Wacker Neuson 1250 CX35-Weidemann Wheel Loader Repair Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Wacker Neuson 1250 CX35-Weidemann Wheel Loader Repair Manual – PDF DOWNLOAD
Language : English
Pages :368
Downloadable : Yes
File Type : PDF
Size:75.8 MB
TABLE OF CONTENTS:
Wacker Neuson 1250 CX35-Weidemann Wheel Loader Repair Manual – PDF DOWNLOAD
Part 1 Safety
1 Repair work
(complete vehicle) 1-7
2 Engine 1-9
3 Hydraulic system 1-11
4 Drive and axles 1-13
5 Brake system 1-15
6 Vehicle frame and
load arm 1-17
7 Electrical system 1-19
Part 2 Technical data, testing
equipment and special tools
1 Technical data 2-7
2 Filling quantities 2-9
3 Tightening torques 2-11
4 Pressure values 2-13
5 Flow rates 2-15
6 Safety stickers 2-17
7 Testing equipment 2-23
71 Test pressure gauge 2-23
72 Flow meter 2-23
73 Test pump 2-24
8 Special tools 2-25
81 Insertion tool 2-25
82 Sealing plate (2 x) 2-25
83 Expulsion and driving sleeves 2-25
84 Driving bolts 2-26
85 Electrical contact key 2-27
86 Generator tester 2-27
87 Half-shells and pull-off fixture 2-28
88 Tool for contact removal 2-29
89 Hose clamp 2-29
9 Hose book 2-31
Part 3 Inspections, maintenance work
and troubleshooting
1 Complete vehicle 3-7
11 Inspection log 3-7
2 Engine 3-9
21 Checking and adjusting the
valve play 3-9
22 Inspecting the exhaust system
for leaks 3-11
23 Checking the radiator
installation 3-12
24 Checking the engine
bearing play 3-13
25 Inspecting the radiator for leaks 3-14
26 Troubleshooting on the engine 3-16
3 Hydraulic system 3-19
31 Checking and adjusting the
starting speed 3-19
32 Checking and adjusting the
inching pedal 3-19
33 Checking and adjusting the
pressure cut-off 3-20
34 Adjusting the driving speed 3-22
35 Checking the variable
displacement pump
supply pressure 3-22
36 Checking the variable
displacement pump
high pressure 3-24
37 Checking the variable
displacement pump
positioning pressure 3-25
38 Checking and adjusting the
control commencement of the
variable displacement motor 3-26
39 Testing the steering hydraulics 3-28
310 Checking the gear pump 3-30
311 Checking the control
valve function 3-32
312 Troubleshooting on the
hydraulic system 3-33
4 Drive and axles 3-37
41 Inspecting the differential lock 3-37
42 Checking the water filling
of the wheels 3-38
43 Troubleshooting on the drive 3-39
Contents
0-8 1000240975 – WDF-6002-00EN 1250 CX35 – 02/2009-1 – WDF-0035-00EN
5 Vehicle frame and
load arm 3-41
51 Checking and adjusting the
curling to load stop 3-41
6 Cab 3-43
61 Checking the heater 3-43
62 Troubleshooting in the cab 3-44
7 Electrical system 3-45
71 Checking the generator 3-45
72 Checking the temperature
sensors 3-45
73 Testing the belt buckle circuit 3-46
74 Testing the fuel level sensor 3-47
75 Troubleshooting on the
electrical system 3-47
Part 4 Replacement and repair
procedures
1 Complete vehicle 4-9
11 Helpful tips 4-9
12 Replacing protective stickers 4-9
2 Engine 4-11
21 Engine (as supplied) 4-11
211 Engine removal 4-11
212 Engine installation 4-13
213 Replacing the front
rubber buffers 4-16
214 Replacing the rear
rubber buffers 4-17
215 Replacing the clutch PA flange 4-18
216 Cleaning the engine
(after toppling the loader) 4-19
22 Radiator 4-21
221 Removing the radiator 4-21
222 Installing the radiator 4-23
23 Air filter system 4-26
231 Replacing the complete air filter 4-26
232 Replacing the air filter housing 4-27
24 Fuel system 4-29
241 Replacing the complete
fuel filter 4-29
242 Replacing the complete main
fuel filter 4-30
243 Replacing the water separator 4-31
244 Replacing the fuel feed pump 4-32
245 Replacing the fuel line 4-33
246 Tank lock emergency opening 4-34
247 Replacing the Bowden cable
of the accelerator 4-34
25 Exhaust system 4-36
251 Replacing the flue 4-36
252 Replacing the muffler and
flexi-pipe 4-37
3 Hydraulic system 4-39
31 Complete vehicle 4-39
