Mustang Articulated Loader AL 406 AL 506 Service Manual(50940008) - PDF DOWNLOAD

®

AL 406 AL506 Articulated Loader

SERVICE MANUAL PART #50940008 Revision A - 03/11

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Mustang Manufacturing Company, Inc.

Table of Contents Chapter 1 — Introduction......................................................................................................1 Chapter 2 — Safety ................................................................................................................3 Mandatory Safety Shutdown Procedure ...................................................................................................... 4 Before Starting ............................................................................................................................................. 4 During Operation.......................................................................................................................................... 5 Service Safety Practices .............................................................................................................................. 6 Fire Hazards ................................................................................................................................................ 8 Crystalline Silica Exposure .......................................................................................................................... 8 Safety Decals............................................................................................................................................... 9 Hazard and Hazard Avoidance Symbols ..................................................................................................... 9

Chapter 3 — Specifications ................................................................................................11 Fluid Capacities/Lubricants........................................................................................................................ 11 Dimensions ................................................................................................................................................ 12 Weights and Capacities ............................................................................................................................. 14 Engine........................................................................................................................................................ 15 Hydraulics .................................................................................................................................................. 15 Electrical System ....................................................................................................................................... 15 Sound Levels ............................................................................................................................................. 15 Wheels ....................................................................................................................................................... 16 FOPS ......................................................................................................................................................... 16

Chapter 4 — Maintenance ...................................................................................................17 Maintenance Introduction........................................................................................................................... 17 Maintenance Schedule .............................................................................................................................. 18 Engine Maintenance .................................................................................................................................. 20 Air Cleaner ................................................................................................................................................. 22 Engine Cooling System.............................................................................................................................. 23 Fuel System ............................................................................................................................................... 25 Checking and Adjusting V-belt Tension ..................................................................................................... 27 Air Conditioning Maintenance .................................................................................................................... 28 Hydraulic System Maintenance ................................................................................................................. 29 Planetary Axles .......................................................................................................................................... 30 Brake Fluid Reservoir ................................................................................................................................ 32 Wheels and Tires ....................................................................................................................................... 33 Lubrication ................................................................................................................................................. 35 Electrical System ....................................................................................................................................... 37 Storing the Loader ..................................................................................................................................... 44 Maintenance Log ....................................................................................................................................... 45

Chapter 5 — Operation........................................................................................................49 Operation Safety ........................................................................................................................................ 49 Controls and Switches ............................................................................................................................... 50 Instrument Panel and Indicators ................................................................................................................ 52 Cab Controls (Cab only) ............................................................................................................................ 54 Warning Indicators ..................................................................................................................................... 56 Operator’s Seat and Ignition Switch........................................................................................................... 57 50940008/AP0311

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Table of Contents Steering Column .........................................................................................................................................58 Hand Throttle ..............................................................................................................................................59 Lift Arm Down-Stop.....................................................................................................................................59 Lift/Tilt Lock.................................................................................................................................................60

Chapter 6 — Chassis........................................................................................................... 61 Tilting the Platform ......................................................................................................................................61 Lowering the Platform .................................................................................................................................62 Repairing or Replacing Platform Switch .....................................................................................................64 Hood Removal ............................................................................................................................................65 Hood Installation .........................................................................................................................................66 Center/Steering Bearing Removal ..............................................................................................................67 Center/Steering Bearing Installation ...........................................................................................................70 Lift Arm Removal ........................................................................................................................................74 Lift Arm Installation .....................................................................................................................................75 Attachment Plate Hydraulics Removal........................................................................................................77 Attachment Plate Hydraulics Installation.....................................................................................................78

Chapter 7 — Engine.............................................................................................................79 Engine Removal..........................................................................................................................................79 Engine Installation.......................................................................................................................................83 Drive Coupling Removal .............................................................................................................................87 Drive Coupling Installation ..........................................................................................................................87 Starter Removal ..........................................................................................................................................88 Starter Installation .......................................................................................................................................88

Chapter 8 — Cooling System ............................................................................................. 89 Radiator/Oil Cooler Removal ......................................................................................................................89 Radiator/Oil Cooler Installation ...................................................................................................................92

Chapter 9 — Axles ............................................................................................................... 95 Front Axle Removal ....................................................................................................................................95 Front Axle Installation .................................................................................................................................98 Rear Axle Removal ...................................................................................................................................100 Rear Axle Installation ................................................................................................................................102

Chapter 10 — Hydraulics .................................................................................................. 103 Work Hydraulics Troubleshooting .............................................................................................................103 Hydrostatic Drive System..........................................................................................................................106 Hydraulics Troubleshooting Diagnostic Flow Charts ................................................................................107 Drive System Pressure Tests ...................................................................................................................121 Work System Pressure Tests ...................................................................................................................124 Steering Circuit Pressure Test ..................................................................................................................125 2-Spool Control Valve Removal................................................................................................................126 3-Spool Control Valve Removal................................................................................................................128 2-Spool Control Valve Installation.............................................................................................................131 3-Spool Control Valve Installation.............................................................................................................133 Lift/Tilt Lock, Power-A-Tach® System and Auxiliary Hydraulics Valve Locations ....................................135 PRINTED IN U.S.A.

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Table of Contents Lift Cylinder Removal............................................................................................................................... 136 Lift Cylinder Installation............................................................................................................................ 137 Tilt Cylinder Removal............................................................................................................................... 138 Tilt Cylinder Installation............................................................................................................................ 138 Steering Cylinder Removal ...................................................................................................................... 139 Steering Cylinder Installation ................................................................................................................... 139 Hydraulic Cylinder Disassembly/Assembly.............................................................................................. 141 Gear/Work Hydraulic Pump Removal ...................................................................................................... 149 Gear/Work Hydraulic Pump Installation ................................................................................................... 149 Piston/Drive Hydraulic Pump Removal .................................................................................................... 150 Piston/Drive Hydraulic Pump Installation ................................................................................................. 152 Hydrostatic Motor Removal...................................................................................................................... 153 Hydrostatic Motor Installation................................................................................................................... 155 Steering Control Valve Removal.............................................................................................................. 156 Steering Control Valve Removal.............................................................................................................. 158 Steering Control Valve Installation........................................................................................................... 159 Steering Control Valve Installation........................................................................................................... 160 Raising Machine for Drive System Troubleshooting ................................................................................ 161 AL 400 Series Hydraulic Schematic – SN 41250 and Up ........................................................................ 163 AL 400 Series Hydraulic Schematic – SN 41249 and Before .................................................................. 164 AL 500 Series Hydraulic Schematic – SN 51242 and Up ........................................................................ 165 AL 500 Series Hydraulic Schematic – SN 51241 and Before .................................................................. 166

