Wacker Neuson TH627 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.

2647 Pages

 

 

MANUAL COVERS:

SERVICE REPAIR MANUAL:

E Introduction
E.1 Notes on the repair manual
Working with the repair manual
Explanation of symbols and abbreviations
Repair instructions
Technical data
Cause of damage
Spare parts
Diesel engine
Gearbox
Hydraulic system
Required tools and screw connections
Procedure
Replacement of components/warranty handling
E.2 Safety instructions
Pay particular attention to the following
Safety symbols and signal words
Explanation
Safety and accident prevention regulations
Leaving the machine
Adjustment and maintenance
Jack up the machine
Parking the machine
Air conditioning
Risk of injury from hydraulic fluids
Pressure accumulator
First-aid measures
E.3 Tightening torques
General tightening torques
Specific tightening torques
Torque values for metric coarse-pitch thread
Screws and nuts
Torque values for metric fine-pitch thread
Screws and nuts
Tightening torques for hydraulic screw connections and air-conditioning screw connections with
sealing cone and O-ring DIN 3865
Tightening torques for hydraulic screw connections with olive DIN 3861
Tightening torques for hydraulic system screw-in spud SDS
Shape B with sealing edge (cutting edge) and shape E with soft O-ring seal
Shape F with O-ring and plug
Shape H with O-ring and chamber ring
Tightening torques for hydraulics rotating threaded fittings
Tightening torques for banjo bolts DIN 7643
Tightening torques for adjustable hydraulics screw-in spuds SDE
Shape F with O-ring
Shape H with O-ring and chamber ring
Tightening torques for brake line threaded fittings
Shape F male fitting screws and shape FS male fitting screws with flare
Tightening torques for worm drive hose clamps
Tightening torques for spring-loaded worm drive hose clamps
1 Maintenance
1.1 Maintenance preparations, instructions
Information on maintenance
Responsibilities and prerequisites
Safety instructions concerning maintenance work
Parking the machine
Jack up the machine
Battery master switch S008
Switch off the battery master switch S008
Switch on battery master switch S008
Safety prop for telescopic boom
Mounting the safety prop onto the lift ram
Vent filter/vacuum pump
Dismantle vent filter/connect vacuum pump
Mount vent filter/remove vacuum pump
1.2 Maintenance overview
Maintenance plan
Important information on the maintenance plan
Service indication
Maintenance label
Explanation of symbols on the maintenance label
1.3 Fluids and lubricants
Fluids and lubricants (overview)
Diesel fuel specification
Coolant
Important notice on operation with biodegradable oils
1.4 Maintenance accesses
Engine cover
Opening the engine cover
Close the engine cover
Engine vat
Engine vat, rear
Open the maintenance access
Close the maintenance access
Lower engine vat
Open the maintenance accesses
Close the maintenance accesses
Engine vat, front
Open the maintenance access
Close the maintenance access
Rear of machine
Opening the cover
Closing the cover
Cabin at front
Opening the cover
Closing the cover
Access Vehicle fuses, Relay
Open control panel
Close control panel
Relays in the foot area (start interlock)
1.5 Cleaning and maintenance work
Important information
Cleaning with washing solvents
Cleaning with compressed air
Cleaning with a high-pressure cleaner or steam jet
Cleaning with flammable anticorrosion protection
Cleaning inside the cabin
The following aids are recommended for cleaning:
Cleaning the seat belt (lap belt)
Cleaning exterior of the machine