311 Depressurizing the
hydraulic system 4-39
312 Replacing the pivot bearing on
the hydraulic cylinder 4-39
313 Sealing the hydraulic cylinder 4-40
32 Driving hydraulics 4-44
321 Replacing the variable
displacement pump 4-44
322 Replacing the annular
shaft seal of the variable
displacement pump 4-45
323 Replacing the variable
displacement motor 4-46
33 Steering hydraulics 4-48
331 Cleaning the priority valve 4-48
332 Replacing the priority valve 4-49
333 Replacing the orbital
steering valve 4-50
334 Removing the steering cylinder 4-51
335 Installing the steering cylinder 4-52
34 Brake hydraulics 4-54
341 Replacing the main
brake cylinder 4-54
342 Replacing the brake
hydraulics tank 4-55
343 Replacing the brake fluid 4-56
344 Venting the brake hydraulics 4-57
345 Sealing the control cartridge 4-58
35 Working hydraulics 4-59
351 Replacing the gear pump 4-59
352 Sealing the gear pump 4-60
353 Removing the control valve 4-62
354 Installing the control valve 4-63
355 Sealing the control valve 4-64
356 Installing the catch on the
control valve 4-67
357 Replacing the cross controller 4-68
358 Replacing the lifting cylinder 4-69
359 Replacing the lifting
cylinder bearing 4-71
3510 Removing the tipping cylinder 4-72
3511 Installing the tipping cylinder 4-73
36 Auxiliary hydraulics and
hydraulic lock 4-74
361 Replacing the cover of the
auxiliary hydraulics 4-74
362 Replacing the three-way valve 4-74
363 Replacing the locking cylinder 4-75
1250 CX35 – 02/2009-1 – WDF-0035-00EN 1000240975 – WDF-6002-00EN 0-9
Contents
37 Tank, filter and hydraulic lines 4-77
371 Replacing the hydraulic
fluid tank 4-77
372 Replacing the complete
return filter 4-78
373 Replacing the pressure filter 4-79
374 Cleaning the pressure filter 4-80
375 Replacing the hydraulic line 4-81
4 Drive and axles 4-83
41 Replacing the drive shaft 4-83
42 Front axle 4-84
421 Removing the front axle 4-84
422 Installing the front axle 4-86
43 Rear axle 4-88
431 Removing the rear axle 4-88
432 Installing the rear axle 4-91
44 Changing the wheel of the
twin tires 4-93
5 Brake system
(mechanical section) 4-95
51 Service brake 4-95
511 Replacing the brake shoes 4-95
512 Replacing the brake drum 4-97
52 Parking brake 4-98
521 Replacing the Bowden cable
of the parking brake 4-98
6 Vehicle frame and
load arm 4-101
61 Front carriage 4-101
611 Replacing the front fender 4-101
612 Replacing the pivot bearing
of the front carriage 4-101
62 Rear carriage and engine hood 4-102
621 Replacing the rear fender 4-102
622 Replacing the battery
retaining plate 4-103
623 Replacing the additional
weight/base plate 4-104
624 Replacing the rear weight 4-105
625 Replacing the engine hood 4-106
626 Replacing the lock of the
engine hood 4-108
627 Emergency release of the
engine hood 4-108
63 Center joint 4-109
631 Detaching the center joint 4-109
632 Connecting the center joint 4-111
633 Replacing the bearing in the
self-aligning bearing 4-115
634 Replacing the lower bearing 4-116
64 Step plate and insulation mats 4-117
641 Removing the operator’s
platform 4-117
642 Installing the operator’s
platform 4-120
643 Replacing the rubber buffers
of the step plate 4-122
644 Replacing the insulation mat 4-123
65 Load arm 4-124
651 Replacing the complete
load arm 4-124
652 Replacing the bearings of
the drawbar 4-127
653 Replacing the lower bearing
of the tipping lever 4-128
66 Tool attachment 4-128
661 Replacing the tool attachment 4-128
662 Replacing the locking pin 4-130
663 Replacing the lock of the
tool attachment (US) 4-131
7 Operator’s platform
and cab 4-133
71 Seat 4-133
711 Replacing the driver’s seat 4-133
712 Replacing the complete
seat belt 4-133
713 Replacing the belt buckle 4-134
72 ROPS bar and driver’s canopy 4-135
721 Replacing the ROPS bar 4-135
722 Replacing the driver’s canopy 4-135
723 Replacing the lower section of
the ROPS bar/driver’s canopy 4-137
