New Holland W50 - User Manual

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W50 - W60

W70 - W80

WHEEL LOADER

Workshop Manual

Print No. 604.13.577 English

V - 2005

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Read and heed carefully the safety instructions listed and follow the precautions recommended to

avoid potential risks and to safeguard your health and your safety.

You will find this symbol in the text of this Manual referred to the following key words:

WARNING - Cautions directed to avoid improper repair interventions involving potential consequences

for the safety of the personnel performing the repairs.

DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other

persons directly or indirectly involved.

IMPORTANT NOTICE

All maintenance and repair interventions explained in this Manual must be performed exclusively by the

Service Organisation of the Manufacturer, observing strictly the instructions explained using, whenever

necessary, the recommended specific tools.

Whoever performs the operations reported without following exactly the precautions is responsible on his own,

for the damages that may result.

Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national,

regional or local distributors, are responsible for any liability arising from any damage resulting from defects

caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing prod-

ucts manufactured or merchandised by the Factory.

In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or

merchandised by the Factory, when failures are caused by the use of parts and/or components not approved

by the Factory.

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Summary

Section 0 Safety Instructions

Fundamental Safety Instructions

Key safety principles, warnings, risks, and organizational measures for safe operation.

Operation Safety Instructions

Guidelines for safe operation of the machine, including pre-operation checks and driving.

Maintenance Safety Instructions

Safety procedures and precautions during maintenance, repair, and cleaning activities.

Warning of Special Dangers

Identifies specific hazards related to electric energy, gas, hydraulics, noise, and chemicals.

Transporting and Towing; Recommissioning Safety

Safety measures for towing, loading, transporting, and recommissioning the machine.

Repairs Safety Instructions

Safety protocols for personnel, pivot joint blocking, pretensioned units, and component dismantling.

Accumulators Safety

Precautions for handling, testing, servicing, and dismantling hydraulic accumulators.

Engine Safety Instructions

Safety guidelines for engine repair and assisted starting procedures.

Welding Operations Safety

Safety requirements for welding, including personnel qualification and pre-operation checks.

Section 1 Service Data

SI- and Additional Units

Conversion tables and explanations for SI units and additional measurement units.

Conversion Tables for Units

Detailed conversion tables for units of length and area.

This document is a Workshop Manual for WHEEL LOADER models W50, W60, W70, and W80. It is identified by Print No. 604.13.577 English, V - 2005.

Function Description

The manual serves as a comprehensive guide for the repair and maintenance of the specified wheel loader models. It is structured into nine sections, covering various aspects of the machine's operation, components, and systems. The primary function of this manual is to provide detailed instructions and data necessary for skilled personnel to perform service, repair, and maintenance tasks safely and effectively, ensuring the machine's smooth running and long service life.

Important Technical Specifications

The manual includes a dedicated "SERVICE DATA" section (Section 1) which provides critical technical specifications. This section covers:

SI- and Additional Units: Standardized units of measurement for length, area, volume, mass, density, inertia moment, and specific volume (Section 1.2.1). It also includes time-related quantities such as time, frequency, rate of revolutions, speed, acceleration, volume flow, mass flow, heat flow, and specific fuel and oil consumption (Section 1.2.2).
Quantities of Force, Energy, and Power: Definitions and conversion tables for force, pressure, mechanical stress, energy, heat capacity, power, and torque/bending moment (Section 1.2.3).
Conversion Tables: Detailed tables for converting units of length (inches, feet, yards, miles to cm, m) (Section 1.3.1) and area (square inches, feet, yards, miles, acres to cm², m², km²) (Section 1.3.2).
Calculation Examples: Guidance on calculating angles of slope, hydraulic outputs (pumps/motors), stroking times of cylinders, and speeds of hydraulic motors (Section 1.4).
Tightening Torques: General information, units of measurement, and specific tightening torques for bolts with standard and metric fine threads (DIN 13-13), O&K Double-hex bolts, O&K Double-hex necked-down bolts, SAE flange-system, and tightening angles (Section 1.5).
Technical Data: Specific data for the engine, axles and gearboxes (W50, W60, W70, W80), hydraulic system, fluids and lubricants, tightening torques, and weights (Section 1.6).

The manual emphasizes the use of original parts to maintain the machine's integrity and performance.

