Wacker Neuson TH522 Telehandler Service Repair Manual + Operators Manual + Parts Manual

 

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Wacker Neuson. Read and print pages, or copy the entire manual to your hard drive.

2028 Pages

 

 

MANUAL COVERS:

SERVICE REPAIR MANUAL:

Content:

E Introduction
E.1 About this Service Manual
E.2 Tightening torques
E.3 Safety instructions
B Operation
B.1 Overview of control elements
B.2 Indicator lights and warning lights (overview)
B.3 Steering system
B.4 Accelerator actuation
B.5 Brakes
B.6 Travel operation
B.7 Differential lock (option)
B.8 Lights/signaling system
B.9 Wiper/washer system
B.10 Heating, ventilation and air conditioning system
B.11 Operating hydraulics
B.12 Attachments
B.13 Work operation
B.14 Emergency lowering
B.15 Options

1 Maintenance:
1.1 Information on maintenance
1.2 Maintenance overview
1.3 Fluids and lubricants
1.4 Maintenance accesses
1.5 Cleaning and maintenance
1.6 Lubrication work
1.7 Fuel system
1.8 Engine lubrication system
1.9 Cooling system
1.10 Air filter
1.11 V-belt/toothed belt
1.12 Hydraulic system
1.13 Electrical system
1.14 Heating, ventilation and air conditioning system (option)
1.15 Washer system
1.16 Axles/traveling drive
1.17 Braking system
1.18 Tires
1.19 Maintenance and servicing work on attachments
1.20 Maintenance of options
1.21 Exhaust gas treatment

2 Engine:
2.1 Complete component (engine 36.7 kW)
2.2 Alternator (36.7 kW)
2.3 Motor starter M001 (36.7 kW)
2.4 Complete component (engine 44.3 kW)
2.5 Alternator (44.3 kW)
2.6 Motor starter M001 (44.3 kW)
2.7 Diesel particulate filter (engine 44.3 kW)
2.8 Fuel tank
2.9 Tank sensor B001

3 Cooling:
3.1 Coolant reservoir

4 Traveling drive:
4.1 Cardan shaft
4.2 Servomotor M17/M18
4.3 Type label – transfer gearbox
4.4 Tightening torques and screw locking
4.5 Drain, filler and check plugs

5 Axles:
5.1 Front axle
5.2 Rear axle
5.3 Type plate – front/rear axle
5.4 Tightening torques and screw locking
5.5 Drain, filler and check plugs

6 Brakes:
6.1 Replacing brake linings

7 Steering system:
7.1 Steering orbitrol S8
7.2 Steering mode valve V64

8 Hydraulic system:

8.1 Hydraulic oil tank Z41
8.2 Variable displacement pump P34/P35
8.3 Quick hitch
8.4 Telescopic boom
8.5 Lift cylinder A57
8.6 Push-out cylinder A59
8.7 Tilt cylinder A58
8.8 Compensation cylinder A60
8.9 Designation of hydraulic components
8.10 Hydraulics diagram – variant 1
8.11 Hydraulics diagram – variant 2
8.12 Hydraulic diagram – variant 3
8.13 Hydraulics diagram – variant 4
8.14 Hydraulics diagram – variant 5
8.15 Hydraulics diagram – 4-way control valve
8.16 Hydraulics diagram – 5-way control valve
8.17 Hydraulics diagram – 6-way control valve
8.18 Hydraulics diagram – 7-way control valve
8.19 Hydraulics diagram – 8-way control valve
8.20 Hydraulics diagram – compensating and lift cylinder
8.21 Hydraulics diagram – push-out cylinder
8.22 Hydraulics diagram – tilt cylinder
8.23 Hydraulics diagram – steering system
8.24 Hydraulic circuit diagram – brakes
8.25 Hydraulic circuit diagram – differential lock
8.26 Hydraulics diagram – 3rd control circuit parallel / 4th control circuit parallel with switchover valve
8.27 Hydraulics diagram – 3rd control circuit serial / 4th control circuit parallel
8.28 Hydraulics diagram – 3rd and 4th control circuit parallel, rear hydraulic connections serial
8.29 Hydraulics diagram – 3rd / 4th control circuit and rear hydraulics parallel, rear hydraulic connections
serial
8.30 Hydraulics diagram – 3rd / 4th control circuit and rear hydraulics parallel, rear hydraulic connections
serial, High Flow a

9 Electrical system:
9.1 Fuse assignment
9.2 Relays
9.3 Electrical components
9.4 Safe load indicator P006
9.5 Limit switches S116/S142
9.6 Malfunctions of the machine electronics (36.3 kW engine)
9.7 Malfunctions of the machine electronics (44.7 kW engine)
9.8 Error code table
9.9 Electrical diagram – electronics, power supply
9.10 Electrical diagram – Perkins 404D-22 engine
9.11 Electrical diagram – Perkins 404D-22 engine
9.12 Electrical diagram – Perkins 404F-22 engine
9.13 Electrical diagram – Perkins 404F-22 engine
9.14 Electrical diagram – Ciam instrument
9.15 Electrical diagram – Bauser instrument
9.16 Electrical diagram – drive function
9.17 Electrical diagram – extension and retraction; VLS; Load control
9.18 Electrical diagram – indicator system; Horn
9.19 Electrical diagram – StVZO (German traffic regulations) lights
9.20 Electrical diagram – StVZO (German traffic regulations) lights
9.21 Electrical diagram – working lights; Rotating beacon
9.22 Electrical diagram – air conditioning; Seat
9.23 Electrical diagram – wiper
9.24 Electrical diagram – 12V electrical connection; Hydraulic control circuits
9.25 Electrical diagram – Hydraulics 1
9.26 Electrical diagram – Hydraulics 2
9.27 Electrical diagram – Radio; Cigarette lighter socket; Interior light
9.28 Electrical diagram – rear force sensorr
9.29 Electrical diagram – steering mode switchover
9.30 Designation of electrical components
9.31 Connector pin assignment
9.32 Pin assignment (only 33.7 kW engine)
9.33 Pin assignment (only 44.3 kW engine)

10 Trim:
10.1 Engine cover
10.2 Underride protection
10.3 Rear covers
10.4 Cabin covers

11 Cabin:
11.1 Seat
11.2 Cabin
11.3 Air conditioning cooler
11.4 Air conditioning system compressor Y031

12 Automatic coupling:
12.1 Ball coupling
12.2 Automatic/rotating trailer coupling
12.3 Self-securing coupling

13 Switch:
13.1 Overview of switch assignment
Index

 

 

Wacker Neuson TH522 Load Charts (272 Pages)

Wacker Neuson TH522 Spare Parts List (861 Pages)

Wacker Neuson TH522 Load Charts

Wacker Neuson TH522 Technical Data (315 Pages)

Wacker Neuson TH522 Specs

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly