Wacker KramerAllrad 2506 Telehandler Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
FILE DETAILS:
Wacker KramerAllrad 2506 Telehandler Service Manual – PDF DOWNLOAD
Language :English
Pages :420
Downloadable : Yes
File Type : PDF
Size:18.0 mb
TABLE OF CONTENTS:
Wacker KramerAllrad 2506 Telehandler Service Manual – PDF DOWNLOAD
1 Cab overview, use, operation
11 Machine outside view 1-2
12 Inside of cab (overview) 1-3
13 Instrument panel, multifunctional lever, switch consoles (overview) 1-4
14 Fields of application and using a machine with an attachment 1-5
15 Legal regulations regarding machine operation 1-6
16 Type labels and component numbers 1-8
17 Key-based drive interlock (option) 1-11
18 Drive interlock with code input (option) 1-13
19 Battery master switch (option) 1-16
110 Avoiding running the engine under low-load conditions 1-17
111 Stopping the diesel engine 1-17
112 Jump-starting the diesel engine (external battery) 1-18
113 Pressure relief on the quickhitch couplers 1-19
114 Overview of steering modes (option) 1-20
115 Steering synchronisation (wheels front/rear axles) 1-21
116 Low-speed control (option) 1-23
117 Rear hydraulic additional control circuit (option) 1-24
118 Hydraulic connection for tipping trailer (option) 1-26
119 Autohitch trailer coupling (option) 1-27
120 Automatic trailer coupling (option) 1-29
121 Hydraulic trailer brake connection (option) 1-31
122 Fitting attachments from other manufacturers (option) 1-32
123 Towing the machine 1-35
2 Specifications
21 Model and trade names (overview) 2-2
22 Frame 2-2
23 Diesel engine 2-2
24 Drive 2-3
25 Axles 2-4
26 Service and parking brake (disc brake) 2-5
27 Steering system 2-5
28 Work hydraulics 2-6
29 Electrical system 2-8
210 Tyres 2-11
211 Machine weight, axle loads 2-11
212 Trailer couplings: trailer weight/drawbar load 2-12
213 Sound levels, noise 2-12
214 Vibrations, oscillation and acceleration values 2-13
215 Coolant compound table 2-13
216 Tightening torques 2-14
217 Standard bucket payloads 2-14
218 Pallet forks payloads 2-15
219 Dimensions with standard bucket 2-17
220 Dimensions with pallet forks 2-18
Inhaltverzeichnis
I-2 Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm
Inhaltverzeichnis
3 Maintenance and service work
31 Explanation of symbols on the maintenance label 3-2
32 Maintenance label 3-3
33 Fluids and lubricants 3-4
34 Maintenance plan (overview) 3-5
35 Important notice regarding maintenance work 3-9
36 Safety strut for telescopic boom 3-10
37 Fuel system 3-11
38 Refuelling 3-12
39 Checking/cleaning the additional fuel filter (water separator, option) 3-12
310 Bleeding the fuel system 3-13
311 Replacing the fuel filter 3-14
312 Diesel engine lubrication system 3-15
313 Filling up engine oil 3-16
314 Change the engine oil 3-17
315 Replacing the engine oil filter cartridge 3-18
316 Diesel engine and hydraulics cooling system 3-19
317 Temperature gauge: diesel engine coolant 3-20
318 Filling up coolant 3-21
319 Cleaning the radiator fins 3-22
320 Draining coolant 3-23
321 Air filter 3-24
322 Replacing the filter cartridge 3-25
323 V-belts 3-26
324 Hydraulic system 3-27
325 Monitoring the hydraulic oil and the return filter indicator lights 3-28
326 Checking the hydraulic oil level once a day 3-29
327 Filling up hydraulic oil 3-29
328 Changing the filter insert 3-30
329 Replacing hydraulic oil 3-31
330 Important notices on the use of biodegradable oil 3-32
331 Checking hydraulic pressure lines 3-33
332 Oil levels: rear axle transfer gearbox 3-34
333 Oil levels: front and rear axle differentials 3-35
334 Oil levels: front and rear axle planetary drives 3-36
335 Lubrication work 3-37
336 Lubrication points on the telescopic boom (overview) 3-38
337 Lubricating with the central lubrication system (option) 3-40
338 Setting the lubrication and break times 3-41
339 Central lubrication system diagram 3-42
340 Installing the high-pressure hoses on the central lubrication system 3-43
341 Instructions for troubleshooting in case of central lubrication system blocking 3-44
342 Repairing a blocking distributor of the central lubrication system 3-45
343 Troubleshooting table for central lubrication system 3-46
344 Maintenance of the brake system 3-47
345 Tyres 3-48
346 Changing wheels 3-49
347 Heating/cab ventilation 3-50
348 Air conditioning (option): maintenance 3-51
349 Functional and visual checks of the air conditioning 3-52
350 Cleaning the heat exchanger (condenser) 3-53
351 Maintenance of the electrical system 3-54
352 Maintenance of the automatic trailer coupling (option) 3-58
353 General maintenance and cleaning work 3-59
354 Maintenance of attachments and of the work equipment 3-61
Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm I-3
Inhaltverzeichnis
4 Engine
41 Diesel engine diagrams 4-2
42 Diagnosis/fuel preheater (electrical diagrams) 4-4
43 Manual throttle diagrams 4-6
44 Engine designation 4-7
45 Fuel specification 4-7
46 Coolant specification 4-7
47 Diesel engine TD 2009 L04 (overview) 4-8
48 Electric components on engine (overview) 4-9
49 Lube oil circuit 4-10
410 Cooling 4-11
411 Adjusting the cable pull for speed regulation 4-12
412 Fuel system 4-13
413 Replacing the cylinder head gasket 4-14
414 Removing/installing the fuel injection pump 4-17
415 Mounting the fuel injection pump 4-19
416 Removing/installing the fuel injectors 4-20
417 Sealing the coolant pump 4-21
418 Removing/installing the thermostat 4-21
419 Checking the thermostat 4-22
420 Assembly instructions: replacing the Visco clutch 4-23
421 Tightening torque table 4-26
422 Diesel engine malfunctions 4-28
I-4 Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm
Inhaltverzeichnis
5 Drive
51 Drive (hydraulic diagram) 5-2
52 Drive diagrams 5-4
53 Making settings with the laptop 5-5
54 Error: Incorrect Tool Key 5-8
55 Importing new data 5-9
56 Drive electronics PLUS+1 mode description 5-11
57 Reading out/deleting the error history 5-12
58 Deleting the error history 5-13
59 Switching the inching potentiometer ON/OFF 5-14
510 Reading in the inching potentiometer again 5-15
511 Reading in the inching potentiometer 5-16
512 Switching the creep gear potentiometer ON/OFF 5-17
513 Switching ON the creep gear potentiometer 5-18
514 Reading in the creep gear potentiometer 5-19
515 Modifying the load stabiliser settings 5-20
516 Error code table 5-21
517 Towing and transporting the machine 5-23
518 Hydraulic pump H1 (model 407 02) test ports and HP valves (overview) 5-23
519 Hydraulic pump H1 (model 407 02) proportional valve and electronics
(overview) 5-24
520 Variable displacement motor H1 110 cm3/rev (overview) 5-25
521 Variable displacement motor H1B (overview) 5-26
522 Model 407 02 test report 5-27
523 Error description for test report model 407 02 5-28
524 Drive with hydraulic pump H1 (hydraulic circuit) 5-29
525 Checking the idling speed 5-30
526 Checking/adjusting starting speed 5-31
527 Adjusting boost pressure 5-32
528 Checking high pressure 5-33
529 Checking driving direction identification 5-34
530 Checking the energisation of the driving direction identification 5-35
531 Checking engine droop (variable displacement pump) 5-36
532 Setting the pump droop speed 5-37
533 Setting engine droop/control initiation of the hydraulic motor 5-38
534 Setting maximum speed 5-39
535 Troubleshooting boost-pressure errors (diagram) 5-40
536 Checking high pressure (HP valves) 5-41
537 Checking pump engine droop, driving direction identification, differential pressure measurement 5-42
6 Axles
61 Differential lock diagrams 6-2
62 Axle type label 6-3
63 Front axle screw connections 6-4
64 Rear axle screw connections 6-5
65 Drain, fill and check plug – front axle 6-6
66 Drain, fill and check plug – rear axle 6-7
67 Front axle tightening torques (Nm) 6-8
68 Rear axle tightening torques (Nm) 6-9
69 Sealing work 6-10
Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm I-5
Inhaltverzeichnis
7 Brakes
71 Brake diagrams 7-2
72 Brakes (hydraulic diagram) 7-4
73 Brake circuit 7-5
74 Trailer brake valve circuit 7-6
75 Service brake function 7-7
76 Parking brake circuit 7-8
77 Service brake 7-9
78 Sealing the brake calliper 7-10
79 Bleeding the brake system with bleed equipment 7-12
710 Setting the brake pedal with the inching potentiometer 7-13
8 Steering system
81 Steering system (hydraulic diagram) 8-2
82 Steering circuit with final-position synchronisation 8-3
83 Steering circuit with front, 4 wheel and crab steering 8-4
84 Steering system adjustment 8-5
85 Hydraulic ports on servostat 8-5
86 Pressure relief valve: adjustment 8-5
87 Sealing steering rams 8-6
88 Sealing steering rams 8-7
89 Checking the steering mode valve 8-8
810 Checking a steering ram 8-9
811 Overview of steering ram setting 8-9
812 How to check and set the steering rams 8-10
813 Checking the track setting (1) 8-11
814 Correcting the track setting (2) 8-11
815 Steering misalignment during final-position synchronisation (3) 8-12
816 Adjustment work 8-13
817 Checking steering synchronisation (4) 8-14
I-6 Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm
Inhaltverzeichnis
9 Work hydraulics
91 20 kph 4-fold control valve (hydraulic diagram) 9-2
92 30 kph 5-fold control valve (hydraulic diagram) 9-4
93 Hydraulics legend 9-5
94 Raising/lowering (diagrams) 9-8
95 Raising/lowering the telescopic boom (hydraulic diagram) 9-10
96 Raising/lowering the telescopic boom, load stabiliser (hydraulic diagram) 9-12
97 Dumping in/out, tilt ram lock (electrical diagrams) 9-14
98 Dumping out (hydraulic diagram) 9-16
99 Tilt ram lock (hydraulic diagram) 9-18
910 Extending/retracting the telescopic boom (black/white) (electrical diagrams) 9-20
911 Extending/retracting the telescopic boom/proportional (electrical diagrams) 9-22
912 Retracting/extending the telescopic boom (hydraulic diagram) 9-24
913 Locking/unlocking the quickhitch (black/white) (electrical diagrams) 9-26
914 Quickhitch diagram designations (black/white, lock/unlock) 9-27
915 Locking/unlocking the quickhitch proportionally (electrical diagrams) 9-30
916 Quickhitch diagram designations (proportional, lock/unlock) 9-31
917 Locking (hydraulic diagram) 9-34
918 Locking/additional control circuit (hydraulic diagram) 9-36
919 Locking/return without pressure (hydraulic diagram) 9-38
920 Safe load indicator (electrical diagrams) 9-40
921 Overload cutoff (hydraulic diagram) 9-42
922 Load stabiliser (electrical diagrams) 9-44
923 Additional control circuit/tipping trailer (hydraulic diagram) 9-46
924 Tipping trailer (hydraulic diagram) 9-48
925 Autohitch (hydraulic diagram) 9-50
926 Autohitch/tipping trailer (hydraulic diagram) 9-52
927 Additional function (electrical diagrams) 9-54
928 Autohitch/additional control circuit/tipping trailer (hydraulic diagram) 9-56
929 Test report for hydraulics 407-02 (2506) 9-57
930 Work hydraulics oil supply 9-58
931 Pump pressure/work hydraulics test port 9-59
932 Control valve (overview) 9-60
933 Control valve design 9-61
934 Checking and setting the work hydraulics 9-62
935 7-fold pilot valve (overview) 9-63
936 4-fold pilot valve (overview) 9-64
937 Pilot control circuit 9-65
938 Load stabiliser circuit 9-66
939 Lift ram circuit 9-67
940 Tilt ram circuit 9-68
941 3rd control circuit 9-69
942 Circuit: additional control circuít and rear tipping trailer 9-70
943 Tilt ram lock circuit 9-71
944 Circuit: Autohitch and tipping trailer ports 9-72
945 Overload cutoff circuit 9-73
946 Load stabiliser 9-74
947 Valve for tilt ram lock 9-76
948 Tipping trailer and additional control circuit valve 9-76
949 Work hydraulics/steering system priority valve 9-77
950 Valves (general overview) 9-77
951 Lift ram (sealing work) 9-78
952 Tilt ram (sealing work) 9-79
953 Push-out ram 9-80
954 Compensating ram 9-81
955 Control ram (quickhitch frame) (sealing work) 9-82
956 Lift, tilt and push-out rams: velocity 9-83
Serv-HB 40702 – Ausgabe 20 * 407-02s_20_enIVZfm I-7
Inhaltverzeichnis
957 Usable consumer pressure at additional control circuit (option) 9-83
958 Overload control (“Smart Handling”) 9-84
959 Overview of safe load indicator 9-90
960 Setting the safe load indicator (0 % point) 9-90
961 Setting the safe load indicator (100 % point stability) 9-91
962 Inspection plan for overload control (model 407 telehandler) 9-93
963 Testing without any load 9-93
964 Testing with load 9-95
965 Functional description of overload control (Smart Handling) 9-97
966 Electric components 9-98
967 Circuit diagram: overload control enabled 9-99
968 Circuit diagram: automatic retraction OFF 9-100
969 Overview of valves 9-101
970 Overview of valve connections and ports 9-101
971 Circuit diagram: overload control 9-102
972 Circuit diagram legend 9-103
973 Extend (solenoid valve Y102) (circuit diagram) 9-104
974 Pallet forks mode (circuit diagram) 9-105
975 Tip switch S084 pressed (circuit diagram) 9-106
976 Electric components 9-107
977 Overload control relay 9-108
978 Installation position: overload control relay 9-109
10 Electrical system
101 Lights (diagrams) 10-2
102 Working lights (diagrams) 10-4
103 Turn indicators/horn/rotating beacon (diagrams) 10-6
104 Window heating/front socket (electrical diagrams) 10-8
105 Wipe/wash system (electrical diagrams) 10-10
106 Seat/air conditioning system (diagrams) 10-12
107 Multimedia/monitoring/cigarette lighter (electrical diagrams) 10-14
108 Cab wiring harness 1000256306-01 10-16
109 Cab wiring harness legend 10-17
1010 Engine wiring harness 1000245802 10-22
1011 Engine wiring harness legend 10-23
1012 Frame wiring harness 1000256307 10-26
1013 Frame wiring harness (legend) 10-27
1014 Cab wiring harness (overload control) 10-30
1015 Cab wiring harness legend 10-31
1015 Frame wiring harness (overload control) 10-34
1016 Frame wiring harness (overload control) (legend) 10-35
1017 Ohm’s Law (current, voltage, resistance); power 10-36
1018 Measuring equipment, measuring methods 10-36
1019 Terminal description 10-37
1020 Colour coding of electric lines 10-41
1021 Switching relay function 10-43
1022 Fuse assignment 10-44
1023 Switching relay assignment on board 10-45
1024 Switching relay assignment on bracket 10-45
1025 Main fuse box with relays in the engine compartment 10-46
1026 Electric units 10-46
1027 Connector description (overview) 10-46
1028 Switch assignment on board (overview) 10-47
1029 Switch assignment on instrument panel (overview) 10-48
1030 Control lever (black/white control) 10-49
1031 Joystick (black/white function) 10-50
1032 Joystick: retracting/extending the telescopic boom (black/white) 10-51
1033 Joystick: unlocking/locking the telescopic boom (black/white) 10-52
1034 Control lever (proportional control) 10-53
1035 Joystick (proportional function) 10-54
1036 Joystick: retracting/extending the telescopic boom (proportional) 10-55
1037 Joystick: unlocking/locking the telescopic boom (proportional) 10-56
1038 Additional control circuit with potentiometer (proportional) 10-57
1039 Proportional controls connector assignment (overview) 10-58
1040 Proportional controls (overview and connections) 10-58
1041 Retrofitting a rotating beacon 10-59
1042 Retrofitting the backup warning system 10-59
1043 Retrofitting 2 front working lights 10-59
1044 Retrofitting 2 rear working lights 10-60
1045 Retrofitting a rear 7-pole socket 10-60
1046 Retrofitting a front 4-pole socket 10-60
1047 Retrofitting 2 working lights on the telescopic boom (from mid 2011) 10-61
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M