Weidemann Telescopic Loader T4512 Service Repair Manual PDF DOWNLOAD

Weidemann Telescopic Loader T4512 Service Repair Manual

FILE DETAILS:

Weidemann Telescopic Loader T4512 Service Repair Manual 

Language : English
Pages : 546
Downloadable : YES
Format : PDF
Size : 185 MB

DESCRIPTION:

Weidemann Telescopic Loader T4512 Service Repair Manual 

Before you read on :

Operating manual : As well as the present repair manual, the operating manual of the loader is required to perform all work completely.
The repair manual consists of six parts:
1. Safety
2. Technical data, test equipment and special tools
3. Inspection, maintenance work and troubleshooting
4. Replacement and repair procedures
5. Circuit diagrams and technical descriptions
6. Documents from suppliers (must be supplemented on-site)
Structure  : Each part is organised according to the structure of the loader in
1. Complete vehicle
2. Engine
3. Hydraulic system
4. Drive and axles
5. Brake system (mechanical part)
6. Frame and telescopic arm
7. Driver platform / cab
8. Electrical system
9. Attachments
Navigation : A table of contents is available in each part of the manual for finding individual sections.
The complete table of contents follows on the next pages after the list of abbreviations and units.
The complete index is included immediately before the “Safety” section.
The index of the respective part of the manual is included at its end.
Validity : The repair manual is applicable for type T4512 telescopic loaders with the following article number:  1000235501

TABLE OF CONTENTS:

Weidemann Telescopic Loader T4512 Service Repair Manual 

Repair Manual T 4512
Content0-7
Preface1-3
Before you read on 1-3
Part 1 – Safety 1-1
Symbols 1-3
Repair work (complete vehicle) 1-5
Safety regulations for repair work
(complete vehicle) 1-5
Engine 1-7
Safety regulations for work on the engine 1-7
Hydraulic system1-9
Safety regulations for work on the
hydraulic system1-9
Drive and axles 1-11
Safety regulations for work on drive and axles 1-11
Brake system 1-13
Safety regulations for work on the
brake system 1-13
Frame and telescopic arm1-15
Safety regulations for work on frame and
telescopic arm 1-15
Electrical system 1-17
Safety regulations for work on the
electrical system 1-17
Part 2 – Technical Data, Test Equipment
and Special Tools 2-1
Overview 2-3
Technical Data – Engine 2-5
Filling quantities 2-7
Tightening torques 2-9
Pressure values2-11
Flow rates 2-13
Safety stickers 2-15
Test equipment 2-19
Hydraulic test pump 2-19
Flow meter 2-19
Alternator tester2-20
Magnetic field tester 2-21
Test manometer2-21
Fuse tester set 2-22
Special tools 2-23
Drive out and drive in drift punches 2-23
Sealing plate (2 x) 2-24
Sleeve, steering cylinder 2-24
Insertion tool 2-25
Pin punch 2-25
Electrical contact tool 2-26
Half shells and puller 2-26
Hose clamp 2-26
Tool for contact removal 2-28
VLS induction switch setting gauge 2-28
Hose log book 2-29
Part 3 – Inspection, Maintenance
and Troubleshooting 3-1
Inspections 3-3
Complete vehicle 3-5
Engine test report3-5
Telescopic arm test report 3-6
Engine 3-7
Check and adjust valve clearance 3-7
Check exhaust system for leaks 3-10
Check radiator installation3-11
Check radiator for leaks 3-12
Engine troubleshooting 3-14
Hydraulic system3-17
Drive hydraulics3-17
Checking and adjusting starting speed 3-17
Checking and adjusting pressure cut-off 3-18
Checking high pressure of the
displacement pump 3-19
Checking supply pressure of the
displacement pump 3-20
Checking signal pressure of the
displacement pump 3-21
Adjusting travel speed 3-22
Checking and adjusting control start of the
displacement engine 3-23
Checking steering hydraulics 3-26
Checking and adjusting inching 3-29
Working hydraulics 3-30
Checking gear pump 3-30
Checking function of the control valve 3-34
Checking function of the throttle control 3-34
Checking Vertical Lift System (VLS)3-35
0- 8 DOK-ID: 1000274281-2 – DE T 4512 – 06/2013 (1000274281-2 – DE)
1Content
1 Content
VLS electronics – plug-in connector test
instruction 3-37
Checking function of the rear hydraulics 3-42
Hydraulic system troubleshooting 3-43
Drive and axles 3-49
Differential lock 3-49
Engageable differential lock, checking 3-49
Checking automatic differential lock 3-50
Checking and adjusting steering 3-52
Checking water filling of the wheels 3-56
Troubleshooting on the drive 3-58
Brake system 3-61
Checking and adjusting brake 3-61
Frame and load arm 3-65
Telescopic arm troubleshooting 3-65
Cab3-67
Checking heater3-67
Troubleshooting in the cab3-68
Electrical system 3-69
Checking alternator 3-69
Checking starter motor 3-70
Checking temperature sensor 3-71
Checking tank sensor 3-72
Calibrating load display 3-72
Troubleshooting on the electrical system 3-77
Part 4 – Replacement and
Repair 4-1
Replacement 4-3
Complete vehicle4-5
Helpful tips 4-5
Replacing protective stickers 4-5
Engine 4-7
Engine 4-7
Replacing cover and holder4-7
Removing engine4-8
Preparing engine for installation 4-13
Installing engine4-16
Replacing hydro bearings4-20
Replacing coupling flange4-21
Cleaning engine (after tipping over of
the loader) 4-21
Radiator 4-23
Replacing expansion reservoir 4-23
Replacing holder for expansion reservoir 4-24
Removing radiator 4-25
Replacing fan cowling 4-27
Installing radiator 4-28
Replacing fan impeller and spacer 4-31
Air filter unit 4-32
Replacing hoses4-32
Replacing complete air filter 4-33
Fuel System 4-34
Replacing complete fuel filter 4-34
Replacing fuel pump 4-36
Replacing fuel lines 4-37
Replacing fuel filler hose 4-38
Tank lock emergency opening 4-39
Replacing breather filter for fuel tank4-40
Replacing ventilation hose for fuel tank 4-41
Replacing fuel tank 4-42
Replacing Bowden cable of the accelerator
actuation 4-44
Exhaust system4-46
Replacing tail pipe 4-46
Replacing exhaust silencer4-46
Replacing holder4-47
Replacing flame pipe 4-48
Replacing flexible pipe 4-49
Hydraulic system4-51
Complete vehicle 4-51
Depressurising hydraulic system 4-51
Seal hydraulic cylinder 4-51
Replacing bearing on the hydraulic cylinder 4-55
Drive hydraulics4-56
Replacing displacement pump 4-56
Replacing shaft sealing ring of the
displacement pump 4-60
Replacing displacement engine 4-61
Steering hydraulics 4-62
Cleaning priority valve 4-62
Replacing priority valve 4-63
Replacing orbital steering unit 4-64