The following aids are recommended for cleaning:
Cleaning the engine and the engine compartment
The following aids are recommended for cleaning:
Checking threaded fittings
Checking pivots and hinges
1.6 Lubrication work
Preparations
Lubricating the rear axle oscillation-type bearing
Lubricating the planetary drive bearing (front and rear axles)
Lubricating the door
Lubricating the telescopic boom
Overview of lubrication points
Lubricating the telescopic boom
Lubricate the pad tracks
Preparing the machine
Lubricate the pad tracks
Post-treatment of the pad tracks with applied smooth paint (optional)
Perform the post-treatment as follows:
Spraying oil onto the slide plates after a salt application (with a spray lance)
Preparing the machine:
Spray the telescopic boom
After spraying oil:
Checking the slide plates
Changing the side plates/Readjusting the filler plates
Dismount the stripper (opt.)
Replace front slide plates
Mount the stripper (opt.)
Replace rear top slide plates
Replace rear lateral slide plates
Replace rear bottom slide plate
Central lubrication system (option)
Functional description of the central lubrication system
Time control
Repair work
Lubricating with the central lubrication system (option)
Setting the lubrication and break times
Lubrication times (S)
Break time (P)
Yellow LED (L)
Filling the central lubrication system (option)
1.7 Fuel system
Safety instructions for refueling
Stationary fuel pumps
If refueling from barrels cannot be avoided, note the following points:
Refuelling
Refuel as follows
Drain fuel
Checking/cleaning the fuel filter
Drain the condensation water as follows:
Replace the fuel filter
Bleeding the fuel system
1.8 Engine lube oil system
Important safety instructions
Checking the engine oil level
Adding engine oil
Changing engine oil
Drain engine oil
Refill engine oil
Replacing the engine oil filter
1.9 Exhaust gas cleaning
ExhaustAfter-treatment System
Emission system overview
Diesel oxidation catalytic converter (DOC)
Diesel particulate filter DPF
Coated Soot Filter or Catalyzed Soot Filter CSF
Regeneration of the diesel particulate filter
Notes
1.10 Cooling system
Safety instructions
Information on inspection and cleaning work on the cooling system
Checking the coolant level
Checking the coolant level:
Adding coolant
Preparations
Adding coolant
Leakage check
Draining/replacing coolant
Draining/replacing coolant:
Adding coolant:
Cleaning the radiator
Preparations
Cleaning the radiator:
Cleaning the radiator with the reversing fan (option)
Cleaning the radiator with the reversing fan (option)
Cleaning with the reversing fan:
1.11 Air filter
Important information on cleaning the air filter
Cleaning the dust valve
Cleaning the dust valve:
Checking the filter cartridge for dirt:
Replacing the filter cartridge
Replacing the filter cartridge and safety cartridge:
1.12 V-belt/toothed belt
Checking/re-tensioning the V-belt (alternator/water pump)
Checking the V-belt (alternator/water pump)
Re-tensioning the V-belt (alternator/water pump)
Change the V-belt (alternator/water pump)
Remove the V-belt (alternator/water pump)
Install the V-belt (alternator/water pump)
Checking/re-tensioning the V-belt reversing fan (opt)
Checking/re-tensioning the V-belt reversing fan (opt)
Changing the reversing fan V-belt (optional)
Remove the V-belt of the reversing (opt)
Install the V-belt reversing fan (opt)
Checking/re-tensioning the V-belt air conditioning (opt)
Checking the V-belt air conditioning (opt)
Re-tensioning the V-belt air conditioning (opt)
Changing the V-belt air conditioning (opt)