Usage Features

The manual outlines various operational and safety instructions for the wheel loader. Key usage features and guidelines include:

Standard Operation: Instructions to avoid unsafe operational modes, familiarize with the site surroundings, ensure the machine is in a safe and reliable state, and operate only with all protective and safety devices in place and functional (Section 0-3).
Visibility and Lighting: Guidance on using the lighting system in poor visibility and after dark.
Passenger Seating: Stipulation that accompanying persons must use designated passenger seats.
Clearance: Warnings to ensure sufficient clearance when driving through underpasses, tunnels, over bridges, or under overhead lines.
Stability: Advice to maintain distance from edges of building pits and slopes, avoid operations that risk machine stability, and never travel across slopes.
Speed Adaptation: Instructions to adapt travelling speed to ground conditions on sloping terrain and change to lower gears before reaching a slope.
Securing the Machine: Procedures for securing the machine against inadvertent movement and unauthorized use before leaving the driver's seat, including shutting off the engine.
Pre-operation Checks: Emphasizes checking the machine for damage, defects, and proper functioning of braking, steering, signalling, and lighting systems before starting work or travel.
Emergency Procedures: Instructions to stop the machine immediately and report malfunctions or changes in behavior.
Transporting and Towing: Guidelines for towing, loading, and transporting the machine according to the Operation and Maintenance Instruction Manual, including prescribed transport position, admissible speed, and route (Section 0-6).

Maintenance Features

The manual provides extensive guidelines for maintenance, emphasizing safety and proper procedures:

Scheduled Maintenance: Adherence to prescribed intervals for adjusting, maintenance, and inspection activities, including part and equipment replacement (Section 0-4).
Personnel Qualification: All maintenance work must be executed by skilled personnel only, with specific training for electrical, chassis, brake, steering, and hydraulic systems (Section 0-2).
Work Area Safety: Ensuring the maintenance area is adequately secured and the machine is secured against inadvertent starting (removing ignition key, attaching warning sign).
Machine Positioning: Maintenance and repair work must be carried out on stable and level ground, with the machine secured against movement and buckling.
Lifting and Securing Loads: Instructions for carefully attaching and securing individual parts and large assemblies using suitable and technically perfect lifting gear. Never work or stand under suspended loads.
Overhead Work: Use of specially designed ladders and working platforms for overhead assembly work.
Cleanliness: Keeping handles, steps, handrails, platforms, and ladders free from dirt, snow, and ice. Cleaning the machine of oil, fuel, or preservatives before maintenance, avoiding aggressive detergents, and protecting openings during cleaning.
Post-Cleaning Checks: Examining fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks, and damage after cleaning.
Tightening Connections: Always tightening screwed connections loosened during maintenance.
Safety Device Refitting: Refitting and checking all safety devices removed for set-up, maintenance, or repair.
Disposal: Safe and environmentally conscious disposal of consumables and replaced parts.
Repair Work: Never starting repair work without reading the Operation and Maintenance Instruction Manual. Special attention to "Fundamental Safety Instructions" and "Inspection and Servicing, Safety Instructions" (Section 0-7).
Pretensioned Units: Warnings against opening damaged pretensioned units and instructions for replacement (Section 0-7).
Dismantling Components: Instructions to wait for the machine to cool down before dismantling, depressurize systems, replace defective components, clean components, and prevent dirt penetration (Section 0-7).
Accumulators: Detailed safety instructions for handling accumulators, which contain nitrogen under high initial pressure. This includes warnings against mechanical handling, welding, or soldering, and mandates that testing and servicing be carried out by experts only. It also specifies depressurizing the hydraulic system, wearing eye protection and gloves, filling with nitrogen only, and reporting defects (Section 0-8).
Engine Maintenance: Specific instructions for engine repair, including shutting off and cooling down the engine, securing the machine, checking V-belts, and seeking expert help for complex repairs (Section 0-9).
Assisted Starting: Safety instructions for using jumper cables, including explosion hazards from battery gases, risk of acid splashes, wearing goggles, and proper connection procedures (Section 0-9).
Welding Operations: Strict safety guidelines for welding, including qualification requirements, accident prevention regulations, and specific steps to take before welding on the machine (disconnecting batteries, protecting terminals, applying welding current terminals close to the welding point, and ensuring current does not flow through critical components) (Section 0-10).