724 Replacing the storage
compartment 4-138
73 Cab 4-139
731 Removing the complete cab 4-139
732 Installing the complete cab 4-141
733 Replacing the windshield
wiper arms 4-144
734 Replacing the windshield
washer container 4-145
735 Replacing the door lock 4-146
736 Replacing the door stay 4-147
737 Replacing the complete door 4-147
738 Replacing the roof grille of
the cab 4-148
739 Replacing the window and
the rubber clamping profile 4-149
7310 Replacing a bonded-in window 4-150
7311 Replacing the complete heater 4-152
74 Steering column 4-154
741 Replacing the instrument
steering column 4-154
742 Replacing the steering wheel 4-155
Contents
0-10 1000240975 – WDF-6002-00EN 1250 CX35 – 02/2009-1 – WDF-0035-00EN
8 Electrical system 4-157
81 Generator, battery and motors 4-157
811 Replacing the generator 4-157
812 Replacing the starter 4-158
813 Replacing the rear windshield
wiper motor 4-159
814 Replacing the front windshield
wiper motor 4-161
82 Switches and sensors 4-162
821 Replacing the switches in
the instrument panel 4-162
822 Replacing the glow-plug
indicator 4-162
823 Replacing the switches in
the cab 4-163
824 Replacing the ignition lock 4-164
825 Replacing the battery
disconnect switch 4-165
826 Replacing the parking
brake switch 4-166
827 Replacing the engine
temperature sensor 4-167
828 Replacing the temperature
sensor of the hydraulic
fluid tank 4-168
829 Replacing the fuel level sensor 4-169
83 Relays, coils and fuses 4-170
831 Replacing the relay 4-170
832 Replacing the solenoid valve
core on the variable
displacement motor 4-171
833 Replacing the solenoid
valve of the variable
displacement pump 4-172
834 Replacing the coil and
core on the variable
displacement pump 4-173
835 Replacing the control unit 4-174
84 Indicator lamps, audible
reverse warning device
and instruments 4-174
841 Replacing the horn 4-174
842 Replacing the audible
reverse warning device 4-175
843 Replacing the engine-hour
indicator 4-176
85 Lighting system 4-177
851 Replacing a complete headlamp
with indicator 4-177
852 Replacing a complete tail lamp 4-178
853 Replacing the headlight 4-178
9 Attachments 4-181
91 Replacing the earth bucket
digging tooth 4-181
92 Replacing the prongs of the
fork & grab 4-181
93 Replacing the hydraulic cylinder
of the fork & grab 4-182
94 Replacing the hydraulic cylinder
of the multi-purpose bucket 4-183
95 Replacing the valve of the
multi-purpose bucket 4-184
Part 5 Circuit diagrams and technical
descriptions
1 Hydraulic circuit diagram 5-7
2 Electrical circuit diagram 5-9
3 Plug assignments /
contact assignments 5-19
31 Plug assignments 5-19
311 Plug connectors of the
standard version, instrument
steering column 5-20
312 Plug connectors of the lighting 5-28
32 Contact assignments 5-30
321 Components of the standard
version, instrument steering
column 5-31
322 Components of the lighting 5-32
4 Technical description 5-35
Part 6 Supplier service manuals
1 Engine workshop manual
(example) 6-7
2 Variable displ pump repair
instructions (example) 6-9
3 Variable displ motor repair
instructions (example) 6-11
4 Repair Manual, Axle
Index
A
Accelerator actuator
Bowden cable, replacing 4-34
Additional weight
Replacement 4-104
Air filter
Housing, replacing 4-27
Replacing complete 4-26
Alternator
See generator 4-157
Annular shaft seal, replacement
Variable displacement pump 4-45
Audible reverse warning device
Replacing 4-175
Auxiliary hydraulics
Cover, replacing 4-74
Axles
Safety instructions 1-13
B
Base plate
Replacement 4-104
Battery disconnect switch
Replacing 4-165
Battery retaining plate
Replacing 4-103
Bearings, replacing
Drawbar 4-127
Lower bearing 4-116
Self-aligning bearing 4-115
Belt buckle
Replacing 4-134
Belt buckle circuit
Testing 3-46
Brake cylinder
see Main brake cylinder 4-54
Brake drum
Replacing 4-97
Brake fluid
Replacing 4-56
