Wacker Neuson TH522 Telehandler Service Repair Manual

Service Repair Manual: 574 Pages
Operators Manual: 314 Pages
Spare Parts Catalog: 861 Pages
Manuals: Service Repair Manual
Category: Wacker Neuson

Table of Content – Wacker Neuson TH522 Manual

Introduction
About This Service Manual
Tightening Torques
Safety Instructions
Operation
Overview of Control Elements
Indicator Lights and Warning Lights (Overview)
Steering System
Accelerator Actuation
Brakes
Travel Operation
Differential Lock (Option)
Lights/Signaling System
Wiper/Washer System
Heating, Ventilation and Air Conditioning System
Operating Hydraulics
Attachments
Work Operation
Emergency Lowering
Options
Maintenance
Information on Maintenance
Maintenance Overview
Fluids and Lubricants
Maintenance Accesses
Cleaning and Maintenance
Lubrication Work
Fuel System
Engine Lubrication System
Cooling System
Air Filter
V-Belt/Toothed Belt
Hydraulic System
Electrical System
Heating, Ventilation and Air Conditioning System (Option)
Washer System
Axles/Traveling Drive
Braking System
Tires
Maintenance and Servicing Work on Attachments
Maintenance of Options
Exhaust Gas Treatment
Engine
Complete Component (Engine 36.7 kW)
Alternator (36.7 kW)
Motor Starter M001 (36.7 kW)
Complete Component (Engine 44.3 kW)
Alternator (44.3 kW)
Motor Starter M001 (44.3 kW)
Diesel Particulate Filter (Engine 44.3 kW)
Fuel Tank
Tank Sensor B001
Cooling
Coolant Reservoir
Traveling Drive
Cardan Shaft
Servomotor M17/M18
Type Label – Transfer Gearbox
Tightening Torques and Screw Locking
Drain, Filler and Check Plugs
Axles
Front Axle
Rear Axle
Type Plate – Front/Rear Axle
Tightening Torques and Screw Locking
Drain, Filler and Check Plugs
Brakes
Replacing Brake Linings
Steering System
Steering Orbitrol S8
Steering Mode Valve V64
Hydraulic System
Hydraulic Oil Tank Z41
Variable Displacement Pump P34/P35
Quickhitch
Telescopic Boom
Lift Cylinder A57
Push-Out Cylinder A59
Tilt Cylinder A58
Compensation Cylinder A60
Designation of Hydraulic Components
Hydraulics Diagram – Variant 1
Hydraulics Diagram – Variant 2
Hydraulic Diagram – Variant 3
Hydraulics Diagram – Variant 4
Hydraulics Diagram – Variant 5
Hydraulics Diagram – 4-Way Control Valve
Hydraulics Diagram – 5-Way Control Valve
Hydraulics Diagram – 6-Way Control Valve
Hydraulics Diagram – 7-Way Control Valve
Hydraulics Diagram – 8-Way Control Valve
Hydraulics Diagram – Compensating and Lift Cylinder
Hydraulics Diagram – Push-Out Cylinder
Hydraulics Diagram – Tilt Cylinder
Hydraulics Diagram – Steering System
Hydraulic Circuit Diagram – Brakes
Hydraulic Circuit Diagram – Differential Lock
Hydraulics Diagram – 3rd Control Circuit Parallel/4th Control Circuit Parallel with Switchover Valve
Hydraulics Diagram – 3rd Control Circuit Serial/4th Control Circuit Parallel
Hydraulics Diagram – 3rd and 4th Control Circuit Parallel, Rear Hydraulic Connections Serial
Hydraulics Diagram – 3rd/4th Control Circuit and Rear Hydraulics Parallel, Rear Hydraulic Connections Serial
Hydraulics Diagram – 3rd/4th Control Circuit and Rear Hydraulics Parallel, Rear Hydraulic Connections Serial, HighFlow and PTO Shaft Single-Acting
Electrical System
Fuse Assignment
Relays
Electrical Components
Safe Load Indicator P006
Limit Switches S116/S142
Malfunctions of the Machine Electronics (36.3 kW Engine)
Malfunctions of the Machine Electronics (44.7 kW Engine)
Error Code Table
Electrical Diagram – Electronics, Power Supply
Electrical Diagram – Perkins 404D-22 Engine
Electrical Diagram – Perkins 404D-22 Engine
Electrical Diagram – Perkins 404F-22 Engine
Electrical Diagram – Perkins 404F-22 Engine
Electrical Diagram – Ciam Instrument
Electrical Diagram – Bauser Instrument
Electrical Diagram – Drive Function
Electrical Diagram – Extension and Retraction; VLS; Load Control
Electrical Diagram – Indicator System; Horn
Electrical Diagram – StVZO (German Traffic Regulations) Lights
Electrical Diagram – StVZO (German Traffic Regulations) Lights
Electrical Diagram – Working Lights; Rotating Beacon
Electrical Diagram – Air Conditioning; Seat
Electrical Diagram – Wiper
Electrical Diagram – 12V Electrical Connection; Hydraulic Control Circuits
Electrical Diagram – Hydraulics 1
Electrical Diagram – Hydraulics 2
Electrical Diagram – Radio; Cigarette Lighter Socket; Interior Light
Electrical Diagram – Rear Force Sensorr
Electrical Diagram – Steering Mode Switchover
Designation of Electrical Components
Connector Pin Assignment
Pin Assignment (Only 33.7 kW Engine)
Pin Assignment (Only 44.3 kW Engine)
Trim
Engine Cover
Underride Protection
Rear Covers
Cabin Covers
Cabin
Seat
Cabin
Air Conditioning Cooler
Air Conditioning System Compressor Y031
Automatic Coupling
Ball Coupling
Automatic/Rotating Trailer Coupling
Self-Securing Coupling
Switch
Overview of Switch Assignment
Index