Wacker Neuson 501S Compact Loader Service Manual – PDF DOWNLOAD

Description

Wacker Neuson 501S Compact Loader Service Manual – PDF DOWNLOAD

FILE DETAILS:

Wacker Neuson 501S Compact Loader Service Manual – PDF DOWNLOAD

Language : English
Pages : 204
Downloadable : Yes
File Type : PDF
Size: 11 MB

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DESCRIPTION:

Wacker Neuson 501S Compact Loader Service Manual – PDF DOWNLOAD

Machine model 501s
Edition 2.1
Language en
Article number 1000155663

Operation:
1.1 Notices on this service manual:

This service manual contains important information on how to service your machine safely,
correctly and economically. Therefore, it aims not only at new operators, but it also serves
as a reference for experienced ones. Your knowledge and skills will help to avoid
dangerous situations and reduce repair costs and downtimes. Furthermore, the reliability
and the service life of the machine will be increased by following the instructions in the
service manual.
Careful and prudent working is the best way to avoid accidents!
Operational safety and readiness of the machine do not only depend on your skill, but also
on maintenance and servicing of the machine.
Insist on using original spare parts when performing maintenance and repair work. This
ensures operational safety and readiness of your machine, and maintains its value.
Your Neuson After-Sales Service will be pleased to answer any further questions
regarding the machine or the service manual.

TABLE OF CONTENTS:

Wacker Neuson 501S Compact Loader Service Manual – PDF DOWNLOAD

Operation
Notices on this service manual 1-2
Identification of warnings and dangers 1-3
Designated use and exemption from liability 1-4
Type labels and component numbers 1-5
Machine overview 1-7
Cab, model 501s with mechanical pilot control (overview) 1-8
Cab, model 501s with mechanical pilot control (legend) 1-9
Model 501s cab overview (hydraulic pilot control) 1-10
Cab, model 501s with hydraulic pilot control (legend) 1-11
Instrument panel overview 1-12
Instrument panel legend 1-13
Engine compartment: overview 1-14
Engine cover (open): overview 1-15
Chassis overview 1-16
Raising/lowering the cab 1-18
Specifications
Chassis 2-2
Engine 2-2
Fuel injection pump 2-3
Capacity 2-3
Tightening torque 2-3
Travelling drive 2-3
Brakes 2-4
Work hydraulics 2-4
Pilot control 2-4
Additional control circuit 2-5
Electrical system 2-5
Fuse box in instrument panel 2-5
Main fuse box with relays 2-5
Relays 2-6
Tyres 2-6
Noise levels 2-6
Vibration 2-7
Coolant compound table 2-7
Dimensions 2-8
Model-specific tightening torques 2-9
General tightening torques 2-9
Tightening torques for hydraulic screw connections (dry assembly) 2-9
Tightening torques for high-resistance screw connections 2-11
Maintenance
Fluids and lubricants 3-2
Maintenance label 3-3
Explanation of symbols on the maintenance label 3-3
Maintenance plan (overview) 3-5
Service package 3-9
Up to serial no DB00692 3-9
From serial no DC00738 3-9
Introduction 3-9
Fuel system 3-10
Specific safety instructions 3-10
Refuelling 3-10
Stationary fuel pumps 3-11
Diesel fuel specification 3-11
I-2 SHB 501s en – Edition 2 1 * SHB_501_21IVZ fm
Bleeding the fuel system 3-11
Emptying the fuel tank 3-12
Fuel prefilter with water separator 3-12
Replacing the fuel filter 3-13
Engine lubrication system 3-14
Checking the oil level 3-14
Adding engine oil 3-15
Changing engine oil 3-15
Replacing the engine oil filter cartridge 3-17
Cooling system 3-18
Specific safety instructions 3-18
Checking the coolant level/adding coolant 3-19
Draining coolant 3-20
Air filter 3-21
Replacing the filter 3-22
Functional check once a week of the dust valve 3-23
V-belt 3-24
Checking V-belt tension 3-24
Retightening the V-belt 3-25
Pressure check 3-26
General 3-26
Checking boost pressure 3-26
Gear pump pressure check 3-27
Checking the parking brake pressure 3-28
Measuring ports: overview 3-28
Test report 3-29
Hydraulic system 3-30
Specific safety instructions 3-30
Checking the hydraulic oil level 3-31
Adding hydraulic oil 3-32
Changing hydraulic oil 3-33
Monitoring the hydraulic oil return filter 3-33
Checking hydraulic pressure lines 3-34
Travelling drive 3-35
Checking the oil level and adding oil 3-35
Draining oil 3-35
Tyre maintenance 3-36
Tyre check 3-36
Wheel change 3-36
Raising and jacking up the machine 3-37
Removing the wheels 3-37
Fitting the wheels 3-37
Lubrication work 3-38
Loader unit 3-38
Lubrication points on the bucket 3-38
Maintenance of attachments 3-38
Electrical system 3-39
Specific safety instructions 3-39
Service and maintenance work at regular intervals 3-39
Instructions concerning specific components 3-40
Alternator 3-40
Battery 3-40
Jump-starting the engine 3-41
General maintenance work 3-42
Cleaning 3-42
General instructions for all areas of the machine 3-42
Inside the cab 3-42
SHB 501s en – Edition 2 1 * SHB_501_21IVZ fm I-3
Exterior of the machine 3-43
Engine compartment 3-43
Screw connections and attachments 3-43
Pivots and hinges 3-43
Engine
Engine 3TNV88-XNSS up to serial no DB00692 (overview) 4-2
Fuel system 4-4
Checking and adjusting valve clearance 4-5
Tightening order for cylinder head bolts 4-6
Checking the injection nozzles 4-7
Pressure check 4-7
Checking the nozzle jet 4-7
Injection time 4-8
Checking injection time 4-8
Setting injection time 4-8
Replacement of fuel injection pump 4-9
Adjusting engine speed 4-10
Compression 4-10
Checking the coolant thermostat 4-10
Checking the thermal switch 4-11
Oil pressure switch 4-11
Checking the coolant circuit 4-12
Engine 3TNV88-BDNSS from serial no DC00738 (overview) 4-13
Fuel system 4-15
Removing the valve cover 4-16
Checking and adjusting valve clearance 4-16
Tightening order for cylinder head bolts 4-17
Checking the injection nozzles 4-18
Pressure check 4-18
Checking the nozzle jet 4-18
Injection time 4-19
Checking injection time 4-19
Setting injection time 4-20
Replacement of fuel injection pump 4-21
