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Cat Caterpillar TH414C Telehandler Service Repair Manual + Operation and Maintenance Manual + Parts Manual on CD
Cat Caterpillar TH414C Telehandler Service Repair Manual + Operation and Maintenance Manual + Parts Manual on CD
Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your CAT. Read and print pages directly from the CD, or copy the entire manual to your hard drive.
1680 Pages
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SERAIL NUMBERS:
SN MJR00150 to Present
SN THM00150 to Present
SN DJB00150 to Present
SN SXJ00150 to Present
SN GAT00150 to Present
SN RCH00150 to Present
SN MLH00150 to Present
SN JJT00150 to Present
SN KEK00150 to Present
SN RWW00150 to Present
SN MWC00150 to Present
SN KKW00150 to Present
SN RRJ00150 to Present
SN RRW00150 to Present
ENGINE:
CAT C3.4
CAT C4.4
MANUAL COVERS:
SERVICE RAPAIR MANUAL:
Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals
Section 2 General Information and Specifications
2.1 Replacement Parts and Warranty Information
2.2 Specifications
2.2.1 Travel Speeds
2.2.2 Hydraulic Cylinder Performance
2.2.3 Platform Hydraulic Performance Specifications
2.2.4 Cylinder Drift
2.2.5 Steering Angle Specifications
2.2.6 Electrical System
2.2.7 Engine Fan Speed
2.2.8 Engine Performance Specifications
2.2.9 Transmission Performance Specifications
2.2.10 Tires
2.3 Fluids and Lubricant Capacities
2.3.1 Fluids
2.3.2 Capacities
2.4 Service and Maintenance Schedules
2.4.1 Every 10 Hours
2.4.2 First 50 Hours
2.4.3 Every 50 Hours
2.4.4 First 250 Hours
2.4.5 Every 250 Hours
2.4.6 Every 500 Hours
2.4.7 Every 1000 Hour
2.4.8 Every 1500 Hours
2.4.9 Every 3000 Hours
2.4.10 Every 6000 Hours or 3 Years
2.4.11 Every 12000 Hours or 6 Years
2.5 Lubrication Schedules
2.5.1 50 Hour Lubrication
2.5.2 500 Hour Lubrication
2.6 Thread Locking Compound
2.7 Torque Charts
2.7.1 SAE Fastener Torque Chart
2.7.2 Metric Fastener Torque Chart
2.8 Hydraulic Connection Assembly and Torque Specification
2.8.1 Definitions
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings
2.8.5 Assembly Instructions for 45° SAE Flare Fittings
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)
2.8.14 Double Wrench Method
2.8.15 FFWR and TFFT Methods
2.8.16 Adjustable Stud End Assembly
2.8.17 O-ring Installation (Replacement)
Section 3 Boom
3.1 Boom System Component Terminology - TH336C, TH337C, TH406C & TH407C
3.2 Boom System - Two Section
3.2.1 Boom System Operation
3.3 Boom Assembly Maintenance
3.3.1 Complete Boom Removal
3.3.2 Complete Boom Installation
3.3.3 Second Section Boom Removal
3.3.4 First Boom Section Removal
3.3.5 Extend/Retract Cylinder Removal
3.3.6 Extend/Retract Cylinder Installation
3.3.7 First Boom Section Installation
3.3.8 Second Boom Section Installation
3.4 Boom System Component Terminology - TH414C
3.5 Boom System - Three Section
3.5.1 Boom System Operation
3.6 Boom Assembly Maintenance
3.6.1 Boom Removal
3.6.2 Second and Third Boom Section Removal