Removing the V-belt air conditioning (opt)
Install the V-belt air conditioning (opt)
1.13 Hydraulic system
Important information
Monitoring the hydraulic oil filter
Hydraulic oil temperature monitoring
Checking the hydraulic oil level
Checking the hydraulic oil level:
Adding hydraulic oil
Changing hydraulic oil
Proceed as follows:
Replace they hydraulic oil suction and return flow filter.
Hydraulic tank – change ventilation filter
Clean the line filter (high pressure filter) strainer insert
Remove the line filter
Mount the line filter
Checking the hydraulic system for leaks
Safety instructions regarding pressure line checks
Checking the condition and age of hydraulic hoses
Important information for the owner of the machine:
1.14 Electrical system
Safety instructions regarding the battery
Checking/replacing the battery
Preparing battery replacement:
Removing the battery
Install the battery
Regular checks and service work on the electrical system
Daily checks before operating the machine
Weekly checks
Checking the alternator
Checking/replacing relays and fuses
Checking/replacing fuses and switching relays:
Check/change relays in foot area (start interlocking)
Checking/replacing switching relays:
Main fuse box with switching relays
Checking/replacing fuses and relays:
Checking/changing relay of 14-pin socket
Checking/replacing switching relays:
1.15 Heating, ventilation, air conditioning
Important information on cabin ventilation
Cleaning/replacing the cabin ventilation filter
Cleaning the recirculated-air filter
Cleaning/replacing the fine-dust filter
Air conditioning (option)
Important safety instructions regarding the air conditioning system
Visual check of the air conditioning system
Cleaning the heat exchanger (condenser)
Cleaning the condenser
Clean the condenser
Emptying/filling the air conditioning system
Drain
Filling up the air conditioning system
1.16 Washer system
Reservoir
1.17 Axles/traveling drive
Check/refill gear lubricant oil
Change gear oil in distribution gear
Checking/refilling oil at differential lock (rear axle)
Change oil in differential (rear axle)
Checking/refilling oil at the differential lock (front axle)
Change oil at the differential lock (front axle)
Checking/refilling oil at the planetary drives
Change oil at the planetary drives
1.18 Brake system
Important safety instructions
Checking/adding brake fluid
Change and vent the brake fluid
In vehicles with hydraulic trailer brake valve (opt.):
1.19 Pressure accumulator
Pre-charge pressure of pressure accumulator
Connecting the filling and testing device
Checking the pressure level
Adjusting the pressure level
Removing the filling and testing device
1.20 Tyres
Important information
Tire check
Dismounting the wheels
Mounting the wheels
1.21 Attachments
1.22 Trailer coupling
Automatic trailer coupling (option)
Cleaning and lubricating the trailer coupling
Check the trailer coupling for wear
Ball trailer coupling ø 80 mm (3.15 in) (option)
Cleaning and lubricating the trailer coupling
Autohitch trailer coupling (option)
Cleaning and lubricating the trailer coupling
1.23 Camera system
Cleaning the screen
Cleaning the camera/switch box/transmission receiver
Replacing the front glass of the camera
1.24 Machine preservation
Important information on anticorrosion protection (option)
Components coated with anticorrosive wax
Measures for maintaining anti-corrosive protection
Cleaning
Applying the protective anticorrosion coating
Treatment of oxidized surfaces
Electric connections
For sheet metal parts

2 Engine
2.1 Kohler KDI 2504 TCR motor
Removing/installing the engine
Preparing work
Technical data
Disassemble
Install
2.2 Engine suspension
Removing/installing engine suspension
Preparing work
Technical data
Remove the engine suspension in front
Install the engine suspension in front
Remove the engine suspension at the rear right and left.
Install the engine suspension at the rear right and left
2.3 Starter M001
Remove / install motor starter
Technical data
Disassemble
Install
2.4 Generator G001
Remove / install alternator
Technical data
Disassemble
Install
2.5 Centaflex-coupling
Remove/install Centaflex coupling
Preparing work
Technical data
Disassemble
Install
2.6 Fuel tank
Remove / install fuel tank
Preparing work
Technical data
Remove
Install
2.7 Tank sensor B001
Remove/install tank sensor B001
Technical data
Disassemble
Install
2.8 Air filter
Remove/install air filter
Technical data
Disassemble
Install
2.9 Accelerator pedal R011
Remove / install accelerator pedal
Technical data
Disassemble
Install
Calibrate accelerator R011
Calibration

3 Cooling
3.1 Combined radiator
Removing/installing the combi cooler
Preparing work
Technical data
Disassemble
Install
3.2 Fan wheel/fan mounting
Removing/installing fan wheel/fan mounting
Preparing work
Technical data
Disassemble
Remove the fan mounting
Assemble the fan mounting
Install
3.3 Hydraulic motor fan
Removing/installing fan hydraulic motor
Preparing work
Technical data
Disassemble
Install
3.4 Fan pump/pump mounting
Removing/installing the fan pump
Preparing work
Technical data
Remove the fan pump
Remove the fan mounting
Install the fan mounting
Install the fan pump

4 Traction drive/gears/ drive shafts
4.1 Variable displacement pump VII
Remove/install variable displacement pump VII
Preparing work
Technical data
Disassemble
Install
4.2 Variable displacement motor VIII
Remove/install variable displacement motor VIII
Preparing work
Technical data
Disassemble
Install
4.3 Cardan shaft
Cardan shaft
Technical data
Disassemble
Install

5 Axles
5.1 Type label and overview
Type label
Overview front axle
Overview rear axle
5.2 Drain, fill and check plugs
Front axle
Rear axle
5.3 Screw connections and tightening torques
Threaded fittings
Screw connection and tightening torques, front axle
Screw connection and tightening torques, rear axle
5.4 Special tools
5.5 Track setting
Preparing work
Adjustment
5.6 Front axle
Completely removing/installing the front axle
Preparing work
Technical data
Disassemble
Install
Synchronising the steering system
Remove/install intermediate gearbox
Preparing work
Technical data
Remove the gearbox
Repairing the gearbox cover
Repairing the transmission
Assembling and installing the transmission
Completely remove/install the differential housing
Preparing work
Technical data
Remove the differential housing
Install the differential housing
Disassemble/assemble the angle drive
Preparing work
Technical data
Removing the angle drive
Dismantle the differential cage
Putting together the differential cage
Replacing the angle drive
Check the contact pattern of the angle drive
Remove/install input bevel gear
Preparing work
Technical data
Removing the input bevel gear
Installing the input bevel gear
Remove/install the differential shift fork
Preparing work
Technical data
Remove the shift fork
Installing the shift fork
Removing/installing the cylinder differential lock
Preparing work
Technical data
Preparatory work
Sealing the cover on the left
Seal-tighten cylinder
Finishing work
5.7 Rear axle
Completely remove/install the rear axle
Preparing work
Technical data
Disassemble
Install
Synchronizing the steering system
Completely remove/install the differential housing
Preparing work
Technical data
Remove the differential housing
Install the differential housing
Change the shaft sealing ring at the differential housing
Preparing work
Technical data
Remove the shaft sealing ring
Install the differential housing
5.8 Front/rear axle planetary drive
Completely removing/installing the planetary drive
Preparing work
Technical data
Removing the planetary drive
Installing the planetary drive
Changing the joint housing shaft sealing ring
Preparing work
Technical data
Removing the planetary drive
Changing the rotary shaft lip seal
Installing the planetary drive
Removing/installing the cover of the planetary drive
Preparing work
Technical data
Remove the cover
Installing the cover
Changing the needle bearing in the cover of the planetary drive
Preparing work
Technical data
Remove the needle bearing
Install the needle bearings
Removing/installing the internal-geared wheel
Preparing work
Technical data
Remove the internal-geared wheel
Installing the internal-geared wheel
Changing the cassette sealing ring of the wheel hub
Preparing work
Technical data
Remove the sealing ring
Installing the sealing ring
5.9 Front axle/rear axle
Change the shaft sealing ring in the axle tube
Preparing work
Technical data
Remove the shaft sealing ring
Install the shaft sealing ring

6 Brakes
6.1 Brake pedal
Adjust brake pedal
Technical data
Adjusting rod assembly to inch potentiometer
Adjusting brake pedal stop screw
6.2 Replacing brake linings
Preparing work
Technical data
6.3 Brake caliper
Remove/install the brake caliper
Preparing work
Technical data
Disassemble
Install
Sealing the brake caliper
Preparing work
Technical data
Sealing
6.4 Brake disk
Remove/install the brake disc
Preparing work
Technical data
Remove the brake disk
Install the brake disk
6.5 Main brake cylinder 030
Removing/installing the master brake cylinder
Preparing work
Technical data
Disassemble
Install
6.6 Parking brake
Removing/installing the wire ropes
Technical data
Removing
Install
Adjusting the parking brake

