216 SE RVICING A ND INSPEC TION
10.7.12
Servicing the electrical system
WARNING
Electric shock hazard.
►
Always disconnect the battery before working on the electrical system if tools, spare parts, etc. with electrical components or contacts could touch it.
Fuse allocation
The electrical circuits of the wheel loader are fused to prevent damage from short circuits and malfunctions. The fuses are located in box 1 and 2 near the starting key receptacle on the right side of the steering column. The second location is on the right hand side of the cab next to operator‘s
seat (Fig. 108).
Electric shock and burn hazards.
►
Do not clean sensitive electrical components
(instrument panel, alternator, compact plug, multi-function lever, etc.) with a high-pressure cleaner.
►
Do not touch incandescent lamps and headlight reflectors with your fingers if the bulbs have been illuminated.
Have malfunctions in the electrical system corrected by trained specialized personnel.
NOTICE:
If an electrical device fails to respond to a control movement, stop the wheel loader as if stopping at the end of a work shift and check the fuse for that circuit. If the fuse has failed, determine the cause of failure and repair the cause.
Insert a new fuse of the specified rating and return to work.
Do not continue work with a failed fuse.
Do not install a fuse with a higher rated capacity than the failed fuse. This can result in serious damage to the electrical circuit.
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There are two 40 ampere fuses in the battery box
(Fig. 107). One is the main fuse for the cab, while
the other is the main fuse for the lights and controls.
For loaders with Deutz engine, there are also two
50 ampere fuses that protect the preheating system.
If one of these fuses is burnt through, there is major damage to the electrical system. Contact your local
Wacker Neuson service center..
Fig. 107
Master fuses
Box 1
Box 2
SE RVICING A ND INSPEC TION 217
Fig. 108
Fuse boxes
Box 3
218 SE RVICING A ND INSPEC TION
Fig. 109
Box 1
Fuse allocation
Box 2
5
6
3
4
7
8
1
2
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Box 3
Item Fused function for Box 1 Rating (A)
1 Available 1
7,5 2 Turn signal
3
Warning flasher
4 Brake light
15
10
5 Side lamp left
6 Side lamp right
7 Low beam light
8 Main beam
7,5
7,5
15
15
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SE RVICING A ND INSPEC TION 219
Item Fused function for Box 2 Rating (A)
9 Engine 10
10 Cab 7,5
11 Instruments, indicator lights
12 Front windshield wiper, Forward warning device
13 Heater fan
14 Available
15 Available
16 Available
7,5
15
15
3
10
7,5
Item Fused function for Box 3 Rating (A)
17 Pressure relief, Loader lift arms locking system 15
18 Control unit, electrical connection 15
19 Front headlights
20 Rear work lights, back-up lights, switch lights
21 Rear window heating
22
Forward warning device, air filter contamination switch
23 Rotating beacon, radio
24 Cab inside light, radio
15
15
15
15
15
10
220 SE RVICING A ND INSPEC TION
Battery
WARNING
Explosion and burn hazard.
Batteries produce and vent gases that can be explosive if concentrated in an unventilated space.
► Do not smoke or use open flames near a stor
age battery.
►
Do not place objects on the battery. If a metallic object such as a wrench contacts both the positive and negative post on the battery, it will cause a direct short and a possible explosion.
Severe burns can result .
►
Cover the battery with protective insulation, or remove the battery entirely, if service work is to be conducted near the battery.
WARNING
Battery fluid is poisonous and corrosive.
► Prevent battery fluid from coming into contact with your skin, eyes, mouth, or clothing.
►
Wear protective gloves and safety goggles.
► If battery fluid contacts skin, immediately rinse the contaminated area with plenty of clean water and seek medical treatment.
ENVIRONMENTAL NOTE
Avoid environmental damage.
Dispose of old batteries in an ecologically sound way, separate from other waste.
The battery has a nominal voltage of 12 volts; the battery capacity is 95 Ah. The battery is located on the left side of
the loader in the rear carriage Item 1 (Fig. 110). To access
it, open the engine enclosure and unscrew the cover plate.
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1
3 2
SE RVICING A ND INSPEC TION 221
Fig. 110
Location of the battery
Servicing the battery
Refer to the operator’s manual for the battery. The operator’s manual for the battery is attached to the side of the battery.
•
Always keep the terminals on the battery and on the connecting cables clean and lubricate them with anticorrosion grease.
•
Make sure that the protective cover of the positive ter-
minal is always in place and closed item 2 (Fig. 110).
•
Note the battery indicator lamp. The indicator lamp is
located on the top of the battery item 3 (Fig. 110):
-
Green - battery charge is OK
-
Black - battery needs to be charged
-
White - battery needs to be replaced.