3.6.3 Third Boom Section and Extend/Retract Cylinder Removal
3.6.4 Third Boom Section and Extend/Retract Cylinder Installation
3.6.5 Second and Third Boom Section Installation
3.6.6 Complete Boom Installation
3.7 Boom Chain Removal/Installation
3.7.1 Retract Chain Removal
3.7.2 Retract Chain Installation
3.7.3 Extend Chain Removal
3.7.4 Extend Chain Installation
3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/ Installation
3.8.1 Extend/Retract Hose Removal
3.8.2 Extend/Retract Hose Installation
3.8.3 Tilt/Auxiliary Hose Removal
3.8.4 Tilt/Auxiliary Hose Installation
3.9 Extend/Retract Cylinder Removal/ Installation
3.9.1 Extend/Retract Cylinder Removal
3.9.2 Extend/Retract Cylinder Installation
3.10 Boom Sections Adjustment
3.10.1 Chain Adjustments
3.11 Boom System Component Terminology - TH514C
3.12 Boom System - Three Section
3.12.1 Boom System Operation
3.13 Boom Assembly Maintenance
3.13.1 Boom Removal
3.13.2 Second and Third Boom Section Removal
3.13.3 Tandem Extend/Retract Cylinder Removal
3.13.4 Third Boom Section Removal
3.13.5 Third Boom Section Installation
3.13.6 Tandem Extend/Retract Cylinder Installation
3.13.7 Second and Third Boom Section Installation
3.13.8 Complete Boom Installation
3.14 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/ Installation
3.14.1 Extend/Retract Hose Removal
3.14.2 Extend/Retract Hose Installation
3.14.3 Tilt-Electrical/Auxiliary Hose Removal
3.14.4 Tilt-Electrical/Auxiliary Hose Installation
3.15 Tandem Extend/Retract Cylinders Removal/Installation
3.15.1 Tandem Extend/Retract Cylinders Removal
3.15.2 Tandem Extend/Retract Cylinders Bleeding Procedure
3.15.3 Tandem Extend/Retract Cylinders Installation
3.16 Boom System Component Terminology - TH417C
3.17 Boom System - Four Section Boom
3.17.1 Boom System Operation
3.18 Boom Assembly Maintenance
3.18.1 Boom Removal
3.18.2 Second, Third and Fourth Boom Section Removal
3.18.3 Third and Fourth Boom Section Removal
3.18.4 Fourth Boom Section Removal
3.18.5 Hose Carrier Removal
3.18.6 Hose Carrier Installation
3.18.7 Fourth Boom Section Installation
3.18.8 Third and Fourth Boom Section Installation
3.18.9 Second, Third and Fourth Boom Section Installation
3.18.10 Complete Boom Installation
3.19 Boom Chain Removal/Installation
3.20 Boom Sections Adjustment
3.20.1 Chain Adjustments
3.21 Boom Extend and Retract Chains - TH414C & TH417C
3.21.1 Boom Chain Inspection
3.21.2 Inspection Guidelines - TH414C
3.21.3 Inspection Guidelines - TH417C
3.21.4 Expose Chains for Inspection
3.21.5 Chain Lubrication
3.22 Boom Wear Pads
3.22.1 Wear Pad Inspection
3.22.2 Boom Wear Pad Installation/Lubrication
3.23 Quick Coupler
3.23.1 Quick Coupler Removal (TH336C, TH337C, TH406C & TH407C)
3.23.2 Quick Coupler Installation (TH336C, TH337C, TH406C & TH407C)
3.23.3 Quick Coupler Removal (TH414C, TH514C & TH417C)
3.23.4 Quick Coupler Installation (TH414C, TH514C & TH417C)
3.24 Forks
3.25 Boom Prop (if equipped)
3.25.1 Installation and Removal Procedures
3.26 Emergency Boom Lowering Procedure
3.26.1 Equipment and Supplies Required
3.26.2 Lowering Procedure
3.27 Boom Retract Sensor Adjustment
3.28 Troubleshooting
Section 4 Cab
4.1 Operator Cab and Covers Component Terminology
4.2 Operator Cab
4.2.1 Operator Cab Safety
4.2.2 Serial Number Plate
4.3 Cab Components
4.3.1 Steering Wheel
4.3.2 Steering Column/Orbital Valve
4.3.3 Service Brake
4.3.4 Electronic Throttle Pedal
4.3.5 Joystick Assembly
4.3.6 Mechanical Throttle Pedal
4.3.7 Mechanical Throttle Pedal Cable
4.3.8 Window Wiper Assembly
4.3.9 Heater System (if equipped)
4.3.10 Heater and Air Conditioning System (if equipped)
4.3.11 Heater/Air Conditioning Controls
4.4 Cab Removal
4.5 Cab Installation
Section 5 Axles, Drive Shafts, Wheels and Tires
5.1 Axle, Drive Shaft and Wheel Component Terminology
5.2 Axle Serial Number
5.3 Axle Specifications and Maintenance Information
5.4 Axle Replacement
5.4.1 Axle Removal
5.4.2 Axle Installation
5.5 Mechanical Park Brake
5.5.1 Mechanical Park Brake Removal
5.5.2 Mechanical Park Brake Installation
5.5.3 Mechanical Park Brake Adjustment
5.6 Hydraulic Park Brake
5.6.1 Park Brake Test
5.7 Brake Inspection
5.8 Steering Angle Adjustment
5.9 Axle Assembly and Drive Shaft Troubleshooting
5.10 Drive Shafts
5.10.1 Drive Shaft Inspection
5.10.2 Drive Shaft Maintenance
5.10.3 Drive Shaft Removal
5.10.4 Drive Shaft Cleaning and Drying
5.10.5 Drive Shaft Installation
5.11 Wheels and Tires
5.11.1 Removing Wheel and Tire Assembly from Machine
5.11.2 Installing Wheel and Tire Assembly onto Machine
5.12 Towing a Disabled Machine
Section 6 Transmission
6.1 Transmission Assembly Component Terminology
6.2 Transmission Serial Number
6.3 Specifications and Maintenance Information
6.4 Transmission Replacement
6.4.1 Transmission Removal
6.4.2 Transmission Installation.
6.4.3 After Transmission Service or Replacement
6.4.4 Transmission Torque Converter Stall Test
6.5 Torque Convertor Diaphragm
6.5.1 Torque Convertor Diaphragm Removal/ Installation
6.6 Troubleshooting
Section 7 Engine
7.1 Introduction
7.1.1 Disclaimer and Scope
7.1.2 Component Terminology
7.2 Engine Serial Number
7.3 Specifications and Maintenance Information
7.4 Engine Cooling System
7.4.1 Surge Tank Cap
7.4.2 Thermostat Replacement
7.4.3 Radiator Assembly Removal - 75 kW
7.4.4 Radiator Assembly Removal - 74.5, 92.6, 93.1 and 106 kW
7.4.5 Radiator Assembly Installation
7.5 Engine Electrical System
7.6 Fuel System
7.6.1 Diesel Fuel
7.6.2 Fuel Tank
7.6.3 After Fuel System Service
7.6.4 Fuel Cooler
7.7 Engine Exhaust System
7.7.1 Exhaust System Removal - 75 kW
7.7.2 Exhaust System Installation - 75 kW
7.7.3 Exhaust System Removal - 74.5 kW
7.7.4 Exhaust System Installation - 74.5 kW
7.7.5 Exhaust System Removal - 92.6 & 106 kW
7.7.6 Exhaust System Installation - 92.6 & 106 kW
7.7.7 Exhaust System Removal - 93.1 kW
7.7.8 Exhaust System Installation - 93.1 kW
7.8 Air Cleaner Assembly
7.8.1 Air Cleaner Assembly Removal - 75 kW
7.8.2 Air Cleaner Assembly Installation - 75 kW
7.8.3 Air Cleaner Assembly Removal - 74.5 kW
7.8.4 Air Cleaner Assembly Installation - 74.5 kW
7.8.5 Air Cleaner Assembly Removal - 92.6 & 106 kW
7.8.6 Air Cleaner Assembly Installation - 92.6 & 106 kW
7.8.7 Air Cleaner Assembly Removal - 93.1 kW
7.8.8 Air Cleaner Assembly Installation - 93.1 kW
7.9 Engine Replacement
7.9.1 Engine/Transmission Removal
7.9.2 Transmission Removal/Installation
7.9.3 Engine Disassembly, Inspection and Service
7.9.4 Engine/Transmission Installation
7.10 Engine Troubleshooting
Section 8 Hydraulic System
8.1 Hydraulic Component Terminology
8.1.1 TH336C, TH337C, TH406C and TH407C
8.1.2 TH417C
8.1.3 TH414C
8.1.4 TH514C
8.2 Safety Information
8.3 Specifications
8.4 Hydraulic Pressure Diagnosis
8.4.1 Pressure Checks and Adjustments
8.5 Hydraulic Circuits
8.5.1 Hydraulic Pressures
8.6 Hydraulic Schematics
8.6.1 TH336C, TH337C, TH406C & TH407C
8.6.2 TH414C, TH514C & TH417C
8.7 Hydraulic Reservoir
8.7.1 Hydraulic Oil Reservoir Draining
8.7.2 Hydraulic Oil Reservoir Filling
8.7.3 Hydraulic Oil Reservoir Removal/ Installation
8.8 Engine Implement Pump
8.8.1 Pump Replacement
8.9 Auxiliary Pump (Platform Equipped Models Only)
8.9.1 Auxiliary Pump Description
8.9.2 Auxiliary Pump Replacement
8.10 Control Valves
8.10.1 Main Control Valve
8.10.2 Reversing Fan Valve
8.10.3 Service Brake Valve
8.10.4 Service Brake Bleeding
8.10.5 Service Brake Test
8.10.6 Steering Orbital Valve
8.10.7 Steer Select Valve
8.11 Boom Ride Control (TH336C, TH337C, TH406C, TH407C - if equipped)
8.11.1 General Accumulator Information
8.11.2 Accumulators
8.11.3 Pre-Charging Accumulator
8.11.4 Checking Pre-Charge
8.12 Hydraulic Cylinders
8.12.1 General Cylinder Removal Instructions
8.12.2 Cylinder Pressure Checking
8.12.3 Steering Cylinders
8.12.4 Cylinder Torque Specifications
Section 9 Electrical System
9.1 Electrical Component Terminology
9.1.1 General Overview
9.2 Specifications
9.3 Safety Information
9.4 Keypad and Display Screen
9.4.1 Keypad
9.4.2 Display Screen
9.5 Software Level 2 Accessibility
9.5.1 Operator Tools
9.5.2 Personalities
9.5.3 Calibration
9.6 Operator Tools
9.6.1 Resetting the Anti theft Code
9.6.2 Hardware Exchange
9.6.3 Confirm Machine Service
9.6.4 Review Service History
9.6.5 Set Service Interval
9.6.6 Cabin Joystick Telescope: X-Axis/Roller
9.7 Fuses and Relays
9.7.1 Engine Compartment
9.7.2 Power Distribution Board
9.8 Electrical System Schematics
9.8.1 Cab Harness Electrical Schematic 1 of 3
9.8.2 Cab Harness Electrical Schematic 2 of 3
9.8.3 Cab Harness Electrical Schematic 3 of 3
9.8.4 Cab Roof, Ride, Float and Boom Extend LImit
9.8.5 Power Distribution Board
9.8.6 Transmission and Reverse Fan
9.8.7 Front Frame, Boom and Options
9.8.8 Rear Frame
9.8.9 LRC Engine, Battery & Platform Stabs
9.8.10 Platform Box
9.8.11 LMIS Option
9.8.12 CAT C4.4 Engine
9.8.13 CAT C3.4 Engine
9.8.14 CAT Product Link
9.8.15 Platform MSSO Harness
9.9 Dielectric Grease Application
9.9.1 Installation
9.9.2 Exclusions
9.10 Engine Start Circuit
9.10.1 Starter
9.10.2 Charging Circuit
9.10.3 Alternator
9.11 Battery
9.11.1 Battery Inspection
9.11.2 Battery Removal/Installation
9.11.3 Battery Disconnect/Connect
9.12 Electrical Master Switch
9.12.1 Electrical Master Switch Removal
9.12.2 Electrical Master Switch Installation
9.13 Window Wiper System (if equipped)
9.13.1 Front Windshield Wiper Motor
9.13.2 Rear Window Wiper Motor
9.13.3 Washer Fluid Reservoir
9.14 Solenoids, Sensors and Senders
9.14.1 Transmission Solenoid Valves
9.14.2 Transmission Oil Temperature Switch
9.14.3 Transmission Mounted Speed Sensor
9.14.4 Engine Coolant Temperature Sensor
9.14.5 Fuel Level Sender
9.14.6 Front and Rear Axle Steering Sensors
9.14.7 Boom Angle Sensor
9.14.8 Back-up Alarm
9.15 Dash Switches
9.15.1 Ignition Key Switch
9.15.2 Dash Switches
9.16 Platform Interlock Checks
9.17 Platform Load System Check
9.18 Load Stability Indicator (LSI) (CE & AUS)
9.18.1 Load Stability Indicator
9.19 LSI Sensor
9.19.1 LSI Sensor Removal
9.19.2 LSI Sensor Installation
9.20 LSI System Calibration
9.20.1 Standard Calibration
9.20.2 Field Calibration
9.20.3 LSI-CAN Check PT
9.20.4 500 Hour - LSI UGM Calibration Check
9.21 Hand Held Analyzer
9.21.1 Analyzer Usage
9.21.2 Analyzer Software Version PX.XX
9.22 Fault Codes
9.22.1 Indicator Cross Reference Table
9.23 Machine Fault Codes
9.24 Engine Fault Codes
9.24.1 92.5 kW & 106 kW
9.24.2 74.5 kW
ENGINE SERVICE REPAIR MANUAL:
Effectivity
Foreword
TOC
Section 1 JLG Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals
Section 2 Safety information / User information
2.1 General
2.2 Specifications
2.2.1 Accident prevention and safety regulations
2.2.2 Cleanliness instructions and measures for working with common rail systems
2.2.3 Additional information and measures for the handling of exhaust aftertreatment systems
2.2.4 Disposal regulations
2.3 Operation Manual And Service Manual
2.4 Explanation Of Symbols
Section 3 Disassembly and Assembly
3.1 Oil Measuring Device
3.1.1 Oil Measuring Device Removal
3.2 Crankcase Breather
3.3 Lubricating Oil Pan
3.3.1 Lubricating Oil Pan Removal
3.3.2 Lubricating Oil Pan Installation
3.3.3 Technical Data
3.4 Flywheel
3.4.1 Flywheel Removal
3.4.2 Flywheel Installation
3.4.3 Technical Data
3.5 V-belt Pulley Add-on
3.6 V-belt Pulley Add-on Fastening Parts
3.7 Cylinder Head Cover (Engine 441-9208)
3.7.1 Cylinder Head Cover Removal
3.7.2 Cylinder Head Cover Installation
3.7.3 Technical Data
3.8 Cylinder Head Cover (Engine 441-9209)
3.8.1 Cylinder Head Cover Removal
3.8.2 Cylinder Head Cover Installation
3.8.3 Technical Data
3.9 Heat Protection Plate (Engine 441-9208)
3.10 Lubricating Oil Cooler
3.10.1 Lubricating Oil Cooler Removal
3.10.2 Lubricating Oil Cooler Installation
3.10.3 Technical Data
3.11 Lubricating Oil Filter
3.12 Injector (Engine 441-9208)
3.12.1 Injector Removal
3.12.2 Injector Installation
3.12.3 Technical Data
3.13 Injector (Engine 441-9209)
3.13.1 Injector Removal
3.13.2 Injector Installation
3.13.3 Technical Data
3.14 Fuel Supply Pump
3.15 Fuel Pipes
3.15.1 High-pressure Line Removal
3.15.2 Injection Pipes Removal
3.15.3 Rail Removal
3.15.4 Pressure Sensor Removal
3.15.5 Pressure Sensor Installation
3.15.6 Pressure Limiting Valve Removal
3.15.7 Pressure Limiting Valve Installation
3.15.8 Mounting Rail
3.15.9 Injection Pipes Installation
3.15.10 High-pressure Line Installation
3.15.11 Technical Data
3.16 Exhaust Turbocharger Intake Nozzle
3.17 Charge Air Manifold
3.18 Charge Air Line
3.19 Coolant Pump Fastening Parts
3.19.1 V-rib Belt Pulley Removal
3.19.2 V-rib Belt Pulley Installation
3.20 Thermostat Test
3.20.1 Thermostat Test In Removed State
3.20.2 Technical Data
3.21 Thermostat
3.21.1 Thermostat Removal
3.21.2 Thermostat Installation
3.21.3 Technical Data
3.22 Exhaust Gas Recirculation Line
3.23 Exhaust Pipe
3.23.1 Exhaust Line Removal
3.23.2 Installing Exhaust Line
3.23.3 Technical Data
3.24 Flutter Valve
3.24.1 Flutter Valve Removal
3.24.2 Flutter Valve Installation
3.24.3 Technical Data
3.25 Exhaust Gas Turbocharger
3.25.1 Turbocharger Removal
3.25.2 Turbocharger Installation
3.25.3 Technical Data
3.26 Lubricating Oil Line
3.26.1 Lubricating Oil Line Removal
3.26.2 Lubricating Oil Line Installation
3.26.3 Technical Data
3.27 Lubricating Oil Return Line
3.27.1 Oil Return Line Removal
3.27.2 Oil Return Line Installation
3.27.3 Technical Data
3.28 V-Belt Pulley (parts to generator)
3.29 Generator Parts
3.30 Generator
3.30.1 Generator Removal
3.30.2 Generator Installation
3.30.3 Technical Data
3.31 Starter
3.31.1 Starter Removal
3.31.2 Starter Installation
3.31.3 Technical Data
3.32 Cable Harness Fastening Parts
3.33 Cable Harness Fastening Parts (Engine 441-9208)
3.34 Impulse Transmitter (Crankshaft)
3.34.1 Impulse Transmitter Removal
3.34.2 Impulse Transmitter Installation
3.34.3 Technical Data
3.35 Temperature Sensor
3.36 Oil Pressure Transmitter
3.37 Connection Housing
3.37.1 Connection Housing Removal
3.37.2 Connection Housing Installation
3.37.3 Technical Data
3.38 Start-aid Glow Plugs
3.38.1 Glow Plugs Removal
3.38.2 Glow Plugs Installation
3.38.3 Technical Data
3.39 Exhaust Gas Treatment Inlet Module (Engine 441-9208)
3.40 Holder (Engine 441-9208)
3.41 Assembly Material Compensator Structure (Engine 441-9208)
Section 4 Special Tools
4.1 Tools
4.1.1 Pump (P/N 449-2474)
4.1.2 Assembly Pliers
4.1.3 Measuring Device (P/N 449-2482)
4.1.4 Torx Tool Set
4.1.5 Rotation Angle Disc (P/N 449-2484)
4.1.6 Check Designation (P/N 449-2485)
4.1.7 Fitting Tool (P/N 449-2487)
4.1.8 Check Designation (P/N 449-2488)
4.1.9 Pliers (P/N 449-2489)
4.1.10 Socket Wrench Insert
4.1.11 Plug (P/N 449-2493)
4.1.12 Assembly Tool
4.1.13 Key (P/N 449-2496)
4.1.14 Lever Tool (P/N 449-2497)
4.1.15 Disassembly Tool
4.1.16 Assembly Device (P/N 449-2500)
Section 5 Engine Electrical Schematic
5.1 Power Harness
5.2 Equipment Harness
Section 6 Wire Sensor Troubleshooting
6.1 Engine Sensor Test
6.2 Engine Sensor Circuit Test
6.3 Signal Wire Test
Section 7 Diagnostics
AXLE SERVICE REPAIR MANUAL 1:
Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operation & Maintenance Manual
1.4 Do Not Operate Tags
1.5 Safety Information
1.5.1 Safety Alert System and Signal Words
1.6 Safety Instructions
1.6.1 Personal Hazards
1.6.2 Equipment Hazards
1.6.3 General Hazards
1.6.4 Operational Hazards
1.7 Safety Decals
Section 2 General Information and Specifications
2.1 General
2.2 Recommendations for Repair Operations
2.2.1 Symbols used in disassembly/ assembly/adjustment procedures
2.3 Product Identification
2.4 Measurements
2.5 General Description
2.6 Technical Features
2.7 Component Specifications
2.7.1 Sensor Specifications
2.7.2 Brake Disks Typical Data
2.7.3 Limited Slip Differential Disks Specifications
2.7.4 Front Axle Main Dimensions (mm)
2.7.5 Rear Axle Main Dimensions (mm)
2.8 Tightening Torques and Sealants
Section 3 Troubleshooting and Maintenance
3.1 Troubleshooting
3.2 Oil Change and Service Checks
3.3 Service Schedule
3.3.1 Lubricants Application Range
3.4 Grease in Assembly
Section 4 Disassembly/Assembly/Adjustment
4.1 Steering Cylinder
4.1.1 General Drawing
4.1.2 Disassembly
4.1.3 Assembly
4.2 Epicyclic reduction gear group
4.2.1 General Drawing
4.2.2 Disassembly
4.2.3 Assembly
4.3 Wheel Hub Group
4.3.1 General Drawing
4.3.2 Disassembly
4.3.3 ASSEMBLY
4.4 Parking Brake Group
4.4.1 General Drawing
4.4.2 Disassembly
4.4.3 Assembly
4.4.4 Parking Brake Caliper
4.5 Flange Group
4.5.1 GENERAL DRAWING
4.5.2 DISASSEMBLY
4.5.3 ASSEMBLY
4.6 Trunnions Group
4.6.1 GENERAL DRAWING
4.6.2 DISASSEMBLY
4.6.3 ASSEMBLY
4.7 Brake Group
4.7.1 General Drawing
4.7.2 Disassembly
4.7.3 ASSEMBLY
4.7.4 Brake Disk Assembly
4.8 Axle Beam Group
4.8.1 GENERAL DRAWING
4.8.2 Disassembly
4.8.3 Assembly
4.9 Differential Support Group
4.9.1 General Drawing
4.9.2 Disassembly
4.9.3 Assembly
4.9.4 Bevel gear marking test.
4.10 Differential Group Limited Slip
4.10.1 General Drawing
4.10.2 Disassembly
4.10.3 Assembly
4.11 Differential Group - Open
4.11.1 General Drawing
4.11.2 Disassembly
4.11.3 Assembly
4.12 Pinion Group
4.12.1 General Drawing
4.12.2 Disassembly
4.12.3 Assembly
4.13 Toe-in/steering angle
4.13.1 General Drawing
4.13.2 Toe-in adjustment
4.13.3 Steering angle adjustment
4.14 Testing After Assembly
4.14.1 Testing methods
Section 5 Special Tools
5.1 Tool Usage
ELECTRICAL SYSTEM
HYDRAULIC SYSTEM
PARTS MANUAL 1 (674 pages):
OPERATION and MAINTENANCE MANUAL 1:
Table of Contents
Section 1 —General Safety Practices
1.1 Hazard Classification System
Safety Alert System and Safety Signal Words
1.2 General Precautions
1.3 Operation Safety
Electrical Hazards
Tip Over Hazard
Travel Hazard
Load Falling Hazard
Lifting Personnel
Driving Hazards on Slopes
Pinch Points and Crush Hazards
Fall Hazard
Chemical Hazards
1.4 Product Link (if equipped)
2.3 Walk-Around Inspection
2.4 Warm-Up and Operational Checks
Warm-Up Check
Operational Check
2.5 Operator Cab
2.6 Windows
Cab Door Window
Rear Window
Section 3 - Controls and Indicators
3.1 General
3.2 Controls
Instrument Panel
Display Screen
Keypad
Ignition
Park Brake
Parking Procedure
Transmission Control Lever (if equipped)
Load Stability Indicator - LSI (CE & AUS)
Steering Column Adjuster
Joystick
Front Console Switches
Right Console Switches
Accessory Control Lever
Reversing Fan (if equipped)
3.3 Anti Theft
3.4 Steer Modes
Manual Steering Alignment Mode Change
All Wheel Assisted Steering Alignment Mode Change
3.5 Operator Seat
Operator Presence (CE & AUS)
Adjustments
Seat Belt
3.6 Boom Indicators
Boom Extension
Boom Angle (AUS)
Section 4 - Operation
4.1 Engine
Starting the Engine
Battery Boosted Starting
Normal Engine Operation
Shut-Down Procedure
4.2 After-Treatment System (S/N MJR00150 & After, S/N DJB00150 & After, S/N GAT00150 & After,
S/N MLH00150 & After, S/N KEK0015
Automatic Regeneration
Manual Regeneration
4.3 Operating with a Non-Suspended Load
Lift Load Safely
Picking Up a Load
Transporting a Load
Leveling Procedure
Placing a Load
Disengaging a Load
4.4 Operating with a Suspended Load
Lift Load Safely
Picking Up a Suspended Load
Transporting a Suspended Load
Leveling Procedure
Placing a Suspended Load
Disengaging a Suspended Load
4.5 Road Operation (CE)
4.6 Loading and Securing for Transport
Tiedown
Lifting
Section 5 - Attachments and Hitches
5.1 Approved Attachments
5.2 Unapproved Attachments
5.3 JLG Supplied Attachments
TH336C, TH337C, TH406C & TH407C
TH414C & TH417C
TH514C
5.4 Telehandler/Attachment/Fork Capacity
5.5 Use of the Load Chart
Capacity Indicator Locations
Sample Load Chart (CE & ANSI)
Sample Load Chart (AUS)
Example
5.6 Attachment Installation
CAT Quick Coupler
JD Coupler
Manitou Coupler
JCB Coupler
Hydraulic Operated Attachment
5.7 Platform Attachment (if equipped)
5.8 Adjusting/Moving Forks
5.9 Attachment Operation
Carriage w/Forks
Side Shift Carriage
Rotate/Side Tilt Carriage and Fork Rotator Carriage
Fork Positioning Carriage
Bucket
Multi-Purpose Bucket
Grapple Bucket
Manure Fork
Bale Handler
Coupler Mounted Hook
Truss Boom
Personnel Work Platform - Fork Mounted
Platform
5.10 Hitches and Trailer Brakes (TH336C, TH337C, TH406C & TH407C)
Retrieval Hitch
Pin Hitch - CUNA C (Italy)
Pin Hitch - CUNA D2 (Italy)
EEC Manual Pin Hitch
EEC Auto Hitch
Piton Frame and EEC Auto Hitch
Hydraulic Hitch
Trailer Brakes
Section 6 - Emergency Procedures
6.1 Towing a Disabled Product
Moving Short Distances
Moving Longer Distance
6.2 Emergency Lowering of Boom
6.3 Emergency Lowering of Boom If Equipped for Platform
Auxiliary Power System
Machine Safety System Override (MSSO)(CE, if equipped)
6.4 Cab Emergency Exit
Section 7 - Lubrication and Maintenance
7.1 Introduction
Clothing and Safety Gear
7.2 General Maintenance Instructions
7.3 Service and Maintenance Schedules
10 & 1st 50 Hour Maintenance Schedule
50 & 1st 250 Hour Maintenance Schedule
250 & 500 Hour Maintenance Schedule
1000, 1500 & 3000 Hour Maintenance Schedule
6000 & 12000 Hour Maintenance Schedule
7.4 Lubrication Schedules
50 Hour Lubrication Schedule
500 Hour Lubrication Schedule
7.5 Operator Maintenance Instructions
Fuel System
Cab Air Filters (if equipped)
Tires
Engine Oil
Engine Cooling System
Hydraulic Oil
Transmission Oil
Air Intake System
Battery
Windshield Washer System (if equipped)
Section 8 - Additional Checks
8.1 General
8.2 Load Stability Indicator System (CE & AUS)
8.3 Boom Interlock (TH414C, TH514C & TH417C)
8.4 Auxiliary Power (If Equipped for Platform)
Section 9 - Specifications
9.1 Product Specifications
Fluids
Fluid Capacities
Tires
Performance
Dimensions
Declaration of Vibration (CE)
Noise Emission Level (CE)
Machine Towing Capacity
Index
OPERATION and MAINTENANCE MANUAL 2:
Table of Contents
Section 1 - General Safety Practices
Section 2 - System Operation
Section 3 - Service and Maintenance
Section 1 - General Safety Practices
1.1 Hazard Classification System
Safety Alert System and Safety Signal Words
1.2 General Precautions
1.3 Operation Safety
Electrical Hazards
Tip Over Hazard
Travel Hazard
Load Falling Hazard
Lifting Personnel
Driving Hazards on Slopes
Pinch Points and Crush Hazards
Fall Hazard
Chemical Hazards
Section 2 - System Operation
2.1 General
2.2 Control Panel
Display
2.3 Operation
System Start Up
Attachment Selection
Lifting Conditions and Alarms
2.4 Diagnostic Data
Alarms and Warnings
LMI Values
Pressure Values
Angle and Length Transducers
LMI Status
Section 3 - Service and Maintenance
3.1 Auto-Diagnostic System
Alarm Codes
This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.
Language: English
Format: PDF - Indexed and Searchable
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