►► Close and latch the cab doors during operation. ►► The cab doors may be latched open during operation if circumstances require. ►► Always latch both doors before operating the wheel loader in the open or closed position. Fig. 18 Cab door locking The cab has one door on the left and one on the right. The cab doors can be locked in two positions: 1. Closed 2. Open (Fig.
O peratin g and operation WL30 5.1.4 Adjusting the steering column WARNING Personal injury or property damage hazard. Adjusting the steering column while the wheel loader is in operation can cause inadvertent machine movement. ►► Do not adjust the steering column while the wheel loader is in operation. ►► Stop the machine first and then adjust the steering column. You can adjust the position of the steering column lengthwise so that it fits your height and posture. 1. Operate the adjustment lever (Fig.
66 O peratin g and operation 5.1.5 Adjusting the operator’s seat WARNING Personal injury or property damage hazard. Adjusting the operator seat while the wheel loader is in operation can cause inadvertent control movements. ►► Do not adjust the operator seat while the wheel loader is in operation. ►► Stop the machine first and then adjust the seat. You can adjust the operator’s seat to fit your height and posture. This keeps your muscles relaxed and prevents you from tiring while working.
O peratin g and operation WL30 5.1.6 2. Weight adjustment: Adjust the weight while sitting in the seat by turning the weight adjustment handle. The weight is set correctly if the height position that has been set via the height adjustment handle can be seen in the view window Item 2a. The middle position of the spring‘s range for the respective height setting will be indicated. 3. Backrest adjustment: Adjust the backrest via the locking lever. The locking lever should lock in the desired position.
68 O peratin g and operation Buckling the seat belt Fig. 22 Buckling the seat belt 1. Sit back in the operator seat, so that your entire back is touching the seat. 2. Place the seat belt 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 section »Adjusting the seat belt« (page 69). Releasing the seat belt 1. Press the red button Item 2 on the belt buckle.
O peratin g and operation WL30 Adjusting the seat belt WARNING Personal injury or property damage hazard. Adjusting the seat belt while the wheel loader is in operation can cause inadvertent control movements. ►► Do not adjust the seat belt while the wheel loader is in operation. ►► Stop the machine first and then adjust the seat belt. Fig. 23 Adjusting the seat belt Lengthening Adjust your seat belt so that it fits snugly. Lengthening the seat belt: 1.
70 O peratin g and operation 5.2 Starting up 5.2.1 WARNING Possibility of injury or equipment damage from inoperable lights or individual functions. ►► Do not drive the loader if the entire lighting system or individual functions are not working. The lever (Fig. 24) is used to control the three functions, lighting, turn signals and forward warning device: The warning and indicator lights display fault messages from the equipment.
O peratin g and operation WL30 • Push the lever away from the operator (position 1): –– The right turn signal is activated. • Pull the lever towards the operator (position 2): –– The left turn signal is activated. • 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 switches on.
72 O peratin g and operation 5.2.2 Wipers and windshield washer system The wipers and windshield washer system are switched on/off using the rocker switches in the cab roof on the right next to the operator’s seat Item 4 and 5 (Fig. 25). Fig. 25 Switches for windshield wipers 4 5 Front window: Rear window: • –– • –– • –– • –– • –– • –– Put the rocker switch Item 4 in position 1: The windshield wiper switches on.
O peratin g and operation WL30 Filling the container for the windshield washer system The container for the windshield washer system is located on the rear side of the cab to the left. Access it by opening the engine enclosure (Fig. 26). WARNING Burn and cutting/shearing hazards from hot or moving engine parts. ►► Do not open the engine enclosure until the engine has stopped. ►► Do not attempt to service the wheel loader until the hot surfaces are comfortable to the touch.
74 O peratin g and operation 5.2.3 Headlights and rotating beacon WARNING Personal injury or property damage hazard. Working and driving lights can blind passing motorists. ►► Do not drive on public roads with working lights illuminated. ►► Confirm that the driving lights are aimed to avoid blinding oncoming traffic. The loader is equipped with headlights and taillights. The headlights are switched on using the rocker switches in the cab roof on the right next to the operator’s seat Item 6 and 7 (Fig.
O peratin g and operation WL30 Front headlights: • Put the rocker switch Item 6 in position 1: –– The headlights switch on. • Put the rocker switch Item 6 in position 0: –– The headlights switch off. Rear headlights: Operate the taillights using the rocker switch Item 7 (Fig. 27) the same way you would the front headlights. 75 The rotating beacon (optional equipment) Use the yellow rotating beacon according to local regulations.
76 O peratin g and operation 5.2.4 Ventilation and heating of the cab Ventilation Fig. 28 Heating controller The cab is ventilated via the doors and rear window. The doors must be locked in open condition (Fig. 18). Heating W The cab heater is located on the right next to the steering column. G Temperature Fan Use the left regulator Item W to adjust the temperature continuously (Fig. 28): Adjust the fan by turning the right regulator Item G (Fig. 28).
O peratin g and operation WL30 Ventilation outlets 5.2.5 Fig. 29 Ventilation outlets You can use the outlets (Fig. 29) to control air flow into cab. In cold weather, warm air supply keeps the windows free of ice and heats the cab in the process. 77 Before starting the engine Before starting the engine: • Make sure that no one is on or near the loader. • Keep the operating elements clean and dry. • Remove or tighten all loose objects in the cab.
78 O peratin g and operation 5.2.6 Starting the engine • • • • • • • • Due to the high viscosity in the hydraulic system at temperatures below 0°C (32°F), major machine damage can occur when the speed is increased immediately. Let the engine run at a low speed at temperatures below 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.
O peratin g and operation WL30 Description of the starting process If the engine does not start Use the starting key to start the loader‘s engine (Fig. 30). 1. Push the foot accelerator. 2. Put in the key - level 0 = no operating voltage. 3. Turn the key left against the spring pressure until the heater-plug indicator is illuminated Preheating: --The heating process is automatically activated when level I is switched on. --The heater indicator light Item 2 (Fig. 13) lights up.
80 O peratin g and operation 5.3 Propulsion operation Description of the propulsion hydraulics See »Hydraulics« section of 3.1 Technical Description on page 41. 5.3.1 Preparation for travel in public traffic • • Before you start travel, make sure that the machine complies with the relevant local regulations. Fork prongs of pallet forks must be dismantled before undertaking trips in public traffic. 1.
O peratin g and operation WL30 5.3.2 Travel speed WARNING Personal injury hazard from tipping or roll-over incidents. To avoid tipping and roll-over incidents: ►► Keep the loader lift arms and bucket load as low as practical ►► Keep the loading site level. ►► match the speed to working conditions to maintain control of the machine ►► Constantly survey the work area for obstructions, vehicles and people to avoid collisions and runover incidents.
82 O peratin g and operation Changing travel directions WARNING Personal injury and machine damage hazards from abrupt directional changes. Actuating the direction switch when the loader is moving will cause the moving loader to change direction abruptly. ►► Do not change the travel direction switch position when the loader is moving in either forward or reverse.
O peratin g and operation WL30 Changing speeds Fig. 31 Changing direction 1 The loader has an overdrive and a crawler gear. Use the button item 2 (Fig. 31) to shift the loader‘s gears. After starting 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 button again: –– The loader shifts from crawler gear to overdrive. Indicator light »18« (Fig. 13 ,page 52) lights up.
