PDF Service Manual Wacker Neuson WL20e Wheel Loader - 10 MB
Get the complete service manual for the innovative Wacker Neuson WL20e electric wheel loader.
This manual covers all aspects of repair and maintenance, including the electric drive system and battery management.
It's an essential guide for technicians to properly service this eco-friendly machine.
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Service Manual
Wheel Loader
WL20e
Vehicle type RL20e
Date 03/2018
Document Number 1000351594
Language [en]
--- Page 3 ---
Contents I
24 Maintenance logs
24.1 Grounded conductor / insulation resistance measurement ................................................................ 24-1
24.2 Measurement at the battery cells ....................................................................................................... 24-3
SHB WL20e * 3.0 I-9
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Einleitung E
Technical data
#
Battery data (option)
Manufacturer Exide
Type 48 V 585 TCSM
Lead acid battery with copper expanded
metal
Design 24 cells with 2 V/cell
Water refill system
Electrolyte circulation
Voltage 48 V
Nominal capacity 300 Ah
Dimensions
Length mm (in) 830 (32.7)
Width mm (in) 414 (16.3)
Height mm (in) 500 (19.7)
Weight (± 5 %) 450 kg (992 lbs.)
Charging time About 6 h
Operating time About 2 – 5 h
Overview AGM battery
Information
The service life of the batteries depends on the application conditions and
the manner of driving.
Battery data (standard)
Manufacturer HOPPECKE Batterie Systeme GmbH
Type Trak | Systemizer Dynamics
Closed lead acid battery in AGM technology
Design
24 cells with 2 V/cell
Voltage 48 V
Nominal capacity 225 Ah
Dimensions
Length 901 mm (35.5 in)
Width 535 mm (21.1 in)
Height 561 mm (22.1 in)
Weight (± 5 %) 450 kg (992 lbs.)
Charging time About 6 h
Operating time About 1.5 – 3.5 h
SHB WL20e * 3.0 E-9
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Introduction E
Tightening torques for hydraulic screw struts SDS
Shape B with sealing edge (cutting edge) and shape E with soft
O-ring seal
Tightening torque Tightening torque
Dimension (light-weight series) (heavy-weight series)
in Nm in Nm
M5 - -
M6 - -
M8 x 1 - -
M10 x 1 18 -
M12 x 1.5 30 35
M14 x 1.5 45 55
M16 x 1.5 60 70
M18 x 1.5 70 110
M20 x 1.5 - 140
M22 x 1.5 140 170
M26 x 1.5 180 220
M27 x 2 190 250
M33 x 2 300 300
M42 x 2 500 550
M48 x 2 550 600
G 1/8 A 20 25
G 1/4 A 35 40
G 3/8 A 70 90
G 1/2 A 100 150
G 3/4 A 180 270
G1A 250 350
G 1-1/4 A 450 500
G 1-1/2 A 550 600
7/16 - 20 (11.1 mm) - -
1/2-20 (UNF) - -
9/16 - 18 (14.3 mm) - -
3/4 - 16 (19.1 mm) - -
7/8 - 14 (22.2 mm) - -
1-1/16 - 12 (27 mm) - -
1-5/16 - 12 (33.3 mm) - -
1-5/8-12 (UNF) - -
1-7/8 - 12 (UNF) - -
2 - 12 (UNF) - -
SHB WL20e * 3.0 E-19
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Introduction E
• Repair work may only be performed by a dealer authorized by the
manufacturer.
• Drain all components before shipping the machine in order to avoid
damage, for example due to temperatures below 0°C/32°F.
• It is prohibited to change the nominal pressure of pressure relief valves
without explicit authorization by the manufacturer!
Before repair/maintenance
• Clean the entire machine, especially connections and threaded unions,
of any traces of oil or preservatives before performing maintenance/
repair work! Use lint-free cleaning rags and do not use aggressive
cleaning agents!
• Before cleaning the loader with water, steam jet (high-pressure
cleaner) or other cleaning agents, cover or tape up all openings which
– for safety and functional reasons – must be protected against
penetrating water, steam or cleaning agents.
Electrical elements are particularly at risk!
After cleaning, remove all covers and tapes applied for that purpose!
• Prior to adjustment, cleaning, and maintenance work as well as recti-
fying functional disorders:
- Stop the engine.
- Remove the battery connector from the machine connection.
• Before any adjustment, cleaning or maintenance work or before recti-
fying any functional faults in the hydraulic system, lower the
attachment and/or infeed unit.
• Due to their function the machine drives are not automatically secured
after stopping the engine.
• In addition, adjustment work can require that the drives are rotated.
However, you must make sure that other persons cannot start the
vehicle or turn the drives.