Replacing pulsation damper 4-66
Brake hydraulics4-67
Inching device (brake) 4-67
Working hydraulics (gear pump, valves) 4-68
Replacing gear pump 4-68
Sealing gear pump 4-69
Removing control valve 4-71
Sealing control valve 4-72
Installing control valve 4-78
Retrofitting latch on the control valve4-79
Replacing overload cut-out valve 4-80
Replacing 3/2 directional control valve
(high speed) 4-81
Replacing 3/2 directional control valve
(differential lock)4-82
Replacing pressure limiter valve on the
compensating cylinder (comfort control) 4-83
Replacing throttle valve (lifting frame) 4-84
Replacing 6/2 directional control valve (VLS) 4-85
Working hydraulics (fan motor, gear pump) 4-86
Replacing fan motor 4-86
T 4512 – 06/2013 (1000274281-2 – DE) DOK-ID: 1000274281-2 – DE 0- 9
Content 1
Replacing gear pump for cooling 4-87
Working hydraulics (hydraulic cylinders) 4-89
Replacing lift cylinder 4-89
Replacing compensating cylinder 4-91
Replacing tilt cylinder 4-94
Replacing extension cylinder 4-96
Replacing lowering brake valve 4-99
Replacing valve cartridge on the lowering
brake valve 4-100
Lowering brake valve for emergency lowering4-101
Additional hydraulics, rear hydraulics and
hydraulic locking 4-103
Replacing hydraulic motor (power take-off shaft)
(option) 4-103
Sealing hydraulic locking4-105
Replacing locking cylinder (Euro mounting) 4-106
Replacing cylinder (three-point
rear mounting)4-107
Replacing control valve for rear hydraulics
(option) 4-108
Replacing switching valve (mechanical) (three-way
valve) of the rear hydraulics 4-110
Replacing switching valve of the
rear hydraulics4-110
Replacing solenoid valve (comfort control) 4-111
Replacing solenoid valve (fourth
control circuit) 4-112
Replacing 2/2 directional control valve
(two-hand operation) 4-113
Replacing solenoid valve (High Flow) 4-114
Replacing hydraulic couplings (lifting frame) 4-115
Replacing hydraulic couplings (fourth control
circuit) 4-116
Replacing hydraulic plug-in couplings
(High Flow) 4-117
Replacing hydraulic quick release couplings (rear
hydraulics) 4-118
Replacing hydraulic plug-in couplings
(three-point mounting) 4-119
Tank, filter and hydraulic lines 4-120
Replacing hydraulic oil tank 4-120
Return filter, complete, replacing 4-122
Replacing hydraulic oil preheater (option) 4-124
Replacing hydraulic line4-124
Replacing hydraulic line (tilt cylinder) 4-125
Replacing hydraulic pipe4-127
Replacing manifold 4-128
Drive and axles4-131
Replacing propeller shaft4-131
Front axle 4-133
Removing front axle 4-133
Preparing new front axle for the installation 4-135
Installing front axle 4-136
Sealing front axle 4-139
Rear axle 4-144
Removing rear axle 4-144
Installing rear axle 4-147
Sealing rear axle 4-151
Steering cylinder 4-154
Removing steering cylinder 4-154
Sealing steering cylinder4-155
Installing steering cylinder 4-158
Brake system 4-161
Service brake 4-161
Replacing brake disc 4-161
Replacing brake pads 4-162
Replacing brake lever 4-163
Replacing brake pedal 4-164
Replacing sliding bearings 4-166
Parking brake 4-170
Replacing operating lever of the parking
brake 4-170
Frame and load arm 4-173
Frame 4-173
Replacing front mudguard 4-173
Replacing rear view mirror 4-173
Rear view mirror, complete, replacing 4-174
Replacing engine cover 4-174
Replacing retaining cable4-176
Replacing locking mechanism and handle of
the engine cover 4-177
Engine cover emergency unlocking4-178
Replacing floor pan 4-179
Replacing registration plate holder (option) 4-180
Removing and attaching rear panelling 4-180
Replacing rear weight 4-181
Replacing cover plate for frame 4-184
Replacing cover plate on engine sump 4-184
Removing engine sump 4-185
Attaching engine sump 4-188
Replacing remote lubrication system 4-191
Holder 4-192
Replacing holder for tail lights (option) 4-192
Replacing holder for rear view mirror 4-193
Replacing holder for mudguard 4-194
Replacing holder for locking
bolt (mechanical) 4-194
Replacing holder for air filter 4-195
Replacing holder for fan 4-196
Replacing holder for fuel filter 4-197
Tool holder 4-198
Replacing locating pin 4-198
Replacing tool holder 4-198
Replacing locking bolt (Euro mounting) 4-199
Replacing locking mechanism of the
tool holder (US) 4-200
Telescopic arm4-201
Replacing guide rail 4-201
Replacing protective cover 4-203
Replacing tipping bar 4-205
Replacing bearings of the tipping bar 4-205
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1Content
1 Content
Replacing tilting lever 4-206
Replacing bearings of the tilting lever 4-207
Removing inner tube 4-208
Installing inner tube 4-212
Replacing sliding plate of the inner tube 4-215
Replacing sliding plates of the outer tube 4-215
Removing telescopic arm, complete 4-217
Attaching telescopic arm, complete4-220
