Service Manual Model 944E-42 S/N 0160041827 & After 31200355 Original December 31, 2011 An Oshkosh Corporation Company
EFFECTIVITY PAGE December 31, 2011 - A - Original Issue 31200355 944E-42 i
EFFECTIVITY PAGE -ii 944E-42 31200355
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
Section Subject Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Page 5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section Subject Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 Page 9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . .
Section iv Subject Page 944E-42
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 944E-42 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS 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. 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.
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 occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.
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.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 944E-42 TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 1 OU0221 Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure. 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.
General Information and Specifications 2.2 2.2.1 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry) Tensile Clamp Load Stress Area Torque Lubricated Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque (Dry or Loctite® 263) K= 0.20 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K=.18 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Magni Coating* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Loctite® Torque Loctite® 262™ 242™ or 271™ OR OR Vibra-TITE™ 131 Vibra-TITE™ 111 or 140 [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.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque Dry or Loctite® 263™ K = 0.20 Sq mm KN [N.m] Torque Lube OR Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K= 0.18 Torque Loctite® 262™ OR Vibra-TITE™ 131 [N.m] [N.m] K=0.15 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Magni Coating* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Clamp Load See Note 4 Sq mm kN Torque Lube OR Loctite® Torque Torque Dry 242™ or 271™ Loctite® 262™ or OR OR Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131 111 or 140 K = .17 K = .16 K = .15 [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 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.
General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 6 23 lb-ft (31 Nm) 23 lb-ft (31 Nm) 1 to 1.5 8 40 lb-ft (54 Nm) 40 lb-ft (54 Nm) 1.5 to 1.75 10 60 lb-ft (81 Nm) 60 lb-ft (81 Nm) 1.5 to 1.75 12 74 lb-ft (100 Nm) 85 lb-ft (115 Nm) 1.0 to 1.5 16 115 lb-ft (156 Nm) 115 lb-ft (156 Nm) 0.75 to 1.0 20 170 lb-ft (230 Nm) 170 lb-ft (230 Nm) 0.
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) minimum, engine at operating temperature.
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 in3 (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 2.3.
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 Type of Coolant 7.
General Information and Specifications Air Conditioning System (if equipped) System Capacity Type of Fluid 2.5 lb (1134 g) Refrigerant R-134a - Tetrafluorethane Window Washer Bottle Capacity 2-14 2.
General Information and Specifications 2.5 2.5.
General Information and Specifications 2.5.
General Information and Specifications 2.5.
General Information and Specifications 2.6 LUBRICATION SCHEDULES a.
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 944E-42 TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section.
Boom 3.2 3.2.1 BOOM SYSTEM 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 boom section and the rear of the first boom section, begins to extend, it forces the second boom section out of the first boom section.
Boom 5. Loosen the extend chain locknut (2) at 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 any trapped pressure in the system. Move the auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the system. 8.
Boom 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 plate inside the boom head.
Boom 10 13 MU1061 MU5061 30. Remove the hydraulic hose rack (13) inside the third boom section. 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.” 11 12 MU0261 29. At the rear of the third boom section, disconnect the retract chain (11) from the anchor link (12).
Boom 3.3.2 Second Boom Section Removal 1. At the front of the first boom section, remove the top and side wear pads. Label all parts for installation. 15 16 14 MU4171 MU1221 7. At the rear of the second boom section, remove the two hose guides (16). 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.
Boom 3.3.3 First Boom Section Removal 18 1 MU0341 MU1411 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 19 MU0281 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.
Boom 9. Use a suitable overhead lifting device and sling to support the boom. 3 5 6 MU0351 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.
Boom 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. 4 5 6 MU0371 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.
Boom 11. Install the boom proximity sensor. The gap between 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. 8 3.3.5 Second Boom Section Installation 1. Install the top, side and bottom wear pads to the rear of the second boom section. 2.
Boom 2. Place the extend chain and clevis, as an assembly on top of the third boom section and allow the chains and clevis to overhang the boom head. DO NOT allow the chain to twist or kink. 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 boom section. Remove the sling. 10 13 11 MU1211 MU0261 3.
Boom 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. 15 20.
Boom 3.4 19 3.4.1 BOOM EXTEND AND RETRACT CHAINS 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. 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.
Boom • Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye. Edge Wear Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.
Boom Cracked Plates Distorted or Battered Link 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. 85 It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
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.
Boom 5. Return to the cab, start the engine and cycle the boom all the way out and all the way in several times. 1 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 and the top of the second boom section at their closest point. Acceptable boom 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 readjusted.
Boom a. Component/Assembly Verification 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. 3 2 MU1411 MU0411 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.
Boom 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 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. Note: Chains and clevis’ are wear items and experience the same stress.
Boom 5. At the front underside of the boom, record the amount of threads extending beyond the locknut. This measurement will be the starting point for adjustment of the boom retract chain. 9 11 MU1211 8. Disconnect the retract chain yoke (11) from the rear of the third boom section. Lay the chain assembly flat behind the boom. MU1411 6. Remove the locknut (9) and washer securing the retract chain to the boom. 10 9. From the rear of the boom, pull the retract chain out of the boom.
Boom 3.5 BOOM WEAR PADS 5 5 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 1 1 MY5510 Ma2070 Inspect all wear pads for wear. If the angle indicators (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 pads as a set if worn or damaged. 3.5.
Boom 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 9 3 6 10 7 5 4 6 8 2 1 7 MU7660 3.6.1 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.
Boom 3.8 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting Problem 1. Boom will not extend or retract. Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/Retract hydraulic system not operating properly. 2. Refer to Section 8.4, “Hydraulic Circuits.” 3. Faulty extend/retract cylinder. 3.
Boom Boom Troubleshooting (Continued) Problem 5. Drooping chain, or jerky boom extend or retract functions. 6. Boom will not raise or lower. 7. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 944E-42 Cause Remedy 1. Chain(s) tension not properly adjusted. 1. Adjust chain(s). 2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to Section 3.4, “Boom Extend and Retract Chains.” 3. Wear pads loose, contaminated, excessively worn or damaged. 3. Replace wear pad.
Boom Boom Troubleshooting (Continued) Problem 8. Rapid boom pad wear. 9. Auxiliary hydraulics will not operate. 10. Excessive chain wear. 3-26 Cause Remedy 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. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3.
Boom 3.9 3.9.1 EMERGENCY BOOM LOWERING 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.
Boom 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 available BOOM LIFT LINE (Lift Cylinder to Block or Block to Frame Bulkhead) BOOM LOWER LINE (Lift Cylinder to Block or Block to Frame Bulkhead) STEP 1 STEP 2 STEP 1 STEP 1 STEP 1 STEP 2 STEP 1 STEP 1 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.
Boom 3.9.5 Hydraulic Hose Replacement - Step 2 3 1 4 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.
Boom This Page Intentionally Left Blank 3-30 944E-42
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 4.6 4.7 944E-42 TITLE Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 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.
Cab and Covers 3. Open the engine cover. Allow the system fluids to cool. WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2 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. OPERATOR’S CAB 2 1 1 4.2.
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.
Cab and Covers 4.3.4 Throttle Pedal a. Throttle Pedal 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 steering wheel, stating that the machine should not be operated. 6 3. Properly disconnect the batteries. 9 7 5 MU3451 6. Disconnect the brake return spring (5). 7.
Cab and Covers 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”. 6 1.
Cab and Covers 4.3.6 Joystick Assemblies Refer to Section 8.7, “Valves and Manifolds,” for removal and installation instructions apply to the front, rear and frame sway joysticks. a. Joystick 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 parking brake and turn the engine OFF. 2.
Cab and Covers 4.4 4.4.1 ENCLOSED CAB (OPTIONAL) COMPONENTS Front Windshield Wiper Switch Refer to Section 9.12.1, “Dash Switches.” 4.4.2 Front Windshield Wiper Motor 5. Place a suitable container beneath the radiator drain plug or petcock. Slowly turn the radiator cap to the first stop, and allow any pressure to escape. Remove the radiator cap. 6. Place a funnel at the base of the radiator to channel the drained coolant into the container.
Cab and Covers 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 Assembly Installation 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 conditioning service technician.
Cab and Covers 8 3 1 2 7 MU4881 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. MU4891 9. Remove the right side console access panel (7).
Cab and Covers 13. Remove the four capscrews, washers and sheer pins (9) that secure the cab mount supports to the frame. 14. If equipped, remove 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 removed, carefully and slowly 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.
Cab and Covers 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 4.7.1 VALVE PLATE 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.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 944E-42 TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 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.
Axles, Drive Shafts, Wheels and Tires 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.
Axles, Drive Shafts, Wheels and Tires 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 rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly. Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machine.
Axles, Drive Shafts, Wheels and Tires Note: The axle will oscillate freely when the cylinder mounting pin is removed. 13. Remove the four capscrews, locknuts and hardened washers (3) securing the front or rear axle supports (rotating trunnions) to the frame. Note: Remove the capscrews at equal intervals to avoid binding. 5. Coat the capscrews (3) with anti-seize compound. Install the capscrews, locknuts and hardened washers securing the axle supports to the frame.
