Wacker Neuson WL38 RL40 Wheel Loader Operator’s Manual 2016 – PDF Download

Description

Wacker Neuson WL38 / RL40 Wheel Loader Operator’s Manual – Document 5100016711

This is the complete operator’s manual for the Wacker Neuson WL38 wheel loader, model designation RL40. Published under document number 5100016711, edition 1.2, dated 01/2016, it is the manufacturer’s own operating and maintenance guide for the machine from pre-shift inspection through operation, transport and routine service. The AEM Safety Manual for wheel loaders/tractors is included as a bound section of this file.

File Details

• Manual type: Operator’s Manual (includes AEM Safety Manual)
• Brand: Wacker Neuson
• Model designation: RL40
• Trade name: WL38
• Document number: 5100016711
• Version: 1.2
• Date: 01/2016
• Language: English [en] – this file also contains the French [kn] translation
• Format: PDF
• Total file pages: 536

Chapters Covered

• 1 Foreword
• 2 Safety
• 3 Introduction
• 4 Putting into operation
• 5 Operation
• 6 Transportation
• 7 Maintenance
• 8 Malfunctions
• 9 Technical data

Chapter 1 – Foreword

Information on the operator’s manual itself, warranty and liability terms, the explanation of symbols used throughout, abbreviations, and conversion tables between metric and US units for volume, length, weight, pressure, force/output, torque, speed and acceleration.

Chapter 2 – Safety

This is the most important chapter for anyone operating the WL38. It covers the safety symbols and signal words (DANGER, WARNING, CAUTION, NOTICE), qualification of operating personnel and the owner’s duties, general conduct, operation, lifting gear applications, trailer operation, operation of attachments, towing/loading/transporting, maintenance and measures for avoiding risks. It includes the California Proposition 65 warnings for battery posts and engine exhaust, battery handling rules, internal combustion engine hazards, bleeding the fuel system and refueling, handling of oil and grease, fire hazards, working near electric and non-electric supply lines, behavior during thunderstorms, noise and cleaning.

Chapter 3 – Introduction

Machine overview with the numbered component diagram, a brief technical description of the machine (chassis, drive, brakes, steering system, hydraulic system, cooling system, electrical system and loader unit), information and regulations on designated use, improper use, spatial limits, fields of application, and the type labels, warning labels and information labels used on the machine.

Chapter 4 – Putting into operation

Cabin and control stand, door opening and locking, emergency exit, adjustment of the standard operator seat and air-suspension seat, steering wheel adjustment, field of vision and rear-view mirror adjustment, the seat belt, fire extinguisher option, the full overview of control elements, indicator lights and warning lights, preparations before startup, and the correct procedures for starting and stopping the engine (including preheating and cold-start behavior).

Chapter 5 – Operation

Steering system, accelerator actuation, brakes (parking brake, service brake and inching), travel operation, speed ranges, differential lock, lights and signaling system, wiper/wash system, heating and ventilation, operating hydraulics, loader unit control lever, locking the loader unit, hydraulic connections, attachments (light material bucket, earth bucket, universal bucket, manure forks, fork-and-grab, pallet forks), working with each attachment, emergency lowering and releasing residual hydraulic pressure, and the available options.

Chapter 6 – Transportation

Towing the machine (including short-circuiting the travel drive via the high-pressure relief valves on the variable displacement pump), loading the machine, blocking the oscillating articulation, crane-lifting and tying down for transport.

Chapter 7 – Maintenance

Maintenance overview and inspection schedules (daily/weekly, 30 h, 500 h, then ongoing intervals), fluids and lubricants with capacities and specifications, maintenance accesses, cleaning, lubrication plan and lubrication work, fuel system, engine lubrication system, cooling system, air filter, V-belt/toothed belt, hydraulic system, electrical system, heating/ventilation/air conditioning, washer system, axles/traveling drive, braking system, tires, attachment maintenance, option maintenance and exhaust gas treatment (diesel particulate filter and diesel oxidation catalyst).

Chapter 8 – Malfunctions

Troubleshooting tables for the diesel engine, the drive and the hydraulic system, with the error/malfunction, possible cause and remedy listed side by side, plus the indicator-light diagnostics for machine electronics and the error-code table for the 35.7 kW / 44.7 kW / 55.4 kW engines.

Chapter 9 – Technical data

Models and trade names, engine data for every engine variant offered in the WL38 (Perkins 404D-22, Perkins 404F-22, Perkins 404F-22T and Deutz TCD 2.9 L4), drive/axles, brakes, tires and tire pressures, steering system, operating hydraulics, electrical system and fuse assignment, tightening torques, coolant, noise emissions, vibration, weights, payload and lift capacity, and dimensions.

AEM Safety Manual

The Association of Equipment Manufacturers (AEM) Wheel Loader/Tractor Safety Manual is included. It walks through a safe working day: following a safety program, preparing for safe operation, starting safely, working safely, loading and unloading, parking safely, performing maintenance safely, and a final knowledge test. This is generic wheel loader/tractor safety content rather than WL38-specific procedures.

What This Manual Enables You to Do

With the Wacker Neuson WL38 operator’s manual on hand, you can run the machine the way the manufacturer intended. You will know the daily and weekly check sequences before the first start, the correct cold-start and warm-up procedure for the Perkins and Deutz engine options, the difference between the fast gear and crawler gear travel modes, how to engage and release the differential lock, and how the loader unit lock and float position actually work. When the loader needs service, you have the lubrication plan, the capacities for engine oil, hydraulic oil, coolant and axle oil, the V-belt tension check, the air filter service procedure and the water-separator drain steps.

On the repair and diagnostic side, the troubleshooting tables let you trace a no-start, an overheating engine, a machine that will not travel, or a hydraulic system that runs hot — with the likely cause and the remedy in front of you. The error-code table takes the guesswork out of machine electronics faults. And the technical data chapter supplies the numbers you need to verify a repair is in spec: engine outputs, oil flows, operating pressures, tightening torques for general fasteners and wheel nuts, tire pressures for every approved tire size, and the full dimensional drawing of the loader.

Because the file is delivered instantly as a PDF after payment, there is no shipping and no waiting. Open it on a laptop in the workshop, on a tablet next to the machine, or print the pages you need for the job and keep them in the cab. Every section is laid out exactly as Wacker Neuson published it — same chapter order, same label references, same technical values.

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