7 Steering
7.1 Steering orbitrol IV
Remove / install steering orbitrol IV
Preparing work
Technical data
Disassemble
Install
Bleed/synchronize steering
7.2 Steering mode valve XXVI
Removing/installing steering mode valve XXVI
Preparing work
Technical data
Disassemble
Install
Bleed/synchronize steering
7.3 Steering cylinder 018/019
Remove/install steering cylinder
Technical data
Disassemble
Install
Bleed/synchronize steering
Sealing steering rams
Disassemble
Reinstall
7.4 Steering column
Completely removing/installing the steering column
Technical data
Disassemble
Install
Removing/installing the steering wheel
Technical data
Disassemble
Install

8 Hydraulics
8.1 Control unit XIII
Remove / install control unit
Preparing work
Technical data
Disassemble
Install
8.2 Hydraulic oil tank XX
Remove/install hydraulic oil tank XX
Preparing work
Technical data
Disassemble
Install
Hydraulic tank tightening torques.
Return flow filter tightening torques
8.3 Working hydraulics Gear pump I
Remove/install gear pump I
Preparing work
Technical data
Disassemble
Install
8.4 Pressure accumulator 077
Removing/installing pressure accumulator for emergency lowering
Preparing work
Technical data
Important information
Remove
Install
8.5 Pressure accumulator 080
Removing/installing pressure accumulator load stabilizer
Preparing work
Technical data
Important information
Remove
Install
8.6 Hose burst valve with load stabiliser XIV
Remove/install hose burst valve using load stabilizer
Preparing work
Technical data
Disassemble
Install
8.7 Hose burst valve for push-out ram 089
Removing/installing the push-out cylinder hose burst valve
Preparing work
Technical data
Disassemble
Install
8.8 Tilt cylinder hose burst valve 087
Removing / installing the tilt ram hose burst valve
Preparing work
Technical data
Disassemble
Install
8.9 Lifting cylinder 085
Removing/installing the lift cylinder
Preparing work
Technical data
Disassemble
Install
Disassemble
Reinstall
8.10 Boom cylinder 089
Remove/install push-out cylinder
Preparing work
Technical data
Disassemble
Install
Disassemble
Reinstall
8.11 Tilt ram 087
Remove/install tilt ram
Preparing work
Technical data
Disassemble
Install
Disassemble
Reinstall
8.12 Compensation cylinder 086
Remove/install compensation cylinder
Preparing work
Technical data
Disassemble
Install
Disassemble
Reinstall
8.13 Lock cylinder 091 (quickhitch facility)
Removing/installing lock cylinder
Preparing work
Technical data
Disassemble
Install
8.14 Telescopic boom
Remove/install inner pipe
Preparing work
Technical data
Disassemble
Install
Remove/install the boom
Preparing work
Technical data
Disassemble
Install
8.15 Tilt rod and rocker arm
Removing/installing the tilt rod
Preparing work
Technical data
Disassemble
Install
Removing/installing rocker arm
Preparing work
Technical data
Disassemble
Install
8.16 Quickhitch
Removing/installing the quickhitch
Preparing work
Technical data
Disassemble
Install
8.17 Telescopic boom hose pipes
Removing/installing hose pipes tilt cylinder/quick release plate in telescopic boom
Preparing work
Technical data
Disassemble
Install

