Wacker Neuson TH744 750 755 942 955 Telehandler Factory Service Repair Manual + Operators Manual

Wacker Neuson TH744 750 755 942 955 Telehandler Factory Service Repair Manual + Operators Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Wacker Neuson. 

2567 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
Required tools and screw connections
Procedure
E.2 Safety instructions
Pay particular attention to the following
Safety symbols and signal words
Safety and accident prevention regulations
E.3 Tightening torques
General tightening torques
Specific tightening torques
Torque values for metric coarse-pitch thread
Torque values for metric fine-pitch thread
Tightening torques for hydraulic screw connections and climate screw fixtures with taper
connections and O-rings DIN 3865
Tightening torques for hydraulic screw connections with cutting ring DIN 3861
Tightening torques for hydraulic screw struts SDS
Tightening torques for hydraulics rotating screw connections
Tightening torques for hollow screws DIN 7643
Tightening torques for adjustable hydraulic screw struts SDE
Tightening torques for brake line screw connections
Tightening torques for worm drive hose clamps
Tightening torques for spring-loaded worm drive hose clamps
1 Maintenance
1.1 Maintenance work, notice
Information on maintenance
Important safety instructions regarding maintenance work
Remove the electrical system
Safety prop for telescopic boom
1.2 Maintenance overview
Maintenance plan
Maintenance label
Explanation of symbols on the maintenance label
1.3 Vehicle fluids and lubricants
Fluids and lubricants (overview)
Diesel fuel specification
Specification of the SCR reducing agent
Coolant
Important notice on operation with biodegradable oils
1.4 Maintenance accesses
Engine cover
Engine vat
Maintenance accesses on the engine vat/cabin
Maintenance access at the rear of the vehicle
Access to the vehicle fuses
1.5 Cleaning and maintenance
Important information on cleaning and maintenance
Cleaning inside the cabin
Cleaning the exterior of the machine
Cleaning the engine and the engine compartment
Checking screw connection
Checking pivots and hinges
1.6 Lubrication work
Preparing lubrication
Lubricating the rear axle oscillation-type bearing
Lubricating the front axle oscillation-type bearing – only for type 416-26/29
Lubricating the planetary drive bearing (front and rear axles)
Lubricate the hydraulic cylinder bearing (hydraulic oscillating-axle interlock option) – only for
model 416-26/29
Lubricating the hydraulic cylinder bearing of the frame leveling (option) – only for model
416-26/29
Lubricate the telescopic arm
Lubricate the pad tracks
Post-treatment of the pad tracks with applied smooth paint (optional)
Checking the slide plates
Replacing slide plates / Readjusting with filler plates
Central lubrication system (option)
Lubricating with central lubrication system
Filling the central lubrication system (option)
1.7 Fuel system
Stationary fuel pumps
Refueling
Drain fuel
Drain the fuel filter
Replacing the fuel prefilter
Replacing the fuel filter
Bleeding the fuel system – TCD 3.6 L4 engine
Bleeding the fuel system – TCD 4.1 L4 engine
1.8 Engine lubrication system
Checking the engine oil level
Top off the engine oil
Changing engine oil
Replacing the engine oil filter
1.9 Exhaust Aftertreatment System (EATS)
Refill the SCR reducing agent / urea solution
Drain the SCR reducing agent (urea solution)
Replace the urea filter
Replace the filling screen for the urea tank
1.10 Setting valve tip clearance
Engine TCD 3.6 L4
Engine TCD 4.1 L4
1.11 Cooling system
Safety instructions for cooling system
Information on inspection and cleaning work on the cooling system
Checking the coolant level
Adding coolant
Draining coolant
Drain the condensation water from the charge air cooler
Cleaning the coolant system – TCD 3.6 L4 engine
Cleaning the coolant system – TCD 4.1 L4 engine
Cleaning the radiator
Cleaning the radiator with the reversing fan (option)
1.12 Air filter
Important information on cleaning the air filter
Clean the dust valve (for vehicles with exhaust aftertreatment)
Check the filter cartridge for contamination (for vehicles with exhaust aftertreatment)
Change the filter cartridge and safety cartridge (for vehicles with exhaust aftertreatment)
Clean the dust valve (for vehicles without exhaust aftertreatment)
Check the filter cartridge for contamination (for vehicles without exhaust aftertreatment)
Change the filter cartridge (for vehicles without exhaust aftertreatment)
1.13 V-belt/flat belt
Checking/tightening/replacing the V-belt – TCD 3.6 L4 engine
Checking/tensioning/changing the V-belt and flat belt – TCD 4.1 L4 engine
1.14 Hydraulic system
Hydraulic oil level monitoring:
Check the hydraulic oil level
Top off hydraulic oil
Changing hydraulic oil
Replacing the hydraulic oil reflux filter
Hydraulic tank – change breather filter
Changing the hydraulic tank suction filter
Replacing the boost-pressure filter of the drive
Cleaning the line filter (filter insert at control valve inlet)
Cleaning the line filter (filter insert at LS line – control valve)
Checking the hydraulic system for leaks
Checking the condition and age of hydraulic hoses
1.15 Electrical system
Maintenance personnel
Safety instructions regarding the battery
Checking/replacing the battery
Regular checks and maintenance work of the electrical system
Checking the alternator
Checking/replacing relays and fuses
1.16 Heating, ventilation and air conditioning
Important information on cabin ventilation
Cleaning/replacing the cabin ventilation filter
Air conditioning (opt)
Important safety instructions regarding the air conditioning system
Air conditioning
Bleeding the air conditioning system – TCD 3.6 L4 engine
Bleeding the air conditioning system – TCD 4.1 L4 engine
Bleeding the air conditioning system – TCD 3.6 L4 engine
Filling the air conditioning system – TCD 4.1 L4 engine
Visual check of the air conditioning system – TCD 3.6 L4 engine
Visual check of the air conditioning system – TCD 4.1 L4 engine
Replace the dehumidifier
Cleaning the heat exchanger (condenser)
1.17 Washer system
Washer system reservoir
1.18 Axles/drive
Check/refill gear lubricant oil
Change gear oil in high speed gearbox
Change the gear oil in a high speed gear box with four-wheel cut-off (opt.)
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 in planetary gearing
1.19 Brake system
Check the wear of the brake disks, front axle
Check the wear of the brake disks, rear axle
Bleeding the service brake
Bleeding the parking brake
Hydr. Bleeding the trailer brake valve
Compressed-air braking system (option)
1.20 Pressure accumulator
Check/fill the pressure accumulator
1.21 Tires
Tire check
Changing wheels
1.22 Attachments
1.23 Trailer coupling
Automatic trailer coupling (option)
Ball trailer coupling ø 80 mm (3.15 in.) (option)
Autohitch trailer coupling (option)
1.24 Exhaust gas treatment
Exhaust After-treatment System
Diesel oxidation catalytic converter (DOC) with SCR catalytic converter – engine TCD 3.6 L4
Diesel oxidation catalytic converter (DOC) with SCR catalytic converter and diesel particulate filter
– engine TCD 4.1 L4
Manual regeneration of the exhaust after-treatment
1.25 Camera system
1.26 Machine preservation
Important notice on anticorrosion protection
Measures for maintaining anticorrosive protection
Cleaning
Application of anticorrosive wax
Treating oxidized surfaces