84 O peratin g and operation Loader travel Braking and stopping 1. Release the parking brake after the engine has warmed up. –– The handbrake indicator light will go off. The loader is ready to travel. 2. Select the travel direction by actuating the travel direction switch. –– The indicator light shows the travel direction selected. You can travel. • Push the accelerator. 3. The loader will be brought up to speed smoothly.
O peratin g and operation WL30 Changing the travel direction WARNING Personal injury and machine damage hazards from abrupt directional changes. Actuating the direction switch when the loader is moving will cause the moving loader to change direction abruptly. ►► Do not change the travel direction switch position when the loader is moving in either forward or reverse. It is not necessary to depress the inching pedal to the end of the movement every time you change direction. 1.
86 O peratin g and operation 5.4 Work operation Before starting to work with the loader: • Survey the work area to determine if people, vehicles and obstacles are in the immediate work area. Do not start work until the work area is clear. • Constantly survey the area during working operation to avoid collision with people, vehicles and obstacles that may inadvertently enter the loader work area. • Verify that all controls are working correctly and the indicator lights are functioning.
WL30 Each time before starting work • • • • • Examine the loader for visible defects 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 the operator taking your place. Perform the checks described in sections 5.1 (page 60) and 5.2.5 (page 77).
88 O peratin g and operation 5.4.1 Operating lever for Loader lift arms • • • • • Keep the loader lift arms and attachment as low as practical when traveling. This improves visibility and stability, and reduces the risk of striking overhead objects such as power lines. Do not activate float control of the loader arms until the bucket or attachment is in contact with the ground or surface to be back dragged. Engaging float with the lift arms raised will cause rapid descent of the lift arms.
O peratin g and operation WL30 Float position ( ) • Press the multi-function lever Item A (Fig. 32) forward across the resistance until it engages: –– The float position engages. • Pull back the multi-function lever Item A across the resistance: –– The 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.
90 O peratin g and operation 5.4.2 Activating the optional hydraulics Activating the optional hydraulics using the control lever Place the optional hydraulic control in neutral when the system is not required. This is necessary to avoid overheating the hydraulic system and improve fuel economy. Clean the quick connecting fittings carefully before connecting the optional hydraulic system fittings together.
O peratin g and operation WL30 91 Detent mechanism for the optional hydraulics Fig. 33 Operating lever for the optional hydraulics L Z This function allows you to operate the optional hydraulic connections in continuous use. This function is necessary for certain attachments powered by a hydraulic motor that necessitates continuous use (e.g. broom). Then you do not have to constantly hold the control lever for the optional hydraulics.
92 O peratin g and operation Activating the optional hydraulics using the button 1 If the detent mechanism or the float position of the optional control lever is engaged, it is not possible to activate the optional hydraulics with the button. Fig. 35 Button for optional hydraulics 2 You can activate the hydraulic connections of the loader lift arms (Fig. 34) using the buttons for the optional hydraulics Item 1 and Item 2 (Fig. 35).
O peratin g and operation WL30 Depressurized return line For some attachments, a depressurized return line is required. 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 that it is not possible to confuse it with the normal connections for the optional hydraulics. Fig.
94 O peratin g and operation 5.4.3 Loader lift arms locking system • • Before traveling from worksite to worksite over extended distances, engage the loader lift arm lock after selecting the height for the travel arms for the travel segment. Do not release the loader lift arm lock until starting the work cycle, or after parking the loader and prior to lowering the lift arms to the ground with the attachment.
O peratin g and operation WL30 5.4.4 Differential lock 1 Avoid damage to the transmission! Only switch on the differential lock if the wheels are not moving. Only use the differential lock for loading work on loose or slippery surfaces! After releasing the button (item 1, Fig. 38), the differential can be locked occasionally. This is noticeable by more effort for steering. Try to release the differential lock by slight right / left steering movements or by changing the direction of travel. Fig.
96 O peratin g and operation 5.4.5 Changing attachments This Operator’s Manual describes only the use of the following attachments: • • • Light cargo buckets Earth buckets Earth buckets with digging teeth If you wish to use optional attachments with your loader, please observe the following: Contact your Wacker Neuson dealer before using any attachment not in the approved list. The dealer and Wacker Neuson technical staff can determine the compatibility of the proposed attachment.
O peratin g and operation WL30 NOTICE Unapproved attachments could overload the loader. This can result in damage to the loader. 1. Before assembly, start-up or maintenance, read the Operator’s Manual for the relevant attachment. 2. Practice using the attachment before working with it the first time. Familiarize yourself ahead of time with all the functions and control elements. • • • • • • When loading, adjust your driving speed to the material being loaded and traction conditions.
98 O peratin g and operation Coupling of attachments WARNING Personal injury hazard. ►► Check the locking pins item 4 (figure 39) to avoid unintentional disconnection of the attachment. Confirm that the hydraulic couplings are correctly matched to operate the attachment. ►► Pressurized hydraulic oil can penetrate the skin, causing infections. ►► If this occurs, seek immediate emergency room treatment. ►► Oil entering the eyes must also be treated immediately in an emergency room.
O peratin g and operation WL30 2 For hydraulically activated attachments: 6. Stop the engine and actuate the control lever for the optional attachment hydraulics several times in both directions. This will release any residual hydraulic pressure in the lines to enable coupling the attachment hydraulic lines. 7. Insert the attachment‘s quick couplers in the appropriate connections for the attachment hydraulic lines on the loader lift arms. 8.
100 O peratin g and operation Uncoupling attachments • • • • • Lower the attachment until it is firmly resting on a hard surface. Close attachments with movable 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 supports, extend them to the support position. Place the attachment only on a hard, even foundation.
O peratin g and operation WL30 5.4.6 101 Bucket Function NOTICE Avoid overloading. Observe the maximum permissible payload. Operate the control lever carefully. The light cargo bucket / earth bucket attachments are intended for loosening, picking up, transporting and dumping materials. The light cargo bucket is used for light materials such as grain, maize and pellets. The earth bucket is used for heavy materials such as gravel, sand, soil and stone.
102 O peratin g and operation Operation Before performing work for the first time, practice handling the bucket. When dumping the bucket and loading vehicles, you can perform two work movements at the same time if necessary, e.g. lifting and dumping or lowering and curling to load. To do so it is necessary to overlay the movement on the control lever (Fig. 40). The float position facilitates stripping during resurfacing work. To do so, lower the bucket with the tip to the ground.
O peratin g and operation WL30 Level indicator With the attachment in a horizontal position, mark the place on the tipping cylinder on which the level indicator is located with a colored line. Item 1 (Fig. 41). Use the level indicator (Fig. 41) in order to assess more effectively the curl position of the attachment from the operator‘s seat. Fig.
104 O peratin g and operation Working with the bucket WARNING Tipping hazards. Improper use of the loader lift arms and bucket may cause the loader to tip, possibly causing injury or equipment damage. ►► Operate the loader 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 and fully loaded bucket unless the ground or operating surface is firm and flat.
WL30 Now raise the loader lift arms slightly so that the weight is on the loader‘s front axle. This is to avoid excess wheel slip. You can also manually restrict wheel slip by inching. O peratin g and operation Fig. 43 Loading work 2 To fill the bucket, curl the bucket as shown in Fig. 43 as the loader arms are slowly raised. Carry the loaded bucket in this position to the location or truck where the material in the bucket is to be deposited.