Axles, Drive Shafts, Wheels and Tires 15. Uncap and connect the steering and brake lines at their axle fittings. 16. Check wheel end and hydraulic reservoir oil levels. 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 for hydraulic leaks, and tighten or repair as necessary. Note: The service brake circuit will need to bled after axle installation. Refer to Section 8.7.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 944E-42 Cause Remedy 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 level low. 2.
Axles, Drive Shafts, Wheels and Tires Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. 5-8 Cause Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Hose fittings loose. 2. Tighten fittings. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
Axles, Drive Shafts, Wheels and Tires Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 944E-42 Cause Remedy 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.
Axles, Drive Shafts, Wheels and Tires 5.4 DRIVE SHAFTS To Transmission 5.4.1 Drive Shaft Inspection and Service Whenever servicing the machine, conduct a visual 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. Attempt to turn each drive shaft in both directions.
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 5 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.
Axles, Drive Shafts, Wheels and Tires 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 Tread “arrows” must point forward 5.6.
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 level plug hole (3), carefully use a screwdriver to spread the brake discs apart. MT2851 3 5. Working through the level plug hole (3), carefully use a screwdriver to spread the brake discs apart. Note: DO NOT damage the surfaces of the brake discs when spreading the brake discs.
Axles, Drive Shafts, Wheels and Tires 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 operation. 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. 13. Remove the blocks from the wheels. SLOWLY tow the machine to a secure location. 14.
Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 944E-42 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications And Maintenance Information . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.
Transmission 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.
Transmission 6.4.1 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 located 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.
Transmission the engine flywheel. Use a engine baring tool or similar device, to prevent the flywheel from turning while removing the capscrews. 4 14. Remove the twelve 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 transmission. Carefully remove the cover and gasket.
Transmission WARNING Risk of personal injury. The transmission may move while hoisting it out of the chassis. Carefully move the transmission and adjust the sling as needed. Keep fingers, hands, legs and other body parts clear of the transmission. 10 9 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 included with a new transmission. 6.4.
Transmission 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. 14 17. Install the engine-to-transmission and transmissionto-axle drive shafts. Refer to Section 5.4.5, “Drive Shaft Installation.” 18.
Transmission 6.5 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Note: Contact your local authorized Service Department if internal transmission repair is required during the warranty period. 6.5.
Transmission 6.5.1 Transmission Troubleshooting (Continued) Problem 2. Low or no pump flow or pressure. 3. Low clutch pressure. 4. Lack of power. 6-8 Cause Remedy 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. Transmission 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.
Transmission 6.5.1 Transmission Troubleshooting (Continued) Problem 5. Transmission overheating (oil above 248° F (120° C)). 6. Grinding or “clunking” noise from transmission. 944E-42 Cause Remedy 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. Transmission filled with incorrect oil, or oil contaminated. 3.
Transmission 6.5.1 Transmission Troubleshooting (Continued) Problem 7. Oil leaking from transmission. 6-10 Cause Remedy 1. Oil leaking from vent (high oil level). 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. Drain plug loose and/or o-rings damaged or missing. 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3.
Transmission 6.6 TRANSFER CASE 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 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 6.7 6.7.1 TRANSFER CASE 6.10 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 1 TRANSFER CASE REPLACEMENT Note: Contact your local authorized service distributor if internal transfer case repair is required during the warranty period.
Transmission 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). 9. Carefully pull the transfer case back from the transmission approximately 3 inches to fully disengage the splined output shaft (4). Once clear, lower the transfer case and remove it from the machine. 6.10.
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 Department 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.
Transmission 6.11.1 Transfer Case Troubleshooting (Continued) Problem 2. Oil leaking from transfer case. Cause Remedy 1. Breather blocked. 1. Clean or replace breather. 2. Plugs or fittings loose. 2. Tighten plugs or fittings. 3. Incorrect oil level. 3. Fill transfer case to correct level with Mobilfluid 424® (ISO Grade 46). (Refer to Section 2.4, “Fluid and Lubricant Capacities.”) 4. Gaps in sealant between housing halves. 4.
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Section 7 Engine Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 944E-42 TITLE Introduction - Cummins QSB 4.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 7.1 7.1.1 INTRODUCTION - CUMMINS QSB 4.5 Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine 7.1.2 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 engine components. The following illustration identifies the components that are referred to throughout this section.
Engine 7.2 ENGINE SERIAL NUMBER The Cummins QSB 4.5 serial number is stamped on a plate which is typically located on the engine rocker cover, but may be located on the side of the gear housing. Information contained in the serial number is required in correspondence with the engine manufacturer. 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. Open the engine cover. Allow the system fluids to cool. 4.
Engine 7.5 ENGINE ELECTRICAL SYSTEM 11 7 8 The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, “Electrical Schematics.” 7 7.6 8 7.6.1 FUEL SYSTEM Diesel Fuel Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair. MU7380 12.
Engine position, engage the parking 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. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank. Note: Have a dry chemical (Class B) fire extinguisher near the work area.
Engine f. Fuel Tank Installation 1. Set the fuel tank on to the tank support. 2. Secure the fuel tank retaining panel with the two previously removed capscrews. Torque to 38-59 lb-ft (50-80 Nm). 3. Install the fuel tank drain plug (3/8 in. NPT square head). 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. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 1 4.
Engine 2. Install the flex pipe (3) and secure with clamp (8). 3. Install the exhaust pipe (2) and secure with clamps (7 & 8). 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 4. Align the elbow portion of the exhaust pipe (2), so the pipe is parallel with the frame of the machine. 3. Open the engine cover. Allow the system fluids to cool. 5. Install the muffler bracket to the frame.
Engine 7.9 7.9.1 ENGINE REPLACEMENT Engine Removal Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.4, “Engine Cooling System.” Several additional components must be removed before engine removal. They will be addressed in the following procedures. 1.
Engine 9 6 7 4 MU2081 22. Remove the engine frame skirt (4) to gain access to the hydraulic reservoir. 8 MU7410 25. Disconnect the connector harness at the return oil filter pressure switch (6). 26. Remove the hydraulic reservoir (7), sliding the tank out from under the engine and away from the engine mount frame (8). 27. Disconnect and remove the transmission hoses. Cap all fittings and openings to keep dirt and debris from entering the system. 28. Remove the reservoir retainer assembly (9). 5 29.
Engine 31. Connect a suitable engine hoist to the front engine lift bracket (11) and the transmission lifting bracket (10). 32. Remove the two elastic locknuts, washers, lower half isolators and capscrews securing the engine mounts to the frame (front). 33. Remove the two elastic locknuts and washers securing the transmission mount to the frame (rear). 34. Carefully lift the engine/transmission assembly out and away from the machine 35. Place engine on ground supports or a suitable engine stand. 36.
Engine Note: Torque all fittings as specified in Section 2.2, “Torque Charts.” 23. Properly connect the batteries. 24. Refill hydraulic reservoir with clean hydraulic oil and check for leaks. 25. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected tightly. Note: Have an assistant stand by with a Class B fire extinguisher. 26. Start the engine and run to normal operating temperature then shut off the engine.
Engine 7.
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Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 944E-42 TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present.
Hydraulic System 8.3 HYDRAULIC PRESSURE DIAGNOSIS Two kits are available to use for hydraulic system maintenance and troubleshooting. The kit is contained in a durable polyethylene carrying case for demanding field service conditions. Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system. The kit includes: • Gauges for testing high and low pressure circuits 8.3.
Hydraulic System 7. Check the pressure gauge reading. It should read as specified in the Pressure Readings column of the charts found in Section 8.4.1, “Hydraulic Pressures.” If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly. 8.
Hydraulic System c. Hydraulic Testing - Dual Joysticks AUXILIARY HYDRAULICS FRONT AXLE ATTACHMENT TILT CYLINDER FRONT STEERING CYLINDER E FRAME SWAY CYLINDER R FTR FTB Ø .041 7 P A P A TRANSFER CYLINDER Ø .
Hydraulic System Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . 950 rpm Full Speed . . . . . . . . . . . . . . . . . . . 2500 rpm Hydraulic Oil Information Oil Type - 10W, meet ISO Grade 46 Capacity - Reservoir . . . . . . 34 gal. (127 liter) Capacity - System . . . . . . . 50 gal. (190 liter) Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
Hydraulic System TEST TEST Valve ADJUST. COMPONENT SEQUENCE LOCATION Port LOCATION DESCRIPTION 8 9 8-8 2 2 — — D Auxiliary Hydraulics PRESSURE READINGS PRESSURE TEST PROCEDURES 2,900-3,100 psi (200-214 bar) With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold over relief and check pressure. If pressure is incorrect, adjust or replace cartridge located in the auxiliary section of the main control valve.
Hydraulic System a. Hydraulic Testing - Single Joystick AUXILIARY HYDRAULICS FRONT AXLE ATTACHMENT TILT CYLINDER FRONT STEERING CYLINDER E FRAME SWAY CYLINDER R FTR FTB Ø .041 7 P A P A TRANSFER CYLINDER Ø .
Hydraulic System Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . . . . 950 rpm Full Speed . . . . . . . . . . . . . . . . . . . 2500 rpm Hydraulic Oil Information Oil Type - 10W, meet ISO Grade 46 Capacity - Reservoir . . . . . . 34 gal. (127 liter) Capacity - System . . . . . . . 50 gal. (190 liter) Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
Hydraulic System TEST TEST Valve ADJUST. COMPONENT SEQUENCE LOCATION Port LOCATION DESCRIPTION Auxiliary Hydraulics PRESSURE READINGS PRESSURE TEST PROCEDURES 2,900-3,100 psi (200-214 bar) With engine at high idle, use the auxiliary hydraulic control lever to check pressure to both male and female connectors. Hold over relief and check pressure. If pressure is incorrect, adjust or replace cartridge located in the auxiliary section of the main control valve.
8-12 REAR WHEEL BRAKE A A LSRV T P P 4 3 .039 .098 INLET/UNLOADER 0.031 BRIDGE DRAIN TRANSACTION 28 1A ACF ACR S2 PPG TA 1B TRANSACTION 0.02 TB EXTEND PBG 2A CV2 PIL .052 DIA. PR DRAIN 60 PSI AUX1 2B SV PB AUXILIARY 0.02 AUX2 FEMALE (RH) MALE (LH) SW .032 DIA. PD 3A RV .032 DIA. UP EF 1.8 CIR P FILTER EC 2 4A HOIST 0.02 HB 18 .052 DIA. EA 3B SW1 CV1 EXTEND 0.02 EB HOIST 1.4 CIR HA 4B 5A P1 LSG LS CF 1 FRAME TILT 0.
Hydraulic System 8.5 HYDRAULIC RESERVOIR FRONT 6. Transfer the used hydraulic oil into a suitable covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 8.5.2 Hydraulic Oil Reservoir Filling 1. Be sure the reservoir is clean and free of all debris. 2. Install a new hydraulic oil filter. 2 1 3.
Hydraulic System 5. Clean and reinstall the drain plug (1) into the reservoir. Torque the drain plug to 25-40 lb-ft (34-54 Nm). 6. Loosen the hose clamps and remove the lower section hydraulic suction hose (2). 6 7. Disconnect the hydraulic oil temperature switch connector (3). 7 8 MU7410 11. Disconnect the connector harness at the return oil filter pressure switch (6). 4 MU2081 8. Remove the engine frame skirt (4) to gain access to the hydraulic reservoir. 12.
Hydraulic System c. Cleaning and Drying 6. Uncap and install the lower hydraulic suction hose. If contaminated oil or foreign material is in the reservoir, the reservoir can usually be cleaned. 7. Fill the reservoir according to specifications. Refer to Section 2.4, “Fluid and Lubricant Capacities.” Note: If a leak is suspected in the reservoir, contact your local authorized Service Department. 8. Check reservoir for leaks. To clean the reservoir: 9. Properly connect the batteries. 10.
Hydraulic System 8.6 HYDRAULIC SYSTEM PUMP 8.6.1 Pump Description Hydraulic system pressure begins at the pump. Various factors are involved in creating the relatively high pressure used in the hydraulic system. Pump rpm, controlled via a transmission input shaft (and dependent on engine rpm), the internal pump passageways and the differential between pump inlet and outlet openings, all contribute to pressure supplied. For internal service instructions contact your local authorized service distributor.
Hydraulic System 2. Place the pump (2) and a new, oiled o-ring (3) into position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 8.7 3. Align the bolt holes with the pump mount holes. Secure the pump to the transmission with the previously used hardware. Torque the capscrews (4) to 69-78 lb-ft (94-106 Nm).
Hydraulic System 5. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding. 8.7.2 Main Control Valve 6 7 8 6. Label, disconnect and cap all hydraulic hoses attached to the main control valve, accumulator charge/secondary function valve and the pilot select valve. Place a suitable container to catch hydraulic fluid drainage from beneath the cab. 9 7. Remove the step assembly from the side of the cab. Refer to Section 4.5, “Cab Removal.
Hydraulic System 3. Remove the three capscrews (10) securing the main control valve to the valve plate. 4. Remove the main control valve from the valve plate by sliding the valve out between the valve plate and the bottom of the cab. b. Main Control Valve Disassembly 11 20 21 22 26 23 24 25 24 18 15 “B” 17 18 15 24 17 15 (MAIN RELIEF) 19 25 15 14 17 15 13 “A” MU4101 17 12 16 1.
Hydraulic System Disassemble each Valve Section 1. Carefully separate the inlet section (12) from the transfer carriage section (13). 2. Remove and discard o-rings from between the two sections. 3. Carefully separate transfer section (13) from the auxiliary hydraulic section (14). 4. Remove any relief valves (15), the unloader valve (16), spool end housings (17) or compensators (18) from individual valve section if equipped.
Hydraulic System 2. Install the relief valve (15) preset to 2400 psi (165 bar) into the “B” side of the transfer carriage section. Torque the relief valve to 33 ± 3.5 lb-ft (45 ± 4,8 Nm). 3. Install the spring and plunger into the spool end housing (17). Place the spool end housing on the end of the spool. Secure the spool end housing to the transfer carriage section and install two capscrews. f. Main Control Valve Installation 1.
Hydraulic System 9. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. a. Front and Rear Joystick Capsule Replacement 14 9 10. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 10 8 12 11.
Hydraulic System 8.7.4 Pilot Select Valve (Dual Joystick) b. Pilot Select Valve Disassembly, Inspection and Reassembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 15 17 16 2 1 MU4021 Pilot pressure from the front joystick flows to the pilot select valve (15).
Hydraulic System 4. Start the machine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic function. 5. Inspect the pilot select valve for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. a. Single Joystick Capsule Replacement 1. Remove the entire single joystick assembly from the cab. Refer to Section 4.3.6, “Joystick Assemblies.” 2.
Hydraulic System 8.7.6 Single Joystick Pilot Select Valve 11 b. Single Joystick Pilot Select Valve Disassembly, Inspection and Reassembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2 3 AX TR 10 X1 EX T 5 HO AU CT B EA Pilot pressure from the joystick flows to the single joystick pilot select valve (10).
Hydraulic System c. Single Joystick Pilot Select Valve Installation a. Frame Sway Joystick Capsule Replacement 1. Position the pilot select valve back onto the valve plate. Install and tighten the two capscrews. 13 8 2. Uncap and reconnect the previously labeled hydraulic hoses. 7 3. Reconnect any electrical connections to the appropriate locations. 9 6. Inspect the pilot select valve for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 7.
Hydraulic System a. Auxiliary Hydraulic Pressure Release Valve Removal 1. Park the machine on a firm, level surface, level the machine, 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 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. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries.
Hydraulic System 6. Inspect the release valve for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8. Reinstall the access plate to the cab floor. 9. Close and secure the engine cover. 8.7.9 8. Label, disconnect and cap all hoses attached to the service brake valve (3). 9.
Hydraulic System Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Install the lower dash panel. 10. Close and secure the engine cover. 8.7.10 Brake Test Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly.
Hydraulic System 8.7.12 Steer Select Valve 10. Remove the steer select valve from the cab. Wipe up any hydraulic fluid spillage in, on, near and around the machine. b. Steer Select Valve and Manifold Installation 3 Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2 1. Place the steer select assembly on a suitable work surface. 2. Transfer the fittings to the new steer select valve.
Hydraulic System c. Steering Test Refer to Section 8.4.1, “Hydraulic Pressures.” 8 1. Conduct a pressure check of the steering hydraulic circuit. 2. Check each steering mode for proper function. 9 7 MU4651 5. Install the left front dash panel (7) and secure with the five washers and capscrews. 6. Install the selector knob and secure with the retaining nut. 7. Connect the drain hose to the top of the select valve. 8. Install the front dash panel (8) and lower dash panel (9). 9.
Hydraulic System 8.7.13 Accumulator Charge/Secondary Function Valve Hydraulic oil from the front pump flows into the accumulator charge/secondary function valve and then is directed to the power steering unit, the two accumulators which direct pressure to the service brakes. Oil also flows from the accumulator charge/secondary function valve to the main control valve, the park brakes in the front axle and also provides pilot pressure to the joysticks. 7.
Hydraulic System 7 15 14 12 2. Align the accumulator charge/secondary function valve with the carriage bolts in the mount holes on the valve plate assembly. Tighten both carriage bolts. 6 11 8 5 16 3. Connect all the previously labeled hydraulic hoses, fittings, wire terminal leads, etc., to the accumulator charge/secondary function valve. 4 10 9 13 3 4.
Hydraulic System Pre-charge Pressure/Temperature Range Operating Temperature Actual Pre-charge Pressure 30°F (-1° C) 414 psi (2854 kPa) 40°F (4° C) 423 psi (2916 kPa) 50°F (10° C) 432 psi (2978 kPa) 60°F (16° C) 441 psi (3040 kPa) 70°F (21° C) 450 psi (3103 kPa) 80°F (27° C) 459 psi (3165 kPa) 90°F (32° C) 468 psi (3227 kPa) 100°F (38° C) 477 psi (3289 kPa) 110°F (43° C) 486 psi (3351 kPa) 120°F (49° C) 490 psi (3378 kPa) 130°F (54° C) 499 psi (3440 kPa) 140°F (60° C) 508 psi (3503
Hydraulic System NEVER charge an accumulator to a pressure more than specified. The proper pressure for these accumulators is 450 ± 35 psi (3103 ± 241 kPa). 10. Slowly adjust the regulator (9) on the nitrogen bottle to read 450 ± 35 psi (3103 ± 241 kPa). Note: Make sure the nitrogen bottle, as well as the charging and gauging assembly used is compatible with the gas valve assembly on the accumulator.
Hydraulic System 8.7.16 Checking Pre-Charge a. Gas Leaks 12 10 11 MU1941 4. Locate the test port (12) on the accumulator charge/ secondary function valve in the “SW” port. Attach a 3000 psi (207 bar) pressure gauge to the test port. 5. Start the engine and allow the accumulators to fully charge. Slowly pump the service brake pedal, while closely watching the test gauge. MU1971 1. If an external leak is suspected, apply soapy water to the gas valve (10) and the seams of the gas bottle (11).
Hydraulic System 8.7.17 Accumulator Charge Troubleshooting Problem 1. Accumulator charging cycle repeats frequently when accumulator is not normally being discharged. 2. Accumulator starts to charge but does not reach high limit. 3. Accumulator charging time too long. 4. Accumulator fails to start charging. 944E-42 Cause Remedy 1. Incorrect accumulator gas charge on one or both accumulators. 1. Check accumulator gas charge. Refer to Section 8.7.16, “Checking Pre-Charge.” 2.
Hydraulic System 8.8 HYDRAULIC CYLINDERS 1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom. Allow sufficient work space around the hydraulic cylinder being removed. Support the boom if the lift/lower cylinder is being removed. Place the travel select lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels. 2.
Hydraulic System Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 300-400° F (149-204° C) will destroy the bond. Avoid overheating, or the parts may become distorted or damaged. Apply sufficient torque for removal while the parts are still hot.
Hydraulic System e. Cylinder Installation 1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into it’s mounting position. 2. Align cylinder bushing and install pin, lock bolt or retaining clip. 3. Connect the hydraulic hoses in relation to the labels or markings made during removal. 8.8.2 Steering Cylinders The steer cylinder is attached to each axle center housing.The steer cylinder assembly can be found in Section 5.3, “Axle Assemblies.
Hydraulic System 8.8.3 Cylinder Torque Specifications a. Lift/Lower Cylinder Locknut Head Counterbalance Valve Hex Plugs 2200-2600 lb-ft (2983-3525 Nm) 500-600 lb-ft (678-814 Nm) 45-50 lb-ft (61-68 Nm) 10-12 lb-ft (14-16 Nm) b. Extend/Retract Cylinder Piston Set Screw Head Counterbalance Valve 330-390 lb-ft (447-529 Nm) 13-15 lb-ft (18-20 Nm) 300-400 lb-ft (407-542 Nm) 45-50 lb-ft (61-68 Nm) c.
Hydraulic System h. Swing Carriage Cylinder (optional) i.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 944E-42 TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 9.11 9.12 9.13 9-2 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Hydraulic Oil Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.3 Dual Hydraulic Oil Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.
Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section. 9.1.
Electrical System 9.2 SPECIFICATIONS 9.4.2 Cab Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 SAFETY INFORMATION WARNING 6 DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 9.4 FUSES AND RELAYS 9.4.1 Engine Compartment 3 MU7590 2 1 The fuse and relay block (6) is mounted under the lower right side of the operators side console.
Electrical System 9.4.3 Cab Harness Fuses and Relays E6 E1 F15 F1 40 40 F16 F2 10 15 F17 F3 15 25 E7 E8 E2 E3 F18 F4 7.5 7.5 F19 F5 7.5 20 F20 F6 10 10 F21 F7 7.5 10 F22 F8 20 10 F23 F9 15 F24 F10 20 7.5 F25 F11 40 F26 F12 25 E9 E4 F27 F13 F28 F14 15 MU7480 No. Amp 1 40 Amp 2 15 Amp 3 Circuit No. Amp Open Cab Machine Main 21 7.
Electrical System 9.5 9.5.1 ELECTRICAL SCHEMATICS Electrical Symbols Directory The following directory shows the most common electrical symbols used in the electrical schematics and circuit diagrams in this section.
944E-42 BA1A 1 sht 2 BA4A BA4A ABA2 1 246 2 4 3 IR_NO BA3 BA3A 6 5 FUSE_BOX_BUSSBAR_A BA4B 40AMPS F1 sht 1 BA4B PWR_BULK_3 A SR_NO SS_NO A 10AMPS F6 20AMPS F5 20AMPS F4 15AMPS F3 1 247 BA4 87 30 15AMPS F2 ST2 150AMPS PB1 F E D IGN_SW BU2 B+ A 8 1 4 1 4 F R N F R N 2 3 2 3 SW1 SW2 ST4A TR9 30 87 6 AD5 7 AD4 1 5 H1 87 BU3 BAR_NO IG2B IG2A BU3B H1A VEH_BULK A3 VEH_BULK 45 BU3A A2 PWR_BULK_6 PWR_BULK_6 C B TRANS 7 TRANS 1
10AMPS 9 3AMPS F9 FUSEBOX_BUS_BAR_B 8 F8 sht 1 BA4A BA4A I H sht 4 LP5A VP3 A sht 3 RT1E VP3 B sht 1 PB3B sht 3 LT1E 12V_BUSSBAR BUZZER D1A D1 sht1BU3C sht3BU3D sht 3 LP4A 1A 1A LVP3 LP5A D8 15 DASH_F 9 D C B A D C B A K TACH LP3 LP2 1A 1A 1A LP4 2 ALT_LAMP DASH_F ALT 18 AFPS_LAMP DASH_F AFPS 16 HOFPS_LAMP DASH_F HOFPS 19 F D13 D4A D6A D10A D12A SENS_BULK J SENS_BULK G D9A D7 AD1 HOFPS D11 8 AFPS_F A B HOTS_F C HOTS_F B FUEL_F A
944E-42 BC1A 12V_BUSSBAR PWR_BULK_3 BC1 C 87 LPR_NO Y LP5 30 sht 2 HZ6 LP6 LP6B 20AMPS F24 24 15AMPS F23 23 20AMPS F22 22 HZ6 U T X 1 49a 1 3 BRSW_1 3 2 WL4 HZ3A 8 HZG WL1 RLG5 HZ3 10 1 215 2 O O P 1 P 1 WL1B 220 BS_2F A 6 BL2 BSG2 3 5 6 LSTALK_12F 8 WL1A 2 3 WL_8F 2 1 3 WL_8F LT1 255 5 5 2 WL_8F 6 WL_8F WL2 sht 2 LT1E 6 HB1 F G B LP3A WL3 LT1A RT1A RT1B LT1B RLG6 WL2A WL3A WLIGHT_BULK_2 B 150 155 140 135 165 A A
9-10 OEM 50 PIN A CONNECTOR ON ECM 5 39 3 44 P2 45 50 49 45 50 36 36 49 26 20 37 35 26 20 37 35 25 25 1 3 4 11 1 3 4 11 19 29 30 31 19 29 31 30 41 FUEL PUMP GND J87H J87L RTS DDS DIS DS SWR ON1 OFF1 WSL ML WLS SL THS THP THG GH2 GH1 (CONNECTS TO P3) OEM_3M 1 2 41 225 FUEL SHUTOFF POWER 2 OEM_50A 12 29 28 20 38 40 OEM_50B ECM WL4 8 8 W P H F E S M D C B A P1 W P H F E S M D C B A OEM_23M WL4C WL4B BPS BPM BPD BPC BPB P5
22 21 22 21 PWM REV TILT 19 18 18 5 2 2 1 POWER GROUND CON_MOD_23F 1 3 4 7 4 6 8 8 5 9 9 6 10 10 7 11 11 13 12 14 13 12 15 14 16 15 16 3 +5VDC PWM RETURN AGND SINGLE JOYSTICK CONTROL MODULE PWM FORW TILT 17 17 19 HALL EFFECT OUTPUT 20 20 23 23 1 JS_JUMP_6F 1 BLACK RED_3 GREEN GREY WHITE PURPLE ORANGE BLUE +5VDC JS_6M 2 2 3 3 RED_1 JS_JUMP_6F JS_6M JS_JUMP_6P 1 2 3 4 5 6 6 EC1 (+5V) 5 4 EC2 EC3 3 AGND SJ_6P SCO SJG2 AH1B 3 2 1 SJG1
Electrical System 9.6 9.6.
Electrical System 9.6.
Electrical System 9.7 ENGINE START CIRCUIT 9.7.1 3. If the starter only “clicks” it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. Starter 4. For additional information on the starting circuit, refer to Section 9.5, “Electrical Schematics.” c. Starter Removal Remove the starter only if it fails. To remove the starter: 1.
Electrical System 9.8 CHARGING CIRCUIT 5. Label and disconnect the wire leads attached to the alternator. 6. Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine. 7. While supporting the alternator with one hand, remove the upper (longer) mounting hardware from the upper alternator mount. Remove the alternator from the machine. b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket.
Electrical System 9.9 9.9.1 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR 8. Remove the metal hex jam nut (7) and metal washers (8) from the motor shaft. 9. Tag and remove any hydraulic or electrical components which will be in the way of removing the wiper motor. Windshield Wiper Motor a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 8.7.9, “Service Brake Valve,” or Section 8.7.
Electrical System 8. Install wiper arm assembly to the wiper motor shaft. The blade should be parallel with the left side of the windshield. Install the wiper washer hose onto the hose adapter. 9. Turn the ignition key to the RUN position and turn front wiper switch to the ON position. Ensure wiper stays on the window through a full stroke. Turn the front wiper switch to the OFF position 8. From the top of the cab, remove the nut (14) from the wiper motor shaft. 9.
Electrical System 3. With the help of an assistant, insert the wiper motor through the roof hole and have the assistant thread the nut onto the wiper motor shaft. Ensure that the motor housing is facing the front of the cab. 4. Secure the tab of the plastic case using the previously removed screw and acorn nut. 5. Remove the rear wiper arm from the rear wiper motor shaft. 5 2 6 FRONT FRONT 7 MU6171 3 1 MU6151 4 5. Tighten the motor shaft nut (1). 6.
Electrical System 3. Reconnect the cab harness to the wiper motor assembly and with the help of an assistant, insert the wiper motor through the rear window hole and have the assistant thread the nut onto the wiper motor shaft. 4. Tighten the motor shaft nut (7). 5. Secure the tab of the plastic case using the previously removed screw and acorn nut. 6. Properly connect the batteries. 4. Properly disconnect the batteries. 5. Remove the nuts and the lock washers from the washer mounting bolts. 6.
Electrical System 9.10 9.10.1 CAB HEATER AND FAN 8. If removing the temperature control knob, disconnect the cable connector and remove control knob. Cab Heater Controls 9. Remove the locknut from the suspect control shaft. Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. 10. Remove the control from the panel. 11. If removing the air conditioning rocker switch, label and disconnect the cab harness connector.
Electrical System 9.11 9.11.1 SWITCHES AND SOLENOIDS d. Ignition Switch Installation 1. Connect the ignition key switch to the previously labeled connectors. Ignition Key Switch The ignition switch is located on the lower right side of the dash. a. Ignition Switch Removal 1. Park the machine on a firm, level surface, level the machine, 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.
Electrical System 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 5. Label and disconnect the pressure switch wiring connector from the harness connector. 6. Remove the switch from the hydraulic oil filter. b. Disassembly DO NOT disassemble the switch. The switch is not serviceable. Replace switch if found to be defective. a. Removal 1.
Electrical System 9.11.4 Auxiliary Hydraulic Pressure Release Switch 4. The ignition switch must be in the RUN position. The engine can be either idling or shut OFF. Press and hold the momentary auxiliary hydraulic pressure release switch for two seconds to release trapped pressure in the auxiliary hydraulic system. If the two auxiliary hydraulic couplings can now be easily connected or disconnected, the switch is operating properly. 5. Close and secure the engine cover. 1 9.11.
Electrical System c. Inspection and Replacement Inspect switch wiring for continuity and shorting in both the ENGAGED and DISENGAGED positions. Replace a defective or faulty switch with a new part. d. Installation and Testing 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 1. Connect the previously labeled wires to the switch. 2. Make sure the symbol is at the bottom of the switch, then press the switch into place in the benzel. 3.
Electrical System 9.11.7 Transmission Shift Control Switch 4 FORWARD and REVERSE positions. Replace a defective or faulty lever with a new part. d. Installation and Testing 1. Position the lever onto the steering column, aligning the pin with the hole in the steering column. 2. Install both screws through the lever and into the collar. Tighten the screws securely, but DO NOT overtighten. Overtightening will cause the lever to break. 3.
Electrical System Note: If the transmission is not shifting properly, the transmission shift control switch (travel select lever), wiring harness or transmission shift solenoids should be checked in order to determine which component is defective.
Electrical System 1 4 MU3991 2 3 4. Label and disconnect the wire harness connector plug (1) on the solenoid valve (2) to be replaced. 5. Remove the solenoid valve and replace. d. Installation 1. Install the solenoid valve along with the retaining bracket and capscrew. 2. Connect the wire harness connector plug to the solenoid connector plug. 3. Properly connect the batteries. 4. Close and secure the engine cover. 5. Test the operation of the transmission.
Electrical System 1. Remove the joystick valve assembly (6) from the side console. Refer to Section 4.3.6, “Joystick Assemblies.” 2. Secure the valve body (7) in a bench vise or by other suitable means. 3. Roll the boot (8) up to expose the locknut at the bottom of the handle. 4. Lift the wire harness bushing (9) to clear the retaining hole in the ring on the joystick assembly. Slide the wire harness out through the slot. d.
Electrical System 4. Disconnect the single joystick harness connector (3) from the joystick connector (4). Check the single joystick harness 6 pin connector (3) with a DMM for battery voltage. Place the negative (-) lead in pin 2 (ground) and the positive (+) lead on pin 1, and test for battery voltage. If battery voltage is not present, the single joystick harness (5) is suspect and should be replaced. If battery voltage is present, the harness is functioning properly. 6.
Electrical System 9.11.11 c. Single Joystick Function Solenoid Valves Boom Angle Sensor The single joystick commands are actuated, both electrically and hydraulically, via a set of solenoid operated cartridges within the single joystick pilot select valve. The single joystick pilot select valve is located on the valve plate which is located under the cab floor.
Electrical System 9.11.12 Coolant Temperature Switch a. Coolant Temperature Switch Removal 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. 1 2 3 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. 3. Open the engine cover. Allow the system fluids to cool. 4.
Electrical System c. Coolant Temperature Switch Installation 1. Thread the switch into the engine. Tighten securely. 2. Connect the previously labeled wiring connector to the switch. 3. Properly connect the batteries. 4. Start the engine. Allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication.
Electrical System b. Fuel Level Circuit Tests 9.11.15 Hourmeter If the fuel level gauge is suspected of giving a false reading, perform the following checks: 1. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank level sender and wiring lead. 2.
Electrical System 9.11.16 Stabilizer Brake Switch 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. 5 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the batteries. 2 3 5. Label and disconnect the electrical connectors attached to the stabilizer brake switch.
Electrical System 5. Install the dust cover (11). c. Stabilizer Brake Switch Adjustment 6. Connect the cab harness electrical connectors to the service brake switch connectors. Note: The service brake switch adjustment will require two people. Enlist the help of an assistant before attempting to follow the adjustment procedure. 7. Properly connect the batteries. 8. Adjust the brake switch. Refer to Section c, “Stabilizer Brake Switch Adjustment.
Electrical System Threaded Mounting Hole Position the brake switch so the Stabil-TRAK “Locked” Mode indicator comes ON at the 150 ±50 psi (10,3 ±3,4 bar) brake pressure. If the brake switch needs to be adjusted, remove the wire leads from the switch, loosen the locknut from the top of the switch mounting bracket and thread the switch in or out until you hear an audible click. 9.
Electrical System 9.13 TROUBLESHOOTING 9.13.1 Engine Fault Codes Retrieval 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL and engage the park brake. 2. Turn the ignition switch to “ON”. 3. Cycle the throttle pedal 3 times. The fault lamp will begin to flash a code number. The light will flash the first digit then pause for a short time and then flash the second digit. 4.
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 134 974 4 Red Remote Accelerator Remote Accelerator Pedal or Lever Position Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 135 100 3 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source 141 100 4 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 143 100 18 Amber Engine Oil Pressure Oi
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 194 520199 4 Amber Cruise Control Cruise Control (Resistive) Signal Circuit Voltage Below Normal, or Shorted to Low Source 195 111 3 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Above Normal, or Shorted to High Source 196 111 4 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 197 111 18 Amber Coolant Level Coolant Level - Data Valid but Belo
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 237 644 2 Amber External Speed Input External Speed Input (Multiple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect 238 3511 4 Amber System Diagnostic code #1 Sensor Supply Voltage #3 Circuit - Voltage Below Normal, or Shorted to Low Source 239 3511 3 Amber System Diagnostic code #2 Sensor Supply Voltage #3 Circuit - Voltage Above Normal, or Shorted to High Source 241 8
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 281 1347 7 Amber Fuel Pump Pressurizing Assembly #1 284 1043 4 Amber Internal Sensor Voltage Supply 285 639 9 Amber SAE J1939 Datalink SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate 286 639 13 Amber SAE J1939 Datalink SAE J1939 Multiplexing Configuration ErrorOut of Calibration 287 91 19 Red Accelerator Pedal Position SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received Net
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 324 653 5 Amber Injector Cylinder #03 Injector Solenoid Cylinder #3 Circuit - Current Below Normal, or Open Circuit 325 656 5 Amber Injector Cylinder #06 Injector Solenoid Cylinder #6 Circuit - Current Below Normal, or Open Circuit 331 652 5 Amber Injector Cylinder #02 Injector Solenoid Cylinder #2 Circuit - Current Below Normal, or Open Circuit 332 654 5 Amber Injector Cylinder #04 Injector Solenoid Cy
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 425 175 2 Amber Oil Temperature 428 97 3 Amber Water in Fuel Indicator Water in Fuel Sensor Circuit - Voltage Above Normal, or Shorted to High Source 429 97 4 Amber Water in Fuel Indicator Water in Fuel Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 431 558 2 Amber Accelerator Pedal Low Idle Switch Accelerator Pedal or Lever Idle Validation Circuit - Data Erratic, Intermittent, or Incorr
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 527 702 3 Amber Circuit - Voltage Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source 528 93 2 Amber Switch - Data 529 703 3 Amber Circuit - Voltage Auxiliary Input/Output 3 Circuit - Voltage Above Normal, or Shorted to High Source 546 94 3 Amber Fuel Delivery Pressure Fuel Delivery Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Sour
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 599 640 14 649 1378 687 SPN Description Cummins Description Red Engine External Protection Input Auxiliary Commanded Dual Output Shutdown Special Instructions 31 Maint Engine Oil Change Interval 103 18 Amber Turbocharger 1 Speed Turbocharger #1 Speed Low - Data Valid but Below Normal Operational Range - Moderately Severe Level 689 190 2 Amber Engine Speed Primary Engine Speed Sensor Error - Data Erratic, Intermittent,
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description 1117 627 2 None Power Supply 1139 651 7 Amber Injector Cylinder #01 Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment 1141 652 7 Amber Injector Cylinder #02 Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment 1142 653 7 Amber Injector Cylinder #03 Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment 11
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 2113 52 16 Amber Coolant Temperature Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Moderately Severe Level 2114 52 0 Red Coolant Temperature Coolant Temperature 2 - Data Valid but Above Normal Operational Range - Most Severe Level 2115 2981 3 Amber Coolant Pressure Coolant Pressure 2 Circuit - Voltage Above Normal, or Shorted to High Source 2116 2981 4 Amber
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color SPN Description Cummins Description 2263 1800 16 Amber Battery Temperature Battery Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level 2264 1800 18 Amber Battery Temperature Battery Temperature - Data Valid but Below Normal Operational Range - Moderately Severe Level 2265 1075 3 Amber Electric Lift Pump for Engine Fuel Fuel Priming Pump Control Signal Circuit Voltage Above Normal, or Shorte
Electrical System Fault Codes SPN Codes FMI Codes Lamp Color 2368 1112 3 2372 95 2373 SPN Description Cummins Description Amber Engine Brake Output #3 Engine Brake Actuator Driver 3 Circuit - Voltage Above Normal, or Shorted to High Source 16 Amber Engine Fuel Filter Differential Pressure Fuel Filter Differential Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level 1209 3 Amber Exhaust Gas Pressure Exhaust Gas Pressure Sensor Circuit - Voltage Above Norm
Electrical System 9.13.3 Troubleshooting with a Digital Multimeter (DMM) Note: Circuits which include any solid-state control modules should only be tested with a ten megohm or higher impedance digital multimeter (DMM), or damage could occur to the module. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present.
Electrical System Measuring Voltage Drop Testing for Continuity The following test determines the difference in voltage potential between two points. The following procedures verify good continuity in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. (POWER ON AT ALL TIMES) 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. FUSE BLOCK 1 With a DMM 3. Disconnect the load. RED (+) 4.
Electrical System Testing for Short to Ground Testing for Electrical Intermittence The following procedures test for a short to ground in a circuit. Perform the following procedure while wiggling the harness from side to side. If possible, continue this at 6-inch intervals while watching the test equipment. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohm position. 4.
Electrical System 5. To remove the relays from inside the engine compartment, label and remove all the wires connected to the suspect relay. 8 10 86 87 87A 30 9 85 MN1821 30 9 85 87A 87 86 MU7580 8 MT3141 8. Apply the proper voltage to the relay coil at terminal 86 (8) and attach the ground (-) probe to terminal 85 (9), ground. An audible click should be heard indicating that the relay is functioning properly. 9. Install the cover (7) to the side console. 10. Properly connect the batteries.
Electrical System Testing Diodes 4 1 5 3 14 2 MU0512 12 13 9 10 7 MU6021 6 8 MU5461 9. To test the operation of the relays, connect a 12-volt DC positive lead to the positive terminal (1 or 6). Connect the negative lead to the mounting bracket or negative post (2 or 7), listening for a “click” sound as the contacts close. Replace the relay if the contacts do not close.
Section 10 Stabil-TRAK™ System Contents PARAGRAPH 10.1 10.2 10.3 10.4 10.5 944E-42 TITLE Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1 Stabil-TRAK™ Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting . . . . . . . . . . . Stabil-TRAK™ System Test . . . .
Stabil-TRAK™ System 10.1 STABIL-TRAK™ SYSTEM 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 Stabil-TRAK™ system. The following illustration identifies the components that are referred to throughout this section.
Stabil-TRAK™ System 10.2 STABIL-TRAK™ DESCRIPTION The patented rear axle lock or Stabil-TRAK™ system works to stabilize the machine under various conditions. The appropriate Operation & Safety manual contains basic Stabil-TRAK™ information; a copy of the Operation & Safety manual should always be available in the storage compartment located on the left inside wall of the cab, next to the seat support.
Stabil-TRAK™ System 10.3 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING Note: Before using the 944E Stabil-TRAK System Troubleshooting chart and diagrams, complete the Section 10.4, “Stabil-TRAK™ System Test”, to determine what part of the system is not functioning properly. Stabil-TRAK™ System Troubleshooting Machine Conditions Switch/ Relay Solenoid Solenoid 12A Solenoid 12B FREE PIVOT MODE SLOW PIVOT MODE LOCKED MODE I LOCKED MODE II LOCKED MODE III Ignition On. Boom Below 40°.
944E-42 10 5 E 20 15 40 F2 F1 OPEN CAB VEHICLE MAIN IGNITION CONTROL TRANSMISSION 15 F3 1 BA3 BA4 TR8 S1 BA1A A B BA2 2 3 C FJ1 4 D FJ2 FUEL SOLENOID F4 6 F FJ3 20 IGNITION POWER F5 7 G FJ4 10 BACK-UP ALARM/HORN F6 F7 STABILITY CIRCUIT 2 J1 1 30 ENGINE OIL PRESSURE 3 J3 WATER TEMPERATURE GAUGE RG6 4 J4 5 J5 FUEL GAUGE 30 DE CAB GRND STUD E F PB4 C S3 TR8 PB6B A S5 B S4 5 PB3 C S2B TR7 DE 25 S5 6 7 J7 BACK LIGHT F J8 GROUND POW
10-6 10 5 E 15 15 40 F2 F1 OPEN CAB VEHICLE MAIN IGNITION CONTROL TRANSMISSION F3 1 BA3 BA4 TR8 S1 BA1A A B BA2 2 3 C FJ1 4 D FJ2 20 FUEL SOLENOID F4 6 F FJ3 20 IGNITION POWER F5 7 G FJ4 10 BACK-UP ALARM/HORN F6 F7 STABILITY CIRCUIT 2 J1 1 30 ENGINE OIL PRESSURE 3 J3 WATER TEMPERATURE GAUGE RG6 4 J4 5 J5 FUEL GAUGE 30 DE RG1 85 CAB GRND STUD E C S3 F PB4 TR8 PB6B A S5 B S4 5 C S2B TR7 DE PB3 25 S5 6 7 J7 BACK LIGHT F J8 GROU
944E-42 10 5 E 20 15 40 F2 F1 OPEN CAB VEHICLE MAIN IGNITION CONTROL TRANSMISSION 15 F3 1 BA3 BA4 TR8 S1 BA1A A B BA2 2 3 C FJ1 4 D FJ2 FUEL SOLENOID F4 6 F FJ3 20 IGNITION POWER F5 7 G FJ4 10 BACK-UP ALARM/HORN F6 F7 STABILITY CIRCUIT 2 J1 1 3 RG6 4 J4 WATER TEMPERATURE GAUGE 5 J5 30 30 85 CAB GRND STUD E F PB4 C S3 TR8 A S5 B S4 5 C S2B TR7 E PB3 25 S5 PB6B 6 RG6 RG7 RG8 RG9 7 BACK LIGHT J7 F POWER 87A 10 J10 TURN SIGNAL
10-8 10 5 E 15 15 40 F2 F1 OPEN CAB VEHICLE MAIN IGNITION CONTROL TRANSMISSION F3 1 BA3 BA4 TR8 S1 BA1A A B BA2 2 3 C FJ1 4 D FJ2 20 FUEL SOLENOID F4 6 F FJ3 20 IGNITION POWER F5 7 G FJ4 10 BACK-UP ALARM/HORN F6 F7 STABILITY CIRCUIT 2 J1 1 30 ENGINE OIL PRESSURE 3 J3 WATER TEMPERATURE GAUGE RG6 4 J4 5 J5 FUEL GAUGE 30 DE RG1 85 CAB GRND STUD E C S3 F PB4 TR8 PB6B A S5 B S4 5 C S2B TR7 DE PB3 25 S5 6 7 J7 BACK LIGHT F J8 GROU
944E-42 10 5 E 20 15 40 F2 F1 OPEN CAB VEHICLE MAIN IGNITION CONTROL TRANSMISSION 15 F3 1 BA3 BA4 TR8 S1 BA1A A B BA2 2 3 C FJ1 4 D FJ2 FUEL SOLENOID F4 6 F FJ3 20 IGNITION POWER F5 7 G FJ4 10 BACK-UP ALARM/HORN F6 F7 STABILITY CIRCUIT 2 J1 1 3 RG6 4 J4 WATER TEMPERATURE GAUGE 5 J5 30 30 85 CAB GRND STUD E F PB4 C S3 TR8 A S5 B S4 5 C S2B TR7 DE PB3 25 S5 PB6B 6 RG6 RG7 RG8 RG9 7 BACK LIGHT J7 POWER 87A 10 J10 TURN SIGNAL (
Stabil-TRAK™ System 10.4 STABIL-TRAK™ SYSTEM TEST Note: The operator must know that the Stabil-TRAK™ system is active and functioning properly. To test the function of the Stabil-TRAK™ system, read the Stabil-TRAK™ System Test instructions and follow Steps 1 through 9 of Section 10.4.2, “Stabil-TRAK™ System Test Procedures.” 10.4.1 Stabil-TRAK™ System Test Instructions • Test the Stabil-TRAK™ system with the machine on a level surface.
Stabil-TRAK™ System Stabil-TRAK™ System Test Procedures Step 1 a. Place the vehicle on a level surface with 0° sway. b. Have the boom fully retracted and horizontal. c. Place an 8" (203 mm) wood or cement block in front of the front left tire. d. Enter the vehicle. e. Fasten the seat belt. FREE PIVOT MODE f. Turn the ignition switch to the RUN position. g. Check to be sure the Stabil-TRAK™ lock light and the slow pivot light are both OFF. Step 2 a. Turn the ignition switch and start the engine. b.
Stabil-TRAK™ System Stabil-TRAK™ System Test Procedures Step 7 a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL DETENT position. b. Lower the boom to exactly 45°. c. Frame sway the vehicle no more than 5° to the left. LOCKED MODE d. Frame sway the vehicle back to 0°. e. Frame sway the vehicle no more than 5° to the right. Note: Observe that frame sway will be slower than normal during this test. f.
Stabil-TRAK™ System 10.5 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The function of the Stabil-TRAK™ system varies under different operating conditions. The basic modes include the FREE PIVOT MODE, SLOW PIVOT MODE and LOCKED MODE. 10.5.1 The hydraulic operation and troubleshooting information for each of these modes are described below. Troubleshooting Symptom Chart Symptom With the boom below 40°, when swaying the frame to the right, the left front tire comes off the ground.
Stabil-TRAK™ System 10.5.2 Stabil-TRAK™Hydraulic Circuit The Stabil-TRAK™ hydraulic circuit can be tested using these basic guidelines. For more hydraulic information, refer to Section 8.4, “Hydraulic Circuits.” Not OK Refer to Section 9.4, “Fuses and Relays.” Not OK Replace cartridge. Not OK Replace check valve(s). Check electrical wiring. If OK Check solenoid cartridge in the Stabil-TRAK™ manifold. Refer to Section 10.2.1, “Stabil-TRAK™ If OK Inspect check valves on the StabilTRAK™ cylinder.
Stabil-TRAK™ System 10.5.4 Hydraulic Circuit Operation - Free Pivot Mode, Rod Oil Out SOLENOID COIL STATE Ø .048 DE DE-ENERGIZED E CHECK VALVE FITTING FTB ENERGIZED Pressure Return Pilot Pressure Suction Load Sense FTR Ø .041 FRAME SWAY CYLINDER PUMP CHECK VALVE FITTING DRAIN SW SW P1 P PBG STABILIZER CYLINDER G2 G3 FTR 3 ACCUMULATOR CHARGE/SECONDARY FUNCTION VALVE V PPG DE LSG LS CF PB EF ACF ACR PIL 2A .030 DIA.
Stabil-TRAK™ System 1 7 Legend 3 8 5 6 2 9 4 Front 10.5.5 1. 2. 3. 4. 5. 6. 7. 8. 9.
Stabil-TRAK™ System 10.5.6 Hydraulic Circuit Operation - Free Pivot Mode, Base Oil Out SOLENOID COIL STATE Ø .048 DE DE-ENERGIZED E CHECK VALVE FITTING FTB ENERGIZED Pressure Return Pilot Pressure Suction Load Sense FTR Ø .041 FRAME SWAY CYLINDER PUMP CHECK VALVE FITTING DRAIN SW SW P1 P PBG STABILIZER CYLINDER G2 G3 FTR ACCUMULATOR CHARGE/SECONDARY FUNCTION VALVE V 3 PPG DE LSG LS CF PB EF ACF ACR PIL 2A .030 DIA.
Stabil-TRAK™ System 7 8 Legend 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 5 1 6 2 9 4 Stabilizer Cylinder Solenoid 12A Solenoid 12B Pressure Reducing Cartridge Solenoid 4A Solenoid 4B Solenoid 3 Check Valve 2A Check Valve 2B MU4261 Front 10.5.7 Hydraulic Troubleshooting - Free Pivot Mode, Base Oil Out Conditions: • Ignition ON, engine running With boom below 40°, when frame swaying to the left, the right front tire comes off the ground.
Stabil-TRAK™ System 10.5.8 Hydraulic Circuit Operation - Slow Pivot Mode, Rod Oil Out SOLENOID COIL STATE Ø .048 DE DE-ENERGIZED E CHECK VALVE FITTING FTB ENERGIZED Pressure Return Pilot Pressure Suction Load Sense FTR Ø .041 FRAME SWAY CYLINDER PUMP CHECK VALVE FITTING DRAIN SW SW P1 P PBG STABILIZER CYLINDER G3 G2 FTR 3 ACCUMULATOR CHARGE/SECONDARY FUNCTION VALVE V PPG DE LSG LS CF PB EF ACF ACR PIL 2A .030 DIA. 1 2B .060 DIA. 2 3 5 .060 DIA.
Stabil-TRAK™ System 9 10 Legend 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 4 5 1 2 3 8 11 6 Stabilizer Cylinder Solenoid 4B .060" Orifice with Solenoid Valve 4B .060" Orifice with Solenoid Valve 4A Solenoid 4A Pressure Reducing Cartridge Solenoid 12A Solenoid 12B Solenoid 3 Check Valve 2A Check Valve 2B MU4261 Front 10.5.
Stabil-TRAK™ System 10.5.10 Hydraulic Circuit Operation - Slow Pivot Mode, Base Oil Out SOLENOID COIL STATE Ø .048 DE DE-ENERGIZED E CHECK VALVE FITTING FTB ENERGIZED Pressure Return Pilot Pressure Suction Load Sense FTR Ø .041 FRAME SWAY CYLINDER PUMP CHECK VALVE FITTING DRAIN SW SW P1 P PBG STABILIZER CYLINDER G3 G2 FTR ACCUMULATOR CHARGE/SECONDARY FUNCTION VALVE V 3 PPG DE LSG LS CF PB EF ACF ACR PIL 2A .030 DIA. 1 2B E .060 DIA. 5 2 4 .060 DIA.
Stabil-TRAK™ System 9 10 7 4 1 5 2 3 8 11 6 Legend 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Stabilizer Cylinder Solenoid 4B .060" Orifice with Solenoid Valve 4B .060" Orifice with Solenoid Valve 4A Solenoid 4A Pressure Reducing Cartridge Solenoid 12A Solenoid 12B Solenoid 3 Check Valve 2A Check Valve 2B MU4261 Front 10.5.
Stabil-TRAK™ System 10.5.12 Hydraulic Circuit Operation - Locked Mode Oil entering the Stabil-TRAK™ manifold at port V flows through solenoid cartridge valve 3 (5), through a 0.030" orifice (6) and check valve 2A (7), to the base end of the stabilizer cylinder (8). The orifice slows the movement of the frame sway. a. Conditions: • Boom angle is above 40° Some of this oil is diverted to the pilot line of check valve 2B (9), opening the valve.
Stabil-TRAK™ System 5 6 Legend 7 3 8 1 2 4 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Solenoid 4A Solenoid 4B Solenoid 12A Solenoid 12B Solenoid 3 .
