TH414C GCTH417C GC CAT Service

Service Manual
Models
TH414C GC,
TH417C GC
S/N KRF00150 & After,
S/N LYN00150 & After,
S/N NAB00150 & After,
S/N NMM00150 & After,
31200959
Revised
May 9, 2014
EFFECTIVITY PAGE
May 9, 2014 - A - Original Issue Of Manual
31200959 TH414C GC, TH417C GC i

EFFECTIVITY PAGE
ii TH414C GC, TH417C GC 31200959

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance - TH414C GC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Boom Chain Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . 3-14
3.6 Extend/Retract Cylinder Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 Boom Sections Adjustment - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.8 Boom System Component Terminology - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Boom System - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Boom Assembly Maintenance - TH417C GC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.11 Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - TH417C GC . . . . . . . . . . 3-29
3.13 Boom Chain Removal/Installation - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.14 Boom Sections Adjustment - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.15 Boom Extend and Retract Chains - TH414C GC & TH417C GC. . . . . . . . . . . . . . . . . . 3-33
3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.17 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.18 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.19 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
TH414C GC, TH417C GC i

Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Park Brake adjustment - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.9 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ii TH414C GC, TH417C GC

Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.7 Wiper/Washer Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.8 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.9 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10 Load Stability Indicator (LSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.12 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.13 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
TH414C GC, TH417C GC iii

iv TH414C GC, TH417C GC

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TH414C GC, TH417C GC 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult the local Caterpillar dealer. numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely.
1.6 SAFETY ALERT SYSTEM AND SIGNAL
Appropriate service methods and proper repair procedures WORDS
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable
operation of the machine. All references to the right side, left
side, front and rear are given from the operator seat looking in DANGER
a forward direction.
Supplementary information is available from the
manufacturer in the form of Service Bulletins, Service DANGER indicates an imminently hazardous situation
Campaigns, Service Training Schools, the service website, which, if not avoided, will result in death or serious injury.
other literature, and through updates to the manual itself.
1.2 DISCLAIMER WARNING

All information in this manual is based on the latest product
information available at the time of publication. The WARNING indicates a potentially hazardous situation which,
manufacturer reserves the right to make changes and if not avoided, could result in death or serious injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION
1.3 OPERATION & MAINTENANCE MANUAL
CAUTION indicates a potentially hazardous situation which,
The mechanic must not operate the machine until the if not avoided, may result in minor or moderate injury.
Operation & Maintenance Manual has been read and
understood, training has been accomplished and operation
of the machine has been completed under the supervision of
an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with each
machine and must be kept in the manual holder located in
the cab. In the event that the Operation & Maintenance
Manual is missing, consult the local Caterpillar dealer before
proceeding.
1-2 TH414C GC, TH417C GC

Safety Practices
1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
CLEANLINESS: Wear eye protection, and clean all
1.7.1 Personal Hazards components with a high pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.7.2 Equipment Hazards machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components,
(chains, slings, brackets, hooks, etc.), verify that it is of the
Caterpillar recommends a maximum pressure of 52 bar
proper capacity, in good working order, and is properly
(750 psi) at a minimum distance of 30,5 cm (12 in) away from
attached.
these components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation,
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
service tools only as recommended.

Safety Practices
1.7.4 Operational Hazards DO NOT mix gasoline or alcohol with diesel fuel. The mixture
can cause an explosion.
ENGINE: Stop the engine before performing any service
unless specifically instructed otherwise. PRESSURE TESTING: When conducting any test, only use test
equipment that is correctly calibrated and in good condition.
VENTILATION: Avoid prolonged engine operation in
Use the correct equipment in the proper manner, and make
enclosed areas without adequate ventilation.
changes or repairs as indicated by the test procedure to
SOFT SURFACES AND SLOPES: NEVER work on a machine achieve the desired result.
that is parked on a soft surface or slope. The machine must be
LEAVING MACHINE: Lower the forks or attachment to the
on a hard level surface, with the wheels blocked before
ground before leaving the machine.
performing any service.
TIRES: Always keep tires inflated to the proper pressure to
FLUID TEMPERATURE: NEVER work on a machine when the
help prevent tipover. DO NOT over inflate tires.
engine, cooling or hydraulic systems are hot. Hot
components and fluids can cause severe burns. Allow NEVER use mismatched tire types, sizes or ply ratings.
systems to cool before proceeding. Always use matched sets according to machine
specifications.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear MAJOR COMPONENTS: Never alter, remove, or substitute any
heavy, protective gloves and eye protection. NEVER check items such as counterweights, tires, batteries or other items
for leaks using any part of your body; use a piece of that may reduce or affect the overall weight or stability of the
cardboard or wood instead. If injured, seek medical attention machine.
immediately. Diesel fluid leaking under pressure can BATTERY: DO NOT charge a frozen battery.Charging a frozen
explode. Hydraulic fluid and diesel fuel leaking under battery may cause it to explode. Allow the battery to thaw
pressure can penetrate the skin, cause infection, gangrene before jump starting or connecting a battery charger.
and other serious personal injury.
Refer to the engine manufacturers manual for specific details 1.8 SAFETY DECALS
concerning the fuel system.
Check that all safety decals are present and readable on the
Relieve all pressure before disconnecting any component,
machine. Refer to the Operation & Maintenance Manual
part, line or hose. Slowly loosen parts and allow release of
supplied with machine for information.
residual pressure before removing any part or component.
Before starting the engine or applying pressure, use
components, parts, hoses and pipes that are in good
condition, connected properly and are tightened to the
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system cap to the first stop
and allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could result
in death or serious injury.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
explosion.

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.5 Transmission Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.1 10 & 1st 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.2 50 & 1st 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6.3 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.6.4 1000 & 3000 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.6.5 6000 & 12000 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.1 TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.2 TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.1 REPLACEMENT PARTS AND WARRANTY 2.2 THREAD LOCKING COMPOUND

INFORMATION
Loctite® ND Industries Description
242TM Vibra-TITETM121 Medium Strength (Blue)
243TM Vibra-TITETM122 Medium Strength (Blue)
271TM Vibra-TITETM140 High Strength (Red)
262TM Vibra-TITETM131 Medium - High Strength (Red)
Loctite® 243TM can be substituted in place of Loctite® 242TM.

Vibra-TITETM 122 can be substituted in place of Vibra-TITETM 121.
1
Model:
Year of Manufacture:
Product Identification Number
Model Year:
Serial Number
Nominal engine power , kW:
Unladen mass: kg
Maximum cap acity: kg
MZ7060
Maximum cap acity at max. Height: kg
100100YYY A
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located on the frame behind the right
front tire.
Note: The replacement of any part on this machine with any
other than factory authorized replacement parts can adversely
affect the performance, durability, or safety of the machine,
and will void the warranty. JLG disclaims liability for any claims
or damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the local
Caterpillar dealer, signed by the purchaser and returned to the
manufacturer when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the service
distributor has returned the business reply card of the
warranty registration form from the manufacturer.

2.3 TORQUE CHARTS
2.3.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Stress Clamp Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia (Loctite® 262TM or
Area Load (Dry) Lubricated or Vibra-TITETM
Vibra-TITETM 131)
111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

2.3.1 SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242TM or 271TM (Loctite® 262TM or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area or Vibra-TITETM 111 or 140) Vibra-TITETM 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque
Tensile Stress (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia Clamp Load (Dry)
Area Vibra-TITETM 111 or 140) Vibra-TITETM 131)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITETM 111 or 140) Vibra-TITETM 131)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625


SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITETM 111 or 140) or Vibra-TITETM 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITETM 111 or 140) or Vibra-TITETM 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

2.3.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 262TM or 271TM (Loctite® 242TM or 271TM
Size Pitch Torque (Lube)
Area See Note 4 (Dry or Loctite® 263TM) or or Vibra-TITETM 111 or
Vibra-TITETM 131) 141)
Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

2.3.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque
Torque (Lube or Loctite®
Clamp Load (Loctite® 262TM or
Size Pitch Tensile Stress Area (Dry or Loctite® 263TM) 242 or 271TM or
TM
See Note 4 Vibra-TITETM 131)
K=0.20 Vibra-TITETM 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Torque (Lube or Loctite® (Loctite® 262TM or
Clamp Load
Size Pitch Tensile Stress Area (Dry or Loctite® 263TM) 242TM or 271TM or Vibra-TITETM 131)
See Note 4
K=0.17 Vibra-TITETM 111 or 140) K=0.15
K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque
Torque
Torque (Lube or Loctite®
Clamp Load See (Loctite® 262TM or
Size Pitch Tensile Stress Area (Dry or Loctite® 263TM) 242TM or 271TM or
Note 4 Vibra-TITETM 131)
K=0.17 Vibra-TITETM 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

2.3.3 Hydraulic Hose Torque Chart

Note: By definition the “Flats Method“ will contain some
variance.
Flats Method:
1. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of the
swivel nut can be detected. Average hand torque is 4
Nm (3 lb-ft).
2. Mark a dot on one of the swivel nut flats and another
dot in line on the hex of the adapter it’s connecting to.
3. Use the double wrench method while tightening to
avoid hose twist.
4. Tighten the connection 6.35 mm (0.25 in) or 1.5 flats.
5. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots indicating that the connection has been
properly tightened.

2.4 SPECIFICATIONS
2.4.1 Travel Speeds
TRANSMISSION APPROXIMATE SPEED

First Gear 5 kph (3 mph)
Second Gear 12 kph (7 mph)
Third Gear 25 kph (15 mph)
2.4.2 Hydraulic Cylinder Performance

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

FUNCTION
TH414C GC TH417C GC
Boom Extend (Boom Level) 14.6 23.4
Boom Retract (Boom Level) 11.7 20.0
Boom Lift 15.5 21.0
Boom Lower 13.3 16.8
Quick Coupler Raise 3.1 3.1
Quick Coupler Lower 2.7 2.8
Frame Level - Full Right to Left 7.1 8.0
Frame Level - Full Left to Right 10.8 12.1
Outrigger - Both Down 6.9 7.0
Outrigger - Both Up 6.2 6.0
Outrigger - Single Down 4.4 4.5
Outrigger - Single Up 4.6 4.6

2.4.3 Electrical System
Battery
Type, Rating 12 V, Negative (-) Ground, Tapered Top Post, Maintenance Free
Quantity 1
Cranking Performance 1 - 830 Cold Cranking Amps @ -18° C (0° F)
Group/Series BCI Group 31
Alternator 14V, 120 Amps
Starter 12V,4 KW
2.4.4 Engine Performance Specifications
Description TCD 3.6 L4

Engine Make/Model CAT TCD
Displacement 3,6 liters (276 in³)
Low Idle 945-955 rpm
High Idle 2295-2345 rpm
Horsepower 74,4 kW (99,7 HP)@ 2200 rpm
Peak Torque N/A
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
2.4.5 Transmission Performance Specifications
Engine kW (Horsepower) Transmission Stall Speed

CAT TCD 3.6 L4 74,4 (99.7) 3 Speed 2030 rpm 2050 rpm

2.4.6 Tires
Note: Wheel lug nut torque is 430-470 Nm (317-347 lb-ft)
Note: Pressures for foam filled tires are for initial fill ONLY.
a. TH414C GC
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
15.5/80-24 TR01 16 Ply Pneumatic 4,1 Bar (59 psi)
Pneumatic 4,0 Bar (58 psi)
15.5-25 L-2 12 Ply
Liquid Filled 4,0 Bar (58 psi)
400/80-24 Power CL N/A Pneumatic 4,0 Bar (58 psi)
370/75-28 DuraForce MH 14 Ply Pneumatic 5,25 Bar (76 psi)
a. TH417C GC
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
14-24 TG02 16 Ply Pneumatic 4,25 Bar (62 psi)
Pneumatic 4,75 Bar (69 psi)
14-24 SGG-2A 16 Ply
Liquid Filled 4,75 Bar (69 psi)
14-24 L2/G2 Radial Pneumatic 5,5 Bar (80 psi)
400/75-28 DuraForce MH 16 Ply Pneumatic 5,25 Bar (76 psi)

2.5 FLUIDS, LUBRICANTS AND CAPACITIES
a. Fluids
S/N KRF00150 & After, NAB00150 & After
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-20 -22 50 -30 10
SAE 0W-30 -22 86 -30 30
SAE 0W-40 -22 104 -30 40
CAT DEO ULS SAE 5W-30 -13 86 -25 30
Engine Crankcase
API CJ-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
SAE 10W -4 104 -20 40
Hydraulic System CAT HYDO Advanced
SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
SAE 30 32 95 0 35
Transmission and
CAT TDTO SAE 50 50 122 10 50
Transfer Case
SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
CAT Synthetic Gear Oil (GO) SAE 75W-140 -22 113 -30 45
Axle Differential* CAT Gear Oil (GO) SAE 80W-90 -10 120 -23 49
and Wheel End CAT Gear Oil (GO) SAE 85W-140 10 120 -12 59
CAT TDTO-TMS CAT TDTO-TMS -4 122 -20 50
Cylinder, Boom
Wear Pad and Axle CAT Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Grease
CAT Extended Life Coolant 50/50 Mix Standard

Engine Coolant
(ELC) 60/40 Mix Cold Weather
#2 Diesel Standard
Ultra Low Sulfur (S
Fuel Blend of #1 and #2 diesel fuels < 15 mg/kg) Cold Weather
(winterized #2)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (197- 0017) required for front axle differential.

S/N LYN00150 & After, NMM00150 & After
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-20 -22 50 -30 10
SAE 0W-30 -22 86 -30 30
SAE 0W-40 -22 104 -30 40
CAT DEO SAE 5W-30 -13 86 -25 30

Engine Crankcase
API CI-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
SAE 10W -4 104 -20 40
Hydraulic System CAT HYDO Advanced
SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
SAE 30 32 95 0 35
Transmission and
CAT TDTO SAE 50 50 122 10 50
Transfer Case
SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
CAT Synthetic Gear Oil (GO) SAE 75W-140 -22 113 -30 45
Axle Differential* CAT Gear Oil (GO) SAE 80W-90 -10 120 -23 49
and Wheel End CAT Gear Oil (GO) SAE 85W-140 10 120 -12 59
CAT TDTO-TMS CAT TDTO-TMS -4 122 -20 50
Cylinder, Boom
Wear Pad and Axle CAT Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Grease
CAT Extended Life Coolant 50/50 Mix Standard

Engine Coolant
(ELC) 60/40 Mix Cold Weather
#2 Diesel Standard
Low Sulfur
Fuel Blend of #1 and #2 diesel fuels (S < 500 mg/kg) Cold Weather
(winterized #2)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (197- 0017) required for front axle differential.

b. Capacities
Engine Crankcase Oil

Capacity with Filter Change 8,0 liter (8.5 quart)
Fuel Tank
Capacity 150 liter (39.6 gallon)
Cooling System
System Capacity 19,0 liter (20 quart)
Transmission System
Capacity with Filter Change 13,5 liter (14.3 qt)
Transfer Case
Capacity 0.75 liter (0.79 qt)
Hydraulic System
System Capacity 180 liter (47.6 gallon)
Reservoir Capacity to Full Mark 90 liter (23.8 gallon)
Auxiliary Hydraulic Circuit Max Flow 100 lpm (26.4 gpm)
Axles
Differential Housing Capacity
TH414C GS
Front Axle 7,3 liter (7.7 quart)
Rear Axle 7,5 liter (7.9 quart)
TH417C GS
Rear Axle 7,5 liter (7.9 quart)
Friction Modifier (197-0017)
Front Axle Differential
0,2 liter (0.2 quart)
(must be premixed with axle fluid)
Wheel End Capacity
TH414C GC 1,4 liter (1.5 quart)
TH417C GC
Rear Axle
If Equipped with Pneumatic Filled Tires 1,4 liter (1.5 quart)
If Equipped with Foam Filled Tires 2,0 liter (2.1 quart)
Air Conditioning System (if equipped)
System Capacity 1,0 kg (2.2 lb)

2.6 SERVICE AND MAINTENANCE

SCHEDULES
2.6.1 10 & 1st 50 Hour
EVERY
10
Check Fuel Check Engine Check Hydraulic Check Tire Check Engine
Level Oil Level Oil Level Condition & Coolant Level
Pressure
Check
Transmission
Oil Level
1st
50
Check Axle Check Wheel Check Boom Check Wheel

Differential Oil End Oil Levels Chain & Tension Lug Nut
Level Torque
MZ8290

2.6.2 50 & 1st 250 Hour
EVERY
50
Drain Fuel/ Check Air Filter Lubrication Check Check Washer

Water Schedule Battery Fluid Level
Separator (if equipped)
Check Cab
Air Filter
1st
250
Change Change Change Axle Change Wheel

Transmission Transfer Case Differential Oil End Oil
Oil & Filter Oil
OB0440

2.6.3 250 & 500 Hour
EVERY
250
Check Transfer Check Check Axle Check Wheel Check Boom

Case Oil Level Fan Belt Differential Oil End Oil Levels Wear Pads
Level
Check Boom
Chain & Tension
EVERY
500
LB/F
T (N
m)
Change Fuel Change Engine Change Check Wheel Lubrication

Filters Oil and Air Filter Lug Nut Schedule
Filter Elements Torque
Check LSI
Calibration
OZ4260

2.6.4 1000 & 3000 Hour
EVERY
1000
Change Change Check Change Change Axle

Transmission Transfer Case Air Intake Hydraulic Differential Oil
Oil & Filter Oil System Fluid & Filters
Change Wheel
End Oil
EVERY
3000
Change
Belt
OAM3771

2.6.5 6000 & 12000 Hours
EVERY
6000
or
3 Years
Add Engine
Coolant
Extender
EVERY
12000
or
6 Years
Change
Engine Coolant
OAM3522
Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for
additional information.

2.7 LUBRICATION SCHEDULE
2.7.1 TH414C GC
OAM3780

2.7.2 TH417C GC
OAM3790

Section 3
Boom
Contents

3.1 Boom System Component Terminology - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance - TH414C GC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Second, Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.4 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.5 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.6 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Boom Chain Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.2 Retract Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.4 Extend Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . . 3-14
3.5.1 Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.6 Extend/Retract Cylinder Removal/Installation - TH414C GC . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.1 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.2 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 Boom Sections Adjustment - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.8 Boom System Component Terminology - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Boom System - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.9.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Boom Assembly Maintenance - TH417C GC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.10.2 Second, Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.10.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.10.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10.5 Fourth Boom Section Removal Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10.6 Hose Carrier Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10.7 Fourth Boom Section Installation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.10.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.10.9 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.10 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10.11 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Boom
3.11 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11.1 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.11.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - TH417C GC . . . . . . . . . 3-29
3.12.1 Tilt/Auxiliary Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.12.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.12.3 Carrier Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.12.4 Carrier Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.13 Boom Chain Removal/Installation - TH417C GC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.14 Boom Sections Adjustment - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.14.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.15 Boom Extend and Retract Chains - TH414C GC & TH417C GC . . . . . . . . . . . . . . . . . . . . . 3-33
3.15.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15.2 Inspection Guidelines - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15.3 Inspection Guidelines - TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.4 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.15.5 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.16.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.16.2 Boom Wear Pad Installation/Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.17 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.18 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.19 Boom Prop (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.19.1 Installation and Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.20.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.20.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY - TH414C GC
The following illustrations identify the components that are
referred to throughout this section.
EXTEND/RETRACT CYLINDER
RETRACT CHAIN
(inside boom)
EXTEND CHAINS
THIRD (inside boom)
BOOM
SECTION
FIRST BOOM
SECTION
SECOND
BOOM
SECTION
AUXILIARY
CONNECTIONS
(if equipped)
TILT CYLINDER
(inside Boom head) MZ7070

Boom
3.2 BOOM SYSTEM - TH414C GC 3.3 BOOM ASSEMBLY MAINTENANCE -

TH414C GC
3.2.1 Boom System Operation
These instructions must be completed in sequence. The
The TH414C GC three section boom consists of the first, second and third boom sections are removed from the first
second and third assemblies with first and second section boom section. The third boom section is removed from the
extend chains, and a single first and second section retract second boom section or the complete boom assembly can
chain. be removed from the machine.
As the extend/retract cylinder, which is anchored at the top Before beginning, conduct a visual inspection of the
rear of the first boom section, and the top front of the second machine and work area, and review the task about to be
boom section begins to extend, it pushes the second boom undertaken. Read, understand and follow these
section out of the first boom section. instructions.The boom assembly consists of the first, second
The boom sections are connected by extend and retract and third section booms and supporting hardware.
chains. These chains are routed around rollers on the front Note: Before removing the boom or boom section, the carriage
and the rear of the second boom section. As the extend/ or any other attachment must be removed from the quick
retract cylinder is forced out hydraulically, the third boom coupler.
section is pulled out by the extend chains.
Before beginning, conduct a visual inspection of the
As hydraulic pressure is applied to the retract port on the
machine and work area, and review the task about to be
extend/retract cylinder, the retract chain pulls the third boom
undertaken. Read, understand and follow these instructions.
section back into the second boom section as the extend/
retract cylinder pulls the second boom section into the first During service of the boom, perform the following:
boom section. 1. Check wear pads. (Refer to Section 3.16.1, “Wear Pad
This mechanical linkage formed by the chains and Inspection.”)
supporting hardware, extends and retracts the third boom 2. Check chain rollers.
section into the second boom section at the same rate.
3. Apply grease at all lubrication points (grease fittings).
The boom section lifts and lowers via action of the lift (Refer to Section 2.7, “Lubrication Schedule.”)
cylinder.
4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

Boom
3.3.1 Boom Removal 3.3.2 Second, Third Boom Section Removal

While the boom sections can be separated from each other 1. Verify the boom assembly is setting on stable, secure
on the machine, it is much safer, more efficient and more cost and suitable supports.
effective to remove the complete boom assembly from the
machine and place it on suitable supports for separation.
Work can then progress at a normal working height.
4
Note: When removing a complete boom assembly use a hoist 2
or crane with a minimum lift capacity of 2721 kg (6000 lbs). 1
1. Remove any attachment from the quick coupler. Refer
to Operation & Maintenance Manual.
2. Remove the quick coupler assembly. Refer to Section
3
3.17.1, “Quick Coupler Removal.”
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower 4
cylinder pin and the compensation cylinder pin, place
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.
4. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
5. Open the engine cover. Allow the system fluids to cool.
6. Properly disconnect the battery. MZ7090
7. Close engine cover to access lift/lower cylinder pin and 2. Properly support the extend/retract cylinder (1) using a
the compensation cylinder pin. hoist or crane.
8. Properly support the boom assembly using a hoist or 3. Label, disconnect and cap the extend/retract cylinder
crane. hoses (2) from the extend/retract cylinder. Cap all
9. Remove boom angle sensor arm. Refer to Section 9.8.7, fittings and openings to prevent dirt and debris from
“Boom Angle Sensor.” entering the hydraulic system.
10. Remove the pin from the rod end of the lift/lower 4. Loosen and remove the extend/retract cylinder bracket
cylinder being careful not to drop the cylinder. Lower (3).
the cylinder to a secure position. 5. Remove one retaining ring from the mounting pin (4) at
11. Remove the pin from the rod end of the compensation each end of the extend/retract cylinder.
cylinder being careful not to drop the cylinder. Lower 6. Remove each mounting pin and remove the extend/
the cylinder to a secure position. retract cylinder and place in a secure location.
12. Lower the boom assembly to level. 7. Label, disconnect and cap the tilt circuit hoses from the
13. Place a sling around the first boom section at the tilt cylinder at the front of the third boom section. Label,
balance points. disconnect and cap the auxiliary circuit hoses from the
quick disconnect fittings at the front of the third boom
14. Label, disconnect and cap all hydraulic hoses attached
section. Cap all fittings and openings to prevent dirt and
to the tubes on the bottom of the boom. Cap all fittings
debris from entering the hydraulic system.
and openings to keep dirt and debris from entering the
hydraulic system. 8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the
15. Raise the boom assembly to allow the removal of the
retaining rings and pin at the barrel end of the tilt
boom assembly pivot pins.
cylinder. Lower the tilt cylinder and place in a secure
16. Confirm that the boom assembly is balanced with the location.
sling and remove the boom assembly pivot pins.
9. Loosen and remove the rear cover and door assembly
17. Lift the boom assembly from the machine and lower from the rear of the first boom section.
onto suitable supports.

Boom
13. Remove the circlip and pin (8) from the retract chain (9)
at the rear of the third boom section. Lay the retract
chain over the rear edge of the first boom section.
5
6
7
5
MZ7080
10
Note: Before removing the extend chains, measure the MZ7130
distance between the face of the jam nut to the end of the chain
clevis. This measurement will be used when reassembling the 14. Pull the second and third boom sections out of the first
boom. boom section approximately 304mm (12 in) to access
the front first section wear pads.
10. Disconnect both tilt hoses and (if equipped) both
auxiliary hoses (5) at the bottom of the first boom 15. Remove all wear pads, shims and backing plates from
section.Plug the hose ends and cap the tube ends to the front inside of the first boom section(10). Label and
prevent dirt and debris from entering the hydraulic tag each set of wear pads being removed.
system. Pull the disconnected hoses out from the rear of 16. Pull the second and third boom sections out of the first
the boom. boom section. Relocate the lifting slings and slowly pull
11. Loosen and remove the lock nut and jam nut (6) on the the two boom sections clear of the first boom section.
retract chain at the front of the first boom section. Lower onto suitable supports.
12. Loosen and remove the lock nut and jam nut (7) on the 17. Inspect the first boom and welds. Consult your local
extend chain at the front of the first boom section. authorized service distributor if structural damage is
detected.
18. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first
boom section. Replace any item if damaged. (Refer to
Section 3.15, “Boom Extend and Retract Chains -
TH414C GC & TH417C GC,” and Section 3.16.1, “Wear
Pad Inspection.”)
Note: It is recommended that if any chain or hose is damaged
that ALL chains or hoses are replaced.
Note: After removing the second and third boom section the
8 retract chain is left laying on the inside of the first boom section
and can be removed, cleaned, inspected and replaced if
required.
9 MZ7120

Boom
3.3.3 Third Boom Section Removal
14
13
11
15 MZ7190
2. Loosen and remove the mounting bolt (13) and bracket

(14) securing the extend chain clevis (15).
MZ7160
1. Pull the tilt hoses and (if equipped) the auxiliary hoses
from the rear of the third boom section.
Note: The bracket (11) holding the tilt hoses and (if equipped)
auxiliary hoses will still secure the tilt hoses and (if equipped)
auxiliary hoses when the top rear wear pads are removed.
16
MZ7150
3. Remove all wear pads, shims and backing plates from

the front inside of the second boom section (16). Label
12
and tag each set of wear pads being removed.
4. Place a sling around the third boom section, lift and
slowly pull the third boom section approximately half
way out of the second boom section. Lower the third
MZ7200
boom section onto a suitable support.
Note: Remove the individual brackets (12) securing the tilt 5. Relocate the sling or using two slings for better stability,
hoses and (if equipped) auxiliary hoses to the main mounting balance the third boom section and slowly pull it out of
bracket (11). the second boom section being careful not to damage
the hydraulic hoses or chains. Lower the third boom
sections onto suitable supports.
Note: After removing the third boom section the extend chain
is left laying on the inside of the second boom section and can
be removed, cleaned, inspected and replaced if required.

Boom
3.3.4 Third Boom Section Installation

Note: During reassembly use Loctite® 243TM on all bolt threads.
Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear 3
Pads.” You may have to final adjust the wear pads after the
boom assembly is installed on the machine and hydraulic 4
power is available.
Note: Coat the interior of all bushings and bores with Mystik
Tetrimoly Grease XD#2 prior to the installation of pins and
bushings. Wear pads and slide areas must be lubricated with
Mystik Tetrimoly Grease XD#2 or an equivalent.
1. Place the second boom section on suitable supports.
2. Lubricate the inside second boom section on areas 2 MZ7190
where the third boom section wear pads will slide.
9. Install the extend chain clevis (2), mounting bracket (3)
3. Lubricate and place the extend chain in the center of
and secure with bolt (4).
the second boom section.
4. Using a suitable sling, balance the third boom section
and carefully slide the 1m-1,2m (3 ft-4 ft) of the third
boom section into the front of the second boom
section.
5. Set the third boom section onto a suitable support and
reset the sling under the boom head of the third boom
section. Carefully slide the third boom section into the
second boom section.
6. Leave 152 mm-203 mm (6 in-8 in) of the third boom
section out to be able to install the wear pads in the
front of the second boom section.
7. With the sling still under boom head, install the wear
pads and spacers in the front of the second boom
section.
MZ7210
8. Install the previously removed tilt hoses and

(if equipped) the auxiliary hoses mounting bracket (1).

Boom
3.3.5 Second and Third Boom Section

Installation
1. Place the first boom section on suitable supports.
5
MZ7220 7
MZ7130
2. From the rear of the boom, feed the tilt hoses (5) and (if
equipped) auxiliary hoses (6) to the proper tube 9. Install the wear pads, spacers and shims at the front of
connections on the bottom of the first boom section. the first boom section (7).
3. Tighten and torque the tilt hoses and (if equipped)
auxiliary hoses. Verify the hoses are aligned square to
the boom.
4. Lubricate the inside first boom section on area’s where
the second boom section wear pads will slide.
5. Lubricate and place the retract chain in the center of the
second boom section with 254mm (10 in) extending
from the rear of the first boom section.
6. Using a suitable sling, balance the second and third
boom sections and carefully slide 0,9 m-1,22 m
(3 ft-4 ft) into the front of the first boom section. 8
7. Set the second and third boom sections onto a suitable

support and reset the sling under the boom head of the
third boom section.
8. Carefully slide the two boom sections into the first
boom section. Leave 152 mm-203 mm (6 in-8 in) in of 9 MZ7120
the two boom sections out to be able to install the wear 10. Install the pin (8) and circlip securing the retract chain
pad block and the wear pads in the front of the first (9) at the rear of the third boom section.
boom section.

Boom
14
10
11
15
MZ7230
MZ7080
14. Install the tilt cylinder in the boom head, install the
11. Install the retract chain (10) at the front of the first mounting pin and keeper bolt, locking the mounting
boom section. Install the lock nut and jam nut. Do Not pin and tilt cylinder (14) into position.
Tighten at this time.
15. Connect the tilt cylinder hoses to the proper fittings on
12. Install the extend chain (11) at the front of the first the tilt cylinder.
boom section. Install the lock nut and jam nut. Do Not
Tighten at this time. 16. If equipped, connect the auxiliary hoses to the proper
fittings (15) on the boom head.
13
12
16
MZ7200
17. Install the individual brackets (16) securing the tilt

MZ7120 hoses and (if equipped) auxiliary hoses to the main
mounting bracket.
13. Feed the tilt hoses (12) and (if equipped) auxiliary hoses
(13) through the top of the third boom section.

Boom
18
19
17
21
20
18 21
21
21 MZ7240
3. Using suitable slings, balance the boom assembly, lift

and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (21).
MZ7090
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
18. Properly support the extend/retract cylinder (17) using 5. With the sling still in place, install the rod end of the lift/
a hoist or crane and lower into place. lower cylinder, pin and lock bolt. Apply
19. Install each mounting pin (18) in the extend/retract Loctite® 243TM and torque to 90 Nm (66 lb-ft).
cylinder.
Note: Raising the boom up or down with the sling may be
20. Install one retaining ring to the mounting pin (18) at necessary so the boom, compensating and lift/lower cylinder
each end of the extend/retract cylinder. bores can be aligned for easier pin installation.
21. Remove caps and/or plugs from all fittings and 6. Uncap and connect the previously labeled extend/
openings. Connect the extend/retract cylinder hoses retract cylinder hoses to the extend/retract cylinder.
(19) to the extend/retract cylinder.
7. Uncap and connect the previously labeled tilt hoses and
22. Install the extend/retract cylinder bracket (20). (if equipped) auxiliary hoses to the appropriate cylinder.
3.3.6 Complete Boom Installation 8. Install the boom angle sensor arm. Refer to Section
9.8.7, “Boom Angle Sensor.”
Note: Lubrication of the boom wear surfaces with
9. Remove slings and/or supports from the boom
Multipurpose Grease is recommended to keep the boom wear
assembly.
surfaces lubricated properly. Lubrication of the boom wear
surfaces is also recommended when the machine is stored, to 10. Properly connect the battery.
help prevent rusting. 11. Start the engine and operate all boom functions several
1. Park the machine on a hard, level surface, place the times to bleed any air out of the hydraulic system. Check
transmission in (N) NEUTRAL, engage the park brake for fluid leaks. Check the hydraulic fluid level in the tank
and shut the engine OFF. and add fluid as required.
2. Place a Do Not Operate Tag on both the ignition key 12. Lower the boom assembly and shut engine OFF.
switch and the steering wheel. 13. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
Note: Grease the boom pivot bores, compensating cylinder rod
end, lift/lower cylinder rod end and pins before installing. 14. Remove the Do Not Operate Tag from both the ignition
key switch and the steering wheel.

Boom
3.4 BOOM CHAIN REMOVAL/INSTALLATION

- TH414C GC
3.4.1 Retract Chain Removal

The removal of the retract chain can be accomplished with
out the complete tear down of the boom sections.
1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Maintenance Manual. 4
2. Park the machine on a hard, level surface, fully retract 5
the boom, level the boom assembly, place the 1
transmission in (N) NEUTRAL, engage the park brake 6
MZ7120
from the rear of the first boom section. 9. Remove the circlip and pin (4) securing the retract chain
6. Properly disconnect the battery. clevis (5) at the rear of the third boom section.
10. Pull the retract chain (6) from between the first and
second boom sections from the rear of the boom
assembly.
11. Unfasten the rope/wire from the retract chain clevis.
3.4.2 Retract Chain Installation

1. Fasten the rope/wire left in the boom from the retract
2 chain removal to the new retract chain clevis and pull
the chain through the boom sections to the
approximate final position. Remove the rope/wire.
2. Install the retract chain, pin and circlip (4) at the rear of
3 the third boom section.
3. Install the retract chain roller assembly, lock nut and
adjusting nut (3) at the front of the first boom section
1 MZ7250 below the boom head.
4. Install the rear cover and door assembly to the rear of
7. Remove the extend chain lock nut, adjusting nut (1) and
the first boom section.
roller assembly (2). Secure extend chain to access the
removal of the retract chain. 5. Properly connect the battery.
8. Remove the retract chain lock nut and adjusting nut (3). 6. Close and secure the engine cover.
Fasten a rope/wire to the end of the clevis to aid in 7. For chain adjustments see Section 3.7.1, “Chain
reinstallation. Adjustments.”
3.4.3 Extend Chain Removal

The removal of the extend chains can be accomplished with
out the complete tear down of the boom sections.
1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Maintenance Manual.

Boom
2. Park the machine on a hard, level surface, fully retract Note: Removal of the retract chain from the rear of the third
the boom, level the boom assembly, place the boom section may be required to access the extend chain clevis
transmission in (N) NEUTRAL, engage the park brake assembly.
9. Loosen and remove the mounting bolt (3) and bracket
3. Place a Do Not Operate Tag on both the ignition key (4) securing the extend chain clevis (5).
10. Pull the extend chain from between the second and
4. Open the engine cover. Allow the system fluids to cool. third boom sections at the rear of the machine.
5. Properly disconnect the battery. 11. Unfasten the rope/wire from the extend chain.
from the rear of the first boom section. 3.4.4 Extend Chain Installation
1. Fasten the rope/wire left in the boom from the extend
chain removal to the new extend chain and pull the
chain through the boom sections to the approximate
final position. Remove the rope/wire.
2. Install the extend chain clevis bracket (4) and mounting
bolt (3) to the extend chain clevis at the rear of the third
boom section.
3. Install the pin and cotter pin (2) securing the extend
chain to the extend chain clevis at the front of the boom
assembly.
2 4. Install the extend chain lock nut and adjusting nut (1) at
the front of the first boom section.
5. Install the rear cover and door assembly to the rear of
the first boom section.
1 MZ7250 6. Properly connect the battery.
7. Close and secure the engine cover.
7. Loosen the extend chain lock nut and adjusting nut (1)
from the extend chain at the bottom of the first boom 8. For chain adjustments see Section 3.7.1, “Chain
section. Adjustments.”
8. Remove the cotter pin and pin (2) securing the extend
chain to the extend chain clevis. Fasten a rope/wire to
the end of the clevis to aid in reinstallation.
5 MZ7190

Boom
3.5 TILT AND AUXILIARY CIRCUIT HOSE

REMOVAL/INSTALLATION - TH414C GC
Hoses that need replaced and are still in one piece can be
removed and replaced without removing sections of the
boom.
3.5.1 Tilt/Auxiliary Hose Removal
MZ7200
1 4. Loosen and remove the clamps (5) securing the tilt

hoses and (if equipped) auxiliary hoses at the rear of the
third boom section.
5. From the rear of the boom, pull the tilt hoses from
2 between the first and second boom sections.
6. From the rear of the boom, pull the tilt hoses from
inside the third boom section.
7. Unfasten the rope/wire from each end of the hose
MZ7230 assembly.
1. Label, disconnect and cap both hoses from the tilt 3.5.2 Tilt/Auxiliary Hose Installation
cylinder (1) and (if equipped) auxiliary fittings (2) at the
front of the boom. Cap all fittings and openings to keep 1. Fasten the rope/wire left in the boom from the hose
dirt and debris from entering the hydraulic system. removal to each end of the new hose at the rear of
boom.
3
2. Slowly pull the rope/wire from the boom head until the
hose end is visible at the boom head.
4 3. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube
connections.
4. Unfasten the rope/wire from each end of the hose.
5. Uncap and connect the hoses to the previously labeled
tubes under the first boom section. Refer to Section
2.3.3, “Hydraulic Hose Torque Chart,” for proper hose
torque.
MZ7220
fittings at the tilt cylinder or the auxiliary fittings. Refer
2. Label, disconnect and cap both tilt hoses (3) attached to to Section 2.3.3, “Hydraulic Hose Torque Chart,” for
the tubes on the bottom of the boom. If equipped, proper hose torque.
label, disconnect and cap both auxiliary hoses (3) 7. Install and tighten the clamps holding the tilt hoses at
attached to the tubes on the bottom of the boom.Cap the rear of the third boom section.
all fittings and openings to keep dirt and debris from
entering the hydraulic system. 8. Properly connect the battery.
3. Fasten a rope/wire to the hose end below the first boom

section.

Boom
3.6 EXTEND/RETRACT CYLINDER REMOVAL/ 3.6.2 Extend/Retract Cylinder Installation

INSTALLATION - TH414C GC 1. Install the extend/retract cylinder (6) onto the top of the
boom assembly.
The extend/retract cylinder hydraulically extends and
retracts the third boom section. 2. Install one mounting pin (9) at each end of the extend/
Seal kits for the extend/retract cylinders are available from retract cylinder and secure with retaining ring.
the local Caterpillar dealer. 3. Uncap and connect the hoses (7) to the previously
labeled fittings at the extend/retract cylinder.
3.6.1 Extend/Retract Cylinder Removal 4. Instal the extend/retract cylinder bracket (8).
1. Remove any attachment from the quick coupler 5. Properly connect the battery.
6. Start the machine and cycle the extend/retract cylinder
2. Park the machine on a hard, level surface, extend the checking for leaks or any alignment problems.
boom to gain access to the extend/retract cylinder pin
in the third boom section, level the boom assembly, 3.7 BOOM SECTIONS ADJUSTMENT -
place the transmission in (N) NEUTRAL, engage the park TH414C GC
brake and shut the engine OFF.
3.7.1 Chain Adjustments
The chains are adjusted by tightening and/or backing off the
adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
9 whenever this procedure is performed.
7
The chains are properly adjusted whenever the following
6
parameters are met.
1. Start the machine, level the boom and retract the
extend/retract cylinder completely. Turn OFF engine.
8
9
11
MZ7090
4. Properly support the extend/retract cylinder (6) using a

hoist or crane. 10 MZ7810
5. Label, disconnect and cap the extend/retract cylinder
hoses (7) from the extend/retract cylinder. Cap all 2. At the bottom front of the boom section, adjust the
fittings and openings to prevent dirt and debris from extend chain (10) and retract chain (11) to achieve the
entering the hydraulic system. proper boom measurements.
6. Loosen and remove the extend/retract cylinder bracket 3. Loosen the jam nut on each chain clevis.
(8).
7. Remove one retaining ring from the mounting pin (9) at
each end of the extend/retract cylinder.
8. Remove each mounting pin and remove the extend/
retract cylinder and place in a secure location.

Boom
MZ7820
4. Adjust the boom chains to obtain dimension (A)

175,0-190,0mm (6.9-7.4 in).
Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.
5. Start the machine and slowly extend and retract the
boom three times.
6. Retract the extend/retract cylinder completely. Turn
OFF engine
7. Repeat step 4 and 5 if necessary.
8. Tighten the extend/retract chain lock nuts (10 & 11) to
120 Nm (86 lb-ft) against the adjusting nut.
to verify the boom extends and retracts properly.
D
C
B
MZ7830
10. With the boom level, extend the boom completely and
retract 50,0mm (2.0 in).
11. Verify dimensions (B) 3900,0mm (153.5 in) and (C)
1950,0mm (76.8 in) are correct.
12. Verify the SAG dimension (D) is 160-165mm
(6.3-6.5 in).
13. Adjust extend chain (10) if required. Repeat steps 9, 10
and 11 if necessary.

