Wacker Neuson WL44, WL54 Wheel Loader Service Repair Manual

Service Repair Manual: 444 Pages
Operators Manual: 250 Pages
Manuals: Service Repair Manual
Category: Wacker Neuson

Table of Content – Wacker Neuson WL44, WL54 Manual

Introduction
Notice on This Service Manual
Technical Data
Tightening Torques
Safety Instructions
Special Tools
Operation
Overview of Control Elements
Indicator Lights and Warning Lights (Overview)
Maintenance
Information on Maintenance
Maintenance Overview
Lubrication Plan
Fluids and Lubricants
Maintenance Accesses
Cleaning and Maintenance
Lubrication Work
Fuel System
Engine Lubrication System
Cooling System
Air Filter
V-Belt/Toothed Belt
Hydraulic System
Electrical System
Heating, Ventilation and Air Conditioning System (Option)
Washer System
Axles/Traveling Drive
Braking System
Tires
Maintenance and Servicing Work on Attachments
Maintenance of Options
Exhaust Gas Treatment
Engine
Perkins Engine 404D-22 (35.7 kW)
Perkins Engine 404F-22 (44.7 kW)
Alternator (44.7 kW)
Starter M001 (44.7 kW)
Diesel Particulate Filter (44.7 kW)
Deutz Engine TCD 2.9 L4 (55.4 kW)
V-Belts (55.4 kW)
Alternator (55.4 kW)
Removing/Installing the Starter (55.4 kW)
Removing/Installing the Air Filter (55.4 kW)
Deutz Engine TD2011 L04w (55.1 kW)
Removing/Installing the Fuel Tank
Cooling
Removing/Installing the Coolant Reservoir
Removing/Installing the Radiator
Removing/Installing Fan Blades
Traveling Drive
Traveling Drive Hose Routing (Example)
Variable Displacement Pump
Variable Displacement Motor
Hydraulic Oil Reservoir
Removing/Installing the Cardan Shaft
Troubleshooting
Axles
Front Axle
Rear Axle
Type Label – Front/Rear Axle
Brake
Removing/Installing the Brake Pedal
Removing/Installing the Parking Brake
Removing/Installing the Parking Brake Bowden Cable
Master Brake Cylinder
Steering System
Hose Routing
Removing/Installing the Steering Wheel
Removing/Installing the Steering Column
Removing/Installing the Steering Column Gas Strut (Comfort Cabin)
Removing/Installing Steering Cylinder A81
Steering Orbitrol S1
Gear Pump
Work Hydraulics
Overview
Hose Routing of Lift, Tilt and Lock Cylinders (WL44)
Hoses of Lift and Tilt Cylinders with Counterbalance Valve
High Flow Hose Routing
Hose Routing for Rear Additional Control Circuit with Control Valve HDS21/1 for Deutz Engines (WL44/WL54)
Hose Routing for Rear Additional Control Circuit with Control Valve HDS21/1 for Perkins Engines (WL44)
Hose Routing for Rear Additional Control Circuit with Control Valve HDS21/2 for Deutz Engines (WL44/WL54)
Hose Routing for Rear Additional Control Circuit with Control Valve HDS21/2 for Perkins Engines (WL44)
Removing/Installing Gear Pump P43/P57
Removing/Installing Lock Cylinder A4
Removing/Installing the Lock Pin
Removing/Installing the Tilt Cylinder
Removing/Installing the Loader Unit
Removing/Installing the Lift Cylinder
Removing/Installing the Reversing Lever
Removing/Installing Solenoid Valve V30
Removing/Installing Vibration Damping Valve V75
Removing/Installing the Quickhitch
Removing/Installing the Operating Lever for the Additional Hydraulic System
Control Valve
Removing/Installing the Control Valve for the Additional Hydraulics System
Designation of Hydraulic Components
Hydraulics Diagram for WL44 – HDM19/4 with HDS21/1 or 6/2 Directional Valve
Hydraulics Diagram for WL44 – HDM19/4 with HDS21/2
Hydraulics Diagram for WL44 – HDM19/3 with HDS21/1 or 6/2 Directional Valve
Hydraulics Diagram for WL44 – HDM19/4 High Flow
Hydraulics Diagram for WL54 – HDM19/4 with HDS21/1 or 6/2 Directional Valve
Hydraulics Diagram for WL54 – HDM19/4 with HDS21/2
Hydraulics Diagram for WL54 – HDM19/3 with HDS21/1 or 6/2 Directional Valve
Hydraulics Diagram for WL54 – HDM19/4 High Flow
Electrics
Fuses
Fuse Assignment
Removing/Installing the Machine Control Unit
Joystick
Removing/Installing the Battery Master Switch
Malfunctions of the Machine Electronics
Electrical Diagram – Electronics and Power Supply (FG01-01)
Electrical Diagram – Electronics CAN Bus (FG01-02)
Electrical Diagram – Perkins Engine 404D-22 (FG02-01)
Electrical Diagram – Perkins Engine 404F-22 (FG02-02)
Electrical Diagram – Perkins Engine 404F-22 (FG02-03)
Electrical Diagram – Deutz Engine TD2011 (FG02-04)
Electrical Diagram – Deutz Engine TCD 2.9 (FG02-05)
Electrical Diagram – Deutz Engine TCD 2.9 (FG02-06)
Electrical Diagram – Deutz Engine TCD 2.9 DPF (FG02-07)
Electrical Diagram – Deutz Engine TCD 2.9 DPF (FG02-08)
Electrical Diagram – Deutz Engine TCD 2.9 DPF (FG02-09)
Electrical Diagram – Instrument (FG03-01)
Electrical Diagram – Drive Function (FG04-01)
Electrical Diagram – Manual Throttle and Manual Inching (FG04-02)
Electrical Diagram – Working Lights, Rotating Beacon and Horn (FG05-01)
Electrical Diagram – StVZO Lighting, Turn Indicator System and Horn (FG06-01)
Electrical Diagram – StVZO Lighting, Front Headlight (FG06-02)
Electrical Diagram – Brake Light and Reversing Light (FG06-03)
Electrical Diagram – Washer System (FG07-01)
Electrical Diagram – Radio, Cigarette Lighter and Interior Light (FG08-01)
Electrical Diagram – Heating and Seat (FG09-01)
Electrical Diagram – Heating and Air Conditioning System (FG09-02)
Electrical Diagram – Hydraulic Control Circuits and 12V Electrical Connection (FG10-01)
Electrical Diagram – Hydraulic Control Circuits and Rear Electrical Connection (FG11-01)
Electrical Diagram – High Flow (FG11-02)
Electrical Diagram – Roll-In Stop and Overload Display (FG11-03)
Electrical Diagram – Loader Unit Stabilizer and Counterbalance Valve (FG11-04)
Electrical Diagram – Central Lubrication System (FG12-01)
Designation of Electrical Components
Trim
Removing/Installing the Engine Cover
Removing/Installing the Base Plate
Removing/Installing the Trailer Power Outlet
Removing/Installing the Trailer Coupling/Chassis Cover
Removing/Installing the Counterweight
Base Weights (WL54)
Cabin
Removing/Installing the Floor Mat
Removing/Installing the Steering Wheel
Removing/Installing the Indicating Instrument
Removing/Installing the Starter
Removing/Installing the Wiper Motor
Heating
Removing/Installing the Cabin
Removing/Installing the Base Plate
Malfunctions
Towing a Machine
Error Code Lists
Mounting Positions
Hydraulics
Electrics