Removing components
• Burn hazard due to hot parts or liquids! Do not remove components as
long as the machine is at operating temperature!
• Clean components thoroughly before removing them!
• Connections and open holes which are exposed when removing a
component must be closed completely to prevent dirt from entering!
SHB WL20e * 3.0 E-29
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Operation
Overview of control elements
B Operation
B.1 Overview of control elements
--- Page 8 ---
Maintenance 1
1.2 Maintenance overview
Daily/weekly maintenance
Work to be performed by the operator Daily Every week
Clean the machine (do not clean the components in the rear section with water) • •
Check the machine for general damage •
Check the hydraulic oil level •
Check the tire condition and pressure •
Check all bolts for tightness •
Check the wheel bolts •
Check the braking system for correct function •
Check the brake fluid •
Check the seat belt •
Check the function of the instruments and indicator lights, as well as the warning and
• •
safety equipment according to the Operator’s Manual
Check the electrical system and lights for correct function •
Check the brake pedal for correct function •
Check the steering system •
Check control levers and switches for correct function •
Check the battery and battery components •
Check all power cable connections for tightness, check all cables for damage and
•
tightness
Check the battery connector for damage and firm seating •
Check the acid level. If necessary top off with demineralized water (only for Exide bat-
•
teries)
Check the attachments •
Perform grease lubrication according to the lubrication plan, including of the attach-
•
ments
Check the protective ROPS/FOPS structure •
Check the machine axles for leaks •
Check the attachments for safety and correct function •
Check the routing of the hoses, pipe lines and electric lines •
Check the axle mounting •
Carry out a general safety check •
SHB WL20e * 3.0 1-5
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Maintenance 1
Opening the engine cover
1
Open the engine cover with the handle. The handle is lockable.
1. Open the engine cover lock by pressing button 1.
➥ The engine cover is unlocked.
2. Raise the engine cover by pulling the handle.
➥ The engine cover is held open by a gas strut.
Closing the engine cover
1. Hold the engine cover on the handle and pull it downward against the
spring action.
2. Make the engine cover lock into place by pressing it downward.
3. Pull on the handle to check whether the engine cover is locked in
place.
W
Fig. 14 Open the engine cover
If necessary, the tailgate of the machine can be opened for maintenance
(for example for replacing the battery).
1. Open the engine cover.
1 Vehicles with Exide battery:
2. Remove screws 2.
3. Unlock the spring locked connecting pin 1.
➥ The tailgate is released.
4. Open the tailgate.
2
Fig. 15
Vehicles with AGM battery:
3 5. Remove screws 3.
➥ The tailgate is released.
6. Open the tailgate.
Fig. 16
SHB WL20e * 3.0 1-15
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Maintenance 1
Bleeding the hydraulic system
WARNING
Injury hazard due to uncontrolled movements of the loader unit!
Air inclusions in the hydraulic system can cause uncontrolled movements
of the loader unit due to pressure loss.
► Bleed the hydraulic system after replacing the hydraulic oil, in the event
of malfunctions in the hydraulic system, after repairs or after extended
periods in which the machine and the hydraulic system are not used.
► Perform bleeding only when seated on the operator seat.
► Ensure that no one is in the danger zone of the machine.
1. Check the oil level in the hydraulic oil reservoir.
➥ If necessary, add hydraulic oil until the oil level is between the “Min”
and “Max” marks on the hydraulic oil dipstick.
2. Engage the starter.
3. Fully extend and retract the piston rods of all hydraulic cylinders
several times.
4. Turn the steering wheel as far as it will go to either side until the
steering system works correctly and without any sounds.
5. Check the oil level in the hydraulic oil reservoir.
➥ If necessary, add hydraulic oil again until the oil level is between the
“Min” and “Max” marks on the hydraulic oil dipstick.
SHB WL20e * 3.0 1-25
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Maintenance 1
Exide battery
Measure cell voltages
Information
Each cell should have 2.13 V with a charged battery. The entire battery
then has 51.12 V.
Only measuring devices should be chosen for measurement that ensure a
precise measurement of the cell voltage. These are usually tools with 4-
digit or 3.5-digit displays and with a DC voltage range of 0-3V.
Increased controls of individual voltages may be an indication of:
► Short circuits in individual cells
► Advanced aging of the battery
1. Battery fully charged.
2. Remove the battery.
3. Insert the measuring tip forcefully into the measurement openings of
the pole screws with slight rubbing movements. In this way, the oxide
layers at the measurement point are removed and the voltage is
measured correctly. Maintenance logs – see "Measurement at the
battery cells" on page 24-3.
SHB WL20e * 3.0 1-35
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Maintenance 1
5. Unscrew Allen screw 2.
6. Add gearbox oil.
➥ Gearbox oil type – see "Fluids and lubricants" on page 1-13.
