Wacker Neuson TH625 Telehandler Service Repair Manual

Table of Content – Wacker Neuson TH625 Manual

• Cab Overview, Use and Operation
  • Machine Outside View
  • Inside of Cab (Overview)
  • Instrument Panel, Multifunctional Lever and Switch Consoles (Overview)
  • Fields of Application and Using a Machine with an Attachment
  • Legal Regulations Regarding Machine Operation
  • Type Labels and Component Numbers
  • Key-Based Drive Interlock (Option)
  • Drive Interlock with Code Input (Option)
  • Battery Master Switch (Option)
  • Avoiding Running the Engine Under Low-Load Conditions
  • Stopping the Diesel Engine
  • Jump-Starting the Diesel Engine (External Battery)
  • Pressure Relief on the Quickhitch Couplers
  • Overview of Steering Modes (Option)
  • Steering Synchronisation (Wheels Front/Rear Axles)
  • Low-Speed Control (Option)
  • Rear Hydraulic Additional Control Circuit (Option)
  • Hydraulic Connection for Tipping Trailer (Option)
  • Autohitch Trailer Coupling (Option)
  • Automatic Trailer Coupling (Option)
  • Hydraulic Trailer Brake Connection (Option)
  • Fitting Attachments from Other Manufacturers (Option)
  • Towing the Machine
• Specifications
  • Model and Trade Names (Overview)
  • Frame
  • Diesel Engine
  • Drive
  • Axles
  • Service and Parking Brake (Disc Brake)
  • Steering System
  • Work Hydraulics
  • Electrical System
  • Tyres
  • Machine Weight and Axle Loads
  • Trailer Couplings: Trailer Weight/Drawbar Load
  • Sound Levels and Noise
  • Vibrations, Oscillation and Acceleration Values
  • Coolant Compound Table
  • Tightening Torques
  • Standard Bucket Payloads
  • Pallet Forks Payloads
  • Dimensions with Standard Bucket
  • Dimensions with Pallet Forks
• Maintenance and Service Work
  • Explanation of Symbols on the Maintenance Label
  • Maintenance Label
  • Fluids and Lubricants
  • Maintenance Plan (Overview)
  • Important Notice Regarding Maintenance Work
  • Safety Strut for Telescopic Boom
  • Fuel System
  • Refuelling
  • Checking/Cleaning the Additional Fuel Filter (Water Separator, Option)
  • Bleeding the Fuel System
  • Replacing the Fuel Filter
  • Diesel Engine Lubrication System
  • Filling Up Engine Oil
  • Changing the Engine Oil
  • Replacing the Engine Oil Filter Cartridge
  • Diesel Engine and Hydraulics Cooling System
  • Temperature Gauge: Diesel Engine Coolant
  • Filling Up Coolant
  • Cleaning the Radiator Fins
  • Draining Coolant
  • Air Filter
  • Replacing the Filter Cartridge
  • V-Belts
  • Hydraulic System
  • Monitoring the Hydraulic Oil and Return Filter Indicator Lights
  • Checking the Hydraulic Oil Level Once a Day
  • Filling Up Hydraulic Oil
  • Changing the Filter Insert
  • Replacing Hydraulic Oil
  • Important Notices on the Use of Biodegradable Oil
  • Checking Hydraulic Pressure Lines
  • Oil Levels: Rear Axle Transfer Gearbox
  • Oil Levels: Front and Rear Axle Differentials
  • Oil Levels: Front and Rear Axle Planetary Drives
  • Lubrication Work
  • Lubrication Points on the Telescopic Boom (Overview)
  • Lubricating with the Central Lubrication System (Option)
  • Setting the Lubrication and Break Times
  • Central Lubrication System Diagram
  • Installing the High-Pressure Hoses on the Central Lubrication System
  • Instructions for Troubleshooting in Case of Central Lubrication System Blocking
  • Repairing a Blocking Distributor of the Central Lubrication System
  • Troubleshooting Table for Central Lubrication System
  • Maintenance of the Brake System
  • Tyres
  • Changing Wheels
  • Heating/Cab Ventilation
  • Air Conditioning (Option): Maintenance
  • Functional and Visual Checks of the Air Conditioning
  • Cleaning the Heat Exchanger (Condenser)
  • Maintenance of the Electrical System
  • Maintenance of the Automatic Trailer Coupling (Option)
  • General Maintenance and Cleaning Work
  • Maintenance of Attachments and Work Equipment
• Engine
  • Diesel Engine Diagrams
  • Diagnosis/Fuel Preheater (Electrical Diagrams)
  • Manual Throttle Diagrams
  • Engine Designation
  • Fuel Specification
  • Coolant Specification
  • Diesel Engine TD 2009 L04 (Overview)
  • Electric Components on Engine (Overview)
  • Lube Oil Circuit
  • Cooling
  • Adjusting the Cable Pull for Speed Regulation
  • Fuel System
  • Replacing the Cylinder Head Gasket
  • Removing/Installing the Fuel Injection Pump