106 O peratin g and operation Excavation work Soft material: Lower the bucket to the ground to lift out soft material and tilt the bucket forward until you have a digging angle. If you start driving the loader forward now, the bucket‘s digging edge will break into the ground. Now make the tilting angle flat to remove as even a layer as possible and to avoid a large amount of wheel slip (Fig. 45).
O peratin g and operation WL30 5.4.7 Tip-overs If the machine tips over, or in the event of an extreme slope condition, take the following steps to avoid engine damage: • Stop the engine as quickly as practical to avoid damage 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 incident. ENVIRONMENTAL NOTE Right the loader as soon as possible so that oil and fuel cannot escape.
108 O peratin g and operation 5.4.8 Precaution measures for various temperature conditions At high outside temperatures At low outside temperatures Take the following precautions at high temperatures to prevent the loader from being damaged: • • • • • Regularly check the cooling system: --Keep the engine coolant and oil coolers clean --Make sure that the coolant level is always correct --Use the proper coolant mix.
O peratin g and operation WL30 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 idle speed until the temperature indicator for the system indicates warming has progressed. • Operate the wheel loader slowly and smoothly to accelerate the warming process. • Observe the hydraulic system filter pressure display to determine if pressure is excessive.
110 O peratin g and operation 5.5 Optional equipment Loader lift arm damping Activate the loader lift arm damper control to improve ride quality and stability during travel with the loader. Disengage the damper control before attempting to use the loader for loading operations. Before engaging the damper feature, verify that the loader bucket or attachment has sufficient clearance with the ground to avoid contact while traveling. The loader lift arms will drop when the damper function is activated.
WL30 Loader lift arm damper activation • 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) downwards: The red indicator light in the switch goes off –– Damping is disengaged. Loader controls can be actuated. O peratin g and operation Fig.
112 O peratin g and operation Optional hydraulics control activation This function allows you to actuate optional hydraulic connections. This function is necessary if the standard 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 the left: –– The left-hand connection is for the pressure side, the right-hand is for the return line.
O peratin g and operation WL30 Electrical connector on the loader lift arms 2 Switch the electrical connector on the lift arms (Fig. 49) by means of the switch, Item 2 (Fig. 50), on the control lever. Fig. 50 Switch for the electrical connector on the loader lift arms The electrical connector on the loader lift arms is used to connect attachments for which certain functions must be activated electrically. Fig.
114 T owin g and transportin g 6 TOWING AND TRANSPORTING 6.1 Towing WARNING Personal injury or equipment damage hazards from improper towing. ►► Do not attempt to tow the machine if the steering system or brake system is not serviceable. Loss of control during towing can occur. Load the wheel loader and transport it to a repair facility with trained technicians. ►► A tow bar is preferred for towing the wheel loader.
T owin g and transportin g WL30 Towing equipment NOTICE Towing the wheel loader can damage the hydrostatic propulsion system unless the following conditions 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 meters (0.3 miles) requires that it be loaded on suitable transport to the repair destination. Do not use the towing equipment to pull trailer loads. Fig.
116 T owin g and transportin g Disconnecting the drive (Bypass- switching) WARNING Possibility of personal injury or equipment damage. 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 secured. Fig.
T owin g and transportin g WL30 To tow the loader, it is necessary that you disconnect the drive. In this case the travel transmission is switched on to free wheeling. For this purpose the variable displacement pump has incorporated high pressure relief valves with bypass function. 1. Tilt the operator cab/platform upward from the left side for access to the high pressure relief valves (refer to Section 10.7.1, pages 158-161). 2. Loosen hex nut Item 2 (Fig. 52). 3. Screw in the stud Item 1 (Fig.
118 T owin g and transportin g 6.2 Transporting Load and transport the loader only according to DOT safety regulations. Only experienced, trained specialized personnel may load and transport the loader. Articulation frame lock Personal injury hazard. Install the articulation frame lock slowly and carefully to reduce the risk of injury. The articulation frame lock is stored on the front frame of the wheel loader as illustrated in Fig 53. It is secured by two pins which are retained by spring pins.
T owin g and transportin g WL30 Fig.
120 T owin g and transportin g Loading on a transport vehicle 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 reduce the slipping hazard during loading. Use a transport vehicle rated to carry the mass of the wheel loader and attachments. Confirm that the transport vehicle is serviceable for the transport task.
T owin g and transportin g WL30 Use the attachment points (Fig. 55) that are marked 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 lifting position. Fig. 55 Attachment points front Fig.
122 T owin g and transportin g Independent driving onto the transport device 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 reduce the slipping hazard during loading. Use a transport vehicle rated to carry the mass of the wheel loader and attachments. Confirm that the transport vehicle is serviceable for the transport task.
T owin g and transportin g WL30 As attachment 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 point label Fig.
124 T owin g and transportin g Fig.
L owerin g loader arms WL30 7 Lowering loader arms Warning Personal injury or equipment damage hazards. In the event the engine stops and can not be restarted with the loader lift arms elevated: • Lower the loader lift arms and attachment until they rest on the ground or work 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 quickly and safely as possible.
126 Relieving residual pressure in the hydraulic system 8 Relieving RESIDUAL PRESSURE IN THE HYDRAULIC SYSTEM WARNING 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. ►► Open only unpressurized hydraulic systems.
Relieving residual pressure in the hydraulic system WL30 Opening the load holding control valves Fig. 59 Reducing residual pressure WARNING 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. Illustration 1 Only trained personnel may open the load holding control valves.
128 Relieving residual pressure in the hydraulic system Fig. 60 Load holding control valve 1 2 For loaders with load holding control valves on the lifting and attachment cylinder, open the valves (Fig. 60). 1. Unscrew the nuts Item 1 2. Unscrew the screw Item 2 until the loader lift arms slowly lowers. • Should the loader lift arms not lower due to friction or insufficient mass, you will have to augment the process using a control cable or ratchet straps. 3.
SECURING THE LOADER WL30 9 129 SECURING THE LOADER The following instructions apply to stopping and parking the loader after daily operation, transporting the loader and to all servicing, inspection and repair work. • • • • • • • • • • • Place the loader on an even, dry surface that can support sufficient weight. Lower the loader lift arms. Engage the parking brake and stop the engine. Switch off all electrical switches.
130 SERVICING AND INSPECTION 10 SERVICING AND INSPECTION 10.1 Basic safety instructions for servicing and inspection Operator’s Manual • • • • Perform servicing and inspection work only if you have read and understood the Operator’s Manual. Observe the basic safety instructions and all the warning signs attached to the loader. The Operator’s Manual describes the work to be performed.
SERVICING AND INSPECTION WL30 Securing the loader and attachment • • • • • • • • Perform servicing and inspection work only if the loader is secured as described in the chapter »Securing the loader«. Crushing hazard. An improperly supported loader lift arm may fall unexpectedly.
132 SERVICING AND INSPECTION Handling combustible fluids Tools • Use diagnostic and repair tools that are in serviceable condition and have been calibrated regularly to ensure accuracy. Consult the Repair Manual for recommended special tools necessary to safely complete the repair task. Cleaning • • • • • • Clean the machine before attempting to diagnose or repair the wheel loader. Do not use flammable solvents. Do not use cleaning agents that create harmful vapors.
SERVICING AND INSPECTION WL30 Residual pressure in the hydraulic system Personal injury hazard. • Pressurized jets of fluid can penetrate human skin. • In the event that oil penetrates the skin, seek immediate medical attention to reduce the risk of infection and complications from infection. • Confirm that the hydraulic system pressure has been relieved before attempting to repair the system or component.
