Service Manual Wacker Neuson WL 48 WL 50 Wheel Loader;

Content:
Part 1) Safety
1. Repair work (complete vehicle)
2. Engine
3. Hydraulic system
4. Drive and axles
5. Brake system
6. Vehicle frame and load arm
7. Operators platform and cab
8. Electrical system

Part 2) Technical data, testing equipment and special tools
1. Technical data
1.1 Technical data for diesel engine
1.2 Technical data for turbo-diesel engine
2. Filling quantities
3. Tightening torques
4. Pressure values
4.1 Pressure values 20 km/h version
4.2 Pressure values 30 km/h version (optional)
5. Flow rates
5.1 Flow rates 20 km/h version
5.2 Flow rates 30 km/h version (optional)
6. Safety stickers
7. Testing equipment
7.1 Test pump
7.2 Flow meter
7.3 Generator tester
7.4 Magnetic field tester
7.5 Test pressure gauge
8. Special tools
8.1 Expulsion and driving sleeves
8.2 Sealing plate (2 x)
8.3 Insertion tool
8.4 Driving bolts
8.5 Electrical contact key
8.6 Half-shells and pull-off fixture
8.7 Hose clamp
8.8 Tool for contact removal
9. Hose book

Part 3) Inspections, maintenance work and troubleshooting
1. Complete vehicle
1.1 Inspection log for Deutz engine
2. Engine
2.1 Checking and adjusting the valve play (Deutz)
2.2 Inspecting the exhaust system for leaks
2.3 Checking the radiator installation
2.4 Inspecting the radiator for leaks
2.5 Troubleshooting on the engine
3. Hydraulic system
3.1 Driving hydraulics
3.1.1 Checking and adjusting the starting speed
3.1.2 Checking and adjusting the pressure cut-off
3.1.3 Checking the variable displacement pump high pressure
3.1.4 Checking the variable displacement pump supply pressure
3.1.5 Checking the variable displacement pump positioning pressure
3.1.6 Adjusting the driving speed
3.1.7 Checking and adjusting the control commencement of the variable displacement motor
3.2 Testing the steering hydraulics
3.3 Checking and adjusting the inching
3.4 Working hydraulics
3.4.1 Checking the gear pump
3.4.2 Checking the function of the pilot control
3.4.3 Checking the control valve function
3.5 Troubleshooting on the hydraulic system
4. Drive and axles
4.1 Inspecting the differential lock
4.2 Checking the water filling of the wheels
4.3 Troubleshooting on the drive
5. Vehicle frame and load arm
5.1 Checking and adjusting the curling to load and dumping stops
6. Cab
6.1 Checking the heater and the air-conditioning unit
6.2 Troubleshooting in the cab
7. Electrical system
7.1 Checking the generator
7.2 Checking the starter
7.3 Checking the temperature sensors
7.4 Testing the fuel level sensor
7.5 Troubleshooting on the electrical system

Part 4) Replacement and repair procedures
1. Complete vehicle
1.1 Helpful tips
1.2 Replacing protective stickers
2. Engine
2.1 Engine (as supplied)
2.1.1 Engine removal
2.1.2 Preparations for engine installation
2.1.3 Engine installation
2.1.4 Replacing the front rubber buffers
2.1.5 Replacing the rear rubber buffers
2.1.6 Replacing the spacer at the rear
2.1.7 Replacing the clutch PA flange
2.1.8 Cleaning the engine (after toppling the loader)
2.2 Radiator
2.2.1 Removing the radiator
2.2.2 Installing the radiator
2.3 Air filter system
2.3.1 Replacing the suction hose
2.3.2 Replacing the complete air filter
2.3.3 Replacing the air filter housing
2.4 Fuel system
2.4.1 Replacing the fuel pre-filter (Deutz)
2.4.2 Replacing the sieve filter of the fuel feed pump (Deutz)
2.4.3 Replacing the fuel line
2.4.4 Replacing the Bowden cable of the accelerator
2.4.5 Replacing the fuel tank
2.5 Exhaust system
2.5.1 Replacing the muffler and tail pipe
2.5.2 Replacing the flue and flexi-pipe
3. Hydraulic system
3.1 Complete vehicle
3.1.1 Depressurizing the hydraulic system
3.1.2 Sealing the hydraulic cylinder
3.1.3 Replacing the pivot bearing on the hydraulic cylinder
3.2 Driving hydraulics
3.2.1 Replacing the variable displacement pump
3.2.2 Replacing the clutch hub
3.2.3 Replacing the annular shaft seal of the variable displacement pump
3.2.4 Replacing the variable displacement motor
3.3 Steering hydraulics
3.3.1 Cleaning the priority valve
3.3.2 Replacing the priority valve
3.3.3 Replacing the orbital steering valve
3.3.4 Removing the steering cylinder
3.3.5 Installing the steering cylinder
3.4 Brake hydraulics
3.4.1 Replacing the main brake cylinder
3.4.2 Replacing the brake hydraulics tank
3.4.3 Venting the brake hydraulics
3.4.4 Replacing the brake fluid
3.4.5 Replacing the 3/2-way valve
3.5 Working hydraulics (gear pump, valves)
3.5.1 Replacing the gear pump
3.5.2 Replacing the gear pump (dual pump)
3.5.3 Sealing the gear pump
3.5.4 Sealing the gear pump (dual pump)
3.5.5 Removing the control valve
3.5.6 Installing the control valve
3.5.7 Sealing the control valve
3.5.8 Replacing the valve of the vibration damping unit
3.5.9 Replacing the diaphragm accumulator of the vibration damping unit
3.6 Working hydraulics (hydraulic cylinder)
3.6.1 Replacing the lifting cylinder
3.6.2 Removing the tipping cylinder
3.6.3 Installing the tipping cylinder
3.6.4 Replacing components of the load holding control valve
3.7 Control hydraulic
3.7.1 Depressurizing the control hydraulic
3.7.2 Replacing the pilot control
3.7.3 Adjusting the resting strength and play of the pilot control
3.7.4 Replacing the pulsation damper
3.7.5 Replacing the diaphragm accumulator
3.7.6 Replacing the 2/2-way valve of the control hydraulic
3.8 Auxiliary hydraulics and hydraulic lock
3.8.1 Replacing the locking cylinder
3.9 Tank, filter and hydraulic lines
3.9.1 Replacing the hydraulic fluid tank
3.9.2 Replacing the complete return filter
3.9.3 Replacing the pressure filter
3.9.4 Cleaning the pressure filter
3.9.5 Replacing the hydraulic line
4. Drive and axles
4.1 Replacing the drive shaft
4.2 Front axle
4.2.1 Removing the front axle
4.2.2 Installing the front axle
4.3 Rear axle
4.3.1 Removing the rear axle
4.3.2 Installing the rear axle
5. Brake system (mechanical section)
5.1 Service brake
5.1.1 Replacing the brake shoes
5.1.2 Replacing the brake drum
5.2 Parking brake
5.2.1 Replacing the Bowden cable of the parking brake
6. Vehicle frame and load arm
6.1 Front carriage
6.1.1 Replacing the front fender
6.1.2 Replacing the front weight
6.2 Rear carriage and engine hood
6.2.1 Replacing the rear fender
6.2.2 Replacing the base plate
6.2.3 Replacing the rear weight
6.2.4 Replacing the engine hood
6.2.5 Emergency release of the engine hood
6.2.6 Replacing the lock of the engine hood
6.3 Center joint
6.3.1 Detaching the center joint
6.3.2 Connecting the center joint
6.3.3 Replacing the bearing in the self-aligning bearing
6.3.4 Replacing the lower bearing
6.4 Insulation mats
6.4.1 Replacing an insulation mat
6.5 Load arm
6.5.1 Replacing the complete load arm
6.5.2 Replacing the bearings of the drawbar
6.5.3 Replacing the bearing of the tipping lever
6.5.4 Replacing the front bearing of the load arm
6.5.5 Replacing the rear bearing of the load arm
6.6 Tool attachment
6.6.1 Replacing the tool attachment
6.6.2 Replacing the locking pin
7. Operators platform and cab
7.1 Seat
7.1.1 Replacing the drivers seat
7.1.2 Replacing the complete seat belt
7.2 Frame
7.2.1 Removing the complete cab
7.2.2 Installing the complete cab
7.2.3 Replacing the front rubber buffers of the cab
7.2.4 Replacing the rear rubber buffers of the cab
7.2.5 Replacing the roof grille of the cab
7.2.6 Replacing the floor mats
7.2.7 Replacing the radio console
7.2.8 Replacing the sun visor
7.3 Windows/windshield and doors
7.3.1 Replacing the windshield wiper arms
7.3.2 Replacing the windshield washer container
7.3.3 Replacing a bonded-in window
7.3.4 Replacing the door
7.3.5 Replacing the door lock
7.3.6 Replacing the door stay
7.3.7 Replacing the window stop
7.4 Steering column
7.4.1 Replacing the steering column
7.4.2 Replacing the cladding of the steering column
7.4.3 Replacing the steering wheel
7.5 Heater and air-conditioning unit
7.5.1 Replacing the Bowden cable of the temperature sensor
7.5.2 Removing and installing the vaporizer of the air-conditioning unit
7.5.3 Removing and installing the air-conditioning compressor
7.5.4 Removing and installing the dryer
7.5.5 Removing and installing the air-conditioning unit condenser
7.6 Cab lift hydraulic
7.6.1 Replacing the hand pump
7.6.2 Replacing the hydraulic cylinder
7.6.3 Replacing the Bowden cable of the cab lift hydraulic
8. Electrical system
8.1 Generator, battery and motors
8.1.1 Replacing the generator (Deutz)
8.1.2 Replacing the starter
8.1.3 Replacing the rear windshield wiper motor
8.1.4 Replacing the front windshield wiper motor
8.1.5 Replacing the heater blower
8.2 Switches
8.2.1 Replacing the battery disconnect switch
8.2.2 Replacing the ignition lock
8.2.3 Replacing the engine temperature sensor
8.2.4 Replacing the temperature sensor of the hydraulic fluid tank
8.2.5 Replacing the return filter overpressure switch
8.2.6 Replacing the parking brake switch
8.2.7 Replacing the switch of the service brake
8.2.8 Replacing the steering column switch
8.2.9 Replacing the switches in the cab
8.3 Sensors
8.3.1 Replacing the fuel level sensor
8.3.2 Replacing the vacuum gauge
8.4 Relays, coils and fuses
8.4.1 Replacing a relay
8.4.2 Replacing the solenoid valve of the variable displacement pump
8.4.3 Replacing the coil and core on the variable displacement pump
8.4.4 Replacing the solenoid valve core on the variable displacement motor
8.4.5 Replacing the control unit
8.5 Indicator lamps, audible reverse warning device and instruments
8.5.1 Replacing the engine-hour indicator
8.5.2 Replacing the fuel tank gauge
8.5.3 Replacing the instrument lighting
8.5.4 Replacing the horn
8.5.5 Replacing the audible reverse warning device
8.6 Lighting system
8.6.1 Replacing a complete headlamp with indicator
8.6.2 Replacing a complete tail lamp
8.6.3 Replacing the headlight
9. Attachments
9.1 Replacing the earth bucket digging tooth
9.2 Replacing the prongs of the fork & grab
9.3 Replacing the hydraulic cylinder of the fork & grab
9.4 Replacing the hydraulic cylinder of the multi-purpose bucket
9.5 Replacing the valve of the multi-purpose bucket

Part 5) Circuit diagrams and technical descriptions
1. Hydraulic circuit diagram
2. Electrical circuit diagram
3. Plug assignments / contact assignments
3.1 Plug assignments
3.1.1 Main plug connections fitting & cab
3.1.2 Plug connections instrument steering column
3.1.3 Plug connections - cab
3.1.4 Plug connections - machine
3.1.5 Plug connections - lighting
3.2 Contact assignments
3.2.1 Components of the instrument steering column
3.2.2 Components of the cab
4. Technical description

Part 6) Supplier service manuals
1. Engine workshop manual (example)
2. Variable displ. pump repair instructions (example)
3. Variable displ. motor repair instructions (example)
4. Planetary axle workshop manual (example)
5. Electrical components