  • Mounting the Fuel Injection Pump
  • Removing/Installing the Fuel Injectors
  • Sealing the Coolant Pump
  • Removing/Installing the Thermostat
  • Checking the Thermostat
  • Assembly Instructions: Replacing the Visco Clutch
  • Tightening Torque Table
  • Diesel Engine Malfunctions
• Drive
  • Drive (Hydraulic Diagram)
  • Drive Diagrams
  • Making Settings with the Laptop
  • Error: Incorrect Tool Key
  • Importing New Data
  • Drive Electronics PLUS+1 Mode Description
  • Reading Out/Deleting the Error History
  • Deleting the Error History
  • Switching the Inching Potentiometer On/Off
  • Reading in the Inching Potentiometer Again
  • Reading in the Inching Potentiometer
  • Switching the Creep Gear Potentiometer On/Off
  • Switching On the Creep Gear Potentiometer
  • Reading in the Creep Gear Potentiometer
  • Modifying the Load Stabiliser Settings
  • Error Code Table
  • Towing and Transporting the Machine
  • Hydraulic Pump H1 (Model 407 02) Test Ports and HP Valves (Overview)
  • Hydraulic Pump H1 (Model 407 02) Proportional Valve and Electronics (Overview)
  • Variable Displacement Motor H1 110 cm³/rev (Overview)
  • Variable Displacement Motor H1B (Overview)
  • Model 407 02 Test Report
  • Error Description for Test Report Model 407 02
  • Drive with Hydraulic Pump H1 (Hydraulic Circuit)
  • Checking the Idling Speed
  • Checking/Adjusting Starting Speed
  • Adjusting Boost Pressure
  • Checking High Pressure
  • Checking Driving Direction Identification
  • Checking the Energisation of the Driving Direction Identification
  • Checking Engine Droop (Variable Displacement Pump)
  • Setting the Pump Droop Speed
  • Setting Engine Droop/Control Initiation of the Hydraulic Motor
  • Setting Maximum Speed
  • Troubleshooting Boost-Pressure Errors (Diagram)
  • Checking High Pressure (HP Valves)
  • Checking Pump Engine Droop, Driving Direction Identification and Differential Pressure Measurement
• Axles
  • Differential Lock Diagrams
  • Axle Type Label
  • Front Axle Screw Connections
  • Rear Axle Screw Connections
  • Drain, Fill and Check Plug – Front Axle
  • Drain, Fill and Check Plug – Rear Axle
  • Front Axle Tightening Torques (Nm)
  • Rear Axle Tightening Torques (Nm)
  • Sealing Work
• Brakes
  • Brake Diagrams
  • Brakes (Hydraulic Diagram)
  • Brake Circuit
  • Trailer Brake Valve Circuit
  • Service Brake Function
  • Parking Brake Circuit
  • Service Brake
  • Sealing the Brake Calliper
  • Bleeding the Brake System with Bleed Equipment
  • Setting the Brake Pedal with the Inching Potentiometer
• Steering System
  • Steering System (Hydraulic Diagram)
  • Steering Circuit with Final-Position Synchronisation
  • Steering Circuit with Front, Four-Wheel and Crab Steering
  • Steering System Adjustment
  • Hydraulic Ports on Servostat
  • Pressure Relief Valve: Adjustment
  • Sealing Steering Rams
  • Checking the Steering Mode Valve
  • Checking a Steering Ram
  • Overview of Steering Ram Setting
  • How to Check and Set the Steering Rams
  • Checking the Track Setting (1)
  • Correcting the Track Setting (2)
  • Steering Misalignment During Final-Position Synchronisation (3)
  • Adjustment Work
  • Checking Steering Synchronisation (4)
• Work Hydraulics
  • 20 kph 4-Fold Control Valve (Hydraulic Diagram)
  • 30 kph 5-Fold Control Valve (Hydraulic Diagram)
  • Hydraulics Legend
  • Raising/Lowering (Diagrams)
  • Raising/Lowering the Telescopic Boom (Hydraulic Diagram)
  • Raising/Lowering the Telescopic Boom, Load Stabiliser (Hydraulic Diagram)
  • Dumping In/Out, Tilt Ram Lock (Electrical Diagrams)
  • Dumping Out (Hydraulic Diagram)
  • Tilt Ram Lock (Hydraulic Diagram)
  • Extending/Retracting the Telescopic Boom (Black/White) (Electrical Diagrams)
  • Extending/Retracting the Telescopic Boom/Proportional (Electrical Diagrams)
  • Retracting/Extending the Telescopic Boom (Hydraulic Diagram)
  • Locking/Unlocking the Quickhitch (Black/White) (Electrical Diagrams)
  • Quickhitch Diagram Designations (Black/White, Lock/Unlock)
  • Locking/Unlocking the Quickhitch Proportionally (Electrical Diagrams)
  • Quickhitch Diagram Designations (Proportional, Lock/Unlock)
  • Locking (Hydraulic Diagram)
  • Locking/Additional Control Circuit (Hydraulic Diagram)
  • Locking/Return Without Pressure (Hydraulic Diagram)
  • Safe Load Indicator (Electrical Diagrams)
