Wacker Neuson WL44, WL54 Wheel Loader Service Repair Manual

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