Replacing front bearing 4-223
Replacing rear bearing 4-224
Replacing trailer coupling (option) 4-225
Rear three-point linkage (option) 4-226
Replacing upper link 4-226
Replacing linkage draw bar 4-226
Replacing lower link 4-227
Replacing rear three-point linkage 4-228
Replacing rear three-point linkage mounting 4-229
Replacing mounting for upper link 4-231
Removing and attaching complete rear
three-point linkage 4-231
Replacing power take-off shaft protection 4-233
Driver platform and cab 235
Attachments 4-235
Replacing FOPS protection grille (option) 4-235
Replacing rear view mirror 4-236
Replacing holder for spot lamps (option) 4-236
Replacing holder for rotating beacon (option) 4-237
Window panes and doors4-238
Replacing windscreen wiper blade 4-238
Replacing windscreen wiper arm 4-239
Replacing windscreen washer liquid reservoir 4-240
Replacing glued-in window glass 4-241
Replacing opening mechanism for the rear
window 4-243
Replacing rear window 4-244
Replacing stay4-245
Replacing rubber buffer 4-246
Replacing locking handle4-248
Replacing door glass 4-249
Replacing locking device4-251
Replacing locking bolt 4-252
Replacing door locking mechanism4-252
Replacing door handle 4-253
Replacing retaining strap4-253
Replacing cab door 4-254
Seat 4-256
Replacing driver seat 4-256
Safety belt, complete, replacing 4-258
Replacing seat rails 4-258
Interior panelling 4-259
Replacing floor mat 4-259
Detaching and fastening instrument panel 4-259
Replacing instrument panel 4-260
Replacing front panelling4-261
Replacing side panelling4-263
Replacing rear panelling4-264
Replacing roof lining 4-265
Replacing blind4-266
Operating lever4-266
Replacing multifunction lever 4-266
Replacing cross controller 4-268
Replacing operating lever for additional
hydraulics 4-269
Replacing switching rod 4-270
Replacing locking lever for
working hydraulics 4-271
Replacing throttle hand lever 4-272
Replacing manual inching (option) 4-273
Frame 4-275
Cab, complete, removing4-275
Cab, complete, attaching4-281
Replacing documents box (option) 4-284
Steering column 4-285
Replacing steering wheel knob 4-285
Replacing steering wheel4-286
Replacing steering column 4-287
Heater 4-288
Replacing cab heater 4-288
Replacing shut-off valve 4-289
Electrical system 4-291
Alternator, battery and motors 4-291
Replacing alternator 4-291
Replacing starter 4-292
Replacing windscreen wiper motor 4-294
Switches and sensors 4-295
Replacing battery disconnector 4-295
Replacing ignition lock 4-296
Replacing oil pressure switch on the engine 4-297
Replacing engine temperature switch 4-298
Replacing brake switch 4-299
Replacing steering column switch 4-300
Replacing switches in the cab 4-301
Adjusting proximity switch4-302
Replacing proximity switch 4-303
Adjusting VLS initiator 4-304
Replacing VLS initiator 4-305
Replacing tank sensor 4-306
Relays, coils and fuses 4-307
Replacing relays 4-307
Replacing stop solenoid 4-308
Replacing coil and core on solenoid valves 4-310
Replacing solenoid valve of the variable
displacement pump 4-310
Replacing coil and core on the variable
displacement pump 4-311
Replacing control unit 4-312
Replacing fuse block 4-313
Indicator lamps, warning buzzer and
instruments 4-314
Replacing instrument cluster 4-314
Replacing load display 4-315
Replacing horn4-315
T 4512 – 06/2013 (1000274281-2 – DE) DOK-ID: 1000274281-2 – DE 0- 11
Content 1
Replacing warning buzzer (option)4-316
Replacing power socket (12 V) 4-317
Lighting equipment 4-317
Completely replacing headlight with
flasher unit 4-317
Replacing complete tail light 4-318
Replacing work light 4-319
Replacing number plate light (option) 4-320
Replacing rotating beacon (option)4-320
Replacing cab light 4-321
Additional electrical equipment 4-321
Replacing 7-pole power socket 4-321
Replacing 3-pole power socket (option) 4-322
Attachments 4-325
Replacing ripping tooth of the earth bucket 4-325
Replacing locking device of the pallet fork 4-325
Replacing tines of the silage fork 4-326
Replacing hydraulic cylinder of the
silage fork 4-327
Replacing hydraulic cylinder of the multi-purpose
bucket 4-328
Replacing valve of the multi-purpose bucket 4-329
Part 5 – Circuit Diagrams and Technical
Descriptions 5-331
Hydraulic circuit diagrams 5-335
Wiring diagram 5-341
Connector pin assignments / contact
assignments 5-365
Connector pin assignments 5-366
Contact assignments 5-373
Technical description 5-375
Engine 5-375
Hydraulics 5-376
Drive and axles 5-379
Part 6 – Supplier
Documentation 6-1
Engine operating manual (example) 6-5
Engine workshop manual (example) 6-7
Displacement pump repair instruction
(example) 6-9
Displacement engine repair instruction
(example) 6-11
Axle workshop manual (example) 6-13
Electrical components 6-15

IMAGES PREVIEW OF THE MANUAL: