Lull 944E-42 Service Manual

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Page 1

An Oshkosh Corporation Company

Service Manual

Model

944E-42

S/N 0160041827 & After

31200355

Original

December 31, 2011

Page 2

Page 3

December 31, 2011 - A - Original Issue

EFFECTIVITY PAGE

31200355 944E-42 i

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EFFECTIVITY PAGE

944E-42 31200355-ii

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SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

2.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2 Boom System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

3.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

3.9 Emergency Boom Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.4 Enclosed Cab (Optional) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

4.7 Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

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Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

5.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7

6.6 Transfer Case Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11

6.7 Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

6.8 Transfer Case Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

6.9 Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

6.10 Transfer Case Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

6.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14

Section 7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction - Cummins QSB 4.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.6 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5

7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

8.6 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16

8.7 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17

8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38

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Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.5 Electrical Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14

9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16

9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

9.11 Switches and Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21

9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.36

9.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37

Section 10

Stabil-TRAK™System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

10.1 Stabil-TRAK™ System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

10.2 Stabil-TRAK™ Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

10.3 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting. . . . . . . . . . . . . . . . . 10.4

10.4 Stabil-TRAK™ System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

10.5 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . 10.13

Section 11

Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

11.1 Transfer Carriage Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2

11.2 Transfer Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.3

11.3 Transfer Carriage Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

11.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22

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Section Subject Page

944E-42

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Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

944E-42

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Page 10

Safety Practices

1.1 INTRODUCTION

This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, co des, regulatio ns and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible continge ncy during operation, maintenance, or testing. When additional information is desired consu l t th e l o c a l distr ibutor.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For op tim al safe ty, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5 SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambula nce, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1 Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3 OPERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the su pervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult the local dist ributor before proceeding.

1-2

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

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Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occur s.

For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

proceeding.

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, o il, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the mach ine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, JLG recommends a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in. (30,5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation,

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

944E-42

1-3

Page 12

Safety Practices

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking und er pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious person al injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the en gine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque . Capture fluid in an appropriate container and dispose of in accor da nce with prevailing environmental regulations.

RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allo w pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, spar ks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in goo d condition. Use the correct equipment in the proper manner, and make changes or repairs as indicate d by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pr essure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connectin g a ba tte r y charger.

1.7 SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safet y Manual supplied with machine for information.

1-4

944E-42

Page 13

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 T orque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.1 10 & 50 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.2 1st 100, 250 & 1st 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5.3 500, 1000 & 2000 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

944E-42

2-1

Page 14

General Information and Specifications

OU0221

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as ind i ca ted in the fi gu re .

Note: The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly proc essed. To guarantee full warranty service, verify that the distrib utor has returned the business reply card of the warranty registration form to JLG.

2-2

944E-42

Page 15

2.2 TORQUE CHARTS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

Description

0100011

242

Vibra-TITETM121

Medium Strength (Blue)

0100019

271

Vibra-TITETM140

High Strength (Red)

0100071

262

Vibra-TITETM131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Values for ZincYellow Chromate Fasteners

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

Lubricated

3. *ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESETORQUE VALUESDO NOTAPPLYTO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

MY4650J

JLG P/N Loctite® P/N

ND Industries P/N

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart

General Information and Specifications

944E-42

2-3

Page 16

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

Values for Zinc Yellow Chromate Fasteners

3. *ASSEMBLYUSES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120

16400 155 210 140 190 115 155

18250 170 230 155 210 130 175

20350 210 285 190 260 160 220

23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

K=.18

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry or Loctite® 263)

K= 0.20

MY4660J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart (Continued)

2-4

944E-42

Page 17

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

4. CLAMP LOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9AND DOES NOT REPRESENT FULLSTRENGTH CAPABILITYOF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating*

Torque

(Dry) K = .17

K=0.16

K=0.15

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

MY4670J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

OR Precoat 85®

2.2.1 SAE Fastener Torque Chart (Continued)

944E-42

2-5

Page 18

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

4. CLAMP LOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9AND DOES NOT REPRESENT FULLSTRENGTH CAPABILITYOF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TMor 271

OR Vibra-TITETM111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners*

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

MY4680J

2.2.1 SAE Fastener Torque Chart (Continued)

2-6

944E-42

Page 19

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMP LOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

Values for Zinc Yellow Chromate Fasteners

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

MY4690J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

General Information and Specifications

944E-42

2-7

Page 20

General Information and Specifications

Size PITCH

Tensile

Stress

Area

Clamp

Load

K = 0.20

K= 0.18

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

Values for Zinc Yellow Chromate Fasteners

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMP LOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT

METHODS TOLERANCE = ±10%

MY4700J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque Dry

Loctite® 263™

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

2.2.2 Metric Fastener Torque Chart (Continued)

2-8

944E-42

Page 21

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

K = .17

K = .16

K = .15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

4. CLAMP LOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

Magni Coating*

MY4710J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

Torque Dry

Loctite® 263™

(Continued)

General Information and Specifications

944E-42

2-9

Page 22

General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

74 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

85 lb-ft

(115 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

0.75 to 1.0

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swiv el nut can be detected. A v e rage hand torque is 3 lb-ft (4 Nm).

2. Mark a dot on one of the swivel nut fla ts and another dot in line on the hex of the adapter it’s connecting to.

3. Use the double wrench method while tightening to avoid hose twist.

4. After the connection has been properly tightene d, mark a straight line across the connecting parts, not covering the dots indicating that the connection has been properly tightened.

32 N/A

Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible.

Torque Wrench:

1. Identify the appropriate application and refer to the above chart for the correct torque value.

2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swiv el nut can be detected. A v erage hand torque is 3 lb-ft (4 Nm).

3. Use the double wrench method while tightening to avoid hose twist.

4. Torque wrench mu st be held at th e center of the g rip. Apply constant force until it clicks.

5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.

270 lb-ft

(366 Nm)

0.75 to 1.0

2-10

944E-42

Page 23

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

First Gear 3.5 mph (5,6 km/hr) Second Gear 6 mph (9,7 km/hr) Third Gear 14 mph (23 km/hr) Fourth Gear 20 mph (32 km/hr)

2.3.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) mi nimum, engine at operating temperature.

Function Approximate Times, in Seconds

Boom Extend (boom level) 11 to 15 Boom Retract (boom level) 13 to 17 Boom Lift (boom retracted) 11 to 15 Boom Lower (boom retracted) 11 to 15 Quick Attach Tilt Up 2.5 to 3.5 Quick Attach Tilt Down 3 to 5 Transfer Carriage Forward (boom retracted and level) 9 to 14 Transfer Carriage Rearward (boom retracted and level) 9 to 13 Frame Sway Left to Right (boom retracted and level) 9 to 11 Frame Sway Left to Right

(boom retracted, raised above 40 Fram e Sway Right to Left (boom retracted and level) 9 to 11 Frame Sway Right to Left

(boom retracted, raised above 40

° and emergency brake engaged)

26 to 30

2.3.3 Electrical System

Battery

Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free Quantity 2 Reserve Capacity 850 Cold Cranking Amps @ 0° F (-18° C) Group/Series Group 27 Alternator 12V, 100 Amps

944E-42

2-11

Page 24

General Information and Specifications

2.3.4 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting

Engine Make/Model Cummins QSB 4.5 Displacement 275 in

(4.5 liters) Low Idle 950 rpm High Idle 2500 rpm Horsepower 110 hp (82 Kw) @ 2500 rpm Peak Torque 360 lb-ft (4488 Nm) @ 1500 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.5 Tires

Note: Standard wheel lug nut torque is 430-470 lb-ft (583-637 Nm).

15.50 x 25 G-2/L-2 Bias-Ply Traction 12 Ply

15.50 x 25 G-2/L-2 Radial 1 Star

15.50 x 25 G-3/L-3 Bias-Ply Rock 12 Ply

370/75x28 DuraForce 14 Ply

Pneumatic 65 psi (4,5 bar)

Foam 798 lb (362 kg)

Pneumatic 65 psi (4,5 bar)

Foam 798 lb (362 kg)

Pneumatic 65 psi (4,5 bar)

Foam 798 lb (362 kg)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb

(210 kg)

73 psi (5,0 bar)

2-12

944E-42

Page 25

General Information and Specifications

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

Capacity with Filter Change 13.5 quarts (12.8 liters)

Type of Oil

0° to 104° F (-20° to 40° C) 15W-40 CD

-40° to 0° F (-40° to 20° C) 0W-40 CD

Fuel Tank

Capacity 45 gallons (171 liters)

Type of Fuel

0° to 104° F (-20° to 40° C) #2 Diesel

-40° to 0° F (-40° to 20° C) #1 Diesel

Anti-Gel

-40° to 0° F (-40° to 20° C) 16 ounces (0,5 liters)

Cooling System

System Capacity W/O Heater 7.7 gallons (29,1 liters)

Type of Coolant 50/50 ethylene glycol & water

Hydraulic System

System Capacity 50 gallons (190 liters) Reservoir Capacity 34 gallons (127 liters)

Type of Fluid Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46)

Transmission

Capacity with Filter Change 4.2 gallons (16 liters)

Type of Fluid Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46)

Transfer Case

Capacity 1.7 quarts (1,6 liters)

Type of Fluid Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46)

Axles

Differential Housing Capacity

Front 12.7 quarts (12,0 liters) Rear 12.5 quarts (11,8 liters)

Wheel End Capacity

Front 2.1 quarts (2,0 liters) Rear 2.2 quarts (2,1 liters) Type of Fluid Mobilfluid 424

944E-42

Tractor Hydraulic Fluid (ISO 46)

2-13

Page 26

General Information and Specifications

Air Conditioning System (if equipped)

System Capacity 2.5 lb (1134 g) Type of Fluid Refrigerant R-134a - Tetrafluorethane

Window Washer Bottle

Capacity 2.1 quart (2 liters)

2-14

944E-42

Page 27

2.5 SERVICE AND MAINTENANCE

MU7640

Check Boom

Wear Pads

Check

Battery

Lubrication

Schedule

Check Transfer

Carriage Rear

Wear Pads

Check Transfer

Carriage

Roller Gap

Check Transfer

Carriage Roll

Back Hoses

Check Air

Intake System

Check

Transmission

Oil Level

EVERY

Check Fuel

Level

Check Hydraulic

Oil Level

Check Engine

Oil Level

Check Engine

Coolant Level

Check Tire

Condition &

Pressure

Drain Fuel/

Water Seprator

EVERY

Check Washer

Fluid Level

(if equipped)

SCHEDULES

2.5.1 10 & 50 Hour

General Information and Specifications

944E-42

2-15

Page 28

General Information and Specifications

MU7300

500

Change Axle Oil

Change Wheel

End Oil

100

Change

Hydraulic

Filters

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Transfer Case Oil

Change

Transmission

Oil and Filter

250

EVERY

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Check Axle

Oil Level

Check Wheel

End Oil Levels

Check Transfer

Case Oil Level

Check Transfer

Carriage Front

Upstop Wear Pads

Change Air

Filter Elements

Check Boom

Extend Chains

and Tension

Lubricate

Boom Extend

Chains

2.5.2 1st 100, 250 & 1st 500 Hour

2-16

944E-42

Page 29

2.5.3 500, 1000 & 2000 Hour

MU7650

2000

EVERY

Change

Engine Coolant

500

EVERY

Change Fuel

Filters

Change Engine

Oil and Filter

1000

EVERY

Change

Transmission

Oil and Filter

Change Axle Oil

Change Wheel

End Oil

Change

Hydraulic

Fluid and Filters

Change Transfer Case Oil

Check

Fan Belt

Check Axle

Brake Discs

Check Boom

Retract Chains

and Tension

Lubricate

Boom Retract

Chains

General Information and Specifications

944E-42

2-17

Page 30

General Information and Specifications

OU2430

EVERY

2.6 LUBRICATION SCHEDULES

a. 50 Hour

2-18

944E-42

Page 31

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1 Boom System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3.1 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3.2 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.3.3 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.3.4 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3.5 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.3.6 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.4.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.4.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.4.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.4.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.4.5 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.4.6 Boom Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.4.7 Extend Chains Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.4.8 Retract Chain Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.5.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.5.2 Wear Pad Installation and Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.6.1 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.6.2 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.9 Emergency Boom Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.9.1 Loss of Engine Power or Hydraulic Pump Failure. . . . . . . . . . . . . . . . . . . 3-27

3.9.2 Hydraulic Line Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.9.3 Hydraulic Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.9.4 Hydraulic Hose Replacement - Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3.9.5 Hydraulic Hose Replacement - Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

944E-42

3-1

Page 32

Boom

MU0161

THIRD BOOM

SECTION

BOOM EXTEND

CHAINS

BOOM RETRACT

CHAIN

SECOND BOOM

SECTION

FIRST BOOM

SECTION

SLAVE

CYLINDERS

QUICK ATTACH

EXTEND/

RETRACT

ATTACHMENT

TILT HYDRAULIC

TUBES

ATTACHMENT

TILT CYLINDER

BOOM

PROXIMITY

SENSOR

AUXILIARY

HYDRAULIC

COUPLERS

WEAR PAD

BOOM ANGLE

INDICATOR

BOOM

PIVOT PIN

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY

The following illustrations identify the components that are referred to throughout this section.

3-2

944E-42

Page 33

Boom

MU0981

MU0221

3.2 BOOM SYSTEM

3.2.1 Boom System Operation

The three section boom assembly consists of first, second and third boom section assemblies . Boom extension and retraction is accomplished via hydraulic power and chain movement.

As the Extend/Retract hydraulic cylinder, which is anchored at the rear of the second b oom section and the rear of the first boom section, begins to extend, it for ces the second boom section out of the first boom section.

The second and third boom sections are connected by extend and retract chains. These chains ar e routed around sheaves on the second boom section. As the second boom section is forced out, the extend ch ain pulls the third boom section out of the second boom section.

As hydraulic pressure is applied to the retract po rt on the extend/retract cylinder, the second bo om section is pulled back into the first boom section, and retract cha in pu lls the third boom section back into the second section.

This mechanical linkage formed by the chains and supporting hardware extends and retracts the second and third boom sections at the same rate.

The first boom section does not extend or retract, but lifts and lowers via action of the lift/lower cylinder.

3.3.1 Third Boom Section Removal

1. Remove any attachment from the quick attach assembly.

Note: If replacing the third section boom, remove the quick attach from the third section. Refer to Section

3.6.1, “Quick Attach Removal.”

2. Park the machine on a hard, level surface, level the machine, position the boom until it is extended approximately 3 to 6 inches (76 to 152 mm), le vel the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

3.3 BOOM ASSEMBLY MAINTENANCE

These instructions must be completed in sequence. The third boom section must be re moved before removing the second boom section. The third and second boom section must be removed at one time before removin g the first boom section.

Before beginning, conduct a visual inspection of the machine and work area, and review the t ask abou t to be undertaken. Read, understand and follow these instructions.

NEVER weld or drill the boom unless approved in writing by the manufacturer. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling.

WARNING

3. At the front of the second boom section, remove the top and side (1) wear pads. Label all parts for installation.

4. Remove the rear boom cover.

944E-42

3-3

Page 34

Boom

MU0211

MU6061

5. Loosen the extend chain loc knut (2) a t the rear of the boom halfway. The locknut must remain fully engaged on the threads of the extend chain clevis.

6. In the cab, start the engine and retract the boom slightly until slack is noticed in the extend chain. Shut the engine OFF.

7. Move the attachment tilt joystick in both directions to relieve an y trapped pressure in the system. Move the auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the system.

8. Place a Do Not Operate Tag on both the igniti on key switch and the steering wheel, stating that the machine should not be operated.

9. Open the engine cover. Allow the system fluids to cool.

10. Properly disconnect the batteries.

11. Remove the clevis pin (3) to disconnect the extend chain yoke from the f irst boom section. La y the chain assembly flat against the third boom section.

12. Label, disconnect and cap the hydraulic hoses (4) attached to the Extend/Retract cylinder. Plug all fittings to keep dirt & debris from en te ring the hydraulic system.

13. Remove the one locknut, key plate, shim(s), flat washer and capscrew on the left and right side of the Extend/Retract cylinder rod trunnion mount (5). Label all parts for installation.

14. Remove the capscrews and washers securing the cylinder tube trunnion clamps to the seco nd boo m section.

3-4

15. Remove the tie wraps from the two hose guards (6) and remove the hose guards from the cylinder hoses.

944E-42

Page 35

Boom

MU0221

MU1211

16. Label, disconnect and cap the attachment tilt hoses at the fittings at the front of the third boom section. Cap all fittings to keep dirt & debris from entering the hydraulic system.

Note: If replacing the third boom section with a new boom section; Remove the female coupler, male nipple and bulkhead fittings from the bulkhead pl ate inside the boom head.

Note: If the third boom section is equipped with remote auxiliary hydraulic couplers, remove the couplers, tubes and mounting plate from the boom head. Transfer the couplers to the boom head of the new boom section.

17. Remove the capscrews holding the hose clamps to their boom mounts at the rear of the third boom section.

18. Use a suitable overhead lifting device and sling, attach to the Extend/Retract cylinder trunnion (7). Rotate and pull the cylinder out of the third boom section far enough to give the attachment tilt and auxiliary hydraulic hoses (8) enough room to be pulled out of the boom.

19. Remove the attachment tilt and auxiliary hydraulic hoses from the third boom section by pulling them out from the top of the third boom section. Lay the hoses behind the machine.

20. Completely remove the Extend/Retract cylinder. Readjust the position of the sling as needed to help balance the cylinder during withdraw. When the cylinder is clear of the machine, carefully lower it to the ground.

21. Remove the clevis pin (9) to disconnect the retract chain yoke from the rear of the third boom section. Lay the chain assembly f lat behind the third boom section.

22. Install a lifting eye to the nut on the attachment tilt cylinder. Attach a suitable overhead lifting device and sling to the lifting eye.

23. Remove the pin from the attachme nt tilt cylin der and lower the cylinder to the ground.

24. Use a suitable overhead lifting device and sling attached to the third boom section; remove slack from the hoist sling, and withdraw the boom 6 ft. (2 m).

25. Remove the bottom wear pads at the front of the second boom section. Label each part for installation.

26. Pull the third boom section straight out of the second boom section. Reposition the slings as needed so the third boom section balances when remov ed from the second boom section. Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over.

944E-42

3-5

Page 36

Boom

MU5061

MU0261

MU1061

27. At the rear of the third boom section, remove the remaining wear pads (10), shims and hardware. Label all parts for installation.

28. Inspect all wear pads for wear. Refer to Section 3.5, “Boom Wear Pads.”

30. Remove the hydr aulic hose r ack (13) inside the third boom section.

29. At the rear of the third boom section, disconnect the retract chain (11) from the anchor link (12).

3-6

944E-42

Page 37

3.3.2 Second Boom Section Removal

MU1221

MU4171

MU1431

1. At the front of the first boom section, remove the top and side wear pads. Label all parts for installation.

2. At the rear of the boom, remove the sheave pin (14) and sheave (15).

3. Use suitable overhead lifting device and sling to lift the second boom section enough to gain access to bottom wear pads. Remove the bottom wear pads. Label all parts for installation.

4. Reposition the sling and continue pulling the second boom section straight out of the first boom section. Reposition the slings as needed so the second boom section balances when removed from the first boom section. Set the second boom section down on blocks on a hard, level surface.

5. Remove the remaining wea r pads. Label all parts for installation.

6. Inspect all wear pads for wear. Refer to Section 3.5, “Boom Wear Pads.”

Boom

7. At the rear of the second boom section, remove the two hose guides (16).

8. Remove the chain sheave (17).

944E-42

3-7

Page 38

Boom

MU1411

MU0281

MU0341

MU1291

3.3.3 First Boom Section Removal

1. At the front of the boom, remove the retract chain locknut (18) and washer.

4. Pull the hydraulic hoses out of the boom. Label all parts for installation.

2. Label, disconnect and cap the hydraulic hoses (19) attached to the attachment tilt and auxiliary hydraulic tubes. Plug all fitting to keep dirt & debris from entering the hydraulic system.

3. Remove all clamps (1) securing the hydraulic tubes and rear hydraulic hoses to the boom and frame. Label and remove the tubes. Cap all hose ends.

3-8

5. Remove the boom proximity sensor (2) from the boom.

944E-42

Page 39

Boom

MU0351

MU0371

9. Use a suitable overhead lifting device and sling to support the boom.

6. Use a suitable overhead lifting device and sling (3) to support the first boom section. Remove any slack from the sling

7. Block up or support the lift/lower cylinder. Remove the cylinder pin and carefully lower the cylinder onto the support.

10. Remove the boom pivot pins (5) and shim washers (6). Label all parts for installation.

11. Carefully lift the first boom section away from the machine. Set the boom section down on a hard, le vel surface.

8. Working on the top of each slave cylinder, remove the cylinder mount pin (4). Lower each cylinder against the transfer carriage. DO NOT stretc h or damage the hydraulic hoses.

944E-42

3-9

Page 40

Boom

MU0371

3.3.4 First Boom Section Installation

1. Use a suitable overhead lifting device and sling and carefully lift the first boom section into place on the transfer carriage.

2. Install the boom pivot pin (5) with the previously used hardware. DO NOT coat the boom pivot pins with anti-seize compound.

3. Add or remove shims (6) as required until a maximum total gap of 0.09 in (2,3 mm) is obtained. Balance the number and thickness of shims equally on both sides. If an additional (odd) shim must be added to obtain the proper gap, add to the right side of the boom.

4. Raise each slave cylinder into position, coat each mount pin (4) and bore hole with anti-seize

compound and install the mounting pins. Loctite 242™ and torque each capscrew to 18-31 lb-ft (13-23 Nm). DO NOT stretch or damage the slave cylinder hydraulic hoses.

5. Use a suitable overhead lifting de vice and sling attached to the lift/lower cylinder. Remove slack from the sling and raise the cylinder into its mount boss on the underside of the boom.

6. Coat the lift/lower cylinder pivot pin and bore hole with anti-seize compound. Install th e pin and secure

with capscrew. Loctite

242™ and torque to

70-77 lb-ft (95-105 Nm).

7. Remove the slings from the lift/lower cylinder, and remove the blocks or supports from beneath the cylinder.

8. As required, install the hydraulic clamps on the boom and secure the attachment tilt and auxiliary hydraulic tubes and hoses within the clamps on the boom and frame. Torque clamp capscrews to 4-8 lb-ft (6-11 Nm).

9. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil.

10. Uncap and connect the previously labeled hydraulic fittings to their appropriate locations.

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944E-42

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11. Install the boom proximity sensor. The gap between

MU4171

MU1431

MU1061

the sensor and the transfer carriage should be

0.12-0.19 in (3-5 mm). Torque the inside jam nut to 33-41 lb-ft (45-55 Nm).

12. At the front of the boom, install the locknut and flat washer to the retract chain clevis. DO NOT twist or kink the retract chain.

3.3.5 Second Boom Section Installation

1. Install the top, side and bottom w ear pads to the rear of the second boom section.

2. Grease the sections of the boom in areas where the wear pads will slide.

3. Use a suitable overhead lifting device and sling, carefully lift and slide the second boom section into the first boom section until it ext ends approximately 6 in (150 mm) from the front of the first boom section.

Boom

5. Install the sheave (8) and sheave pin at the rear of the second boom section. Coat sheave pin with antiseize compound. Loctite capscrews to 36-66 lb-ft (50 -90 Nm).

6. At the front of the second boom section, install the sheave and sheave pin. Coat the sheave pin with anti-seize compound. Loctite capscrews to 90-162 lb-ft (1 23-220 Nm).

7. Install the top, side and bo ttom wear pads to the inside of the first boom section.

242™ and torque

4. At the rear of the second boom section, install the

two hose guides (7). Loctite

242™ and torque

capscrews to 10-19 lb-ft (14-26 Nm).

3.3.6 Third Boom Section Installation

1. Install the hose guide (9) to its original orientation. Secure in place with the previously used hardware.

Loctite capscrews to 10-19 lb-ft (14 -26 Nm) and torque the rear capscrews to 21-38 lb-ft (29-52 Nm).

242™ all capscrews. Torque the middle

944E-42

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Page 42

Boom

MU0261

MU5061

MU1211

MU0221

2. Place the extend chain and clevis, as an assembly on top of the third boom section and allo w the chains and clevis to overhang the boom head. DO NOT allow the chain to twist or kink.

3. At the rear of the boom, attach the ret ract chain (10) to the same hole in the anchor link (11) with the

previously used hardware. Loctite

242 ™ and torque

to 37-66 lb-ft (50-90 Nm).

6. Using a suitable overhead lifting device and sling, carefully slide the third boom section into the second boom section.

7. Install the bottom wear pads at the front of the second boom section.

8. Slide the third boom section into the second bo om section. Remove the sling.

9. Install the extend chain yoke to the third boom section. Coat the clevis pin (13) with anti-seize compound.

4. Install the top, side an d bottom wear pad s (12) to the rear of the third boom section.

5. Grease the sections of the boom in areas where the wear pads will slide.

3-12

10. From the rear of the boom, push the attachment tilt and auxiliary hydraulic hoses (14) through the third boom section along the hose guides. Leave enough hose out of the back of the boom for the Extend/ Retract cylinder to be installed.

11. Use a suitable overhead lifting device and sling to carefully raise and position the Extend/Retract cylinder into the rear of the third boom section. Readjust the sling as needed to help balance the cylinder in the sling during installation.

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Page 43

Boom

MU6061

MU6071

12. After the manifold clears the hoses and is inside the boom, push the hydraulic hoses the rest of the way into the boom.

17. Lift the attachment tilt cylinder into position and coat the mount pin and bore hole with anti-seize compound. Install the mount pin.

18. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil.

19. Loosely install the female coupler, male nipple and bulkhead fittings to the bulkhead plate inside the boom head.

20. Uncap and connect the previously labeled attachment tilt and auxiliary hydraulic fittings to their appropriate locations.

21. Install the hose guards to the tilt cylinder hoses . The guard edges should overlap inside and out side of the other hose guard.

22. Install the top an d sid e wear pads to the fr on t of th e second boom section.

13. Install the cylinder trunnion clamps (15) with the

previously used hardw are. Loctite

242™ and torque

capscrews to 245-274 lb-ft (333-372 Nm).

14. Position one end of the cylinder ro d trunnion against its mounting boss. Install the cylinder trunnion clamps using the previously used hardware. Check that the gap (16) between the shim and the first boom section is within 0.07 in (1,8 mm) on both sides of the cylinder trunnion. Loctite

242™ and

torque all capscrews to 21-38 lb-ft (29-52 Nm).

15. Remove the sling and hoist.

16. Attach a suitable overhead lifting device and sling to the lifting eye of the at tachment tilt cylinder.

23. Working from the rear of the boom, move the attachment tilt and auxiliary hydraulic hoses (17) until there is approximately a 0.5 in (12 mm) gap between the Extend/Retract cylinder trunnion (18) and the hoses.

24. Install the attachment tilt and auxiliary hy draulic hose clamps to their mounting brac kets at t he rear of the second boom section.

Note: ALWAYS use new o-rings when servicing the machine.

25. Uncap and connect the previously labeled Extend/ Retract cylinder hoses to their appropriate locations.

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Boom

MU0211

26. If needed, pull the second boom section out slightly to align the extend chain yoke with the bracket. Route the extend chain yoke and chains around the sheave on the second boom section. Connect the yoke to the anchor bracket on the first boom section with the clevis pin (19). Coat the clevis pin with antiseize compound.

27. Check and adjust the boom chains. Refer to Section

3.4.5, “Boom Chain Tension Check.”

28. Properly connect the batteries.

29. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as necessary. Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required.

30. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

31. Install the rear cover to the boom.

32. Close and secure the engine cover.

3.4 BOOM EXTEND AND RETRACT

CHAINS

3.4.1 Boom Chain Inspection

WARNING

Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability.

Under normal operating conditions the boom extend chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operati ng conditions and requir e more frequent inspection intervals.

Environments in which material handling machines operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres, in addition to ab rasive exposures such as sand and grit. Some effects can be as follows:

• Moisture - Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation.

• Chemical Solutions or Vapors - Corrosive attac k on the chain components and/or the m echanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time.

3-14

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Boom

MZ1463

MY1360

• Abrasives - Accelerated wearing and scoring of

the articulati ng mem b er s of th e ch ain (pin s and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate aper tures), wear and scoring are not readily noticeable to the naked eye.

Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain.

• Attempting to “inch” loads which are beyond the rated capacity of the machine.

The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted.

The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain fle x es back an d forth ov er the sheave , the bearing joints (pins and inside link plates) gradually incur wear due to articulation .

3.4.2 Inspection Guidelines

1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

3. The extend chains will be visible for inspection with the machine in this state.

4. While doing the chain inspection, check all chain clevis ends f or distortion or crac king and she av e s f or bearing wear or grooving from the chain.

5. Inspect the retract chains every 1000 hours of operation.

6. Inspect the chains for the following conditions:

Edge Wear

Check the chain fo r wear on the link plate edges caused by running back and forth ov er the sheave. The maximum reduction of material should not exceed 5%. Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave. If the measured plate height (1) is 5% less than the normal plate height (2), discard and replace the chain.

Elongation

It is important to measure the chain in the section that moves ov e r the shea v es because it rece ive s the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as the middle of the chains.

It is best to measure in 12 pin increments from pin center to pin center . F or e xamp le, if the links ar e one inch from pin center to pin center, the distance should be 12 in (305 mm). If the links are 3/4 in (9,5 mm) apart, the distance after 12 pins should be 9 in (229 mm).

944E-42

If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.

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Boom

MZ1466

MZ1465

7 8

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

Distorted or Battered Link Plates

Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing.

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.

Cracked Plates

Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety.

It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.

The types of cracks are:

• Fatigue Cracking Fatigue crac ks (9) are a result of repeated cyclic loading beyond the chain’s endurance limit.

• Stress Corrosion Cracking - The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearan ce. Corrosion fatigue is the combined action of an aggressiv e environment and cyclic stress.

Other Modes of Failure

Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (6). Chain with rotated/displaced heads (7) or abnormal pin protrusion (8) should be replaced immediately.

DO NOT attempt to repair the chain by welding or driving the pin(s) back into the ch ain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored.

Any wear pattern on the pin heads or t he sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.

• Ultimate Strength Failure These types of failures are caused by overloads far in excess of the design load. Either fractured plates (1) or enlarged holes (2) can occur. If eit her of these failures occurs, the chain should be replaced immediately.

•Tight Joints

- All joints in the chain should flex freely. Tight joints (3) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosio n and rust or bent pins, replace the chain.

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Boom

3.4.3 Expose Chains for Inspection

b. Extend Chains

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position.

2. Fully extend the boom and shut the engine OFF.

The extend chains will be visible for inspection with the machine in this state.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, an y chain is found to be damaged or stretched, the chain must recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time.

c. Retract Chains

The retract chains are only partially visible through th e rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. The retract chain must be removed from the boom in order to be fully inspected. This must be done every 1000 hours or whenever the retract chain is removed from the boom. If there is ANY question t hat one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary.

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis’ be replaced at the same time.

be replaced. It is

3.4.4 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent).

The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.

To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces.

Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation.

Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often.

Lubrication of chains on machines working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist or an authorized distributor be consulted for guidance.

3.4.5 Boom Chain Tension Check

1. Make sure the attachment is attached to the boom head before doing the tension check.

2. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch and level the boom.

3. Slowly, fully extend the boom and retract it about halfway. Fully extend the boom, then retract it 2 in (51 mm) (one inch per section). Turn the engine OFF.

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Boom

OA0493

4. Measure the sag (1) in the top boom extend chain between the bottom of the chain an d the top of the boom at their closest point. Acceptable boom chain sag is between 3.0 in (76 mm) and 4.0 in (102 mm). If the measurement is still less than 3.0 in (76 mm), the boom chain needs to be adjusted.

If the measurement is either less than, o r greater than the range given, the boom chains need to be adjusted. Continue with Section 3.4.6, “Boom Chain Tension Adjustment” to adjust the chain system.

5. Start the engine, retract the boom completely and turn the engine OFF.

3.4.6 Boom Chain Tension Adj ustment

Note: Always perform Section 3.4.5, “Boom Chain Tension Check” before adjusting the boom chain tension.

1. Park the machine on a hard, level surface, level the

2. Remove the rear boom cover.

3. Adjust the extend chain by tightening or loosening

4. If the chain sag measurement is less than 3.0 in

machine, retract the boom, lev e l the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

the retract chain adjustment nut on the front underside of the first boom section.

(76 mm), the retract chain adjustment nut needs to be tightened. If the chain sag measurement is more than 4.0 in (102 mm), the retract chain adjustment nut needs to be loosened.

5. Return to the cab, start the engine and cycle the boom all the way out and all t he wa y in several times.

6. Fully extend the boom, then retract it 2 in (51 mm) Shut the engine OFF.

7. Measure the sag in the top boom extend chain between the bottom of the chain an d the to p of the second boom section at their closest point. Acceptable boom sag is betwee n 3.0 in (76 mm) and

4.0 in (102 mm). If the measurement is still less than

3.0 in (76 mm), the boom chain needs to be readjusted.

Note: If all the adjustment has been used up on the retract chain adjustment nut and the extend chain is not within the acceptable sag range, the clevis at the top front of the first boom section will need to be repositioned.

8. Return to the cab, start the engine and fully retra ct the boom. With the boom horizontal, extend the boom out approximately 2 ft (610 mm) and shut the engine OFF.

9. At the front underside of the first boom section, loosen the retract chain adjustment nu t. Back the n ut off until the top of the nut is flush with the end of the threaded clevis.

10. Return to the cab. Have an assistant watch at the front underside of the first boom section. Slowly retract the boom until the retract ch ain adjustment nut touches the cle vis mounting tab on th e underside of the first boom section.

11. At the front to p of th e firs t bo om sect ion , move the extend chain clevis to the next hole toward the rear of the mounting plates. Coat the mounting pin and bore hole with anti-seize compound and reinstall the pin.

12. Return to the cab, start the engine and fully retract the boom. Shut the engine OFF.

13. At the front underside of the first boom section, tighten the retract chain adjustment nut to remove the excess slack from the chains.

14. Make sure that the chain system is properly tensioned. Refer to Section 3.4.5, “Boom Chain Tension Check.”

15. Install the rear boom cover.

3-18

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Page 49

a. Component/Assembly Verification

MU0411

MU1411

MU0211

The third to second boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate.

Measure the separation (2) between the third and second boom section top plates. The distance should be at least

8.5 in (216 mm) and not greater than 9.5 in (241 mm) with the boom fully retracted and the chains properly tensioned. A distance of less than 8.5 in (216 mm) could result in interference and cause damage to boom components.

If the distance is less than 8.5 in (216 mm):

1. Tighten the retract chain locknut (3) on the bottom of the first boom section.

2. Measure the distance and tighten until the distance is between 8.5 in (216 mm) and 9.5 in (241 mm). If the locknut cannot be tightened any more, loosen the locknut until one full thread on the clevis protrudes beyond the collar of the locknut.

3. Verify that the extend chain clevis (4) is not mounted in the last hole in the anchor plate. If the clevis can be moved to the next hole, do so and check the chain tension. Refer to Section 3.4.5, “Boom Chain Tension Check.”

4. Measure the distance again and tight en locknut until the distance is between 8.5 in (216 mm) and 9.5 in (241 mm).

5. Install the rear boom cover.

6. If the third to second boom separation distance cannot be achieved, contact your local authorized service distributor.

Boom

If the distance is greater than 9.5 in (241 mm):

1. Loosen the retract chain loc kn ut (3) on the bottom of the first boom section one or two turns. A minimum of one full thread on the clevis m ust protrude be yond the collar of the locknut.

2. Measure the distance and loosen the locknut until the distance is between 8.5 in (216 mm) and 9.5 in (241 mm) or until one full thread on the clevis protrudes beyond the colla r of the locknut.

3. Verify that the extend chain clevis (4) is not mount ed in the first hole in the anchor plate. If the clevis can be moved to the next hole, do so and check the chain tension. Refer to Section 3.4.5, “Boom Chain Tension Check.”

4. Measure the distance again and loosen the locknut until the distance is between 8.5 in (216 mm) and

9.5 in (241 mm).

5. Install the rear boom cover.

6. If the third to second boom separation distance cannot be achieved, contact your local authorized service distributor.

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Boom

MU0261

MU0211

3.4.7 Extend Chains Removal and Replacement

1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF.

2. Place a Do Not Operate Tag on both the igniti on key switch and the steering wheel, stating that the machine should not be operated.

3. Properly disconnect the battery.

4. Remove the boom rear cover.

5. At the rear of the third boom section, disconnect the retract chain (5) from the anchor link (6).

Note: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis’.

7. Remove the extend chain sheave (8).

8. Attach one end of a string or wire to the e xtend chain yoke. The string or wire must be long enough to pull the extend chain through the boom.

9. Pull the extend chain out through the rear of the boom. Remove the wire fr om the clevis, but not from inside the boom.

10. Inspect wear and condition of the booms, chains, clevis’, chain sheaves, extend/retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace any worn or damaged parts. DO NOT attempt to make any repairs to the chain.

11. Attach the wire to the new extend chain and pull it through the boom between the third and second boom section.

12. At the front of the second boom section, coat the sheave pin and bore with anti-seize compound.

Install the sheave. Loctite

242™ and torque the

capscrew to 90-162 lb-ft (1 23-220 Nm).

13. If needed, pull the boom out slightly to align the extend chain y oke with the shea v e. Route th e exten d chain around the sheave on the second boom section. Coat the clevis pin and bore ho le with antiseize compound. Install the e xtend cha in y ok e to the first boom section.

14. At the rear of the boom, install the retract chain to

the anchor link. Loctite

242™ and torque to 37-66

lb-ft (50-90 Nm).

15. Check and adjust boom chain tension. Refer to Section 3.4.5, “Boom Chain Tension Check.”

16. Install the rear boom cover.

17. Properly connect the battery.

6. Remove the cle vis pin (7) from the extend chain yoke at the front of the boom. Lay the chain assembly flat against the third boom section.

3-20

3.4.8 Retract Chain Removal and Replacement

1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF.

2. Place a Do Not Operate T ag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Properly disconnect the battery.

4. Remove the boom rear cover.

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5. At the front underside of the boom, reco rd the

MU1411

MU3901

MU1211

amount of threads extending beyond the locknut. This measurement will be the starting point for adjustment of the boom retract chain.

6. Remove the locknut (9) and washer securing the retract chain to the boom.

Boom

8. Disconnect the retract chain yoke (11) from the rear of the third boom section. Lay the chain assembly flat behind the boom.

9. From the rear of the boom, pull the retract chain out of the boom. Remove the wire from the clevis, but not from the inside of the boom.

10. Inspect wear and condition of the booms, chains, clevis’, chain sheaves, extend/retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace a worn or damaged chain. DO NO T att empt to make any repairs to the chain.

7. Attach a wire or string to the threaded clevis with a threaded eye (10) or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than th e diameter of the threads on the clevis. The wire or string will be used to pull the chain back through the boom during reassembly.

944E-42

Note: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part.

11. Attach the wire to the new retract chain.

12. From the rear of the boom, push the threaded clevis end of the retract chain under the chain sheave and down between the second and first boom sections. Have an assistant pull the string or wire from the front of the boom.

13. Guide the clevis through the hole in the tab at the front of the boom.

14. Install the retract chain yoke on the rear of the third boom section.

15. Remove the string or wire from the end of the clevis.

16. Secure the clevis with a loc knut and w asher. Tighten the locknut on the retract chain clevis until the amount of threads protruding beyon d the locknut is the same as the measurement recorded during removal of the retract chain.

17. Check and adjust retract chain tension. Refer to Section 3.4.5, “Boom Chain Tension Check.”

18. Install the boom rear cover.

19. Properly connect the battery.

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Boom

Ma2070

MAM1390

MY5510

MY3620

3.5 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear pads with metal inserts.

A total of 30 wear pads are installed on the boom sections.

3.5.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicator s (1) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pa ds as a se t if worn or damaged.

3.5.2 Wear Pad Installation and Lubrication

• Maintain a total boom section clearance (5) of

0.070 - 0.130 in (1,78 - 3,30 mm) both the horiz ontal and vertical directions.

Note: Inspect all wear pads. Replace as necessary.

The following wear pad procedure must be followed to insure the proper wear pad installation:

• The wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite

242™ and installing

mounting bolts.

• Apply Loctite

242™ to all wear pad mounting bolts.

• A spacer (2) with holes must be used before any shim (3) is used.

• A shim (3) must be inserted between the spacer (2) and wear pad support plate, block or boom section (4).

• The number of shims can vary at each shim point.

• The bottom wear pads must be shimmed equally on

each side.

• The length of the wear pad bolt depends on the number of shims, spacers and washers being used.

• The thickness of each threaded wear pad insert is

0.312 in (7,92 mm)(A).

• The bolt length should be determined by measuring the distance from the f ace of the insert to the face of the boom (B) including any spacer, shim(s) and washer(s).

• Bolt thread engagement in the wear pad insert should be 0.275 ± 0.040 in (6,98 ± 1,0 mm).

• One or two hardened washers are to be used on each wear pad bolt except where noted otherwise. DO NOT use more than two hardened washers.

• Use only one hardened washer if mounti ng bolts are recessed.

• Wear Pad Bolt Torque: M8-1.25 Bolt, 29 lb-ft (39 Nm) M10-1.5 Bolt, 55 lb-ft (75 Nm)

• Torque wear pad bolts after shimming is completed.

• Lubricate the f ace and pockets of each wear pad

after being installed.

Boom Section Wear Pad Pathway Lubrication:

• Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease.

20. Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.

3-22

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Boom

MU7660

MH6460

3.6 QUICK ATTACH ASSEMBLY

3.7 FORKS

Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately.

Daily Inspection

3.6.1 Quick Attach Removal

1. Remove the lock bolt holding (6) the tilt cylinder rod end pin (7) to the quick attach assembly (8). Remove the Tilt Cylinder pin.

2. Support the quick attach assembly. Remove the capscrew and locknut (9) securing the quick attach pivot pin (10) to the quick attach assembly. Remove the quick attach pivot pin and assembly. Record the location and quantity of the shim washers as the pin is being removed.

3. Inspect the above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.

3.6.2 Quick Attach Installation

1. Assemble the quick attach to the boom h ead. Line up the quick attach between the mounts on the boom head. The quick attach shou ld be centered in the boom head. Reassemble the shims betw een the quick attach and the boom head.

2. Coat the quick attach head pin with an anti-seize compound. Insert the quick attach head pin through the quick attach and boom head. Secure with the previous capscrew and locknut.

3. Align the quick attach with the tilt cylinder rod end and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the locking bolt. Torque as required.

944E-42

1. Inspect forks (1) for cracks, paying special attention to heel (2) and mounting tubes (3).

2. Inspect forks for broken or bent tips (4) and twisted blades (5) and shanks (6).

Yearly Inspection

1. Straightness of the upper face of blade (5) and the front face of shank (6) should not e xceed 0.5 percent of the length of blade or height of shank.

2. Angle (7) between upper face of blad e and front f ace of shank should not exceed 93 degrees.

3. Thickness of blade (8) and shank (9) should not be reduced to 90 percent of original thickness.

Note: Contact the local distributor with the fork part number to find the manufactured dimensions of the fork blade.

4. Ensure fork length (10) is adequate for intended loads.

5. Fork markings should be legible, re-stamp if required.

6. Compare fork tips (11) when mounted on a carriage. Maximum difference in height of f ork tips is 3 percent of the length of the blade (10).

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Boom

3.8 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during opera tion of the boom.

Boom Troubleshooting

Problem Cause Remedy

1. Boom will not extend or retract.

2. Boom shifts to right or left when extending.

3. Excessive boom pivot pin noise and/or wear.

4. Excessive Compensation cylinder pivot pin noise and/ or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/Retract hydr aulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder, Refer to Section

4. Broken chains or anchors. 4. Replace chains as needed.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bushing(s). 2. Replace bushing(s) and

1. Insufficient lubrication. 1. Lubricate at regular intervals.

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

8.7.17, “Accumulator Charge Troubleshooting.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.5.2, “Wear Pad Installation and Lubrication.”

Refer to Section 2.6, “Lubrication Schedules.”

lubricate at regular intervals

Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed.

3-24

2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals.

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Boom Troubleshooting (Continued)

Problem Cause Remedy

Boom

5. Drooping chain, or jerky boom extend or retract functions.

6. Boom will not raise or lower. 1. Broken hydr aulic hoses or tubes

1. Chain(s) tension not properly adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed.

3. Wear pads loose, contamin ated, excessively worn or damaged.

4. Contaminated, corroded or rusted wear pad sliding surfaces.

5. Extend/Retract hydr aulic system not operating properly.

6. Damaged boom section. 6. Replace the damaged boom

and/or connection leaks.

1. Adjust chain(s).

Refer to Section 3.4, “Boom Extend and Retract Chains.”

3. Replace wear pad. Refer to Section 3.5.2, “Wear Pad Installation and Lubrication.”

4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

5. Refer to Section 8.4, “Hydraulic Circuits.”

section. Refer to Section 3.3, “Boom Assembly Maintenance.”

1. Locate break, replace hose(s) or tube(s), tighten connections.

7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.

2. Lift/Lower hydraulic system not operating properly.

3. Faulty Lift cylinder. 3. Repair cylinder. Refer toSection

4. Seized boom pivot pin bushing. 4. Replace bushing.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

2. Refer to Section 8.4, “Hydraulic Circuits.”

8.7.17, “Accumulator Charge Troubleshooting.”

Refer to Section 2.5, “Service and Maintenance Schedules.” Replace worn pins as needed. Refer to Section 8.7.17, “Accumulator Charge Troubleshooting.”

lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.”

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Boom

Boom Troubleshooting (Continued)

Problem Cause Remedy

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and

correct as needed. Refer to Section 3.5.2, “Wear Pad Installation and Lubrication.”

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

9. Auxiliary hydraulics will not operate.

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer

1. Auxiliary hydraulic system not operating properly.

2. Chain sheav e(s) not properly lubricated.

3. Chain sheave(s) not rotating freely.

2. Reduce cycle times.

3. Remove contamination and/ or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8, “Hydraulic System.”

to Section 3.4.1, “Boom Chain Inspection.”- Replace chains as needed.

2. Lubricate chain sheave. (Refer to Section 2.5, “Service and Maintenance Schedules.”

3. Lubricate chain sheave . Refer to Section 2.5, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as nee ded.

3-26

4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedules.” Replace chains as needed.

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3.9 EMERGENCY BOOM LOWERING

OU1061

Boom

3.9.1 Loss of Engine Power or Hydraulic Pump Failure

Note: In the event of total loss of engine power or hydraulic pump failure with an elevated load, the situation must be properly evaluated and dealt with on an individual basis. Contact your local Authorized distributor for specific instructions for your particular situation.

Note: Refer to Section 5.7, “Towing a Disabled Machine,” if needed.

In any event, the machine should be secured until the situation has been properly evaluated. Secure the machine by following the procedures below.

1. Clear the area around the machine of all personnel.

2. Block all four wheels.

3. Section off a large area under the boom with string or tape to restrict any personnel from entering this

potentially dangerous area.

WARNING

DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before servicing that requires the boom to be up .

4. Temporarily block up or support the outer boom so that it cannot be lowered.

5. If the load is in a position where it can removed safely, completely remove the load from the carriage , otherwise leave the load in place.

6. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3.9.2 Hydraulic Line Failure

In case of hydraulic line failure, there are step-by-step procedures available to assist you in safely retracting and then lowering the boom. Read this section from start to finish before performing any of these procedures so you fully understand the process and dange r i nvolved. If you are unsure about any part of these procedures contact your local Authorized distributor for specific instructions on your particular situation.

Note: For boom retract and lower, the hydraulic lines MUST be replaced, then retracted and lower the boom in it’s normal fashion.

doing any

WARNING

Be aware that the boo m must first be retracted and than lowered to avoid machine tipover.

In any case of hydraulic line failure, it is critical to correctly identify which hydraulic line has failed. Identify the hydraulic line that has failed and use the table Section

3.9.3, “Hydraulic Hose Replacement, ”on the following page to determine which step to follow to re tract and lower the boom.

The hydraulic lines are:

• Boom Extend line - Extend Cylinder to Block (1)

• Boom Retract Line - Extend Cylinder to Block (2)

• Boom Extend line - Block to Frame Bulkhead (3)

• Boom Retract Line - Block to Frame Bulkhead (4)

• Boom Lower Line - Lift Cylinder to Block (5)

• Boom Lift Line - Lift Cylinder ot Block (6)

• Boom Lower Line - Block to Frame Bulkhead (7)

• Boom Lift Line - Block to Frame Bulkhead (8)

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Boom

OU1061

3.9.3 Hydraulic Hose Replacement

NORMAL STEPS

HYDRAULIC LINE THAT FAILED

Follow this step if parts are available Follow this step if parts are not

BOOM LIFT LINE

(Lift Cylinder to Block or Block to

Frame Bulkhead)

BOOM LOWER LINE

(Lift Cylinder to Block or Block to

Frame Bulkhead)

BOOM EXTEND LINE

(Extend Line to Block or Block to

Frame Bulkhead)

BOOM RETRACT LINE

(Extend Line to Block or Block to

Frame Bulkhead)

3.9.4 Hydraulic Hose Replacement - Step 1

1. Clear area of any unnecessary personnel.

2. Block all four wheels.

3. If the load is in a position where it can removed safely, completely remove the load from the carriage , otherwise leave the load in place.