9 Electrical system
9.1 Main fuse box N025
Removing/installing the main fuse box N025
Technical data
Disassemble
Install
9.2 Control lever D002
Remove/install control lever D002
Technical data
Disassemble
Install
9.3 Instrument panel
Remove/install instrument panel
Technical data
Disassemble
Install
9.4 Inch potentiometer R002
Remove / install inch potentiometer
Technical data
Disassemble
Install
Calibrate inch potentiometer R002
Adjustment
9.5 Rotary angle encoder Lifting arm R023
Removing/installing the turning angle transmitter
Technical data
Disassemble
Install
Setting turning angle transmitter on lifting arm R023
Adjustment
9.6 Travel sensor for bucket repositioning B028
Remove/install travel sensor with rod
Technical data
Disassemble
Install
9.7 Creep gear potentiometer R003
Removing/installing the crawler gear potentiometer
Technical data
Disassemble
Install
Calibrating the creep gear potentiometer R003
Calibration
9.8 Hand throttle potentiometer R012
Removing/installing the manual throttle potentiometer
Technical data
Disassemble
Install
Calibrate hand throttle potentiometer B R012
Calibration
9.9 Load sensor B008
Remove/install load sensor
Preparing work
Technical data
Disassemble
Install
It is essential that the following steps are observed:
9.10 Safe load indicator P006
Calibrate safe load indicator
Technical data
Calibrating the 0 % point
Calibrating the 100% point
LED colours
Error codes during normal operation
Error codes in calibration mode
9.11 Controller
Removing/installing controller N004
Technical data
Disassemble
Install
Removing/installing diesel motor electronics N005
Technical data
Disassemble
Install

12 Trim
12.1 Engine cover
Remove/install engine cover
Preparing work
Technical data
Disassemble
Install
12.2 V-belt cover
Remove/install V-belt cover
Technical data
Remove
Install
12.3 Transmission tunnel cover
Remove/install transmission tunnel cover
Technical data
Disassemble
Install
12.4 Underride protection
Remove/install underride protection (standard)
Technical data
Remove
Install
Remove/install underride protection (closed)
Technical data
Disassemble
Install
12.5 Cab front covering
Remove/install cab front covering
Technical data
Disassemble
Install
12.6 Cladding in the cabins
Remove/install cladding below the instrument panel
Technical data
Disassemble
Install

14 Cab
14.1 Operator seat
Remove/install driver’s seat
Technical data
Remove
Install
14.2 Cabin
Removing/installing cab
Preparing work
Technical data
Disassemble
Install
14.3 Cabin bearing
Removing/installing cab bearings
Preparing work
Technical data
Disassemble
Install

15 Heating/air conditioning
15.1 Heater/air conditioning system
Remove/install heater/air conditioning system
Preparing work
Special tools
Technical data
Disassemble
Install
15.2 Air conditioning system compressor Y031
Remove / install air conditioning system compressor
Preparing work
Technical data
Disassemble
Install
15.3 Air conditioning cooler (capacitor)
Remove/install air conditioning cooler (condenser)
Preparing work
Technical data
Disassemble
Install
15.4 Dehumidifier
Remove / install dehumidifier
Preparing work
Technical data
Disassemble
Install

17 Automatic coupling
17.1 Autohitch
Removing/installing the autohitch
Preparing work
Technical data
Disassemble
Install
Change bolt A
Preparatory work
Install the new pin B
Replacing the sensor plate and counterbracket
17.2 Height-adjustable trailer coupling
Remove / install trailer coupling
Preparing work
Technical data
Disassemble
Installation
17.3 Automatic/rotating trailer coupling
Remove / install trailer coupling
Technical data
Disassemble
Install
17.4 Tow coupling
Remove / install tow coupling
Technical data
Disassemble
Install

23 Central lubrication system
23.1 Central lubrication unit M016
Remove/install central lubrication unit
Technical data
Disassemble
Install
23.2 Distributing block
Remove/install distributor block
Technical data
Disassemble
Install

 

Wacker Neuson TH627 Operators Manual (486 Pages)

Wacker Neuson TH627 Spare Parts List (553 Pages)

Wacker Neuson TH627 System Handbook (897 Pages)

Wacker Neuson TH627 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

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