Chapter 11 — Machine/Drive Controllers ........................................................................167 Machine and Drive Controllers................................................................................................................. 167 Machine Controller................................................................................................................................... 168 Drive Controller (Plus+1 Module)............................................................................................................. 172 Service Communication Kit and PLUS+1 GUIDE Service Tool Software................................................ 173 Plus+1 Service Tool Navigation/Overview ............................................................................................... 174 Software Log Monitoring Screen.............................................................................................................. 175 Electrical Inputs/Outputs Monitoring Screen............................................................................................ 176 Electrical Status Error Reporting Screen ................................................................................................. 177 System Definition Error Count/Timestamp Reset Screen........................................................................ 178 Drive Controller Pedal Calibration Parameters ........................................................................................ 179 Pump Profiling Screen/Drive “Creep” Adjustment.................................................................................... 179 Pedal Calibration Procedure .................................................................................................................... 181

Chapter 12 — Electrical System .......................................................................................183 Battery Removal ...................................................................................................................................... 183 Battery Installation ................................................................................................................................... 184 AL 400 Series (Serial Numbers 41250 and up) Complete Electrical Schematic ..................................... 185 AL 400 Series (Serial Numbers 41250 and up) Steering Column Electrical Schematic .......................... 186 AL 400 Series (Serial Numbers 41250 and up) Chassis Electrical Schematic ........................................ 187 AL 400 Series (Serial Numbers 41250 and up) Engine Electrical Schematic.......................................... 188 AL 400 Series (Serial Numbers 41250 and up) FOPS, Power-A-Tach® and Tail Light Electrical Schematic ................................................................................................................................................ 189 AL 500 Series (Serial Numbers 51242 and up) Complete Electrical Schematic (Includes Air Conditioning Option) ................................................................................................................................ 190 50940008/AP0311

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Table of Contents AL 500 Series (Serial Numbers 51242 and up) Steering Column Electrical Schematic (Includes Air Conditioning Option) .................................................................................................................................191 AL 500 Series (Serial Numbers 51242 and up) Chassis Electrical Schematic (Includes Air Conditioning Option) ......................................................................................................................................................192 AL 500 Series (Serial Numbers 51242 and up) Engine Electrical Schematic (Includes Air Conditioning Option) ......................................................................................................................................................193 AL 500 Series (Serial Numbers 51242 and up) FOPS, CAB, Power-A-Tach® and Tail Light Electrical Schematic (Includes Air Conditioning Option) ..........................................................................................194 AL 400 Series (Serial Numbers 41249 and below), AL 500 Series (Serial Numbers 51241 and below) Complete Electrical Schematic .................................................................................................................195

Chapter 13 — Troubleshooting ........................................................................................ 197 Engine.......................................................................................................................................................197 Indicator Lamps / Seals and Hoses ..........................................................................................................199 Hydraulic System ......................................................................................................................................200 Hydrostatic Drive System..........................................................................................................................202

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Introduction INTRODUCTION IMPORTANT: The word “IMPORTANT” indicates situations that can result in possible damage to the machine.

Safety Symbol Manitou Americas, in cooperation with the Society of Automotive Engineers, has adopted this:

NOTE: The word “NOTE” indicates particularly useful information.

special

or

Contents and Use of this Manual

Safety Alert Symbol This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual or on the machine, you are reminded to BE ALERT! Your personal safety is involved!

This Service Manual contains information about the safe and proper maintenance, service and troubleshooting for the machine. Additionally, it contains basic operation information, but is not intended as a replacement for the Operator’s Manual that was provided with the machine. Refer to the Operator’s Manual for complete and detailed operation information.

Signal Words

Major points of safe operation and maintenance are detailed in the Safety chapter of this manual.

Follow the instructions in the Operator’s Manual S afe ty , O p er at io n a nd M ai nte na nc e ch ap ter s , concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Americas is not liable for damage resulting from the failure to follow these regulations.

DANGER “DANGER” indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

CAUTION

WARNING

Improper operation, inspection, maintenance, and/ or service of the machine can cause injury or death. Read and understand the contents of the Operator’s Manual COMPLETELY and become familiar with the machine before operating it.

“WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

Some illustrations in this manual may show doors, guards and shields open or removed for illustrative purposes only. BE SURE all doors, guards and shields are in their proper operating positions BEFORE starting the engine to operate the machine.

CAUTION “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It is also used to alert users of unsafe practices.

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Because of ongoing product improvements, information included in this manual may not exactly match the machine. Manitou Americas reserves the right to modify and improve products at any time without notice or obligation.

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Introduction Machine Orientation

Service Parts

“Right” and “left”, as described in this manual, are determined from a position sitting in the operator’s seat and facing forward.

When ordering service parts, provide complete information about the part and he quantity required.

Also provide the model and serial numbers of the machine. For your safety and continued proper operation, use only genuine service parts.

NOTE: The machine model number is stamped on the right front axle attachment plate, and is also found on the type lable located on the front right side of the machine.

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Safety CHAPTER 1 — SAFETY Use of this machine is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense.

Such hazards include: hillside operation, overloading, load instability, poor maintenance, and using the machine for a purpose for which it was not intended or designed.

This manual and decals on the machine warn of safety hazards and should be read and observed closely.

Before operating the machine, first read and study the safety information in this manual, and the safety information in the Operator’s Manual. Additionally, anyone who operates or works on the machine must be familiar with these safety precautions.

Mustang Manufacturing always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards.

Operators must be alert, however, because some a r e a s c a n n o t b e g u a r d e d o r s h i e l d e d wi t h o u t preventing or interfering with proper operation.

This safety alert symbol means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! This symbol is used throughout this manual an d on the decals on th e machine.

DANGER

WARNING

“DANGER” indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

The machine must be equipped with a FallingObject Protective Structure (FOPS) when the machine is intended for applications where there is a risk of falling objects.

WARNING

Different applications may require optional safety equipment. Be sure you know the work site hazards and equip the machine and the operator as necessary.

The information in this manual does not replace any applicable safety rules and laws. Before operating the machine, learn the rules and laws for your area. Make sure the machine is equipped as required according to these rules/laws.

“WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Some photographs in this manual may show doors, guards and shields open or removed for the purposes of illustration only. Be sure that all doors, guards and shields are in the proper operating positions before starting the engine to operate the machine.

“CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It is also used to alert users of unsafe practices.

It is essential that operators are thoroughly trained in the safe operation of the machine and handling loads.

Operators must not be physically or mentally impaired.

Do not allow minors or unqualified personnel to operate the machine, or to be near the machine unless they are properly supervised. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

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Safety Mandatory Safety Shutdown Procedure

• Mustang loaders are designed and intended to be used only with Mustang attachments and approved attachments. To avoid possible personal injury, equipment damage and performance problems, use only attachments that are approved for use on and within the operating capacity of the machine.

Contact the Mustang Company for information on attachment approval and compatibility with specific machine models. Mustang cannot be responsible if the machine is used with a non-approved attachment.

BEFORE cleaning, adjusting, lubricating, fueling or servicing the machine, or leaving it unattended: 1. Bring the machine to a complete stop on a level surface. Avoid parking on an incline or hillside, but if this is not possible, park across the slope and block the tires.

• Remove all trash and debris from the machine every day, especially in the engine compartment, to minimize the risk of fire.

2. Be sure all working equipment and/or attachments are stopped and the auxiliary valve is in neutral.

3. Lower the lift arm and attachment completely.

• Always face the machine and use the hand holds and steps when entering and exiting the machine.

Do not jump off the machine.

4. Place forward/reverse drive switch (on top of the joystick) into the neutral position.

• Do not use starting fluid (ether).

5. Apply the parking brake.

• Walk around the machine and inspect it before using it. Look for damage, loose or missing parts, leaks, etc.

6. Move the throttle to low idle position and shut off the engine.

• Warn all nearby personnel before starting the machine.

7. Wait for all movement to stop. Turn the ignition key to the “I” or RUN position and move the multipurpose joystick in all directions to verify that the hydraulic system is de-pressurized.

• Check for proper tire pressure in all four tires before operating the machine and add air if necessary.

Improperly pressurized tires adversely affect machine stability. Regularly check wheel fasteners for tightness. See “Maintenance Schedule” on page 18.

8. Turn off the ignition and remove the key.

9. Unfasten the seat belt, remove the ignition key and take it with you. Exit the machine using the hand holds.

• Contact the proper local authorities for utility line locations BEFORE starting to dig. In North America, contact the North American One-Call Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and Canada.

ONLY when these precautions have been taken can you be sure it is safe to proceed. Failure to follow this procedure could result in death or serious injury.

• Before working near power lines (either aboveground or buried cable-type), always contact the power utility and establish a safety plan with them.

Before Starting • Do not modify the Roll-Over Protective Structure (“ROPS”) unless instructed to do so in Mustangapproved installation instructions. Modifications, such as welding, drilling or cutting, can weaken the structure and reduce the protection it provides. A damaged ROPS cannot be repaired – it must be replaced.

• If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces.

• The operator’s area, steps and hand holds must be free of oil, dirt, ice and unsecured objects.

• To ensure safe operation, replace damaged or worn-out parts with genuine Mustang service parts.

• If a lighting system is installed, check its operation before working in darkness.

• If the machine is equipped with a cab, always keep the windshield and windows clean. Poor visibility can cause accidents.

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Safety • Machine stability is affected by: the weight of the load being carried, height of the load, machine speed, turn angle, width of the machine across the tires, abrupt control movements and driving over uneven terrain. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, THROWING THE OPERATOR OUT OF THE SEAT OR MACHINE, RESULTING IN DEATH OR SERIOUS INJURY. Therefore: ALWAYS operate with the seat belt fastened around the operator. Do not exceed the machine’s rated operating capacity, especially when turned, because this reduces the load that will cause the machine to tip over. Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.

• Use warning tag/control lockout procedures during service. Alert others that service or maintenance is being performed by tagging operator’s controls — and other machine areas if required — with a warning notice.

• NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to the controls.

• Replace damaged safety decals and a lost or damaged operator’s manual.

• Terrain and soil conditions at the work site, approaching traffic, weather-related hazards and any above-or below-ground obstacles and hazards should be observed and monitored by all work crew members.

• Never carry riders. Do not allow others to ride on the machine or attachments, because they could fall or cause an accident.

• Read the operator’s manual provided with each attachment used with the machine before starting the engine.

• Always look to the rear, over both shoulders, before backing up.

During Operation

• Only start the engine while seated in the operator’s seat with the seat belt fastened around the operator.

• ALWAYS fasten the seat belt securely and properly.

Never operate the machine without the seat belt fastened around the operator.

• Only operate the controls while seated in the operator’s seat with the seat belt properly fastened.

• Check indicators and displays for normal conditions after starting the engine. Listen for unusual sounds and remain alert for other potentially hazardous conditions.

• Always keep hands and feet inside the operator’s compartment while operating the machine.

• New operators must first operate the machine in an open area away from bystanders. Practice with the controls until the machine can be operated safely and efficiently.

• Do not overload the machine. See “Weights” on page 14 for the load limits.

• Do not raise or drop a loaded bucket or attachment suddenly. Abrupt movements under load can cause serious instability.

• Wear safety goggles, ear and head protection as needed while operating the machine. Operator must wear protective clothing when appropriate.

• Check that attachments are securely fastened to the All-Tach®/Power-A-Tach® hitch before working.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area without adequate ventilation.

Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced.

• Never activate the float function with the bucket or attachment loaded or raised, because this will cause the lift arm to lower or bucket to dump rapidly.

• Do not drive too close to an excavation or ditch. Be sure that the surrounding ground has adequate strength to support the weight of the machine and the load.