2 Engine
2.1 Engine TCD 3.6 L4
Removing/installing the engine
2.2 Starter M001 – Engine TCD 3.6
Remove / install motor starter
2.3 Alternator G001 – Engine TCD 3.6
Remove / install alternator
2.4 EAT console – Engine TCD 3.6
Remove/install EAT console
2.5 Diesel oxidation catalytic converter DOC – Engine TCD 3.6
Removing/installing the DOC
2.6 Intermediate pipe – Engine TCD 3.6
Removing/installing the intermediate pipe
2.7 Mixing section – Engine TCD 3.6
Removing/installing the mixing section
2.8 SCR catalytic converter – Engine TCD 3.6
Removing/installing the SCR catalytic converter
2.9 NOX sensor B093 – engine TCD 3.6
Remove/install the NOX sensor
2.10 Temperature sensor B090 – Engine TCD 3.6
Remove/install the temperature sensor
2.11 NOX sensor B094 – engine TCD 3.6
Remove/install the NOx sensor
2.12 Exhaust back pressure sensor B092 – Engine TCD 3.6
Removing/installing the exhaust back pressure sensor
2.13 Temperature sensor B029 – Engine TCD 3.6
Remove/install the temperature sensor
2.14 Water separator – Engine TCD 3.6
Remove / install water separator
2.15 Engine TCD 4.1
Removing/installing the engine
2.16 Starter M001 – Engine TCD 4.1
Remove / install motor starter
2.17 Alternator G001 – Engine TCD 4.1
Remove / install alternator
2.18 EAT console – Engine TCD 4.1
Remove/install EAT console
2.19 CRT – Engine TCD 4.1
Removing/installing the CRT
2.20 Intermediate pipe – Engine TCD 4.1
Removing/installing the intermediate pipe
2.21 Mixing section – Engine TCD 4.1
Removing/installing the mixing section
2.22 SCR catalytic converter – Engine TCD 4.1
Removing/installing the SCR catalytic converter
2.23 NOX sensor B093 – Engine TCD 4.1
Remove/install the NOx sensor
2.24 Temperature sensor B090 – Engine TCD 4.1
Remove/install the temperature sensor
2.25 NOX sensor B094 – Engine TCD 4.1
Remove/install the NOx sensor
2.26 Exhaust back pressure sensor B092 – Engine TCD 4.1
Removing/installing the exhaust back pressure sensor
2.27 Differential pressure sensor B037 – Engine TCD 4.1
Important safety instructions
Remove/install differential pressure sensor
2.28 Temperature sensor B029 – Engine TCD 4.1
Remove/install the temperature sensor
2.29 Temperature sensor B030 – Engine TCD 4.1
Remove/install the temperature sensor
2.30 Water separator – Engine TCD 4.1
Stationary fuel pumps
Remove / install water separator
2.31 Air filter
Remove/install air filter
2.32 Centaflex-coupling
Remove/install Centaflex coupling
2.33 Fuel tank
Important safety instructions
Removing/installing the fuel tank
2.34 Tank sensor B001
Remove / install tank sensor
2.35 Discharge module
Remove/install discharge module
2.36 DEF tank
Important safety instructions
Removing/installing the DEF tank
2.37 Extraction unit
Remove/install extraction unit
2.38 Accelerator pedal R011
Important safety instructions
Remove / install accelerator pedal