➥ The gearbox oil must be up to the bottom edge of the filler opening.
7. Screw in hexagon socket screw.
Information
Filling and drain plugs are located in the same positions on the front and
2 rear axles.
Perform maintenance on the gearbox and axles according to the
Fig. 50 maintenance intervals specified in this manual.
Check the oil level in the distributor gearbox
Preparations
1. Park the machine on firm, level and dry ground.
2. Apply the parking brake.
3. Lower the loader unit to the ground.
4. Disengage the starter.
Duct
1. Unscrew Allen screw 1.
1
➥ The gearbox oil must be up to the bottom edge of the filler opening.
2. Add gearbox oil if necessary.
➥ Gearbox oil type – see "Fluids and lubricants" on page 1-13.
Fig. 51
3. Screw in hexagon socket screw.
Change the gear oil in the distributor gearbox
Preparations
1. Park the machine on firm, level and dry ground.
2. Apply the parking brake.
3. Lower the loader unit to the ground.
4. Disengage the starter.
Duct
Environment
Use a suitable container to collect the gearbox oil as it drains and dispose
of it in an environmentally friendly manner.
1. Position a suitable container with sufficient volume underneath the
distributor gearbox – see "Fluids and lubricants" on page 1-13.
1 2. Unscrew the drain plug 1.
3. Completely drain the gearbox oil.
Fig. 52
4. Screw in drain plug.
SHB WL20e * 3.0 1-45
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Maintenance
Tires
Maintenance 1
1.15 Tires
Information on tires
WARNING
Risk of death due to incorrect assembly work!
Incorrect assembly work of tires and rims causes serious injury or death.
► Welding and cutting the rims is prohibited.
► Replace damaged rims by new ones.
NOTICE
Damage to differentials due to different-sized wheels and tires.
Only install wheels or tires on the machine from the same manufacturer,
of the same size and that have the same wear condition.
SHB WL20e * 3.0 1-55
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Maintenance 1
Measurement at the main contactor
1. Disconnect the plug of the battery charger.
2. Remove battery connector.
3. Remove the cover of the main contactor.
4. Carry out a visual check. Replace damaged cables or components
before measurement.
5. Connect the ground connection 1 to the vehicle frame.
6. Adjust the measuring instrument: test voltage 100 V, limit value
0.08 MOhm.
CAUTION
Risk of an electric shock
Test voltage of 100 volts exists at the measuring tips.
► Do not touch the vehicle during the measurement.
1
Fig. 77
7. Measure resistance value at the mains input side 2.
8. Measure the resistance value at the output side 1.
WARNING
Accident hazard due to electric current!
► With a measured value of < 80 kOhm, the machine is no longer ready
for operation.
► No voltage from the battery charger or from the battery may be applied
1 2 to the machine.
Fig. 78
► Possible remedial measures – see "Troubleshooting the insulation
resistance measurement" on page 1-70
SHB WL20e * 3.0 1-65
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Engine 2
3. Properly attach the hydraulic motor 4 with endless loop 5 and attach to
4 5 the crane.
Fig. 97
4. Carefully position the electric motor on the distributor gearbox.
7 5. Tighten the screws.
6
8
6
Fig. 98
Disassemble
1. Remove screws 2.
1
2. Remove the spring force brake 1 from the hydraulic motor.
2
Fig. 99
SHB WL20e * 3.0 2-5
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Axles
Front axle
4 Axles
4.1 Front axle
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Brakes
Brake pedal
5 Brakes
5.1 Brake pedal
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Steering system
Steering orbitrol S3
6 Steering system
6.1 Steering orbitrol S3
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Steering system
Steering column
Steering system 6
6.3 Steering column
Removing/installing the steering column
Preparing work
Tools:
• Suitable receptacle for collecting the hydraulic oil
• Plugs (different sizes) for closing the oil lines
Technical data
Weight Designation
7.5 kg Steering column
Environment
Use a suitable container to collect the hydraulic oil as it drains off and
dispose of it in an environmentally friendly manner!
Removing
1. Release the pressure in the hydraulic system – see “Releasing
residual pressure in the hydraulic system” on page E-32.
2. Remove the cover plate of the steering column – see “Disassemble”
on page 12-14.
SHB WL20e * 3.0 6-11
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Steering system 6
5. Press the shaft into the bearings from above with an appropriate press-
in tool 3.
3
Fig. 190
6. Lightly grease the bolts and bearings.
4 7. If necessary, insert spacer rings on the bolt.
8. Place the pendulum bearings 4 onto the bolts from above.
9. Adjust the front and rear carriage if necessary.
10.Press the pendulum bearings onto the bolts from above with a suitable
tool.
Fig. 191
11.If necessary, insert spacer rings 6 on the bolts.
5 12.Use 1 circlip 5 each.
13.Screw 2 zerk fittings 7 into the pendulum bearings.
6 7
Fig. 192
14.Press protection caps 8 on the pendulum bearings 9 into the bores.
8 15.Check all circlips for a correct seat.
9
Fig. 193
SHB WL20e * 3.0 6-21
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Hydraulic system 7
Item Designation
A1 3rd control circuit left
B1 3rd control circuit right
A2 Roll in tipping cylinder
B2 Roll out tipping cylinder
A3 Raise boom
B3 Lower boom
P from priority valve connection EF
T To reservoir
B043 Position sensor spool I
B044 Position sensor spool II
B045 Position sensor spool III
1 Primary valve (225 bar)
2 Secondary valve (90 bar)
Torque settings
Straight Cap nut
Item
screw-in connection hydraulic hose
A1
B1
A2
B2 For torque settings, see chap-
40 Nm
A3 ter: Introduction/Torque settings
B3
P
T
The control valve V108 is installed in the rear in vehicles without
hydraulic connections
Function description
The control valve V108 serves to supply the individual functions of the
work hydraulics with oil.
The control valve V108 is an open system. This means that the oil coming
from the priority valve connection EF is guided directly via the
connection P and connection T into the tank Z67 when the work
hydraulics are not actuated. The section 2 is provided with a secondary
valve 2. The system pressure is limited by the primary valve 1 to 225 bar.
The position of gate I, II and III is monitored by the associated position
sensors B043, B044 and B045.
SHB WL20e * 3.0 7-3
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Hydraulic system 7
Removing/installing the gear pump motor
Preparing work
Tools:
• Suitable lifting tackle with a
carrying capacity of at least 40 kg
Technical data
Weight Designation
34 kg M031 Gear pump motor (electric motor)
3.5 kg Motor holder
Disassemble
1
1. Remove the base plate – see “Removing” on page 14-2.
2. Remove the gear pump – see “Remove” on page 7-18.
2 3. Label mounting positions of the cables.
4. Remove the cable 1 of the speed sensor.
5. Remove the three-phase current cable 2.
3 6. Remove the cable 3 of the temperature sensor.
Fig. 209
SHB WL20e * 3.0 7-13
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Hydraulic system
Lock pins
Hydraulic system 7
7.5 Lock pins
Removing/installing lock pins
Technical data
Information
If the lock pin is corroded, check whether the guide is clean and grind it
out if necessary.
Removing
1 1. Remove the lock cylinder – see “Removing” on page 7-20
2. Dislodge lock pin 2 from guide 1 in an inward direction.
2
Installation
1. Slightly grease guide 1 and pin 2.
2. Put new pin 2 into guide 1 from the inside.
3. Install the lock cylinder – see “Installation” on page 7-21.
4. Grease the lock pin.
Fig. 230
SHB WL20e * 3.0 7-23
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Hydraulic system 7
Install
1 2 3
1. Screw in and tighten any screwed connections.
2. Attach a tilt cylinder 2 with appropriate lifting gear 3 and insert so that
the bottom-side bolt receptacles line up completely.
3. Slightly grease the bearing and bolt.
4. Drive in the bolt 1.
4 5. Screw in the screw 4 with washer and tighten.
Fig. 250
6. Screw hydraulic lines 7 and 10 on the connections of the tilt cylinder
5 6 7 8 and tighten.
7. Tighten the bracket 9.
8. Extend and lower the tilt cylinder 8 so that the rod-side bolt receptacles
line up completely.
9. Insert any spacer rings if necessary.
9 10 10.Slightly grease the bearing and bolt.
11.Drive in the bolt 6.
12.Coat the thread of the screw 5 with a locking agent.
Fig. 251 13.Screw in and tighten the screw 5 with a spring washer and spacer ring.
14.Lubricate the lift cylinder bearing.
SHB WL20e * 3.0 7-33
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Hydraulic system 7
3. Unscrew and close the hydraulic line 2.
4. Remove the hydraulic line.
2
Fig. 267
Installation
1. Select the required hydraulic line.
2. Screw the hydraulic line 1 onto the coupling and tighten.
1
Fig. 268
3. Screw the hydraulic line 2 onto the screw connection and tighten.
2
Fig. 269
SHB WL20e * 3.0 7-43
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Hydraulic system 7
Diagrams
7.23 Hydraulics Diagram – Vehicle with 4th control circuit and all options
A16 Hydraulic components
1 Designation
L S3 R A4 A47 A48 A37
A4 Lock cylinder