222 SE RVICING A ND INSPEC TION
Disconnecting and connecting the battery / changing the battery
WARNING
Personal injury hazards.
Do not open the engine enclosure or attempt to tilt the operator cab/platform if the engine is running.
Follow the instructions in Section 10.7.1, pages
170-174, for opening the engine enclosure and
tilting the cab.
Always follow the correct sequence when disconnecting the battery.
– Disconnecting:
First the negative pole and then the positive pole.
– Connecting:
First the positive pole and then the negative pole.
(-)
5 (+)
4
Fig. 111
Removing the battery
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SE RVICING A ND INSPEC TION 223
Removing the battery:
1. Stop the loader on a horizontal surface and set the parking brake.
2. Lower the loader lift arms and attachment to the ground or work surface.
3. Stop the engine.
4. Before disconnecting the battery, switch off all electrical controls (and the battery disconnect switch) and remove the starting key.
5. Open the engine enclosure (Ref. Section 10.7.1, pages
170-171).
6. Remove the cover plate.
7. Loosen the negative battery cable clamp item (–)
(Fig. 111) and remove the clamp from the post. Position
the cable so it is not touching the machine. Wrap an insulating material around the conducting part of the cable clamp to eliminate the risk of electrical shock.
8. Remove the protective cover item 2 (Fig. 110) to gain
access to the cable clamp bolt. Loosen the positive battery cable clamp and remove the clamp from the post.
Position the cable so it is not touching the machine. Wrap an insulating material around the conducting part of the cable clamp to eliminate the risk of electrical shock.
9. Remove the battery support retaining bolt, item 4
(Fig. 111).
10. Remove the battery with the lifting aid incorporated in
the battery identified as item 5 (Fig. 111). If the battery
does not have an integral lifting aid, use a special strap that fits over each pole and provides a means to remove the battery.
Install the battery following the steps in the reverse order.
224 SE RVICING A ND INSPEC TION
10.8
Jump-starting / emergency starting
WARNING
Explosion and burn hazard.
Batteries produce and vent gases that can be explosive if concentrated in an unventilated space.
► Do not smoke or use open flames near a storage battery.
►
Do not place objects on the battery. If a metallic object such as a wrench contacts both the positive and negative post on the battery, it will cause a direct short and a possible explosion. Severe burns can result .
►
Cover the battery with protective insulation, or remove the battery entirely, if service work is to be conducted near the battery.
► If a second machine or vehicle is used as the jump start battery source, ensure that the vehicles/machines do not touch.
►
Do not attempt to jump start a frozen or defective battery. A short circuit or rapid increase in heat within the battery can cause an explosion.
►
Do not connect two batteries in series (negative post to positive post) because the voltage output will be 24 volts and damage the electrical system of the wheel loader.
►
Use only jump-starting batteries with the same voltage.
►
Use serviceable jumper cables with a heavy duty 12 volt rating.
►
Lay out the jumper cables so that they cannot be struck by rotating engine parts.
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Before jump-starting, check if the loader‘s dead battery is functional:
1. Switch off all the loader‘s electrical controls.
2. Switch the starting key to position 1 (operation). The warning lights must light up now!
3. If the warning lights do not light up, the battery is defective. In that case, the loader must not be started! Install a new replacement battery.
2
3 s r
1
4
SE RVICING A ND INSPEC TION 225
Fig. 112
Connecting the jumper cables
226 SE RVICING A ND INSPEC TION
Getting ready Starting the engines
1. Switch off all the loader‘s electrical controls.
2. Switch the starting key to position 0.
3. Drive the vehicle with the good battery (charged battery) near but not touching the loader.
4. Switch off all electrical controls on the vehicle with the good battery and stop the engine.
1. Start the engine of the vehicle with the good battery and let it run at an increased speed.
2. Attempt to start the loader engine.
3. If the engine does not start after 15 seconds, wait one minute before trying again.
4. Once the engine has started, let both engines continue to idle with the jumper cables connected for about another two minutes.
Connect the jumper cables
(The correct sequence must be adhered to)
1. Connect the red jumper cable Item r (Fig. 112) to the
positive pole of the dead battery Item L.
2. Connect the red jumper cable to the positive pole of the
charged battery Item V (Fig. 112).
3. Connect the black jumper cable Item s to the negative pole of the charged battery.
4. Connect the black jumper cable to the negative pole of the dead battery.
Detach the jumper cables
(As with connecting, follow the correct sequence):
1.
Disconnect the black jumper cable first from the nega
tive pole of the dead battery and then from the negative pole of the charged battery.
2.
Disconnect the red jumper cable first from the positive pole of the charged battery and then from the positive pole of the dead battery.