  • Overload Cutoff (Hydraulic Diagram)
  • Load Stabiliser (Electrical Diagrams)
  • Additional Control Circuit/Tipping Trailer (Hydraulic Diagram)
  • Tipping Trailer (Hydraulic Diagram)
  • Autohitch (Hydraulic Diagram)
  • Autohitch/Tipping Trailer (Hydraulic Diagram)
  • Additional Function (Electrical Diagrams)
  • Autohitch/Additional Control Circuit/Tipping Trailer (Hydraulic Diagram)
  • Test Report for Hydraulics 407-02 (2506)
  • Work Hydraulics Oil Supply
  • Pump Pressure/Work Hydraulics Test Port
  • Control Valve (Overview)
  • Control Valve Design
  • Checking and Setting the Work Hydraulics
  • 7-Fold Pilot Valve (Overview)
  • 4-Fold Pilot Valve (Overview)
  • Pilot Control Circuit
  • Load Stabiliser Circuit
  • Lift Ram Circuit
  • Tilt Ram Circuit
  • 3rd Control Circuit
  • Additional Control Circuit and Rear Tipping Trailer
  • Tilt Ram Lock Circuit
  • Autohitch and Tipping Trailer Ports
  • Overload Cutoff Circuit
  • Load Stabiliser
  • Valve for Tilt Ram Lock
  • Tipping Trailer and Additional Control Circuit Valve
  • Work Hydraulics/Steering System Priority Valve
  • Valves (General Overview)
  • Lift Ram (Sealing Work)
  • Tilt Ram (Sealing Work)
  • Push-Out Ram
  • Compensating Ram
  • Control Ram (Quickhitch Frame) (Sealing Work)
  • Lift, Tilt and Push-Out Rams: Velocity
  • Usable Consumer Pressure at Additional Control Circuit (Option)
  • Overload Control (Smart Handling)
  • Overview of Safe Load Indicator
  • Setting the Safe Load Indicator (0% Point)
  • Setting the Safe Load Indicator (100% Point Stability)
  • Inspection Plan for Overload Control (Model 407 Telehandler)
  • Testing Without Any Load
  • Testing with Load
  • Functional Description of Overload Control (Smart Handling)
  • Electric Components
  • Circuit Diagram: Overload Control Enabled
  • Circuit Diagram: Automatic Retraction Off
  • Overview of Valves
  • Overview of Valve Connections and Ports
  • Circuit Diagram: Overload Control
  • Circuit Diagram Legend
  • Extend (Solenoid Valve Y102) (Circuit Diagram)
  • Pallet Forks Mode (Circuit Diagram)
  • Tip Switch S084 Pressed (Circuit Diagram)
  • Overload Control Relay
  • Installation Position: Overload Control Relay
• Electrical System
  • Lights (Diagrams)
  • Working Lights (Diagrams)
  • Turn Indicators/Horn/Rotating Beacon (Diagrams)
  • Window Heating/Front Socket (Electrical Diagrams)
  • Wipe/Wash System (Electrical Diagrams)
  • Seat/Air Conditioning System (Diagrams)
  • Multimedia/Monitoring/Cigarette Lighter (Electrical Diagrams)
  • Cab Wiring Harness 1000256306-01
  • Cab Wiring Harness Legend
  • Engine Wiring Harness 1000245802
  • Engine Wiring Harness Legend
  • Frame Wiring Harness 1000256307
  • Frame Wiring Harness Legend
  • Cab Wiring Harness (Overload Control)
  • Cab Wiring Harness Legend
  • Frame Wiring Harness (Overload Control)
  • Frame Wiring Harness (Overload Control) Legend
  • Ohm’s Law: Current, Voltage, Resistance and Power
  • Measuring Equipment and Measuring Methods
  • Terminal Description
  • Colour Coding of Electric Lines
  • Switching Relay Function
  • Fuse Assignment
  • Switching Relay Assignment on Board
  • Switching Relay Assignment on Bracket
  • Main Fuse Box with Relays in the Engine Compartment
  • Electric Units
  • Connector Description (Overview)
  • Switch Assignment on Board (Overview)
  • Switch Assignment on Instrument Panel (Overview)
  • Control Lever (Black/White Control)
  • Joystick (Black/White Function)
  • Joystick: Retracting/Extending the Telescopic Boom (Black/White)
  • Joystick: Unlocking/Locking the Telescopic Boom (Black/White)
  • Control Lever (Proportional Control)
  • Joystick (Proportional Function)
  • Joystick: Retracting/Extending the Telescopic Boom (Proportional)
  • Joystick: Unlocking/Locking the Telescopic Boom (Proportional)
  • Additional Control Circuit with Potentiometer (Proportional)
  • Proportional Controls Connector Assignment (Overview)
  • Proportional Controls (Overview and Connections)
  • Retrofitting a Rotating Beacon
  • Retrofitting the Backup Warning System
  • Retrofitting Two Front Working Lights
  • Retrofitting Two Rear Working Lights
  • Retrofitting a Rear 7-Pole Socket
  • Retrofitting a Front 4-Pole Socket
  • Retrofitting Two Working Lights on the Telescopic Boom (From Mid-2011)