Brake hydraulics
Tank, replacing 4-55
Venting 4-57
Brake shoes
Replacing 4-95
Brake system
Safety instructions 1-15
C
Cab
Removing complete 4-139, 4-141
Switches, replacing 4-163
Cardan shaft
see Drive shaft 4-83
Center joint
Connecting 4-111
Detaching 4-109
Circuit diagram
Electrical circuit diagram 5-9
Hydraulic circuit diagram 5-7
Cleanliness 4-9
Clutch PA flange
Replacing 4-18
Contact assignment 5-19
Control cartridge
Sealing 4-58
Control valve
Catch, installing 4-67
Checking the function 3-32
Installing 4-63
Removing 4-62
Sealing 4-64
Cross controller
Replacing 4-68
Curling to load stop
Checking and adjusting 3-41
D
Description
see Technical description 5-35
Differential lock
Inspecting 3-37
Digging tooth, replacing
Earth bucket 4-181
Door
Replacing complete 4-147
Door lock
Replacing 4-146
Door stay
Replacing 4-147
Drawbar
Bearings, replacing 4-127
Drive
Safety instructions 1-13
Drive shaft
Disassembling 4-83
Replacing 4-83
Temporary securing 4-84
Index
0-12 1000240975 – WDF-6002-00EN 1250 CX35 – 02/2009-1 – WDF-0035-00EN
Driver’s canopy
Lower section, replacing 4-137
Replacing 4-135
Driver’s seat
Replacing 4-133
Driving bolts 2-26
Driving motor
see Variable displacement motor 4-46
Driving sleeve 2-25
Driving speed
Adjusting 3-22
E
Electrical circuit diagram 5-9
Electrical contact key 2-27
Electrical system
Safety instructions 1-19
Engine
Cleaning after toppling 4-19
Installation 4-13
Removal 4-11
Safety instructions 1-9
Temperature sensor, replacing 4-167
Troubleshooting 3-16
Workshop manual (example) 6-7
Engine bearing
Play, checking 3-13
Engine hood
Emergency release 4-108
Replacing 4-106
Replacing the lock 4-108
Engine temperature gauge, replacing
see Engine-hour indicator, replacing 4-176
Engine-hour indicator
Replacing 4-176
Exhaust system
Inspecting for leaks 3-11
Expulsion sleeve 2-25
F
Fender
Replacing front 4-101
Replacing rear 4-102
Filling quantities 2-9
Flow meter 2-23
Flow rates 2-15
Flue
Replacing 4-36
Fork & grab
Hydraulic cylinder, replacing 4-182
Prongs, replacing 4-181
Front axle
Installing 4-86
Relieving the load 4-85
Removing 4-84
Front carriage
Pivot bearing, replacing 4-101
Fuel feed pump
Replacing 4-32
Fuel filter
Replacing complete 4-29
Fuel level sensor
Replacing 4-169
Testing 3-47
Fuel line
Replacing 4-33
Fuel tank gauge, replacing
see Engine-hour indicator, replacing 4-176
G
Gear pump
Checking 3-30
Replacing 4-59
Sealing 4-60
Generator
Checking 3-45
Replacing 4-157
Generator tester 2-27
Glow-plug indicator
Replacing 4-162
H
Half-shells and pull-off fixture 2-28
Handbrake
see Parking brake 4-98
Headlamp
Replacing complete 4-177
Headlight
Replacing 4-178
Heater
Checking 3-43
Replacing complete 4-152
High pressure, checking
Variable displacement pump 3-24
Horn
Replacing 4-174
see Audible reverse warning device 4-175
Hose book 2-31
Hose clamp 2-29
1250 CX35 – 02/2009-1 – WDF-0035-00EN 1000240975 – WDF-6002-00EN 0-13
Index
Hydraulic circuit diagram 5-7
Hydraulic cylinder
Sealing 4-40
Hydraulic fluid tank
Replacing 4-77
Temperature sensor, replacement 4-168
Hydraulic line
Replacing 4-81
Hydraulic motor
see Variable displacement motor 4-46
Hydraulic pump
see Gear pump 4-59
see Variable displacement pump 4-44
Hydraulic system
Depressurizing 4-39
Safety instructions 1-11
I
Ignition lock
Replacing 4-164
Inching pedal
Checking and adjusting 3-19
Insertion tool 2-25
Instrument panel
Switches, replacing 4-162
Instrument steering column
Replacing 4-154
Insulation mat
Replacing 4-123
L
Lifting cylinder
Bearings, replacing 4-71
Installing 4-70
Removing 4-69
Replacing 4-69
Load arm
Replacing complete 4-124
Safety instructions 1-17
Locking agent 4-9
Locking cylinder
Replacing 4-75
Locking pin
Replacing 4-130
Lower bearing
Replacing 4-116
M
Main brake cylinder
Replacing 4-54
Main fuel filter
Replacing complete 4-30
Muffler
Replacing 4-37
Multi-purpose bucket