• Never allow anyone under a raised lift arm.

Lowering the lift arm or a falling load can result in death or serious personal injury.

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Safety • To avoid tipping, keep loads as low as possible during transport and while turning. Keep the bottom of the bucket or load no higher than wheel axle height during transport and turning.

• Avoid slowing suddenly while carrying a load.

Sudden slowing can cause the load to drop off the attachment or the machine to tip over.

• Slow down the work cycle and use slower travel speeds in congested or populated areas. Use c om mon l y un de r st oo d si g nal s so t ha t o th er members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

• Do not turn the machine when lifting loads. As loads are lifted, a drastic shift in stability can occur, which can greatly increase the possibility of a rollover.

• If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which can only protect the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

• Use a signal person if you cannot see the entire work area clearly, in high traffic areas and whenever the operator’s view is not clear.

• Do not place limbs near moving parts. Severing of body parts can result.

• Do not use the loader to lift or transport people.

• The ROPS must be replaced if a overturn incident occurs. The protection offered by the ROPS will be impaired if it has been damaged in an overturn incident.

• Stay alert for people moving through the work area.

When loading a truck, the operator should always know where the driver is.

• Exposed hydraulic hoses could react with explosive force if struck by a falling or overhead items. NEVER allow hoses to be hit, bent or interfered with during operation. Replace any hoses that are damaged.

Electrical Energy • Stay away from high-voltage lines. Serious injury or death can result from contact or proximity to highvoltage electric lines. The machine does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

Avoiding Rollover Accidents • Operate the controls smoothly to prevent jerking or bouncing. Operate on level, stable surfaces. Load, unload and turn on solid, level ground.

• Depending upon the voltage in the power line and atmospheric conditions, strong current shocks can occur if the bucket is closer than 3 m (10 ft.) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

• Drive up and down inclines, not across them. Drive slowly on inclines. Keep the heavy end of the machine pointed uphill.

• Evenly distribute the load on the attachment. Secure unstable loads so they do not shift or fall.

Service Safety Practices

• Do not make sharp turns on inclines. Avoid steep inclines.

• Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine.

• Use care on loose ground. Loose, soft ground or uneven, broken terrain can cause dangerous sideload conditions and possible tip-over and injury.

• Never attempt to bypass the keyswitch to start the engine. Use only the proper jump-starting procedure explained in “Using a Booster Battery (JumpStarting)” on page 42.

• If you must cross railroad tracks, ditches, curbs or similar surfaces, cross at an angle and drive slowly.

• Stay away from steep edges on loading docks, ramps, ditches, retaining walls and trenches.

• Avoid sharp turns and high speeds while carrying loads. The stability of the machine is greatly reduced during sharp turns. Additionally, the load may shift to the side during turns, greatly increasing the possibility of a rollover.

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Safety • Do not run the engine if repairs are being performed alone. There should always be at least two people working together if the engine must be run during service.

• Never use your hands to search for hydraulic fluid leaks. Instead, use a piece of paper or cardboard.

Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor or gangrene may result.

• Always use adequate tools while working on the machine. Inappropriate tools could break or slip, causing injury, or they may not adequately perform intended functions.

• Always wear safety glasses with side shields when striking metal against metal. In addition, it is recommended that a softer (chip-resistant) material be used to cushion the blow, otherwise, serious injury to the eyes or other parts of the body could result.

• Unless necessary for servicing the engine, do not open the engine cover while the engine is running.

• Do not use the machine when maintenance is scheduled to be performed. Postponing maintenance can result in a serious reduction of the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

• Do not smoke or have any spark- or flameproducing equipment or materials in the area while filling the fuel tank or working on the fuel or hydraulic systems.

• Only tow the machine as described in the Operator’s Manual.

• Do not attempt to loosen or disconnect any hydraulic lines, hoses, fittings, covers or caps without first relieving hydraulic circuit pressure. Relieve hydraulic pressure by performing the Mandatory Safety Shutdown Procedure (page 4) and slowly loosening the hydraulic reservoir filler cap. Be careful not to touch any hydraulic components that have been in recent operation, because they can be hot and cause burns.

Battery Hazards • Use the battery disconnect switch, or disconnect the ground cable from the negative battery terminal, to disconnect the battery before performing electrical service or electrical welding on the machine.

• When disconnecting at the battery terminals, remove the cable connected to the negative terminal first. When installing a battery, connect the positive terminal cable first.

• Do not attempt to remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, engine coolant is extremely hot and under pressure. Always wait for the engine to cool before attempting to relieve pressure and remove the radiator cap.

Failure to heed this warning could result in severe burns.

• Sparks and open flames can set off explosive batter y gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight.

Contact between a loose terminal and post can create an explosive spark.

• Never rely on jacks or other similar supports if it is necessary to elevate the machine for service. Use only solid support blocking.

• When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

• Refer to the Parts Manual for information about assembly of components. Always use the correct parts and the proper torques — incorrect fastener connections can dangerously weaken assemblies.

• Never jump-start the machine if it has a frozen battery. The battery could explode. Thaw a frozen battery before charging it or attaching jumper cables.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area unless there is adequate ventilation.

• Flush eyes with water for 10-15 minutes if battery acid is splashed in the face. Anyone swallowing battery acid must have immediate medical aid. Call the Poison Control Center at 1-800-222-1222 in the United States.

• Operators should also be aware of any open windows, doors or duct work into which exhaust gases may be carried, exposing others to danger.

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Safety Fire Hazards

Crystalline Silica Exposure

• The machine must be cleaned on a regular basis to avoid the buildup of flammable debris, such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, creates a fire hazard.

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational Safety and Health (NIOSH) indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime.

NIOSH recommends an exposure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr workday during a 40-hr work week. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection, and regular medical examinations for exposed workers.

• The machine has several components that operate at high temperatures under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce spar ks. These conditio ns mak e it extr emely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

• Add fuel, oil, antifreeze and hydraulic fluid to the machine only in well ventilated areas. The machine must be parked with controls, lights and switches turned off. The engine must be turned off before fueling.

• Do not smoke while filling the fuel tank, while working on the fuel or hydraulic systems, or while working around the battery.