134 SERVICING AND INSPECTION Handling fuel, oil and grease 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 fluid. • In the event of contact with hot fluid seek emergency room treatment immediately. • Avoid skin and eye contact with oils and greases. Wear protective gloves and safety goggles. • Do not use fuel or solvents to clean your skin.
SERVICING AND INSPECTION WL30 Batteries Personal injury hazard. Battery acid is corrosive to metallic surfaces and harmful to human skin. • Wear protective clothing, goggles and gloves when working near batteries. • If battery acid contacts the skin, wash immediately in clear water. • Seek the advice of a doctor for treatment of skin burns. • In the event acid contacts eyes, rinse immediately with clear water and seek immediate medical attention. Explosion hazard.
136 SERVICING AND INSPECTION Engine exhaust fumes • • Diesel engine exhaust fumes are harmful. Do not inhale exhaust gas. Do not operate the wheel loader in a closed space. For servicing and inspection work performed in a closed space, extract the exhaust fumes using an extraction system and ventilate the space well. Electrical system • • • Always observe the correct order when disconnecting the battery. --Disconnecting: First the negative pole and then the positive pole.
WL30 After maintenance • • • • After completing maintenance and inspection work, always 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 seat. Perform a functional test with the loader after completing servicing and inspection work.
138 SERVICING AND INSPECTION 10.
SERVICING AND INSPECTION WL30 Weekly servicing Perform the following tasks: • • • • • • • • • Clean fuel filter for the presettling reservoir (if present) Check axles for leaks Check hydraulic fluid cooler and water radiator for leaks and dirt Check exterior condition of the radiators, i.e.
140 SERVICING AND INSPECTION First inspection after 50 operating hours Maintenance and inspection personnel must have specialized knowledge of servicing and inspection work on the loader. Follow the Operator’s Manual for the engine. To assure proper functioning of the machine, it is required that the first inspection be performed after 50 operating hours, but at the latest 3 months after initial start-up, by a Wacker Neuson dealer or a mechanic at a Wacker Neuson factory agent.
WL30 Tasks to be performed (check) Check the electrical system Check the foot brake and parking brake, adjust if necessary Check the hydraulic steering Check the lighting system (if present) Check the idle speed Check the valve clearance, 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 air filter, replace if necessary Change the hydro return filter Have al
142 SERVICING AND INSPECTION Inspection after 500 operating hours Maintenance and inspection personnel must have specialized knowledge of servicing and inspection work on the loader. Follow the Operator’s Manual for the engine. This inspection is performed once after the first 500 operating hours. Should the loader not reach 500 operating hours during the first year of operation, perform this inspection once 12 months after starting up the loader.
WL30 Tasks to be performed (check) Check the acid level of the battery Check: Instruments, indicators + audible warning devices Check the electrical system Check the foot brake and parking brake, adjust if necessary Check the hydraulic steering 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 engine enclosure and door locking mechanisms, adjust if necessary Ch
144 SERVICING AND INSPECTION Tasks to be performed (check) Set the valve clearance Change the hydraulic fluid Change the hydro 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 shafts Lubricate all the levers, cables and hinges with oil Check all the oil levels The following inspection intervals apply after this inspection: 500 hours inspection
SERVICING AND INSPECTION WL30 Inspection intervals Maintenance and inspection personnel must have specialized knowledge of servicing and inspection work on the loader. Follow the Operator’s Manual for the engine. Perform the maintenance work listed in the inspection schedule depending on which interval has been reached first, that is, if either the number of operating hours have been reached or the time specified in the schedule has elapsed.
146 SERVICING AND INSPECTION Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc. Operating hours: 1500, 2500, 3500, 4500, etc.
SERVICING AND INSPECTION WL30 Work to be performed Check the lighting system – (if present) Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc. Operating hours: 1500, 2500, 3500, 4500, etc. X X monthly X annually X Check the exhaust system X X Check the hinge pins and joint bushings X X Check the center pivot bolts and bearings X X Check the pressure relief valves in the hydraulic system Check the idle speed X X X X X X Check max.
148 SERVICING AND INSPECTION Work to be performed Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc. Check ROPS/FOPS structures Check the condition of the tires and the tire pressure Operating hours: 1500, 2500, 3500, 4500, etc.
SERVICING AND INSPECTION WL30 Work to be performed Operating hours: 250, 750, 1000, 1250, 1750, 2000, 2250, 2750, 3000, etc. Check all the oil levels X Check according to the Ordinance on Industrial Safety and Health Operating hours: 1500, 2500, 3500, 4500, etc. monthly annually 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.
150 SERVICING AND INSPECTION 10.3 Lubrication schedule Lubricate all the 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Fig.
SERVICING AND INSPECTION WL30 Item Point of lubrication Nipples Item Point of lubrication Nipples 1 Engine enclosure hinges [2] 13 Small tie rod, rear [1] 2 Door hinges [4] 14 Small tie rod, front [1] 3 Brake pedal bearing (in the cab) [1] 15 Cab tilting hinge, rear [1] Brake lever bearing (under the cab) [1] 16 Drive shaft, rear [1] 4 Accelerator (in the cab) [1] 17 Steering cylinder, rear (remote lubrication) [1] 5 Center pivot bearing, top [2] 18 Cab tilting hinge,
152 SERVICING AND INSPECTION 10.4 Cleaning the loader WARNING Burn hazard. High pressure water at the maximum recommended temperature (80°C (176°F)) will cause severe burns and is extremely hazardous if contact is made with the eyes. ►► Wear protective clothing and safety goggles while cleaning the machine. Clean the wheel loader frequently, particularly the access systems, to prevent slips and falls when entering and leaving the operator station.
SERVICING AND INSPECTION WL30 When the loader is new (in the first three months), only clean it with a sponge. As the paintwork on the underside is not fully hardened, the paintwork can be damaged if cleaned with a high-pressure cleaner. Please note when cleaning the loader with a highpressure cleaner: Maximum water pressure 130 bar (1885 psi). Maximum water temperature 80°C (176°F).
154 SERVICING AND INSPECTION 10.5 General safety check Immediately rectify any damage detected during the safety check. Damaged parts must be immediately repaired or replaced. Do not use the loader again until the damage has been rectified professionally.
SERVICING AND INSPECTION WL30 10.6 Specifications and filling quantities When filling oil, the oil level must correspond to the dip stick or control screw markings. Item Capacity in liters / gallons Fluid / grease nipple Specification Fuel reservoir 53 14.00 Diesel fuel Engine oil with filter 8,3 2.19 Engine oil SAE 10 W 40 Ambient temperature -20°C to +40°C (-4°F to +104°F) API CG-4 / API CH-4 See engine manual Cooling system contents 11,5 3.
156 SERVICING AND INSPECTION 10.7 Maintenance and inspection work 10.7.1 Perform maintenance and inspection work only if the loader is secured as described in Section 9, page 129 »Securing the loader«. The operator cab/platform can be tilted for access to the wheel loader systems for inspection, maintenance and repair. Refer to section 10.7.1 pages 158-161 for detailed instructions on how to tilt the operator cab/platform.
SERVICING AND INSPECTION WL30 If the engine stops and can not be restarted from the operator 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 the problem. Fig. 62 Handle for the engine enclosure Remove all tools and objects from the engine and the engine compartment before closing the engine enclosure. Open and close the engine enclosure using the handle provided.
158 SERVICING AND INSPECTION Tilting the operator’s platform WARNING Improperly tilting the cab can cause personal injury or damage to equipment. ►► Before tilting the cab remove loose objects from the cab to avoid control/indicator damage. ►► Close and confirm that the doors are latched ►► Do not attempt to tilt the cab until the wheel loader has cooled to the point that the engine and hydraulic system are comfortable to touch.
SERVICING AND INSPECTION WL30 1 Fig.
160 SERVICING AND INSPECTION Tilting the operator’s platform: 1. Remove any loose objects from the operator’s platform. 2. Make sure there is sufficient room to the right of the loader. 3. Close the cab doors. 4. Open the engine enclosure. 5. Remove the two mounting bolts from the support bracket on the left of the operator’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.
SERVICING AND INSPECTION WL30 Fig. 65 Cab safety support 161 Lowering the operator’s platform: 1. Remove the support bar from the pocket and return it to storage on the crosspiece underneath 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 the mounting bolts immediately after lowering the operator’s platform back in place. 4.
162 SERVICING AND INSPECTION 10.7.2 Servicing the engine WARNING Shearing, pinching, and crushing hazards exist when the engine is running. ►► Do not open the engine enclosure until the engine has stopped. Burn hazard. The engine, engine exhaust and cooling system exceed 93°C (200°F) at operating temperature. Touching the engine compartment components can cause severe burns. ►► Stop the engine and wait until the engine compartment components are cool enough to touch before performing service work.
SERVICING AND INSPECTION WL30 163 2 Fig. 66 Checking the engine oil / filling the oil 1 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground or working surface. 3. Stop the engine. 4. Wait until the engine has cooled and the dipstick is comfortable 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 stick with a clean, lint-free cleaning rag. 8.
164 SERVICING AND INSPECTION Adding engine oil Use the correct oil grade (see Section 10.6, page 155 »Specifications and filling quantities«). Use a funnel with tube extension as aid for filling. If the fluid level is under the »Maximum« mark, the fluid must be added: Open the oil filler neck Item 2 (Fig. 66). Add the engine oil. Check the oil level. Add engine oil until the oil level is at the »Maximum« mark. 5. Close the oil filler neck Item 2 (Fig. 66). 1. 2. 3. 4.
SERVICING AND INSPECTION WL30 Fig. 67 Engine oil drain opening 2 1 165 1. Bring the engine to operating temperature and allow to cool until the drain plug is comfortable to touch. 2. Stop the loader on a horizontal surface and set the parking brake. 3. Lower the loader lift arm and attachment to the ground or working surface. 4. Stop the engine. 5. Place a container with sufficient volume to avoid spillage under the drain opening. 6.
166 SERVICING AND INSPECTION Changing the engine oil filter Once the engine oil has been drained: 1. Change the engine oil filter (see the section »Changing the engine oil filter«). 2. Unscrew the supplied hose Item 2 (Fig. 67) and screw the sealing plug back in. 3. Open the oil filler neck Item 2 (Fig. 66): 4. Add engine oil until the oil level has reached the »Maximum« mark. 5. Start the engine and let it idle until the engine oil indicator light goes out. 6.
SERVICING AND INSPECTION WL30 The engine oil filter is located on the left side of the engine (Fig. 68). 1. Put a receptacle for draining oil under the engine oil filter. 2. Unscrew the engine oil filter item 1 (Fig. 69): 3. Clean the sealing surface of the filter 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.
168 SERVICING AND INSPECTION 10.7.3 Servicing the fuel system The fuel passes from the reservoir through a pre-filter and a sieve with water separator and is then conveyed by an electric feed pump through the main filter to the fuel injection pump. The filters and the feed pump are located in the engine compartment. To access them, open the engine enclosure and tilt the operator’s platform. WARNING Personal injury hazard. Moving engine components can crush or cut.
WL30 SERVICING AND INSPECTION Servicing the water separator 1. Place a receptacle under the water separator Item 1 (Fig. 70). 2. Unscrew the drain plug 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. Fig. 70 Water separator 1 Check the filter screen in the water separator. If required: 5. Remove the inspection glass and clean it. 6. Clean or replace the filter screen. 7.
170 SERVICING AND INSPECTION Changing the fuel pre-filter a The fuel pre-filter Item 2 (Fig. 71) can only be replaced in conjunction with the entire housing. 1. 2. 3. 4. 5. 6. 2 Fig. 71 Fuel pre-filter, main fuel filter Place a receptacle under the fuel pre-filter. Remove the hose clamps from the fuel pre-filter. Disconnect the fuel hoses. Replace the fuel pre-filter. Connect the fuel hoses. Attach the hose clamps for the fuel pre-filter.
SERVICING AND INSPECTION WL30 Changing the main fuel filter 1. Place a receptacle under the main fuel filter item 3 (Fig. 71). 2. Unscrew the screw Item a (Fig. 71). 3. Remove the main fuel 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 that they fit correctly. 6. Replace the main fuel filter. 7. Put on the filter cover. 8.
172 SERVICING AND INSPECTION Venting the fuel system 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 now be started. Fig.
SERVICING AND INSPECTION WL30 10.7.4 Servicing the air filter system The loader is equipped with a dry air filter for filtering the engine intake air. The dry air filter consists of a main filter and a safety filter element. To access the dry air filter, open the engine enclosure. WARNING Crushing/shearing hazard. Moving engine parts can crush and cut.
174 SERVICING AND INSPECTION Check main air filter element / clean / replace Air filter dust valve Check if the outlet slot on the dust valve Item 1 (Fig. 74) is clear. Remove dust accumulation by pinching the valve. a 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 inspection glass in the maintenance display, Item 3 (Fig. 74) . To reset the display, press the button Item a (Fig. 74). 3 2 Fig.
SERVICING AND INSPECTION WL30 Checking / changing the safety filter 1. Remove the fasteners on the cover Item 2 (Fig. 74) and take off the cover. 2. Remove the main filter element Item 1 (Fig. 75). Do not remove the safety filter element in the process. 3. Perform a visual inspection of the intake manifold between the filter and the engine for leaks and tight fit. The intake manifold must not display any exterior damage. 4.
176 SERVICING AND INSPECTION 10.7.5 Servicing the cooling system The radiator is installed behind the diesel engine. The left part contains hydraulic oil; the right part is intended for cooling the engine (Fig. 76). WARNING Crushing/shearing hazard. Moving engine parts can crush and cut. ►► Do not open the engine enclosure unless the engine is stopped to avoid hazards from moving objects (cooling fan and drive belts for the fan and alternator). Burn hazard.
WL30 The temperature indicator light is connected to two temperature sensors; one is located on the engine (Fig. 77), the other on the hydraulic oil reservoir (Fig. 78). To ascertain whether the engine or hydraulic oil (or both) have become too hot, disconnect the cable on one of the two temperature sensors. SERVICING AND INSPECTION Fig.
178 SERVICING AND INSPECTION Checking the coolant level / refilling the coolant WARNING Burn hazard. Hot fluid (exceeding 93°C (200°F)) will spray under pressure. Contact with skin will cause severe burns. ►► Do not remove the radiator cap if the engine is at operating temperature. Poison hazard. Coolant can be harmful or fatal if swallowed. ►► If hot coolant makes contact with the skin or eyes, rinse immediately with clear water and seek immediate medical attention.
