Operator s Manual Wheel Loader WL 50 Wacker Neuson

www.wackerneuson.com Operator’s Manual Wheel Loader WL 50

May 2013 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. In addition to the information regarding operation, this Operator’s Manual also contains important maintenance and operating instructions for conserving the value of your loader. Furthermore, we will show you how to operate your loader in an environmentally sound manner. Should you have any questions or problems relating to your loader, please contact your Wacker Neuson partner or im- porter. They will be happy to respond to your questions, suggestions or criticisms at any time. :H DUH FRQ¿GHQW WKDW \RX ZLOO EH YHU\ VDWLV¿HG ZLWK \RXU QHZ :DFNHU 1HXVRQ ORDGHU Wacker Neuson SE

CONTENTS 2 TABLE OF CONTENTS PREFACE............................................................................................................................................................... 7 1 BASIC INFORMATION ..................................................................................................................................... 8 1.1 Notes about this Operator’s Manual ....................................................................................................... 9 1.2 Explanation of the symbols used in this Operator’s Manual ................................................................. 10 1.3 Warranty and liability............................................................................................................................. 12 1.4 Intended use ......................................................................................................................................... 13 2 BASIC SAFETY INSTRUCTIONS .................................................................................................................. 16 2.1 Organizational measures ...................................................................................................................... 17  6HOHFWLRQ DQG TXDOL¿FDWLRQ RI SHUVRQQHO  EDVLF GXWLHV ......................................................................... 19 2.3 Safety instructions for certain operating phases .................................................................................. 20 2.3.1 Safety instructions for normal operation ............................................................................................... 20 2.3.2 Safety instructions for other operating modes ...................................................................................... 22 2.4 Safety instructions for particular hazards ............................................................................................. 25 2.4.1 Forklift attachment ................................................................................................................................ 25 2.4.2 Working near overhead power lines ..................................................................................................... 26 2.4.3 Electrical power..................................................................................................................................... 27  )O\LQJ VSDUNV  ¿UH GDQJHU..................................................................................................................... 27 2.4.5 Gas, dust, steam, smoke ...................................................................................................................... 28 2.4.6 Hydraulics, pneumatics ......................................................................................................................... 28 2.4.7 Tip-overs ............................................................................................................................................... 29 2.4.8 Noise ..................................................................................................................................................... 29 2.4.9 Oils, grease and other chemical substances ........................................................................................ 29  7UDQVSRUWLQJ DQG WRZLQJ  UHVWDUWLQJ ..................................................................................................... 30

CONTENTS 3 WL50  )LQDO GHFRPPLVVLRQLQJ  GLVPDQWOLQJ .................................................................................................... 30 2.7 Safety labels used................................................................................................................................. 31 2.8 Safety devices....................................................................................................................................... 36 2.8.1 Fire extinguisher ................................................................................................................................... 36 2.8.2 Rotating beacon .................................................................................................................................... 36 2.8.3 Seat belt ................................................................................................................................................ 37 2.8.4 Emergency exit ..................................................................................................................................... 38 2.8.5 Backup alarm for reverse drive ............................................................................................................. 38 2.8.6 Battery disconnect switch ..................................................................................................................... 39 2.8.7 Loader lift arm locking system .............................................................................................................. 40 3 TECHNICAL DATA.......................................................................................................................................... 41 3.1 Technical description ............................................................................................................................ 41 3.2 Loader data ........................................................................................................................................... 43  3URGXFW LGHQWL¿FDWLRQ QXPEHU SODWHV..................................................................................................... 45 3.4 Dimensions ........................................................................................................................................... 46 4 DESCRIPTION OF THE INDICATOR, WARNING AND CONTROL ELEMENTS ......................................... 48 4.1 Operating elements and instruments .................................................................................................... 48 4.2 Control and warning indicator lights...................................................................................................... 50 4.3 Indicator devices ................................................................................................................................... 54  6ZLWFKHV  URWDU\ VZLWFKHV .................................................................................................................... 55 4.5 Rocker switches .................................................................................................................................... 56 5 OPERATING AND OPERATION .................................................................................................................... 60

CONTENTS 4 5.1 Before starting up ................................................................................................................................. 60 5.1.1 Fueling .................................................................................................................................................. 60 5.1.2 Operation .............................................................................................................................................. 62 5.1.3 Doors and windows............................................................................................................................... 64 5.1.4 Adjusting the operator’s seat ................................................................................................................ 67 5.1.5 Adjusting the steering column............................................................................................................... 70 5.1.6 Seat belt ................................................................................................................................................ 71 5.2 Starting up ............................................................................................................................................ 74 5.2.1 Lighting system and forward warning device ........................................................................................ 74 5.2.2 Wipers and windshield washer system ................................................................................................. 76 5.2.3 Headlights and rotating beacon ............................................................................................................ 78 5.2.4 Ventilation and heating of the cab......................................................................................................... 80 5.2.5 Before starting the engine..................................................................................................................... 82 5.2.6 Starting the engine................................................................................................................................ 83 5.3 Propulsion operation ............................................................................................................................. 86  3UHSDUDWLRQ IRU WUDYHO LQ SXEOLF WUDI¿F .................................................................................................... 86 5.3.2 Travel speed.......................................................................................................................................... 87 5.3.3 Stopping and parking ............................................................................................................................ 91 5.4 Work operation...................................................................................................................................... 92 5.4.1 Operating lever for Loader lift arms ...................................................................................................... 94 5.4.2 Loader lift arms locking system ............................................................................................................ 96 5.4.3 Activating the optional hydraulics.......................................................................................................... 97 5.4.4 Differential lock ................................................................................................................................... 100 5.4.5 Changing attachments ........................................................................................................................ 102 5.4.6 Tip-overs ............................................................................................................................................. 107 5.4.7 Bucket ................................................................................................................................................. 108