Stabil-TRAK™ System 10.5.14 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Right Conditions: • Ignition ON, engine running With boom above 40°, when frame swaying to the right, the left front tire comes off the ground. • Boom angle is above 40° • Travel select lever in (N) NEUTRAL, or park brake ON, or service brake ENGAGED Check electrical wiring. Not OK Refer to Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting Not OK Replace cartridge. Not OK Replace check valve(s).
Stabil-TRAK™ System 10.5.15 Hydraulic Circuit Operation - Locked Mode, Frame Sway Left a. Conditions Oil from the rod end of the frame sway cylinder flows, through the check valve (4) opened by incoming pilot pressure oil, through the check valve with a 0.041" orifice (5), to the FTR port of the Stabil-TRAK™ manifold.
Stabil-TRAK™ System 10 6 9 13 11 8 12 14 7 15 Front 10.5.16 Legend 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Solenoid 3 Check Valve 2B Stabilizer Cylinder Check Valve 2A .030" Orifice Plug Solenoid 4A Solenoid 4B Solenoid 12A Solenoid 12B Pressure Reducing Cartridge MU4261 Hydraulic Troubleshooting - Locked Mode, Will Not Frame Sway Left Conditions: • Ignition ON, engine running With boom above 40°, when frame swaying to the left, the right front tire comes off the ground.
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Section 11 Transfer Carriage Contents PARAGRAPH 11.1 11.2 11.3 11.4 944E-42 TITLE Transfer Carriage Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.1 Transfer Carriage Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.2 Transfer Carriage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Carriage 11.1 TRANSFER CARRIAGE 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 name and location of the major assemblies of the transfer carriage. The following illustration identifies the components that are referred to throughout this section.
Transfer Carriage 11.3 WARNING DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. 11.2 11.2.1 TRANSFER CARRIAGE Transfer Carriage Description The transfer carriage, along with the transfer cylinder, make up the “Place Ace” feature. This feature makes it possible to land materials from a parked, level vehicle by transferring the boom load forward at any height.
Transfer Carriage 11.3.1 Transfer Carriage Removal 1. Level the vehicle, place the travel select lever in the (N) NEUTRAL DETENT position, engage the parking brake. 2 9. 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. 10.
Transfer Carriage 10 7 7 9 9 11 MU1701 8 6 MU1692 18. Remove the pin (8) from lift cylinder (6). Lower and place the cylinder on support blocks on a firm level surface. 19. Label, disconnect and cap all hydraulic hoses connecting the slave cylinders (9) to the hydraulic tubes (10). Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system. 20. Label, disconnect and cap the hydraulic tubes (10) from the hydraulic junction manifold (7).
Transfer Carriage 1 29. Remove capscrews, shims, and rear wear pads. Count and label their position for later replacement. 4 30. Remove capscrews, shims, and front wear pads. Count and label their position for later replacement. 2 8 3 7 3 MU1741 2 26. Remove pin bolt and locknut from rear roller pin (1). Slide the roller pin out and remove the rear rollers (2) and shims (3) from both sides of the transfer carriage (4). Count and label the rear rollers and shims for later replacement. 6 MU1791 31.
Transfer Carriage 11.3.2 Transfer Carriage Installation 1. Insert front roller pin (6), front roller (7) and shims (8) in their previously labeled positions. 7 6 ® 2. Coat the capscrews with Loctite 242 (blue). Torque capscrew to 43 - 78 lb-ft (59 - 106 Nm). 3. Repeat steps 11.3.2 and 2 for the other front roller. 4. Coat the capscrews with Loctite® 242 (blue). Replace capscrews, shims, and wear pads in their previously labeled positions. Torque capscrew to, 21 - 38 lb-ft (29 - 52 Nm). 9 5.
Transfer Carriage 16 6 15 4 17 5 2 13 14 MU1701 3 ® 14. Coat the capscrew with Loctite 242 (blue). Replace the hydraulic tubes (15) and mounting bracket with capscrew. Torque the hydraulic tubes (15) to the hydraulic junction manifold (16) to 45 - 59 lb-ft (61 80 Nm). 15. Replace the slave cylinder hydraulic hoses (17) according to their previously labeled positions. Torque the connections at the slave cylinder to, 50 - 60 lb-ft (67 - 81 Nm).
Transfer Carriage 11.3.3 Rear Wear Pad Check Note: The attachment should remain attached to the quick attach for these checks. 7 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 7 2. Leave the transfer carriage completely retracted. MU1641 18. Coat the bolts with Loctite® 242 (blue).
Transfer Carriage 11.3.4 Rear Wear Pad Shimming 11.3.5 Note: The attachment should remain attached to the quick attach for this procedure. Rear Wear Pad Replacement Note: The attachment should remain attached to the quick attach for this procedure. 1. Park the machine on a firm, level surface, level the machine, fully extend the boom with the attachment being slightly off the ground, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 1.
Transfer Carriage 11.3.6 11.3.8 Front Upstop Wear Pad Check Front Upstop Wear Pad Shimming 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 5 OU1001 9 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. Open the engine cover. Allow the system fluids to cool. 8 4.
Transfer Carriage 11.3.9 Front Upstop Wear Pad Replacement Note: The attachment should remain attached to the quick attach for this procedure. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL and engage the park brake. 2. Leave the transfer carriage completely retracted. 3. Fully extend the boom. The attachment must remain slightly off the ground. Turn the machine OFF. 3 2 11.3.
Transfer Carriage 11.3.11 Rear Roller Shimming Note: The attachment should remain attached to the quick attach. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom and transfer carriage, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 10 10 2. Lift the boom with a hoist to remove pressure off the rear rollers. There should be a gap between the rollers and the rails. 3.
Transfer Carriage 13. Coat the bolts with Loctite® 242 (blue). Replace the bolts and stop blocks (10) at the rear, left and right side of the frame. Torque bolt to, 302 - 390 lb-ft (410 - 530 Nm). 14. Coat the locknuts with Loctite® 242 (blue). Install locknuts, washers, Lull logo plate and black backing at the rear of the vehicle. Torque locknuts to, 29 - 51 lb-ft (40 - 70 Nm). 5. Start the engine and move the transfer carriage about halfway back. Shut the vehicle OFF.
Transfer Carriage 11.3.13 Front Roller Shimming Note: The attachment should remain attached to the quick attach. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom and transfer carriage, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Lift the boom with a hoist to remove pressure off the front rollers. There should be a gap between the rollers and the rails. 3.
Transfer Carriage 11.3.15 Front Roller and Bushing Replacement Note: The attachment should remain attached to the quick attach. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom and transfer carriage, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Lift the boom with a hoist to remove pressure off the front rollers. There should be a gap between the rollers and the rails. 3.
Transfer Carriage 11.3.16 Rear Roller and Bushing Replacement Note: The attachment should remain attached to the quick attach. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom and transfer carriage, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Lift the boom with a hoist to remove pressure off the front rollers. There should be a gap between the rollers and the rails. 3.
Transfer Carriage Note: DO NOT apply any grease or anti-seize compound to bushing or roller pin. 11.3.18 Slave Cylinder Pivot Bushing Replacement 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 5 4 MU3191 2 3. Inspect the boom pivot bushings (5).
Transfer Carriage 11.3.19 Transfer Cylinder Replacement The transfer cylinder is located on the left rear side of the main frame and is connected to the main frame and transfer carriage. Its function is to control forward and backward movement of the transfer carriage. It has a maximum operating pressure of 3500 psi (241 bar) and has a stroke limit of 80 inches (2.032 mm). 5 a.
Transfer Carriage 7. If you are replacing the pin, remove the bottom snap ring (7). b. Transfer Cylinder Installation 8. Shut the engine OFF. 1. Lift the transfer cylinder into position on the vehicle chassis. 9. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 2. Replace two bolts securing the transfer cylinder to the frame. 10. Open the engine cover. Allow the system fluids to cool. 3.
Transfer Carriage c. Transfer Carriage Bearing Replacement 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, level the boom, place the transmission control lever in (N) NEUTRAL and engage the park brake. 2. Move the transfer carriage all the way forward. 7. From under the vehicle remove the transfer cylinder bearing (7) from the transfer carriage mount. 8. Replace a new transfer cylinder bearing (7) into the transfer carriage mount. 9. Properly connect the batteries.
Transfer Carriage 11.4 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the transfer carriage. 11.4.1 Transfer Carriage Troubleshooting Problem 1. Transfer carriage will not extend or retract. 2. Jerky transfer carriage extend or retract functions. 11-22 Cause Remedy 1. Broken transfer cylinder hydraulic hose(s) or tube(s) and/ or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections.
Transfer Carriage 11.4.1 Transfer Carriage Troubleshooting Problem 3. Transfer carriage shifts to right or left when extending. 4. Excessive transfer carriage roller pin noise and/or wear. 5. Premature transfer carriage pad wear. 6. Transfer carriage drifts forward on it’s own. 944E-42 Cause Remedy 1. Transfer carriage rollers improperly shimmed. 1. Re-shim the transfer carriage. (Refer to Section 11.3.11, “Rear Roller Shimming,” and Section 11.3.13, “Front Roller Shimming.”) 2.
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31200355 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.