Adjusting engine speed 4-22
Compression 4-22
Checking the coolant thermostat 4-22
Checking the thermal switch 4-23
Oil pressure switch 4-23
Checking the coolant circuit 4-24
Engine trouble 4-24
Hydraulic system
Danfoss MPT 025 hydraulic pump (mechanically pilot-controlled) 5-2
Pump unit: exploded view 5-4
Hydraulic pump A10VG28 (hydraulically pilot-controlled) 5-5
Main valve block 5-7
Ports (mechanically pilot-controlled) 5-7
Legend 5-7
Main valve block diagram (mechanically pilot-controlled) 5-8
Legend 5-9
Auxiliary hydraulics control 5-11
Function 5-11
Pump control 5-12
Pump sections (mechanically pilot-controlled) 5-13
Pump sections (hydraulically pilot-controlled) 5-14
Mechanical controls 5-15
I-4 SHB 501s en – Edition 2 1 * SHB_501_21IVZ fm
Control lever 5-15
Drive control 5-16
Hydraulic control 5-17
Control levers (ISO) 5-17
Travelling drive 5-25
Function 5-25
Drive (exploded view) 5-26
Travelling drive layout (mechanically pilot-controlled) 5-27
Travelling drive layout (hydraulically pilot-controlled) 5-28
Valves 5-29
3/3 directional valve (flush valve) 5-29
Troubleshooting in the hydraulic system 5-30
Hydraulics diagram 5-31
Up to serial no DB00692 (mechanically pilot-controlled) 5-31
From serial no DC00738 – ISO controls (hydraulically pilot-controlled) 5-32
From serial no DC00738 – H controls option (hydraulically pilot-controlled) 5-33
Hydraulics diagram (legend) 5-34
Hydraulics diagram 501S A3 5-35
Up to serial no DB00692 (mechanically pilot-controlled) 5-35
From serial no DC00738 – H controls option (hydraulically pilot-controlled) 5-37
Electrical system
Ohm’s Law (current, voltage, resistance); power 6-2
Measuring equipment, measuring methods 6-2
Cable colour coding 6-4
Relays 6-4
Use, mode of function 6-4
Electric units 6-5
Fuse box in instrument panel 6-5
Main fuse box with relays 6-5
Relays 6-6
Socket 6-6
Control levers 6-7
Right-hand control lever 6-7
SHB 501s en – Edition 2 1 * SHB_501_21IVZ fm I-5
Left-hand control lever 6-7
Instrument panel overview 6-8
Switches (overview) 6-9
Alternator 6-9
Starter 6-9
Wiring diagram up to serial no DB00167 (legend) 6-11
Wiring diagram up to serial no DB00167 6-12
Wiring diagram from serial no DB00168 (legend) 6-13
Wiring diagram from serial no DB00168 6-14
Engine – chassis wiring harness 1000147293 up to DB00692 (legend) 6-15
Engine – chassis wiring harness 1000147293 up to DB00692 6-16
Engine – chassis wiring harness 1000183063 from DC00738 (legend) 6-17
Engine – chassis wiring harness 1000183063 from DC00738 6-18
Switches wiring harness 1000139289 up to DB00692 (legend) 6-19
Switches wiring harness 1000139289 up to DB00692 6-21
Switches wiring harness 1000183064 from DC00738 (legend) 6-22
Switches wiring harness 1000183064 from DC00738 6-24
Rear lights wiring harness 1000147262 (option) up to DB00692 6-25
Wiring diagram A3 up to DB00167 (legend) 6-28
Wiring diagram A3 up to DB00167 6-29
Wiring diagram A3 from DB00168 (legend) 6-30
Wiring diagram A3 from DB00168 6-31
Engine – chassis A3 wiring harness 1000147293 up to DB00692 (legend) 6-32
Engine – chassis A3 wiring harness 1000147293 up to DB00692 6-33
Engine – chassis A3 wiring harness 1000183063 from DC00738 (legend) 6-34
Engine – chassis A3 wiring harness 1000183063 from DC00738 6-35
Switches A3 wiring harness 1000139289 up to DB00692 (legend) 6-36
Switches A3 wiring harness 1000139289 up to DB00692 6-37
Switches A3 wiring harness 1000183064 from DC00738 (legend) 6-38
Switches A3 wiring harness 1000183064 from DC00738 6-39
Rear lights wiring harness 1000147262 (option) 6-40
Options
Rear working light 7-2
Wiring harness 7-2
Connections 7-2
BP-Biohyd SE 46 7-3
Properties 7-3
Panolin biodegradable oil 7-3
Properties 7-3
Immobilizer antitheft protection 7-3
Rotating beacon 7-4
Wiring harness 7-4
Connections 7-4
Crane-handling bracket 7-5
FOPS roof level 2 7-5
Accelerator pedal 7-5
Inside rearview mirror 7-6
Position 7-6
Comfort seat 7-6
Properties 7-6
Rearview mirror package 7-6
Backup warning system 7-7
Up to serial no DB00692 7-7
Function 7-7
Position 7-7
I-6 SHB 501s en – Edition 2 1 * SHB_501_21IVZ fm
From serial no DC00738 7-8
Parallel bucket lift 7-10
Function 7-10
Hydraulic diagram 7-11
Layout 7-11
Side window 7-12
Paint other than standard 7-12
Road travel certification 7-12
Airboss tyres 7-13

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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