Boom
3.8 BOOM SYSTEM COMPONENT

TERMINOLOGY - TH417C GC
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 boom system. The following
illustration identifies the components that are referred to
throughout this section.
EXTEND/RETRACT CYLINDER
RETRACT CHAIN
(fourth boom section)
(not shown)
EXTEND CHAIN
(fourth boom section)
FIRST BOOM SECTION
RETRACT CHAIN
(third boom section)
(not shown)
EXTEND CHAINS - 2
(third boom section)
(not shown)
SECOND BOOM SECTION
THIRD BOOM
SECTION
FOURTH BOOM SECTION
AUXILIARY
CONNECTIONS
(if equipped)
MZ7260
TILT CYLINDER

Boom
3.9 BOOM SYSTEM - TH417C GC 3.10 BOOM ASSEMBLY MAINTENANCE -

TH417C GC
3.9.1 Boom System Operation
These instructions must be completed in sequence. The
The four section boom consists of the first, second, third and second, third and fourth boom sections are removed from
fourth assemblies with double third section extend chains, a the first boom section.The third and fourth boom sections
single fourth section extend chain, a single third and fourth are removed from the second boom section.The fourth
section retract chains. boom section is removed from the third boom section.
As the extend/retract cylinder, which is anchored at the front Before beginning, conduct a visual inspection of the
of the second boom section, and the rear of the first boom machine and work area, and review the task about to be
section begins to extend, it forces the second boom section undertaken. Read, understand and follow these
out of the first boom section. instructions.The boom assembly consists of the first, second
The first, second, third and fourth boom sections are and third section booms and supporting hardware.
connected by extend and retract chains. These chains are Note: Before removing the boom or boom section, the carriage
routed around sheaves on the second and third boom or any other attachment must be removed from the quick
sections. As the second and third boom sections are forced coupler.
out, the extend chains pull the third and fourth boom
sections out of the second boom section. Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
As hydraulic pressure is applied to the retract port on the
undertaken. Read, understand and follow these instructions.
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chains pulls During service of the boom, perform the following:
the third and fourth boom sections back into the second 1. Check wear pads. (Refer to Section 3.16.1, “Wear Pad
boom section. Inspection.”)
This mechanical linkage formed by the chains and 2. Check chain rollers.
supporting hardware, extends and retracts the third and
3. Apply grease at all lubrication points (grease fittings).
fourth boom sections at the same rate.
(Refer to Section 2.7, “Lubrication Schedule.”)
The first boom section does not extend or retract, but lifts
4. Check for proper operation by operating all boom
and lowers via action of the lift cylinder.
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

Boom
3.10.1 Boom Removal 3.10.2 Second, Third and Fourth Boom Section
While the boom sections can be separated from each other
Removal
on the machine, it is much safer, more efficient and more 1. Verify the boom assembly is setting on stable, secure
cost- effective to remove the complete boom assembly from and suitable supports.
the machine and place it on suitable supports for separation.
Work can then progress at a normal working height.
Note: When removing a complete boom assembly use a hoist 2
or crane with a minimum lift capacity of 6000 lbs. 1
1. Remove any attachment from the quick coupler 4
3
2. Remove the quick coupler assembly. Refer to Section
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place 4
6. Properly disconnect the battery.
MZ7270
7. Close engine cover to access lift/lower cylinder pin and
the compensation cylinder pin. 2. Properly support the extend/retract cylinder (1) using a
hoist or crane.
8. Properly support the boom assembly using a hoist or
crane. 3. Label, disconnect and cap the extend/retract cylinder
hoses (2) from the extend/retract cylinder. Cap all
9. Remove boom angle sensor arm. Refer to Section 9.8.7, fittings and openings to prevent dirt and debris from
“Boom Angle Sensor.” entering the hydraulic system.
10. Remove the pin from the rod end of the lift/lower 4. Loosen and remove the extend/retract cylinder bracket
cylinder being careful not to drop the cylinder. Lower (3).
the cylinder to a secure position.
5. Remove one retaining ring from the mounting pin (4) at
11. Remove the pin from the rod end of the compensation each end of the extend/retract cylinder.
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position. 6. Remove each mounting pin and remove the extend/
retract cylinder and place in a secure location.
12. Lower the boom assembly to level.
7. Label, disconnect and cap the tilt circuit hoses from the
13. Place a sling around the first boom section at the tilt cylinder at the front of the third boom section. Label,
balance points. disconnect and cap the auxiliary circuit hoses from the
14. Label, disconnect and cap all hydraulic hoses attached quick disconnect fittings at the front of the third boom
to the tubes on the bottom of the boom. Cap all fittings section. Cap all fittings and openings to prevent dirt and
and openings to keep dirt and debris from entering the debris from entering the hydraulic system.
hydraulic system. 8. Place a sling through the opening at the top of the
15. Raise the boom assembly to allow the removal of the boom head and around the tilt cylinder and remove the
boom assembly pivot pins. retaining rings and pin at the barrel end of the tilt
16. Confirm that the boom assembly is balanced with the cylinder. Lower the tilt cylinder and place in a secure
sling and remove the boom assembly pivot pins. location.
17. Lift the boom assembly from the machine and lower 9. Loosen and remove the rear cover and door assembly
onto suitable supports. from the rear of the first boom section.

Boom
6 12
5
MZ7280
Note: Before removing the extend chains, measure the

distance between the face of the jam nut to the end of the chain
clevis. This measurement will be used when reassembling the
boom. MZ7300
10. Loosen and remove the lock nut and jam nut (5) on the
14. Pull the second, third and fourth section booms out 152
retract chain at the front of the first boom section.
mm to 203 mm (6 in to 8 in) and remove all the wear
11. Loosen and remove the lock nuts and jam nuts (6) on pads, shims and backing plates from the front inside of
the extend chains at the front of the first boom section. the first section boom (12). Label all parts for
installation.
15. Using a sling around the front of the second boom
section, lift and slide the three boom sections 75% of
the way out of the first boom section. Set the boom
head down on a suitable support, then center the sling
to be able to balance the three boom sections being
removed. Carefully pull the three boom sections the
remainder of the way out of the first boom section and
set the three boom sections down on suitable supports.
16. Remove the retract chain from the inside of the first
boom section. Clean and inspect chains. Replace if
8 damaged.
9 17. Label, disconnect and cap the Tilt and (if equipped)
10 Auxiliary hydraulic hoses from tubes at bottom front of
first boom section. Plug all fittings to prevent dirt and
MZ7290
11
debris from entering hydraulic system. Clean and
inspect the hoses. Replace if damaged.
12. At the rear of the boom, label, disconnect and cap both
Tilt hoses (8) and (if equipped) both Auxiliary hoses (9) 18. Inspect the boom and welds. Consult your local
from the brackets attached to the third boom section. authorized service distributor if structural damage is
Cap all fittings to prevent dirt and debris from entering detected.
the hydraulic system. 19. Inspect hoses, hardware, wear pads, mounting points,
13. Remove the clip and pin (10) from the retract chain chains and other components visible with the first
clevis that is attached to the rear of the third section boom section. Replace any item if damaged. (Refer to
boom. Lay the retract chain (11) over the rear of the first Section 3.15, “Boom Extend and Retract Chains -
boom section. TH414C GC & TH417C GC,” and Section 3.16.1, “Wear
Pad Inspection.”)

Boom
Note: It is recommended that if any chain or hose is damaged

17
3.10.3 Third and Fourth Boom Section Removal
1. Verify the boom assembly is setting on stable, secure
and suitable supports.
16
15
15
MZ7320
MZ7310
4. At the top front of the second boom section (16),
13 14 13 remove the jam nuts and nuts and washers from the
extend chain clevis (17).
Note: Removal of the retract chain roller from the rear of the
5. Pull the third boom section out 152 mm to 203 mm (6 in
second boom section may be required to access the extend
to 8 in). Remove the top wear pads, shims and backing
chain clevis assemblies.
plate from the second boom section. Label and tag each
2. Loosen and remove the mounting bolts (13) and set of wear pads being removed.
bracket (14) securing each extend chain clevises (15). 6. Remove the side wear pads, shims and backing plates
3. Fasten a rope/wire to each extend chain clevis. from either side of the rear of the second boom section.
Label and tag each set of wear pads being removed.
7. Place a sling around the front of the third boom section.
Lift and slide the two boom sections 75% of the way out
of the second boom section. Set the boom head down
on a suitable support, then center the sling to be able to
balance the two boom sections being removed.
Carefully pull the two boom sections the remainder of
the way out of the second boom section and set the
two boom sections down on suitable supports.
8. Remove the extend chains from bottom of second
boom section. Clean and inspect chain. Replace if
damaged.
9. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

Boom
10. Inspect hardware, wear pads, mounting points, chains

and other components visible with the second boom
section. Replace any item if damaged. (Refer to Section
3.15, “Boom Extend and Retract Chains - TH414C GC &
24
TH417C GC,” and Section 3.16.1, “Wear Pad Inspection.”)
11. It is recommended that if any chain or hose is damaged
3.10.4 Fourth Boom Section Removal

25
1. Verify the boom assembly is setting on stable, secure
and suitable supports.
18
23
20 MZ7350
19
6. At the top front of the third boom section (23), Lay the
extend chain and clevis (24) over the front of the fourth
boom section.(25).
7. Remove the top wear pads, shims and backing plate
from the third boom section. Label and tag each set of
wear pads being removed.
the front of the third boom section. Label and tag each
MZ7330
22 21 set of wear pads being removed.
2. At the rear of the boom, loosen and remove the hose 9. Place a sling around the front of the fourth boom
brackets (18) attached to the third boom section section. Lift and slide the two boom sections 75% of the
securing tilt hoses (19) and (if equipped) the auxiliary way out of the third boom section. Set the boom head
hoses (20). Label, disconnect and cap both Tilt hoses down on a suitable support, then center the sling to be
and (if equipped) both Auxiliary hoses. Cap all fittings to able to balance the two boom sections being removed.
prevent dirt and debris from entering the hydraulic Carefully pull the fourth boom section the remainder of
system. the way out of the third boom section and set the fourth
3. Remove the clip and pin from the retract chain clevis boom section down on suitable supports.
(21) that is attached to the rear of the fourth section
boom. Lay the retract chain over the rear of the third
boom section.
4. Remove the retract chain from top of third boom
section. Clean and inspect chain. Replace if damaged.
5. Loosen and remove the two bolts securing the hose
carrier (22) to the third boom section.

Boom
3.10.5 Fourth Boom Section Removal Only

26
Note: Removal and installation of the hose carrier can also be
performed by removing only the fourth boom section if
required.
27
29
MZ7360 28
10. Remove the extend chain (26) from top of fourth boom
section. Clean and inspect chain. Replace if damaged.
30 MZ8370
11. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is 1. Disconnect the extend chain clevis (27) from the rear of
detected. the fourth boom section.
12. Inspect hardware, wear pads, mounting points, chains 2. At the rear of the boom, label, disconnect and cap both
and other components visible with the second boom Tilt hoses (28) and (if equipped) both Auxiliary hoses
section. Replace any item if damaged. (Refer to Section (29) from the tubes attached to the third boom section.
3.15, “Boom Extend and Retract Chains - TH414C GC & Cap all fittings to prevent dirt and debris from entering
TH417C GC,” and Section 3.16.1, “Wear Pad Inspection.”) the hydraulic system.
13. It is recommended that if any chain or hose is damaged 3. Loosen and remove the two bolts securing the hose
that ALL chains or hoses are replaced. carrier (30) to the third boom section.
the front of the third boom section. Label and tag each
set of wear pads being removed.
5. Place a sling around the front of the fourth boom
section. Lift and slide the two boom sections 75% of the
way out of the third boom section. Set the boom head
down on a suitable support, then center the sling to be
able to balance the two boom sections being removed.
Carefully pull the fourth boom section the remainder of
the way out of the third boom section and set the fourth
boom section down on suitable supports.
3.10.6 Hose Carrier Removal/Installation

Refer to Section 3.11, “Hose Carrier Assembly,” for detailed
hose carrier removal and installation.

Boom
3.10.7 Fourth Boom Section Installation Only 3.10.8 Fourth Boom Section Installation
1. Using a suitable sling, balance the fourth boom section Note: During reassembly use Loctite® 243TM on all bolt threads.
and carefully slide 914 mm to 1219 mm
Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear
(3 ft to 4 ft) into the front of the third boom section. Set
Pads.” You may have to final adjust the wear pads after the
the fourth boom section head onto suitable support
boom assembly is installed on the machine and hydraulic
and reset sling under the boom head of the fourth
power is available.
boom section. Carefully slide the fourth boom section
into the third boom section. Leave Note: Coat the interior of all bushings and sheaves with Mystik
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom Tetrimoly Grease XD#2 prior to the installation of pins and
section out to be able to install wear pads in front of the bushings. Wear pads and slide areas must be lubricated with
third boom section. Mystik Tetrimoly Grease XD#2 or an equivalent.
2. With the sling still under boom head install the bottom 1
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. Tighten as required.
3. Install the two bolts securing the hose carrier (30) to the
third boom section.
4. At the rear of the boom, remove the caps from both Tilt
hoses (28) and (if equipped) both Auxiliary hoses (29).
Connect each hose to the previously labeled tubes
attached to the third boom section.
5. Connect the extend chain clevis (27) to the rear of the
fourth boom section.
MZ7360
1. Install the extend chain (1) on the top rear of fourth

boom section. Lay the extend chain the length of fourth
boom section.
2. Grease the inside third boom section on area’s where
the fourth boom section wear pads will slide.
3. Using a suitable sling, balance the fourth boom section
and carefully slide 914 mm to 1219 mm
(3 ft to 4 ft) into the front of the third boom section. Set
the fourth boom section head onto suitable support
and reset sling under the boom head of the fourth
boom section. Carefully slide the fourth boom section
into the third boom section. Leave
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom
section out to be able to install wear pads in front of the
third boom section.

Boom
4. With the sling still under boom head install the bottom 3.10.9 Third and Fourth Boom Section
front wear pads and backing plates on the third boom Installation
section. Lower the fourth boom section and install the
1. Install the extend chains on the bottom inside of second
top front and side wear pads and backing plates on the
boom section. Lay the extend chain the length of
third boom section. Do not shim or tighten bolts at this
second boom section.
time.
Note: Grease wear pads, bores and pins during assembly.
5. Retract the fourth boom section the remainder of the
way into the third boom section.
6. Shim all wear pads on the front of the third boom
section. Torque bolts to 90 Nm (66 lb-ft).
2
7
7
4
3
MZ7310
8 9 8
2. Grease the inside second boom section on areas where

the third boom section wear pads will slide.
3. Using a suitable sling, balance the third and fourth
boom sections and carefully slide 914 mm-1219 mm
(3 ft - 4 ft) into the front of the second boom section. Set
MZ7330 the third and fourth boom sections onto a suitable
6 5
support and reset the sling under the boom head of the
7. At the rear of the boom, install the hose brackets (2) to fourth boom section. Carefully slide the third and fourth
the third boom section securing tilt hoses (3) and (if boom sections into the second boom section. Leave 152
equipped) the auxiliary hoses (4). mm-203 mm (6 in - 8 in) of the third boom section out
to be able to install the wear pads in the front of the
8. Remove caps on both Tilt hoses and (if equipped) both second boom section.
Auxiliary hoses. Install hoses and torque as required.
4. With the sling still under third boom section, install the
9. Lay the retract chain (5) the length of third boom bottom front wear pads and backing plates on the
section. second boom section. Lower the third boom section
10. Install the pin and clip to the retract chain clevis (5) to and install the top front and side wear pads and backing
the top rear of the fourth section boom. plates on the second boom section. Do not shim or
11. Install the two bolts securing the hose carrier (6) to the tighten bolts at this time.
third boom section. Torque as required. Note: Installation of the retract chain roller from the rear of the
second boom section may be required if removed to access the
extend chain clevis assemblies.
5. Secure the extend chains to the each extend chain
clevises (7)
6. Install the mounting bolts (8) and bracket (9) securing
each extend chain clevises (7).

Boom
Note: Grease wear pads, bores and pins during assembly. 3.10.10 Second, Third and Fourth Boom Section
Installation
10
11
12
MZ7610
1. Install the retract chain (12) to bottom front inside of

the first boom section. Install the lock nut and jam nut.
Lay the retract chain over the rear of the first boom
section.
13
MZ7320
7. Install the extend chain (10) to the top front of the 14

second boom section (11). Install the lock nut and jam
nut.
8. Shim all wear pads on the rear of the third boom section
and front of the second boom section. Torque bolts to
90 Nm (66 lb-ft).
MZ7220
2. Install the tilt hoses (13) and auxiliary hoses (14) to the
tubes mounted at the bottom front of the first boom
section. Verify both sets of hoses are run through the
opening at the bottom front of the first boom section
and parallel with the retract chain. Lay the tilt hoses and
auxiliary hoses over the rear of the first boom section.
Note: Keep the retract chain, tilt and auxiliary hoses centered
in the first boom section while installing the second boom
section into the first boom section.
3. Grease the inside first boom section on area’s where the
second boom section wear pads will slide.

Boom
4. Using a suitable sling, balance the second, third and

fourth boom sections and carefully slide
914 mm - 1219 mm (3 ft - 4 ft) into the front of the first
boom section. Set the second, third and fourth boom
sections onto a suitable support and reset sling under
the boom head of the fourth boom section. Carefully
slide the second, third and fourth boom sections into
the first boom section. Leave 152 mm - 203 mm
(6 in - 8 in) of the second boom section out to be able to
install wear pads in front of the first boom section.
5. With the sling still under the third boom section, install
the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and 18
install the top front and side wear pads and backing
19
plates on the first boom section. Do not shim or tighten
bolts at this time. 17
MZ7290
6. Retract the second, third and fourth boom sections the 16
remainder of the way into the first boom section.
9. Attach the retract chain (16), pins and clips to the
Note: Shim wear pads as needed to maintain an even gap of
clevises (17) at the rear of the second boom section.
0,5-1,5 mm (0.002-0.06 in) between the wear pads and the next
boom section. The number of shims can vary at each shim Note: Adjust all extend chains using the measurement taken in
point. the beginning of the tear down procedure. Depending on the
7. Shim all wear pads on the rear of the second boom extent of the parts being replaced, the above measurement is to
section and front of the first boom section. Torque as be used as a starting point ONLY.
required. 10. Remove the caps from the Tilt hoses (18)(and if
equipped) Auxiliary hoses (19) and connect to the
appropriate fittings at the rear of the second boom
section. Torque as required.
21
22
15 20
23
MZ7610 24
8. Attach the extend chains (15) at the bottom front of the

first boom section. Install the lock nut and jam nut.
11. Using a suitable sling around the barrel end of the Tilt
cylinder (20), raise the Tilt cylinder into boom head.
Align the Tilt cylinder barrel end bore with the boom
head bore (21) and install the Tilt cylinder pin and
mounting bolt and nut (22).

Boom
Note: Grease Tilt cylinder barrel end bore and pin before 3.10.11 Complete Boom Installation
installing. 1. Park the machine on a hard, level surface, place the
12. Remove the plugs from the fittings on the Tilt cylinder transmission in (N) NEUTRAL, engage the park brake
and the caps from the Tilt hoses from the hose carrier. and shut the engine OFF.
Install both Tilt hoses (23). Torque as required. 2. Place a Do Not Operate Tag on both the ignition key
13. If equipped, remove the plugs from the Auxiliary fittings switch and the steering wheel.
and the caps from the Auxiliary hoses from the hose
carrier. Install both Auxiliary hoses (24). Torque as
required.
26
30
25
31
27
29
31
31
31
MZ7590
28 3. Using suitable slings, balance the boom assembly, lift

and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (31).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
5. With the sling still in place, install the rod end of the lift/
MZ7270 lower cylinder, pin and lock bolt.
14. Attach a sling around a balance point on the Extend/ Note: Raising the boom up or down with the sling may be
Retract cylinder (25) and carefully set on top of the first necessary so the boom, compensating and lift/lower cylinder
boom section. bores can be aligned for easier pin installation.
Note: Grease Extend/Retract cylinder barrel end bore and rod 6. Uncap and connect the previously labeled extend/
end bore and pins before installing. retract cylinder hoses to the extend/retract cylinder.
15. Align the Extend/Retract cylinder barrel end (26) with 7. Uncap and connect the previously labeled tilt hoses and
bore at rear of the first boom section. Install the pin and (if equipped) auxiliary hoses to the appropriate cylinder.
retaining clip (27). 8. Install the boom angle sensor arm. Refer to Section
16. Align the Extend/Retract cylinder rod end with bore at 9.8.7, “Boom Angle Sensor.”
front of the second boom section. Install the pin and 9. Remove slings and/or supports from the boom
retaining clip (28). assembly.
17. Install Extend/Retract cylinder support (29). Torque as 10. Start the engine and operate all boom functions several
required. times to bleed any air out of the hydraulic system. Check
18. Uncap and connect the previously labeled extend/ for fluid leaks. Check the hydraulic fluid level in the tank
retract cylinder hoses (30) to the extend/retract and add fluid as required.
cylinder. 11. Lower the boom assembly and shut engine OFF.
Note: Torque extend and retract chains lock/jam nuts to 115- 12. Clean up all debris, hydraulic fluid, etc., in, on, near and
125Nm (85-92 lb-ft). around the machine.

Boom
3.11 HOSE CARRIER ASSEMBLY 3.11.2 Hose Carrier Installation

1. Place a sling around the center of the hose carrier to be
Note: Removal and installation of the hose carrier can also be
able to balance the hose carrier while being installed.
performed by removing only the fourth boom section if
required. 2. Carefully slide the hose carrier (5) halfway into the
fourth boom section.
3.11.1 Hose Carrier Removal 3. Remove the sling and push the hose carrier assembly
1. Refer to Section 3.10.4, “Fourth Boom Section the remainder of way into the fourth boom section.
Removal,”for detailed removal instructions. 4. Apply Loctite® 243TM to the previously removed
2. Set the forth boom section on level ground, reposition mounting bolts.
the slings and slowly turn the boom section over. 5. Install the twelve bolts (six per side)(4) on the fourth
Reposition the slings and set the boom section on boom section.
suitable supports. 6. Install the mounting bolts (3) securing the tilt hoses and
2 1 (if equipped) both auxiliary hoses brackets at the rear of
the fourth boom section.
7. Insert the tilt hoses (6)(and if equipped) auxiliary hoses
(7) into the hose carrier tray (2).
6 7
8. Install the hose carrier tray (2) into the fourth boom
section and secure the hose carrier tray with mounting
bolts (1).
9. Using slings, slowly turn the boom section over.
Reposition the slings and set the boom section on
suitable supports.
10. Refer to Section 3.10.8, “Fourth Boom Section
3 3 Installation,” for detailed installation instructions.
4 MZ7371
5
3.12 BOTTOM TILT AND AUXILIARY CIRCUIT
3. Loosen and remove the two bolts (1) securing the hose HOSE REMOVAL/INSTALLATION -
carrier tray (2). TH417C GC
4. Pull the tray (2) from the rear of the fourth boom
section.
3.12.1 Tilt/Auxiliary Hose Removal
5. With fourth boom section setting on suitable supports
The following procedures can be performed without
loosen and remove the each bolt (3) securing the tilt
disassembling the boom assembly.
hoses and (if equipped) both auxiliary hoses brackets at
the rear of the fourth boom section. 1. Remove any attachment from the quick coupler
6. Loosen and remove the twelve bolts (six per side)(4) on
the fourth boom section. 2. Remove the quick coupler assembly. Refer to Section
7. Pull the hose carrier (5) halfway out of fourth boom
section by hand and set on a suitable support. Place a 3. Park the machine on a hard, level surface, fully retract
sling around the center of the hose carrier to be able to the boom, raise the boom assembly to access lift/lower
balance the hose carrier while being removed. cylinder pin and the compensation cylinder pin, place
8. Carefully slide the hose carrier (5) the remainder of the
way out of the fourth boom section and set down on
suitable supports. 4. Place a Do Not Operate Tag on both the ignition key
9. Secure the tilt hoses (and if equipped) the auxiliary
hoses with nylon ties. Remove tilt and/or auxiliary hoses 5. Open the engine cover. Allow the system fluids to cool.
if required. 6. Properly disconnect the battery.

Boom
3.12.2 Tilt/Auxiliary Hose Installation

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.
2. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube
connections.
3. Unfasten the rope/wire from each end of the hose.
tubes under the first boom section. Refer to Section
2.3.3, “Hydraulic Hose Torque Chart,” for proper hose
35 torque.
36
fittings at the tilt cylinder or the auxiliary fittings. Refer
to Section 2.3.3, “Hydraulic Hose Torque Chart,” for
proper hose torque.
6. Properly connect the battery.
MZ7520
3.12.3 Carrier Tilt/Auxiliary Hose Removal
7. Label, disconnect and cap both Tilt hoses (35) and (if
equipped) both Auxiliary hoses (36). Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.
35
40
36
38 37
MZ7220
8. Label, disconnect and cap both Tilt hoses (35) attached

MZ7530
to the tubes on the bottom of the boom. If equipped,
label, disconnect and cap both Auxiliary hoses (36) 39
attached to the tubes on the bottom of the boom.Cap 1. Label, disconnect and cap both Tilt hoses (37) and (if
all fittings and openings to keep dirt and debris from equipped) both Auxiliary hoses (38). Cap all fittings to
entering the hydraulic system. prevent dirt and debris from entering the hydraulic
9. Fasten a rope/wire to the hose end below the first boom system.
section. 2. Fasten a rope/wire to the end of each disconnected
10. From the rear of the boom, pull the tilt hoses (and if hose.
equipped) auxiliary hoses from between the first and 3. Loosen and remove lower clamp (39) securing both Tilt
second boom sections. hoses (37) and (if equipped) both Auxiliary hoses (38).
11. Unfasten the rope/wire from the end of the hose 4. Slowly pull each hose assembly halfway out of the rear
assembly. boom assembly.

Boom
5. Loosen and remove upper clamp (40) securing both Tilt 3.13 BOOM CHAIN REMOVAL/INSTALLATION
hoses (37) and (if equipped) both Auxiliary hoses (38). - TH417C GC
The removal of the extend and/or retract chain can only be
accomplished with the complete tear down of the boom.
3.14 BOOM SECTIONS ADJUSTMENT -

37
38 TH417C GC
3.14.1 Chain Adjustments

The chains are adjusted by tightening and/or backing off the
adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.
Fully retract and level the boom.
A B
MZ7570
6. Label, disconnect and cap both Tilt hoses (37) and

C
(if equipped) both Auxiliary hoses (38). Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.
7. Slowly pull each hose assembly the remainder of the
way out of the rear boom assembly.
8. Disconnect the rope/wire from each end of the hose
assemblies.
3.12.4 Carrier Tilt/Auxiliary Hose Installation

1. Connect the previously removed rope/wire to the new
Tilt hoses (37) and (if equipped) both Auxiliary hoses MZ7860
(38).
The boom is properly adjusted whenever the following
2. Carefully feed the hoses through the rear of the boom parameters are met.
assembly while pulling the wire/rope connected to the
hose from the front of the boom head. A. 127-137mm (4.9-5.4 in)
B. 180-190mm (7.08-7.48 in)
3. Carefully feed the hoses through the rear of the boom C. 45mm (1.77 in) (No Adjustment)
assembly while pulling the wire/rope connected to the If adjustments are needed: Start the machine, level the
hose from the bottom rear of the boom assembly. boom and extend the boom 0,91m to 1,2m
4. Remove any caps and connect each Tilt hoses (37) and (3 ft to 4 ft). Turn OFF engine.
(if equipped) both Auxiliary hoses (38) to the previously
labeled connection. Torque as required.
5. At the rear of the boom, tighten the previously
loosened clamps (39) securing the Tilt hoses (37) and (if
equipped) both Auxiliary hoses (38).

Boom
11. The distance between the extend chains and the each
boom section should measure 140-145 mm (5.5-5.7 in).
3 12. Loosen the locknuts on the extend chains and adjust if
necessary. Tighten locknuts to 120 Nm (86 lb-ft).
to verify the boom extends and retracts properly.
MZ7870
4
1 2
1. Loosen the locknuts on the extend and retract chains.
2. Adjust extend chains (1) and retract chain (2) to ensure
a gap of (B) between the back of the second boom
section and the back of the third boom section.
3. Adjust extend chain (3) and retract chain (4) to ensure a
gap of (A) between the back of the third boom section
and the back of the fourth boom section.
4. Tighten the extend and retract chain lock nuts to 120
Nm (86 lb-ft) against the adjusting nut.
5. Start the machine and slowly extend and retract the
boom three times.
6. Retract the extend/retract cylinder completely. Turn
OFF engine.
7. Verify boom section dimensions. Repeat steps 1 thru 3 if
necessary.
8. Start the machine, lower the out riggers if necessary and
extend the boom to maximum extension, then retract
51 to 76 mm (2 to 3 in). Shut machine off.
5
MZ7990
6
9. Measure the distance (5) between the top of extend
chain and the top of the third boom section.
10. Measure the distance (6) between the top of both
extend chains and the bottom of the second boom
section.

Boom
3.15 BOOM EXTEND AND RETRACT • High velocity movement of load, followed by
sudden, abrupt stops.
CHAINS - TH414C GC & TH417C GC
• Carrying loads in suspension over irregular surfaces
such as railroad tracks, potholes, and rough terrain.
3.15.1 Boom Chain Inspection
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
WARNING The above load cycles and environmental conditions make it
impossible to predict chain life. It is therefore necessary to
Worn pins, stretched or cracked links or corrosive conduct frequent inspections until replacement life can be
environments can cause chain failure. A chain failure predicted.
could result in uncontrolled boom movement, loss of
load or machine instability. The boom chain’s normal life expectancy can be expressed
as a maximum percent of elongation. This is generally 3%.
Under normal operating conditions the boom chains will As the chain flexes back and forth over the sheave, the
need to be inspected every 250 hours of operation. The bearing joints (pins and inside link plates) gradually incur
retract chains need to be exposed and inspected every 1000 wear due to articulation.
hours of operation. Refer to the Service Manual for the
proper procedure. Environmental conditions and dynamic 3.15.2 Inspection Guidelines - TH414C GC
impulse/shock loads can drastically affect normal operating
conditions and require more frequent inspection intervals. a. Retract Chain
Environments in which material handling vehicles operate 1. Park the machine on a firm, level surface, raise the boom
can vary widely from outdoor moisture to temperature to to a horizontal (level) position, place the transmission in
mildly corrosive or highly corrosive industrial atmospheres, (N) NEUTRAL, engage the park brake switch.
in addition to abrasive exposures such as sand and grit.
Some effects can be as follows: 2. Fully extend the boom until the retract chain is taut.
Shut the engine off.
• Moisture - Corrosive rusting reduces chain strength
by pitting and cracking. 3. The retract chain will be visible for inspection with the
vehicle in this state.
• Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of 4. While doing the chain inspection, check all chain clevis
cold storage results in moisture from condensation. ends, pins for distortion or cracking and sheaves for
bearing wear or grooving from the chain.
• Chemical Solutions or Vapors - Corrosive attack on
the chain components and/or the mechanical
connections between the chain components. b. Extend Chains
Cracking can be (and often is) microscopic. Going 1. Park the machine on a firm, level surface, raise the boom
from microscopic cracking to complete failure can to a horizontal (level) position, place the transmission in
be either abrupt or may require an extended period
(N) NEUTRAL, engage the park brake switch.
of time.
2. Fully retract the boom. Shut the engine off.
• Abrasives - Accelerated wearing and scoring of the
articulating members of the chain (pins and plates), 3. Both extend chain clevises and pins will be visible for
with a corresponding reduction in chain strength. inspection with the vehicle in this state.
Due to the inaccessibility of the bearing surfaces 4. Limited visual inspection of the extend chains is
(pin surfaces and plate apertures), wear and scoring
possible. For complete extend chain inspection, the
are not readily noticeable to the naked eye.
extend chains must be removed from the boom. For
Following are some examples of dynamic shock loading extend chain removal, refer to Section 3.4.3, “Extend
which can impose abnormal loads above the endurance limit Chain Removal,” and Section 3.4.4, “Extend Chain
of a leaf chain. Installation.”
5. Inspect the extend and retract chains every 250 hours of
operation.
6. Inspect the chains for the following conditions:

Boom
Edge Wear 3.15.3 Inspection Guidelines - TH417C GC

1. Park the machine on a firm, level surface, raise the boom
to a horizontal (level) position, place the transmission in
(N) NEUTRAL, engage the park brake switch.
1 2 2. Fully extend the boom until the extend chain is taut.
Shut the engine off.
3. The extend chains will be visible for inspection with the
MZ1463 vehicle in this state.
Check the chain for wear on the link plate edges caused 4. While doing the chain inspection, check all chain clevis
by running back and forth over the sheave. The ends for distortion or cracking and sheaves for bearing
maximum reduction of material should not exceed 5%. wear or grooving from the chain.
Measure and compare to a normal link plate height by 5. Inspect the retract chains every 1000 hours of
measuring a portion of chain that does not run over the operation. Refer to the Service Manual for proper
sheave. If the measured plate height (1) is 5% less than
procedure.
the normal plate height (2), discard and replace the
chain. 6. Inspect the chains for the following conditions:
Elongation Edge Wear
It is important to measure the chain in the section that Check the chain for wear on the link plate edges caused
moves over the sheaves because it receives the most by running back and forth over the sheave. The
frequent articulation. Measuring the chain near its clevis maximum reduction of material should not exceed 5%.
terminals could give an inaccurate reading. The ends of This can be compared to a normal link plate height by
the chains, near the clevis terminal, will not have flexed measuring a portion of chain that does not run over the
as frequently, if at all, as the middle of the chains. sheave.
It is best to measure in 12 pin increments from pin
a. Extend Chains (fourth to third section)
center to pin center. For example, if the links are
25 mm (1 in) from pin center to pin center, the distance The extend chains between the fourth and third boom
should be 305 mm (12 in). If the links are 19 mm (.75 in) sections measures 18 mm (.713 in) (1). If the
apart, the distance after 12 pins should be 229 mm (9 measurement of the worn chain is less than 17 mm
in). (.677 in) (2), the chain should be replaced.
4 b. Extend Chains (third to second section)

3
2 1
MZ1463
The extend chains between the third and second boom

sections measures 29,6 mm (1.2 in) (1). If the
measurement of the worn chain is less than 28,6 mm
MY1360
(1.1 in) (2), the chain should be replaced.
If the distance measured (3) is 3% greater than the
normal length (4), discard and replace the chain.

Boom
Elongation Distorted or Battered Link Plates

It is important to measure the chain in the section that
moves over the sheaves because it receives the most 85
frequent articulation. Measuring the chain near its clevis
terminals could give an inaccurate reading. The ends of
the chains, near the clevis terminal, will not have flexed
as frequently, if at all, as nearer the middle of the chains.
a. Extend Chains (fourth to third section)

MZ1466
4
3
Distorted or battered link plates (5) on a leaf chain can cause
tight joints and prevent flexing.
Turning or Protruding Pins
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces
between pin and link plates. When chain is allowed to
operate in this condition, a pin or series of pins, can
begin to twist out of a chain, resulting in failure.
MY1360 7
6
When the original length (3) of 305 mm (12.00 in) per 8
foot of extend chain between the fourth and third
MZ1465
boom sections has elongated from wear to a length (4)
of 313 mm (12.36 in), the chain should be discarded and
replaced. Examine the pin head rivets to determine if the “VEE”
flats are still in correct alignment (6). Chain with rotated/
Measure across a span of 16 pins at the center of the displaced heads (7) or abnormal pin protrusion (8)
extend chain. Measure from pin center to pin center. should be replaced immediately.
Because the retract chain is inside the boom you will not
be able to measure the chain. DO NOT attempt to repair the chain by welding or
driving the pin(s) back into the chain. Once the press fit
The maximum measurement allowed is 313 mm(12.36 integrity between outside plates and pins has been
in). If the measurement is more than 313 mm (12.36 in), altered, it cannot be restored.
the chain should be replaced.
Any wear pattern on the pin heads or the sides of the
link plates indicates misalignment in the system. This
b. Extend Chains (third to second section)
condition damages the chain as well as increases
When the original length (3) of 317 mm (12.5 in) per frictional loading and should be corrected.
foot of extend chain between the third and second
boom sections has elongated from wear to a length (4)
of 325 mm (12.8 in), the chain should be discarded and
replaced.
Measure across a span of 10 pins at the center of the
extend chain. Measure from pin center to pin center.
Because the retract chain is inside the boom you will not
be able to measure the chain.
The maximum measurement allowed is 325 mm(12.8
in). If the measurement is more than 325 mm (12.8 in),
the chain should be replaced.

Boom
Cracked Plates 3.15.4 Expose Chains for Inspection

Inspect the chains very carefully, front and back as well
as side to side, for any evidence of cracked plates. If any c. Retract Chain
one crack is discovered, the chain should be replaced in 1. Park the machine on a firm, level surface. Place the
its entirety. transmission in (N) NEUTRAL, engage the park brake
It is important, however to determine the cause of the switch and raise the boom to a horizontal (level)
crack before installing a new chain so the condition position.
does not repeat itself. 2. Fully extend the boom until the retract chain is taut.
The types of cracks are: Shut the engine OFF.
• Fatigue Cracking - The retract chain will be visible for inspection with the
Fatigue cracks (1) are a machine in this state.
1
result of repeated cyclic While doing the chain inspection, check all chain clevis ends
loading beyond the MZ1467 for distortion or cracking and sheaves for bearing wear or
chain’s endurance limit.
grooving from the chain.
• Stress Corrosion If during the inspection, if any chain is found to be damaged
Cracking - The outside
2 or stretched, the chain must be replaced. It is recommended
link plates are
particularly MZ1468
that when any chain is replaced, that all the chains and
susceptible to stress clevises be replaced at the same time.
corrosion cracking (2).
d. Extend Chains
• Corrosion Fatigue Cracking - Corrosion fatigue
cracks are very similar to fatigue cracks in The extend chains are only partially visible through the rear
appearance. Corrosion fatigue is the combined of the boom with all the sections retracted. It is possible to
action of an aggressive environment and cyclic see a section of the extend chain as the boom is slowly
stress. extended. If there is ANY question that one or both extend
Other Modes of Failure chains are damaged, the extend chains should be removed,
inspected and replaced if necessary.
• Ultimate Strength Failure -
These types of failures are Refer to Section 3.15, “Boom Extend and Retract Chains -
caused by overloads far in 3 TH414C GC & TH417C GC.”
excess of the design load. MZ1469
Note: DO NOT attempt to repair a chain. Replace a stretched
Either fractured plates (3) or 4 or damaged chain with a new part. Always replace both the
enlarged holes (4) can occur. If
either of these failures occurs, chain and the clevis. It is recommended that when any chain is
the chain should be replaced MZ1470 replaced, that all chains and clevis’ be replaced at the same
immediately. time.
• Tight Joints -
All joints in
the chain
should flex
freely. Tight
joints (5) 5 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or bent
pins, replace the chain.

Boom
3.15.5 Chain Lubrication 3.16 BOOM WEAR PADS

After inspection and before being returned to service,
chains must be lubricated with Multipurpose Grease-NLGI The boom wear pads are flat rectangular plastic blocks with
Grade 2. metal inserts.
The lubricant must penetrate the chain joint to prevent 3.16.1 Wear Pad Inspection
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to make 1
sure the lubricant penetrates to the working surfaces
between the pins and links. 1
To prepare the chain for lubrication, the chain plates should
MZ7680
be brushed with a stiff brush or wire brush to clear the space
between the plates so that lubricant can penetrate to the Inspect all wear pads for wear. If the angle indicators (1) on
working surfaces. the ends of the wear pads are visible, the wear pads can be
Lubricant may be applied with a narrow paint brush or reused. If the pads show uneven wear (front to back), they
directly poured on, but the chain should be well flooded should be replaced. Replace pads as a set if worn or
with lubricant and the boom should be extended and damaged.
retracted to be sure that the lubricant penetrates to the
working surfaces. All surplus lubricant should be wiped 3.16.2 Boom Wear Pad Installation/Lubrication
away from the external surfaces. DO NOT use a solvent for
this wiping operation. The boom has been factory lubricated for proper wear pad
break-in and will normally require minor further lubrication.
Regular application of lubricant is necessary to make sure However, after replacing any wear pad(s), or after prolonged
that all working surfaces are adequately lubricated. In periods of inoperation, lubrication of the boom wear surfaces
extremely dusty conditions, it may be necessary to lubricate
with Multipurpose Grease is recommended to keep the
the chains more often. Refer to Section 2.6, “Service and
Maintenance Schedules,” and Section 2.7, “Lubrication boom wear surfaces lubricated properly. Lubrication of the
Schedule,” for detailed information. boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special The following wear pad procedure must be followed to
consideration. Contact the local Caterpillar dealer for insure the proper wear pad installation:
guidance. • The wear pad inserts and mounting bolts MUST be
clean before mounting bolts are installed.
• Apply Loctite® 243TM to all wear pad mounting bolts.
MAM1390
• A spacer (2) with holes must be used before any shim

(3) is used.
• A shim (3) must inserted between the spacer (2) and
wear pad support plate, block or boom section (4).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on

Boom
each side. 3.17 QUICK COUPLER

Note: The following procedures covers all styles of quick
couplers.
3.17.1 Quick Coupler Removal

1. Lower attachment to ground, tilt forward to access
coupler pin, set park brake and turn off engine.
2. If equipped with a hydraulic quick coupler device, refer
to Operation & Maintenance Manual.
5
MZ7660
• Maintain a total boom section clearance of

0,5-1,5mm (0.020 to 0.060 in) between the wear pad
and the next boom section (5).
A
8
B
8 9
MY3620
• The length of the wear pad bolt depends on the MZ7690

number of shims, spacers and washers being used. 6 7
• The thickness of each threaded wear pad insert is 10mm
3. Remove the bolts and lock bracket (6) holding the rod
(0.393 in) (A).
end tilt cylinder pin to the quick coupler assembly.
• The bolt length should be determined by measuring Remove the rod end pin (7).
the distance from the face of the insert to the face of the
boom (B) including any spacer, shim(s) and washer(s). 4. Support the quick coupler assembly. Remove the bolts
• Bolt thread engagement in the wear pad insert should (8) and pin (9) from the quick coupler assembly.
not extend. 5. Inspect the above pins for nicks or surface corrosion.
• One or two hardened washers are to be used on each Use fine emery cloth to fix minor nicks or corrosion. If
wear pad bolt except where noted otherwise. damaged or if it cannot be repaired the pin must be
DO NOT use more than two hardened washers. replaced.
• Use only one hardened washer if mounting bolts are
recessed. 3.17.2 Quick Coupler Installation
• Wear Pad Bolt Torque:
1. Apply Loctite® 243TM to all mounting bolts.
M12 x 20, 95-105Nm - M12 x 25, 95-105Nm
M12 x 30, 95-105Nm - M12 x 35, 95-105Nm 2. Assemble the quick coupler to the boom head. Line up
M12 x 40, 95-105Nm - M12 x 80, 95-105Nm the quick coupler between the mounts on the boom
• Lubricate the face and pockets of each wear pad after head. The quick coupler should be centered in the
being installed. boom head.
Boom Section Wear Pad Pathway Lubrication: 3. Coat the quick coupler pivot pin with Anti-Seize Lube.
• Clean and lightly grease all wear pad pathways with Insert the quick coupler pivot pin (9) through the quick
Multipurpose Grease. coupler and boom head. Secure with the previously
• Clean and lightly grease the hose carrier guide bar removed bolts (8).
pathway with Multipurpose Grease. 4. Align the quick coupler with the rod end tilt cylinder
and insert the coupler pin (7) and replace the lock
bracket and bolt assembly (6).

Boom
5. If equipped, reconnect the hydraulic attachment hoses 3.19 BOOM PROP (IF EQUIPPED)
to the quick disconnect fittings on the left side of the
boom head.
3.18 FORKS
WARNING
A raised boom can fall if a hydraulic component is
Forks should be cleaned and inspected prior to being removed. Remove any load, retract the boom and install
attached to carriage. If the following criteria is not met, forks the boom prop or a suitable supporting stand before
must be removed from service immediately. working under a raised boom.
12 3.19.1 Installation and Removal Procedures
15 a. Prop Installation
16 14 1. Park the machine on a firm, level surface. Place the

13
transmission in (N) NEUTRAL, engage the park brake
11
switch.
10 2. Raise the boom to an angle of approximately 20
degrees. Stop engine.
15 3. Place a Do Not Operate Tag on both the ignition key
4. Before installing the boom prop, inspect the prop for
14 18 damage. Do not use if the prop is damaged or if the
locking pins are damaged or missing.
17 MH6460
Daily Inspection
1. Inspect forks (10) for cracks, paying special attention to
heel (11) and mounting tubes (12).
2. Inspect forks for broken or bent tips (13) and twisted
blades (14) and shanks (15).
Yearly Inspection
1. Straightness of the upper face of blade (14) and the
front face of shank (15) should not exceed 0.5 percent of 21
the length of blade or height of shank.
2. Angle (16) between upper face of blade and front face
of shank should not exceed 93 degrees.
3. Thickness of blade (14) and shank (15) should not be 20
reduced to 90 percent of original thickness.
19
Note: Contact the local Caterpillar dealer with the fork part
20
number to find the manufactured dimensions of the fork blade.
4. Ensure fork length (17) is adequate for intended loads.
5. Fork markings should be legible, re-stamp if required. MAM4080
6. Compare fork tips (18) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of 5. Align lift cylinder prop (19) so the locking pins (20) are
the length of the blade (17). on the bottom side of the lift/lower cylinder rod (21).
Install the boom prop (19) onto the lift/lower cylinder
(19). Install locking pins (20).

Boom
6. Start the engine and SLOWLY lower the boom until 3.20 EMERGENCY BOOM LOWERING
there is a clearance of 6 mm (0.25 in) between the end PROCEDURE
of the boom prop and the lift/lower cylinder rod end
(21).
WARNING
NOTICE To avoid instability of the machine, the extend/retract
EQUIPMENT DAMAGE. DO NOT operate with the boom cylinder MUST BE fully retracted prior to retracting the
prop in place. Damage to the boom prop and/or the lift/ lift cylinder. If circumstances prevent retraction of the
lower cylinder could occur. extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of
7. Shut OFF engine. the extend/retract cylinder as soon as possible.
b. Prop Removal
3.20.1 Equipment and Supplies Required
1. If needed, start machine and slowly raise the boom until
Auxiliary Hydraulic Power Supply:
the boom prop is clear of the lift/lower rod end.
• Portable hydraulic unit or another machine with an
2. Remove the locking pins (20) and boom prop (19) from
auxiliary hydraulic power supply with a capacity to
the lift cylinder. Return the boom prop to the proper
hold up to 35 L (9 gal) of hydraulic oil from the
location and secure.
machine during lowering process.
3. Lower boom, shut engine OFF.
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.5, “Fluids, Lubricants and
Capacities.”
Hoses:
• Two Hydraulic Hoses - Approximately 3,0 m
(10 ft) each, with a minimum I.D. of
9,5 mm (0.375 in) and a minimum rating of
275,8 bar (4000 psi).
Fittings:
• Two -8 EO Caps
• Two -8 EO Plugs
Adaptors:
• Two -8 EO Adaptors
Note: Machine extend/retract and lift/lower hoses are -8 ORFS.
The adaptor size may vary depending on the hose ends of the
auxiliary hydraulic power supply.

Boom
3.20.2 Lowering Procedure 8. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
a. Retract the boom as follows:
b. Lower the boom as follows:
1. Remove the cover at the rear corner of the cab.
2. Place a suitable receptacle under the main control valve. 1. Place a suitable receptacle under the main control valve.
2. Label and disconnect the lift/lower cylinder hoses
(6 & 7) from the main control valve. Install plugs in hoses
to prevent fluid loss. Cap all fittings and openings to
keep dirt and debris from entering the hydraulic system.
Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.
3. Using the hoses and fittings specified, connect the
7
hoses between the auxiliary hydraulic power supply
5 and the hoses removed from the main control valve lift/
lower section of the affected machine. Hose (7) is the
supply (lower) and hose (6) is the return. Connect the
hoses in the proper order to ensure that the boom is
lowered, not raised.
4. Use the auxiliary power supply to lower the boom.
5. Loosen and remove the jumper hoses and reconnect
the lift/lower cylinder hoses.
4
6. Transfer any hydraulic oil into a suitable, covered
6
container, and label the container as “Used Oil.” Dispose
of used oil at an approved recycling facility.
7. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
MZ7710 8. Install the previously removed rear cover.
VIEW FROM REAR OF CAB
3. Label and disconnect the extend/retract cylinder hoses

(4 & 5) from the main control valve. Install plugs in hoses
to prevent fluid loss. Cap all fittings and openings to
keep dirt and debris from entering the hydraulic system.
Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.
4. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
extend/retract section of the affected machine. Retract
hose (5) is the supply and extend hose (4) is the return.
Connect the hoses in the proper order to ensure that
the cylinder is retracted, not extended.
5. Use the auxiliary power supply to retract the extend/
retract cylinder.
6. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.
7. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.” Dispose
of used oil at an approved recycling facility.

Boom
3.21 TROUBLESHOOTING
This section provides an easy reference guide covering the
most common problems that occur during operation of the
boom.
Problem Possible Causes Remedy

1. Boom will not extend or retract 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits.”
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

8.10.1, “General Cylinder Removal
Instructions.”
2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.16, “Boom Wear
Pads.”
3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.7, “Lubrication
Schedule.” Replace worn pins as
needed.
2. Worn bearing(s). 2. Replace bearing(s) and lubricate

at regular intervals Refer to
Section 2.7, “Lubrication
Schedule.”
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/or Refer to Section 2.7, “Lubrication
wear. Schedule.” Replace worn pins as
needed.
2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.5, “Hydraulic

operating properly. Circuits.”
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.10.1, “General Cylinder Removal
Instructions.”
4. Seized boom pivot pin bushing. 4. Replace bushing.

Boom

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.
2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to

Section 3.7, “Boom Sections
Adjustment - TH414C GC.”
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to Section

excessively worn or damaged. 3.16, “Boom Wear Pads.”
4. Contaminated, corroded or rusted 4. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits.”
6. Damaged boom section. 6. Replace the damaged boom

section.
7. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.6, “Service and
Maintenance Schedules.” Replace
worn pins as needed. Refer to
Section 8.10.1, “General Cylinder
Removal Instructions.”
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.7, “Lubrication
Schedule.”
8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.16,
“Boom Wear Pads.”
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or rusted 3. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section , “Running H/F 1.”
operate. operating properly.

Boom

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to
Section 3.15, “Boom Extend and
Retract Chains - TH414C GC &
TH417C GC.”- Replace chains as
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. Refer to

lubricated. Section 2.6, “Service and
Maintenance Schedules.”
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.6, “Service and
Maintenance Schedules.” Repair or
replace chain sheave(s) as needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.6, “Service and
Maintenance Schedules.” Replace
chains as needed.

Section 4
Cab and Covers
Contents

4.1 Operator Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column/Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Window Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.7 Heater/Air Conditioning System (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.8 Air Conditioning (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Cab and Covers
4.1 OPERATOR CAB AND COVERS

COMPONENT TERMINOLOGY
To understand safety, operation and maintenance
operator/mechanic be familiar with names and locations of
major assemblies of machine cab and covers. The following
illustration identifies components that are referred to
FRAME LEVEL LSI INDICATOR

INDICATOR
INSTRUMENT ACCESSORY CONTROL

STEERING WHEEL CLUSTER LEVER
LOAD STEERING
CHART IGNITION
COLUMN SWITCH CONSOLE SWITCHES
ADJUSTER
TRANSMISSION
CONTROL LEVER
CLIMATE JOYSTICK
CONTROLS
CONSOLE
SWITCHES
SERVICE BRAKE PEDAL

ACCELERATOR MZ0770
PEDAL
PARK BRAKE

Cab and Covers
4.2 OPERATOR CAB 4.3 CAB COMPONENTS
4.3.1 Steering Wheel

WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all safety
precautions as outlined in the “Safety Practices” section of 1. Park machine on a firm, level surface, level machine fully
this manual. retract boom, lower boom, place transmission control
lever in (N) NEUTRAL, engage park brake and shut
4.2.1 Operator Cab Safety engine OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
WARNING 3. Open engine covers. Allow system fluids to cool.
The protection offered by this ROPS/FOPS will be 4. Properly disconnect battery.
impaired if subjected to any modification or structural
damage, at which time replacement is necessary. ROPS/
FOPS must be properly installed using fasteners of correct
1
size, grade, and torqued to their specified value. 3
WARNING
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
components requires cab replacement.
Refer to the appropriate parts manual for ordering
information.
4.2.2 Serial Number Plate

2
The cab serial number plate is located on the left side of the
cab, below the seat. Information specified on the serial MAH0430
number plate includes the cab model number, the cab serial
number and other data. Write this information down in a 5. Carefully pry center button (1) out of steering wheel.
convenient location to use in cab correspondence.
6. Mark steering wheel and shaft to ensure proper
installation. Remove nut (2) securing the steering wheel
(3) to splined steering column shaft.
7. Use a steering wheel puller to remove steering wheel (3)
from splined shaft.
b. Steering Wheel Installation

1. Install steering wheel (3) onto splined steering column
shaft.
2. Secure steering wheel with nut (2).
3. Press center button (1) onto steering wheel.
4. Properly connect battery.
5. Close and secure engine covers.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

Cab and Covers
4.3.2 Steering Column/Orbitrol Valve 7. Label, disconnect and cap hydraulic hoses attached to
orbitrol valve (1).
a. Steering Column and Orbitrol Valve Removal 8. Remove steering wheel (2). Refer to Section 4.3.1,
1. Park machine on a firm, level surface, level machine fully “Steering Wheel.”
retract boom, lower boom, place transmission control 9. Disconnect and remove the accessory control lever (3),
lever in (N) NEUTRAL, engage park brake and shut and if equipped, transmission control lever (4).
engine OFF. Disconnect control lever(s) harness from the main cab
2. Place a Do Not Operate Tag on both ignition key switch harness.
and steering wheel. 10. Have an assistant hold the orbitrol valve from outside of
3. Open engine covers. Allow system fluids to cool. cab. Remove bolts (5) securing orbitrol valve to cab.
4. Properly disconnect battery. 11. Remove the steering column (6) through the dash panel
opening.
5. Remove lower dash panel in cab.
Note: DO NOT disassemble orbitrol valve. The orbitrol valve is
not serviceable and must be replaced in its entirety, if defective.
UPPER COVER b. Steering Column and Orbitrol Valve Installation

1. Install steering column to original orientation in cab.
2. Have an assistant hold orbitrol valve in original
orientation from outside cab. Install steering column to
valve with previously removed hardware.
3. Install accessory control lever, and if equipped,
transmission control lever. Connect control lever(s)
harness connector to main cab harness and install steering
wheel assembly.
4. Uncap and connect previously labeled hydraulic hoses
to orbitrol valve.
5. Carefully examine all connections one last time before
LOWER COVER engine start-up. Rectify any faulty conditions.
MZ7770
6. Remove access covers from front of cab.
7. Start engine and check operation of steering system.
Check for hydraulic fluid leaks. Check hydraulic fluid
2
level in tank and add fluid as required.
3 8. Install protective cover to front of cab.
9. Install lower dash panel in cab.
10. Close and secure engine cover.
and steering wheel.
c. Steering Test
4 Conduct a pressure check of the steering hydraulic circuits at
the main control valve. Refer to Section 8.4.1, “Pressure
5
6 Checks and Adjustments.”
1
MAM3930

Cab and Covers
4.3.3 Service Brake
a. Brake Valve Removal

Refer to Section 8.9.2, “Service Brake Valve,” for removal
information.
b. Brake Valve Installation

7
Refer to Section 8.9.2, “Service Brake Valve,” for installation
information.
4.3.4 Electronic Throttle Pedal
a. Throttle Pedal Removal

1. Park machine on a firm, level surface, level machine fully
retract boom, lower boom, place transmission control
lever in (N) NEUTRAL, engage park brake and shut MZ7790
engine OFF.
2. Place a Do Not Operate Tag on both ignition key switch 6. Remove hardware (7) securing pedal assembly.
and steering wheel. 7. Disconnect electrical connection to pedal assembly.
3. Open engine covers. Allow system fluids to cool. 8. Remove throttle pedal assembly from cab.
4. Properly disconnect battery.
b. Throttle Pedal Installation
1. Position throttle pedal in its mounting location in cab.
UPPER COVER 2. Reconnect electrical connection to pedal assembly.
3. Secure throttle pedal into position with previously used
hardware (7).
4. Install protective covers.
and the steering wheel.
LOWER COVER MZ7770
5. Remove access covers from front of cab.

Cab and Covers
4.3.5 Joystick Assembly b. Joystick Assembly Installation

1. Connect previously labeled electrical connectors
a. Joystick Assembly Removal
to joystick.
1. Park machine on a firm, level surface, level machine fully 2. Secure joystick assembly to cab using hardware
retract boom, lower boom, place transmission control removed earlier.
engine OFF. 3. Properly connect battery.
2. Place a Do Not Operate Tag on both ignition key switch 4. Test joystick functions.
and steering wheel. 5. Close and secure engine cover.
3. Open engine covers. Allow system fluids to cool. 6. Remove Do Not Operate Tag from ignition key switch
4. Properly disconnect battery. and steering wheel.
4.3.6 Window Wiper Assembly

Refer to Section 9.7, “Wiper/Washer Wiper Motor,” for
removal and installation information.
3
4.3.7 Heater/Air Conditioning System
(if Equipped)
Note: If machine is equipped with air conditioning,
DO NOT loosen or disconnect any air conditioning hoses until
the air conditioning system has been properly drained by the
local distributor or certified air conditioning service center.
a. Heater Assembly Removal

1. Park machine on a firm, level surface, level machine fully
engine OFF.
and steering wheel.
3. Open engine covers. Allow system fluids to cool.
5. Place a suitable container beneath radiator. Slowly turn
surge tank cap and allow any pressure to escape.
MZ7800 Remove surge tank cap.
6. Place a funnel at base of radiator to channel drained
5. Remove hardware securing joystick assembly (3). coolant into container. Remove drain plug and allow
6. Lift joystick from its mounting position. coolant to drain.
7. Label and disconnect electrical connectors attached to 7. Transfer coolant to a container with a cover, and label as
joystick. “Used Coolant.” Dispose of used coolant at an approved
recycling facility.
8. Remove joystick assembly.
8. Tighten radiator drain plug.

Cab and Covers
4 5
MZ7850
9. Remove heater cover (4) inside cab.

MZ7840
11. Label and disconnect electrical connections.

UPPER COVER
12. Label and remove hoses connected to heater.
13. If equipped, label and disconnect air conditioning hoses
attached to heater assembly.
14. Remove bolts (5) securing heater assembly to cab.
Remove heater assembly.
b. Heater Assembly Installation

1. Position heater assembly to original orientation to cab.
Secure with previously removed hardware.
2. Connect previously labeled electrical connections.
3. Connect previously labeled heater hoses to appropriate
locations.
4. If equipped, connect previously labeled air conditioning
hoses to appropriate locations.
5. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
LOWER COVER MZ7770 system capacity is listed in Section 2.5, “Fluids,
Lubricants and Capacities.”
10. Remove access covers from front of cab. 6. Properly connect battery.
7. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
Note: STOP engine immediately if any leakage is noted, and
make any necessary repairs before continuing.
8. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
9. Install protective covers.
10. Install heater cover inside cab.
and steering wheel.

Cab and Covers
4.3.8 Air Conditioning (if Equipped)

If the air conditioning system requires servicing, contact the
local Caterpillar dealer or certified air conditioning service
center. Refer to Section 2.5, “Fluids, Lubricants and 3
Capacities,” for refrigerant type and capacity.
2
4.4 CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary. ROPS/
FOPS must be properly installed using fasteners of
MZ7840
correct size and grade, and torqued to their specified
value. 9. Label, disconnect and cap all hydraulic hoses attached
to the steering orbitrol valve (2). Cap all fittings and
Note: To help ensure safety and optimum performance, openings to keep dirt and debris from entering
replace cab if it is damaged. Refer to appropriate parts manual hydraulic system.
for ordering information.
Inspect cab, its welds and mounts. If modification, damage, a to the brake assembly (3). Cap all fittings and openings
cracked weld and/or fatigued metal is discovered, replace to keep dirt and debris from entering hydraulic system.
cab. Contact local Caterpillar dealer with any questions about
suitability or condition of a cab.
Note: Remove and label cab components as needed before
removing cab from machine. Label, disconnect and cap
hydraulic hoses. Transfer cab parts to replacement cab after
replacement cab is securely mounted on machine.
1. Park machine on a firm, level surface. Allow sufficient
overhead and side clearance for cab removal. Level
machine, fully retract boom, lower boom, place travel
select lever in (N) NEUTRAL position, engage park brake
and shut engine OFF.
2. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and
side clearance for cab removal.
3. Open engine cover. Allow system fluids to cool.
5. Place a funnel at base of cooling system to channel
drained coolant into suitable container. Remove drain MZ7890
plug and allow coolant to drain.
11. Remove rear cab cover and securing hardware.
6. Transfer coolant to a container with a cover, and label as
12. Disconnect cab ground strap.
“Used Antifreeze.” Dispose of used coolant at an
approved recycling facility. 13. Label and disconnect the cab harness connectors. Move
the harnesses clear of the cab to prevent damage
7. Replace and tighten drain plug.
during cab removal.
8. Label and disconnect cab heater hoses. Refer to Section
4.3.7, “Heater/Air Conditioning System (if Equipped).”

Cab and Covers
18. When all wiring, hydraulic hoses and fasteners are

disconnected or removed, carefully and slowly lift cab
4 4 and remove it from frame. Readjust position of sling as
needed to help balance cab during removal.
19. When cab is completely clear of machine, carefully
lower it to ground. Block up or support cab so it does
not move or fall.
20. Assure that no personnel enter cab while it is being
removed from machine.
21. Inspect and replace machine parts that are exposed
with cab removed. Repair or replace as required.
MZ7910
14. Install four lifting eye bolts with a minimum lifting

capacity of 363 kg (800 lb) in the existing lifting holes at
the top corners of the cab (4).
15. Use a hoist or overhead crane and sling with a minimum
lifting capacity of 363 kg (800 lb) attached to the four
eye bolts. DO NOT attempt to lift the cab at this point.
5
MZ7900
16. Remove four bolts (5) securing cab to frame.

17. Remove mirrors and all other cab components as
needed, if not previously removed.

Cab and Covers
4.5 CAB INSTALLATION Note: When engine is initially started, run it briefly at low idle
and check machine for any visual sign of fluid leakage. STOP
1. Block all four wheels to help prevent machine from engine immediately if any leakage is noted. Make any
moving. Assure that there is sufficient overhead and necessary repairs before continuing.
side clearance for cab installation.
14. Wait for engine to cool and check coolant level. Add
2. Attach a sling with a minimum lifting capacity of coolant as required to bring coolant to proper level.
363 kg (800 lb) through lifting eyes of cab.
15. Install protective covers to front of cab.
3. Use a hoist or overhead crane and sling attached to cab.
16. Install the mirrors and all other cab components as
Carefully begin to align cab with mounting holes in
needed, if removed.
frame. Stop and check that wiring, hydraulic hoses,
cables, etc., will not be pinched or damaged as cab is 17. Install protective cover to rear of cab.
positioned. Readjust position of sling as needed to help 18. Unblock wheels.
balance cab during installation.
4. Install four cab to frame mount bolts, washers and nuts to
145–155 Nm (107–114 lb-ft).
and steering wheel.
5. Connect previously labeled cab harness connectors to
their appropriate locations.
6. Reconnect cab ground strap.
7. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
8. Reconnect any remaining electrical connections to their
appropriate locations.
9. Reconnect heater hoses to cab heater. Refer to Section
4.3.7, “Heater/Air Conditioning System (if Equipped).”
10. Fill cooling system completely with coolant, allowing
time for coolant to fill engine block. Cooling system
capacity is listed in Section , “.”
12. Carefully examine all cab components, fasteners, etc.,
one last time before engine start-up. Rectify any faulty
conditions.
13. Start engine and check operation of all controls. Check for
hydraulic fluid leaks. Check hydraulic fluid level in tank
and add fluid as required.

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Park Brake adjustment - TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.9 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.9.5 Drive Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.10.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.10.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.1 AXLE, DRIVE SHAFT AND WHEEL

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.
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
TRANSMISSION
REAR AXLE WHEEL

FRONT STEERING HUBS
CYLINDER
REAR DRIVE SHAFT
FRONT DRIVE SHAFT
FRONT AXLE WHEEL

HUB
FRONT AXLE REAR AXLE

ASSEMBLY T414C GC MZ8360 ASSEMBLY
REAR STEERING
CYLINDER
TRANSMISSION
FRONT STEERING
CYLINDER
REAR DRIVE SHAFT REAR AXLE WHEEL

HUBS
FRONT DRIVE SHAFT
FRONT AXLE WHEEL

HUB
FRONT AXLE
ASSEMBLY TH417C GC
MZ8350

5.4 AXLE REPLACEMENT

WARNING
5.4.1 Axle Removal
precautions as outlined in the “Safety Practices” section of
this manual.
WARNING
5.2 AXLE SERIAL NUMBER An improperly supported machine can fall. Safely raise
and adequately support the machine so that it will
Front and rear axle serial number plate is located on the remain stable and in place before attempting to remove
inside of each axle on right side of the center section. an axle.
Information on the serial number plate is required in
The front and rear axle assemblies differ in that front axle
correspondence regarding the axle.
assembly is equipped with a parking brake mechanism and a
Supply information from the axle serial number plate when limited slip feature; rear axle has neither. The following steps
communicating about the axle assembly or the outline a typical axle removal procedure, suitable for either
axle components. front or rear axle assembly.
Cleanliness is extremely important. Before attempting to
5.3 AXLE SPECIFICATIONS AND remove the axle, thoroughly clean the machine. Avoid
MAINTENANCE INFORMATION spraying water or cleaning solution on electrical
components. If using a steam cleaner, seal all openings
For axle, oil specifications and maintenance information, before steam cleaning.
refer to Section 2.5, “Fluids, Lubricants and Capacities.”
Note: Clear the work area of all debris, unnecessary personnel,
Detailed axle service instructions are provided in the
etc. Allow sufficient space to raise the machine and to remove
following publications:
the axle.
• Axle Service Manual (P/N 31200162)
1. Park machine on a firm, level surface, level machine, fully
• Parts Manual (P/N 31200958) retract boom, lower boom, place transmission in (N)
NEUTRAL, engage parking brake, and shut engine OFF.
and steering wheel.
5. Remove bolts securing fender assembly to axle.

Note: The wheel and tire assemblies must be re-installed later

with the directional tread pattern “arrows” facing in the
direction of forward travel.
14. Remove the drive shaft assembly. Refer to Section 5.9.3,
“Drive Shaft Removal.”
15. On front axle, remove capscrew and locknuts securing
lower position cylinder-mount pin to the front cylinder.
Tap the cylinder mount pin out, and move the cylinder
MZ7620 to prevent it from interfering with axle removal.
16. Remove bolts and locknuts securing axle to frame.
1
17. Remove axles from machine using jack, hoist or
overhead crane and sling supporting axle. DO NOT raise
or otherwise disturb machine while removing axle.
Balance axle and prevent it from tipping, turning or
falling while removing it from beneath machine. Place
the axle on a suitable support or holding stand.
5.4.2 Axle Installation

2 1. If applicable, raise machine using a suitable jack or
hoist. Place suitable supports beneath the frame and
lower the machine onto the supports, allowing enough
room for axle installation.
MZ7630 2. Before proceeding, ensure machine will remain in place
during axle installation.
6. If axle will be disassembled after removal, place a 3. Block front and rear of both tires on axle that is already
suitable receptacle under axle (1) and wheel hub (2) installed on machine.
drain plugs. Remove drain plugs and allow oil to drain
4. Using a suitable jack, hoist or overhead crane and sling,
into receptacle. Transfer used oil into a suitable covered
remove axle from its support or holding stand. Balance
container, and label container as “Used Oil.” Dispose of
axle and prevent it from tipping, turning or falling while
used oil at an approved recycling facility.
positioning it beneath machine. DO NOT raise or
7. Disconnect LSI sensor at the rear axle. otherwise disturb machine while installing the axle.
8. Label, disconnect and cap steering and brake lines at 5. Keep axle supported and balanced on the jack, hoist or
axle. Wipe up any spilled oil. overhead crane and sling throughout the installation
9. TH414C GC Front Axle Only - Disconnect park brake procedure.
cable. 6. Position axle under frame, and align axle housings with
10. Block front and rear of both tires on axle that is not holes in frame.
being removed. Ensure that machine will remain in 7. Apply Loctite® 262 to each mounting bolt.
place during axle removal before proceeding.
8. Install axle mounting bolts and nuts. Tighten and torque
11. Raise machine using a suitable jack or hoist. Place as required.
suitable supports under both sides of frame and lower
9. Install the drive shaft assemblies. Refer to Section 5.9.5,
machine onto supports. Ensure that machine will
“Drive Shaft Installation.”
remain in place during axle removal.
10. If reinstalling an axle previously removed from machine,
12. Support axle that is being removed with a suitable jack,
position driveshaft yoke on axle according to alignment
hoist or overhead crane and sling. DO NOT raise axle or
marks made earlier.
machine.
11. If installing a new axle, note position of driveshaft yoke
13. Remove both the wheel and the tire assemblies
from the axle that is being removed. Refer to at transmission. Align driveshaft yoke on axle in same
Section 5.10.1, “Removing Wheel and Tire Assembly plane as yoke on transmission.
from Machine.” 12. Connect the steering and brake lines at axle.

13. TH414C GC Front Axle Only - Connect park brake 22. Check hydraulic reservoir oil level.
cable. 23. Start engine. Turn steering wheel several times
3 4 lock to lock, operate frame tilt function several
times in both directions and check function of brakes.
Check for hydraulic leaks, and tighten or repair as
necessary.
24. Install fender assembly. Torque as required.
MZ7620
and steering wheel.
1 Note: Service brake circuit will need to bled after axle
14. Tighten axle oil drain plugs (1), loosen and remove the installation. Refer to Section 8.9.3, “Service Brake Bleeding.”
axle oil fill plug (3). Loosen and remove check fill plug
(4). Fill until oil level reaches bottom of check fill plug. 5.5 BRAKE INSPECTION
Refer to Section 2.5, “Fluids, Lubricants and Capacities,”
for proper oil and capacities. Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information.”
MT0220
15. Rotate wheel hubs 90 degrees so wheel hub drain plug

becomes the fill plug (2). Refer to Section 2.5, “Fluids,
Lubricants and Capacities,” for proper oil and capacities.
16. Install the wheel and tire assemblies. Refer to Section
5.10.2, “Installing Wheel and Tire Assembly onto
Machine.”
17. Carefully remove jack, hoist or overhead crane and sling
supporting axle.
18. Carefully raise machine using a suitable jack or hoist.
Remove supports from beneath frame and lower
machine to ground.
19. Remove blocks from front and rear of both tires on
other axle.
Note: ALWAYS use new o-rings when servicing machine.
20. Install new o-rings into fittings. Lubricate o-rings with
clean hydraulic oil.
21. Uncap and connect steering and brake lines at their axle
fittings.

5.6 PARK BRAKE ADJUSTMENT - TH414C GC

1. Park the machine on a slight grade, fully retract boom,
level the boom, place transmission in (N) NEUTRAL, set
the parking brake. The machine should not move. If the
machine moves, adjust the park brake.
2. Apply service brake and disengage the park brake.
MM
60
MAM4100
3. Depress the release lever (1) and push the park brake
lever (2) down.
4. Adjust the park brake cable by turning the adjuster
knob (2) clockwise to increase park brake force. Turn the
adjuster knob counterclockwise to decrease park brake
force.
5. If park brake cannot be adjusted, refer to Section 5.3,
“Axle Specifications and Maintenance Information,” for
detailed axle information.
5.7 STEERING ANGLE ADJUSTMENT

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information.”

5.8 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.5, “Fluids, Lubricants
and Capacities.”
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. Refer to Section 2.5, “Fluids,
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level.
Refer to Section 2.5, “Fluids,
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) worn 2. Repair or replace universal joints

or damaged. as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as needed.

unbalanced.


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged or tighten plugs to 130 Nm
axle housings). missing. (96 lb-ft).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

missing and/or worn or damaged fork shaft (axle shaft).
shaft sealing surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or worn input shaft. Adjust ring and pinion
or damaged pinion (input) shaft alignment and bearing preload as
sealing surfaces. described in the Axle Repair
Manuals.
5. Axle casing to brake housing and/ 5. Replace o-rings and seals.

or brake housing to differential
assembly o-rings and/or seals
worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews to 390 Nm
(288 lb-ft).
7. Differential and/or axle housing(s) 7. Replace housing(s) as needed.

damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 60 Nm
(44 lb-ft).
2. O-ring between hub and housing 2. Replace o-ring.

(planet carrier) damaged or
missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to 55

Nm (41 lb-ft).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.5, “Fluids, Lubricants
and Capacities.”
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer to Section 2.5, “Fluids,
contaminated or oil level low. Lubricants and Capacities.”
3. Dragging park brake. 3. Adjust park brake cable as

needed. Refer to Section Note:,
“Service brake circuit will need to
bled after axle installation. Refer
to Section 8.9.3, “Service Brake
Bleeding.”.”
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering cylinder

internally. as needed.
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. to Section 5.5, “Brake Inspection.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear. Refer
machine or braking power to Section 5.5, “Brake Inspection.”
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.9.3, “Service
operating properly. Brake Bleeding.”
3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).

5.9 DRIVE SHAFTS TO AXLE
5.9.1 Drive Shaft Inspection

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. Look for excessive looseness, 2
TO TRANSMISSION
missing parts, cracks or other damage. Worn or damaged 1
drive shafts and cross and bearing assemblies may cause an
excessive amount of vibration or noise.
3
Note: To ensure optimum performance, the driveshaft MT0350
assemblies are specially balanced as a unit at the factory. When 4
servicing any flange yoke, slip yoke or drive shaft tube, order a 7. Remove bolts (1) and straps (2) securing bearing cross
complete assembly if components are bent or damaged. Refer to the transmission output shaft flange. Discard bolts.
to the appropriate parts manual for ordering information. 8. Remove bolts (3) and straps (4) securing bearing crosses
Note: Any bolt removed from the drive shaft assembly MUST to axle.
be replaced. Do Not re-torque. 9. Remove drive shaft assembly.
10. Repeat above procedure on rear drive shaft.
5.9.2 Drive Shaft Maintenance
Refer to Section 2.5, “Fluids, Lubricants and Capacities,” for 5.9.4 Drive Shaft Cleaning and Drying
information regarding the lubrication of the grease fittings 1. Disassemble and clean all parts using an approved
on the drive shafts. cleaning fluid. Allow to dry.
2. Remove any burrs or rough spots from all machined
5.9.3 Drive Shaft Removal surfaces. Re-clean and dry as required.
5.9.5 Drive Shaft Installation
retract boom, lower boom, place transmission in (N)
NEUTRAL, engage parking brake, and shut engine OFF. 1. Raise drive shaft assembly into position. The slip yoke
end of drive shaft mounts toward axle. If reinstalling a
drive shaft previously removed, align flange yokes
and steering wheel.
according to the alignment marks made during
3. Open engine cover. Allow system fluids to cool. removal.
4. Properly disconnect battery. Note: Yokes at both ends of drive shaft must be in same plane
5. Block the wheels. to help prevent excessive vibration.
6. The drive shaft assembly is a balanced assembly. Mark 2. Apply Loctite® 243TM to all mounting bolts.
the yoke and axle, transmission and the shaft and slip
3. Install the two straps (2) and four new bolts (1) securing
yoke so that these components can be returned to their
the bearing crosses to the transmission. Torque
original positions when reinstalled. Yokes at both ends
capscrews to 38 Nm (lb-ft).
of the drive shaft must be in the same plane to help
prevent excessive vibration. 4. Install the two straps (4) and four new bolts (3) securing
the bearing crosses to the axle. Torque capscrews to 38
Nm (lb-ft).
5. Repeat above procedure on rear drive shaft.
8. Unblock wheels.
and steering wheel.

5.10 WHEELS AND TIRES machine onto support and to remove wheel and tire
assembly.
5. Lower machine onto support.
WARNING 6. Remove lug nuts and washers in alternating pattern.
Mismatched tire sizes, ply ratings or mixing of tire types 7. Remove wheel and tire assembly from machine.
(radial tires with bias-ply tires) may compromise machine
stability and may cause machine to tip over. 5.10.2 Installing Wheel and Tire Assembly onto
Machine
It is recommended that a replacement tire to be same size,
ply and brand as originally installed. Refer to appropriate
5
parts manual for ordering information. If not using an
approved replacement tire, It is recommended that
replacement tires have following characteristics:
• Equal or greater ply/load rating and size of original
• Tire tread contact width equal or greater than original
• Wheel diameter, width and offset dimensions equal to
original
• Approved for application by the tire manufacturer
(including inflation pressure and maximum tire load)
The rims installed have been designed for stability
MZ6020
requirements which consist of track width, tire pressure and
load capacity. Size changes such as rim width, center piece
location, larger or smaller diameter, etc., without written Note: The wheel and tire assemblies must be installed with
factory recommendations, may result in unsafe condition directional tread pattern “arrows” facing in direction of forward
regarding stability. travel.
Foam filled tires have a positive effect on the weight, stability Note: Verify valve stems face outward on all wheel and tire
and handling characteristics of the machine, especially assemblies.
under load. The use of hydrofill as a tire-fill substance is not 1. Position wheel onto studs on wheel end of axle.
recommended because of possible environmental impact.
2. Install wheel washers onto studs.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire 3. Start all lug nuts by hand to prevent cross threading.
does not provide an airtight seal. Check tire inflation Apply one drop of lubrication oil.
pressures when the tires are cold. When mounting a tire on
the wheel, the tire must be mounted on the wheel respective 1 8
of the directional tread pattern of the tire; this produces a left
or right tire and wheel assembly.
6 3
5.10.1 Removing Wheel and Tire Assembly from
Machine
1. Park machine on a firm, level surface, level machine, fully 9 10
and steering wheel. 4 5
3. Loosen but DO NOT remove the lug nuts on the wheel
and tire assembly to be removed. 7 2 MY4200
4. Place a suitable jack under axle pad closest to wheel
being removed. Raise machine and position a suitable
support beneath axle. Allow sufficient room to lower

4. Tighten lug nuts in an alternating pattern as indicated in

previous figure. Torque to 340-380 Nm (251-280 lb-ft) FRONT VIEW
5. Remove machine from supports.
and steering wheel.
5.11 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted after
exhausting all other options. Make every effort to repair
machine and move it under its own power.
5.11.1 TH414C GC Only

1. Fully retract the boom. Position attachment
approximately 610 mm (24 in) above the ground.
1
Note: If total loss of power has occurred, refer to Section 3.20,
“Emergency Boom Lowering Procedure.”
WARNING REAR VIEW

Do not attempt to tow a machine that is loaded or the
boom/attachment is raised more than approximately
610 mm (24 in).
2. Remove load from machine.

3. Place transmission in (N) NEUTRAL, engage park brake
4. Block all four wheels.
WARNING
Block all four wheels when preparing the machine for
towing to prevent any unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.9, 2

“Drive Shafts.”
MZ7650
6. Secure machine to a suitable towing vehicle.

a. For towing or retrieval from front of machine, attach
towing equipment to lifting points (1).
b. For towing or retrieval from rear of machine, attach
towing equipment to the retrieval hitch (2).

a. Manually Releasing the Park Brake
WARNING 5 5
Use a vehicle of sufficient capacity to tow the machine.

Tow vehicle must be capable of providing braking for
both vehicle and machine.
7. Clear area of any unnecessary personnel.

8. Have an operator seated in machine operator cab.
9. Remove blocks from all four wheels. 5 5
MZ1020
10. Disengage machine park brake.
11. Tow machine to a secure location.
1. Loosen the nuts of the screws (5) for the manual release
Note: Tow machine at a very slow speed. of the braking units. Draw the nuts back approximately
12. After towing is complete, engage park brake. 6 mm.
13. Block all four wheels. 2. Tighten the screws until they are gently seated on the
driving plate.
14. Reinstall front and rear drive shafts. Refer to Section 5.9,
“Drive Shafts.” 3. Carefully tighten each release screw a 1/4 turn at a time
in sequence until all have been turned on full turn 360°.
15. Repair machine as necessary.
4. Repeat steps 1 thru 3 for other side of differential.
Note: Block the wheels of the machine BEFORE attempting to
release the park brake. Once the park brake is released the Note: After machine has been towed to a secure location,
machine’s park brake AND service brakes are inoperable. reactivate parking brake. Carefully follow procedures from start
to finish. Contact local Caterpillar dealer if you are unsure
5.11.2 TH417C GC Only about any part of the procedure, or for specific instructions
concerning your particular situation.
1. Fully retract the boom. Position attachment
approximately 610 mm (24 in) above the ground.
Note: If total loss of power has occurred, refer to Section 3.20,
“Emergency Boom Lowering Procedure.”
WARNING
Do not attempt to tow a machine that is loaded or the
boom/attachment is raised more than approximately
610 mm (24 in).
2. Remove load from machine.

3. Place transmission in (N) NEUTRAL, engage park brake
WARNING
Block all four wheels when preparing the machine for
towing to prevent any unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.9,

“Drive Shafts.”

6. Clear area of any unnecessary personnel.

FRONT VIEW 7. Have an operator seated in machine operator cab.
8. Remove blocks from all four wheels.
9. Disengage machine park brake.
10. Tow machine to a secure location.
Note: Tow machine at a very slow speed.
11. After towing is complete, engage park brake.
13. Reinstall front and rear drive shafts. Refer to Section 5.9,
“Drive Shafts.”
14. Repair machine as necessary.
Block the wheels of the machine BEFORE attempting to release
the park brake. Once the park brake is released the machine’s
1
park brake AND service brakes are inoperable.
5.11.3 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE attempting to
REAR VIEW reset the machine’s park brake. Once the park brake is released
the machine’s park brake AND service brakes are inoperable.
5 5
5 5
MZ1020
1. Loosen each release screw (5), only 1/4 turn at a time, in

sequence, until each screw has lost contact with the
2 guide pin.
2. Remove screws along with nuts and seals. Replace seals,
MZ7650
lubricate screws with a silicone-based grease and re-
install screws along with nuts.
5. Secure machine to a suitable towing vehicle. 3. Adjust the nut of the screw heads in relation to the arm
a. For towing or retrieval from front of machine, attach by 1.18 in (30 mm).
towing equipment to lifting points (1). 4. Repeat steps 1 thru 3 for other side of differential.
b. For towing or retrieval from rear of machine, attach 5. After repairs to machine have been made, start machine
towing equipment to the retrieval hitch (2). and check park brake and service brakes for proper
function. Refer to Section 8.7.4, “Service Brake
WARNING Bleeding,” Section 8.7.5, “Service Brake Test,” and
Section 8.7.6, “Steering Orbitrol Valve.”
Use a vehicle of sufficient capacity to tow the machine.
Tow vehicle must be capable of providing braking for
both vehicle and machine.

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.4 Transmission Torque Converter Stall Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.1 Torque Convertor Diaphragm Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Transmission
6.1 TRANSMISSION ASSEMBLY

of the major assemblies of the transmission. The following
ENGINE SPEED
TRANSMISSION OIL SENSOR
FILTER
TRANSFER CASE
TRANSMISSION BREATHER
BREATHER
TRANSFER CASE
OIL FILLER HOLE
TRANSMISSION
DIPSTICK
SHIFT SOLENOIDS
FORWARD CLUTCH
PRESSURE CHECK TRANSFER CASE
PORT MAGNETIC DRAIN PLUG
TRANSFER CASE OIL
REVERSE CLUTCH LEVEL GLASS
PRESSURE CHECK
PORT
TRANSMISSION OIL
FILLER HOLE
MAGNETIC DRAIN
PLUG
TRANSMISSION LIFT
POINT
MZ7100

Transmission
6.4 TRANSMISSION REPLACEMENT

WARNING Cleanliness is of extreme importance. Before attempting to
DO NOT service the machine without following all safety remove the transmission, thoroughly clean the exterior of
precautions as outlined in Section 1, “Safety Practices,” of the transmission to help prevent dirt from entering during
this manual. the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and
Note: These instructions cover only the routine maintenance, other electrical components.
removal, installation and troubleshooting of the transmission.
Refer to the local Caterpillar dealer and the applicable 6.4.1 Transmission Removal
Transmission Service Manual for assistance with
comprehensive transmission diagnosis, repair and component
replacement. WARNING
NEVER lift a transmission alone; enlist the help of at least
6.2 TRANSMISSION SERIAL NUMBER one assistant or use a suitable hoist or overhead crane
and sling with a minimum lifting capacity of
454 kg (1000 lb).
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission
control lever in (N) NEUTRAL, engage park brake and
shut engine OFF.
switch and steering wheel.
1
5. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining.”
6. If not previously removed, remove the implement
pump. Refer to Section 8.8.1, “Pump Replacement.”
MZ7110
7. Refer to Section 7.9, “Engine Replacement,” for detailed
removal instructions.
The transmission serial number plate (1) is located on the
8. Thoroughly clean the transmission and the surrounding
front of the transmission case behind the oil dipstick.
area, including all hoses and fittings, before proceeding.
Information contained in the serial number is required in
correspondence with the transmission manufacturer. 9. Place a suitable receptacle under transmission/
transfer case drain plugs. Remove the transmission
6.3 SPECIFICATIONS AND MAINTENANCE drain plug, and allow the transmission oil to drain into
the receptacle.
INFORMATION
10. Remove transmission transfer case drain plug, and allow
For transmission, oil specifications and maintenance transfer case oil to drain into receptacle.
information, refer to Section 2, “General Information and 11. Transfer used transmission oil into a suitable, covered
Specifications.” container, and label container as “Used Oil.” Dispose of
Detailed transmission service instructions are provided in the used oil at an approved recycling facility. Clean and
following publications: reinstall the transmission and transfer case drain plugs.
• Service Manual (P/N 31200163)
• Parts Manual (P/N 31200958)

Transmission
6.4.2 Transmission Installation
WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
3 and sling.
Note: Apply Loctite® 243TM to all transmission bolts before
installation.
2
MZ7140 1. Use a suitable hoist or overhead crane, secure
transmission with a lifting strap or chain to transmission
12. Remove access cover (2) from the engine bell housing lifting bracket.
(3). This will allow access to remove torque convertor
2. Install transmission to engine and secure with bolts and
flex plate bolts and washers from the engine flywheel.
washers (4) previously removed. Torque to
13. Turn engine over slowly by hand and align each of 38–46 Nm (28–34 lb-ft).
torque convertor flex plate bolts to be accessed.
3. Remove hoist or overhead crane and sling.
Remove them one at a time.
4. Turn engine over slowly by hand and align and install
each of torque convertor flex plate bolts and washers to
4
engine flywheel through access opening on engine bell
housing. Install them one at a time. DO NOT fully
4 tighten until all of bolts are in place.
5
5. Torque flex plate bolts to 35–39 Nm (26–29 lb-ft).
6. Install the hydraulic pump. Refer to Section 8.8.1, “Pump
Replacement.”
7. Refer to Section 7.9.4, “Engine/Transmission
Installation,”for detailed engine/transmission
installation instructions.
MZ7160
14. Remove bolts and washers (4) holding transmission to

engine.
15. Use a suitable hoist or overhead crane, secure the
transmission with a lifting strap or chain to lifting
bracket secured to lifting point (5).
Note: Lifting bracket is NOT included with transmission.
16. Lift transmission clear of engine, and lower it onto
suitable supports or secure it to a stand built especially
for transmission or engine service. Secure transmission
so that it will not move or fall.
17. Remove any external transmission components as
required. Cover all transmission openings.

Transmission
6.4.3 After Transmission Service or 6.4.4 Transmission Torque Converter Stall Test
Replacement 1. Start the machine and bring engine to normal
In general: operating temperature.
1. Disconnect and clean all transmission hoses. When Engine—75° ± 5° C (167° ± 40° F)
possible, remove transmission lines from machine for Hydraulic Oil—60° ± 5° C (140° ± 40° F)
cleaning.
Torque Converter—80° ± 5° C (176° ± 40° F)
2. Properly clean transmission oil cooler.
2. Ensure that transmission neutralizer switch is in the OFF
3. Install a new hydraulic filter. position.
4. Check transfer case oil level and add oil as required. 3. With engine at high idle and service brake fully
depressed, shift transmission into the highest forward
7 gear.
4. With transmission in stall condition, torque converter
speed output should be 0 rpm.
5. Record stall speed at a steady state condition after 10
seconds in stall state.
6. Shift the transmission back to neutral after completion
of the test. Allow engine to idle for two minutes to allow
transmission to return to normal operating
temperatures.
7. Refer to Section 2.4.5, “Transmission Performance
Specifications,” for detailed stall speed information.
6.5 TORQUE CONVERTOR DIAPHRAGM

MZ7170
8
6.5.1 Torque Convertor Diaphragm Removal/
• Transfer Case: Remove transfer case fill plug (7) and
Installation
verify oil level at transfer case oil level glass (8). Add oil
as required and torque plug to 34–44 lb-ft (46–60 Nm). Refer to Section 6.3, “Specifications and Maintenance
5. Check transmission oil level and add oil as required. Information,” for detailed Torque Convertor Information.
• Transmission: With engine running at low idle and 6.6 TROUBLESHOOTING

transmissiom cold, check oil level. Verify oil level is at
“Max” mark on dipstick. Add oil if required. Refer to Section 6.3, “Specifications and Maintenance
6. Check torque on drive shaft yoke capscrews. Information,” for detailed Torque Convertor Information.
7. Run engine for two minutes at idle to help prime
transmission oil lines.
8. Recheck level of fluid in hydraulic oil reservoir with
engine running at idle.
9. Add oil as necessary until oil level is visible in upper
gauge window. Recheck oil level when it reaches
operating temperature 83-94° C (180-200° F).
10. Recheck all drain plugs, lines, connections, etc., for leaks,
and tighten where necessary.

Transmission
This Page Intentionally Left Blank

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3.1 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.3 Radiator Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7.3 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7.4 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9.1 Engine/Transmission Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9.2 Transmission Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.3 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.9.4 Engine/Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Engine
7.1 INTRODUCTION 7.2 ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block,
7.1.1 Disclaimer and Scope above the oil filter. Information contained in the serial
These instructions are written for worldwide use. In number is required in correspondence with the engine
territories where legal requirements govern engine smoke manufacturer.
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that after 7.3 SPECIFICATIONS AND MAINTENANCE
maintenance, service and repair of the engine, engine INFORMATION
operation does not violate local regulations.
Note: Detailed engine service instructions (covering For engine, coolant and oil specifications, and maintenance
disassembly, inspection, internal repair, assembly, adjustment information, refer to Section 2, “General Information and
and troubleshooting information) are provided in appropriate Specifications.”
engine service manual.A gradual running-in (break-in) of a
new engine is not necessary. Full load can be applied to a new
engine as soon as the engine is put into service and the coolant
temperature is at least 60° C (140° F). Extended light-load
operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.

Engine
7.3.1 Component Terminology

of the engine components. The following illustration
identifies the components that are referred to throughout
this section.
ALTERNATOR
TURBO CHARGER
OIL FILTER
MZ7390
STARTER
FUEL INJECTOR
PUMP
MZ7400

Engine
7.4 ENGINE COOLING SYSTEM

1
7.4.1 Surge Tank Cap
A 1 Bar (14.5 psi) cap is used on the surge tank. An incorrect
or malfunctioning cap can result in the loss of coolant and a
hot running engine.
7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If engine seems to take a long time to warm up,
thermostat may be stuck in the open position and
requires replacement.
MZ7410
• If engine runs hot, check temperature of upper
radiator hose. 7. Remove capscrews securing thermostat housing (1) to
• If hose is not hot, thermostat may be stuck in closed engine.
position. 8. Remove thermostat housing, old gasket and
• If engine has overheated, performance may suffer, thermostat. Clean all gasket surfaces. DO NOT let any
indicating other damage including a leaking debris into thermostat opening.
cylinder head gasket, cracked cylinder head or Note: ALWAYS use correct thermostat and install a new gasket.
block, and/or other internal engine damage. NEVER operate engine without a thermostat, or engine
damage will result.
a. Thermostat Removal
1. Park machine on a firm, level surface, level machine, fully b. Thermostat Installation
retract boom, lower boom, place transmission control 1. Install engine thermostat, thermostat gasket and
lever in the (N) NEUTRAL position, engage parking thermostat housing. Secure with the previously
brake, and shut engine OFF. removed capscrews.
2. Place a Do Not Operate Tag on both ignition key switch 2. Properly connect battery.
and steering wheel.
3. Open surge tank cap, and fill the radiator completely
3. Open engine cover. Allow system fluids to cool. with a 50/50 mixture of ethylene glycol and water. Add
4. Properly disconnect battery. coolant solution at a maximum rate of 1.3 gallons per
5. Slowly turn surge tank cap to first stop and allow any minute (5 liters per minute). Replace and tighten
pressure to escape. Remove surge tank cap. radiator cap. Add coolant to surge tank until 1/4 to 1/2
full. This overfilling will compensate for any air trapped
6. Place a funnel at base of radiator to channel drained in cooling system.
coolant into container. Loosen the drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a 4. Run engine to operating temperature. Visually check for
properly labeled container. Dispose of properly if leaks with engine running. Check coolant level in surge
coolant needs to be replaced. Replace the radiator drain tank and fill, or drain, as necessary.
plug. 5. Close and secure engine cover.
6. Remove Do Not Operate Tags from both ignition key

Engine
7.4.3 Radiator Assembly Replacement 8. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
Before considering radiator assembly replacement for other
than obvious damage, conduct a cooling system pressure 9. Slowly turn surge tank cap to first stop and allow any
test check coolant specific gravity, coolant level, fan belt pressure to escape. Remove surge tank cap.
tension and dash panel temperature indicator. 10. Place a suitable container beneath radiator drain.
• If engine runs hot, check temperature of upper radi- 11. Place a funnel at base of radiator to channel drained
ator hose. coolant into a container. Open drain plug and slowly
• If hose is not hot, thermostat may be stuck in closed remove to allow coolant to drain. Transfer coolant into a
position. properly labeled container. Dispose of properly if
coolant needs replaced. Close radiator drain plug.
• If engine has overheated, performance may suffer,
indicating other damage including a leaking cylinder
head gasket, cracked cylinder head or block, and/or
other internal engine damage.
a. Radiator Assembly Removal

5
lever in the (N) NEUTRAL position, engage parking
brake, and shut engine OFF.
and steering wheel.
MZ7430
3
12. Label and disconnect the outer hydraulic cooler hose
(5). Cap all fittings and openings to prevent
dirt and debris from entering hydraulic system.
4 MZ7440
5. Remove hood (2), end cover (3) and belly pan (4) from
engine compartment.
6. Place a suitable receptacle under transmission drain
plug. Remove transmission drain plug, and allow the
transmission oil to drain into receptacle.
7. Transfer used transmission oil into a suitable, covered
container, and label container as “Used Oil.” Dispose of
used oil at an approved recycling facility. Clean and
reinstall transmission drain plug

Engine
b. Radiator Assembly Installation

9
7 6 1. Place radiator assembly in engine compartment at the
8 original orientation. Secure with the previously used
hardware.
2. Uncap and connect previously labeled hoses to radiator,
transmission cooler and oil cooler.
3. Fill hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling.”
4. Fill transmission. Refer to Section 2.5, “Fluids, Lubricants
and Capacities.”
5. Open surge tank cap and fill the radiator completely
with coolant. Replace and tighten surge tank cap. Refer
to Section 2.5, “Fluids, Lubricants and Capacities.” for
proper capacities.
6 7. Run engine to operating temperature. Visually check for
leaks with engine running. Check all fluid levels for
correct levels.
MZ7450
8. Install the end cover, hood and belly pans on the engine
8 9 compartment.
13. Label and disconnect both transmission cooler hoses
(6). Cap all fittings and openings to prevent dirt and
and the steering wheel.
debris from entering hydraulic system.
14. Loosen and remove radiator assembly mounting bolts,
washers and (if equipped) shims. Note the number of
shims being used and there location.
15. Label, disconnect and cap hoses attached to coolant
recovery tank (7). Remove coolant recovery tank and
mounting plate
16. Loosen and remove air intercooler tubes (8) from
radiator assembly.
17. Loosen and remove the radiator hoses (9) from radiator
assembly.
18. Carefully lift the radiator assembly out of the
engine compartment.
Note: Fan Guard can be removed after radiator assembly is
removed and placed in a secure location.

Engine
7.5 ENGINE ELECTRICAL SYSTEM 2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
The engine electrical system, including the starter, alternator 3. Open engine cover. Allow system fluids to cool.
and primary wiring, is described in Section 9.5, “Electrical
System Schematics.” 4. Properly disconnect battery.
Note: If replacing the tank, remove all internal and external
7.6 FUEL SYSTEM components from the old tank, and retain for use on the
replacement tank.
7.6.1 Diesel Fuel Note: Have a dry chemical (Class B) fire extinguisher near the
work area.
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, 1 2
inferior fuel can lead to poor performance and expensive
engine repair.
Note: Due to precise tolerances of diesel injection systems,
keep fuel clean, and free of dirt and water. Dirt and water in fuel
system can cause severe damage to both injection pump and
injection nozzles. Use #2 diesel fuel with a minimum Cetane
rating of 40. #2 diesel fuel gives best economy and performance
under most operating conditions. Fuels with Cetane numbers
higher than 40 may be needed in high altitudes or extremely
low ambient temperatures to help prevent misfiring and
excessive smoking.
Inform owner/operator of machine to use #2 diesel fuel,
unless ambient temperatures are below 0° C (32° F). When
temperatures are below 0° C (32° F), a blend of #1 diesel and
#2 diesel fuels (known as “winterized” #2 diesel) may be
used.
Note: #1 diesel fuel may be used, however, fuel economy will MZ7470
be reduced.
If equipped for ULS, use a ultra low sulfur content fuel with 5. Remove hardware (1) securing fuel tank to frame.
a cloud point (temperature at which wax crystals form in 6. Support fuel tank with a floor jack or suitable supports.
diesel fuel) at least 10° below lowest expected fuel Remove hardware (2) securing fuel tank
temperature. Viscosity of fuel must be kept above 1.3 support to cab.
centistrokes to provide adequate fuel system lubrication. 7. Lower fuel tank and support bracket away from cab
If equipped for LS, use a low sulfur content fuel with a cloud being careful to minimize fluid spillage.
point (temperature at which wax crystals form in diesel fuel) 8. Label, disconnect and cap fuel lines.
at least 10° below lowest expected fuel temperature.
Viscosity of fuel must be kept above 1.3 centistrokes to 9. Disconnect fuel sender.
provide adequate fuel system lubrication. 10. Remove fuel tank drain plug, and drain fuel into
an approved and suitable container. Dispose of
7.6.2 Fuel Tank fuel properly.
Note: Fuel tank is a one piece unit. It is located under the cab. If it is
determined that fuel tank must be removed, fuel must be drained
before tank removal. Always dispose of fuel properly.
a. Fuel Tank Removal

Engine
b. Disassembly f. Fuel Tank Installation

Fuel tank is a one-piece unit and cannot be disassembled. 1. Using a floor jack, lift fuel tank and support bracket to
Fuel level indicator can be removed and reused on new their original orientation on cab.
replacement tank. Dispose of old tank according to local 2. Connect previously labeled fuel hoses to their
regulations concerning hazardous materials disposal. appropriate locations. Secure with clamps. Connect fuel
sender.
c. Cleaning and Drying
3. Secure the fuel tank with previously used hardware.
If contaminated fuel or foreign material is in the tank, tank Remove floor jack.
can usually be cleaned.
4. Fill fuel tank according to specifications.Refer to Section
To clean the fuel tank: 2.5, “Fluids, Lubricants and Capacities.”
1. Have a dry chemical (Class B) fire extinguisher near work 5. Check fuel tank for leaks.
area.
2. Remove the fuel or oil tank drain plug, and safely drain
any fuel into a suitable container. Dispose of fuel
properly. 8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
3. Clean fuel tank with a high pressure washer, or flush
tank with hot water for five minutes and drain water.
Dispose of contaminated water properly.
7.6.3 After Fuel System Service
4. Add a diesel fuel emulsifying agent to tank. Refer to 1. Drain and flush the fuel tank if it was contaminated.
manufacturer’s instructions for correct emulsifying 2. Vent air from fuel system in accordance with
agent-to-water mixture ratio. Refill tank with water, and instructions found in the appropriate Engine Operation
agitate mixture for 10 minutes. Drain tank completely. & Maintenance Manual.
Dispose of contaminated water properly. 3. Fill the fuel tank with fresh, clean diesel fuel as required.
5. Refill fuel tank with water until it overflows. Completely
flush tank with water. Empty fuel tank, and allow it to
dry completely.
d. Assembly
Fuel level indicator can be removed and reused on new
replacement tank. Dispose of old tank according to
local regulations concerning hazardous materials
disposal regulations.
e. Inspection
1. Inspect fuel tank thoroughly for any cracks, slices, leaks
or other damage.
2. With fuel tank removed from machine, plug all
openings except one elbow fitting. Install elbow fitting,
and apply approximately 7-10 kPa (1-1.5 psi) of air
pressure through elbow. Check reservoir
for leaks by applying a soap solution to exterior
and look for bubbles to appear at cracked or damaged
area.

Engine
7.7 ENGINE EXHAUST SYSTEM 8. Remove tail pipe from exhaust pipe.
Note: Emission Sensitive Exhaust. Assembly must be replaced

exactly as removed. Contact your local Caterpillar dealer before
removing the muffler system.
6
7.7.1 Exhaust System Removal 7
3 9
lever in (N) NEUTRAL position, engage parking brake,
and steering wheel. 8 MZ7500

9. Loosen and remove exhaust pipe V-band clamps (6) and
4. Properly disconnect battery. exhaust pipes (7).
10. At bottom of muffler, loosen both muffler hangars (8).
11. Carefully remove hangers and lower the muffler from
the machine.
12. Loosen and remove V-band clamp (9) securing exhaust
1
MZ7440 pipe (3) to muffler.
13. Remove exhaust pipe.
5. Remove belly pan (1).
7.7.2 Exhaust System Installation
4
Note: Keep all clamps loosened until entire exhaust system is in
place.
1. Install exhaust pipe (3) to muffler.
2. Install muffler and secure with hangars. Do not tighten
5 hangars.
3. Install the tail pipe (5) to the exhaust pipe (3) and secure
to frame with previously used clamps (2 & 4). Do Not
Tighten.
4. Install exhaust pipe V-band clamps (6) and exhaust
pipes (7). Adjust the muffler, tail and exhaust pipes for
proper clearance then tighten all clamps.
5. Torque clamps (8) to 16–20 Nm (12–15 lb-ft).
2
6. Torque clamps (2 & 4) to 11–13 Nm (8–9.5 lb-ft).
3
7. Torque clamps (6) to 9–11 Nm (6.6–8 lb-ft).
9. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
MZ7490
10. Install belly pan.
6. Loosen and remove clamp (2) at exhaust pipe (3). 11. Close and secure engine cover.
7. Loosen and remove clamp (4) securing tail pipe (5).

Engine

and steering wheel.
7
7.7.3 Exhaust System Removal
and steering wheel. 8
MZ7440
1
9
5. Remove belly pan (1).
10
4
3
5
MZ7480
9. Loosen and remove exhaust pipe clamps (6)

10. Loosen and remove V-band clamp (7) securing exhaust
pipe (8).
11. Remove exhaust pipe (8).
12. Remove hardware(9) securing muffler to frame.
13. Carefully lower muffler from machine.
2 3
14. Loosen and remove clamp (10) securing exhaust pipe
(3) to muffler.
15. Remove exhaust pipe.
MZ7490
6. Loosen and remove clamp (2) at exhaust pipe (3).

7. Loosen and remove clamp (4) securing tail pipe (5).
8. Remove tail pipe from exhaust pipe.

Engine
7.7.4 Exhaust System Installation

Note: Keep all clamps loosened until entire exhaust system is in
place.
1. Install exhaust pipe (3) to muffler and secure with clamp
(10).
2. Install muffler and secure with hardware removed
earlier. Do not tighten hangars.
3. Install the tail pipe (5) to the exhaust pipe (3) and secure
to frame with previously used clamps (2 & 4). Do Not
Tighten.
4. Install exhaust pipe (8) to muffler with clamps (6). Do
Not Tighten.
5. Secure exhaust pipe to engine exhaust pipe with
V-band clamp (7). Do Not Tighten.
6. Adjust the muffler, tail and exhaust pipes for proper
clearance then tighten all clamps.
7. Torque clamps (7) to 16–20 Nm (12–15 lb-ft).
8. Torque clamps (2 & 4) to 11–13 Nm (8–9.5 lb-ft).
9. Torque clamps (6) to 9–11 Nm (6.6–8 lb-ft).
11. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
12. Install belly pan.
and steering wheel.

Engine
7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation

1. Install the air cleaner assembly (14) to the air cleaner
NOTICE mounting plate and secure with the previously used

hardware.
NEVER run the engine with only the inner safety element 2. Place the loosened clamp (12) over the air intake elbow
installed. (13) and install elbow on the air cleaner assembly.
Tighten clamp.
Note: Refer to the appropriate machine Operation &
Maintenance Manual for the correct element change 3. Properly connect battery.
procedure. 4. Close and secure engine cover.
7.8.1 Air Cleaner Assembly Removal and steering wheel.
and steering wheel.
.
14
12
13
15
16
MZ7510
5. Loosen and remove clamp (12) securing air intake tube

(13) to air cleaner (14).Pull air intake elbow off air
cleaner.
6. Remove bolts (15) securing air cleaner straps (16) to air
cleaner (14). Remove air cleaner assembly.

Engine
7.9 ENGINE REPLACEMENT Note: Engine/transmission harness is routed and attached to

engine/transmission using hold-down clamps and plastic wire
ties at various places on engine. Before removing engine/
7.9.1 Engine/Transmission Removal transmission, ensure that harness
Note: The radiator assembly must be removed from the has been completely separated (disconnected) from engine/
machine before engine/transmission removal. Refer to Section transmission. Move harness clear of engine/transmission, and
7.4.3, “Radiator Assembly Replacement.” Several additional with help of an observer, ensure that engine/transmission
components must be removed before engine/transmission clears the harness during removal.
removal. They will be addressed in the following procedures.
11. Label and disconnect all electrical wire connections on
1. Park machine on a firm, level surface, level machine, fully engine/transmission.
and steering wheel.
4. Properly disconnect battery(s) and remove.
5. Properly drain hydraulic oil system. Refer to Section 8.7, 3
“Hydraulic Reservoir,” for detailed instructions.
6. Properly drain transmission. Refer to Section 6.4.1,
“Transmission Removal,” for detailed instructions.
7. Mark position of cover to help with cover adjustment
when being reinstalled.
MZ7540
12. Disconnect and cap the fuel inlet line (3).
MZ7440
8. Remove hood (1), end cover (2) and belly pan from
engine compartment.
9. Remove the heater and cooling hoses attached to the
4
engine.
10. Label, disconnect and cap/plug all hydraulic
connections on the engine/transmission. MZ7580
13. Disconnect and cap the fuel return line (4) located near
rear engine mount.
14. Label and remove all clamps securing any fuel line on
engine.

Engine
15. Remove exhaust pipe from exhaust manifold. Refer to 7.9.3 Engine Disassembly, Inspection
Section 7.7, “Engine Exhaust System.” and Service
Note: Emission Sensitive Exhaust. Assembly must be replaced Engine disassembly, internal inspection, service, repair and
exactly as removed. assembly procedures are covered in the CAT Service Manual.
Several special engine service tools are required to properly
16. Remove air cleaner assembly. Refer to Section 7.8, “Air
service the engine. Contact the local Caterpillar dealer for
Cleaner Assembly.”
further information.
17. Remove drive shaft assemblies.Refer to Section 5.9.3,
Note: If engine is being replaced, there may be external
“Drive Shaft Removal.”
components that will be required to be transferred from original
18. Secure engine with a lifting strap or chain from engine to replacement engine depending upon who you purchase
appropriate lifting points. Use a suitable hoist or new engine from and configuration of your replacement engine.
overhead crane Refer to appropriate CAT user manual for detailed procedures that
. cover transfer of original engine components to replacement
engine.
5
7.9.4 Engine/Transmission Installation
1. Attach a lifting chain to the front and rear engine
lift brackets, and lift engine/transmission clear of
the ground.
Note: Apply Loctite® 243TM to the engine mount bracket bolts
before installation.
2. Lift engine/transmission and slowly push and lower into
engine compartment. Have an assistant ensure that
engine/transmission clears frame, hose and harness
components during engine/transmission installation.
Position engine/transmission brackets over frame
5 MZ7550 mounts.
3. Align motor mount holes and install front mounting
19. Loosen and remove four engine/transmission mounting bolts and washers.
bolts (5).
4. Align motor mount holes and install rear mounting
20. Slightly lift and pull engine/transmission out of bolts and washers.
machine. Have an assistant ensure that
engine/transmission clears all frame components 5. Lower engine onto mounts and remove lifting chains.
during removal. 6. Install flat washer, lock washer and nut on front two
21. Place engine/transmission on a flat, level surface. mounting bolts.
7. Remove lifting chains.
7.9.2 Transmission Removal/Installation 8. Torque engine /transmission mounting bolts (5)
1. Refer to Section 6.4, “Transmission Replacement,” for to 241 Nm (178 lb-ft).
detailed transmission removal and 9. Install air cleaner. Refer to Section 7.8.2, “Air Cleaner
installation instructions. Assembly Installation.”
10. Install exhaust pipe. Refer to Section 7.7, “Engine
Exhaust System.”
11. Install radiator assembly. Refer to Section 7.4.3,
“Radiator Assembly Replacement.”
12. Install drive shaft assemblies. Refer to Section 5.9.5,
“Drive Shaft Installation.”
13. Connect and secure all the previously labeled hydraulic
hoses, fuel lines and electrical wire connections on
engine and transmission.

Engine
14. Install heater and cooling hoses to engine and tighten 7.10 TROUBLESHOOTING
clamps (if equipped).
15. Install hood (1), end covers (2) and belly pan from engine Refer to Section 7.3, “Specifications and Maintenance
compartment and adjust if necessary. Information,” for detailed engine service information.
16. Install and properly connect battery(s).
17. 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.
18. Check for proper fluid levels prior to startup.
Refer to Section 2.5, “Fluids, Lubricants and Capacities.”
19. Start engine and run to normal operating temperature
then shut off engine. While engine is cooling, check for
leaks.
20. Allow engine to cool. Check radiator coolant level, and
top off with coolant.
21. Check for leaks from engine, main hydraulic pump and
lines, transmission, hydraulic reservoir and fuel tank.
Check levels of all fluids and lubricants. Fill
as required.
Note: During full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep transmission in (N) NEUTRAL.
22. Check engine rpm at full throttle.
23. Purge the hydraulic system of air by operating all boom
functions through their entire range of motion several
times.
24. Check hydraulic oil level. If oil is warm, oil level should
be visible in upper gauge window.
25. Check for proper operation of all components.
26. Turn engine OFF.
27. Install the oil pan cover underneath the
engine compartment.
and steering wheel.

Engine

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.1 TH414C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.2 TH417C GC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.7.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.7.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.7.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.8.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.9.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9.3 Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9.4 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.5 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.6 Outrigger/Stabilizer Valve and Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.7 Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.9.8 Brake Damper Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.9.9 Pre-Charging Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.9.10 Checking Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.11 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.10 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.10.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.10.2 Cylinder Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.10.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.10.4 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

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
EXTEND/RETRACT
CYLINDER
LIFT/LOWER COMPENSATION
CYLINDER CYLINDER
TILT CYLINDER
IMPLEMENT
PUMP MZ7730
OUTRIGGER LEVELING CYLINDER HYDRAULIC FLUID MAIN

CYLINDERS (BEHIND TIRE ON RIGHT SIDE) RESERVOIR CONTROL
VALVE

Hydraulic System
8.2 SAFETY INFORMATION 8.3 SPECIFICATIONS

Refer to Section 2.4, “Specifications,” for hydraulic system
WARNING specifications.
DO NOT service the machine without following all safety 8.4 HYDRAULIC PRESSURE DIAGNOSIS
precautions as outlined in Section 1, “Safety Practices,” of
this manual.
8.4.1 Pressure Checks and Adjustments
Petroleum-based hydraulic fluids are used in this machine.
When diagnosing trouble in the hydraulic system, use the
The temperature of hydraulic fluid increases during the
hydraulic testing information in Section 8.5.1, “Hydraulic
operation of various hydraulic functions. A heated
Pressures.”
petroleum-based hydraulic fluid presents a fire hazard,
especially when an ignition source is present. In general, follow the steps below whenever conducting
pressure checks and performing adjustments:
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully 1. Park the machine on a firm, level surface. Engage the
examine any deterioration and determine whether any park brake, place the transmission in (N) NEUTRAL, level
further use of the component would constitute a hazard. If in the boom and turn the engine OFF.
doubt, replace the component. 2. At the proper test port, install a pressure gauge capable
Whenever you disconnect a hydraulic line, coupler, fitting or of measuring at least 10% more pressure than that
other component, slowly and cautiously loosen the part which the circuit being checked operates under.
involved. A hissing sound or slow seepage of hydraulic fluid 3. Start the engine. Operate machine functions several
may occur in most cases. After the hissing sound has ceased, times to allow hydraulic oil to reach operating
continue removing the part. Any escaping oil should be temperature. The hydraulic oil temperature should be
directed into an appropriate container. Cap or otherwise between 38-49° C (100-120° F). If a temperature gauge
block off the part to prevent further fluid seepage. or thermometer is unavailable, the hydraulic oil reservoir
Hydraulic system maintenance will, at times, require that the should be warm to the touch.
engine be operated. Always follow safety precautions. 4. Refer to Section 8.5.1, “Hydraulic Pressures,” for testing
A major cause of hydraulic component failure is procedures.
contamination. Keeping the hydraulic fluid as clean as 5. Fully depress the accelerator pedal if required. Place and
possible will help avoid downtime and repairs. Sand, grit and hold the joystick in the position needed to operate the
other contaminants can damage the finely machined particular machine function being checked. Continue
surfaces within hydraulic components. If operating in an holding the joystick in position until pressure readings
exceptionally dirty environment, change filters and inspect are taken.
the fluid more often. When servicing the system, cap or plug
6. Check the pressure gauge reading. It should read as
hydraulic fittings, hoses and tube assemblies. Plug all
specified in the Pressure Readings column of the charts
cylinder ports, valves and the hydraulic reservoir, and pump
found in Section 8.5.1, “Hydraulic Pressures.” If the
openings until installation occurs. Protect threads from
reading is not as specified, turn the engine OFF and
contamination and damage.
check other components in the system. Verify that all
Some hydraulic functions are actuated by interfacing with related hydraulic components and electrical switches,
electrical system components (switches, solenoids and sensors, solenoids, etc. are operating correctly.
sensors). When the hydraulic system is not functioning
7. Adjust the relief valve by turning the adjustment screw.
properly, check the electrical aspect of the malfunctioning
Turning clockwise will increase the pressure; turning the
circuit also.
screw counterclockwise will decrease the pressure.
Some hydraulic functions are actuated by interfacing with
8. Start the engine and check the pressure again. Turn the
electrical system components (switches, solenoids and
engine OFF. If there is pressure reading in the gauge,
sensors). When the hydraulic system is not functioning
bleed it off then disconnect or remove the pressure
properly, check the electrical aspect of the malfunctioning
gauge from the machine.
circuit also. Refer to Section 9.5, “Electrical System
Schematics,” in this manual.

Hydraulic System
8.5 HYDRAULIC CIRCUITS b. Adjusting Maximum Hydraulic Pressure

1. Shut the machine off. Remove the cap on the relief (if
This section covers the hydraulic circuits and includes listings
necessary).
for all hydraulic function pressures, where and how to check
those pressures and a hydraulic schematic. 2. Start the machine and loosen the jam nut on the relief
(1). Turn the relief clockwise to increase pressure or
Electrical and hydraulic functions are often related. Verify
counter-clockwise to decrease pressure. Set to the
that the electrical components of the circuit are functioning
correct pressure.
properly whenever troubleshooting the hydraulic circuit.
3. Tighten the jam nut and recheck the pressure at full
Always check the following before beginning to
throttle. If the reading is within specification, shut the
troubleshoot a circuit that is not functioning correctly.
machine off, install the safety cap and remove the
1. Check the hydraulic oil level in the reservoir. If oil is cold, gauge from the test port.
oil level should be visible in the lower gauge window
4. If the proper pressure cannot be set, use the
with all cylinders retracted.
accompanying hydraulic schematic and/or the electrical
2. Check hoses, tubes, fittings and other hydraulic schematic to help troubleshoot and correct the
components for leaks, bends, kinks, interference, etc. problem.
3. Check for air in the hydraulic system. Erratic machine
performance and/or spongy cylinder operation are c. Adjusting Maximum Steering Pressure
signs of air in the hydraulic system. 1. Shut the machine off.
If air in the hydraulic system is suspected, you will hear 2. Install a digital or a 345 bar (5000 psi) gauge to the
air leakage when hydraulic fittings are loosened and see appropriate test port on the hydraulic manifold.
air bubbles in the hydraulic fluid.
3. Select 2 wheel steer, run engine at high idle, turn
Loose fittings, faulty o-rings or seals, trapped oil, leaks, steering wheel one direction to lock. Hold and check
system opened for service, etc., can cause air in the pressure.
system. Determine what is causing air to enter the
system and correct it. Bleed air from the system. Note: Do Not operate any other function while checking
steering pressure.
8.5.1 Hydraulic Pressures Note: The steering pressure is pre-set from the manufacturer
and cannot be adjusted.
a. Checking Pressure
4. If the proper pressure cannot be set, use the
1. Start the machine and warm the hydraulic system to accompanying hydraulic schematic and/or the electrical
operating temperature. schematic to help troubleshoot and correct the
2. Shut off the machine and install a digital or a 345 bar problem.
(5000 psi) gauge to the appropriate test port on the
main control valve.
3. Start the machine, run the engine at idle and bottom
the appropriate hydraulic function. Refer to Section
8.5.1, d. “Pressure Specifications,” for the correct
pressure rating.

Hydraulic System
d. Pressure Specifications
Hydraulic Test Port Procedure Adjustment Pressure Range

Circuit Location
Connect gauge to LS1 port, select 2
wheel steer, run engine at high idle, turn
steering wheel one direction to lock. 175-185 Bar
1 Steer Pressure LS1 (A) N/A
Hold and check pressure. (2538-2683 PSI)
Note: Do not operate any other function
while checking pressure.
Connect gauge to LS1 port, level boom 265-275 Bar
2 Load Sense LS1 (A) N/A
and bottom boom retract. (3843-3988 PSI)
P1 (B) Connect gauge to P1 port, retract boom
Maximum Pump 275-285 Bar
3 LS1 (A) and bottom against frame. Repeat using 1
Pressure (3988-4133 PSI)
V (C) port LS1, then port V.
P1 (B) Connect gauge to P1 port, check
Stand-By 30-34 Bar
4 LS1 (A) pressure at Low idle with no function. N/A
Pressure (435- 493 PSI)
V (C) Repeat using port LS1, then port V.
Auxiliary Auxiliary Connect gauge to Auxiliary Coupling, 270-290 Bar
7 N/A
Pressure Port check pressure at coupling. (3916-4209 PSI)
Note: All pressure check are to be performed at High Idle unless noted.
1
C MZ7740

8-6
8.6
8.6.1
8 7 6 5 4 3 2 1
COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
V1
BORE: 150
H ROD: 90 H
STROKE: 1292
CLOSED CENTRES: 1698
CBV RATIO: 4:1
CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
V1 V2 STROKE: 400 STROKE: 400
TH414C GC
BORE: 85 CLOSED CENTRES: 710 CLOSED CENTRES: 710
ROD: 65
STROKE: 3750 FRAME LEVELLING
CLOSED CENTRES: 4472 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
CBV SETTING: 320 BAR
BORE: 120
BORE: 95
ROD: 80
ROD: 50
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
T1
Hydraulic System
T2 T1 T2 T1
G G
MALE AUXILIARY COUPLING V2 V1 V2 V1

V1
FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
HYDRAULIC SCHEMATICS
BAR BAR BAR BAR BAR
T2
T1 T2
CONTAMINATION TEST POINT
270
F BAR
F
35 BAR
2 MM LS
LS 1
L/MIN
14
E BAR E
LS1
P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST
P
B1
D D
FRONT AXLE L
STEERING STROKE: 208MM
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.4CC
RETURN FILTER NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
L
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR
C C
R1
LD P T SERVICE BRAKE
180
MASTER CYLINDER &
BAR FOOT PEDAL ASSEMBLY
TOTAL DISPLACEMENT: 27.5 TO
49CC
240
BAR
T R CRAB 4WS
A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV
0.5MM 0.75MM
COOLER BYPASS
B B
CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 8.3CC
PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM
IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
RESERVOIR
A A
FILL VOLUME: 105L
APPROXIMATE SYSTEM VOLUME: 180L
8 7 6 5 4 3 2 1
MZ7750C
TH414C GC, TH417C GC

8.6.2
8 7 6 5 4 3 2 1
COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
V1
BORE: 170
ROD: 100
H STROKE: 1333 H
CLOSED CENTRES: 1782
CBV RATIO: 4:1

CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
V1 V2 STROKE: 400 STROKE: 400
BORE: 110
TH417C GC
CLOSED CENTRES: 710 CLOSED CENTRES: 710

ROD: 80
STROKE: 3610 FRAME LEVELLING
CLOSED CENTRES: 4526 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
BORE: 120
BORE: 105
ROD: 80
ROD: 55
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
T1
T2 T1 T2 T1
G G
MALE AUXILIARY COUPLING V2 V1 V2 V1

V1
FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
BAR BAR BAR BAR BAR
T2
T1 T2
CONTAMINATION TEST POINT
270
F BAR F
35 BAR
2 MM LS
LS 1
L/MIN
14
E BAR E
LS1
P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST
P
B1
2
D D
3
L 1
FRONT AXLE
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.6CC
S
R B'
RETURN FILTER NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
L N
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR
B
C R1 C
PARK BRAKE
LD P T SERVICE BRAKE VALVE
180
MASTER CYLINDER & VALVE SHOWN WITH
BAR FOOT PEDAL ASSEMBLY THE BRAKE
TOTAL DISPLACEMENT: 27.5 TO DISENGAGED.
49CC RELEASE PRESSURE:
21 TO 35 BAR
240
BAR
T R CRAB 4WS
A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV
0.5MM 0.75MM
COOLER BYPASS
B B
CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 8.5CC
PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM
IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
RESERVOIR
A FILL VOLUME: 105L A
Hydraulic System
APPROXIMATE SYSTEM VOLUME: 190L
8 7 6 5 4 3 2 1
MZ7760C
8-7
Hydraulic System
8.7 HYDRAULIC RESERVOIR 8.7.2 Hydraulic Oil Reservoir Filling

1 1. Be sure the reservoir is clean and free of all debris.
5
4 2. Install a new hydraulic oil filter.
3
3. Fill the reservoir with oil until oil level is visible in the
gauge window (3). Refer to Section 2.5, “Fluids,
6 5. Close and secure the engine cover.
6
6. Start machine and check all hydraulic functions for
2
proper operation. Check for any hydraulic oil leaks. Shut
MZ8000 machine OFF and check hydraulic oil level. If oil is warm,
oil level should be visible in the gauge window (3). Add
The hydraulic reservoir (1) is located under the cab. hydraulic oil if necessary.
7. Close the hydraulic oil filler cab access panel at the
8.7.1 Hydraulic Oil Reservoir Draining bottom left rear of the cab.
1. Park the machine on a firm, level surface, level the 8. Remove the Do Not Operate Tag from the ignition key
machine, fully retract the boom, lower the boom, place switch and the steering wheel.
the transmission in (N)NEUTRAL, engage the park brake
and shut the engine OFF. 8.7.3 Hydraulic Oil Reservoir Removal/
2. Place a Do Not Operate Tag on both the ignition key Installation
switch and the steering wheel. If it is determined that the hydraulic oil reservoir must be
3. Open the engine cover. Allow the system fluids to cool. removed, the hydraulic oil must be drained before the
reservoir is removed. Always dispose of hydraulic oil
properly.
5. Open the hydraulic oil filler cab access panel at the
bottom left rear of the cab. a. Reservoir Removal
6. Open the filler cap on the hydraulic oil reservoir. 1. Park the machine on a firm, level surface, level the
Remove the drain plug (2) on the bottom of the machine, fully retract the boom, lower the boom, place
hydraulic oil reservoir. the transmission in (N) NEUTRAL, engage the park brake
7. Transfer the used hydraulic oil into a suitable covered and shut the engine OFF.
container, and label as "Used Oil". Dispose of used oil at 2. Place a Do Not Operate Tag on both the ignition key
an approved recycling facility. Clean and reinstall the switch and the steering wheel.
drain plug. Torque drain plug to
35 Nm (25 lb-ft). 3. Open the engine cover. Allow the system fluids to cool.
8. Wipe up any hydraulic fluid spillage in, on, near and 4. Properly disconnect the battery.
around the machine and the work area. 5. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
to the hydraulic oil reservoir. Cap all fittings and
openings to keep dirt and debris from entering the
hydraulic system.
7. Remove the two bolts securing the fill tube/bracket (4).
8. Remove the bolt (5), nuts and strap (6) securing the
hydraulic oil reservoir to the frame.
9. Remove the hydraulic oil reservoir.

Hydraulic System
b. Disassembly d. Inspection
Dispose of the old reservoir according to local regulations 1. Inspect the hydraulic oil reservoir thoroughly for any
concerning hazardous materials disposal. cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
7-10 kPa (1-1.5 psi) of air pressure through the elbow.
Check the reservoir for leaks by applying a soap solution
to the exterior and look for bubbles to appear at the
cracked or damaged area.
e. Assembly
1. Install the previously removed fittings, adapters and
tubes in the correct orientation.
MZ8010
2. Properly torque all fittings and adapters as required.
1. Note the orientation of all fittings, adapters and tubes
f. Reservoir Installation
on the hydraulic tank.
2. Label and remove all fittings, adapters and tubes from 1. Place the hydraulic oil reservoir into its original
the hydraulic tank. orientation.
2. Secure the hydraulic oil reservoir to the frame with the
c. Cleaning and Drying previous mounting hardware.
If contaminated hydraulic oil or foreign material is in the 3. Uncap and connect the previously labeled hydraulic
tank, the tank can usually be cleaned. hoses to their appropriate locations. Be sure all lines are
free of kinks and sharp bends.
To clean the hydraulic oil reservoir:
4. Fill the reservoir with oil until oil level is visible in the
1. Have a dry chemical (Class B) fire extinguisher near the
gauge window. Refer to Section 2.5, “Fluids, Lubricants
work area.
and Capacities.”
2. Remove the hydraulic oil reservoir drain plug, and safely
5. Check the hydraulic oil reservoir for leaks.
drain any hydraulic oil into a suitable container. Dispose
of hydraulic oil properly. 6. Properly connect the battery.
3. Clean the hydraulic oil reservoir with a high-pressure 7. Close and secure the engine cover.
washer, or flush the tank with hot water for five minutes 8. Start machine and check all hydraulic functions for
and drain the water. Dispose of contaminated water proper operation. Check for any hydraulic oil leaks. Shut
properly. machine OFF and check hydraulic oil level. If oil is warm,
oil level should be visible in the gauge window. Add
hydraulic oil if necessary.
9. Remove the Do Not Operate Tag from the ignition key

Hydraulic System
8.8 ENGINE IMPLEMENT PUMP b. Pump Installation

1. Apply Loctite® 243TM to all mounting bolts.
8.8.1 Pump Replacement 2. If the adapter plate was removed, place into position
with a new, oiled o-ring on the engine. Secure with the
a. Pump Removal previously used hardware.
1. Park the machine on a firm, level surface, level the 3. Place the pump and a new, oiled o-ring into position on
machine, fully retract the boom, lower the boom, place the adapter plate. Align the pump shaft with the
the transmission in (N) NEUTRAL, engage the park brake internal gear, so that the machined teeth mesh
and shut the engine OFF. together.
2. Place a Do Not Operate Tag on both the ignition key 4. Align the bolt holes with the pump mount holes. Secure
switch and the steering wheel. the pump to the adapter plate with the two bolts and
3. Open the engine cover. Allow the system fluids to cool. washers. Torque as required.
4. Properly disconnect the battery. 5. Uncap and connect the previously labeled hydraulic hoses
to their appropriate locations.
5. Drain the hydraulic reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining.” Note: Prime the pump by filling the case with fresh, filtered
6. Thoroughly clean the pump and surrounding area, hydraulic oil from a clean container through suction port (9)
including all hoses and fittings before proceeding. before installing hose and flanges.
Note: Cap all hoses as you remove them to prevent 6. Fill the hydraulic reservoir. Refer to Section 8.7.2,
unnecessary fluid spillage. “Hydraulic Oil Reservoir Filling.”
7. Check all routing of hoses and tubing for sharp bends or
7. Label, disconnect and cap the hydraulic hoses attached
interference with any rotating members.
to the pump.
9 8. Inspect for leaks and check all fluid levels. The hydraulic
7 8 reservoir oil level must be to the middle of the sight
gauge.
7 11. Start machine and verify proper operation.
c. Implement Pump Test

MZ8020 Refer to Section 8.4.1, “Pressure Checks and Adjustments.”
8. Remove the two bolts and two lockwashers (7) securing

the pump (8) to the adapter plate. Remove the o-ring
located between the plate and the pump. Wipe up any
hydraulic oil spillage.
9. If necessary, remove the four bolts securing the adapter
plate to the transmission. Remove the adapter plate.
Note: DO NOT disassemble the operating pump. The pump is
pre-set from the manufacturer.

Hydraulic System
8.9 CONTROL VALVES fittings to allow any trapped pressure in the hydraulic
system to escape.
8.9.1 Main Control Valve 10. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
The main control valve is mounted at the rear of the cab.
11. Support the valve and remove the four bolts securing
2 the main control valve to the frame. Remove the main
control valve.
b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the tie
rods.
3
2. Disassemble each section assembly as required.
4 Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
5 Note: DO NOT adjust any of the relief valve assemblies.
1 Tampering with a relief valve will irrevocably alter pressure in the
affected circuit, requiring recalibration or a new relief valve.
Disassemble each Valve Section

MZ8060 1. Carefully separate the load sense outlet section (5) from the
next section.
6
2. Remove the o-rings from between the two sections.
The main control valve assembly (1) consists of working
sections with their own valve assemblies, each providing a 3. Carefully separate each remaining section.
specific hydraulic function. Those functions are: 4. Remove any check valves, compensator valves, anti-
lift/lower (2), extend/retract (3), tilt (4) and auxiliary (5). cavitation valves or shock valves from individual valve
section if equipped.
a. Main Control Valve Removal 5. Keep all parts being removed from individual valve
1. Park the machine on a firm, level surface, level the sections tagged and kept together.
machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake c. Main Control Valve Parts Cleaning
and shut the engine OFF. Clean all components with a suitable cleaner, such as
2. Place a Do Not Operate Tag on both the ignition key triclorethylene, before continuing. Blow dry.
3. Open the engine cover. Allow the system fluids to cool. d. Main Control Valve Parts Inspection
4. Properly disconnect the battery. Inspect all parts and internal passageways for wear, damage,
etc. If inner surfaces of any component DO NOT display an
5. Remove the main control valve cover.
ultra-smooth, polished finish, or are damaged in any way,
6. Thoroughly clean the main control valve and replace the damaged part. Often, dirty hydraulic fluid causes
surrounding area, including all hoses and fittings, failure of internal seals, damage to the polished surfaces
before proceeding. within the component, and wear of and/or harm to other
7. Place a suitable container to catch hydraulic fluid parts.
drainage beneath the cab.
8. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
9. Label, disconnect and cap all the hydraulic hoses, tubes
and wires at the main control valve. Slowly turn hose

Hydraulic System
e. Main Control Valve Assembly 9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
parts to help ensure proper sealing and operation. Lubricate 10. Install main control valve cover.
seals and o-rings with clean hydraulic oil. 11. Close and secure the engine cover.
Assemble each Valve Section
1. Reassemble any check valves, compensator valves, anti-
cavitation valves or shock valves from each individual g. Main Control Valve Test
valve sections if equipped.
Conduct a pressure check of the hydraulic system in its
2. Install the end caps on each end of the valve section. entirety. Adjust pressure(s) as required. Refer to Section 8.5.1,
“Hydraulic Pressures.”
Assemble the Main Control Valve.
1. If removed, install all four tie rods into the end main
control valve section.
2. Stand the end main control valve section on end.
3. Install the proper o-rings and load sense shuttle on the
inner face of the end main control valve section. Align
the next valve section over the three tie rods and slide
onto the end main control valve section.
4. Using the proper o-rings and load sense shuttle, repeat
step three for the remaining valve sections and lastly
the inlet end valve section.
5. Install the nuts on the tie rods (6) and torque to 25Nm
(18.5 lb-ft).
f. Main Control Valve Installation

1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the main
control valve. Slide the main control valve into position,
and tighten the bolts.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a clean
container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and connect
all hoses, clamps, etc. to the main control valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling.”
7. 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.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.

Hydraulic System
8.9.2 Service Brake Valve b. Service Brake Valve Installation

1. Install the service brake valve to its original orientation
a. Service Brake Valve Removal
in the cab. Secure with the previously used hardware.
1. Park the machine on a firm, level surface, level the 2. Install the service brake pedal.
the transmission in (N) NEUTRAL, engage the park brake 3. Uncap and connect the previously labeled hydraulic
and shut the engine OFF. hoses to the service brake valve.
2. Place a Do Not Operate Tag on both the ignition key 4. Check the routing of all hoses, and tubing for sharp
switch and the steering wheel. bends or interference with any rotating members, and
install tie wraps and/or protective conduit as required.
3. Open the engine cover. Allow the system fluids to cool. Tighten all tube and hose clamps.
4. Properly disconnect the battery. 5. Properly connect the battery.
5. Remove the access covers from the outside of the cab. 6. 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.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
1
8. Wipe up any hydraulic fluid spillage in, on, near and
9. Install the cover panel in the cab.
10. Install the access covers to the outside of the cab.
4
8.9.3 Service Brake Bleeding

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. There are two brake bleeder
locations on the front and rear axles. Work with an assistant
to perform this procedure.
1. Place the transmission in (N) NEUTRAL, engage the park
brake, and start the engine.
2 3
MZ7720
6. Label, disconnect and cap all hoses attached to the

service brake valve (1).
7. Remove the cover panel in the cab (2).
8. Disconnect and remove the brake pedal (3).
9. Remove the two nuts (4) securing the service brake
valve to the cab.
10. Remove the valve through the front of the cab.
Note: DO NOT disassemble the service brake valve. The service
brake valve is not serviceable and must be replaced in its
entirety, if defective.

Hydraulic System
8.9.4 Service Brake Test

TH417C GC
1. Install a digital or a 70 bar (1000 psi) gauge to the test
port on the brake valve (behind the front cover of the
cab).
2. Start the machine and apply pressure to the service
2 brake pedal. A maximum pressure of 44 bar
(638 psi) should be achieved.
3. If further testing is required, refer to Section 8.5.1,
“Hydraulic Pressures.”
2
8.9.5 Steering Orbitrol Valve
The steering orbitrol valve is located at the base of the
steering wheel shaft, concealed by the front access covers.
The valve is not serviceable and must be replaced in its
entirety if defective. For detailed information refer to Section
TH414C GC 4.3.2, “Steering Column/Orbitrol Valve.”
8.9.6 Outrigger/Stabilizer Valve and Brake

Damper
2
4
MZ8070
2. Remove the plastic cap from the left brake bleeder (2).
Attach one end of a length of transparent tubing over MZ8090
the brake bleeder. Place the other end of this tubing in a

The outrigger/stabilizer valve (3) controls the direction of
suitable transparent container that is partially filled with
hydraulic fluid flow to each outrigger cylinder and the
hydraulic oil. The end of the tubing must be below the
stabilizer cylinder. The outrigger/stabilizer valve and brake
oil level in the container.
damper is attached inside the frame in front of the front axle.
3. DO NOT open the brake bleeder without holding the
Verify the correct operation of the outrigger/stabilizer valve
tubing firmly on the bleeder. There is pressure at the
solenoids before considering replacement of the valve. Refer
brakes. Carefully open the bleeder. Have the assistant
to Section 9.5, “Electrical System Schematics.” The body of
depress the brake pedal. Close the brake bleeder when
the outrigger/stabilizer valve is not serviceable and must be
air bubbles no longer appear in the oil. Release the
replaced if defective.
brake pedal. Remove the tubing from the brake bleeder.
4. Repeat steps 2 and 3 for the right brake bleeder and the
left and right rear axle bleeders.

Hydraulic System
a. Outrigger/Stabilizer Valve Removal c. Outrigger/Stabilizer Valve Installation

1. Park the machine on a firm, level surface, level the 1. Install the outrigger/stabilizer valve to the frame using
machine, fully retract the boom, raise and support the the previously removed nuts and washers.
boom, place the transmission in (N) NEUTRAL, engage 2. Connect all the hydraulic hoses, fittings, solenoid wire
the park brake, lower each outrigger and shut the engine terminal leads, etc., to the outrigger/stabilizer valve
OFF.
3. Check the routing of all hoses, wiring and tubing for
2. Place a Do Not Operate Tag on both the ignition key sharp bends or interference with any rotating members,
switch and the steering wheel. and install tie wraps and/or protective conduit as
3. Open the engine cover. Allow the system fluids to cool. required. Tighten all hose clamps.
4. Properly disconnect the battery. 4. Properly connect the battery.
5. Remove the access cover from the top front of the 5. Remove boom support.
frame. 6. Start the engine and run at approximately 1/3-1/2
6. Label, disconnect and cap the hydraulic hoses and the throttle for about one minute without moving the
electrical plugs connected to the outrigger/stabilizer machine or operating any hydraulic functions.
valve. 7. Inspect for leaks and check the level of the hydraulic
7. Remove the nuts holding the outrigger/stabilizer valve fluid in the reservoir. Shut the engine OFF.
to the frame.
Note: Check for leaks and repair as required before continuing.
8. Remove the outrigger/stabilizer valve from the Add hydraulic fluid to the reservoir as needed.
machine. Wipe up any hydraulic fluid spillage in, on,
near and around the machine. 8. Wipe up any hydraulic fluid spillage in, on, near and
b. Outrigger/Stabilizer Valve Disassembly, Cleaning, 9. Install the previously removed access cover.
Inspection and Assembly 10. Close and secure the engine cover.
1. Place the outrigger/stabilizer valve assembly on a 11. Remove the Do Not Operate Tag from the ignition key
suitable work surface. switch and the steering wheel.
2. Separate the outrigger/stabilizer valve solenoids from
the spool. Discard the o-rings. d. Outrigger/Stabilizer Valve Test
3. Clean all components with a suitable cleaner before Refer to Section 8.5.1, “Hydraulic Pressures.”
inspection. 1. Conduct a pressure check of the outrigger/stabilizer
4. Inspect the solenoid cartridges for proper operation. valve hydraulic circuit.
Check by shifting the spool to ensure that it is 2. Check each outrigger/stabilizer valve mode for proper
functioning properly. Check that the spring is intact. function.
Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the steer select valve 8.9.7 Brake Damper
for wear, damage, etc. If inner surfaces of the manifold
The brake damper is a 250 bar (3626 psi) diaphragm damper.
DO NOT display an ultra-smooth, polished finish, or
The pneumatic damper is operated by compressed gas. Gas
components are damaged in any way, replace the
and hydraulic oil occupy the same container. When oil
manifold or appropriate part. Often, dirty hydraulic fluid
pressure rises, incoming oil compresses the gas. When oil
causes failure of internal seals and damage to the
pressure drops, the gas expands.
polished surfaces within the secondary function
The gas is separated from the oil by a piston. This prevents
manifold.
the mixing of gas and oil and keeps gas out of the hydraulic
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new system.
parts to help ensure proper sealing and operation. Lubricate The damper must be “pre-charged” with gas before use in
seals and o-rings with clean hydraulic oil. the hydraulic system. This is done by filling the gas chamber
6. Install the solenoids in the outrigger/stabilizer valve with dry nitrogen to a pressure of 35 bar
housing. (507 psi). The schrader valve is located under the protective
cap at the top of the damper. The schrader valve is used for
pre-charging and testing the damper.

Hydraulic System
a. Damper Removal 6. Remove the Do Not Operate Tag from the ignition key
1. Remove any attachment from the machine. Park the
machine on a firm level surface and fully retract the 7. Refer to Section 8.9.9, “Pre-Charging Damper,” for
boom. Raise the boom to allow sufficient work space damper pre-charging instructions.
around the frame to allow the damper to be removed.
Support the boom. Place the travel select lever in (N) 8.9.8 Brake Damper Charging
NEUTRAL, engage the park brake, shut the engine OFF This section covers the charging of the damper system.
and chock wheels.
The damper is located and mounted at the front of the
2. Place a Do Not Operate Tag on both the ignition key machine, between the frame rails. The internal parts of the
switch and the steering wheel. damper are not serviceable. If the internal piston is leaking,
3. Open the engine cover. Allow the system fluids to cool. or the seals on the top or bottom cap are leaking, the damper
4. Properly disconnect the battery. requires replacement.
5. Pump the brake pedal several times to dissipate any The damper pre-charge pressure will vary depending on the
excess pressure in the brake system. ambient temperature that the damper was pre-charged at
and the actual operating temperature of the damper.
8.9.9 Pre-Charging Damper

Note: Replacement damper are not pre-charged when
shipped.
WARNING
NEVER fill an damper with oxygen! An explosion could
6
result if oil and oxygen are mixed under pressure. Only fill
damper with dry nitrogen.
7
Pre-charge the damper with nitrogen gas only. Nitrogen gas
5
is free of water vapor and oxygen which makes it harmless to
internal parts and will not react if mixed with oil under
pressure.
MZ8090
6. Disconnect and cap or plug the hydraulic hose (5) at the

damper (6).
NOTICE
Never fill an damper with air. Air contains moisture which can
7. Remove the two straps (7) securing the damper to the
cause corrosion. This corrosion may damage seals and ruin
mounting bracket.
the damper.
8. Remove the damper.
Never charge an damper to a pressure more than specified.
The proper pressure for the damper is 35 bar (507 psi).
Note: Make sure the nitrogen bottle, as well as the charging
b. Damper Installation and gauge assembly used is compatible with the schrader valve
assembly on the damper. The nitrogen bottle and all
1. Secure the damper (6) to the mounting bracket with the
components must be rated for a pressure at least as high as the
two nylon straps (7).
nitrogen source. It is strongly recommended that the nitrogen
2. Uncap and connect the hydraulic hose (5) to the bottle has a high pressure regulator.
damper.
A damper fill kit is required to properly charge the damper.
3. Remove the boom support. Refer to the parts manual or contact the local Caterpillar
4. Properly connect the battery. dealer.
5. Close and secure the engine cover. Use the following steps to properly pre-charge each damper:

Hydraulic System
13. When the correct pressure is reached, back the “T”

handle (10) on the damper fill kit all the way out
13
(counter-clockwise). Bleed the pressure from the hose
by turning the gas valve/bleed valve out to relieve the
14
pressure.
14. Turn the gas valve/bleed valve (12) all the way in and
remove the schrader adapter (11) from the valve on the
9 damper.
15. Reassemble the protective cap onto the gas valve on
8 11 the damper.
8.9.10 Checking Pre-Charge

12
10 a. Gas Leaks
MZ8110
1. Thoroughly clean the top of each damper (8).

2. Make sure the nitrogen supply is shut off.
3. Attach the damper fill kit (9) to the nitrogen bottle.
1
4. Remove the protective cap from the gas valve on the
damper.
5. Back the “T” handle (10) on the damper fill kit all the 2
way out (counter-clockwise). Attach the schrader MZ8100
adaptor (11) to the gas valve on the damper. Tighten

securely. 1. If an external leak is suspected, apply soapy water to the
gas valve (1) and the fitting of the gas bottle (2). If
6. Turn the gas valve/bleed valve (12) on the damper fill kit
bubbles form, the damper has to be replaced.
all the way in.
2. If an internal leak is suspected, check for foaming oil in
7. Turn the “T” handle (10) all the way in to open the valve
the hydraulic reservoir and/or no damper action. If any
core on the damper.
of these signs are evident, the damper has to be
8. Open the valve (13) on the nitrogen bottle. replaced.
9. Slowly adjust the regulator (14) on the nitrogen bottle
to read 35 bar (507 psi).
10. Close the main valve (13) on the nitrogen bottle.
11. Back the “T” handle (10) on the damper fill kit all the
way out (counter-clockwise).
12. Let the pre-charge on the damper set for 10-15 minutes.
This will allow the gas temperature to stabilize. If the
desired pre-charged range is exceeded, turn the “T”
handle (10) all the way in. With the main valve (13)
closed on the nitrogen bottle, turn the gas valve/
bleeder valve (12) out to bleed pressure off the damper.
Turn the valve all the way in and check the pressure
reading on the regulator gauge.

Hydraulic System
8.9.11 Steer Select Valve b. Steer Select Manifold and Valve Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select solenoids from the spool.
Discard the o-rings.
3. Clean all components with a suitable cleaner before
inspection.
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
3 5. Inspect internal passageways of the steer select valve
for wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
components are damaged in any way, replace the
manifold or appropriate part. Often, dirty hydraulic fluid
MZ8080
causes failure of internal seals and damage to the
The machine can be used in the front-wheel, four-wheel or polished surfaces within the secondary function
crab steering mode. The steer select valve (3) controls the manifold.
direction of hydraulic fluid flow to the steering cylinder Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
mounted on each axle. The steer select valve is attached parts to help ensure proper sealing and operation. Lubricate
inside the frame between the can and the front axle. seals and o-rings with clean hydraulic oil.
Verify the correct operation of the steer select valve
6. Install the solenoids in the steer select housing.
solenoids before considering replacement of the valve. Refer
to Section 9.5, “Electrical System Schematics.” The housing of
c. Steer Select Valve and Manifold Installation
the steer select valve is not serviceable and must be replaced
if defective. 1. Install the steer select valve to the mounting plate
under the left front side of the frame using the two
a. Steer Select Manifold and Valve Removal bolts.
1. Park the machine on a firm, level surface, level the 2. Connect all the hydraulic hoses, fittings, solenoid wire
machine, fully retract the boom, lower the boom, place terminal leads, etc., to the steer select valve
the transmission in (N) NEUTRAL, engage the park brake 3. Check the routing of all hoses, wiring and tubing for
and shut the engine OFF. sharp bends or interference with any rotating members,
2. Place a Do Not Operate Tag on both the ignition key and install tie wraps and/or protective conduit as
switch and the steering wheel. required. Tighten all hose clamps.
3. Open the engine cover. Allow the system fluids to cool. 4. Properly connect the battery.
4. Properly disconnect the battery. 5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
5. Label, disconnect and cap the hydraulic hoses and the
machine or operating any hydraulic functions.
electrical plugs connected to the steering select valve.
6. Inspect for leaks and check the level of the hydraulic
6. Remove the bolts holding the steer select valve to the
fluid in the reservoir. Shut the engine OFF.
mounting plate on the frame.
7. Remove the steer select valve from the machine. Wipe Note: Check for leaks and repair as required before continuing.
up any hydraulic fluid spillage in, on, near and around Add hydraulic fluid to the reservoir as needed.
the machine. 7. Wipe up any hydraulic fluid spillage in, on, near and

Hydraulic System
9. Remove the Do Not Operate Tag from the ignition key a. General Cylinder Disassembly
1. Clean the cylinder with a suitable cleaner before
disassembly. Remove all dirt, debris and grease from the
d. Steering Test
cylinder.
Refer to Section 8.5.1, “Hydraulic Pressures.” 2. Clamp the barrel end of the cylinder in a soft-jawed vise
1. Conduct a pressure check of the steering hydraulic or other acceptable holding equipment if possible.
circuit.
2. Check each steering mode for proper function.
WARNING
8.10 HYDRAULIC CYLINDERS Significant pressure may be trapped inside the cylinder.
Exercise caution when removing a counterbalance valve or a
pilot-operated check valve from a cylinder.
8.10.1 General Cylinder Removal Instructions
1. Remove any attachment from the machine. Park the Note: Avoid using excessive force when clamping the cylinder
machine on a firm level surface and fully retract the in a vise. Apply only enough force to hold the cylinder securely.
boom. Allow sufficient work space around the hydraulic Excessive force can damage the cylinder tube.
cylinder being removed. Support the boom if the lift/ 3. If applicable, remove the counterbalance valve from the
lower cylinder is being removed. Place the transmission side of the cylinder barrel.
in (N) NEUTRAL, engage the park brake, shut the engine
OFF and chock wheels. Note: DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment or replacement is
2. Place a Do Not Operate Tag on both the ignition key necessary, replace the counterbalance valve with a new part.
4. Extend the rod as required to allow access to the base of
the cylinder.
4. Label, disconnect and cap or plug hydraulic hoses in
relation to the cylinder. Note: Protect the finish of the rod at all times. Damage to the
surface of the rod can cause seal failure.
5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can 5. Using a pin spanner wrench, unscrew the head gland
actually support the cylinder. from the tube. A considerable amount of force will be
needed to remove the head gland. Carefully slide the
6. Remove the lock bolt and/or any retaining clips
head gland down along the rod toward the rod eye,
securing the cylinder pins. Remove the cylinder pins.
away from the cylinder barrel.
7. Remove the cylinder.
Note: When sliding the rod and piston assembly out of the
8. Wipe up any hydraulic fluid spillage in, on, near and barrel, prevent the threaded end of the barrel from damaging
around the machine, work area and tools. the piston. Keep the rod centered within the barrel to help
prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the bond of
the sealant between the piston and the rod before the piston
can be removed.
MZ0400

Hydraulic System
Some cylinder parts are sealed with a special organic sealant c. Cylinder Inspection
and locking compound. Before attempting to disassemble
1. Inspect internal surfaces and all parts for wear, damage,
these parts, remove any accessible seals from the area of the
etc. If the inner surface of the cylinder barrel does not
bonded parts. Wipe off any hydraulic oil, then heat the part(s)
display a smooth finish, or is scored or damaged in any
uniformly to break the bond. A temperature of 149-204° C
way, replace the barrel.
(300-400° F) will destroy the bond. Avoid overheating, or the
parts may become distorted or damaged. Apply sufficient 2. Remove light scratches on the piston, head gland, rod
torque for removal while the parts are still hot. The sealant or inner surface of the cylinder barrel with a 400-600 grit
often leaves a white, powdery residue on threads and other emery cloth. Use the emery cloth in a rotary motion to
parts, which must be removed by brushing with a soft brass polish out and blend the scratch(es) into the
wire brush prior to reassembly. surrounding surface.
9. Remove the piston head from the rod and carefully slide 3. Check the piston rod assembly for run-out. If the rod is
the head gland off the end of the rod. bent, it must be replaced.
10. Remove all seals, back-up rings and o-rings from the
d. General Cylinder Assembly Instructions
piston head and all seals, back-up rings and o-rings
from the head gland. 1. Use the proper tools for specific installation tasks. Clean
tools are required for installation.
Note: The head gland bearing will need to be inspected to
determine if replacement is necessary. 2. Install new seals, back-up rings and o-rings on the
piston and new seals, back-up rings, o-rings and
DO NOT attempt to salvage cylinder seals, sealing rings or o- bearing on the head gland.
rings. ALWAYS use a new, complete seal kit when rebuilding
hydraulic components. Consult the parts catalog for Note: The extend/retract cylinder has a spacer that MUST be
ordering information. installed over the rod AFTER the head gland and BEFORE the
piston head.
b. Cylinder Cleaning Instructions
3. Fasten the rod eye in a soft-jawed vise, and place a
1. Discard all seals, back-up rings and o-rings. Replace with padded support under and near the threaded end of
new items from seal kit to ensure proper cylinder the rod to prevent any damage to the rod.
function.
Note: Protect the finish on the cylinder rod at all times.
2. Clean all metal parts with an approved cleaning solvent Damage to the surface of the rod can cause seal failure.
such as trichlorethylene. Carefully clean cavities,
grooves, threads, etc. 4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the cylinder
Note: If a white powdery residue is present on threads or parts, rod. Apply Loctite® 243TM and install the set screw in the
it can be removed by using a soft brass wire brush. Wipe clean piston head. Refer to Section 8.10.4, “Cylinder Torque
with Loctite® Cleaner prior to reassembly. Specifications” for torque specifications for the piston
head and the set screw.
Note: Avoid using excess force when clamping the cylinder
barrel in a vise. Apply only enough force to hold the cylinder
barrel securely. Excessive force can damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder barrel
from damaging the piston head. Keep the cylinder rod centered
within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.

Hydraulic System
7. Screw the head gland into the cylinder barrel and 8.10.3 Steering Cylinders
tighten with a spanner wrench. Refer to Section 8.10.4,
The steer cylinder is attached to each axle center housing.
“Cylinder Torque Specifications” for torque
The steer cylinder is covered in the appropriate
specifications for the head gland.
manufacturer’s axle literature.Detailed axle service
8. If applicable, install new counter balance valve into instructions (covering the axle, differential, brakes and
block on the cylinder barrel. wheel-end safety, repair, disassembly, reassembly,
adjustment and troubleshooting information) are provided
e. General Cylinder Installation in the appropriate Axle Disassembly & Assembly Manual.
1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder into TH414C GC, TH417C GC Manual P/N
it’s mounting position.
Service 31200162
2. Align cylinder bushing and install pin, lock bolt or
retaining clip. Parts 31200958
3. Connect the hydraulic hoses in relation to the labels or

markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full mark
with oil.
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
6. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed. Shut the engine
OFF.
8.10.2 Cylinder Pressure Checking

Attach a 345 bar (5000 psi) gauge to the test port on the P1
port on the hydraulic manifold to check the system pressure.
For more information, refer to Section 8.4.1, “Pressure Checks
and Adjustments.”
Note: If a hydraulic cylinder pressure is greater than the main
control valve pressure, increase the main control valve pressure
by adjusting the main relief. Generally, one half turn clockwise
will be adequate to check an individual circuit. Activate the
circuit and if pressure is obtained turn the main relief counter
clockwise one half turn. Re-check the main relief setting and
adjust if necessary.

Hydraulic System
8.10.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston V1 Plug V2 Plug CB Valve

TH414C GC 1500 Nm (1106 lb-ft)
2000 Nm (1475 lb-ft) 85 Nm (63 lb-ft) 85 Nm (63 lb-ft) N/A
TH417C GC 480 Nm (354 lb-ft)
b. Extend/Retract Cylinder

TH414C GC 900 Nm (664 lb-ft) 1000 Nm (738 lb-ft)
100 Nm (74 lb-ft) 170 Nm (125 lb-ft) N/A
c. Tilt Cylinder

All
1200 Nm (885 lb-ft) 1500Nm (1106 lb-ft) 85 Nm (63 lb-ft) 85 Nm (63 lb-ft) 85 Nm (63 lb-ft)
Machines
d. Compensation Cylinder
Model Head Piston

All Machines 800 Nm (590 lb-ft) 1000 Nm (738 lb-ft)
e. Frame Level Cylinder

85 Nm (63 lb-ft) 85 Nm (63 lb-ft) 40 Nm (30 lb-ft)
f. Outrigger Cylinder

All Machines 1500 Nm (1106 lb-ft) 1000 Nm (738 lb-ft) 85 Nm (63 lb-ft) 85 Nm (63 lb-ft) 40 Nm (30 lb-ft)

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5.1 Cab Harness Electrical Schematic 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5.2 Cab Harness Electrical Schematic 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.3 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.5.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.5.5 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.5.6 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.5.7 Option Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.6 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.6.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.6.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.7 Wiper/Washer Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.7.1 Front Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.7.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.7.3 Roof Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.7.4 Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.8 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.2 Transmission Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.3 Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8.4 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8.5 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.6 Boom Retract Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8.8 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.9 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.9.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.9.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

Electrical System
9.10 Load Stability Indicator (LSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

9.10.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.10.2 LSI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.10.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.10.4 LSI-CAN Check PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.10.5 500 Hour - LSI UGM Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.11.1 Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.11.2 Analyzer Software Version V6.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.12 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.12.1 Indicator Cross Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.13 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.13.1 Help Comment (00X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.13.2 Power Up (21X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.13.3 Cabin Controls (23X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.13.4 Function Prevented (25X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.13.5 Output Drivers (33X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.13.6 Engine (43X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.13.7 Battery Supply (44X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.13.8 Transmission & Drive System (46X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.13.9 Communications (66X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.13.10 Load Moment (85X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.13.11 Hardware (99X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48

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
9.1.1 General Overview
POWER
DISTRIBUTION
BOARD
LOAD STABILITY
UGM INDICATOR (LSI)
CONTROLLER
JOYSTICK
DISPLAY
PANEL
IGNITION KEY
SWITCH
ALTERNATOR
STARTER
ECM
CONTROL
BATTERY
DISCONNECT
MZ8380

Electrical System
9.2 SPECIFICATIONS 9.4 POWER DISTRIBUTION BOARD

Electrical system specifications are listed in Section 2, Power distribution board is located in cab. For access,
“General Information and Specifications.” remove screws securing the small side panel to cab.
9.3 SAFETY INFORMATION
WARNING
precautions as outlined in Section 1, “Safety Practices,” of
this manual.
F13 F25 F31 F10 F7 F8 F9
K6
K1
F12 F11 F17 F18 F16 F15 F14
K3
K4
F21 F22 F19 F20
K9
K5
F26 F24 F23 F32
K8
F28
F29
F27
F30
F1 F2 F3 F4 F6 F5
K7
MAM3690
Fuse/Relay Function Amp Rating

F1 Right Hand HI Beam 7.5
F2 Right Hand LOW Beam 7.5
F3 Left Hand HI Beam 7.5
F4 Left Hand LOW Beam 7.5
F5 Left Hand Side Lights 7.5
F6 Right Hand Side Lights 7.5
F7 Headlight Flash Power 15

Electrical System
Fuse/Relay Function Amp Rating

F8 Lights Battery 1 15
F9 Lights Battery 2 15
F10 Key Battery 15
F11 Forward Worklights 15
F12 Rear Worklights 15
F13 Glow Out 15
F14 AC Power 30
F15 Option Power 1 15
F16 Option Power 2 15
F17 Option Power 3 (Cab AC Switch) 15
F18 Option Power 4 (Stabilizers Deploy) 15
F19 Beacon 15
F20 Brake Lights Power 15
F21 Rear Wiper 20
F22 Front Wiper 20
F23 Power Socket 15
F24 Fan 20
F25 ECM Power 30
F26 Key 1 15
F27 Fuel Relay 20
F28 Reverse Alarm/Reverse Light 15
F29 Joystick/Display 10
F30 Controller Power 25
K1 Flasher
K3 Options Power
K4 Fuel Relay
K5 REVERSE ALARM Relay
K6 WORKLIGHTS
K7 Ignition Power 1 Relay

9-6
9.5
9.5.1
1 2 3 4 5 6 7 8
X249
202 CNTRL PWR YEL 6mm²
1
010 GND BLK 6mm² TO PCB
1
X233 GD119
204 LSI PWR YEL
[8,C] 1 PWR
041 GND BLK
03-CAB 2-[8,D] 2 GND
527 LSI CANCEL
3 SWITCHED OUT
LSI SEN 1 -VE BLU
[3,C] 4 SENSOR 1 -VE
LSI SEN 2 -VE RED
[3,C] 5 SENSOR 2 -VE
LSI SEN +VE BLK
DISPLAY,LSI
[3,C] 6 SENSOR VE+
708 CAN HI 5 RED 0.75mm²
H 7 CAN H H
709 CAN LO 5 BLK 0.75mm²
8
CO01-J8
CAN L
4
3
2
1
LSI SEN SHLD1
[3,C] NC1
CO01-J1 WHITE
306 REV RL 360 SEAT SW2 1mm²
03-CAB 2-[1,D] 1 REVERSING ALARM AND LIGHTS RELAY SEAT SW 2 35
028-1 GND BLK
2 34
514 SPD VLV 028-2 GND BLK
3 STABS AND FRAME LEVELING SPEED VALVE 33 03-CAB 2-[1,B]
703 CAN LO 2 BLK 0.75mm² 415-1 SW LT
POWER
POWER
[8,D] 4 32
GROUND
GROUND
702 CAN HI 2 RED 0.75mm² 415-2 SW LT
[8,D] 5 31 03-CAB 2-[2,B] 7
338 ENG STRT 329 2WS LOCK
+
6 ENGAGE STARTER 30 8
327 TRANS 1 230 SPD PWR YEL 421 2WS IND
7 TRANS 1ST TRANS SPD PWR 29 3
324 2WS
8 28 2
705 CAN LO 3 BLK 0.75mm² S25 707 CAN LO 4 BLK 0.75mm² 521 4WS VLV
9 27 1
703 CAN LO 2 BLK 0.75mm² 423 4WS IND
10 26
Electrical System
704 CAN HI 3 RED 0.75mm² 706 CAN HI 4 RED 0.75mm² 422 CRAB IND
11 25
S43 702 CAN HI 2 RED 0.75mm² 705 CAN LO 3 BLK 0.75mm² 522 CRAB VLV
12 CAN 1 LOW 24 6
322 BM RETRACT 310 STEER PWR
13 BOOM RETRACT 23 5
(SHOWN IN 2WS)
314 FWD 324 2WS

14 FORWARD INPUT 22 4
SWITCH,STEER SELECT

15 21 9
+
709 CAN LO 5 BLK 0.75mm² 707 CAN LO 4 BLK 0.75mm² WHT 331-2 ST DEPL LH
16 STAB DEPLOYED LH 20 10
S45
17 19 SW376
G 708 CAN HI 5 RED 0.75mm² 706 CAN HI 4 RED 0.75mm² 034 GND BLK G
18 BOOM ANGLE SENSOR GROUND 18
S47 710 CAN HI 6 RED 0.75mm²
19 17
328 TRANS 2 028-7 GND BLK
20 TRANS 2ND 16 7
337 TRANS TEMP 415-7 SW LT +
21 TRANS TEMP 15 8
214 JYSTK LOCK YEL
22 MICROPROCESSOR PWR 14 1
704 CAN HI 3 RED 0.75mm² 215 KEY IGN YEL
23 CAN 1 HIGH 13 2
WHT 323 SEAT SW1
24 SEAT SWITCH 12 3
214 JYSTK LOCK YEL 329 2WS LOCK
25 JOYSTICK LOCK 11 4
216 KEY IGN YEL
26 10 5
310 STEER PWR
27 9 X995 X995-1 6
308-2 IVS PWR
F 28 BOOM EXTENSION LIMIT 8 2 2
028-7 GND BLK

9
309 IVS SIG 002 TW.PAIR (RX) WHT 330-2 ST DEPL RH +
E [8,C] 29 RX STAB DEPLOYED RH 7 1 1 10
SWITCH,JOYSTICK OVVERIDE
THROTTLE PEDAL 037-2 IVS GND BLK 003 TW.PAIR (TX)

D [8,C] 30 TX 6 SW142
308-1 PED PWR S357
C 31 5 X995-2
307 PED SIG 525-2 ALT D+ 320 BM ANG
B 32 ALTERNATOR EXCITE BOOM ANGLE 4 2
037-1 PED GND BLK 201 KEY PWR YEL
A 33 MICROPROCESSOR PWR 3 1
S356 028-6 GND BLK
SN749 34 AIR FILTER RESTRICTION 2 03-CAB 2-[8,B]
415-6 SW LT
35 1 03-CAB 2-[8,B]
028-7 GND BLK
BLACK CO01-J7 7
415-7 SW LT +
CO01-J2 GREY 8
216 KEY IGN YEL
WHT 331-2 ST DEPL LH

WHT 330-2 ST DEPL RH
F X368 1 8 3 F
037 PED GND BLK 217 KEY IGN YEL
A 2 7 2
307 PED SIG 518 RH O/R UP 528 LSI OUT
B 3 RIGHT STAB UP VALVE 6 1
308 PED PWR
C 4 ALL WHEEL STEER VALVE 5 4
309 IVS SIG 516 FRAME LVL RH
D 5 FRAME LEVEL RIGHT VALVE 4 5
337 TRANS TEMP
E 6 3 6
525-2 ALT D+ 515 FRAME LVL LH
F 7 FRAME LEVEL LEFT VALVE 2 9
SWITCH,LSI OVERRIDE
525-1 ALT D+ 506 TILT UP 302 TRANS SPD +

G 8 TILT UP VALVE TRANS SPD 1 10
710 CAN HI 6 RED 0.75mm² 510 AUX A
H 9 AUX 1 VALVE BLACK CO01-J12 SW375
711 CAN LO 6 BLK 0.75mm² 520 LH O/R UP 028 GND BLK
J 10 LEFT STAB UP VALVE 03-CAB 2-[8,C]
338 ENG STRT 500 LIFT UP 415 SW LT
K 11 LIFT UP VALVE 03-CAB 2-[1,D]
313 CLUTCH SW 028-1 GND BLK
L 12 7
TO ENGINE 312 ECM IGN 415-1 SW LT +
M 13 8
530 HYD FLTR 524 LEVEL L
N 14 3
325 TRANS F 517 RH O/R DN 217 KEY IGN YEL
O 15 RIGHT STAB DOWN VALVE 2
326 TRANS R 526 LEVEL R
P 16 CRAB STEER VALVE 1
328 TRANS 2 YEL 224 KEY PWR
ELECTRICAL SYSTEM SCHEMATICS
Q 17 03-CAB 2-[8,D] 4
327 TRANS 1
R 18 5
302 TRANS SPD 507 TILT DN
S 19 TILT DOWN VALVE 6
230 SPD PWR YEL 511 AUX B
AUX 2 VALVE
SWITCH,FRAME LEVEL
T 20 9
519 LH O/R DN CONTROLLER, GRD MODULE +
U 21 LEFT STAB DOWN VALVE 10
501 LIFT DN
E V 22 LIFT DOWN VALVE SW414 E
313 CLUTCH SW
W 23 CLUTCH SWITCH
530 HYD FLTR
X 24 HYD FILTER RESTRICTION GD86
Cab Harness Electrical Schematic 1 of 2
321 FUEL LVL

25 FUEL LEVEL NC CAN SHLD
26 14
433 BUZZER
[8,D] 27 BUZZER 13
422 CRAB IND
28 12 4W CRAB STEER
423 4WS IND
29 11 4W STEER
421 2WS IND
30 10 2W STEER
312 ECM IGN
31 ECM IGNITION 9 STEERING PRES
326 TRANS R
32 TRANS REVERSE 8 PARK BRAKE
325 TRANS F 703 CAN LO 2 BLK 0.75mm²
33 TRANS FORWARD [1,H] 7 CAN LO
DISPLAY
504 TELE IN 702 CAN HI 2 RED 0.75mm²

34 TELE IN VALVE [1,H] 6 CAN HI
503 TELE OUT
35 TELE OUT VALVE 5 FUEL SENSE
040 GND BLK
4 GND
701 CAN LO 1 BLK 0.75mm² CAN LO
3
2 CAN HI
LIFT RTN
TELE RTN
STAB RTN
TILT RTN
AUX RTN
JOYSTICK LOCK LED
PARK BRAKE
ALTERNATOR D+
ENGINE START
FRAME LEVEL LEFT
LOAD MOMENT CUTOUT
2ND GEAR INPUT
NEUTRAL INPUT
REVERSE INPUT
PRE HEAT
1ST GEAR INPUT
3RD GEAR INPUT
4TH GEAR INPUT
LOAD MOMENT SHUT OFF LED
2 WHEEL STEER LED
CRAB STEER LED
ALL WHEEL STEER LED
FRAME LEVEL RIGHT
LOAD MOMENT SHUT OFF
CRAB STEER INPUT (BUCKET SHAKE)
ALL WHEEL STEER INPUT
203 DISP PWR YEL
1 IGN RUN
AH118 CONT
BLACK
BLUE
433 BUZZER
[2,E]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
D AH118-
D
039 GND BLK
040 GND BLK
BUZZER
CO01-J3
CO01-J4
316 REV
AH118 PULSE
315 NEUT
523 P BRK
318 GEAR 2
317 GEAR 1
319 GEAR 3
528 LSI OUT
524 LEVEL L
526 LEVEL R
525-1 ALT D+
502 LIFT RTN

508 TILT RTN
512 AUX RTN
200 KEY IGN YEL
301 PREHEAT
505 TELE RTN

300 KEY STRT
03-CAB 2-[1,D]
527 LSI CANCEL

104 KEY BATT RED
513 SPD VLV RTN

03-CAB 2-[1,D]
203 DISP PWR YEL

03-CAB 2-[8,D]
WHT 323 SEAT SW1
03-CAB 2-[1,D]
360 SEAT SW2 1mm²
03-CAB 2-[8,D]
206 JYSTK PWR YEL
[8,C] 03-CAB 2-[8,D]
212 KEY PWR YEL
03-CAB 2-[8,D]
204 LSI PWR YEL
[8,H] 03-CAB 2-[8,D]
201 KEY PWR YEL
03-CAB 2-[8,D]
039 GND BLK
03-CAB 2-[8,D]
002 TW.PAIR (RX)
[3,F] 03-CAB 2-[8,C]
003 TW.PAIR (TX)
[3,F] 03-CAB 2-[8,C]
WHT 331-2 ST DEPL LH
08-OPTS-[4,A]
WHT 330-2 ST DEPL RH
C 08-OPTS-[4,A] C
206 JYSTK PWR YEL
[8,C]
031 GND BLK
03-CAB 2-[8,D]
207 PWR SKT YEL 1.5mm²
03-CAB 2-[1,D]
052 GND BLK 1.5mm²
03-CAB 2-[8,D]
205 BRK LT POWER YEL 1.5mm²
03-CAB 2-[1,D]
420 BRK LT SW WHT 1.5mm²
03-CAB 2-[1,D]
[8,H]
[8,H]
[8,H]
[8,H]
03-CAB 2-[8,D]
027 GND BLK
TO PCB 1
X233-1
LSI SEN SHLD1

LSI SEN +VE BLK
S102
B B
420 BRK LT SW WHT 1.5mm²
205 BRK LT POWER YEL 1.5mm²
212 KEY PWR YEL

314 FWD
315 NEUT
316 REV
317 GEAR 1
318 GEAR 2
319 GEAR 3
206 JYSTK PWR YEL
031 GND BLK
300 KEY STRT
301 PREHEAT
200 KEY IGN YEL
104 KEY BATT RED
207 PWR SKT YEL 1.5mm²
052 GND BLK 1.5mm²
1
2
3
4
SW76
1
4
3
5
6
2
7
8
1
2
3
4
5
6
1
2
3
SW16
JS404
MS367
SW415
SW16-1
50B
50A
17B
17A
19B
19A
58B
58A
15B
15A
30B
30A
513 SPD VLV RTN

514 SPD VLV
515 FRAME LVL LH
516 FRAME LVL RH
517 RH O/R DN
518 RH O/R UP
519 LH O/R DN
520 LH O/R UP
521 4WS VLV
522 CRAB VLV
LSI SEN SHLD2
LSI SEN 1 -VE BLU
LSI SEN 2 -VE RED
LSI SEN +VE BLK
322 BM RETRACT
321 FUEL LVL
320 BM ANG
034 GND BLK
510 AUX A
511 AUX B
512 AUX RTN
500 LIFT UP
501 LIFT DN
502 LIFT RTN
503 TELE OUT
504 TELE IN
505 TELE RTN
506 TILT UP
507 TILT DN
508 TILT RTN
II
F
III
N
R
PWR
X363
1
2
3
4
5
6
7
8
9
BN
YEL
GRN
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
WHT
POWER SOCKET
SWITCH, BRAKE PEDAL

GND
PWR
TO FRAME
CAN HI
I
II
III
CAN LOW
PLUGGED
PLUGGED
FWD
NEUT
REV
1
1
1
2
2
0
0
3
3
3
SWITCH,FNR
P
P
P
P
120 OHM CAN 1

JOYSTICK,ELOBAU
A SWITCH,IGNITION A
UNLESS OTHERWISE SPECIFIED,

ALL WIRES 1.0mm%%172
ALL WIRES ARE WHITE
1 2 3 4 5 6 7 8
MZ7920F

MZ7930F
A
B
C
D
LB91
030-1 GND BLK
PCB 06-PCB-[6,D] 6
419-4 LH TURN
11
12
10
9
8
7
6
5
4
3
2
1
3
+ 418-4 RH TURN
10
XK2
INDIC
02-CAB 1-[8,D]
02-CAB 1-[8,D]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
9
D1
D2
02-CAB 1-[3,H]
02-CAB 1-[8,F]
8
7
1
5
030-1 GND BLK 418-3 RH TURN 1.5 mm²
1
2
LAMP, HI BEAM & INDIC
HI BEAM
056 GND BLK
030 GND BLK

056-2 GND BLK
4
409-1 HI BEAM
+ 1
306 REV RL
613-2 COND RL WHT
615 COND FAN 2mm²

415 SW LT
YEL 200 KEY IGN

RED 104 KEY BATT
WHT 323 SEAT SW1
231 FLASH RLY IGNT YEL
SW409
113 FLASH RLY BATT RED
228 COND PWR YEL 2mm²
401 FOG LT
207 PWR SKT 1.5 mm²
10
YEL 205 BRK LT POWER
+ 028-2 GND BLK

9 02-CAB 1-[8,H]
420 BRK LT SW WHT1.5 mm²
028-4 GND BLK

419-1 LH TURN
419-3 LH TURN
6
418-1 RH TURN
X285-4
5
401 FOG LT 419-3 LH TURN 1.5mm²
4 1
401 FOG LT 415 SW LT
1 2
208 FOG LT PWR YEL 418-3 RH TURN 1.5 mm²
2 3
S123
420 BRK LT SW WHT1.5 mm²

3 4
415-2 SW LT WHT 323 SEAT SW1
SWITCH, FOG LIGHTS
8 02-CAB 1-[8,H] 5
+
S124
028-4 GND BLK 207 PWR SKT 1.5 mm²

7 6
S125
415-3 SW LT 218 R WIPE PWR YEL 1.5mm²

7
028-4 GND BLK
8
S127
S126
TO PCB SHT.6
229 FAN PWR YEL 1.5mm²

113-1 FLASH BAT RED 9
227 F WIPER YEL 1.5mm²
231-1 FLASH RLY IGNT YEL 10
YEL 205 BRK LT POWER
11
306 REV RL
12
2
2
SW410
418/9-2 HAZARDS 1mm²
10
+ 028-4 GND BLK
9
028-3 GND BLK 419-2 LH TURN 1.5mm²
6
425-1 FLASH 49A 1.5mm²
5
418/9-1 HAZARDS 1.5mm² 418-2 RH TURN 1.5mm²
4
231-1 FLASH RLY IGNT YEL S96
056-1 GND BLK
3
424 FLASH 49 1.5mm²
613-2 COND RL WHT
2
056-3 GND BLK
113-1 FLASH BAT RED

SWITCH,HAZARDS
1
615-2 COND FAN 1.5mm²
415-3 SW LT
[3,A]
[3,A]
[3,A]
[3,A]
[3,A]
[3,A]
8
+ 028-3 GND BLK
D5
D4
7
228-2 COND PWR YEL 1.5mm²
228-1 COND PWR YEL 1.5mm²
231-2 CLEARSKY IGNT YEL
113-2 CLEARSKY BATT RED
415-4 SW LT
227 F WIPER YEL 1.5mm²
028-8 GND BLK

SW411
10
[3,D]
[3,D]
[3,D]
[3,D]
[3,D]
[3,D]
+
X122
9
BLK 056-1 GND
X285-2
3
2
1
410 SIDE LT 1.5mm²

4 WHT 615-2 COND FAN
108 LT BAT 2 RED 1.5mm² 1
WHT 613-2 COND RL
5 WHT 615-1 COND FAN

2
6
411 DR LT 1.5mm² 3
1 RED 104 KEY BATT
107 LT BAT 1 RED 1.5mm² 4
3
2
1
3
2
1
2
5
3
3
3
X122-2
6
X122-3
415-4 SW LT
SWITCH,DRIVING LIGHTS
8 113-1 FLASH BAT RED 1mm²

+ 028-8 GND BLK 7
7
415-5 SW LT 8
610 RF WASH
028-5 GND BLK 9
107 LT BAT 1 RED 1.5mm²
10
TO PCB SHT.6
YEL 200 KEY IGN

11
WHT 603 AC SW PWR
12
F.WASH 611 F WASH 1.5mm² 108 LT BAT 2 RED 1.5mm²
1 13
HORN 111 HORN YEL YEL 228-1 COND PWR
2 14
419-3 LH TURN 1.5mm²
418-3 RH TURN 1.5mm²
YEL 228-2 COND PWR

S48
SW370-WASH 15
BLK 056-4 GND
F.WIPE PWR 227-2 F WIPER YEL 1.5mm²

8
YEL 231-1 CLEARSKY IGNT
RED 113-1 CLEARSKY BATT
12
F.WIPE L 604 F WIPE L 1.5mm²
2
F.WIPE H 605 F WIPE H 1.5mm² X285-5
1
FLASH 49A 425-2 FLASH 49A 1.5mm²
10 1
LH TURN 419 LH TURN 1.5mm² WHT 330 ST DEPL LH
9 2
RH TURN 418 RH TURN 1.5mm² S359 WHT 613-1 AC PRESS
11 3
S358 S52 425 FLASH 49A 1.5mm²
6 4
FLASH BATT 110-1 FLASH BAT RED 1.5mm² WHT 331 ST DEPL RH
7 5
DRV LT 411 DR LT 1.5mm² 003 TW.PAIR (TX)
4
4 6
S362
4
MAIN BEAM 409 HI BEAM 1.5mm² 424 FLASH 49 1.5mm²

3 7
TO PCB SHT.6
08-OPTS-[7,B]
08-OPTS-[7,B]
08-OPTS-[7,B]
LO BEAM 414 LO BEAM 1.5mm²
5 8
002 TW.PAIR (RX)
SW370-TURN 9
X997
X996
3 3
2 2
1 1
4 4
3 3
2 2
1 1
4
3
2
1
3
2
1
111 HORN YEL

1
X997-2
X996-2
X997-1
X996-1
046 GND BLK

227-1 F WIPE PWR RED 1.5mm²
HORN
AH254
SWITCH,TURN/WIPER COLUMN
BLK 064 GND
WH69
BLANKING PLUG
BLANKING PLUG
D3
604-2 F WIPE P 604-2 F WIPE P
WHT 612-2 COND RL
WHT 330 ST DEPL LH
P 1
WHT 331 ST DEPL RH
WHT 603 AC SW PWR
WHT 613-1 AC PRESS
BLK 056-1 GND
604-1 F WIPE L
L 2
227-1 F WIPE PWR RED 1.5mm² S115
12v 3
M 605 F WIPE H 1.5mm²
H 4
5
5
5
038 GND BLK 1.5mm²
G 6
WIPER, FRONT MOTOR

08-OPTS-[4,A]
08-OPTS-[4,A]
08-OPTS-[4,A]
08-OPTS-[8,C]
08-OPTS-[8,C]
08-OPTS-[8,C]
08-OPTS-[8,C]
WH116-F
611 F WASH 1.5mm² X285-3
1
029 GND BLK 028 GND BLK
M 2 1
029-1 GND BLK 041 GND BLK
FRONT
2
038 GND BLK 1.5mm²
3
610 RF WASH 029 GND BLK
4
609 R WASH 030 GND BLK
1 5
029-1 GND BLK 031 GND BLK
M 2 6
046 GND BLK
WH116-R 7
REAR
032 GND BLK 1.5mm²
8
TANK,DUAL WASHER,PUMPS
050 GND 1.5mm²
9
TO PCB SHT.6
BLK 052 GND

SW412 10
BLK 064 GND
10 11
+ 218 R WIPE PWR YEL 1.5mm² BLK 039 GND
9 12
218 R WIPE PWR YEL 1.5mm²
4
608 R WASH
5
607 R WIPE P 1.5mm²
6
609 R WASH X285-1
6
1
6
606 R WIPE L 1.5mm² 401 FOG LT

2 1
608 R WASH 523 P BRK
3 2
SWITCH,REAR WIPER
415-5 SW LT WHT 360 SEAT SW2
8 3
+ 028-6 GND BLK YEL 204 LSI PWR
7 4
415-6 SW LT YEL 203 DISP PWR
5
028-5 GND BLK YEL 206 JYSTK PWR
6
WH384 YEL 212 KEY PWR
7
53a V+ 218 R WIPE PWR YEL 1.5mm² YEL 201 KEY PWR
1 8
31 G 032 GND BLK 1.5mm²
M 2 9
53 L 606 R WIPE L 1.5mm²
3 10
TO PCB SHT.6
607 R WIPE P 1.5mm² 208 FOG LT PWR YEL

4 11
WIPER,REAR
31b P 224 KEY PWR YEL 1.5MM
12
409-2 HI BEAM 1.5mm²
13
414 LO BEAM 1.5mm²
14
410 SIDE LT 1.5mm²
15
WH262-F
601 FAN M 1.5mm²
2
MED 600 FAN L 1.5mm²
1
M LOW
4
GND 602 FAN H 1.5mm²
3
7
HI
7
HEATER FAN MOTOR

SW263
1
HI 602 FAN H 1.5mm²
4
MED 601 FAN M 1.5mm²
3
LOW 600 FAN L 1.5mm²
415-6 SW LT
2 224 KEY PWR YEL 1.5MM
028-6 GND BLK

WHT 360 SEAT SW2
YEL 206 JYSTK PWR
002 TW.PAIR (RX)

003 TW.PAIR (TX)
YEL 203 DISP PWR
YEL 212 KEY PWR
YEL 201 KEY PWR
YEL 204 LSI PWR
SWITCH,FAN
031 GND BLK
523 P BRK
BLK 052 GND

BLK 039 GND
028 GND BLK

041 GND BLK
+
PWR
02-CAB 1-[8,E]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,D]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,C]
02-CAB 1-[8,F]
02-CAB 1-[8,H]
02-CAB 1-[4,C]
02-CAB 1-[8,C]
02-CAB 1-[8,F]
02-CAB 1-[8,F]
8
8
A
B
C
D
Cab Harness Electrical Schematic 2 of 2 9.5.2
Electrical System
MZ7980F
A
B
C
D
213 KEY 1 YEL

TO PCB SHT.6
210 KEY 1 YEL

1
323 SEAT SW1
2
11
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
10
9
8
7
6
5
4
3
2
1
213 KEY 1 YEL

3
1
219 SEAT SW2 WHT

X301
SEAT SWITCH
4
1
211 KEY 1 YEL

SN57
023
020
022
021
033
042
027
026
025
523 P BRK
407 STOP LT
402 REV LT
323 SEAT SW1
210 KEY 1 YEL
403 RH TAIL LT
GND BLK
GND BLK
GND BLK
406 LH TURN LT
408 LH TAIL LT
221 KEY 1 YEL
405 RH TURN LT
401 LH FOG LT
SW77
404 LICENCE LT
400 REV ALARM
523 P BRK
2
413 LH HI BEAM LT
417 RH HI BEAM LT
219 SEAT SW2 1 mm²
211 KEY 1 YEL

1 N/O
GND BLK 1.5mm²
GND BLK 1.5mm²
BLK GND 1.5mm²
BLK GND 1.5mm²
GND BLK 1.5mm²
GND BLK 1.5mm²
412 LH LOW BEAM LT

416 RH LOW BEAM LT
3
N/C
PARK BRAKE
SHOWN IN OFF POSN
AH313
020 GND BLK
2
400 REV ALARM
1
ALARM,BACKUP
TAIL
022 GND BLK 1.5mm²
1
BACK 401-1 LH FOG LT S330
2
2
2
402-1 LH REV LT S331
3 LB314
408-1 LH TAIL LT 023 GND BLK
4 2
TURN 407-1 LH STOP LT 404 LICENCE LT
5 1
406-1 LH TURN LT S333
6
LIGHT,LICENCE
LIGHT,LEFT TAIL
7
STOP
LB306
S332
FOG
406 LH TURN LT 321 FUEL LVL
1
S336 035 GND BLK
2
TAIL
SN302
021 GND BLK 1.5mm²
1
BACK
SENSOR, FUEL LEVEL
405-1 RH TURN LT
2
407-2 RH STOP LT
3
403-1 RH TAIL LT
4
+
TURN 402-2 RH REV LT SN304

5
401-2 RH FOG LT S326 036 GND BLK
3
6 2
S327 221-1 BM RETRACT YEL
3
7 1
STOP 403 RH TAIL LT 322 BM RETRACT
LIGHT,RIGHT TAIL
LB312 3
S334
SWITCH, PROX
-
BOOM RETRACT
FOG
405 RH TURN LT
S335
LOW
033 BLK GND 1.5mm²
1
412 LH LOW BEAM LT
2
HIGH 413 LH HI BEAM LT
3
408-2 LH SIDE LT
4
406-2 LH TURN LT
5
SIDE
6
LIGHT,LEFT HEADLIGHT
LB308
TURN
4
4
LOW
042 GND BLK 1.5mm²
1
416 RH LOW BEAM LT
2
HIGH 417 RH HI BEAM LT
3
403-2 RH SIDE LT
4
405-2 RH TURN LT
5
SIDE
6 SN303
034 GND BLK
LB309 1
221-2 BM ANG YEL
LIGHT,RIGHT HEADLIGHT
2
TURN 320 BM ANG
3
SENSOR, ANGLE, BOOM
026 GND BLK 1.5mm²

025 GND BLK 1.5mm²
5
S329
S328
5
026-4 GND BLK

026-3 GND BLK
026-2 GND BLK
026-1 GND BLK
025-4 GND BLK
025-3 GND BLK
025-2 GND BLK
025-1 GND BLK
SN305
LSI SEN SHIELD
NC
LSI SEN 1 -VE BLU HV310-AW
LIN BUS C
LSI SEN +VE BLK 521 4WS VLV
+V B 1
LSI SEN 2 -VE RED 026-3 GND BLK
-V A 2
HV310-CB
SENSOR, LSI
522 CRAB VLV
1
026-4 GND BLK
2
VALVE, STEER SELECT
6
6
HV307-LS-UP
510 AUX A 520 LH O/R UP
1 1
512-1 AUX RTN 026-2 GND BLK
2 2
AUX A
HV316 HV307-LS-DN
519 LH O/R DN
1
511 AUX B 026-1 GND BLK
1 2
512-2 AUX RTN
2
AUX B
HV317 S318 HV307-RS-UP
518 RH O/R UP
1
500 LIFT UP 025-4 GND BLK
1 2
502-1 LIFT RTN
2 HV307-RS-DN
HV292 517 RH O/R DN
LIFT UP
1
025-3 GND BLK
2
501 LIFT DN
1
502-2 LIFT RTN
2 HV307-FL-RT
HV293 S298 516 FRAME LVL RH
LIFT DN
1
025-2 GND BLK
2
503 TELE OUT
1 HV307-FL-LT
505-1 TELE RTN 515 FRAME LVL LH
2 1
VALVE, FRAME LEVEL/STAB
7
025-1 GND BLK
7
HV294 2
TELE OUT
504 TELE IN
1 HV307-SPD
505-2 TELE RTN 514 SPD VLV
2 1
S299 513 SPD VLV RTN
HV295
TELE IN
2
506 TILT UP
1
508-1 TILT RTN
2
TILT UP
HV296
507 TILT DN
1
508-2 TILT RTN
2
HV297 S300
TILT DN
508 TILT RTN
511 AUX B
507 TILT DN
506 TILT UP
510 AUX A
321 FUEL LVL
516 FRAME LVL RH
515 FRAME LVL LH
513 SPD VLV RTN
512 AUX RTN

522 CRAB VLV
521 4WS VLV
514 SPD VLV
320 BM ANG
505 TELE RTN

502 LIFT RTN
504 TELE IN
503 TELE OUT
501 LIFT DN
500 LIFT UP
034 GND BLK
322 BM RETRACT
LSI SEN +VE BLK
LSI SEN 2 -VE RED
LSI SEN 1 -VE BLU
LSI SEN SHIELD
520 LH O/R UP
519 LH O/R DN
518 RH O/R UP
517 RH O/R DN
8
X311
9
8
7
6
5
4
3
2
1
11
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
10
8
CAB
A
B
C
D
Frame 9.5.3
Electrical System
MZ7950F
A
B
C
D
1
1
X897 100A X898

102 GLOW PWR RED 4AWG
TO GLOW RLY 1 1 1
RL896-2 IP05
TO PCB 1 101 CAB PWR RED 4AWG
X773
X04 150A X03
101 CAB PWR RED 4AWG
1 1 1
X110 IP02
102 GLOW PWR RED 4AWG
1
X374 EC599-B+
RED 100 2/0AWG
1 1 M
BT600+ EC599
2
2
1
EC599-B-
BATTERY
STARTER
GENERIC
GENERIC
BLK 001 2/0AWG

1 1
BT600-
MS604-A-1
BLK 001 2/0AWG
1
BLK 002 2/0AWG
1
SWITCH
MS604-B-1
BATTERY DISCONNECT
BLK 002 2/0AWG

1
X605
BLK 005 2/0AWG
1
FRAME
X635
003 GND BLK 6AWG
ENGINE BAY
1
X1013
003 GND BLK 6AWG
TO PCB 1
3
X106
3
BLK 005 2/0AWG
1
X634
ENGINE BLOCK
BLK 004 2/0AWG
1
FRAME
X602
BLK 004 2/0AWG
1
CAB
X603
4
4
A
B
C
D
Battery 9.5.4
Electrical System
9-10
9.5.5
1 2 3 4 5 6 7 8
XK2.1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
1
2
3
4
5
6
7
8
9
10
11
12
13
14
FLASHER RELAY BATT F31 10A BATT
1
ENGINE FRAME FLASHER RELAY IGN PWR F32 10A IGN PWR 2
X63
2
X398
GND
3 K2.2 AIRCON RELAY (OPTION)
GND
GND
GND
GND
GND
GND
GND
GND
GND
FOG
GND
KEY 1
KEY 1
4 3
KEY 1
ROOF WIPER RADIO BEACON WORKLIGHTS
1
2
3
1
2
3
4
1
2
3
1
2
3
4
5
SPARE 1
SPARE 2
P BRAKE
5 2 (30)
STOP LT
GLOW IN
LIC PLATE
REV OUT
SEAT SW 1
ECM PWR
SEAT SW 2
LH TURN LT
87a
GLOW OUT
REV ALARM
FUEL PUMP
LH SIDE LT
6 1
RH SIDE LT
LH HI BEAM
RH HI BEAM
RH TURN LT
X401.1
X275.1
X250.1
X252.1
30
STABS DEP LH
STABS DEP RH
7 6 (86)
FUEL RL GND
LH LOW BEAM
RH LOW BEAM
GND
GND
GND
GND
GND
BULKHEAD SIDE
SW LT
87
COND FAN PWR 1

SW LT
COND FAN PWR 2

SW LT
8 5 (87a)
86
KEY BAT
BEACON
RF WASH
9 4 (85)
F WRK LT
AC TEMP SWITCH O/P

R WRK LT
OPT PWR 1
OPT PWR 2
10 9 85
OPT PWR 4 (STABS DEP)

11 8 (87)
12 7
D D
Electrical System
X285-4.1 RH HI BEAM F1 7.5A HI BEAM

LH TURN LT
1
SW LIGHTS RH LOW BEAM F2 7.5A LOW BEAM
2
RH TURN LT
3
STOP LT LH HI BEAM F3 7.5A HI BEAM
4
SEAT SW 1
5
POWER SOCKET LH LOW BEAM F4 7.5A LOW BEAM
6
REAR WIPER
7
SW LT LH SIDE LT F5 7.5A SIDE LT
8
FAN
9
FRONT WIPER RH SIDE LT F6 7.5A SIDE LT
10
BRAKE LIGHTS PWR
11
Power Distribution Board
REV RL REV RL HEADLIGHT FLASH PWR F7 15A BATT

12
LIGHTS BAT 1 F8 15A BATT
LIGHTS BAT 2 F9 15A BATT

X285-2.1
COND FAN PWR 2 KEY BAT F10 15A BATT
1
COND FAN PWR 1
2
SPARE 1 F WRK LT F11 15A F WORKLIGHTS
3
KEY BAT
4
KEY BAT R WRK LT F12 15A R WORKLIGHTS
5
KEY BAT
6 C
HEADLIGHT FLASH PWR GLOW OUT F13 15A
C 7
SPARE 2
8
RF WASH AC PWR F14 30A AC OUT
9
LIGHTS BAT 1
10
KEY SIG OPT PWR 1 F15 15A OPT PWR
11
OPT PWR 3 (CAB AC SWITCH)
12
LIGHTS BAT 2 OPT PWR 2 F16 15A OPT PWR
13
AC PWR
14
AC PWR OPT PWR 3 (CAB AC SWITCH) F17 15A OPT PWR
15
OPT PWR 4 (STABS DEP) F18 15A OPT PWR

X285-5.1
KEY 1 BEACON F19 15A IGN PWR 3
1
STABS DEP RH
2
AC TEMP SWITCH O/P BRAKE LIGHTS PWR F20 15A IGN PWR 3
3
49a
4
STABS DEP LH REAR WIPER F21 20A IGN PWR 3
5
RX
6
49 FRONT WIPER F22 20A IGN PWR 3
7
C2
8
TX POWER SOCKET F23 15A IGN PWR 2
9
FAN F24 20A IGN PWR 2
ECM PWR F25 30A ECM PWR

X285-1.1
B FOG KEY 1 F26 15A IGN PWR 2 B
1
P BRAKE
2
SEAT SW 2 FUEL RL F27 20A IGN PWR 1
3
JOYSTICK/DISPLAY
4
JOYSTICK/DISPLAY REV ALARM/REV LT F28 15A IGN PWR 1
5
JOYSTICK/DISPLAY
6
KEY 1 JOYSTICK/DISPLAY F29 10A IGN PWR 1
7
KEY 1
8
GND CONTROLLER PWR F30 25A IGN PWR 1
9
KEY 1
10
KEY 1
11
KEY 1
12
HI BEAM
13
LOW BEAM
14
SIDE LT
15
X285-3.1
GND
1
GND
2
GND
3
GND
4
GND
5
GND
GND
BATT
6
GND
7
GND
8
A GND A
9
CONTROLLER PWR
GND
BATT
GND
10
GND
11
GND
FUEL RL GND
REV ALARM/REV LT
GND
GND
BATT
GND
BATT
GND
BATT
49
49a
GND
X232
1
1
1
C2
X249.1
X233.1
GND
12
30 BATT
87 OPT PWR
86 KEY SIG
85
30 FUEL RL
87 FUEL PUMP
86 KEY 1
85
30
87 REV OUT
86 REV RL
85
30 BATT
87 F WORKLIGHTS
86 RH TAIL
85
30
87 IGN PWR 1
86 KEY SIG
85
30
87 IGN PWR 2
86 KEY SIG
85
30
87 IGN PWR 3
86 KEY SIG
85
87a
87a
87a
87a
87a
87a
87a
49
31
C2
49a
JOYSTICK/DISPLAY
TX
RX
GND
X276
K9
1
2
3
4
K3 OPTIONS POWER K4 K5 K6 WORKLIGHTS K7 K8
K1 FLASHER REVERSE IGN PWR 1 IGN PWR 2 IGN PWR 3
ANALYZER FUEL RELAY
ALARM RELAY RELAY RELAY
RELAY
1 2 3 4 5 6 7 8
MZ7940F

1 2 3 4 5 6 7 8
9.5.6
X985 X984
WHT 730 TWISTED PAIR 3 + 1.5mm² WHT 730 TWISTED PAIR 3 + 1.5mm²
33 62
BLK 731 TWISTED PAIR 3 - 1.5mm² BLK 731 TWISTED PAIR 3 - 1.5mm² HYD FILTER PRES
16 35 SWITCH, TRANS TEMP GLOW PLUGS
WHT 732 TWISTED PAIR 4 + 1.5mm² WHT 732 TWISTED PAIR 4 + 1.5mm² SWITCH, PRES, AIR FILTER GLOW RELAY
48 42
BLK 733 TWISTED PAIR 4 - 1.5mm² BLK 733 TWISTED PAIR 4 - 1.5mm² FUEL PUMP
18 37
32 38
ALTERNATOR
M
BLK 735 TWISTED PAIR 5 - 1.5mm² BLK 735 TWISTED PAIR 5 - 1.5mm²
H 2 61 H
B+
L
W
46 40
BLK 737 TWISTED PAIR 6 - 1.5mm² BLK 737 TWISTED PAIR 6 - 1.5mm² FUEL FILTER
3 41
1
1
1
2
1
1
1
1
1
1
1 TO STARTER B+ TERMINAL
1
2
3
4
1
1
1
1
339 ENG START RL 0.75mm²
6 2
X889

5 20
X994
SN251
SN690
EC900
EC894-
EC894+
SN250-1
SN250-2
RL1037-1
RL1037-2
RL1037-3
RL1037-4
4 19
EC885-L
EC885-W
EC885-B+
YEL 740 TWISTED PAIR 8 + 0.75mm² YEL 740 TWISTED PAIR 8 + 0.75mm²
Engine
37 14
GRN 741 TWISTED PAIR 8 - 0.75mm² GRN 741 TWISTED PAIR 8 - 0.75mm²
52 13
TWISTED PAIR 8 - SHLD 0.75mm² TWISTED PAIR 8 - SHLD 0.75mm²
53 9
YEL 742 TWISTED PAIR 9 + 0.75mm² YEL 742 TWISTED PAIR 9 + 0.75mm²
39 15
311 AIR FLTR

GRN 743 TWISTED PAIR 9 - 0.75mm² GRN 743 TWISTED PAIR 9 - 0.75mm²
530 HYD FLTR

043-2 GND BLK
54 21
TWISTED PAIR 9 - SHLD 0.75mm² TWISTED PAIR 9 - SHLD 0.75mm²
043-1 GND BLK

043-2 GND BLK
337 TRANS TEMP
38 1
352 RAIL PRESS 0.75mm² 352 RAIL PRESS 0.75mm²
7 32
044 GND BLK 1.5mm²

8 57
103 ALT B+ RED 2AWG
348 FUEL FLT WHT 0.75mm²

104 ENG START PWR RED 0.75mm²
9 3
10 4
106 GLOW RL RED
334 FUEL PUMP FLYW 1.5mm²

11 5
335 GLOW IN FLYW 1.5mm²
525 ALT D+
047 GLOW RLY SW BLK 0.75mm²
12 6
590 GLOWPLUGS GRY 10mm²

13 7
112 ALT B+ RED 2AWG

590 GLOWPLUGS GRY 10mm²
14 8
15 10
G D2.1 17 11
G
19 47
20 48
21 12
X891
1
22 59
336 GLOW OUT 0.75mm² 348 FUEL FLT WHT 0.75mm²
23 16
351 BST PRESS 0.75mm² 354 BST PRESS 0.75mm²
24 22
150A
353 RAIL PRESS 0.75mm² S995 353 RAIL PRESS 0.75mm²
25 31
IP893
354 RAIL PRESS 0.75mm² 354 RAIL PRESS 0.75mm²
26 25
355 BST PRESS 0.75mm² 355 BST PRESS 0.75mm²
1
27 29
356 COOL TEMP 0.75mm² 356 COOL TEMP 0.75mm²
ENGINE CONNECTOR
28 24
X892
357 OIL PRESS 0.75mm² 357 OIL PRESS 0.75mm² 357 OIL PRESS 0.75mm²
29 27
S1000 350 FUEL FLT WHT 0.75mm²
30 33
31 60
34 17
047 GLOW RLY SW BLK 0.75mm²
35 18
36 58 X59
037 PED GND BLK 0.75mm²
1 30 A
358 BST PRESS 0.75mm² 358 BST PRESS 0.75mm² 307 PED SIG 0.75mm²
40 28 B
366 ENG 0.75mm² 308 PED PWR 0.75mm²
41 34 C
309 IVS SIG 0.75mm²
F 42 36 D F
359 BST PRESS 0.75mm² 359 BST PRESS 0.75mm² 337 TRANS TEMP
43 23 E
360 OIL PRESS 0.75mm² 360 OIL PRESS 0.75mm² 525-2 ALT D+
44 26 F
S397 525-1 ALT D+
45 39 G
47 43 H
49 44 J
338 ENG STRT 0.75mm²
50 45 K
361 EXH GAS 0.75mm² 313 CLUTCH SW 0.75mm² TO CAB HARNESS
51 46 L
362 EXH GAS 0.75mm² 312 ECM IGN 0.75mm²
55 49 M
363 EXH GAS 0.75mm² 530 HYD FLTR
56 50 N
364 EXH GAS 0.75mm² 325 TRANS F
57 52 O
365 EXH GAS 0.75mm² 326 TRANS R
58 51 P
328 TRANS 2
59 53 Q
327 TRANS 1
60 54 R
302 TRANS SPD WHT
55 S
230 SPD PWR YEL
X986 56 T
105-1 ECM PWR RED 2.5mm²
1 U
006-1 GND BLK 2.5mm²
2 V
3 W
4 X
5
E 6 X396 E
7 1
105-2 ECM PWR RED 2.5mm² 105 ECM PWR RED FLYW 4mm² 105 ECM PWR RED FLYW 4mm²
8 2
105-3 ECM PWR RED 2.5mm² S880 334 FUEL PUMP FLYW 1.5mm²
9 3
006-1 GND BLK 2.5mm² 335 GLOW IN FLYW 1.5mm²
10 4
006-2 GND BLK 2.5mm² 336 GLOW OUT FLYW 1.5mm²
11 5
006-3 GND BLK 2.5mm² 006 GND BLK 4mm² 045 FUEL RL GND BLK FLYW 1.5mm²
12 6
345 COOLANT WHT 0.75mm² S902 228 KEY 1 YEL FLYW 1.5mm²
13 7
336 GLOW OUT 0.75mm² 336 GLOW OUT FLYW 1.5mm² 615-4 COND FAN FLYW 1.5mm² TO PCB SHT.6
14 8
313 CLUTCH SW 0.75mm² S1052 313 CLUTCH SW 0.75mm² S24 615-3 COND FAN FLYW 1.5mm²
15 9
309 IVS SIG 0.75mm² 613-1 AC PRESS WHT FLYW 1.5mm²
16 10
330-1 ST DEPL LH FLYW 1.5mm²
17 11 X998-2
532 GND BLACK 331-1 ST DEPL RH FLYW 1.5mm²
18 12
223 KEY IGN FLYW 1.5mm² 1
19 13
061 GND FLYW 1.5mm² 2 BLANKING PLUG
20 14
3
21
22
X998 X998-1
23 615-4 COND FAN FLYW 1.5mm² WHT 615-4 COND FAN
1 1 08-OPTS-[8,C]
24 615-3 COND FAN FLYW 1.5mm² WHT 615-3 COND FAN
2 2 08-OPTS-[8,C]
25 613-1 AC PRESS WHT FLYW 1.5mm² WHT 613-1 AC PRESS
045 FUEL RL GND BLK 0.75mm² S25 045 FUEL RL GND BLK FLYW 1.5mm² 3 3 08-OPTS-[8,C]
26
D 27
D
339 ENG START RL 0.75mm² X999 X999-1
28
347 COOLANT WHT 0.75mm² 330-1 ST DEPL LH FLYW 1.5mm² WHT 330-1 ST DEPL LH
29 1 1 08-OPTS-[3,A]
331-1 ST DEPL RH FLYW 1.5mm² WHT 331-1 ST DEPL RH
30 2 2 08-OPTS-[3,A]
223 KEY IGN FLYW 1.5mm² YEL 223 KEY IGN
31 3 3 08-OPTS-[3,A]
061 GND FLYW 1.5mm² BLK 061 GND
32 4 4 08-OPTS-[3,A]
33
X999-2
34
338 ENG STRT 0.75mm² S1087 338 ENG STRT 0.75mm²
35 1
36 2
230 SPD PWR YEL BLANKING PLUG
37 1 SIG 3
364 EXH GAS 0.75mm² 043-1 GND BLK 302 TRANS SPD WHT
38 2 GND 4
SPEED
531 GND BLK 043 GND BLK 1.5mm²

SENSOR
39 SN97
40 S354
41 HV272
043-3 GND BLK
42 2
327 TRANS 1
43 1
GENERIC
363 EXH GAS 0.75mm²

TRANS 1ST
44
45
D2.2 308 PED PWR 0.75mm²
46 HV271
043-4 GND BLK
C 47 2 C
328 TRANS 2
48 1
GENERIC
TRANS 2ND
49
50
51 HV273
043-5 GND BLK
52 2
727 CAN LO 14 BLK 0.75mm² S351 723 CAN LO 12 BLK 0.75mm² 326 TRANS R
53 1
GENERIC
716 CAN HI 9 RED 0.75mm² S350 714 CAN HI 8 RED 0.75mm² 714 CAN HI 8 RED 0.75mm²
TRANS REV
54
55
366 ENG 0.75mm²
56 HV274
344 WATER/FUEL WHT 0.75mm² 043-6 GND BLK
57 2
325 TRANS F
58 1
GENERIC
TRANS FL
59
60 X08
349 FUEL FLT WHT 0.75mm² 228 KEY 1 YEL FLYW 1.5mm²
61 A
037 PED GND BLK 0.75mm² 007 GND BLK
62 B
307 PED SIG 0.75mm²
63 C
343 WATER/FUEL WHT 0.75mm²
64 D
65 E
715 CAN LO 8 BLK 0.75mm² 715 CAN LO 8 BLK 0.75mm² S989 713 CAN LO 7 BLK 0.75mm²
66 F DIAGNOSTIC
S352 723 CAN LO 12 BLK 0.75mm² S915 721 CAN LO 11 BLK 0.75mm²
67 G
B 722 CAN HI 12 RED 0.75mm² 720 CAN HI 11 RED 0.75mm² B
68 H
S916
69 J
70 K
71 L
362 EXH GAS 0.75mm² S990 712 CAN HI 7 RED 0.75mm²
72 M
104 ENG START PWR RED 0.75mm²
73 NC
74
75
717 CAN LO 9 BLK 0.75mm² S353
76 X917 X917T
724 CAN HI 13 RED 0.75mm² 120 OHM
77 A
78 B
79 C
80
81
82
83
84

85

311 AIR FLTR

86
044 GND BLK 1.5mm²
043 GND BLK 1.5mm²
048 GND BLK
049 GND BLK
007 GND BLK
006 GND BLK 4mm²
346 COOLANT WHT 0.75mm² 531 GND BLK

87
532 GND BLACK

049 GND BLK
048 GND BLK

345 COOLANT WHT 0.75mm²
312 ECM IGN 0.75mm²
88
A A
X06
X07
89
X906
X903
1
2
4
3
2
1
2
1
2
1
B
A
B
A
C
C
X901
X895
1
90
WATER/FUEL COOLANT LVL
X13
X14
91
X348 X345
X349 X346
92
93
1.5K
1.5K
94
GND STUD
GND STUD
120 OHM
120 OHM
Electrical System
1 2 3 4 5 6 7 8
MZ7960F
9-11
9-12
9.5.7
1 2 3 4 5 6 7 8
PRODUCT LINK RADIO WORKLIGHTS GENERIC

SWITCH,CAB WORKLIGHTS 2920206
WORKLIGHT RR WORKLIGHT RL WORKLIGHT FL WORKLIGHT FR
MS21-1
1
6
5
4
3
2
1
+
+
2
X275
JS404-1
3
112 RADIO BATT RED 112 RADIO BATT RED
1
2
1
2
1
2
1
2
4 1
7
8
3
2
1
6
5
4
9
10
224 RADIO IGN YEL
751 CAN LO 18 BLK 0.75mm² 5 2
LB12
LB11
LB10
LB09
053 GND BLK
SW864
6 3
224 RADIO IGN YEL
747 CAN LO 16 BLK 0.75mm² S129 749 CAN LO 17 BLK 0.75mm² 7
12 053 GND BLK
746 CAN HI 16 RED 0.75mm² S130 748 CAN HI 17 RED 0.75mm² 8
D 11 D
MS21
Electrical System
429 SW LT
10 617 LH SPK+
RADIO
1 1
051-1 GND BLK

051-2 GND BLK
430-1 F WRK LT
430-2 F WRK LT
031 GND BLK

MS392LH+
050-1 GND BLK
050-2 GND BLK

S143 755 CAN LO 20 BLK 0.75mm² 2
051-4 GND BLK

431-2 R WRK LT
431-1 R WRK LT
8
Option Harnesses
616 LH SPK- 616 LH SPK-

S144 754 CAN HI 20 RED 0.75mm² 3 1
206 JYSTK PWR YEL

7 617 LH SPK+
752 CAN HI 19 RED 0.75mm² 4 MS392LH-
6 618 RH SPK+
753 CAN LO 19 BLK 0.75mm² 5 S358 S357
5 619 RH SPK- 618 RH SPK+
225 F WRK LT YEL 1.5mm²
226 R WRK LT YEL 1.5mm²

6 1
430 F WRK LT WHT 1.5mm²
431 R WRK LT WHT 1.5mm²

4 X252
231 P.LINK IGNT YEL S146 231-1 P.LINK IGNT YEL 7 MS393RH+ 225 F WRK LT YEL 1.5mm² S356 S359
PRODUCTLINK PL421
3 03-CAB 2-[4,A] 619 RH SPK- 1
056-3 GND BLK S147 056-4 GND BLK 8 1 226 R WRK LT YEL 1.5mm²
6
5
4
3
2
1
2
JS404-2
2 03-CAB 2-[4,A]
MS393RH-
RH SPEAKER LH SPEAKER
113-1 P.LINK BATT RED 429 SW LT
1 03-CAB 2-[4,A] 3
050 GND BLK 1.5mm²
X128 4
051 GND BLK 1.5mm² 051-3 GND BLK 1.5mm²
X145 5
231-2 P.LINK IGNT YEL S98
A 6
056-6 GND BLK
B
C
D AIRCON 07-ENGINE-[8,D]
E 07-ENGINE-[8,D]
613-1 AC PRESS WHT
F 07-ENGINE-[8,D]
G S992 612-2 COND RL WHT
03-CAB 2-[5,D]
H
613-1 AC PRESS 1 mm² WHT
J 03-CAB 2-[5,D]
PRODUCTLINK DIAG CONN

603 AC SW PWR WHT
03-CAB 2-[5,D]
056-1 GND BLK
03-CAB 2-[5,D]
C C
WIPER,ROOF
BEACON ROOF WIPER
SWITCH,WIPER ROOF
M
BEACON SWITCH
31b
BEACON SOCKET
+
+
P
L 53
V+ 53a
G 31
+
+
1
2
3
4
7
8
3
2
1
6
5
4
9
10
058 GND BLK
059 GND BLK
059 GND BLK
058 GND BLK
613-1 AC PRESS WHT
WH390
7
8
3
2
1
4
5
6
9
10
1
2
614 AC COMP WHT
614 AC COMP WHT
613-1 AC PRESS 1 mm² WHT
612-1 AC TEMP WHT
603 AC SW PWR WHT
612 AC SWITCH SIG WHT
056-1 GND BLK
SW256
X776
B
A
B
A
LB83
SW94
WH753-2
WH753-1
SN252
2
1
1
1
2
1
WH1260
F
A
B
E
C
D
SW154
SN153-2
SN153-1
428 SW LT
+
622 RF WASH
427 SW LT
055-2 GND BLK
M
M
GND STUD
053-2 GND BLK

620 RF WIPE L 1.5mm²
AC COMPRESSOR
621 RF WIPE P 1.5mm²

620 RF WIPE L 1.5mm²
621 RF WIPE P 1.5mm²

CONDENSOR FANS SWITCH,AC
222-3 RF WIPE PWR YEL

222-3 RF WIPE PWR YEL
SWITCH, PRES, AC SWITCH,AC TEMP
220 KEY 1 YEL 1.5mm²

220 KEY 1 YEL 1.5mm²
X132
222-1 RF WIPE PWR YEL 1.5mm²

222-2 RF WIPE PWR YEL 1.5mm²
1
6
5
4
3
2
1
219 OPT PWR 1 YEL 1.5mm²

CLEARSKY
2
S400
JS404-3
3
X250 X401
219 OPT PWR 1 YEL 1.5mm² 222 RF WIPE PWR YEL 1.5mm² 4
1 1
053 GND BLK 1.5mm² 055 GND BLK 1.5mm² S399 5
2 2 747 CAN LO 16 BLK 0.75mm² S133 751 CAN LO 18 BLK 0.75mm²
427 SW LT S99 428 SW LT 6
B 3 3 746 CAN HI 16 RED 0.75mm² S134 750 CAN HI 18 RED 0.75mm² B
622 RF WASH 7
4 748 CAN HI 17 RED 0.75mm²
8
5 749 CAN LO 17 BLK 0.75mm²
9
6 S140 755 CAN LO 20 BLK 0.75mm²
10
S141 754 CAN HI 20 RED 0.75mm²
11
031 GND BLK
206 JYSTK PWR YEL

12
13
14
231 CLEARSKY IGNT YEL S137 231-1 CLEARSKY IGNT YEL
15 03-CAB 2-[4,A]
CLEARSKY MODULE
056-5 GND BLK S139 056-4 GND BLK
6
5
4
3
2
1
JS404-4
STABS DEPLOYED FRAME STABS DEPLOYED CAB 16 03-CAB 2-[4,A]

113 CLEARSKY BATT RED S138 113-1 CLEARSKY BATT RED
17 03-CAB 2-[4,A]
LEFT STABILIZER RIGHT STABILIZER 18
SWITCH,PROX SWITCH,PROX 19 X136
LEFT STABILIZER RIGHT STABILIZER LB77 056-6 GND BLK
064 GND BLK S78 064-1 GND BLK 20 A
SWITCH, PRES SWITCH, PRES 6 03-CAB 2-[5,D] 231-2 CLEARSKY IGNT YEL
330-3 ST DEPL LH S79 330 ST DEPL LH 21 B
- + - + 3 03-CAB 2-[5,D]
+ 331-2 ST DEPL LH 22 C
10 02-CAB 1-[8,C]
23 D
LH
9
E
8
F
7
2
1
3
A
B
C
A
B
C
2
1
3
G
5 113-2 CLEARSKY BATT RED
RH
H
2
SN365
SN366
CLEARSKY DIAG CONN
SN371
SN372
064-2 GND BLK 330-2 ST DEPL RH J
4 02-CAB 1-[8,C]
331-3 ST DEPL RH 331 ST DEPL RH
LAMP,STABS DEPLOYED
+ 1 03-CAB 2-[5,D]
S80
A A
061-1 GND BLK

061-2 GND BLK
333 ST PRESS LH
330-1 ST DEPL LH
332 ST PRESS RH
223-1 KEY IGN YEL

333 ST PRESS LH
332 ST PRESS RH
331-1 ST DEPL RH
223-2 KEY IGN YEL

330-1 ST DEPL LH
07-ENGINE-[8,D]
331-1 ST DEPL RH
07-ENGINE-[8,D]
223-1 KEY IGN YEL
223-2 KEY IGN YEL S370 223 KEY IGN YEL
07-ENGINE-[8,D]
061-1 GND BLK S369 061 GND BLK
07-ENGINE-[8,D]
061-2 GND BLK
MZ8430F
1 2 3 4 6 7 8

Electrical System
9.6 ENGINE START CIRCUIT 3. If starter only “clicks” it may indicate that battery is
discharged, or that there is a loose or corroded battery
cable connection. Check battery state of charge and
9.6.1 Starter battery condition first, then check cables and cable
connections.
4. For additional information on starting circuit, refer to
Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove starter only if it fails. To remove starter:
and steering wheel.
1
MZ8040
a. Testing Starter on Engine

MZ7440
If starter (1) does not engage when ignition key switch is 2
turned, check following:
1. Main fuse may be blown, requiring replacement. Check 5. Remove belly pan (2).
for cause of blown fuse. 6. Remove wires from solenoid stud. Remove positive (+)
2. There may be a defect in ignition key switch, ignition battery cable from starter. Label and disconnect wire
wiring or starter solenoid. from starter solenoid housing stud. Record how wires
are installed to ensure correct installation later.
3. Check battery condition. Clean battery posts and
connectors at each end of battery cables. 7. Loosen but DO NOT remove hardware securing starter.
Support starter securely as it is relatively heavy and will
4. Check for broken wiring and damaged insulation on fall if not supported.
wiring. Replace all broken or damaged wiring.
8. Support starter and remove fasteners securing starter.
5. Check all connections at starter solenoid, key Remove negative (-) ground cable from its starter
switch and wiring harness plugs. Clean and tighten all mounting bolt.
connections.
9. Remove starter from machine.
6. If starter still does not operate after these checks have
been performed, check starting circuit. d. Starter Installation
b. Starter Circuit Checks 1. Position starter in its mounting opening on flywheel

housing. Position negative (-) ground cable over correct
1. Check wires and connections for looseness, corrosion, starter mounting bolt. Secure starter with previously
damage, etc. used hardware.
2. If a “whirring” noise is heard but engine does not turn 2. Connect positive (+) battery cable to solenoid stud.
over, starter is spinning but not engaging flywheel. The Install wires to solenoid stud, and secure with lock
starter drive or solenoid that pushes drive forward to washer and nut.
engage flywheel may be defective. Missing or damaged
teeth on flywheel can also prevent starter from cranking 3. Connect battery negative (-) cable to battery negative (-)
engine. terminal.

Electrical System
5. Remove Do Not Operate Tag from ignition key switch 4. Properly disconnect battery.
and steering wheel. 5. Install a drive ratchet into square hole in serpentine belt
tensioner bracket. Note Belt routing for future
9.6.2 Charging Circuit serpentine belt installation.
6. While lifting automatic belt tensioner away from belt,
remove fan serpentine belt.
Note: Record how alternator is installed to ensure correct
2 installation later.
7. Label and disconnect wire leads attached to alternator.
8. Remove lower mounting capscrew securing alternator to
lower mounting hole on engine.
9. While supporting alternator, remove upper mounting
hardware from upper alternator mount. Remove
alternator from machine.
b. Alternator Installation
1. Position alternator and align with upper alternator
mount on engine bracket. Insert upper (longer)
mounting hardware through alternator mount. Thread
longer capscrew into alternator front mount. DO NOT
MZ8050
tighten completely at this time.
Before using a battery charger, an attempt can be made to 2. Align lower alternator mount hole with lower mounting
recharge battery by jump-starting machine (Refer to the bracket on engine and insert lower mounting capscrew.
appropriate Operation & Safety Manual). Allow engine to Tighten lower capscrew and upper capscrew securely.
run, which will enable alternator (2) to charge the battery. 3. Place a drive ratchet into square hole on serpentine belt
If engine alternator charging warning indicator illuminates, tensioner bracket. Apply pressure against tensioner
perform following checks: bracket and route serpentine belt onto alternator and
engine pulleys. Release and check tensioner pulley to
1. Check all battery cable connections at battery, and
verify that it is pivoting freely in order to provide the
verify that they are clean and tight.
proper tension on belt. Check for proper belt alignment.
2. Check external alternator wiring and connections, and (Refer to appropriate Operation & Safety Manual.)
verify that they are in good condition.
4. Connect previously labeled wire leads to alternator.
3. Check fan belt condition and tension.
4. Run engine and check alternator for noise. A loose drive
pulley, loose mounting hardware, worn or dirty internal
alternator bearings, a defective stator or defective 7. Remove Do Not Operate Tag from ignition key switch
diodes can cause noise. Replace a worn or defective and steering wheel.
alternator.
9.6.3 Alternator
a. Alternator Removal
and steering wheel.

Electrical System
9.7 WIPER/WASHER WIPER MOTOR b. Disassembly

DO NOT disassemble the motor. The motor is not
9.7.1 Front Windshield Wiper Motor serviceable. Replace motor if found to be defective.
a. Removal c. Inspection and Replacement

1. Park machine on a firm, level surface, level machine, fully Inspect motor terminals for continuity. Replace motor if
retract boom, lower boom, place transmission in (N) continuity is not found.
d. Installation and Testing
and steering wheel. 1. Align motor with mounting holes and secure motor to
3. Open engine cover. Allow system fluids to cool. mounting bracket.
4. Properly disconnect battery. 2. Connect electrical harness to wiper motor.
5. Remove front access cover. 3. Secure mounting bracket to machine with
hardware (5) removed earlier.
4. Connect wiper linkage to the wiper motor shaft.
3
Note: Align the wiper linkage arm with the flat on the motor
shaft to ensure wiper stroke covers window area, and it does
not swipe past the glass area.
5. Connect the reservoir hose to wiper linkage.
7. Turn ignition key switch to RUN position, and operate
windshield wiper in both LOW and HIGH speeds to
ensure proper operation and that correct wiper travel is
achieved.
4 8. Install front access cover.
5
and steering wheel.
MZ8160
6. Disconnect reservoir hose from wiper linkage (3).

7. Remove wiper linkage (4).
8. Loosen and remove hardware (5) holding wiper
assembly mounting bracket to machine.
9. Disconnect electrical harness connectors from the
wiper motor.
10. Loosen and remove hardware holding wiper motor to
mounting bracket.
Note: Retain all hardware removed from wiper assembly for
possible reuse on replacement motor housing.
11. Remove motor from wiper assembly.

Electrical System
9.7.2 Rear Window Wiper Motor 9. Loosen and remove hardware (10) holding wiper motor
assembly to window.
a. Removal
1. Park machine on a firm, level surface, level machine, fully possible reuse on replacement motor housing.
10. Remove wiper assembly from window.
2. Place a Do Not Operate Tag on both ignition key switch b. Disassembly
and steering wheel.
3. Open engine cover. Allow system fluids to cool. serviceable. Replace motor if found to be defective.
c. Inspection and Replacement
Inspect motor terminals for continuity. Replace motor if
continuity is not found.
7 6
d. Installation and Testing
1. Align wiper assembly with mounting holes and secure
assembly to window.
2. Connect wiper linkage to the wiper motor shaft.
Note: Align the wiper linkage arm with flat on motor shaft to
ensure wiper stroke covers window area, and it does not swipe
past the glass area.
3. Connect reservoir hose to wiper linkage.
MZ8130
4. Connect electrical harness to wiper motor.
5. Remove hardware securing motor access cover (6).
wiper motor (7).
achieved.
7. Secure motor access cover (6) with hardware removed
earlier.
10 8. Close and secure engine cover.
and steering wheel.
8 9
MZ8120


Electrical System
9.7.3 Roof Window Wiper Motor c. Inspection and Replacement

Inspect motor terminals for continuity. Replace motor if
a. Removal
continuity is not found.
retract boom, lower boom, place transmission in (N) d. Installation and Testing
NEUTRAL, engage parking brake, and shut engine OFF. 1. Align wiper assembly with mounting holes and secure
2. Place a Do Not Operate Tag on both ignition key switch assembly to machine.
and steering wheel. 2. Connect wiper linkage to wiper motor shaft.
Note: Align wiper linkage arm with flat on motor shaft to
4. Properly disconnect battery. ensure wiper stroke covers window area, and it does not swipe
past glass area.
1 3. Connect reservoir hose to wiper linkage.

4. Connect electrical harness to wiper motor.
achieved.
7. Secure access cover with hardware removed earlier.
MZ8150 9. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
5. Remove hardware securing access cover (1).
wiper motor.
3
4
MZ8140

9. Loosen and remove hardware (4) holding wiper motor
assembly to machine.
possible reuse on replacement motor housing.
10. Remove wiper assembly from window.
b. Disassembly
serviceable. Replace motor if found to be defective.

Electrical System
9.7.4 Washer Tank b. Disassembly

The washer motor and reservoir (5) is located in cab DO NOT disassemble the pump. The pump is not
underneath the dash. It is labeled as a unit and cannot be serviceable. Replace pump if found to be defective.
serviced separately.
c. Installation and Testing
a. Removal
1. Connect windshield washer hoses to washer tank.
1. Park machine on a firm, level surface, level machine, fully 2. Connect cab wiring harness connectors to washer tank
retract boom, lower boom, place transmission in (N) connectors.
3. Align washer tank with mounting holes and secure with
2. Place a Do Not Operate Tag on both ignition key switch previously used hardware.
and steering wheel.
4. Fill the washer fluid reservoir with washer fluid.
5. Install the outside cover at the front of the cab.
5. Remove the outside cover at the front of the cab.
and steering wheel.
MZ8170
6. Remove hardware (2) securing tank to machine.

7. Label and disconnect harness connectors from washer
tank connectors.
8. Remove washer hoses from washer tank.
9. Remove washer tank from cab.

Electrical System
9.8 SOLENOIDS, SENSORS AND SENDERS
9.8.1 Transmission Solenoid Valves
MZ8180
MZ8190
Note: If the transmission is not shifting properly, the
transmission shifter, wiring harness or transmission shift
solenoids (6) should be checked in order to determine 5. Unplug transmission oil temperature switch connector
which component is defective. Specific information to from wiring harness connector.
determine which travel position and corresponding 6. The switch is threaded into transmission housing.
component is not responding can be found in the detailed Remove the switch.
transmission service instructions (covering repair,
disassembly, reassembly and adjustment information) are b. Transmission Oil Temperature Switch Inspection and
provided in the Replacement
following publications:
Inspect switch and wiring harness connector terminals
Detailed transmission parts and service information can be for continuity. Replace a defective or faulty switch with a new
found in appropriate parts and/or service manuals. part.
The transmission should be checked, serviced and repaired
only by experienced service technicians who c. Transmission Oil Temperature Switch Installation and
are aware of all safety instructions and particular component Testing
features. 1. Thread transmission oil temperature switch into
Note: Contact your Caterpillar dealer if internal transmission transmission housing snugly, then connect switch
repair is required during the warranty period. connector to wiring harness connector.
9.8.2 Transmission Oil Temperature Switch 3. Check for proper fluid level.
a. Transmission Oil Temperature Switch Removal 4. Start engine, allow it to reach operating temperature
and observe operator display cluster for warning
The transmission oil temperature switch (7) is located next to indication. If switch is not defective, problem could be
transfer case below converter housing. elsewhere; possibly in a shorted wire, damaged
1. Park machine on a firm, level surface, level machine, transmission, improper or low fluid, etc.
fully retract boom, lower boom, place transmission in 5. Close and secure the engine cover.
(N) NEUTRAL, engage park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both the ignition key and steering wheel.
Electrical System
9.8.3 Transmission Mounted Speed Sensor 9.8.4 Engine Coolant Temperature

10 Sensor
MZ8200
Transmission speed sensor (8) is located on the side of the MZ6840

transmission bell housing.
Engine coolant temperature sensor (9) is located on left side
a. Transmission Mounted Speed Sensor Removal of engine.
1. Park machine on a firm, level surface, level machine, a. Engine Coolant Temperature Sensor Removal
fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF. 1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in
2. Place a Do Not Operate Tag on both the ignition key (N) NEUTRAL, engage park brake and shut engine OFF.
3. Open engine cover. Allow system fluids to cool. switch and steering wheel.
4. Properly disconnect battery. 3. Open engine cover. Allow system fluids to cool.
5. Unplug the speed sensor connector (9) from the wiring 4. Properly disconnect battery.
harness connector.
5. Unplug engine coolant temperature sensor connector
6. Loosen screw (10) holding clamp and remove sensor. from wiring harness connector.
b. Transmission Mounted Speed Sensor Inspection and 6. Loosen and remove engine coolant temperature sensor
Replacement from engine block.
Inspect sensor and wiring harness connector terminals for b. Engine Coolant Temperature Sensor Inspection and
continuity. Replace a defective or faulty sensor with a new Replacement
part.
Inspect sensor and wiring harness connector terminals for
c. Transmission Mounted Speed Sensor Installation continuity. Replace a defective or faulty sensor with a new
and Testing part.
1. Install sensor in transmission, install clamp on sensor. c. Engine Coolant Temperature Sensor Installation and
Secure with screw removed earlier. Testing
2. Connect sensor plug to wire harness. 1. Apply a lubricate to o-ring on temperature sensor.
3. Properly connect battery. 2. Thread engine coolant temperature sensor into engine
4. Close and secure engine cover. block. Tighten and torque the sensor to
5. Remove Do Not Operate Tag from ignition key switch 17-23 Nm (12.5-17 lb-ft).
and the steering wheel. 3. Connect sensor connector to wiring harness connector.

Electrical System
5. Check for proper coolant level. 6. Check for broken, shorted, frayed, disconnected or
6. Start engine, allow it to reach operating temperature damaged wiring between fuel level indicator wiring at
and observe operator instrument cluster for warning cab, fuse and relay panel, ignition key switch, and from
indication. If sensor is not defective, the problem could fuel level sender on fuel tank through wiring in the cab.
be elsewhere; possibly in a shorted wire, improper- 7. Check fuel level sender. A defective fuel level sender in
running engine, improper or low coolant, obstructed or fuel tank may also prevent fuel level indicator from
faulty radiator, coolant pump, loose fan belt, defective moving. Refer to Section 9.5, “Electrical System
instrument display, etc. Schematics,” for further information.
9.8.6 Boom Retract Sensor
and steering wheel. The boom retract sensor is located inside rear of boom.
9.8.5 Fuel Level Sender a. Boom Retract Sensor Testing

1. Ensure boom is fully retracted and verify using cab
a. Fuel Level Indicator Testing display that boom retract switch is activated.
1. Fuel level sender wiring harness leads can be accessed 2. Extend the boom 100mm and verify using cab display
from lowered fuel tank. Refer to Section 7.6.2, “Fuel that boom retract switch is deactivated.
Tank,” for detailed fuel tank removal and installation.
If boom retract sensor is suspected of giving a false reading,
2. Disconnect fuel level sender wiring harness leads. perform following checks:
3. With the help of an assistant, touch both harness leads 3. Check for loose or defective wiring, faulty ground
together. connections, and corrosion on boom retract sensor and
4. From operator cab, have assistant turn ignition key wiring lead.
switch to RUN position. DO NOT start engine. Observe 4. Check that ignition terminal has current and that fuse in
fuel level indicator needle on operator instrument fuse panel is not blown.
cluster. Reading must be at FULL mark.
5. Check for broken, shorted, frayed, disconnected or
5. Turn ignition key switch to OFF position. Fuel level damaged wiring between display wiring at cab, fuse
indicator needle should return to EMPTY position. and relay panel, ignition key switch, and from boom
retract sensor on boom through wiring in cab.
b. Fuel Level Circuit Tests
If fuel level sender (2) is suspected of giving a false reading, b. Boom Retract Sensor Removal
perform following checks: 1. Park machine on a firm, level surface, level machine,
1. If fuel level indicator needle does not move, check fuel fully retract boom, lower boom, place transmission in
tank for fuel. (N) NEUTRAL, engage park brake and shut engine OFF.
2. Check for loose or defective wiring, faulty ground 2. Place a Do Not Operate Tag on both the ignition key
connections, and corrosion on fuel tank sender and switch and steering wheel.
wiring lead. 3. Open engine cover. Allow system fluids to cool.
3. If fuel level indicator needle does not move after 4. Properly disconnect battery.
ignition key switch is turned to RUN position, use a test
lamp to determine whether current is flowing from
ignition switch to fuel level sender.
4. If fuel level indicator does not move and a faulty or
defective fuel level sender in fuel tank has been ruled
out, and in addition, wiring and connectors have been
checked and ruled out, fuel level indicator is defective
and must be replaced.
5. Check that ignition terminal has current and that fuse in
fuse panel is not blown.

Electrical System
9.8.7 Boom Angle Sensor

The boom angle sensor is located at the top left inside rear of
the boom.
a. Boom Angle Sensor Removal

1. Park the machine on a firm, level surface, level the
switch and the steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the engine to cool.
2 5. Disconnect the boom angle sensor electrical connector.
TH414C GC
1 3
MZ8260
5. Unplug boom retract sensor connector (1) from wiring

harness connector.
6. Loosen hardware securing boom retract sensor (2) and
remove boom retract sensor from boom.
c. Engine Boom Retract Sensor Inspection and B

Replacement
Inspect sensor and wiring harness connector terminals for
continuity. Replace a defective or faulty sensor with a new TH417C GC
part.
3
d. Boom Retract Sensor Installation
1. Secure boom retract sensor (2) to boom.
2. Connect boom retract sensor connector to wiring harness
connector. MZ8210
3. Properly connect battery. 6. Loosen and remove the nut holding the rod assembly
4. Close and secure engine cover. (3) to the sensor arm.
5. Remove Do Not Operate Tag from ignition key switch 7. Loosen and remove the two bolts holding the sensor to
and steering wheel. the sensor bracket.
6. 8. Remove the sensor assembly.

Electrical System
9. If necessary, remove the sensor bracket. 9.8.8 Back-up Alarm

The back-up alarm is located at the rear of the machine.
b. Boom Angle Sensor Inspection and Replacement
When the transmission is shifted to (R) REVERSE, the back-up
Inspect the sensor and the wiring harness connector alarm will automatically sound.
terminals for continuity. Replace a defective or faulty sensor
with a new sensor. Place the transmission in (R) REVERSE to test the back-up
alarm. The back-up alarm must not sound when the
c. Boom Angle Sensor Installation transmission is in (N) NEUTRAL or (F) FORWARD. Also, with
the ignition key switch in the RUN position, the back-up
1. If necessary, install the sensor bracket. alarm will sound when the transmission is shifted into the
2. Install the sensor assembly to the sensor seat and (R) REVERSE position.
tighten both bolts.
a. Disassembly
3. Install the rod end to the sensor arm and tighten nut.
4. If necessary, measure and set the rod length (3) as DO NOT disassemble the back-up alarm. Replace a defective
required. or faulty alarm with a new part.
Machine Rod Length 9.9 DASH SWITCHES

TH414C GC (A) 375 mm (14.75 in)
Note: For information on the front windshield wiper, rear
TH417C GC (B) 230 mm (9.05 in)
window wiper and washer systems, refer to Section 9.7, “Wiper/
5. Plug the electrical connector into the sensor assembly. Washer Wiper Motor.”
9.9.1 Ignition Key Switch
8. Remove the Do Not Operate Tag from the ignition key a. Ignition Key Switch Removal
switch and the steering wheel. 1. Park the machine on a firm, level surface, level the
d. Boom Angle Sensor Adjustment the transmission in (N) NEUTRAL, engage the park brake
1. Access Level 2 can be reached by pressing buttons C and shut the engine OFF.
and OK at the same time. 2. Place a Do Not Operate Tag on both the ignition key
2. Enter Access Level 2 password 33271. switch and the steering wheel, stating that the machine
3. Choose Calibration menu and select “Boom Angle”.
4. Press OK button when asked “Calibrate Boom Angle
Sensor?”. 4. Properly disconnect the battery
5. Follow prompts. First move boom to lowest position, 5. Remove the screws securing the lower dash panel.
press OK button. 6. Remove the hex nut securing the ignition key switch to
6. Follow prompts. Move boom to highest position, press the dash.
OK button. 7. Lower the dash panel to gain access to the rear of the
7. If calibration is successful, Analyzer will indicate ignition switch. Push the switch through the panel.
“Calibration: Complete”. 8. Label and disconnect the electrical connections
If calibration fails, Analyzer will indicate “Calibration attached to the switch.
Failed”. The boom angle sensor position may need to be
9. Remove the switch from the machine.
adjusted or the boom sensor rod may need adjusted.

Electrical System
b. Disassembly 5. Install the lower dash panel.

DO NOT disassemble the ignition key switch. Replace a 6. Properly connect the battery.
defective switch with a new part. 7. Close and secure the engine cover.
8. Start engine to verify proper operation of the ignition
switch.
To determine the proper operation of the ignition key switch, 9. Remove the Do Not Operate Tag from the ignition key
using the following chart, test the wires on the back of the switch and the steering wheel.
switch for continuity with an ohmmeter.
0 9.9.2 Dash Switches
P I
a. Switch Removal
II
1. Park the machine on a firm, level surface, level the
III
MZ2130 and shut the engine OFF.
5. Pull the frame out of the dash, disconnect the harness
connector to the switch in question and push the switch
out of the frame.
MZ2140
b. Disassembly
Test the ignition key switch for continuity, by checking from
the power (#30) wire to each of the following wires in each DO NOT disassemble the dash switch. Replace a defective
switch position. Continuity should be present as indicated in switch with a new part.
the following chart:
Switch Position Test for Continuity Between Wire
#30 and wires: Inspect the switch terminals for continuity and shorting in
both the engaged and disengaged positions. Replace a
P #58 defective or faulty switch with a new switch.
I #15
II #15 & #19 d. Switch Installation
III #15, #17 & #50 1. Connect the switch to the cab harness connector.
2. Position the switch over the rectangular switch bezel
If all connections do not show proper continuity, replace the
and snap into position.
ignition switch.
3. Properly connect the battery
d. Ignition Key Switch Installation 4. Start the machine and check the replaced switch for
1. Connect the previously labeled electrical connections proper function.
to the ignition key switch. 5. Close and secure the engine cover.
2. Push the ignition key switch through the hole in the 6. Remove the Do Not Operate Tag from the ignition key
dash. switch and the steering wheel.
3. Secure the switch to the dash with the previously used
hex nut.
4. Verify that each ignition position is properly connected.

Electrical System
9.10 LOAD STABILITY INDICATOR (LSI)
9.10.1 Load Stability Indicator WARNING

TIP OVER HAZARD. If the green, orange and red LEDs
WARNING flash and warning buzzer sounds, retract and lower boom
immediately. Determine cause and correct before
TIP OVER HAZARD. The LSI considers only longitudinal continued use.
stability limitations, observe all operating parameters.
Failure to follow operating parameters of the telehandler • Test the LSI (6) at the beginning of each work shift.
could damage the equipment and/or cause tip over. 1.Fully retract and level the boom, with no load.
Note: The Load Stability Indicator is NOT a serviceable item. Do not raise the boom during this test.
The LSI must be inspected and/or replaced by your Caterpillar 2.Level frame using level in cab.
dealer. 3.Press the system check button on the LSI display. This
will cause all LEDs to flash on and an audible warning
4 to sound. This indicates that the system is
5 functioning properly. If the test gives a different
result, the system is not functioning properly and the
1
3
machine must be removed from service and repaired
6 before continued operation.
2 9.10.2 LSI Sensor

OZ4100
The LSI (1) provides visual and audible indication of forward

stability limitations when machine is static on firm, level 7
surface.
• Green LED (2) will illuminate when LSI power is on.
• When approaching forward stability limitations LEDs
progressively illuminate, green (3), then orange (4) and
finally red (5).
• If the red LED iluminates, the warning buzzer also
sounds.
• The orange LED (4) illuminates when either of the
following occurs:
MZ8230
• The boom is fully retracted.
• The park brake is not applied and transmission con- The LSI sensor (7) is bolted on the top left of the rear axle.
trol lever is in the forward or reverse position. Note: If the rear axle is removed or replaced, the LSI Sensor
• When approaching forward stability limitations, visual must be installed AFTER the rear axle is installed and setting on
and audible indication is provided and the automatic all four wheels.
function cut-out and/or slow down feature is disabled.
a. LSI Sensor Removal
• Travel in accordance with the requirements set forth in
Section 1 - General Safety Practices. 1. Remove any fork carrier or attachment from the
• When placing a load, ensure axles are not fully steered machine.
in either direction. 2. Park the machine on a firm, level surface, level the
machine, fully retract the boom, fully raise the boom,
place the transmission in (N) NEUTRAL, engage the park
brake and shut the engine OFF.

Electrical System

6. Disconnect the LSI electrical connector. 9
7. Loosen, remove and discard the two bolts holding the
LSI assembly to the rear axle.
8. Remove and discard the sensor assembly.
b. LSI Sensor Installation

1. Ensure threads of both bolt holes are clean and free
from rust, water and debris.
2. Clean the bare metal with a degreasing agent, Loctite®
MZ8250
7063.
3. Remove any excess degreasing agent and allow to dry. 5. Apply an 3mm (0.125 in) bead of Loctite® A2460
Adhesive to each metallic mounting pad (9) on the
sensor. The bead should center on the mounting hole
and be equally spaced between the hole and the edge
of the mounting pad as shown above.
6. Do Not spread the bead prior to mounting the sensor.
8
7. Fit the sensor, ensuring the lead exits in the corner
direction. Secure with two new bolts - Socket HD
Capscrew M10x35x1.5, Grade 12.9.
Note: It is important to prevent distortion of the sensor
element, therefore tighten each bolt finger tight. Alternately
tighten each bolt to 35 Nm (26 lb-ft) and finally to 70-80 Nm
(52-59 lb-ft).
8. Permanently mark position of bolt head and sensor
body.
9. Apply a thin bead of sealant around the perimeter of
the sensor.
MZ8240 10. Leave the machine undisturbed for a minimum of 1
hours before moving.
4. Apply a thin film of Loctite® Initiator #1 (may also be
denoted as Initiator #5) activator approximately 6 cm² (1 11. Plug the electrical connector into the sensor assembly.
in²) to the two flat metal surfaces (8) of the sensor, 12. Properly connect the battery.
ensuring the adhesive is spread evenly over the entire 13. Close and secure the engine cover.
surface.
Note: Follow all adhesive manufacturer’s recommendations switch and the steering wheel.
including storage life.
15. Drive the machine over speed bumps or similar
obstacles to exercise the epoxy bond.
16. Calibrate the LSI system, refer to Section 9.10.3, “LSI
System Calibration.”

Electrical System
9.10.3 LSI System Calibration 9. Lower boom until level. If equipped, fully raise
outriggers. Pressing the LMI Override button may be
a. Standard Calibration required to lower the boom.
To calibrate the LSI, certain conditions must be met: 10. Attach the previously removed standard carriage, forks
and weight.
• The sensor must be installed according to Section
9.10.2, “LSI Sensor.” 11. Slowly extend the boom until the rear axle weight in the
following table is achieved.
• The machine control system must be powered on for at
least 10 minutes before calibration. Model Weight on Rear Axle
• The operator must remain in the cab. TH414C GC 1000 kg (2205 lb)
• The calibration shall be conducted with the standard TH417C GC 1290 kg (2844 lb)
carriage and forks attached and weights as necessary (a
range of 60 - 80% of maximum weight capacity). 12. Press the SYSTEM CHECK button on the LSI display and
• The machine must be on a level surface with the wheels release. As the calibration point is recorded, buzzer
steered straight and park brake off, with straight driving sounds and the LEDs will flash and perform a sequence
over a distance of at least 2 m (6.5 ft) being the last until all are flashing.
movement before entering a calibration point. 13. Perform the LSI- CAN Check PT to finalize the
• While utilizing the LSI override button, 10 times lift and calibration. Refer to Section 9.10.4, “LSI-CAN Check PT.”
lower the boom stopping suddenly to induce the rear
axle to bounce.
• Position the rear tires centrally on the scales.
• The calibration must be completed within 30 minutes
after starting procedure.
Calibration Procedure:
1. Start and position the machine to perform the
calibration procedure.
2. Remove the standard carriage and weight assembly.
3. Fully retract the boom and lower the outriggers. Shut
the machine OFF.
4. With ignition key in OFF position, press and hold
SYSTEM CHECK button on LSI display and turn ignition
key to engine START position. Release the ignition key
when engine start is achieved, but continue to hold
SYSTEM CHECK button on LSI display until the orange
LED on LSI display goes out and buzzer sounds
(approximately 3 seconds). Release SYSTEM CHECK
button.
5. The LEDs will perform a rolling sequence. When only the
third green LED illuminates, press the SYSTEM CHECK
button.
6. The first green LED then illuminates. With no
attachment, outriggers down and boom fully retracted,
lift boom to maximum boom angle.
7. Press the SYSTEM CHECK button on the LSI display and
release. The first 3 green LEDs will illuminate. The third
then second green LEDs will go out as the calibration
point is recorded.
8. The first green LED goes out and buzzer sounds then
the red LED illuminates.
Electrical System
b. Field Calibration forward over a distance of at least 2 m (6.5 ft) before

entering a calibration point.
To calibrate the LSI, certain conditions must be met:
5. Lower the outriggers, place test weight on ground,
• The sensor must be installed according to Section apply park brake and shut engine OFF. Do Not move
9.10.2, “LSI Sensor.”
machine.
• The test weight matches the model being calibrated in Field Calibration Procedure:
the table shown on page 9-52.
Note: The following procedure must be completed within 30
• The calibration shall be conducted with standard
minutes of starting the procedure.
carriage and forks attached to the machine.
• While utilizing the LSI override button, 10 times lift and 1. With ignition key in OFF position, press and hold
lower the boom stopping suddenly to induce the rear SYSTEM CHECK button on LSI display and turn ignition
axle to bounce. key to engine START position. Release the ignition key
when engine start is achieved, but continue to hold
Note: If the test weight is not known, follow steps 1 & 2. SYSTEM CHECK button on LSI display until the orange
Test Weight LED on LSI display goes out and buzzer sounds
Model Xtip (1) Xcal (2) (approximately 3 seconds). Release SYSTEM CHECK
(W)
button.
TH414C GC 1000 kg 2509 mm 1916 mm
(2205 lb) (99 in) (75 in) 2. The LEDs will perform a sequence. When only the third
green LED illuminates, press the SYSTEM CHECK button.
TH417C GC 1000 kg 2837 mm 1713 mm
(2205 lb) (81 in) (67 in) 3. The first green LED then illuminates. With no
attachment and boom retracted, lift boom fully.
4. Press the SYSTEM CHECK button on the LSI display and
1
release. The first 3 green LEDs will illuminate. The third
then second green LEDs will go out as the calibration
A B C
point is recorded.
TH414C GC 5. The first green LED goes out and buzzer sounds then
the red LED illuminates.
6. Lower boom and without moving the machine, pick up
the proper test weight (W) listed in the table. Pressing
1 the LMI Override button may be required to lower the
boom.
2
A B C D
A B C
TH417C GC
MZ8270 TH414C GC
1. With the estimated test weight on the forks, start the

machine and extend the boom horizontally until the
machine starts to tip. This point should be at an
2
extension of Xtip (1) of the second boom section. If the
machine is not tipping at this extension, weight needs
to be added or removed from the forks.
2. By confirming that the machine tips at this point, the A B C D
correct amount of weight is now on the forks.
TH417C GC
3. The machine control system must be powered on for at MZ8270
least 10 minutes before calibration. 7. With the boom horizontal, slowly extend the boom to
4. The machine must be on a level surface with the wheels the distance of Xcal (2). The proper calibration weight is
steered straight and park brake OFF. Drive the machine now on the rear axle and the LSI can now be calibrated.

Electrical System
8. Press the SYSTEM CHECK button on the LSI display and 9.10.5 500 Hour - LSI UGM Calibration Check
release. As the calibration point is recorded, buzzer
1. The machine must be on a level surface, wheels steered
sounds and the LEDs will flash and perform a sequence
straight and park brake ON.
until all are flashing.
2. Start machine
9. Perform the LSI- CAN Check PT to finalize the
calibration. Refer to Section 9.10.4, “LSI-CAN Check PT.” 3. Press the “C” and “OK” buttons simultaneously on the
keypad or the analyzer.
Note: The following procedure MUST BE performed to finalize
the LSI System Calibration. 4. Go to “ACCESS LEVEL 3” and press “OK”.
5. Enter the proper access code and press “OK”.
9.10.4 LSI-CAN Check PT 6. “ACCESS LEVEL 2” is now visible.
With the LSI calibrated, the UGM also needs calibrated and 7. Go to “OPERATOR TOOLS” menu, press “OK”.
verified.
8. Scroll to “LSI_CAN SYSTEM CHECK”.
1. The machine must be on a level surface, wheels steered
9. “PERFORM LSI_CAN SYSTEM CHECK?”, use the arrow
straight and park brake ON.
keys to change “NO” to “YES”.
2. Start the machine.
10. Follow and execute the screen instructions:
3. Press the “C” and “OK” buttons simultaneously on the
a. “Remove Weights and Attachments”, press “OK”.
keypad or the analyzer.
b. “Fully deploy stabilizers”, press “OK”.
4. Go to “ACCESS LEVEL 3” and press “OK”.
c. “TELESCOPE IN and FULLY LIFT UP”, press “OK”.
5. Enter the proper access code and press “OK”.
d. “STOP, WAIT ONE MINUTE”, wait at least one minute
6. “ACCESS LEVEL 2” is now visible. and press “OK”.
7. Go to “CALIBRATIONS” menu, press “OK”. e. “PRESS ENTER TO START TEST”, press “OK”.
8. Scroll to “LSI_CAN CHECK PT”. f. Screen will show: “PRESS ENTER TO START TEST:
PASS”.
9. “SET LSI_CAN CHECK POINT”, use the arrow keys to
change “NO” to “YES”. g. Must receive a “PASS”.
10. Follow and execute the screen instructions: h. Press “C” for approximate two seconds to return to
normal display screen.
a. “Remove Weights and Attachments”, press “OK”.
i. LSI UGM Calibration Check is now complete.
b. “Fully deploy stabilizers”, press “OK”.
11. Return machine to service.
c. “TELESCOPE IN and FULLY LIFT UP”, press “OK”.
d. “STOP, WAIT ONE MINUTE”, wait at least one minute
and press “OK”.
e. “PRESS ENTER TO SET CHECK POINT”, press “OK”
f. Screen defaults back to “CALIBRATIONS: LSI_CAN
CHECK POINT”.
g. Press “C” for approximate two seconds to return to
normal display screen.
h. LSI Can Check is now complete.
11. Return machine to service.

Electrical System
9.11 HAND HELD ANALYZER

The hand held analyzer can be used in place of the cab
display panel.
3 4
5 6
MZ6040
1. Cable Connector.
2. Analyzer Display Screen.
3. Escape Key: To return home or access previous menu.
4. Enter Key: Stores and selects Top Level, Sub Level and
Items Menus.
5. Up/Down Arrow Keys: Change adjustable values.
6. Left and Right Arrow Keys: Used to move between Top
Level, Sub Levels and Item Menus.
9.11.1 Analyzer Usage

Help messages can be viewed using the Analyzer
(P/N 330-5251). The Help messages can be accessed by
pressing the ENTER key while viewing the current Help
message. The Help message shall be EVERYTHING OK when
no fault is present. The Analyzer cable plugs into the X276
connector of the Power Distribution Board located behind
the operator seat.
For more information, contact your Caterpillar dealer.

9.11.2
ANALYZER MENU
note, some screens may
Note: The layout shows all possible analyz er screens. Please note, le depending upon machine configuration.
ma not be a vailable configur
STRUCTURE

MENU: HELP: (001)
HELP:PRESS ENTER EVERYTHING OK
LOG: *(XXXXX)
X:XXXXXXXXXXXXXX
(SHEET 1 of 3)
MENU: MODEL: MARKET : LOAD MONITORING: BOOM RETRACTED PRODUCT LINK: OPERATOR TRANS SELECT: AUX FUNCTION: SPEED LIMIT :
MACHINE SETUP TH414C GC CE LSI-CAN SWITCH: YES NO PRESENCE: YES COLUMN NO 20KPH
MODEL: MARKET : TRANS SELECT: SPEED LIMIT :

TH417C GC ANSI JOYSTICK UNRESTRICTED
MARKET :
AUSTRALIA
MENU: SYSTEM TEST :

SYSTEM TEST ACTIVATE?
Analyzer Software Version V6.3
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS DRIVE / STEER CABIN JOYSTICK CABIN FUNCTIONS STABILIZERS FRAME LEVEL ENGINE TRANSMISSION SYSTEM LOAD MOMENT CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
DRIVE DIRECITION CABIN JOYSTICK MAIN LIFT STABILIZER FRAME LEVEL OPERATING STATE: TRANS REVERSE GROUND MODULE LOAD MOMENT CAN1 STATISTICS CALIBRATION DATA DATALOG: ON-TIME GROUND MODULE
CMD: NEUTRAL X-AXIS: 0% INPUT : 0% INPUT: 0% LEFT INPUT: LOW ENGINE STOPPED COIL: OFF VOLTAGE: 12.0V STATUS: STABLE RX / SEC: XXXXX LIFT CAL1: 150 XXXH XXM SOFTWARE: PX.X
GEAR SELECTION CABIN JOYSTICK MAIN LIFT LEFT STABILIZER FRAME LEVEL DRIVELINE TRANS FORWARD AMBIENT LOAD MOMENT CAN1 STATISTICS CALIBRATION DATA DATALOG:ENGINE GROUND MODULE
CMD: 2 X-AXIS: NEUTRAL COMMANDED: 0mA UP COIL: OFF RIGHT INPUT : LOW NEUTRAL: ON COIL: OFF TEMPERATURE: 0C OVERRIDE: NO TX / SEC: XXXXX LIFT CAL2: 900 XXXH XXM CNST DATA: PX.X
PARK BRAKE CABIN JOYSTICK MAIN LIFT LEFT STABILIZER FRAME LEVEL BATTERY TRANS 1ST GEAR BOOM ANGLE: LOAD MOMENT %: CAN1 STATISTICS DATALOG: DRIVE GROUND MODULE
SWITCH: CLOSED Y-AXIS: 0% ACTUAL: 0mA DOWN COIL: OFF LEFT COIL: OFF VOLTAGE: 12.0V COIL: OFF 10.0 DEG 0% BUS OFF: XXXXX XXXH XXM HARDWARE: REV 08
PARK BRAKE CABIN JOYSTICK TELESCOPE RIGHT STABILIZER FRAME LEVEL COOLANT TRANS 2ND GEAR BOOM ANGLE RAW MOMENT CELL1 CAN1 STATISTICS DATALOG: LIFT GROUND MODULE
STATUS: ON Y-AXIS: NEUTRAL INPUT : 0% UP COIL: OFF RIGHT COIL: OFF TEMPERATURE: 20C COIL: ON COUNTS: 200 RAW VALUE: 250 PASSIVE: XXXXX XXXH XXM S / N: XXXXXX
CLUTCH LOCK CABIN JOYSTICK TELESCOPE RIGHT STABILIZER FRAME LEVEL OIL PRESSURE: HIGH TRANS OIL BOOM RETRACTED MOMENT CELL2 CAN1 STATISTICS DATALOG: TELE. GROUND MODULE
SWITCH: CLOSED L-ROLLER: 0% COMMANDED: 0mA DOWN COIL: OFF COMMANDED: 0mA 2.75BAR SWITCH: CLOSED SWITCH: CLOSED RAW VALUE: 250 MSG ERROR:XXXXX XXXH XXM P / N: XXXXXXXXXX
CABIN JOYSTICK TELESCOPE STABILIZER SPEED CONTROL AMBIENT TRANSPORT MODE: DATALOG: AUX. CABIN JOYSTICK
L-ROLLER: NEUTRAL ACTUAL: 0mA COMMANDED: 0mA ACTUAL: 0mA TEMPERATURE: 0C IN TRANSPORT XXXH XXM SOFTWARE: XXXX
CABIN JOYSTICK FORK TILT SPEED CONTROL FRAME LEVEL FUEL LEVEL TELESCOPE DATALOG: LSI-CAN CABIN DISPLAY
R-ROLLER: 0% INPUT : 0% ACTUAL: 0mA OPERATION: OK SENSOR: 100% STATUS: EXTENDED XXXXXH - PASS SOFTWARE: PX.X
CABIN JOYSTICK FORK TILT STABILIZER ENGINE SPEED HYDRAULIC FILTER DATALOG: LSI-CAN MODULE
R-ROLLER: NEUTRAL COMMANDED: 0mA OPERATION: OK ACTUAL: 1000 RPM SWITCH: CLOSED MAX TEMP: 100C SOFTWARE: PX.XX
CABIN JOYSTICK FORK TILT STABILIZER INPUT OPERATOR DATALOG: ANALYZER:

TRIGGER: OFF ACTUAL: 0mA 1 DEPLOYED: NO PRESENCE: OPEN MIN TEMP: 0C ANALYZER V6.3
CABIN JOYSTICK AUX. HYDRAULICS STABILIZER INPUT DATALOG:

BUTTON 2: OFF INPUT : 0% 2 DEPLOYED: NO MAX VOLTS: 12.0V
CABIN JOYSTICK AUX. HYDRAULICS DATALOG:

FNR: NEUTRAL COMMANDED: 0mA ANTI-THEFT : 0000
CABIN JOYSTICK AUX. HYDRAULICS DATALOG:

NEUTRALIZER: OFF ACTUAL: 0mA RENTAL: XXXH XXM
CABIN JOYSTICK CONTINUOUS AUX. DATALOG:

UPSHIFT: OFF INPUT : LOW ERASE RENTAL?
CABIN JOYSTICK CONTINUOUS AUX.