CONTENTS 5 WL50 5.4.8 Precaution measures for various temperature conditions ...................................................................114 5.5 Optional equipment ..............................................................................................................................116 6 TOWING AND TRANSPORTING ................................................................................................................. 124 6.1 Towing ................................................................................................................................................. 124 6.2 Transporting ........................................................................................................................................ 128 7 LOWERING LOADER ARMS........................................................................................................................ 135 8 RELIEVING RESIDUAL PRESSURE IN THE HYDRAULIC SYSTEM ........................................................ 136 9 SECURING THE LOADER ........................................................................................................................... 139 10 SERVICING AND INSPECTION................................................................................................................... 140 10.1 Basic safety instructions for servicing and inspection ........................................................................ 140 10.2 Servicing and inspection intervals ...................................................................................................... 148 10.3 Lubrication schedule ........................................................................................................................... 160 10.4 Cleaning the loader ............................................................................................................................. 162 10.5 General safety check .......................................................................................................................... 164  6SHFL¿FDWLRQV DQG ¿OOLQJ TXDQWLWLHV ..................................................................................................... 165 10.7 Maintenance and inspection work ...................................................................................................... 166 10.7.1 Preparation for maintenance and inspection work.............................................................................. 166 10.7.2 Servicing the engine ............................................................................................................................171 10.7.3 Servicing the fuel system.................................................................................................................... 177  6HUYLFLQJ WKH DLU ¿OWHU V\VWHP .............................................................................................................. 181 10.7.5 Servicing the cooling system .............................................................................................................. 184

CONTENTS 6 10.7.7 Servicing the air conditioning system ................................................................................................. 191 10.7.6 Servicing the hydraulic system ........................................................................................................... 192 10.7.8 Servicing the axles.............................................................................................................................. 201 10.7.9 Servicing the brakes ........................................................................................................................... 205 10.7.10 Servicing the tires and wheels ............................................................................................................ 208  6HUYLFLQJ WKH FDE YHQW ¿OWHU................................................................................................................. 212 10.7.12 Servicing the air conditioning system ................................................................................................. 213 10.7.13 Servicing the electrical system ........................................................................................................... 214  -XPSVWDUWLQJ  HPHUJHQF\ VWDUWLQJ .................................................................................................... 222 10.9 Loader storage .................................................................................................................................... 225 11 TROUBLESHOOTING AND EMERGENCY MAINTENANCE...................................................................... 228 12 SAFETY INSTRUCTIONS FOR REPAIRS................................................................................................... 232 12.1 General safety regulations for repairs................................................................................................. 232 12.2 Engine ................................................................................................................................................. 235 12.3 Welding work ...................................................................................................................................... 235 12.4 Hydraulic system................................................................................................................................. 237 12.5 Brakes ................................................................................................................................................. 237  ),1$/ 6+87'2:1 2) 7+( /2$'(5  '(&200,66,21,1* ................................................................. 238 14 APPENDIX .................................................................................................................................................... 240 14.1 Ordering replacement parts ................................................................................................................ 240  ,QVSHFWLRQ YHUL¿FDWLRQ ......................................................................................................................... 242 Index ............................................................................................................................................................ 246 /LVW RI ¿JXUHV ...................................................................................................................................................... 250

7 WL50 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. 2EVHUYLQJ WKH VSHFL¿FDWLRQV LQ WKLV 2SHUDWRU¶V 0DQXDO DV- sures:  proper, safe, professional operation of the loader  professional service, cleaning and care of the loader Observe the applicable OSHA 1910 and 1926 safety regulations when they apply to the user. ,I UHTXLUHG WKH XVHURSHUDWRU VKRXOG VXSSOHPHQW WKH 2S- erator’s Manual with instructions and regulations regarding environmental protection and national regulations relating to accident prevention. All persons involved in work on or with the loader must read and apply this Operator’s Manual, for example with regard to:  operation, including setup, maintenance during operation, care, disposal of auxiliary materials and operating materials as well as disposal of the entire loader.  maintenance (inspection, servicing, care).  transport. Should you have questions about this Operator’s Manual, please contact your dealer or visit us at www.wackerneuson.com. The Operator’s Manual must always be located in the loader or at the place where it is being used. This Operator’s Manual is not designed for pur- poses of extensive maintenance work. Such work must be performed by approved professionals.

8 Each new user must be instructed before using the loader IRU WKH ¿UVW WLPH 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 compart- PHQW SURYLGHG LQ WKH RSHUDWRU VWDWLRQFDE 1 BASIC INFORMATION If it is not possible to rule out hazards to persons or material during work according to the loader‘s intended use, these hazards will be indicated by means of safety labels. Instructions relate to the direction of travel of the loader; this means that, when directional information is given, it can be assumed that this refers to the direction of travel of the loader.

Operator s Manual Wheel Loader WL 50 Wacker Neuson

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