• Take care to avoid spilling combustible fluids, such as oil or fuel, on a hot engine.

• Static electricity can produce dangerous sparks at the fuel-filling nozzle. In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the fuel filler neck, to provide a ground. Be sure that a ground wire is connected from the machine to the service truck before fueling begins.

• Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured • It is recommended that a 2.27 kg (5 lbs.) or larger, multi-purpose “A/B/C” fire extinguisher be mounted withi n r eac h of the ope rato r. Chec k the f ir e extinguisher periodically and be sure that work site crew members are trained in its use.

• Oil leaks can ignite on hot components. Repair any damaged or leaking components before using machine.

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Safety Safety Decals Refer to the Operator’s and Parts Manuals for a detailed description of safety-associated decals applied to the machine.

Hazard and Hazard Avoidance Symbols

Safety Hazard

Fire Hazard

Run-Over Hazard

Injected Fluid Hazard

Hot Liquids Hazard

Poisonous Vapors Hazard

No Smoking

No Open Flames

Read Operator’s Manual

Wear Seatbelt

Keep Distance

Wear Eye Protection

Avoid Power Lines

Remove Key

Crush Hazard

Read Maintenance/Service Information

Crush Hazard

Hot Surface Hazard

Safety Lock Rotating Fan Keep Away

Falling Object Hazard

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Safety NOTES

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Specifications CHAPTER 2 — SPECIFICATIONS Fluid Capacities/Lubricants Application Diesel Engine Oil Specification Season/Temp. Range Capacity Diesel Fuel Specification

Season/Temp. Range Capacity Hydraulic Oil System/Tank Hydraulic Oil Specification Season/Temp. Range Capacity Biodegradable Oil Specification Season/Temp. Range Capacity Axle Oil Hubs (each) Front Center Rear Center Grease Specification Season/Temp. Range Capacity Engine Coolant System/Radiator Specification Season/Temp. Range Capacity Windshield Washer Specification Season/Temp. Range Capacity Air Conditioning Refrigerant

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AL 400 Series

AL 500 Series

API CD or Higher (United States) ACEA E-3, E-4, E-5 (European Union) SAE 10W-30: -20°C (-4°F) to 30°C (86°F) SAE 15W-40: -15°C (5°F) to 40°C (104°F) SAE 20W-50: -10°C (14°F) to 50°C (122°F) 7.4 L (2.0 gal.)

LSD or ULSD (low sulfur or ultra-low sulfur), below 500 PPM. Up to 5% (B5) mixture of BioDiesel allowed.

1-D or 2-D, ASTM D975-94 (United States) EN 590:96 (European Union) ISO 8217 DMX (International) BS 2869-A1 or A2 (United Kingdom) Dependent on Outside Temperatures 67 L (17.7 gal.)

UTTO Fluid (Mobil 424 or equivalent) Year-Round 40 L (10.6 gal.)

Panolin BioFluid LS Year-Round 42 L (11 gal.)

0.4 L (0.4 qt.) UTTO Fluid (Mobil 424 or equivalent) 2.5 L (2.6 qt.) UTTO Fluid (Mobil 424 or equivalent) 3.2 L (3.4 qt.) UTTO Fluid (Mobil 424 or equivalent) KF2K-25 Lithium Year-Round As Required Long-life coolant ASTM D4985, D6210 (United States) SAE J814D, J1941, J1034 or J2036 (International) Year-Round 6.4 L (6.8 qts.)

—

11

Windshield Washer Fluid Year-Round 1.3 L (1.4 qts.)

737 g. (26 oz.) R134a

50940008/BP0311

Specifications Dimensions

X 400 Series Y J K

N

L

F

M H Z BB E

S

AA

D B A

C

F

F G

W

R

U

T

V P CC

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Specifications

Ref. A B C D E F

Description Length (with bucket on ground) Length (without bucket) Front Wheel Center to Pivot Point Wheelbase Rear Overhang Height to top of ROPS/Cab

G

Folded 2-Post ROPS Height

H J K L M N P R

Hood Height Maximum Reach Height Bucket Hinge Pin Height Ground Plane to Bucket Edge Height Dump Clearance at Full Height Dump Reach at Full Height Width Over Tires ROPS Width

S T U V W X Y Z AA BB CC

Ground Clearance Turning Radius w/Bucket Outer Turning Radius Inner Turning Radius Articulation Angle from Center Rollback Angle at Height Max. Dump Angle at Full Height Bucket Rollback Angle on Ground Attachment Pivot Clearance Wheel Radius Bucket Width (standard)

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Millimeters (Inches) unless otherwise noted AL 400 Series AL 500 Series 2-Post 4-Post 2-Post 4-Post ROPS ROPS ROPS ROPS/ Cab 4224 (166.3) 4511 (177.6) 3550 (139.8) 3790 (149.2) 570 (22.4) 723 (28.5) 1617 (63.7) 1741 (68.5) 1184 (46.6) 2474 2310 2473 2310 (97.4) (90.9) (97.4) (90.9) 1895 — 1895 — (74.6) (74.6) 1521 (59.9) 3550 (139.8) 3617 (142.4) 3002 (118.2) 3055 (120.3) 2770 (109.1) 2860 (112.6) 2215 (87.2) 2300 (90.6) 267 (10.5) 445 (175) 1195 (47.0) 1380 (54.3) 985 1030 985 1030 (38.8) (40.8) (38.8) (40.8) 246 (9.7) 265 (10.4) 3123 (123.0) 3220 (126.8) 2643 (104.1) 2750 (108.3) 1365 (53.7) 45° 35° 47° 53° 40° 203 (8.0) 212 (8.3) 385 (15.2) 405 (15.9) 1524 (60.0)

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Specifications Weights and Capacities SAE Weights and Capacities AL 500 Series Description

Operating Weight Shipping Weight Rated Operating Capacity Static Tipping Loads Standard Bucket - Straightb Standard Bucket - SAE J732 Turn

b

Standard Pallet Forks - Straightc Standard Pallet Forks- SAE J1197 Turn

c

2-Post ROPS 3307 (7290) 3182 (7016) 1118 (2466)

kg (lbs.)a AL 500 Series 4-Post ROPS 3357 (7400) 3235 (7131) 1145 (2524)

Cab 3452 (7610) 3380 (7451) 1165 (2568)

2237 (4932)

2290 (5049)

2330 (5136)

1771 (3904)

1800 (3969)

1860 (4101)

1634 (3602)

1682 (3708)

1703 (3755)

1278 (2817)

1333 (2939)

1352 (2981)

a. Measured on firm and level ground. Equipped with full fluids, counterweight and 75 kg (165 lbs.) operato, 33x15.5-16.5 tires, fluid-filled rear tires (air-filled rear tires have reduced capacities) and counterweight. b. Equipped w/ 1524 mm (60”) dirt/construction bucket. c. Equipped w/ pallet forks with 1067 mm (42”) tines and 533 mm (21”) load center.

ISO Weights and Capacities AL 500 Series and AL 400 Series Description

Operating Weight Shipping Weight Rated Operating Capacity

kg (lbs.)a AL 400 Series 2-Post 4-Post ROPS ROPS 2740 2790 (6041) (6151) 2618 2668 (5772) (5882) 901 901 (1987) (1987)

2-Post ROPS 3054 (6732) 3021 (6660) 1118 (2466)

AL 500 Series 4-Post ROPS 3106 (6847 3071 (6770) 1145 (2460)

3267 (7202) 3166 (6980) 1165 (2560)

1802 (3973) 1181 (2603) 1332 (2937) 874 (1927)

1993 (4394) 1357 (2992) 1532 (3377) 1041 (2295)

1993 (4394) 1357 (2992) 1532 (3377) 1041 (2295

1993 (4394) 1357 (2992) 1532 (3377) 1041 (2295

Cab

Static Tipping Loads Standard Bucket - Straightb Standard Bucket - ISO 6016 Turnb Standard Pallet Forks - Straightc Standard Pallet Forksc - ISO 6016 Turnc

1802 (3973) 1181 (2603) 1332 (2937) 874 (1927)

a. Measured on firm and level ground. Equipped with full fluids and 75 kg (165 lbs.) operator.

AL 500 Series equipped with 31x15.5x16.5 tires.

AL 400 Series equipped with 12 x 16.5. b. Equipped w/ 1524 mm (60”) dirt/construction bucket. c. Equipped w/ pallet forks with 1000 mm (39”) tines and 500 mm (20”) load center.

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Specifications Engine Description

AL 400 Series

AL 500 Series

Manufacturer

Yanmar

Type

4-cylinder, 4-cycle, In-line, Water-cooled Diesel

Engine Model

4TNV88-BKGWL

Displacement

2190 cc (133.6 cid)

Cyl. Bore x Stroke

88 x 90 mm (3.5 x 3.5”)

Net Power

35 kW (47 hp)

Engine Speed

2800 rpm

Combustion

Direct Injection

Starting Aid

Pre-heating Glow Plug

Max. Travel Speed

20 km/h (12.4 mph)

Hydraulics Description Work Hydraulics Hydraulic System System Pressure Drive Hydraulics Hydraulic System System Pressure Reservoir Capacity Bucket Breakout Force

AL 400 Series

AL 500 Series 57 L/min (15 gpm) 207 bar (3000 psi) 117 L/min (31 gpm) 410 bar (5946 psi) 42 L (11 gals.)

10749 lbf (47.8 kN)

Electrical System Description

AL 400 Series

Alternator Starter Battery

AL 500 Series 12V - 55 A 12V - 2.3 kW 850 CCA - 74 Ah

Sound Levels Description A-Weighted Sound Power Level A-Weighted Sound Pressure Level at Operator’s Position

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AL 400 Series

AL 500 101 dB(A) 91 dB(A)

50940008/BP0311

Specifications Wheels Description Wheel Fastener Torque

AL 400 Series

AL 400 Series 319 Nm (235 lbf-ft)

NOTE: See tire sidewall for inflation pressures, except where noted.

IMPORTANT: 500 Series units are equipped standard with fluid-filled rear tires. Air-filled rear tires significantly reduce load capacities.

FOPS Description FOPS Rating (per ISO 3449)

AL 400 Series

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16

AL 500 Series Level 1

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Maintenance — Maintenance Introduction CHAPTER 3 — MAINTENANCE Maintenance Introduction

CAUTION

Proper care and service improves machine operational readiness and service life. Perform maintenance as indicated in the operator’s manual provided with the machine.

Allow only trained and authorized personnel, with full knowledge of safe procedures, to perform machine maintenance and service.

WARNING

IMPORTANT: Malfunctions caused by unauthorized modifications and alterations are not covered under warranty.

Read and understand the Safety chapter, starting on page 3, before servicing the machine. Follow all applicable warnings and instructions. Check for correct function after servicing the machine.

Failure to follow instructions can result in injury or death.

Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury. Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Do not use the machine when maintenance is due.

Postponed maintenance can result in a serious reduction of the service life of the machine, costly equipment failures, and contribute to unsafe operating conditions.

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Maintenance — Maintenance Schedule Maintenance Schedule

CAUTION

Use the following table with the service procedures included in the this chapter.

IMPORTANT: The following maintenance intervals apply to average operating conditions and loads.

Under extreme operating conditions, more frequent maintenance may be required. The hour meter indicates total operating time. Use the hour meter to determine when scheduled maintenance is due.

Do not postpone maintenance. Postponed maintenance can result in a serious reduction of the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

Check, Clean and Inspect Maximum Interval Service Procedure Clean machine Check machine for general wear/damage Check attachments for wear/damage Check engine oil level and condition Check coolant level and condition Check brake fluid level Check hydraulic fluid level Check windshield washer system

10 Hours (or daily)

50 Hours (or weekly)

Monthly

250 Hours (or every six months)

500 Hours (or annually)

x x x x x x x x

Check exhaust for excessive smoke emission Check air filter indicator; replace filter if necessary Check tire condition and pressure

x

Check wheel fasteners for damage/tightness

xa

Check hydraulic cylinder piston rods for wear/damage; clean if necessary Check ROPS structure (all fasteners must be installed and securely tightened) Check coolant system for leaks, dirt and debris; hoses for cracks/damage Check battery electrolyte level (if applicable)

x

x x x

x x x

Check engine and engine mounts

x

Check for hydraulic system for leaks, proper routing Check anti-freeze mixture

x x x x x

Check V-belt tension and condition Check engine cover lock Check engine idle Check hinge pins, joint bushings, pivot bolts and bearings Check for exhaust system damage

x x x x x x

Clean battery terminals Replace fuel filter Check timing belt Check fuel injectors Check electrical system for damage, wiring routing

x

a. Check before first use and every two hours after tightening until fastener torque stabilizes; every month thereafter.

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Maintenance — Maintenance Schedule Leakage Check Maximum Interval Service Procedure Check engine for oil/coolant leaks Check cooling system for leaks

10 Hours (or daily)

50 Hours (or weekly)

Monthly

250 Hours (or every six months)

500 Hours (or annually)

250 Hours (or every six months)

500 Hours (or annually)

x x x x

Check hydraulic system for leaks Check axles for leaks

Lubrication and Filter Changes Maximum Interval Service Procedure Lubricate grease zerks according to lubrication diagram Lubricate all levers, cables and hinges with oil Lubricate driveshaft universal and slip joint

10 Hours (or daily)

50 Hours (or weekly)

Monthly

x x x

Change engine oil/filter

xa

x x x x x

Change axle oil Change hydraulic fluid and return filter Change fuel filter; clean pre-filter Change coolant

xb

Change cabin air filter a. After first 50 hours; every 250 hours thereafter. b. Replace if needed.

Functional Check Maximum Interval Service Procedure

10 Hours (or daily)

Check seat belt

x

Check brake inch pedal and parking brake functions; adjust if necessary Check steering

x

Check windshield wipers Check instruments, indicator lights and audible warning devices Check lighting system (if installed)

PRINTED IN U.S.A.

50 Hours (or weekly)

Monthly

250 Hours (or every six months)

500 Hours (or annually)

x x x x

19

50940008/AP0311

Maintenance — Engine Maintenance Engine Maintenance

Changing Engine Oil and Filter Change the engine oil and filter after the first 50 hours of use; every 250 hours thereafter.

WARNING Allow engine and hydraulic system components to cool before performing maintenance.

Engine Oil Engine Oil Level Check 1. Position the machine on a level surface, if necessary.

2. Perform the “Mandatory Procedure” on page 4.

Safety

1

Shutdown

Figure 2 – Engine Access Panel

3. Wait until the machine has cooled down. See “Service Safety Practices” on page 6.

1. Engine Access Panel

4. Open engine cover.

1. Position the machine on a level surface, if necessary.

2. Perform the “Mandatory Procedure” on page 4.

1

Safety

Shutdown

3. Wait for the machine to cool down.

4. Remove the engine access panel (1, Figure 2).

2 NOTE: Removing engine access panel requires two people.

Figure 1 – Oil Dipstick and Fill Cap 1. Oil Dipstick 2. Oil Fill Cap

5. Remove the dipstick (1, Figure 1). Wipe dipstick with a clean cloth.

6. Insert the dipstick (1, Figure 1) until it is fully inserted, and remove.

7. Read markings on the dipstick, markings represent FULL and LOW (add oil) levels.

See “Maintenance Schedule” on page 18 for the service interval for replacing the engine oil and filter.

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Maintenance — Engine Maintenance 9. Reinstall and tighten the drain plug.

5. Position a waste oil collection container to catch draining oil (1, Figure 3).

10. Reinstall the engine access panel (1, Figure 2).

NOTE: Reinstalling engine access panel requires two people.

11. Remove the oil fill cap (2, Figure 1) and add the recommended oil. See “Fluid Capacities/ Lubricants” on page 11.

12. Start the engine and let it run for several minutes at low idle. Stop the engine. Wait until the machine has cooled down.

1

13. Check for leaks at the oil filter and drain plug.

Check the oil level. If necessary, add oil until the oil level is at the top mark on the dipstick.

Figure 3 – Waste Oil Collection Container 1. Waste Oil Collection Container

NOTE: Dispose of waste engine oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste engine oil onto the ground or down a drain.

6. Remove the drain plug (1, Figure 4) from the oil pan and allow the oil to drain into the waste oil collection container.

1

Figure 4 – Oil Pan Drain Plug 1. Oil Pan Drain Plug

7. Remove the oil filter, using a filter wrench as necessary.

8. Put clean oil on the new oil filter gasket. Install the filter and tighten 3/4 rotation past the point where the gasket contacts the filter head.

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50940008/AP0311

Maintenance — Air Cleaner Air Cleaner

3. Clean any debris from the housing. Leave the inner filter element installed during this step to prevent debris from entering the engine intake manifold.

IMPORTANT: Do not operate the engine without the air cleaner components installed or damage to the engine could occur. Failure to follow air cleaner servicing instructions can also cause engine damage.

The air cleaner consists of an outer (primary) filter element, an inner (secondary) filter element, an air filter restriction indicator and a dust valve. If the air cleaner becomes restricted, the air filter restriction indicator (1, Figure 5) turns red to warn the operator that the element(s) require service. Push the reset button located on the end of the indicator after installing a clean filter element(s). Pinching the dust valve (2, Figure 5) opens a slit at the end of the valve, allowing accumulated dust in the end of the element cover to drop out without removing the cover.

1

Only replace the inner element every third time the outer element is replaced, unless the outer element is damaged or the inner element is dirty.

4

3

2

Be sure that the restriction indicator, air cleaner intake hose, clamps and mounting bracket hardware are properly tightened.

6

Accessing the Outer and Inner Filter Elements 1. Perform the “Mandatory Procedure” on page 4.

Safety

5

Shutdown

2. Open the engine cover.

7

3. Unlatch the clamps on the air cleaner housing and remove the element cover.

4. Clean any debris from the cover.

Changing the Outer Filter Element 1. Perform the “Mandatory Procedure” on page 4.

Safety

Figure 5 – Dual-Element Air Cleaner Shutdown

1. Air Filter Restriction Indicator 2. Dust Valve 3. Element Cover 4. Clamp 5. Air Cleaner Housing 6. Outer Filter Element 7. Inner Filter Element

2. Carefully remove the outer filter element. Do not remove the inner filter element unless it is to be replaced. See “Changing the Inner Filter Element” on page 23.