DNSHIFT: OFF FEATURE: INACTIVE
MZ8420I
Electrical System
9-31
9-32
MENU: ACCESS LEVEL:

ACCESS LEVEL 0 CODE 00000
Electrical System
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

(SHEET 2 of 3)
PERSONALITIES MAIN LIFT TELESCOPE 14M TELESCOPE 17M FORK TILT STABILIZERS FRAME LEVEL AUX. FUNCTION
MAIN LIFT: TELESCOPE X-AXIS TELESCOPE: FORK TILT: STABILIZERS: FRAME LEVEL: AUX. FUNCTION:
ACCEL UP: X.Xs ACCEL IN: X.Xs ACCEL IN: X.Xs ACCEL UP: X.Xs ACCEL UP: X.Xs ACCEL LEFT : X.Xs ACCEL COILA: X.Xs
MAIN LIFT: TELESCOPE X-AXIS TELESCOPE FORK TILT: STABILIZERS: FRAME LEVEL: AUX. FUNCTION:
DECEL UP: X.Xs DECEL IN: X.Xs DECEL IN: X.Xs DECEL UP: X.Xs DECEL UP: X.Xs DECEL LEFT : X.Xs DECEL COILA: X.Xs
ACCEL DOWN: X.Xs ACCEL OUT : X.Xs ACCEL OUT: X.Xs ACCEL DOWN: X.Xs ACCEL DOWN: X.Xs ACCEL RIGHT: X.Xs ACCEL COILB: X.Xs
DECEL DOWN: X.Xs DECEL OUT : X.Xs DECEL OUT: X.Xs DECEL DOWN: X.Xs DECEL DOWN: X.Xs DECEL RIGHT: X.Xs DECEL COILB: X.Xs
MIN UP: XXXmA MIN IN: XXXmA MIN IN: XXXmA MIN UP: XXXmA MIN UP: XXXmA MIN LEFT: XXXmA MIN COILA: XXXmA
MAX UP: XXXmA MAX IN: XXXmA MAX IN: XXXmA MAX UP: XXXmA MAX UP: XXXmA MAX LEFT: XXXmA MAX COILA: XXXmA
MIN DOWN: XXXmA MIN OUT: XXXmA MIN OUT: XXXmA MIN DOWN: XXXmA MIN DOWN: XXXmA MIN RIGHT: XXXmA MIN COILB: XXXmA
MAIN LIFT: TELESCOPE X-AXIS TELESCOPE FORK TILT: STABILIZERS: FRAME LEVEL: AUX FUNCTION:
MAX DOWN: XXXmA MAX OUT: XXXmA MAX OUT: XXXmA MAX DOWN: XXXmA MAX DOWN: XXXmA MAX LEFT: XXXmA MAX COILB: XXXmA
SOFT-LIFT UP: TELESCOPE ROLLER STAB RAMP: AUX. FUNCTION:

SET ANGLE %: X% ACCEL IN: X.Xs INIT STEP: XXXmA PRS REL: XXXmA
SOFT-LIFT UP: TELESCOPE ROLLER STAB RAMP: AUX. FUNCTION:

SET DERATE % XX% DECEL IN: X.Xs STEP SIZE: XXXmA PRS REL: X.Xs
SOFT-LIFT DOWN: TELESCOPE ROLLER STAB RAMP:

SET ANGLE %: X% ACCEL OUT : X.Xs STEP TIME: XXXms
SOFT-LIFT DOWN: TELESCOPE ROLLER

SET DERATE % XX% DECEL OUT : X.Xs
DUAL OPERATION: TELESCOPE ROLLER

SET ANGLE %: X% MIN IN: XXXmA
DUAL OPERATION: TELESCOPE ROLLER

SET DERATE % XX% MAX IN: XXXmA
LIFT RAMP: TELESCOPE ROLLER

INIT STEP: XXXmA MIN OUT: XXXmA
LIFT RAMP: TELESCOPE ROLLER

STEP SIZE: XXXmA MAX OUT: XXXmA
LIFT RAMP:
STEP TIME: XXms
MZ8400I

(SHEET 3 of 3)
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALBIRATIONS:

CALIBRATIONS BOOM ANGLE PARK BRAKE TEST LSI-CAN CHECK PT TRANS SERVICE
CALIBRATE BOOM PERFORM PARK SET LSI-CAN CONFIRM TRANS

ANGLE SENSOR? BRAKE TEST? CHECK POINT : NO SERVICE: NO
PRESS ENTER AT SET PARK BRAKE REMOVE WEIGHTS CONFIRM TRANS

LOWEST POSITION. AND ATTACHMENTS SERVICE: YES
BOOM ANGLE: SHIFT TO FULLY DEPLOY

CALIBRATING SECOND GEAR STABILIZERS
LIFT UP. PRESS WARNING: DRIVE TELESCOPE IN AND

ENTER AT TOP. WILL BE ENGAGED FULLY LIFT UP
BOOM ANGLE: FORWARD TO START **** STOP ****

CALIBRATING NEUTRAL TO PAUSE WAIT 1 MINUTE
CALIBRATION: PARK BRAKE TEST PRESS ENTER TO

COMPLETE COMPLETE SET CHECKPOINT.
CALIBRATION: PARK BRAKE TEST

FAILED FAILED
CALIBRATION:
SENSOR FAULT
BOOM ANGLE RAW:

COUNTS: XXXX
MENU: CHANGE CONFIRM MACHINE REVIEW SET SERVICE VEHICLE SPEED TEMPERATURE: OIL PRESSURE: CABIN JOYSTICK: LSI-CAN SYSTEM REVIEW LSI TYRE SELECTION:
OPERATOR TOOLS ANTI-THEFT CODE? SERVICE? SERVICE HISTORY? INTERVAL: 500H UNITS: KPH CELSIUS BAR TELESCOPE: X- AXIS CHECK: SUSPENDED LOG?
ENTER CURRENT SERVICE SERVICE HISTORY PERFORM LSI-CAN LSI SUSPEND LOG
CODE: 0000 COMPLETE? 1: XXXH XXM SYSTEM CHECK?NO 1: XXXH XXM - OFF
YES:ENTER,NO:ESC
ENTER NEW REMOVE WEIGHTS

CODE: 0000 AND ATTACHMENTS
MZ8410I
FULLY DEPLOY
STABILIZERS
TELESCOPE IN AND
FULLY LIFT UP
**** STOP ****

WAIT 1 MINUTE
PRESS ENTER TO
START TEST: PASS
Electrical System
9-33
Electrical System
9.12 FAULT CODES

Active faults and fault memory will be displayed at the
operator level of access. Active faults will also be displayed as
a blink code at the controller on-board LED. The 25 previous
faults are logged in fault memory, which can be accessed by
choosing ENTER while viewing active fault messages.
9.12.1 Indicator Cross Reference Table

Indicator Assignment
4
1 Machine System Distress
2 Engine Fault Warning
3 Engine Fault Critical
4 Machine Locked
5 Service
6 Hydraulic Filter Restriction
7 Air Filter Restriction 11 KPH
8 Low Steer Pressure 1127 RPM
127°C
9 Low Engine Oil Pressure

10 Battery Low or Not Charging
11 High Transmission Oil Temperature
12 High Engine Coolant Temperature
13 Low Fuel Level
16 Chassis Not Level
MZ8280

Electrical System
9.13 MACHINE FAULT CODES
9.13.1 Help Comment (00X)
Fault
Message Indicators Other Actions Taken Trigger for Fault Latch Until
Code
The system detects no problems

EVERYTHING OK 001
exist.
9.13.2 Power Up (21X)
Fault
Code
POWER CYCLE 211 - - Power was cycled ON. -
The cabin
JOYSTICK AXES NOT
The cabin joystick X & Y axis input The cabin joystick’s X or Y axis is not joystick’s X and
IN NEUTRAL POSITION 215 5000Ms
shall be ignored neutral at power-up Y axis return to
AT POWER UP
neutral
The cabin joystick’s S1 push button

The push
JOYSTICK BUTTON 5 The cabin joystick S1 push button (downshift) is pressed at power-up
217 5000Ms button is
ACTIVE AT POWER UP (downshift) is prevented Machine Setup’s TRANS SELECT set
released
to JOYSTICK, then log a fault.
The cabin joystick’s S2 push button

The push
JOYSTICK BUTTON 4 The cabin joystick S2 push button (upshift) is pressed at power-up
218 5000Ms button is
ACTIVE AT POWER UP (upshift) is prevented Machine Setup’s TRANS SELECT set
released
to JOYSTICK, then log a fault.
FRAME LEVEL RIGHT

Frame Level Left & Right are UGM J4-30 Frame Leveling Right
INPUT – INVALID 2119 5000Ms Power cycled
prevented Switch is closed at power-up
SIGNAL
FRAME LEVEL LEFT

Frame Level Left & Right are UGM J4-9 Frame Leveling Left
INPUT – INVALID 2120 5000Ms Power cycled
prevented Switch is closed at power-up
SIGNAL
CONTINUOUS The switch is

The cabin joystick’s S switch is closed
AUXILIARY Continuous Auxiliary Hydraulics are open
2122 5000Ms at power-up
HYDRAULICS SWITCH prevented momentarily
Only if Aux configured
HIGH AT POWER UP (1,000Ms)
The push
JOYSTICK TRIGGER
The cabin joystick trigger is The cabin joystick’s trigger is button is
SWITCH ACTIVE AT 2123 5000Ms
prevented – Stabilizers pressed at power-up released
POWER UP
(150Ms)
JOYSTICK LEFT The roller

ROLLER NOT IN THE The ARF roller is prevented (Fork Tilt The cabin joystick’s left roller (ARF) is returns to
2124 5000Ms
NEUTRAL POSITION or Telescope) not neutral at power-up neutral
AT POWER UP (150Ms)
JOYSTICK RIGHT The roller

The cabin joystick’s right roller (ARR)
ROLLER NOT IN THE The ARR roller is prevented – returns to
2125 5000Ms is not neutral at power-up
NEUTRAL POSITION Auxiliary Hydraulics neutral
Only if Aux configured
AT POWER UP (150Ms)

Electrical System
9.13.3 Cabin Controls (23X)
Fault
Code
UGM J4-9 Frame Level Left and UGM
CONFLICTING FRAME Frame Level Left and Frame Level
2322 5000Ms J4-17 Frame Level Right digital Power cycled
LEVEL SIGNALS Right are prevented
inputs are energized together
Elobau Cabin Joystick configured:

Cabin joystick transmits a DM1
(SPN:FMI) with 0Xf010:E2, 0Xf011:E2,
or 0Xf012:E2
CABIN JOYSTICK – X
2323 Continuously Cabin joystick X-axis is prevented Cabin joystick transmit 1022 as the Power cycled
AXIS FAULT
X-Axis position
Cabin joystick transmits Error (1:0)
for the X-Axis
Neutral, Left, or Right Position

or 0Xf022:E2
CABIN JOYSTICK – Y
2324 Continuously Cabin joystick Y-axis is prevented Cabin joystick transmits 1022 as the Power cycled
AXIS FAULT
Y-Axis position
for the Y-Axis Neutral, Forward, or
Backward Position

CABIN JOYSTICK – UP Downshift & upshift buttons are
2327 Continuously for the upshift button Power cycled
BUTTON FAULT prevented
(SPN:FMI) with 0Xf064:FF

CABIN JOYSTICK – Cabin joystick transmits Error (1:0)
Downshift & upshift buttons are
DOWN BUTTON 2326 Continuously for the downshift button Power cycled
prevented
FAULT Cabin joystick transmits a DM1

AUX Continuous function requests Cabin joystick transmits Error (1:0)
CABIN JOYSTICK –
will be ignored by the UGM for the AUX Continuous Auxiliary;
AUX CONTINOUS 2330 Continuously Power cycled
(Continuous Auxiliary; Auxiliary Auxiliary Pressure Release) button
FAULT
Pressure Release) Cabin joystick transmits a DM1
UGM J2-24
Hydraulic Filter
Five minutes after engine start, UGM
Restriction
HYDRAULIC FILTER J2-24 Hydraulic Filter Restriction
2332 5000Ms – Switch digital
RESTRICTION Switch digital input is grounded for
input is not
25,000Ms
grounded for
1,000Ms
LOAD MOMENT UGM J4-33 Load Moment Shutoff

Load Moment Shutoff Switch is
SHUTOFF INPUT – 2336 5000Ms digital input is energized at power Power cycled
ignored
INVALID SIGNAL up or for 40 Seconds

Electrical System
The Boom
Angle Sensor
BOOM ANGLE Boom angle sensor reading is +99° The UGM detects that a valid boom
Calibration
SENSOR – NOT 2343 5000Ms Lift Up and Down is de-rated to 60% angle sensor calibration has not
procedure is
CALIBRATED (Constant Data) been performed
performed
successfully
BOOM ANGLE Boom angle sensor reading is +99° UGM J7-4 Boom Angle Sensor
SENSOR – OUT OF 2344 5000Ms Lift Up and Down is de-rated to 60% analog input is more than 4.5V (max Power cycled
RANGE HIGH (Constant Data) sensor counter in constant data)
UGM J7-4 Boom Angle Sensor

BOOM ANGLE Boom angle sensor reading is +99°
analog input is less than 0.6V (min
SENSOR – OUT OF 2345 5000Ms Lift Up and Down is de-rated to 60% Power cycled
angle sensor counter in constant
RANGE LOW (Constant Data)
data)
Main Lift Up or Down valve current

greater than 900Ma;
the engine is running; BOOM ANGLE
SENSOR – NOT CALIBRATED (2342)
not active; BOOM ANGLE SENSOR –
OUT OF RANGE HIGH (2344) not
BOOM ANGLE Boom angle sensor reading is +99° active; BOOM ANGLE SENSOR – OUT
SENSOR – NOT 2346 5000Ms Lift Up and Down is de-rated to 60% OF RANGE LOW (2345) not active; Power cycled
RESPONDING (Constant Data) LIFT – CURRENT FEEDBACK READING
TOO LOW (33287) not active; boom
not within +3.0° of mechanical stop;
boom angle > +10° (for bucket tear
out capability); boom angle sensor
does not change at least 0.5° in
4,000Ms; DEBUG à BOOM NR is NO
Engine is running, the cabin joystick

is not neutral, and one of the
following situations occurs. Entire cabin
SYSTEM INTERLOCK – The cabin joystick’s X-Axis, Y-Axis,
Auxiliary Pressure Release (S Switch) joystick is
SET JOYSTICK INPUTS 2347 - Thumb wheel A, and Thumb wheel B
is closed but the function is not neutral
TO NEUTRAL are prevented
activated momentarily
CANBUS FAILURE – CABIN JOYSTICK
(6617) fault becomes active
The switch is
UGM J4-8 Engine Start digital input
ENGINE START INPUT open
2348 5000Ms Engine Start is prevented energized after the engine is
– INVALID SIGNAL momentarily
running for more than 7,000Ms
(1,000Ms)
Machine Setup’s MODEL is

TH414C GC;
at least one Stabilizer is not
deployed; Lift Up attempted; boom
angle > +60°
LIFT ANGLE DERATED Stabilizer 1 and
Machine Setup’s MODEL is
– STABILIZERS NOT 2349 5000Ms Lift Up is prevented 2 are deployed
TH417C GC;
DEPLOYED (250Ms)
at least one Stabilizer is not
deployed; Lift Up attempted; boom
angle > +60°
Refer to Stabilizer Deployed Switch 1
& 2 functionality

CABIN JOYSTICK – Left Roller shall be prevented (Fork
2350 Continuously (SPN:FMI) with 0Xf030:E2, 0Xf031:E2, Power cycled
LEFT ROLLER FAULT Tilt / Telescope)
or 0Xf032:E2

Electrical System

or 0Xf042:E2
for the Auxiliary Roller Neutral,
CABIN JOYSTICK – Right Roller shall be prevented
2351 Continuously Backward, or Forward position Power cycled
RIGHT ROLLER FAULT (Auxiliary Hydraulics)
Cabin joystick transmits 1022 as the
Auxiliary Roller position
Machine Setup’s AUXILIARY
FUNCTION SELECT is set to YES, then
log a fault.

CABIN JOYSTICK –
Button 1 shall be prevented – for the Trigger switch
STABILIZER BUTTON 2352 Continuously Power cycled
Stabilizers Cabin joystick transmits a DM1
FAULT

CABIN JOYSTICK –
Button 6 shall be prevented – for the Neutralizer switch
NEUTRALIZER 2329 Continuously Power cycled
NEUTRALIZER Cabin joystick transmits a DM1
BUTTON FAULT

or 0Xf052:E2
for the Forward, Neutral, or Reverse
Direction Selection shall be Neutral
CABIN JOYSTICK – switches
23115 Continuously Flash both Direction and Gear at Power cycled
FNR SWITCH FAULT Cabin joystick transmits Switch
1.25Hz
Closed (0:1) for more than one
position (Forward, Neutral, Reverse)
for 500Ms
Machine Setup’s TRANS SELECT is
set to JOYSTICK, then log a fault.
Machine Setup’s OPERATOR

OPERATING MODE
PRESENCE is YES; and operator is not Operator is
INTERLOCK – 23120 Continuously –
present (refer to Operator Presence present
OPERATOR PRESENCE
functionality)

Electrical System
9.13.4 Function Prevented (25X)
Fault
Code
FUNCTION
25XXX - - - -
PREVENTED
MODEL CHANGED –
HYDRAULICS Hydraulic functions are prevented Machine Setup’s MODEL was
259 Continuously Power cycle
SUSPENDED – CYCLE Engine Start is prevented changed
POWER
FUNCTIONS LOCKED
Re-program
OUT – CONSTANT Hydraulic functions are prevented UGM Constant Data version does
2520 Continuously UGM; Power
DATA VERSION Engine Start is prevented not agree with Application
cycled
IMPROPER
ENGINE START UGM J4-8 Engine Start digital input UGM J4-6 Park
PREVENTED – PARK 2525 5000Ms Engine Start is prevented is high (key in start position) and Brake is high
BRAKE NOT SET UGM J4-6 Park Brake is low (not set). (set; 250Ms).
UGM J4-8 Engine Start digital input

Cabin joystick’s
ENGINE START is energized;
or column
PREVENTED – SHIFT the cabin joystick’s FNR switch is set
2529 5000Ms Engine Start is prevented shifter’s FNR
LEVER NOT IN to forward or reverse; the cabin
switch is set to
NEUTRAL column shifter FNR switch is set to
neutral
forward or reverse.
SYSTEM TEST MODE Hydraulic functions are prevented System Test has been activated
2548 5000Ms Power cycle
ACTIVE Engine Start is prevented using the Analyzer
Power cycled
or boom
BOOM RETRACTED Machine Setup’s BOOM RETRACT is
Boom extended (ignore J7-23Boom retracted
SENSOR FAULTY – 2560 Continuously YES and the J7-23 Boom Retracted
Retracted Switch) switch
SENSING INVALID Switch becomes unhealthy
becomes
healthy
9.13.5 Output Drivers (33X)
Fault
Code
OUTPUT DRIVERS 33XXX - - - -
MAIN LIFT UP VALVE – Open-circuit is detected on UGM J2-

33181 5000Ms Lift Up is prevented Power cycled
OPEN CIRCUIT 11
Lift Up is prevented
MAIN LIFT VALVES – Short to battery is detected on UGM
33182 Continuously Lift Down is prevented Power cycled
SHORT TO BATTERY J2-11 or UGM J2-22
UGM J3-2 Lift Return is disabled
Lift Up is prevented
MAIN LIFT UP VALVE – Lift Down is prevented Short to ground is detected on UGM
33183 Continuously Power cycled
SHORT TO GROUND UGM J3-2 Lift Return is disabled J2-11
MAIN LIFT DOWN

Open-circuit is detected on UGM J2-
VALVE – OPEN 33184 5000Ms Lift Down is prevented Power cycled
22
CIRCUIT

Electrical System
MAIN LIFT DOWN Lift Up is prevented

Short to ground is detected on UGM
VALVE – SHORT TO 33185 Continuously Lift Down is prevented Power cycled
J2-22
GROUND UGM J3-2 Lift Return is disabled
MAIN TELESCOPE OUT

VALVE – OPEN 33186 5000Ms Telescope Out is prevented Power cycled
35
CIRCUIT
Telescope Out is prevented

MAIN TELESCOPE
Telescope In is prevented Short to battery is detected on UGM
VALVES – SHORT TO 33187 Continuously Power cycled
UGM J3-4 Telescope Return is J2-34 or UGM J2-35
BATTERY
disabled

MAIN TELESCOPE OUT
Telescope In is prevented Short to ground is detected on UGM
VALVE – SHORT TO 33188 Continuously Power cycled
UGM J3-4 Telescope Return is J2-35
GROUND
disabled
MAIN TELESCOPE IN
VALVE – OPEN 33189 5000Ms Telescope In is prevented Power cycled
34
CIRCUIT

MAIN TELESCOPE IN
Telescope In is prevented Short to ground is detected on UGM
UGM J3-4 Telescope Return is J2-34
GROUND
disabled
Fork Tilt Mode is active;

FORK TILT UP VALVE –
33191 5000Ms Fork Tilt Up is prevented Open-circuit is detected on UGM J2- Power cycled
OPEN CIRCUIT
8
Fork Tilt Up is prevented

FORK TILT VALVES – Short to battery is detected on UGM
33192 Continuously Fork Tilt Down is prevented Power cycled
SHORT TO BATTERY J2-8 or J2-19
UGM J3-6 Tilt Return is disabled
Fork Tilt Up is prevented Fork Tilt Mode is active;

FORK TILT UP VALVE –
33193 Continuously Fork Tilt Down is prevented Short to ground is detected on UGM Power cycled
SHORT TO GROUND
UGM J3-6 Tilt Return is disabled J2-8
FORK TILT DOWN Fork Tilt Mode is active;

VALVE – OPEN 33194 5000Ms Fork Tilt Down is prevented Open-circuit is detected on UGM J2- Power cycled
CIRCUIT 19
FORK TILT DOWN Fork Tilt Up is prevented Fork Tilt Mode is active;
VALVE – SHORT TO 33195 Continuously Fork Tilt Down is prevented Short to ground is detected on UGM Power cycled
GROUND UGM J3-6 Tilt Return is disabled J2-19
Auxiliary Function-A is prevented

AUXILIARY
Continuous Auxiliary Hydraulics is Open-circuit is detected on UGM J2-
FUNCTION-A VALVE – 33196 5000Ms Power cycled
prevented 9
OPEN CIRCUIT
Auxiliary Release is prevented

Auxiliary Function-B is prevented
AUXILIARY
UGM J3-14 Aux Return is disabled
FUNCTION-A/B Short to battery is detected on UGM
33197 Continuously Continuous Auxiliary Hydraulics is Power cycled
VALVES – SHORT TO J2-9 or UGM J2-20
prevented
BATTERY

AUXILIARY
UGM J3-14 Aux Return is disabled Short to ground is detected on UGM
FUNCTION-A VALVE – 33198 Continuously Power cycled
Continuous Auxiliary Hydraulics is J2-9
SHORT TO GROUND
prevented

Electrical System

AUXILIARY
Continuous Auxiliary Hydraulics is Open-circuit is detected on UGM J2-
FUNCTION-B VALVE – 33199 5000Ms Power cycled
prevented 20
OPEN CIRCUIT

AUXILIARY
UGM J3-14 Aux Return is disabled Short to ground is detected on UGM
FUNCTION-B VALVE – 33200 Continuously Power cycled
Continuous Auxiliary Hydraulics is J2-20
SHORT TO GROUND
prevented
STABILIZER/FRAME
Stabilizers are prevented Open-circuit is detected on UGM J1-
LEVEL SPEED VALVE – 33201 5000Ms Power cycled
Frame Level is prevented 3
OPEN CIRCUIT
Stabilizers are prevented

STABILIZER/FRAME
Frame Level is prevented Short to battery is detected on UGM
LEVEL SPEED VALVE – 33202 Continuously Power cycled
UGM J3-5 Stabilizer / Frame Level J1-3
SHORT TO BATTERY
Speed Return is disabled
Stabilizers are prevented

STABILIZER/FRAME
Frame Level is prevented Short to ground is detected on UGM
LEVEL SPEED VALVE – 33203 Continuously Power cycled
UGM J3-5 Stabilizer / Frame Level J1-3
SHORT TO GROUND
Speed Return is disabled
LEFT STABILIZER
Left & Right Stabilizer Down is Open circuit is detected on UGM J2-
DOWN VALVE – OPEN 33222 5000Ms Power cycled
prevented 21
CIRCUIT
LEFT STABILIZER
Stabilizers are prevented Short to battery is detected on UGM
DOWN VALVE – 33223 Continuously Power cycled
Frame Level is prevented J2-21
SHORT TO BATTERY
LEFT STABILIZER
Left & Right Stabilizer Down is Short to ground is detected on UGM
DOWN VALVE – 33224 5000Ms Power cycled
prevented J2-21
SHORT TO GROUND
LEFT STABILIZER UP
Open circuit is detected on UGM J2-
VALVE – OPEN 33225 5000Ms Stabilizers are prevented Power cycled
10
CIRCUIT
LEFT STABILIZER UP
BATTERY
LEFT STABILIZER UP
VALVE – SHORT TO 33227 5000Ms Stabilizers are prevented Power cycled
J2-10
GROUND
RIGHT STABILIZER
Left & Right Stabilizer Down is Open circuit is detected on UGM J2-
DOWN VALVE – OPEN 33228 5000Ms Power cycled
prevented 15
CIRCUIT
RIGHT STABILIZER
DOWN VALVE – 33229 Continuously Power cycled
SHORT TO BATTERY
RIGHT STABILIZER
Left & Right Stabilizer Down is Short to ground is detected on UGM
DOWN VALVE – 33230 5000Ms Power cycled
prevented J2-15
SHORT TO GROUND
RIGHT STABILIZER UP
VALVE – OPEN 33231 5000Ms Stabilizers are prevented Power cycled
3
CIRCUIT

Electrical System
RIGHT STABILIZER UP
BATTERY
RIGHT STABILIZER UP
VALVE – SHORT TO 33233 5000Ms Stabilizers are prevented Power cycled
J2-3
GROUND
FRAME LEVEL LEFT

VALVE – OPEN 33234 5000Ms Frame Level Left is prevented Power cycled
7
CIRCUIT
FRAME LEVEL LEFT

BATTERY
FRAME LEVEL LEFT

VALVE – SHORT TO 33236 5000Ms Frame Level Left is prevented Power cycled
J2-7
GROUND
FRAME LEVEL RIGHT

VALVE – OPEN 33237 5000Ms Frame Level Right is prevented Power cycled
5
CIRCUIT
FRAME LEVEL RIGHT

BATTERY
FRAME LEVEL RIGHT

VALVE – SHORT TO 33239 5000Ms Frame Level Right is prevented Power cycled
J2-5
GROUND
Deactivate output J2-32

Transmission Reverse Coil.
Flash the “Gear Selection” and the
TRANSMISSION
“Drive Direction” symbols on the Open circuit is detected on UGM J2-
REVERSE COIL – OPEN 33246 Continuously Power cycled
LCD of the cabin’s display at 1.25Hz. 32
CIRCUIT
when Calibration’s TRANS SERVICE is
NO

TRANSMISSION
“Drive Direction” symbols on the Short to battery is detected on UGM
REVERSE COIL – 33247 Continuously Power cycled
LCD of the cabin’s display at 1.25Hz. J2-32
SHORT TO BATTERY
NO

TRANSMISSION
“Drive Direction” symbols on the Short to ground is detected on UGM
REVERSE COIL – 33248 Continuously Power cycled
SHORT TO GROUND
NO

Electrical System

Transmission Forward Coil.
TRANSMISSION
“Drive Direction” symbols on the Open circuit is detected on UGM J2-
FORWARD COIL – 33252 Continuously Power cycled
LCD of the cabin’s display at 1.25Hz. 33
OPEN CIRCUIT
NO

TRANSMISSION
“Drive Direction” symbols on the Short to battery is detected on UGM
SHORT TO BATTERY
NO

TRANSMISSION
“Drive Direction” symbols on the Short to ground is detected on UGM
SHORT TO GROUND
NO
Deactivate output J1-7 Transmission

1st Gear Coil.
TRANSMISSION 1ST Open circuit is detected on UGM J1-
33258 Continuously “Drive Direction” symbols on the Power cycled
GEAR COIL – OPEN 7
LCD of the cabin’s display at 1.25Hz.
CIRCUIT
NO

1st Gear Coil.
TRANSMISSION 1ST Short to battery is detected on UGM
GEAR COIL – SHORT J1-7
TO BATTERY
NO

1st Gear Coil.
TRANSMISSION 1ST Short to ground is detected on UGM
TO GROUND
NO

Transmission 2NDt Gear Coil.
TRANSMISSION 2ND Open circuit is detected on UGM J1-
GEAR COIL – OPEN 20
CIRCUIT
NO

Electrical System

Transmission 2NDt Gear Coil.
TRANSMISSION 2ND Short to battery is detected on UGM
TO BATTERY
NO

Transmission 2ND Gear Coil.
TRANSMISSION 2ND Short to ground is detected on UGM
TO GROUND
NO
ENGAGE STARTER
OUTPUT – OPEN 33282 5000Ms – Power cycled
6
CIRCUIT
Engage Starter digital output

ENGAGE STARTER
prevented Short to battery is detected on UGM
OUTPUT – SHORT TO 33283 Continuously Power cycled
De-Energize ECM Power digital J1-6
BATTERY
output (to stop engine)
ENGAGE STARTER
Engage Starter digital output Short to ground is detected on UGM
OUTPUT – SHORT TO 33284 5000Ms Power cycled
prevented J1-6
GROUND
ALTERNATOR
Alternator Excitation digital output UGM J4-7 Alternator D+ is energized
EXCITATION LINE – 33285 5000Ms Power cycled
is prevented 2,000Ms after engine has stopped
SHORT TO BATTERY
Actual lift up / down (UGM J3-2) &

commanded current disagree by
LIFT – CURRENT
>125Ma when command is >250 Ma
FEEDBACK READING 33287 5000Ms – Power cycled
for 1000Ms
TOO LOW
Actual lift up / down current <
225Ma and PWM is >40% for 100ms
Actual telescope in / out (UGM J3-4)

& commanded current disagree by
TELESCOPE –
CURRENT FEEDBACK 33288 5000Ms – Power cycled
for 1000Ms
READING TOO LOW
Actual telescope in / out current <
Actual stabilizer / frame leveling

(UGM J3-6) & commanded current
STABILIZERS/FRAME
disagree by >125Ma when
LEVEL – CURRENT
33289 5000Ms – command is >250 Ma for 1000Ms Power cycled
FEEDBACK READING
Actual stabilizer / frame leveling
TOO LOW
current < 225Ma and PWM is >40%
for 100ms
Actual fork tilt up / down (UGM J3-6)

& commanded current disagree by
FORK TILT – CURRENT
FEEDBACK READING 33290 5000Ms – Power cycled
for 1000Ms
TOO LOW
Actual fork tilt up / down current <

Electrical System
Actual auxiliary function A / B (UGM

AUXILIARY J3-14) & commanded current
HYDRAULICS – disagree by >125Ma when
33291 5000Ms – Power cycled
CURRENT FEEDBACK command is >250 Ma for 1000Ms
READING TOO LOW Actual auxiliary A / B current <
REVERSE ALARM AND

LIGHTS – OPEN 33210 5000Ms – Power cycled
1
CIRCUIT
REVERSE ALARM AND

Short to battery is detected on UGM
LIGHTS-SHORT TO 33211 5000Ms – Power cycled
J1-1
BATTERY
REVERSE ALARM AND

LIGHTS-SHORT TO 33212 5000Ms – Power cycled
J1-1
GROUND
9.13.6 Engine (43X)
Fault
Code
ENGINE 43XXX - - - -
UGM J4-7
Engine running > 3,000Ms and UGM
ALTERNATOR Alternator D+
4320 5000Ms – J4-7 Alternator D+ digital input is
CHARGING FAILURE is high for
low
3,000Ms
9.13.7 Battery Supply (44X)
Fault
Code
BATTERY SUPPLY 44XXX - - - -
BATTERY VOLTAGE UGM detects the battery voltage is <

Hydraulic functions are prevented
TOO LOW – SYSTEM 441 - 9V for at least 500Ms; engine is not Power cycled
All digital outputs are disabled
SHUTDOWN cranking
BATTERY VOLTAGE
Hydraulic functions are prevented UGM detects the battery voltage >
TOO HIGH – SYSTEM 442 - Power cycled
All digital outputs are disabled 16V for at least 250Ms
SHUTDOWN
UGM detects
UGM detects battery voltage < 11V
BATTERY VOLTAGE battery voltage
445 5000Ms – for 3,000Ms, and the engine is
LOW >11V for
running
10,000Ms
REFERENCE VOLTAGE UGM detects its reference voltage is

OUT OF RANGE – 447 5000Ms Hydraulic functions are prevented out of range (>5.4V or <4.6V) for Power cycled
GROUND 1000Ms.

Electrical System
9.13.8 Transmission & Drive System (46X)
Fault
Code
TRANSMISSION
46XXX - - - -
& DRIVE SYSTEM
UGM J1-21 Transmission

HIGH TRANSMISSION Temperature is grounded for a
UGM J1-21 is
OIL TEMPERATURE 461 Continuously – period of 3 seconds or more. Please
not grounded
CRITICAL put persistence timer in constant
data.
Deactivate and inhibit output J2-33

Transmission Forward. A high signal is detected on more
Deactivate and inhibit output J2-32 than one of drive direction inputs
Only input J4-
CONFLICTING DRIVE Transmission Reverse. (J4-18 Neutral / J7-22 Forward / J4-
462 Continuously 18 Neutral is
DIRECTION SIGNALS Deactivate and inhibit output J1-1 19 Reverse) at the same time for a
HIGH.
Reversing Alarm and Lights. period of 3 seconds or more. Log
Deactivate and Inhibit output J1-6 only if Column shifter is configured.
Engine Start

Transmission Forward.
J4-18 Neutral and J7-22 Forward and
J4-19 Reverse are simultaneously Only input J4-
DRIVE DIRECTION Transmission Reverse.
463 Continuously LOW for a period of 3 seconds or 18 Neutral is
SIGNAL LOST Deactivate and inhibit output J1-1
more. Log only if Column shifter is HIGH.
Reversing Alarm and Lights.
configured.
Deactivate and Inhibit output J1-6
Engine Start
Maintain the output of the last valid

gear selected or 3rd Gear if the fault If more than one of the gear
is present at startup. Transmission
selection inputs, J4-21 1st Gear / J4- J4-6 Park Brake
drive direction signals will still be
CONFLICTING GEAR 11 2nd Gear / J4-22 3rd Gear, are is HIGH and
464 Continuously acknowledged in this case.
SELECTION SIGNALS HIGH simultaneously for a period of issue cleared or
Flash last valid gear selection or flash
3 seconds. Log only if Column shifter power cycled.
3rd Gear at 1.25Hz if the fault is
is configured.
present at startup on the LCD of the
cabin’s display.
Maintain the output of the last valid

gear selected or 3rd Gear if the fault
is present at startup. Transmission If J4-21 1st Gear and J4-11 2nd Gear
J4-6 Park Brake
drive direction signals will still be and J4-22 3rd Gear are
GEAR SELECTION is HIGH and
465 Continuously acknowledged in this case. simultaneously LOW for a period of 3
SIGNAL LOST issue cleared or
Flash last valid gear selection or flash seconds or more. Log only if Column power cycled.
3rd Gear at 1.25 Hz if the fault is shifter is configured.
present at startup on the LCD of the
cabin’s display.
Display “99” as Vehicle Speed on

cabin display
Restrict direction and gear selection
to present state or associated Direction Selection is Forward or
Vehicle speed
VEHICLE SPEED neutral state when this occurs Reverse;
counts
SENSOR – NOT 468 5000Ms during operation Park Brake is not engaged;
detected for
RESPONDING Retain this fault through power engine RPM >1400 RPM;
5,000Ms
cycles no vehicle speed counts >30,000Ms
Restrict direction and gear selection
to F3, N3, R3 if this fault is active
from the previous power cycle

Electrical System
9.13.9 Communications (66X)
Fault
Code
COMMUNICATIONS 66XXX - - - -
Electronic Engine is configured;

CANBUS FAILURE –
666 Continuously Engine Start is prevented ECM messages not detected > Power cycled
ENGINE CONTROLLER
250Ms
UGM detects > 500 Bus-Off

CANBUS FAILURE –
conditions during a power cycle or
EXCESSIVE CANBUS 6613 Continuously – Power cycled
> 22 Bus-Off conditions in 1,000Ms
ERRORS
(4 times in a row)
Engine is not cranking; Cabin Joystick

CANBUS FAILURE –
6617 Continuously Hydraulic functions are prevented Cabin Joystick messages not messages
CABIN JOYSTICK
detected for at least 1,000Ms detected
CANBUS FAILURE – Cabin Display messages could not

6618 Continuously – Power cycled
CABIN DISPLAY address claim.
Machine Setup’s PRODUCT LINK is

CANBUS FAILURE – YES; TCU messages
6622 - –
TCU MODULE TCU messages not detected > 30 detected
seconds
CANBUS FAILURE –
Machine Setup’s PRODUCT LINK is
TELEMATICS CANBUS 6629 - Power cycled
YES;
LOADING TOO HIGH
Machine Setup’s LOAD

MONITORING is LSI-CAN UGM does
Load Moment Cutout assumed to be not detect the LSI-CAN on the
CANBUS FAILURE – LSI 6638 Continuously Power cycled
100% CANbus > 1000msec and an ENGINE
STOPPED or ENGINE RUNNING state
exists for a period of one second.

Electrical System
9.13.10 Load Moment (85X)
Fault
Code
LOAD MOMENT 85XXX - - - -
Load Monitoring configured; LSI System

Load Moment Cutout assumed to be
LSI NOT CALIBRATED 8514 5000Ms LSI System reports Fault #6 – System does not
100%
not calibrated report Fault #6
Load
LSI DETECTED BUT Load Monitoring is not configured;
8515 Continuously Hydraulic functions are prevented Monitoring is
NOT CONFIGURED LSI System messages detected
configured
Load Monitoring configured;

LSI LOAD CELL A – Load Moment Cutout assumed to be
8516 Continuously LSI System reports Fault #4 – Load Power cycled
OUT OF RANGE 100%
Cell A – Out of Range

LSI LOAD CELL B – Load Moment Cutout assumed to be
8517 Continuously LSI System reports Fault #5 – Load Power cycled
OUT OF RANGE 100%
Cell B – Out of Range

LSI CUTOUT OUTPUT
Load Moment Cutout assumed to be LSI System reports Fault #7 – Open
– SHORT TO BATTERY 8518 Continuously Power cycled
100% or Short Circuit condition on 100%
OR OPEN CIRCUIT
Cutout digital output

Verification using OPERATOR TOOLS Verification or
LSI OUT OF Load Moment Cutout assumed to be à LSI-CAN SYSTEM CHECK indicated Calibration
8519 5000Ms
CALIBRATION 100% FAIL performed
(refer to Load Monitoring à successfully
Verification functionality)
9.13.11 Hardware (99X)
Fault
Code
HARDWARE 99XXX - - - -

EEPROM FAILURE – Engine Start is prevented The control system has detected an
CHECK ALL SETTINGS ECM Power is de-energized to EEPROM issue
shutdown engine
Hydraulic functions are prevented Machine

FUNCTIONS LOCKED
Engine Start is prevented Machine Setup’s MODEL is Setup’s MODEL
OUT – MACHINE NOT 9924 5000Ms
ECM Power is de-energized to UNKNOWN is set; Power
CONFIGURED
shutdown engine cycled
Hydraulic functions are prevented Current feedback calibration data in

CURRENT FEEDBACK Engine Start is prevented the Manufacturing Data Area
GAINS OUT OF RANGE Fuel Relay is energized to shutdown (0x4050; J3-1, J3-2, J3-4, J3-5, J3-6,
engine J3-14) to are not within 204-307
CURRENT FEEDBACK Hydraulic functions are prevented Checksum for the current feedback
CALIBRATION Engine Start is prevented calibration data in the
CHECKSUM ECM Power is de-energized to Manufacturing Data Area (0x4050)
INCORRECT shutdown engine was improper

Electrical System
MACHINE Hydraulic functions are prevented Machine Setup

CONFIGURATION OUT Engine Start is prevented UGM detects a parameter range is properly
OF RANGE – CHECK 9949 Continuously issue with Machine Setup configured;
ECM Power is de-energized to
ALL SETTINGS shutdown engine Power cycled
Elobau Joystick configured:

Hydraulic functions are prevented (SPN:FMI)
CABIN JOYSTICK –
9976 Continuously Direction selection shall be neutral with 0Xf001:EC, 0Xf002:EC, Power cycled
INTERNAL FAILURE
(If FNR configured) 0Xf005:EC
Cabin joystick transmitted an
undocumented DM1 (SPN:FMI)
Hydraulic functions are prevented Personalities

EEPROM VALUE – OUT Engine Start is prevented UGM detects a parameter range are properly
9978 Continuously
OF RANGE ECM power is de-energized to issue with Personalities configured;
shutdown engine Power cycled

UGM detects a Low sense FET failure
GROUND MODULE Engine Start is prevented
9986 Continuously (all high-sensing digital inputs are Power cycled
VLOW FET FAILURE ECM power is de-energized to
shutdown engine high)

FUNCTIONS LOCKED LSI System transmitted Major /
Load Moment Cutout assumed to be
OUT – LSI SOFTWARE 99151 Continuously Minor Software version that is not Power cycled
100%
VERSION IMPROPER compatible (P0.11 or greater; P1.x
allowed)

LSI FAULTY – SYSTEM Load Moment Cutout assumed to be
99152 Continuously LSI System reports Fault #1 – CRC Power cycled
FLASH CRC ERROR 100%
Error in System Flash

LSI FAULTY – DATA Load Moment Cutout assumed to be
99153 Continuously LSI System reports Fault #2 – CRC Power cycled
FLASH CRC ERROR 100%
Error in Data Flash

LSI FAULTY – LOAD
Load Moment Cutout assumed to be LSI System reports Fault #3 –
CELLS A AND B 99154 Continuously Power cycled
100% Excessive Data Variance between
DISAGREEMENT
Load Cell A and Load Cell B

Electrical System

31200959

TH414C GCTH417C GC CAT Service

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TH414C GCTH417C GC CAT Service

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Service Manual

May 9, 2014 - A - Original Issue Of Manual

31200959 TH414C GC, TH417C GC i

ii TH414C GC, TH417C GC 31200959

TH414C GC, TH417C GC i

ii TH414C GC, TH417C GC

TH414C GC, TH417C GC iii

iv TH414C GC, TH417C GC

PARAGRAPH TITLE PAGE

TH414C GC, TH417C GC 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.2 DISCLAIMER WARNING

1-2 TH414C GC, TH417C GC

1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

TH414C GC, TH417C GC 1-3

1-4 TH414C GC, TH417C GC

PARAGRAPH TITLE PAGE

TH414C GC, TH417C GC 2-1

2.1 REPLACEMENT PARTS AND WARRANTY 2.2 THREAD LOCKING COMPOUND

Loctite® 243TM can be substituted in place of Loctite® 242TM.

Before ordering parts or initiating service inquiries, make

2-2 TH414C GC, TH417C GC

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

TH414C GC, TH417C GC 2-3

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

2-4 TH414C GC, TH417C GC

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

TH414C GC, TH417C GC 2-5

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

2-6 TH414C GC, TH417C GC

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

TH414C GC, TH417C GC 2-7

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-8 TH414C GC, TH417C GC

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

TH414C GC, TH417C GC 2-9

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-10 TH414C GC, TH417C GC

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

TH414C GC, TH417C GC 2-11

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

2-12 TH414C GC, TH417C GC

2.3.3 Hydraulic Hose Torque Chart

TH414C GC, TH417C GC 2-13

2.4.1 Travel Speeds

TRANSMISSION APPROXIMATE SPEED

2.4.2 Hydraulic Cylinder Performance

APPROXIMATE TIMES (seconds)

2-14 TH414C GC, TH417C GC

2.4.3 Electrical System

2.4.4 Engine Performance Specifications

Description TCD 3.6 L4

2.4.5 Transmission Performance Specifications