SERVICING AND INSPECTION WL30 179 Checking the antifreeze mix Check the coolant level at regular intervals. If you look into the radiator opening (Fig. 79) from above, the radiator fins should be covered with coolant. Make sure that enough antifreeze is always present in the coolant, even in summer, as antifreeze also prevents internal corrosion of the radiator and the engine. Fig.
180 SERVICING AND INSPECTION Changing the coolant NOTICE Replace the coolant after two years of use. 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 reduce the potential for air entrapment during filling. Use the capacity guide on page 155. Fill until the coolant is below the neck of the radiator cap spout. Replace the cap and run the engine briefly.
SERVICING AND INSPECTION WL30 181 Cleaning the cooling system The greater the amount of dust in the air, the more frequently the radiator has to be checked and cleaned. Always cover up the suction connection of the air filter before cleaning the radiator. Do not damage the radiator fins when cleaning the radiator. Straighten any twisted radiator fins carefully.
182 SERVICING AND INSPECTION 10.7.6 Servicing the hydraulic system WARNING Crushing/shearing hazard. Moving engine parts can crush and cut. ►► Do not open the engine enclosure unless the engine is stopped to avoid hazards from moving objects (cooling fan and drive belts for the fan and alternator). Burn hazard. The operating temperature of the hydraulic system is 93°C (200°F). Contact with skin will cause severe burns. ►► Rinse with water immediately and seek medical treatment. Injury hazard.
SERVICING AND INSPECTION WL30 Hydraulic fluid cooler 183 Ventilation filter / hydraulic fluid filler neck The oil radiator is installed behind the diesel engine (Fig. 82). The left part contains hydraulic oil; the right part is intended for cooling for 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-belt is taut and in good condition and whether the radiator air flow is blocked. Fig.
184 SERVICING AND INSPECTION Checking the hydraulic fluid level The hydraulic oil reservoir is located on the left side of the rear frame. To access it, open the engine enclosure (reference Section 10.7.1, pages 158-161). Never let the oil level drop below the »Minimum« mark on the dip stick. When adding oil, never let the »Maximum« mark on the dip stick be exceeded. Oil cloudiness means that water or air is in the system, which could damage the hydraulic pump.
SERVICING AND INSPECTION WL30 185 Adding hydraulic fluid Use the correct oil grade (reference Section 10.6, page 155 »Specifications and filling quantities«). Open the hydraulic oil filler neck cap Item 1 (Fig. 83) carefully so that the pressure can escape from the reservoir. Fig. 83 Ventilation filter 1 Fig. 84 Hydraulic fluid dip stick If the fluid level is under the »Maximum« mark, add hydraulic fluid until the maximum level is reached. 1. 2. 3. 4.
186 SERVICING AND INSPECTION Changing the hydraulic fluid WARNING Burn hazard. The operating temperature of the hydraulic system is 93°C (200°F). Contact with skin will cause severe burns. ►► Wear protective clothing. ►► Rinse affected areas with water immediately and seek medical treatment. Refer to Section 10.6, page 155 »Specifications and filling quantities« to determine the necessary container volume to avoid spillage. ENVIRONMENTAL NOTE Avoid environmental damage.
SERVICING AND INSPECTION WL30 Fig. 85 Hydraulic fluid drain plugs 187 Once the hydraulic fluid has been drained: 1. Remove the filter insert Item b (Fig. 87). 2. Clean the reservoir bottom and reservoir interior with hydraulic or detergent oil through the opening. 3. Replace the filter element of the return filter (see the 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.
188 SERVICING AND INSPECTION Changing the return filter element The hydraulic system is equipped with a return filter Item 2 (Fig. 86). It is connected to an indicator light. An installed bypass valve secures the return valve against positive pressure. Replace the filter element of the return filter Item b. (Fig. 87) during inspections or if the indicator light for the return filter on the instrument panel is illuminated between inspection intervals.
SERVICING AND INSPECTION WL30 2 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground or work surface. 3. Stop the engine. 4. Relieve the residual hydraulic pressure using the procedure 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): Replace the gasket if it is damaged.
190 SERVICING AND INSPECTION Venting the hydraulic system WARNING Possibility of injury or equipment damage. Trapped air in the hydraulic system will cause erratic or inadvertent movement of the loader arms. ►► Before returning the loader to work after servicing, it is necessary to purge any air trapped in the hydraulic system. 1. Check the fluid level in the hydraulic fluid reservoir. If necessary, add hydraulic fluid until the fluid level is at the »Maximum« mark. 2.
SERVICING AND INSPECTION WL30 10.7.7 Servicing the axles Service the transmission and the axles according to the inspection intervals specified in this Operator’s Manual. Checking / filling and draining screws can be found in the same place on the front and rear axles. The axial piston oil motor of the loader‘s drive hydraulics is mounted on the transfer case. The transfer case is connected to the rear axle of the loader. The front axle is powered via the drive shaft.
192 SERVICING AND INSPECTION Fig. 89 Transfer case c d Fig. 90 Wheel reduction e 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground 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 Item e (Fig. 90) is horizontal. 5.
SERVICING AND INSPECTION WL30 Changing the axle oil WARNING Burn hazard. The transmission oil operating temperature can cause serious burns if contact is made with skin. ►► If hot oil contacts the skin, seek medical attention immediately for burn treatment. The complete axle (transfer case, differential, axle tube, wheel drives) shares a common oil supply. If some of the oil must be changed, then afterwards, all oil levels must be checked to ensure that sufficient oil is in the axle. Refer to section 10.
194 SERVICING AND INSPECTION 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground or work surface. 3. Stop the engine. 4. Place a sufficiently large receptacle under the drain opening of the differential housing item b (Fig. 88). 5. Remove the hex socket plug Item a (Fig. 88); the transmission oil will now drain more quickly. 6. Remove the hex socket plug Item b (Fig. 88). 7. The transmission oil drains off. 8.
SERVICING AND INSPECTION WL30 10.7.8 Servicing the cab vent filter Change the cab air filter annually, or more frequently under dusty conditions. 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. 91). 1. 2. 3. 4. Remove the lid of the filter housing. Remove the filter. Insert a new filter. Replace the lid of the filter housing. Fig.
196 SERVICING AND INSPECTION 10.7.9 Servicing the brakes WARNING Personal injury hazard. The service and parking brakes are essential for safe operation of the wheel loader. Loss of control is hazardous to the operator as well as other people on the work site or public roads. ►► Always check brake performance at the start of each work shift and stay alert to changes in response or capacity. A loss in response or capacity must be corrected.
SERVICING AND INSPECTION WL30 ENVIRONMENTAL NOTE Avoid environmental damage. Do not allow oil and 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. The brake fluid reservoir is on the left at the back, underneath the engine enclosure (Fig. 92). The control marks »MAX« and »MIN« are on the side of the container.
198 SERVICING AND INSPECTION 10.7.10 Servicing the tires and wheels WARNING Injury or explosion hazards. ►► Do not attempt to remove or install tires on the rims. Special tools and training are required to dismount and mount tires safely. Contact a qualified technician for tire repair service. ►► Do not weld or attempt to use any type of flame to heat the rim with the tire mounted on the rim. Tires can release gas with age creating an explosive atmosphere internally.
SERVICING AND INSPECTION WL30 Air pressure table for tires 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground or work surface. 3. Stop the engine. 4. Remove the valve stem cap on the tire valve. 5. Place the pneumatic chuck of the filling device on the tire valve so that it stays in place. 6. Inflate the tires to the specified pressure. 7. Remove the pneumatic chuck of the filling device from the tire valve. 8.
200 SERVICING AND INSPECTION Changing wheels WARNING Injury hazard. An improperly secured machine can move or fall unexpectedly while changing wheels. To remove a wheel for service: ►► stop the loader on a flat surface ►► lower the loader lift arms and attachment to the ground or work surface ►► engage the parking brake ►► chock a wheel ►► Determine the mass of the wheel loader and use a lifting device rated for the mass.
WL30 1. Stop the loader on a horizontal surface with a hard foundation and set the parking brake. 2. Lower the Loader lift arms and attachment to the ground or work surface. 3. Stop the engine. 4. Position the 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 the ground. 7. Remove the wheel bolts and the wheel. 8. Install the new wheel and the wheel bolts. 9.
202 SERVICING AND INSPECTION 10.7.11 Servicing the electrical system WARNING Electric shock hazard. ►► Always disconnect the battery before working on the electrical system if tools, spare parts, etc. with electrical components or contacts could touch it. Electric shock and burn hazards. ►► Do not clean sensitive electrical components (instrument panel, alternator, compact plug, multi-function lever, etc.) with a high-pressure cleaner.
SERVICING AND INSPECTION WL30 A 40 ampere capacity master fuse is located below the operator’s platform (Fig. 93). Fig. 94 Fuse boxes Box 1 Fig.
SERVICING AND INSPECTION F013 F023 F026 F014 F015 F016 Item Fused function for Box 1 Rating (A) F017 F021 Front headlights 15 F022 Front windshield wipers 10 F018 F023 Rear windshield wipers 10 F019 F024 Rear tail lights 15 F025 Rotating beacon, radio 10 F026 Cab courtesy light, radio 10 F020 FR 10 FR 10 F022 F025 FR 15 F012 F021 F024 FR 5 F011 FR 20 Box 1 Box 2 Fig.
SERVICING AND INSPECTION WL30 Item Fused function for Box 2 Rating (A) Item Fused function for Box 2 Rating (A) F001 Turn signal (blinkers), hazard warning lights 15 F011 Available F002 Horn, rotating beacon 10 Electrical connector on the lift arms, other opF003 tional equipment F012 15 F013 Available F004 Stopper, generator, fuel pump 10 F014 Available F005 Available 10 F015 Available F006 Optional equipment 10 F016 Left low beam 7,5 10 F017 Right low beam 7,5 F018 Main beam
206 SERVICING AND INSPECTION Battery WARNING Explosion and burn hazard. Batteries produce and vent gases that can be explosive if concentrated in an unventilated space. ►► Do not smoke or use open flames near a storage battery. ►► Do not place objects on the battery. If a metallic 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 .
SERVICING AND INSPECTION WL30 207 Servicing the battery Fig. 96 Location of the battery Refer to the operator’s manual for the battery. The operator’s manual for the battery is attached to the side of the battery item 2 (Fig. 97). • 1 • • 3 4 Fig. 97 Servicing the battery 2 Always keep the terminals on the battery and on the connecting cables clean and lubricate them with anticorrosion grease. Make sure that the protective cover of the positive terminal is always in place and closed item 3 (Fig.
208 SERVICING AND INSPECTION Disconnecting and connecting the battery / changing the battery WARNING Personal injury hazards. Do not open the engine enclosure or attempt to tilt the operator 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 disconnecting the battery. – Disconnecting: First the negative pole and then the positive pole.
WL30 SERVICING AND INSPECTION 209 Removing the battery: 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the loader lift arms and attachment to the ground or work surface. 3. Stop the engine. 4. Before disconnecting the battery, switch off all electrical controls (and the battery disconnect switch) and remove the starting key. 5. Open the engine enclosure (Ref. section 10.7.1, page 156). 6. Tilt the operator cab/ platform (Ref. section 10.7.1, pages 158-161). 7.
210 SERVICING AND INSPECTION 10.8 Jump-starting / emergency starting WARNING Explosion and burn hazard. Batteries produce and vent gases that can be explosive if concentrated in an unventilated space. ►► Do not smoke or use open flames near a storage battery. ►► Do not place objects on the battery. If a metallic 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 .
SERVICING AND INSPECTION WL30 Before jump-starting, check if the loader‘s dead battery is functional: 1. Switch off all 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 defective. In that case, the loader must not be started! Install a new replacement battery. r 2 V 1 L 3 s 4 Fig.
212 SERVICING AND INSPECTION Getting ready Starting the engines 1. Switch off all the loader‘s electrical controls. 2. Switch the starting key to position 0. 3. Drive the vehicle with the good battery (charged battery) near but not touching the loader. 4. Switch off all electrical controls on the vehicle with the good battery and stop the engine. 1. Start the engine of the vehicle with the good battery and let it run at an increased speed. 2. Attempt to start the loader engine. 3.
SERVICING AND INSPECTION WL30 10.9 213 Loader storage The specified measures refer to shutting down and re-starting the loader over longer periods of time. Follow the Operator’s Manual for the engine. Note: Before beginning the shutdown procedures, drive the Wheel Loader to its storage location. Shutting down the loader 1. Park the loader as described in section 9, page 129 »Securing the loader«. 2. Engage the articulated frame lock (Ref. Section 6.2, page 118). 3.
214 SERVICING AND INSPECTION Preserving the engine Storing the battery: 1. Clean the engine in a suitable place using a high-pressure cleaner. 2. Bring the engine to operating temperature. 3. Drain the engine oil and dispose of it in an ecologically sound manner. 4. Pour anti-corrosion oil into the engine. 5. Drain the fuel from the reservoir. 6. Produce a mixture of 90% fuel and 10% anti-corrosion oil and pour it into the fuel reservoir. 7. Let the engine idle for 10 minutes before turning it off. 8.
WL30 Restarting the loader 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the engine preservative. Install the battery. Check the air pressure of the tires. Remove the preservative for the hydraulic cylinders‘ piston rods. Lower the loader. Check the functioning of the electrical system. Unblock the articulated joint. Vent the hydraulic system. Check the functioning of the steering and the brakes. SERVICING AND INSPECTION Remove preservatives from the engine 1.
216 T roubleshootin g and emer g ency maintenance 11 Troubleshooting and emergency maintenance 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 attract Check the fuses Fuel line is leaky
T roubleshootin g and emer g ency maintenance WL30 Fault / malfunction Possible cause Remedy The engine is getting too hot The engine radiator / oil cooler air flow is restricted by debris Clean it Coolant level is too low Fill it up The thermostat is jammed Have the thermostat replaced at the garage V-belt loosened from the fan blade Tighten the V-belt Oil level is too low or too high Adjust the oil level Hydraulic oil cooler is dirty Clean it V-belt loosened from the fan blade Tighten t
T roubleshootin g and emer g ency maintenance 218 Suction hose Filter Reservoir Oil Oil grade Temperature Wear Cooler System Oil motor Auxiliary pump Scavenging valve Scavenging needle »G« Transmission pump Rotary direction »S« Transmission pump Troubleshooting for transmission pump / oil engine Suction pressure Measuring point Cause Supply pressure Measuring point Accessories Brake / accumulator Cooler Cooler not blocked Clutch Brake Waste oil-leakage Oil temperature Connecting wire Supply
Cause Driving speed is not reached Cause Diesel engine Speed Control pressure Inching Transmission pump Diesel engine Speed Loader Loader Gear ratio Tires Tire diameter Diesel engine Fuel-injection pump Fuel filter Transposition Control pressure Pressure cut-off Not enough driving power Transmission pump Cause High-pressure valves Wear Transposition Transmission pump Engine is pressed hard Cause Transmission pump Choke Suction pressure Control pressure Commencement of control Inching Dri
220 S afety instructions for repairs 12 Safety instructions for repairs The »Safety instructions for repairs« section does not consist of instructions for repairs, but rather of safety instructions which, in addition to the generally valid safety regulations for repair work, refer to hazards that could occur during repair work, and of notes which should prevent the machine from being damaged during repairs. Specific repair instructions are not included in this Operator’s Manual. 12.