Hydraulic cylinder, replacing 4-183
Valve, replacing 4-184
O
Operator’s platform
Installing 4-120
Removing 4-117
Orbital steering valve
Replacing 4-50
P
Parking brake
Bowden cable, fitting 4-87, 4-99
Bowden cable, removing 4-85, 4-98
Bowden cable, replacing 4-98
Switch, replacing 4-166
Pivot bearing
Replacing 4-39
Plug assignment 5-19
Plug connectors of the instrument
steering column 5-20
Positioning pressure, checking
Variable displacement pump 3-25
Pressure cut-off
Checking and adjusting 3-20
Pressure filter
Cleaning 4-80
Replacing 4-79
Pressure value
Variable displacement pump and
variable displacement motor 2-13
Priority valve
Cleaning 4-48
Replacing 4-49
Protective stickers
Replacement 4-9
Index
0-14 1000240975 – WDF-6002-00EN 1250 CX35 – 02/2009-1 – WDF-0035-00EN
R
Radiator
Checking installation 3-12
Inspecting for leaks 3-14
Installation 4-23
Removing 4-21
Rear axle
Holding 4-89
Installing 4-91
Removing 4-88
Rear muffler
see Muffler 4-37
Rear weight
Replacing 4-105
Relay
Replacing 4-170
Repair work
Safety instructions 1-7
Replacing the rubber buffers
Engine, front 4-16
Return filter
Replacing the complete 4-78
Roof grille
Replacing 4-148
ROPS bar
Lower section, replacing 4-137
Replacing 4-135
Rubber buffer, replacing
Engine, rear 4-17
Step plate 4-122
S
Safety stickers
Meaning and position 2-17
Sealing plate 2-25
Seat belt
Replacing 4-133
Self-aligning bearing
Replacing bearings 4-115
Small parts 4-9
Solenoid valve
Coil, replacing 4-173
Solenoid valve, replacing 4-171
Variable displacement pump 4-172
Solenoid valve, replacing the core
Variable displacement motor 4-171
Starter
Replacing 4-158
Starting speed
Checking and adjusting 3-19
Steering cylinder
Installing 4-52
Removing 4-51
Steering hydraulics
Testing 3-28
Steering wheel
Replacing 4-155
Step plate
Rubber buffer, replacing 4-122
Stickers
see protective stickers 4-9
Storage compartment
Replacing 4-138
Supply pressure, checking
Variable displacement pump 3-22
Switch, replacing
Parking brake 4-166
Switches, replacing
Cab 4-163
Instrument panel 4-162
T
Tail lamp
Replacing the complete 4-178
Tank lock
Drilling open 4-34
Emergency opening 4-34
Technical data 2-7
Technical description 5-35
Temperature sensor, replacement
Hydraulic fluid tank 4-168
Temperature sensor, replacing
Engine 4-167
Temperature sensors
Checking 3-45
Test pressure gauge 2-23
Test pump 2-24
Three-way valve
Replacing 4-74
Tightening torques
General 2-11
Special 2-11
Tipping cylinder
Installing 4-73
Removing 4-72
Tipping lever
Lower bearing, replacing 4-128
Tool attachment
Replacing 4-128
Tool attachment (US)
Lock, replacing 4-131
1250 CX35 – 02/2009-1 – WDF-0035-00EN 1000240975 – WDF-6002-00EN 0-15
Index
Tool for contact removal 2-29
Toppling the loader
see Engine, cleaning after toppling 4-19
Transmission pump
see Variable displacement pump 4-44
Troubleshooting
Cab 3-44
Drive 3-39
Electrical system 3-47
Hydraulic system 3-33
Twin tires
Wheel, changing 4-93
V
Valve play
Checking and adjusting 3-9
Variable displacement motor
Repair instructions (example) 6-11
Replacing 4-46
Solenoid valve core, replacing 4-171
Variable displacement motor
control commencement
Checking and adjusting 3-26
Variable displacement pump
Annular shaft seal, replacement 4-45
Coil, replacement 4-173
High pressure, checking 3-24
Repair instructions (example) 6-9
Replacing 4-44
Solenoid valve, replacing 4-172
Supply pressure, checking 3-22
Vehicle frame
Safety instructions 1-17
W
Water separator
Replacing 4-31
Wheels
Water filling, checking 3-38
Window, replacing
Bonded-in window 4-150
Window with rubber clamping profile 4-149
Windshield washer container
Replacing 4-145
Windshield wiper arms
Replacing 4-144
Windshield wiper motor, front
Replacing 4-161
Windshield wiper motor, rear
Replacing 4-159
Rad, austauschen 4-94
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