4. Temporarily block up or support the outer boom.

5. Replace the failed hydraulic line with a new part.

• Boom Extend line - Extend Cylinder to Block (1)

• Boom Retract Line - Extend Cylinder to Block (2)

• Boom Extend line - Block to Frame Bulkhead (3)

3-28

available

STEP 1 STEP 2

STEP 1 STEP 1

STEP 1 STEP 2

STEP 1 STEP 1

• Boom Retract Line - Block to Frame Bulkhead (4)

• Boom Lower Line - Lift Cylinder to Block (5)

• Boom Lift Line - Lift Cylinder ot Block (6)

• Boom Lower Line - Block to Frame Bulkhead (7)

• Boom Lift Line - Block to Frame Bulkhead (8)

6. Check the hydraulic oil level, add oil if needed.

7. Remove the blocking or support from the outer boom.

8. Return to cab, fasten seat belt and start engine.

9. Tilt the carriage upward, if necessary, for clearance before retracting the boom.

10. Slowly retract the boom.

11. Slowly lower the boom and ground the carriage.

12. Shut off engine.

13. Completely remove the load from the carriage , if not previously done.

14. Return to cab, fasten seat belt and start engine.

15. Cycle the lift/lower and extend/retract cylinders sever al times to b leed air from the system. Chec k f or leaks.

16. Recheck hydraulic oil level. Add oil if necessary.

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3.9.5 Hydraulic Hose Replacement - Step 2

OU1061

USE IN CASE OF: BOOM LIFT LINE FAILURE - Lift Cylinder to Block (1) BOOM LIFT LINE FAILURE - Block to Frame

Bulkhead (2) BOOM EXTEND LINE FAILURE - Extend Cylinder to

Block (3) BOOM EXTEND LINE FAILURE - Block to Frame

Bulkhead (4)

1. Clear area of any unnecessary personnel.

2. Block all four wheels.

3. Place a container under the failed hose to catch any hydraulic oil that may escape from this procedure.

4. Return to the cab, fasten seat belt and start engine.

5. Slowly retract the boom.

6. Slowly lower the boom and ground the carriage.

7. Shut off engine.

8. Completely remove the load fro m th e carriage , if not previously done.

9. Place an Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

10. Have the machined serviced immediately. Replace any failed hydraulic lines with new parts.

11. Return to the cab, fasten seat belt and start engine.

12. Cycle the lift/lower and extend/retract cylinders sever al times to bleed air from the syst em. Check f or leaks.

13. Recheck hydraulic oil level. Add oil if necessary.

14. T ransfer any waste oil to a properly labeled container and dispose of accordingly.

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Boom

This Page Intentionally Left Blank

3-30

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Section 4

Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Steering Column and Steering Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.3 Service Brake Valve and Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.4 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.5 Throttle Position Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.6 Joystick Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.4 Enclosed Cab (Optional) Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.1 Front Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.2 Front Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.3 Windshield Washer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.4 Skylight Wiper Washer & Rear Window Washer Switch . . . . . . . . . . . . . 4-8

4.4.5 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.6 Windshield/Skylight/Rear Wiper Washer Reservoir w/Pump. . . . . . . . . . 4-8

4.4.7 Rear Wiper Switch/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.8 Heater/Defroster System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.7 Valve Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7.1 Valve Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7.2 Valve Plate Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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Page 62

Cab and Covers

MU6262

TRANSMISSION

CONTROL LEVER

STEERING

WHEEL

MIRROR

ACCELERATOR

PEDAL

SERVICE BRAKE

PEDAL

OPERATOR’S CAB

HOOD

OPTIONAL

SINGLE

JOYSTICK

SEAT

FRAME SWAY

JOYSTICK

BOOM LIFT/LOWER,

EXTEND/RETRACT

JOYSTICK

ATTACHMENT TILT &

TRANSFER CARRIAGE

JOYSTICK AND AUXILIARY

HYDRAULIC BUTTON

4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.

4-2

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WARNING

MU5991

MU3151

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

4.2 OPERATOR’ S CAB

4.2.1 Cab Safety

WARNING

The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value.

Cab and Covers

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Remove the front display panel. Label and disconnect the electrical connector attached to the display panel.

6. Remove the lower dash panel.

DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage to cab structural components requires cab replacement. The lives of the operator and others are potentially at stake.

To help ensure optimum safety, protection and performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

4.2.2 Serial Number Decal

The cab serial number decal is located on the inside of the cab, above the rear window opening. Information specified on the serial number plate includes the cab model number, the cab serial number and othe r data. Write this information down in a convenient location to use in cab correspondence.

4.3 CAB COMPONENTS

4.3.1 Steering Column and Steering Valve

a. Steering Valve Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

7. Remove the steering wheel and disconnect and remove the travel select lever (1) and turn signal lever (2).

8. Label, disconnect and cap the four hoses from the top of the steering valve (3). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose on the left of the steering valve. Cap the fitting on the steering valve.

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Page 64

Cab and Covers

9. Disconnect the horn button wire from the cab wiring harness.

10. Support the bottom of the steering valve, and remove the four capscrews and lockwashers. Remove the steering valve through the lower dash panel opening.

11. Remove the steering column (4), by pushing it down, and removing it through the lower dash panel opening.

Note: DO NOT disassemble the steering valve. The steering valve is not serviceable and must be replaced in its entirety, if defective.

b. Steering Valve Installation

1. Install the steering column and steering valve, by inserting them through the lower dash panel opening. Position steering valve in the cab to its original orientation. Secure the steering valve and column with the previously used hardware . Torque to 13 lb-ft (18 Nm).

Note: ALWAYS use new o-rings when servicing the machine.

2. Install new o-rings into the fittings. Lubricate the orings with clean hydraulic oil.

3. Uncap and connect the previously labeled load sense hose to the steering valve.

4. Install new o-rings into the steering v alv e fittings . Lubricate the o-rings with clean hydraulic oil.

5. Uncap and connect the remaining previously labeled four hoses to the steering valve.

6. Connect the horn button wire to the cab wiring harness.

7. Install the travel select le v e r, turn signal lever and steering wheel. Torque the steering wheel nut to 50 lb-ft (68 Nm).

8. Connect the previously labeled electrical connector to the display panel. Install the display panel.

9. Properly connect the batteries.

10. Carefully examine all connections one last time before engine start-up. Rectify any faulty conditions.

11. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

12. Install the lower dash panels.

13. Close and secure the engine cover.

c. Steering Test

Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.3. 1, “Pressure Checks and Adjustments.”

4.3.2 Steer Select Valve

a. Steer Select Valve Removal

Refer to Section 8.7.12, “Steer Select Valve,” for removal information

b. Steer Select Valve Installation

Refer to Section 8.7.12, “Steer Select Valve, ” for installation information

4.3.3 Service Brake Valve and Pedal

a. Brake Valve Removal

Refer to Section 8.7.9, “Service Brake Valve,” for removal information.

b. Brake Valve Installation

Refer to Section 8.7.9, “Service Brake Valve,” for installation information.

c. Service Brake Pedal Removal

2. Place a Do Not Operate T ag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

5. Remove the lower dash panel.

4-4

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6. Disconnect the brake return spring (5).

MU3451

MU3561

7. Remove the retaining clips and slid e brake pedal shaft (6) out, toward the right side console, from the pedal support and brake pedal assembly.

8. Remove the bushings (7) from the brake pedal tube.

9. Remove the service brake pedal from the cab.

Cab and Covers

4.3.4 Throttle Pedal

a. Throttle Pedal Removal

2. Place a Do Not Operate T ag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Properly disconnect the batteries.

d. Service Brake Pedal Installati on

Note: The bushings are a self-lubricating soft material and should be inspected for reuse prior to installation.

1. Install the bushings (7) into the ends of the brake pedal tube.

2. Slide the shaft (6) through the brake pedal tube and install the shims and retaining clips.

3. Reattach the brake return spr in g (5).

4. Adjust the service brake as needed. Ref er to Section

9.11.16, c. “Stabilizer Brake Switch Adjustment.”

5. Install the lower dash panel.

6. Properly connect the batteries.

7. Close and secure the engine cover.

4. Remove the lower (8), right front and right side (9) console access panels.

5. Disconnect the throttle return spring (10).

6. Disconnect the electrical harness connector.

7. Remove the retaining clips (11) and shims (12) and slide the shaft out, towards the left, from the throttle assembly.

8. Remove the throttle pedal assembly from the cab.

b. Throttle Pedal Installation

1. Position the thr ottle pedal in its mounting location within the cab.

2. Secure the throttle pedal in place with previously used hardware.

3. Reconnect the wire harness plug to the front of the throttle pedal.

4. Attach the return spring to the throttle pedal.

5. Properly connect the batteries.

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Page 66

Cab and Covers

MU5741

MU5761

4.3.5 Throttle Position Sensor Replacement

a. Throttle Position Sensor Removal

The throttle position sensor controls the engine speed. It is designed to sense the position of the throttle pedal and send the signal back to the engine control module. The sensor is located on the bracket below the dash where the throttle pedal is attached. The sensor must be tested while it is still on the machine. Refer to step “C”.

2. Disconnect the ECM cab harness connector (1) from the throttle position sensor (2).

3. Disconnect the bottom of the return spring (3) from the bolt at the bottom of the mounting bracket inside the cab.

4. Remove the clevis locking pin (4) from the clevis on the linkage assembly.

5. Remove the two slotted pan head screws securing the sensor and linkage assembly to the mounting bracket.

6. Slide the sensor (2) and linkage assemb ly out of t he slot on the mounting plate.

7. Remove the snap ring ( 5) and flat washer securing the sensor to the linkage assembly (6).

b. Throttle Position Sensor Installation

1. Slide the sensor onto the linkage assembly shaft.

2. Lock in place on the shaft using the flat washer and snap ring.

3. Slide the sensor and linkage assembly into the slot on the mounting plate.

4. Line up the hole in the clevis on the linkage assembly with the hole on the throttle pedal stop plate.

5. Secure the clevis with the clevis locking pin.

6. Center and secure the sensor to the cab mounting bracket with two slotted pan head screws, washers and nuts. Torque nuts to 2-4 lb-ft (1,5-3 Nm).

7. Connect the ECM cab harness connector to the throttle rotary sensor.

8. Start the engine. Engine rpm should increase as soon as the throttle pedal is depressed and contin ue to increase until the throttle pedal is fully depressed.

c. Throttle Position Sensor Adjustment

1. Inspect the sensor terminals for continuity. Attach the ohmmeter leads to the tw o outside pins , 1 a nd 3. The resistance reading should be approxima tely 4,000 - 6,000 ohms, whethe r the pedal is at rest or at fully depressed. Attach the ohmmeter leads to pins 2 and 3. The resistance reading should be approximately 2,000 ohms, with the throttle at rest and change to approximately 4,000 ohms, with the throttle pedal fully depressed.

2. Replace the sensor if the readings are not as described in step 1.

4-6

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Cab and Covers

MU3881

MU5811

4.3.6 Joystick Assemblies

Refer to Section 8.7, “Valves and Manifolds,” fo r removal and installation instructions apply to the front, rear and frame sway joysticks.

a. Joystick Assembly Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Properly disconnect the batteries.

5. Lift the joystick console (3) away from the cab and label the hydraulic hoses (4) and electrical connectors (5).

6. Disconnect and cap all hydraulic hoses attached to the joystic ks. Cap all fitting s and openin gs to pre v en t dirt and debris from entering the hydraulic system.

7. Remove the capscrews holding the joystick base to the console and remove the joystick assembly through the bottom of the console.

b. Joystick Assembly Installation

1. Secure the joystic k to the console with th e previo usly used hardware.

2. Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations.

3. Connect the electrical plug (front joystick only).

4. Place the joystick console on the cab and secure it with the previously removed hardware.

Note: Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and /or pr otective conduit as required.

4. Remove the access (1) and console panel (2) in the cab.

Note: Record the location, and label all hydraulic hoses to ensure correct installation.

5. Install the access panel.

6. Properly connect the batteries.

7. Test all joystick functions for proper performance.

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4.4 ENCLOSED CAB (OPTIONAL) COMPONENTS

4.4.1 Front Windshield Wiper Switch

Refer to Section 9.12.1, “Dash Switches.”

4.4.2 Front Windshield Wiper Motor

Refer to Section 9.9.1, “Windshield Wiper Motor.”

4.4.3 Windshield Washer Control

Refer to Section 9.12.1, “Dash Switches.”

4.4.4 Skylight Wiper Washer & Rear

Window Washer Switch

Refer to Section 9.12.1, “Dash Switches.”

4.4.5 Skylight Wiper Motor

Refer to Section 9.9.2, “Skylight Wiper Motor.”

4.4.6 Windshield/Skylight/Rear Wiper

Washer Reservoir w/Pump

5. Place a suitable container b eneath the radiat or dr ain plug or petcock. Slowly turn the radiator cap to the first stop, and allo w any pressure to escape. Remo ve the radiator cap.

6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug or petcock and allow the coolant to drain.

7. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

8. Close the radiator drain plug or petcock.

Refer to Section 9.9.4, “Windshield Washer Reservoir and Pump.”

4.4.7 Rear Wiper Switch/Motor

Refer to Section 9.9.3, “Rear Wiper Switch/Motor.”

4.4.8 Heater/Defroster System

a. Heater Assembly Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF.

Note: For machines equipped with air conditioning, before the heater assembly can be removed, the air conditioning hoses and electrical connections must be completed by an authorized air conditionin g service technician. A technician will also be needed to restore the connections when the heater assembly is installed.

2. Place a Do Not Operate Tag on both the igniti on key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

9. Remove the seat, washer fluid reservoir and seat mounting panel (6).

10. Remove the right side console access panel (7).

11. Disconnect the heater wire from the cab harness.

12. Label and remove all duct hoses at the heater assembly.

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13. Label, disconnect and cap the heater hoses at the heater.

14. Remove the three capscrews and washers securing the heater assembly to the cab.

15. Carefully slide the heater assembly forward and out from under the seat support riser.

b. Heater Assem b ly In st a lla ti on

Note: For machines equipped with air conditioning, before the heater assembly can be installed, the air conditioning hoses and electrical connections must be completed by an authorized air conditionin g service technician.

IMPORTANT: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

11. Wait for the engine to cool and check the coolant level. Ad d coolant as requ ired to bring the coolan t to the proper level.

12. Close and se cu re engi ne cover.

4.5 C AB REMOVAL

WARNING

Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

1. Install the heater assembly (1) by tilting it up and sliding it under the seat support riser.

2. Install the three cap screws and washers to secure the heater assembly to the cab.

3. Install the coolant hoses (2) on the heater assembly and tighten the hose clamps.

4. Connect all duct hoses to the heater assembly.

5. Connect heater wiring to the cab harness.

6. Install the seat mounting panel.

7. Install the operators seat.

8. Install the right side console access panel.

9. Refill the cooling system. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

10. Properly connect the batteries.

Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact an authorized service distributor with any questions about the suitability or condition of a cab.

Note: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacem en t ca b is securely mounted on the machine.

1. Park the machine on a firm, level surface. Allow sufficient over head and side clearance for cab removal. Level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brak e and shut the engine OFF.

2. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient o verhead and side clearance for cab removal.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

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MU5011

MU4891

MU5021

5. Block the boom (1) sufficiently enough to provide access to the hydraulic hoses between the cab, hydraulic valve plate and the engine compartment

6. Label, disconnect and plug the hydraulic hoses leaving the cab and going to the hydraulic cylinders, brakes and engine compartment. All of the hoses may be accessed either above (3) or below (2) the frame.

9. Remove the right side console access panel (7).

Note: Record the location, and label all electrical cables to ensure correct installation.

10. Disconne ct all of the ele ct rical connections (8) that run from the cab out to the frame and engine compartment.

11. If equipped, Disconnect the heating and air conditioning hoses and electrical connections.

12. Remove the mirror from the left side of the cab.

7. Disconnect the supply and return fuel lines (4) at the fuel tank (5).

8. Disconnect the electrical connection (6) to the fuel level sending unit.

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13. Remove the four capscrews, washers and sheer pins (9) that secure the cab mount supports to the frame.

14. If equipped, re m ove the skylight glass.

15. Use a suitable overhead lifting device and attach to the top of the cab.

16. When all wiring, hydraulic hoses and fasteners are disconnected or remov ed, carefully and slo wly lift the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal.

17. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being remo v e d from the machine.

18. Inspect the condition of the fittings, clamps, h ydraulic hoses, etc. Replace parts as indicated by their condition.

19. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

20. Remove the valve plate assembly from underneath the cab. Refer to Section 8.7.2, “Main Control Valve.”

21. Remove the four capscrews, rebound wa shers and cab isolators (10) that secure the cab to the front and rear cab mount supports.

22. Transfer all remaining components from the original cab into the new cab.

23. DO NOT attempt to transfer any decals from the original cab into the new replacement cab. Always replace decals with new parts. Refer to the appropriate Parts Manual to order new decals.

4.6 CAB INSTALLATION

1. Install the cab mount support to the front and rear of the cab. Use the four capscrews, rebound washers and cab isolators (10). Torque capscrews to 225 - 350 lb-ft (305 - 474 Nm).

2. Install the valve plate asse mb ly from underneath the cab. Refer to Section 8.7.2, “Main Control Valve.”

3. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation.

4. Attach a suitable ov erh ead lifting de vice to the to p of the cab.

5. Carefully begin to lift and align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.

6. If equipped, install the skylight glass.

7. Install the four capscrews, washers and sheer pins (1). Torque capscrews to 1,450 - 1,85 0 lb- ft (1,966 - 2,508 Nm).

8. Connect all electrical connections that run from the cab out to the frame and engine compartment.

9. Install the right side consol e ac ce ss pa ne l.

10. Connect the supply and return fuel lines at the fuel tanks.

11. Connect the electrical connection to the fuel level sending unit.

12. If equipped, connect heating and air conditioning hoses and electrical connections. Refer to Section

4.4.8, “Heater/Defroster System.”

13. Uncap and reconnect the hydraulic hose s going from the hydraulic cylinders, brakes and engine compartment to the cab. All the hoses may be accessed either above or below the frame.

14. Remove the b loc king from betw een the fr ame and lift/ lower cylinder .

15. Properly connect the batteries.

16. Carefully examine all cab compone nt s, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions.

17. Start the engine and chec k the operation of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

18. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

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19. Install the mirrors and all other cab components as needed, if removed.

20. Unblock the wheels.

21. Close and secure the rear door.

4.7 VALVE PLATE

4.7.1 Valve Plate Removal

1. Park the machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the igniti on key switch and steering wheel, stating that the machine should not be operated.

3. Properly disconnect the batteries.

4. Attach a suitable lifting device to the cab step and remove the slack.

5. Remove the four capscrews and washers from the cab step and lower to the ground.

9. Remove the tw o cotter pins , washers and valv e plate hinge pins (4).

10. Disconnect, label, cap and plug all hydraulic hose connections and fittings.

11. Disconnect and label all electrical connections.

12. Remove the valve plate from the machine.

13. Service individual valve plate components as required. Refer to Section 8.7.2, “Main Control Valve.”

4.7.2 Valve Plate Installation

6. Support the valve plate (1) with a suitable lifting device.

7. From under the valve plate, remove the two capscrews and washers (2) securing the plate to the cab mount frame. Lower the valve plate.

8. Disconnect the two tethers (3) from the cab mounting frame.

1. Use a suitable lifting de vice to lift the valve plate into position under the cab.

2. Uncap and reconnect the previously labeled electrical and hydraulic hose connections. To properly reconnect all hydraulic conne ctions ref er, to Section 2.2, “Torque Charts.”

3. Replace the hinge plate pins, washers and cotter pins to secure the valve plate to the cab mount frame.

4. Reconnect the two tethers to the cab mount frame.

5. Lift the valve plate and secure with two capscrews and washers.

6. Attach a suitable lifting de vice to the cab step and lift into position under the cab.

7. Replace the four capscrews and washers securing the cab step. Torque the capscrews to 43 - 78 lb-f t (59 - 106 Nm).

8. Properly disconnect the batteries.

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Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5-2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.4 Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.5 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-7

5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-11

5.5.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . 5-12

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.6.1 Brake Disc Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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MU0611

FRONT AXLE

ASSEMBLY

FRONT

STEER ING

CYLINDER

FRONT DRIVE

SHAFT

REAR DRIVE

SHAFT

REAR STEERING CYLINDER

REAR AXLE

ASSEMBLY

STABILIZER

CYLINDER

SUPPORT

TRUNNIONS

FRAME SWAY

CYLINDER

SUPPORT

TRUNNIONS

5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.

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5.2 GENERAL INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information.

Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, et c.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace any damaged, worn, cracked, seized or otherwise improper parts that could affect the safe and proper functioning of th e mach ine , axles and drive shafts.

5.3 AXLE ASSEMBLIES

5.3.1 Axle Serial Number Plate

The front axle serial number plate is located on a mounting pad on the inboard portion of the right beam trumpet. The rear axle serial nu mber plate is located on a mounting pad on the inboard portion of the left trumpet. Information on the serial number plate is required in correspondence regarding the axle.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.2 Axle Specifications

General axle specifications are found in Section 2.4, “Fluid and Lubricant Capacities.”

5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle, differential, brakes and wheel-end sa fe ty, re pa ir , disassembly, reassembly, adjustment and troubleshooting information) are provided in th e appropriate ZF Axle Repair Manual.

Machine ZF Model Axle P/N

944E MS-T 3060 II Front 31200695 944E MS-T 3055 II Rear 31200694

5.3.4 Axle Maintenance

CLEANING: Clean parts with machined or ground

surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and th e interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.

DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinn ing them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemica l to help protect them from corrosion. I f storing components for a prolonged period, wrap them in wax paper.

PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.

SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary.

Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly . I f replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.

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MU6790

5.3.5 Axle Replacement

c. Axle Removal

The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the re ar axle has neither. The following steps outline a t ypical axle removal procedure, suitable for either th e front or the rear axle assembly.

Cleanliness is extremely important. Before att empt ing to remove the axle, thoroughly clean the machine. Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning.

Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

2. Place a Do Not Operate Tag on both the igniti on key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batteries.

6. Label, disconnect and cap the steering and brake lines at the axle. Cap all fittings to prevent dirt & debris from entering the hydraulic system. Wipe up any spilled oil.

7. Block the front and rear of both tir es on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding.

8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.

9. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.

10. Remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.5.1, “Removing Wheel and Tire Assembly fr om Machine.”)

Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel.

11. Remove the drive shaft assemb ly. Refer to Section

5.4.3, “Drive Shaft Removal.”

5. If the axle will be disassembled after removal, place a suitable receptacle under the axle drain plug (1). Remove the dr ain plug a nd allo w the a xle oil to dr ain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

5-4

12. Remove the capscrew and locknut securing the lower position cylinder-mount pin (2) to the cylinder. Tap the cylinder mount pin ou t, an d move the cylinder to prevent it from interfering with axle removal.

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MT0822

1 1

Note: The axle will oscillate freely when the cylinder mounting pin is removed.

13. Remove the four ca pscrews, locknuts and hard en ed washers (3) securing the front or rear axle supports (rotating trunnions) to the frame.

Note: Remove the capscrews at equal intervals to avoid binding.

14. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine .Place the axle on a suitable support or holding stand.

5.3.6 Axle Installation

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise the machine using a suitable jack or hoist. Place suitable support s bene a th th e frame and lower the machine onto the supports, allowing enough room for axle installatio n. Ensure that the machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.

Note: AL W AYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening.

Note: If you are installing the rear axle it may be easier to install the capscrews if the transfer carriage was moved all the way forward.

4. Position the axle under the frame, and align the support trunnion holes with the holes in the frame.

5. Coat the capscrews (3) with anti-seize compound. Install the capscrews, locknuts and hardened washers securing the axle supports to the frame. Torque capscrews to 600 - 680 lb-ft (813 - 922 Nm).

Note: If new frame sway (front) or stabilizer (rear) cylinder bearings (4) have been installed in the axle, the fracture (5) in the bearing race must be po sition ed a t t he 9 o’clock or 3 o’clock position as shown below.

6. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin (2) through the cylinder and cylinder anchor. Secure the cylindermount pin with one capscrew and new locknut.

7. Apply multi-purpose grease through the se lf- tapp ing lube fitting to lubricate the self-align bearing and the cylinder-mount pin.

8. Install the drive shaft assemb lies. (Refer to Section

5.4.5, “Drive Shaft Installation.”)

9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yok e on the axle in the same pla ne as the yoke on the transmission.

10. Install the wheel and tire assemblies. Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.”

11. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

12. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

13. Remove the blocks from the front and rear of both tires on the other axle.

machine.

14. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

Note: ALWAYS use new o-rings when servicing the

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15. Uncap and co nn ect the steering and brake lines at their axle fittings.

16. Check wheel end and hydraulic reservoir oil leve ls.

17. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes . Check f or h ydraulic leaks, a nd tighten or repair as necessary.

Note: The service brake circuit will need to bled after axle installation. Refer to Section 8.7.10, “Brake Test.”

18. Close and secure the engine cover.

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5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Axle and/or wheel end housings

filled with incorrect oil or oil lev el low.

2. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end housings and fill to correct level

with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

8. Axle housing damaged. 8. Replace damaged parts.

1. Universal joint(s) worn or damaged.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint assembly(ies) incorrectly

1. Repair or replace universal joints as needed.

2. Determine cause an d re pa ir as needed.

1. Tighten capscrews to correct torque.

tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft(s) damaged/ unbalanced.

2. Repair or replace universal joints as needed.

3. Replace drive shaft(s) as needed.

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Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the ZF Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).

7. Replace housing(s) as needed.

5. Oil leaking from wheel end housing (planet carrier).

6. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

1. Hose fittings loose. 1. Tighten fittings.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

41 lb-ft (55 Nm).

2. Replace o-rings and seals.

3. Replace piston rod seal.

5-8

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Page 81

Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with

Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

2. Drain axle and fill to correct lev el

with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

3. Worn or damaged swivel bearings.

9. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

10. Excessive noise when brakes

1. Brake discs worn. 1. Check brake discs for wear.

are engaged.

3. Replace swivel bearings as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Repair or replace steering cylinder as needed.

Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

12. Brakes will not hold the

1. Brake discs worn. 1. Check brake discs for wear.

machine or braking power reduced.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Replace o-rings and seals.

Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Replace o-rings and seals.

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5-9

Page 82

Axles, Drive Shafts, Wheels and Tires

MT0350

To Axle

To Transmission

5.4 DRIVE SHAFTS

5.4.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduc t a visua l inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later.

Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Atte mpt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.

Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.

5.4.2 Drive Shaft Maintenance

Refer to Section 2.4, “Fluid and Lubricant Capacities.” for information regarding the lubrication of the grea se fittings on the drive shafts.

5.4.3 Drive Shaft Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lev er in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the igniti on key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Block the wheels.

6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibr ation.

7. Remove the four bolts (1) and two straps (2) securing the bearing cross to the transmission output shaft flange. Discard bolts.

8. Remove the four bolts (3) and two straps (4) securing the bearing crosses to the axle. Discard bolts.

9. Remove the front drive shaft assembly.

10. Repeat the above procedure on the rear drive shaft.

5.4.4 Drive Shaft Cleaning and Drying

1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

2. Remove and burrs or rough spots from all machined surfaces. Re- clean and dry as required.

5.4.5 Drive Shaft Installation

1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal.

Note: The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

2. Apply Loctite

3. Install the two straps (2) and four new bolts (1) securing the bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm).

4. Install the two straps (4) and four new bolts (3) securing the bearing crosses to the axle. Torque bolts to 55-60 lb-ft (75-81 Nm).

5. Repeat the above procedure on the rear drive shaft.

6. Properly connect the battery.

7. Close and secure the engine cover.

8. Unblock the wheels.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

242™ to all mounting bolts.

5-10

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Page 83

5.5 WHEELS AND TIRES

MY4190

WARNING

Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over.

It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, It is recommended that replacement tires have the following characteristics:

• Equal or greater ply/load rating and size of original.

• Tire tread contact width equal or greater than

original.

• Wheel diameter, width and offset dimensions equal to the original.

• Approved for t he application b y the ti re manuf acturer (including inflation pressure and maximum ti re load).

The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability.

Foam filled tires have a positive effect on the weight, stability and handling characteristics of the machine, especially under load. The use of hydrofill as a tire-fill substance is not recommended because of possible environmental impact.

Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used if a tire does not provide an airtight seal. Check tire inflation pressures when the tires are cold. When mou nt ing a t ire on the wheel, the tire must be mounted on the wheel respective of the directional tread patter n of the tire ; th is produces a left or right tire and wheel assembly.

Axles, Drive Shafts, Wheels and Tires

The wheel and tire assemblies must be installed with the directional tread pattern “arrows” (5) facing in the direction of forward travel.

5.5.1 Removing Wheel and Tire Assembly from Machine

1. Park the machine on a firm, le vel surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place an Do Not Operate Tag on both the ignition key swit ch and steering wheel, stating that the machine should not be operated.

3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.

5. Lower the machine onto the support.

6. Remove lug nuts and lug washers in an alternating pattern.

7. Remove the wheel and tire assembly from the machine.

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5-11

Page 84

Axles, Drive Shafts, Wheels and Tires

MAH0460

Tread “arrows” must point

forward

Install tires onto wheels to

rotate in proper direction

MY4200

OU0742

5.5.2 Installing Wheel and Tire Assembly onto Machine

Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

7. Drive the machine and aggressively steer and brake several times. Re-torque the lug nuts.

5.6 BRAKES

5.6.1 Brake Disc Inspection

Check the brake disks for wear every 1,000 hours of operation or yearly.

For more information on brake disc inspection, refer to the appropriate axle repair manual.

a. Front Axle

1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.

2. Remove the four capscrews securing the valve plate cover to the cab floor. Remove the cover.

1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.

3. Start all nuts by hand to prev ent cr oss threading. DO NOT use a lubricant on threads or nuts.

4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 430-470 lb-ft (583-637 Nm).

5. Remove machine from supports.

5-12

to the park brake gauge port (1) on the secondary function manifold (2) mounted on the valve plate.

Note: DO NOT turn the key switch to the ON position. DO NOT release the parking brake switch. Oil pressure

3. Attach a remote portable hydraulic pressurizing unit

will be lost and parking brake will be engaged.

CAUTION

DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Applying to much pressure may damage the brake seals.

4. Pressurize the parking brake with the pressurizing unit. Close the needle valve on the pressurizing unit.

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Page 85

5. Working through the level plug hole (3), carefully use

MT2851

MT2841

a screwdriver to spread the brake discs apart.

Axles, Drive Shafts, Wheels and Tires

b. Rear Axle

1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.

2. Working through the le ve l plug hole (3), carefu lly use a screwdriver to spread the brake discs apart.

Note: DO NOT damage the surfaces of the brake discs when spreading the brake discs.

3. Using a feeler gauge , chec k the gap (4) betw een the brake discs (5). If the gap is greater than 0.143 in. (3,65 mm), replace the brake discs.

Note: DO NOT damage the surfaces of the brake discs when spreading the brake discs.

6. Using a feeler gauge, chec k the gap ( 4) between the brake discs (5). If the gap is greater than 0.185 in. (4,7 mm), replace the brake discs.

Note: If the brake discs and worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time.

7. Repeat steps 4 and 5 for the other side of the axle.

8. Fill the axle with Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46) through the axle fill hole until the oil level is even with both axle level holes. Fill the axle slowly, allow time for the oil to run across the differential.

9. Reassemble the level plugs using new o-rings.

10. Install the axle fill plug into axle housing.

11. Remove the remote portable hydraulic pressurizing unit from the port.

Note: If the brake discs and worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time.

4. Repeat steps 4 and 5 for the other side of the axle.

5. Fill the axle with Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46) through the axle fill hole until the oil level is even with both axle level holes. Fill the axle slowly, allow time for the oil to run across the differential.

6. Reassemble the level plugs using new o-rings.

7. Install the axle fill plug into axle housing.

5.7 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power. Towing the machine improperly can result in damage to the machine drivetrain.

Note: In the event the machine is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual ba sis. Contact your local Authorized distributor for specific instructions for your particular situation.

If it is necessary to tow the machine a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the work site or o n a roadway, prepare the machine for towing as follows:

1. Remove the load from the machine.

2. Fully retract the transfer carriage.

3. Fully retract the boom. Position the forks approximately 24 in (607 mm) above the ground. Refer to Section 3.9, “Eme rgency Boom Lowering,” if needed.

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Page 86

Axles, Drive Shafts, Wheels and Tires

OU0742

WARNING

BLOCK ALL FOUR WHEELS. Failure to do so could

result in machine roll-away.

4. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.

5. Position the towing vehicle in place. Attach a rigid tow bar to the disabled machine.

12. Watch the pressure gauge on the pressurizing unit to ensure that the pressure in the park brake system does not drop during the towing oper ation.

13. Remove the blocks from the wheels. SLOWLY tow the machine to a secure location.

14. When towing is comple te d, re m ove the pressur izing unit and replace the cab floor.

6. Remove the cover (1) from the cab floor to gain access to the valve plate under the cab.

7. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (2) on the accumulator charge/secondary function valve (3) located under the cab floor.

8. Clear the area of all unnecessary personnel.

9. Have an operator seated in the machine.

10. Turn the key switch to the ON position (with the engine not running), release the park brake (park brake switch off).

11. Pressurize the park brake with the pressurizing unit. DO NOT exceed 650 psi (45 bar). Close the pump

needle valve on the pressurizing unit.

CAUTION

DO NOT exceed 650 psi (45 bar) when pressurizing the park brake. Applying to much pressure may damage the brake seals.

5-14

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Page 87

Section 6

Transmission

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5

6.4.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.4.4 After Transmission Service or Replacement. . . . . . . . . . . . . . . . . . . . . . . 6-6

6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.5.1 Transmission Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 Transfer Case Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.7 Transfer Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.7.1 Transfer Case Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.8 Transfer Case Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.9 Transfer Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.10 Transfer Case Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.10.1 Transfer Case Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.10.2 Transfer Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.11.1 Transfer Case Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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Page 88

Transmission

MU7290

OUTLET

(TRANSMISSION)

HOSE

OIL FILTER

INLET

(TRANSMISSION)

HOSE

DIPSTICK AND

FILL TUBE

RADIATOR/OIL

COOLER

INLET (COOLER)

HOSE

TORQUE

CONVERTER

OUTLET (COOLER)

HOSE

THERMAL

BYPASS VALVE

6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

6-2

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Page 89

Transmission

MT1071

6.4.1 Transmission Removal

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

6.2 TRANSMISSION SERIAL NUMBER

The transmission serial number plate is locat ed on the pump side (front) of the transmission at the bottom right toward the machine frame. Information specified on the serial number plate includes the transmission model number, the transmission serial number and other data. Information on the serial number plate is required in correspondence regarding the transmission.

6.3 TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION

For transmission, oil specifications and maintenance information, refer to Section 2, “G enera l I nfor mation an d Specifications.”

Detailed transmission service instructions are provided in the following publications:

• Service Manual (P/N 31200241)

• Parts Manual (P/N 8990462)

6.4 TRANSMISSION REPLACEMENT

Note: Contact the local distributor if internal transmission repair is required during the warranty period.

WARNING

NEVER lift a transmission alone; enlist the help of at

least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg).

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, r aise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate T ag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Temporarily bloc k up or support the boom.

4. Open the engine cover . Al low the system fl uids to cool.

5. Properly disconnect the batteries.

6. Remove the engine cover.

7. Remove the air cleaner assembly and cover the exposed intake to prevent dirt and debris from entering the engine.

8. Raise the machine up and place all four wheels on blocks so there is a minimum of 36 in. (914 mm) of clearance between the ground and the bottom of the engine pod.

9. Remove the engine-to- transmission and transmission-to-axle drive shafts. Refer to Section

5.4.3, “Drive Shaft Removal.”

Note: Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroug hly clean the exterior of the transmission to help prevent dirt from entering during the replacemen t process. A void spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.

10. Working through the engine flywheel inspection and access hole (1), remove the four hex head

944E-42

capscrews (2) securing the co nverter diaphragm to

6-3

Page 90

Transmission

MU7600

MU7610

MU6491

the engine flywheel. Use a engine baring tool or similar device, to prevent the flywheel from tur nin g while removing the capscrews.

11. Label and remove the transmission inlet hose (3) and transmission outlet hose (4) from the fittings on the transmission only. Cap and plug all fittings and hoses to prevent dirt and debris from contaminating the transmission fluid.

12. Remove the gear pump from the tr ansmission. Ref er to Section 8.6.3, “Pump Replacement,” for removal procedures.

13. Install a lifting ring to top of the transmission (5). Connect a lifting strap or chain to th e lifting ring on top of the transmission, and to a suitable hoist or overhead crane. Remove any slack prior to lifting, but DO NOT raise the transmission at this time. Connect another suitable lifting device to the lifting device on the flywheel en d of the engine. Remove the slack, but do not lift the engine.

14. Remove the twelv e hex bolts (6) securing the torque converter housing to the rear of the engine.

15. Label and disconnect the transmission shift solenoid wiring harness connectors on the transmission.

16. Remove all the capscrews securing the shift valve body cover to the tr ansmission. Carefully remov e the cover and gasket. Watch for any check valve balls within the valve body.

17. Remove any wire ties or clamps as they relate to anchor points on the transmission.

18. Remove the six capscrews (6) securing the transmission to the transmission mount (7).

19. Remove the two transmission isolator mounts (8) from the transmission mount and the engine pod frame. Remove the mount from the engine.

20. Carefully separate the transmission and the engine. While separating the transmission from the engine, carefully lower the both th e eng ine and tr an smission at the same time.

21. Use the hoist connected to the transmission to lower the transmission down onto a skid and remove the transmission from under the engine pod.

22. Secure the transmission to a stand or other means to inspect and repair.

23. Remove any external transmission components as required, including temperature switch and fittings. Cover all openings.

24. Remove the transmission oil filter and dispose of properly. Clean the filter mounting surface. Cover or

cap the oil filter mount.

6-4

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Page 91

MU6501

WARNING

Risk of personal injury. The transmission may move while hoisting it out of the chassis. Carefully mov e the transmission and adjust the sling as needed. Keep fingers, hands, legs and other body par t s cl ea r of the transmission.

6.4.2 Transmission Inspection and Internal Repair

If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are in cluded with a new transmission.

6.4.3 Transmission Installation

1. Install the temperature switch and fittings.

2. Install new transmission filter and torque to 20-25 lb-ft (27-34 Nm).

3. Carefully position the transmission assembly under the engine pod.

4. Use a hoist or overhead crane and sling attached to the lifting eye (9) at the top of the transmission. Operate the hoist or crane to remove any slack prior to lifting, but DO NOT raise the transmission at this time.

5. Clean all mating surfaces on both the engine and transmission prior to assembly.

6. Operate the hoist or crane to lift and position the transmission against the flywheel housing. Raise or lower the rear of the engine as needed to align the transmission to the engine. Be careful not to lower the engine to the point where the fan will contact the radiator fins.

Transmission

7. Begin securing the transmission to the flywheel housing with twelve M10 x 1.5 x 45 mm hex head cap screws (10). Tighten the capscrews evenly, in stages, to insure that the transmission converter housing installs evenly against the engine transmission housing. When all the capscrews have been installed, torque to 39-45 lb-ft (54-61 Nm).

8. Position the tr ansmission mount plate (11) in place at the rear of the transmission.

9. Reinstall the two transmission isolator mounts (12). Install the 5/8-11 x 3-3/4 in. grade 8 cap screws from the top through the isolators. Secure in place with the lower isolator half, rebound washer and new elastic locknut. Torque to 106-191 lb-ft (14-259 Nm).

10. Line up the holes in the plate with the mounting holes in the transmission. Secure the mounting plate with six capscrews (13) and torque to 107-192 lb-ft (145-260 Nm).

944E-42

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Page 92

Transmission

MT1071

MU3851

11. Working through the engine flywheel inspection and access hole (14), install the four hex head capscrews (15) securing the converter diaphragm to the engine flywheel. Use a engine baring tool or similar device, to prevent the flywheel from tur nin g while installing the capscrews.

12. Install the shift valve body cover (16). Be sure the gasket remains in place and secure with capscrews. Torque to 84 lb-ft (9,5 Nm).

13. Install the gear pump from the transmission. Refer to Section 8.6.3, “Pump Replacement,” for installation procedures.

14. Reconnect the wire harness connectors to the solenoids (17) on the transmission. Snap the connectors all the way onto the solenoids.

15. Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmission. Torque all fittings as specified in Section 2.2, “Torque Charts.”

16. Transmission oil may be added through the dipstick

tube. Remove the dipstick and add Mobilfluid 424 (ISO Grade 46). Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

17. Install the engine-to-transmission and transmissionto-axle drive shafts. Refer to Section 5.4.5, “Drive Shaft Installation.”

18. Install the previously removed air cleaner assembly and reconnect the wire harness to the air intake sensor.

19. Install the engine cover.

20. Carefully remove the blo cks f rom under the mach ine wheels and lower to the ground.

21. Properly connect the batteries.

22. Close and secure the engine cover.

6.4.4 After Transmission Service or

Replacement

In general:

1. Check the transmission oil level and add oil as required.

2. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning.

3. Drain and flush the entire transmission cooling system.

4. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

5. Reassemble all components and fill the transmission with clean, fresh Mobilfluid 424 through the dipstick tube opening (19). Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT o v erfill. Reinstall the dipstick when finished.

6. Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines.

7. Recheck the le vel of the fluid in the tra nsmission with the engine running at idle.

8. Add Mobilfluid 424

(ISO Grade 46) as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil le ve l when it reaches operating temperature 180-200° F (83-94° C).

9. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

(ISO Grade 46)

6-6

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Page 93

6.5 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission.

Note: Contact your local authorized Service Department if internal transmission repair is required during the warranty period.

6.5.1 Transmission Troubleshooting

The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Problem Cause Remedy

Transmission

1. Transmission will not engage or will not shift properly.

1. Oil level too high or low. 1. Fill transmission to correct level with Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”)

2. Travel select lever not

functioning properly and/or a fault in the wiring harness.

3. Transmission valve body

solenoids not functioning properly.

4. Pilot-operated shift valves not

operating properly.

5. Pump output pressure low. 5. Refer to Section 6.5.1,

6. Clutch piston o-rings damaged. 6. Replace o-rings.

7. Clutch discs worn or damaged. 7. Replace clutch discs.

2. Refer to Section 9.5, “Electrical Schematics.”

3. Refer to Section 9.5, “Electrical Schematics.”

4. Clean the valve spoo l and housing. Replace return spring as needed.

“Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

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8. Coupling shafts or gear teeth damaged.

8. Replace couplings.

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Page 94

Transmission

6.5.1 Transmission Troubleshooting (Continued)

Problem Cause Remedy

2. Low or no pump flow or pressure.

1. Low oil level. 1. Fill transmission to correct level

with Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”)

2. T ransmission filled with incorrect oil, or oil contaminated.

2. Drain transmission and fill to correct level with Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”)

3. Pump suction pipe screen clogged.

3. Clean, repair and/or replace suction pipe.

4. Central shaft damaged. 4. Replace central shaft.

5. Pump worn or damaged. 5. Repair or replace pump assembly.

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level

with Mobilfluid 424 (ISO Grade 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Main pressure valve stuck open. 2. Clean the valve spool and housing.

3. Broken or worn coupling shaft or

3. Replace coupling and/or o-rings.

piston o-rings.

4. Pressure reducing valve stuck

open.

4. Clean the valve spoo l and housing.

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Low engine rpm causes converter stall.

2. Adjust the engine rpm to specifications. Refer to Cummins Service Manual.

3. Pump output pressure is low. 3. Refer to Section 6.5.1, “Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

4. Clutch discs worn or damaged. 4. Replace clutch discs.

5. Transmission overheating. 5. Refer to Section 6.5.1, “Transmission Troubleshooting,” Problem 5. “Transmission overheating (oil above 248° F (120° C)).”

6-8

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Page 95

6.5.1 Transmission Troubleshooting (Continued)

Problem Cause Remedy

Transmission

5. Transmission overheating (oil above 248° F (120° C)).

6. Grinding or “clunking” noise from transmission.

1. Low oil level. 1. Fill transmission to correct level

with Mobilfluid 424 (ISO Grade 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Clogged radiator. 2. Remove debris from the radiator.

3. T ransmission filled with incorrect

oil, or oil contaminated.

3. Drain transmission and fill to correct level with Mobilfluid 424 (ISO Grade 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

4. Excessive “roading.” 4. Stop and idle the engine.

5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

6. Pump worn or damaged. 6. Repair or replace pump assembly.

7. Engine thermostat stuck. 7. Replace engine thermostat.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. T ransmission filled with incorrect

oil.

2. Drain transmission and fill to correct level with Mobilfluid 424 (ISO Grade 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

3. Incorrect clutch engagement . 3. Refer to Section 9.11.8, “Transmission Solenoid Valves.”

4. Internal damage. 4. Repair or replace parts as needed.

5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate). Refer to Section 6.4.1, “Transmission Removal.”

6. Loose diaphragm (flex plate)

6. Tighten capscrews.

mounting capscrews.

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Page 96

Transmission

6.5.1 Transmission Troubleshooting (Continued)

Problem Cause Remedy

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil

level).

2. Drain plug loose and/or o-rings damaged or missing.

3. Hose fittings loose. 3. Tighten fittings.

4. Oil leaking at valve b odies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight).

5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft

6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight).

7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage).

1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm).

4. Replace gaskets and/or tighten capscrews to 7 lb-ft (9,5 Nm).

(46 Nm).

6. Replace o-rings and/or tighten capscrews to 85 lb-ft (115 Nm).

7. Replace converter and/or input shaft seal.

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8. Oil leaking at output shaft (output shaft seal damaged).

9. Housing damaged. 9. Replace housing as needed.

8. Replace output shaft seal.

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Page 97

6.6 TRANSFER CASE COMPONENT

MU1071

REAR AXLE

OUTPUT SHAFT

ENGINE SUPPORT

STRUCTURE

(REFERENCE)

TRANSMISSION

ASSEMBLY

TRANSFER CASE

ASSEMBLY

FRONT AXLE

OUTPUT SHAFT

TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section. It is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the transfer case. The following illustration identifies the components that are referred to throughout this section.

Transmission

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Page 98

Transmission

MU1081

6.7 TRANSFER CASE

6.7.1 Transfer Case Description

The ZF Model TB92-I4 transfer case is a single speed, mechanical unit designed for heavy duty commercial use. The transfer case is located beneath the frame of the machine, mounted directly to the transmission.

6.8 TRANSFER CASE SERIAL NUMBER

The ZF serial number plate (1) is riveted to the front of the transfer case above the breather (2). Information specified on the serial number plate includes Type (TB92-I4), Serial Number, ZF reference number, Oil Specification (oil type) and Ratios (final gear ratio, 1: 1). Write this information down in a convenient location to use in a transfer case correspondence.

6.10 TRANSFER CASE REPLACEMENT

Note: Contact your local authorized service distributor if internal transfer case repair is required during the warranty period.

Note: To help ensure safety and optimum performance, replace the transfer case if it is damaged. Refer to the appropriate parts manual for ordering information.

Cleanliness is of extreme importance. Before attempting to remove the transfer case , thoroughly clean the ext erior of the case to help prevent dirt from enterin g during the replacement process. Avoid spraying water or cleaning solution onto or near electrical components.

6.9 TRANSFER CASE MAINTENANCE

Information regarding checking the transfe r case oil level and /or changing the transfer case oil is located in Section 2, “General Information and Specifications.”

Detailed transfer case service instructions covering repair, disassembly, reassembly, adjustment and troubleshooting information is provided in the ZF Model TB92-I4 Transfer Case Operating and Repair Manual,

JLG P/N 8990495 (ZF P/N 5871.134.022).

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Page 99

Transmission

MU6800

MU1131

6.10.1 Transfer Case Removal

WARNING

NEVER lift a transmission alone; enlist the help of at

least one assistant or use a suitable hoist or overhead crane and sling with a minimum lifting capacity of 1000 lb (454 kg).

Note: This operation can be performed with the transmission/transfer case still attached to the power train.

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Temporarily block up or support the boom.

4. Open the engine cover. Allow the system fluids to cool.

5. Properly disconnect the batteries.

6. Remove the engine-to- transmission and transmission-to-axle drive shafts. Refer to Section

5.4.3, “Drive Shaft Removal.”

7. Connect a lifting strap or chain to the transfer case and to a suitable hoist or overhead crane. Remove any slack prior to lifting.

9. Carefully pull the transfer case back from the transmission approximately 3 inches to f ully disengage the splined output shaft (4). Once clear, lower the transfer case and remove it from the machine.

6.10.2 Transfer Case Installation

1. Connect a lifting strap or chain to the transfer case and to a suitable hoist or overhead crane. Raise the transfer case into position (make certain that the alignment dowel pin is located in t h e corre ct transfer case hole (5).

2. Align the dowel pin (5) of the transfer case with the hole in the transmission and also the input spline of the transfer case with the output shaft of the transmission. Carefully press the transfer case onto the output shaft until the mating surfaces of both cases meet.

3. Install the fourteen capscrews (2-rear/long, 12-front/short) and torque to 140 lb-ft (190 Nm).

4. Refer to Section 5.4.5, “Drive Shaft Installation,” for installation of the drive shafts.

5. Properly connect the batteries.

6. Close and secure the engine cover.

8. Remove the f ourteen capscrews (2 -rear, 12-front)(3) securing the transfer case to the transmission.

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Transmission

6.11 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that may occur during operation of the transfer case.

Note: Contact your local authorized Service Departmen t if internal transfer case repair is required during the warranty period.

The transfer case should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component.

6.11.1 Transfer Case Troubleshooting

Problem Cause Remedy

1. Excessive transfer case noise.

1. Oil level too low. 1. Fill transfer case to correct level

with Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”)

2. Transfer case filled with incorrect oil.

2. Drain transfer case and fill to correct level with Mobilfluid 424 (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”

3. Excessive bearing “end play”. 3. Check bearing end play and correct with shims as needed.

4. Worn or damaged bearings. 4. Replace bearings as needed.

5. Worn or broken gear teeth. 5. Replace gears as needed.

6. Contamination in transfer case. 6. Check for foreign particles.

7. Incorrect assembly of parts. 7. Check assembly of transfer case components.

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