3 Cooling
3.1 Radiator
Safety instructions for cooling system
Removing/installing the radiator
3.2 Fan motor 014
Removing / installing fan motor
3.3 Reversing valve III
Remove / install reversing valve

4 Transmission/coupling/ cardan shafts
4.1 Cardan shafts
Safety instructions
Removing / installing front cardan shaft
Removing / installing rear cardan shaft
Safety instructions
4.2 High-speed transmission ICVD
Removing / installing high-speed gearbox
4.3 Repairing the high-speed gearbox ICVD
Removing the high-speed gearbox
Overview of tools
Control cover torques
Removing the control cover
Installing the control cover
Mounting the forward-reverse spool valve
Installing the control cover
4.4 High-speed transmission P370
Removing / installing high-speed gearbox
4.5 Repairing the high-speed gearbox P370
Control cover torques
Overview: high-speed transmission P370
Remove/install control cover
Removing the control cover
Flush valve and scouring slide valve
Seal the TB ram
Changing high pressure seals
Sealing the cardan shaft flange
Remove the speed sensor
Seal screw Qmin

5 Axles
5.1 Front axle
Removing/installing the front axle
5.2 Rear axle
Removing/installing the rear axle
5.3 Type label – front/rear axle
5.4 Tightening torques 416-22-28-29
Tightening torque / screw locking
5.5 Tightening torques Model: 416-24-26
Tightening torque / screw locking
5.6 Sealing work
Seal the drive flange
Seal the final drive
Disassemble axle tube
Seal the shifting cylinder of the differential
5.7 Differential
Front axle differential lock
Front axle differential
Rear axle differential
Input bevel gear
Adjusting the crown wheel
5.8 Steering angle
Setting the steering angle of the front axle
Adjusting the steering angle of rear axle
5.9 Special tools

6 Brakes
6.1 Disable/enable the parking brake
Disable/enable the parking brake model 416-22/416-28/416-29
Disable/enable the parking brake model 416-24/416-26
Brake model 416-22/416-28/416-29
Brake model 416-24/416-26
6.2 Brake pedal
Adjusting the brake pedal / inching sensor
6.3 Brake valve XVIII
Remove / install brake valve
6.4 Compressed air tank (opt.)
Remove / install compressed air tank
6.5 Compressed air compressor – Engine TCD 3.6
Remove/install air compressor
6.6 Compressed air compressor – Engine TCD 4.1
Remove/install air compressor

7 Steering system
7.1 Steering orbitrol IV
Removing/installing the steering orbitrol
7.2 Steering mode valve 103
Remove / install steering mode valve
7.3 Steering cylinder 018/019
Remove/install steering cylinder
7.4 Steering sensor B004/B005
Removing / installing steering sensor

8 Hydraulic system
8.1 Control unit XIII
Remove / install control unit
8.2 Hydraulic oil tank XX
Removing/installing the hydraulic oil reservoir
8.3 Tandem pump 001.1
Remove/install tandem pump
8.4 Variable displacement pump
Removing/installing the variable displacement pump
8.5 Hydraulic pump VII
Remove/install hydraulic pump
8.6 Quickhitch
Removing/installing quickhitch plate
8.7 Telescopic boom
Remove/install boom
8.8 Boom (outer pipe)
Remove/install outer pipe
8.9 Boom (inner pipe)
Remove/install inner pipe
8.10 Lifting cylinder 085
Important information about removing/installing a lifting cylinder
Removing/installing the lift cylinder
8.11 Boom cylinder 089
Important information about removing/installing a push-out cylinder
Remove/install push-out cylinder
Remove / install push-out ram
8.12 Tilt ram 087
Important information about removing/installing a tilt cylinder
Remove/install tilt ram
Remove / install tilt ram
8.13 Compensation cylinder 086
Important information about removing/installing a compensation cylinder
Remove/install compensation cylinder
Removing / installing the compensation cylinder
8.14 Control ram 091
Important information about removing/installing a control ram
Sealing the control ram 091
8.15 Level cylinder 156
Important information about removing/installing a level cylinder
Removing / installing level cylinder
Seal-tighten level cylinder
Description of level cylinder
8.16 Lock cylinder 157
Important information about removing/installing a lock cylinder
Removing / installing lock cylinder
Seal-tighten lock cylinder
Description of lock cylinder