S afety instructions for repairs WL30 Articulated frame lock • • Removing components: WARNING Burn hazard. Engine components and fluids can get very hot during operation. ►► Do not remove components when the loader is warm from operation. Always install the articulating joint lock when performing repair work in the articulation crush zone. Remove the articulated joint lock and store it properly (Ref. Section 6.2, page 118) after completing the repair work.
222 S afety instructions for repairs Do not remove seals or sealing wax: After completing the repair: • • • • Changing rated pressures for relief valves is prohibited without the express consent of Wacker Neuson. Do not damage or remove seals and sealing wax on the engine, the pressure limiting valves and accumulators. If an area is repainted and a safety label is damaged or obliterated, replace the label before using the machine.
S afety instructions for repairs WL30 12.2 • Engine 12.3 223 Welding work WARNING Improper handling of the ROPS/FOPS can compromise its integrity. ►► Do not drill, weld, straighten, or bend the ROPS / FOPS protective structures. ►► Allow only trained authorized personnel to install new ROPS / FOPS structures. Perform repair work only if the loader is secured as described in Section 9, page 129 »Securing the loader«. • • Only a certified trained welder shall perform welding work.
224 S afety instructions for repairs Before performing welding work on the loader After welding has been completed: • • • • • • Disconnect the battery as described in this Operator’s Manual. Disconnect the positive pole (terminal B+) on the generator. Switch OFF the battery disconnect switch (if present). Protect bare terminals and connections against shortcircuiting. Attach the welding grounding terminal in the immediate vicinity of the welding site.
S afety instructions for repairs WL30 12.4 • • • • • Hydraulic system Before performing repair work, relieve the pressure in the hydraulic system as described in Section 8, page 126 »Relieving residual pressure in the hydraulic system«. Replace damaged and leaky hydraulic lines and hoses with new ones. Do not use used hoses. Replace hydraulic hoses after six years of use. Dispose of any leaking oil and waste containing oil in an ecologically sound manner.
226 F i n a l s h u t d o w n o f t h e l oa d e r / d e c o m m i s s i o n i n g 13 FINAL SHUTDOWN OF THE LOADER / DECOMMISSIONING ENVIRONMENTAL NOTE Avoid environmental damage. Do not allow oil and waste containing oil to spill on the ground or get into bodies of water! Dispose of different materials and operating fluids/ auxiliary materials separately and in an ecologically sound manner. Should you no longer plan to use the loader as intended, make sure that it is shut down, i.e.
WL30 Disposing of the loader: • • • • Subsequent recycling of the loader must take place in accordance 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, depending on the material. Take care to separate the materials when recycling. Make sure that operating and auxiliary aids are disposed of in an ecologically sound manner.
228 A ppendi x 14 Appendix 14.1 Ordering replacement parts Use only »original Wacker Neuson replacement parts« for your loader. This is especially necessary in the case of hydraulic hoses. Use only original hydraulic hoses or hydraulic hoses of comparable quality. Always provide the following data for ordering replacement parts. This is the only way we can assure smooth processing of your order and delivery of the replacement parts.
A ppendi x WL30 Enter the most important data for your loader on this page. In this way, you can quickly access the vehicle ID no. and other important data when ordering replacement parts. Loader type: Vehicle ID no.: Engine type: Engine no.
230 A ppendi x 14.2 Inspection verification 2nd Inspection Enter the inspections as they are performed.
A ppendi x WL30 4th Inspection 6th Inspection Performed on: Performed on: Operating hours: Operating hours: Stamp / signature of the garage Stamp / signature of the garage 5th Inspection 7th Inspection Performed on: Performed on: Operating hours: Operating hours: Stamp / signature of the garage Stamp / signature of the garage 231
232 A ppendi x 8th Inspection 10th Inspection Performed on: Performed on: Operating hours: Operating hours: Stamp / signature of the garage Stamp / signature of the garage 9th Inspection 11th Inspection Performed on: Performed on: Operating hours: Operating hours: Stamp / signature of the garage Stamp / signature of the garage
WL30 For personal notes A ppendi x 233
234 I nde x Index Activating the optional hydraulics.......................................................................................................................... 90 Activating the optional hydraulics using the button............................................................................................... 92 Activating the optional hydraulics using the control lever...................................................................................... 90 Adding engine oil.................
WL30 I nde x Changing wheels................................................................................................................................................. 200 Checking / changing the safety filter................................................................................................................... 175 Checking the antifreeze mix................................................................................................................................
236 I nde x Headlights and rotating beacon............................................................................................................................ 74 Hydraulic fluid cooler........................................................................................................................................... 183 If the engine does not start...................................................................................................................................
WL30 I nde x Servicing the brakes............................................................................................................................................ 196 Servicing the cooling system.............................................................................................................................. 176 Servicing the electrical system...........................................................................................................................
238 L ist of fi g ures List of figures Fig. 1 Document pocket............................................................................................................................. 12 Fig. 2 Transport of large bales or packaged goods................................................................................... 25 Fig. 3 Location of the Safety labels............................................................................................................ 31 Fig. 4 Fire extinguisher....
WL30 L ist of fi g ures Fig. 24 Lighting / forward warning device.................................................................................................... 71 Fig. 25 Switches for windshield wipers........................................................................................................ 72 Fig. 26 Location of the windshield washer container................................................................................... 73 Fig. 27 Headlight and rotating beacon switches...
240 L ist of fi g ures Fig. 47 Switch for loader lift arm vibration damping.................................................................................... 111 Fig. 48 Optional hydraulics control lever...................................................................................................... 112 Fig. 49 Electrical connector on the loader lift arms..................................................................................... 113 Fig.
WL30 L ist of fi g ures Fig. 70 Water separator............................................................................................................................... 169 Fig. 71 Fuel pre-filter, main fuel filter........................................................................................................... 170 Fig. 72 Changing the main fuel filter............................................................................................................ 171 Fig.
242 L ist of fi g ures Fig. 93 Master fuse...................................................................................................................................... 203 Fig. 94 Fuse boxes....................................................................................................................................... 203 Fig. 95 Fuse allocation................................................................................................................................. 204 Fig.
WL30 L ist of fi g ures 243
Wacker Neuson SE Preußenstraße 41 80809 München Tel. +49 89 35402-0 Fax +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 Neuson Machinery (HK) Ltd. Skyline Tower, Suite 2303, 23/F 39 Wang Kwong Road, Kwoloon Bay Hong Kong Tel.: +852 3188 5506 Fax: +852 2406 6021 Art.-Nr.