9 Electrical system
9.1 Battery isolator relay K141
Remove/install battery disconnect relay K141
9.2 Board
Remove / install board
9.3 Steering electronics D001
Remove / install steering electronics
9.4 Control lever D002
Remove / install control lever
9.5 Instrument panel (left)
Remove / install dashboard, left
9.6 Instrument panel, right
Remove / install dashboard, right
9.7 Rotary angle encoder Lifting arm R023
Removing/installing the turning angle transmitter
Setting turning angle transmitter on lifting arm R023
9.8 Preheating time control unit K005
Remove/install the preheating time control unit K005
9.9 Travel sensor for bucket repositioning B028
Remove/install travel sensor with rod
9.10 Inch potentiometer R002
Remove / install inch potentiometer
9.11 Load sensor B008
Remove/install load sensor
9.12 Safe load indicator P006
Calibrate safe load indicator
Zero point calibration
Calibrating the 100% point
9.13 Power brake load cell B051
Remove / install power brake load cell
9.14 Frame controller N004
Remove / install frame controller
9.15 Additional controller N016
Remove / install additional controller
9.16 Cab controller N015
Remove / install cabin controller

12 Trim
12.1 Engine cover
Removing/installing the engine cover
12.2 V-belt cover – Engine TCD 3.6
Remove/install V-belt cover
12.3 V-belt cover – Engine TCD 4.1
Remove/install V-belt cover
12.4 Transmission tunnel cover
Remove/install transmission tunnel cover
12.5 Underride protection
Remove/install underride protection
12.6 Cab front covering
Remove/install cab front trim
12.7 Discharge module trim
Remove/install discharge module trim

14 Cabin
14.1 Operator seat
Remove/install operator seat

15 Heating/air conditioning
15.1 Heat exchanger
Remove/install heater box
15.2 Blower M004
Remove/install blower
15.3 Air conditioning system compressor Y031
Removing / installing air conditioning system compressor
15.4 Air conditioning cooler
Remove/install air conditioning cooler
15.5 Evaporator
Remove/install evaporator
15.6 Dehumidifier
Remove / install dehumidifier

17 Automatic coupling
17.1 Autohitch
Remove/install autohitch
17.2 Height adjustable ball hitches
Remove / install trailer coupling
17.3 Automatic/rotating trailer coupling
Remove / install trailer coupling
17.4 Tow coupling
Remove / install tow coupling

23 Central lubrication system
23.1 Central lubrication unit M016
Remove/install central lubrication unit
23.2 Distributing block
Remove/install distributor block

Wacker Neuson TH744 750 755 942 955 System Manual (1252 Pages)

Wacker Neuson TH744 750 755 Operators Manual (514 Pages)

Lift Charts

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

• Vertical Lift System (VLS): A driver assistance system designed to improve productivity and stability during high-reach operations.
• Compact design: The machines are built with maneuverability in mind, making them suitable for job sites with limited space.
• High lifting capacity: Despite their compact size, these telehandlers offer impressive payload capabilities, particularly in the TH755 and TH955 models.
• Ergonomics: The operator cabs are designed for comfort and ease of use, featuring ergonomic joysticks and clear layouts.
• Engine efficiency: Newer models feature engine speed reduction for lower fuel consumption, and some models use advanced Deutz engines.
• Versatile attachments: A wide range of attachments can be used with the TH-series, making them adaptable for various tasks. 

• Common issues: Leaks and loss of power.
• Troubleshooting: Check fluid levels, inspect for worn seals and gaskets, and ensure the hydraulic pump is functioning correctly. 

• Common issues: Difficulty starting and excessive exhaust smoke.
• Troubleshooting: Inspect the battery and fuel system for problems. Excessive smoke can indicate coolant or oil burning in the engine. 

• Common issues: Battery problems and faulty controls.
• Troubleshooting: Clean corrosion from the battery terminals and check for worn-out switches or damaged wiring. 

• Common issues: Wear and tear on the extending cylinders or blockages in the hydraulic lines.
• Troubleshooting: Regular inspection and maintenance are needed to prevent safety issues and productivity loss.