NOTE: Cleaning the outer filter element is not recommended; replace instead.

50940008/AP0311

4. Install the new outer filter element.

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Maintenance — Engine Cooling System Changing the Inner Filter Element

Engine Cooling System

1. Complete all steps in “Accessing the Outer and Inner Filter Elements” on page 22.

Checking Coolant Level

2. Remove the outer filter element.

1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

3. Before removing the inner filter element from the housing, clean away any dirt built up in the housing.

Leave the inner filter element installed during this step to prevent debris from entering the engine intake manifold.

2. Open the engine cover (2, Figure 6). Check the coolant level in the expansion reservoir (1, Figure 6). The expansion reservoir must be 1/3 to 1/2 full for a cold engine and 2/3 to 3/4 full for a hot engine.

4. Remove the inner filter element.

5. Check the inside of the housing for any damage that may interfere with the elements.

1

6. Be sure that the element sealing surfaces are clean.

7. Install the new inner filter element.

8. Reinstall/replace the outer filter element.

9. Latch the clamps to secure the element cover.

2

10. Check the hose connections and be sure they are all clamped and tightened properly.

Figure 6 – Cooling System (AL 500 Series shown) 1. Expansion Reservoir 2. Engine Cover

WARNING Do not remove the cap when the coolant is hot.

Serious burns may occur.

3. Slowly loosen the cap and allow pressure to escape.

4. Completely remove the cap and add coolant as necessary. See “Fluid Capacities/Lubricants” on page 11 for coolant specification.

5. Reinstall the radiator cap.

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50940008/AP0311

Maintenance — Engine Cooling System Cleaning Cooling System 1. Perform the “Mandatory Procedure” on page 4

5. Remove the engine access panel. See “Changing Engine Oil and Filter” on page 20, step 4.

Safety

Shutdown

6. Position a collection container, capacity 8 liters (2 gallons), underneath the radiator drain.

2. Allow engine to cool.

7. Open radiator drain valve (1, Figure 8). Drain valve is located at bottom of radiator, above frame member. Drain valve opening faces the front of the machine.

3. Open engine cover.

4. Clean radiator and oil cooler by blowing air or high pressure water through the fins.

.

IMPORTANT: High pressure may bend the fins.

Proceed with caution. Blow air in opposite direction of fan direction to dislodge debris.

Draining/Refilling Cooling System 1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

2. Allow engine to cool.

1

3. Open engine cover.

WARNING

Figure 8 – Cooling System (AL 500 Series shown)

Do not remove radiator cap when the coolant is hot. Serious burns may occur.

1. Drain Plug

8. Drain the coolant into the container.

4. Slowly loosen radiator cap (1, Figure 7) and allow pressure to escape. Remove cap.

IMPORTANT: Always dispose of coolant according to environmental laws. DO NOT pour onto the ground or down a drain.

9. Close radiator drain valve.

1

10. Replace engine access cover.

11. Completely fill the radiator with premixed coolant.

See “Fluid Capacities/Lubricants” on page 11 for coolant specification.

12. Reinstall radiator cap.

13. Complete all steps in “Checking Coolant Level” on page 23.

14. Run the engine until it is at operating temperature.

Figure 7 – Radiator Cap (AL 500 Series shown)

15. Perform the “Mandatory Procedure” on page 4.

1. Radiator Cap

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Safety

Shutdown

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Maintenance — Fuel System 16. Allow the engine to cool.

4. Add fuel into fuel filler neck (2).

17. Open the engine cover.

IMPORTANT: Only use low sulfur or ultra-low sulfur diesel fuel. See “Fluid Capacities/Lubricants” on page 11.

18. Check the coolant level in the expansion reservoir.

The reservoir must be 1/3 to 1/2 full for a cold engine and 2/3 to 3/4 full for a hot engine.

Changing Fuel Filter 1. The fuel filter (1, Figure 10) is located in the fuel line before the fuel pump. Access the fuel filter by opening the engine cover and tilting the operator’s platform. See “Tilting the Platform” on page 61.

Replace the fuel filter at regular intervals specified.

See “Maintenance Schedule” on page 18.

Fuel System

WARNING Only use proper grade diesel fuel. See “Fluid Capacities/Lubricants” on page 11. Diesel fuel is flammable. Keep the machine away from open flames. Do not smoke when refueling or when working on the engine. Stop the engine before fueling. Failure to follow instructions can cause fire and result in injury or death.

Adding Fuel 1. Perform the “Mandatory Procedure” on page 4.

Safety

1

Shutdown

2. High quality diesel fuel is required for correct engine performance. See “Fluid Capacities/ Lubricants” on page 11.

Figure 10 – Fuel Filter (AL 500 Series shown) 1. Fuel Filter

1 The fuel filter is located on the left side of the loader.

1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

2. Shut off the fuel supply by turning the fuel shut-off valve on top of the water separator to OFF.

2

3. Remove the fuel filter.

Figure 9 – Fuel Fill Neck (AL 500 Series shown)

4. Lubricate new fuel filter gasket with diesel fuel.

5. Install and tighten the filter 3/4 turn past point the where the gasket contacts the filter head.

1. Fuel Cap 2. Fuel Filler Neck

6. Turn shut-off valve on water separator to ON. 3. Remove fuel cap (1, Figure 9).

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50940008/AP0311

Maintenance — Fuel System 7. The engine is self-priming. To remove air before starting, turn the ignition key to the ON position for 30 seconds.

ON

Water Separator Maintenance

OFF 1

The water separator contains a red indicator ring that will float on top of any accumulated water. Under normal conditions this ring sits at the bottom of the separator. If the red ring is somewhere between the bottom and the white ring (2, Figure 11), then the accumulated water must be drained.

1. Perform the “Mandatory Procedure” on page 4.

Safety

2

Shutdown

2. To view the water separator, use the slot in front of the right-rear tire, near the step.

3 Figure 11 – Water Separator

3. Access the water separator underneath the loader, near the right-rear wheel. Check for water in water separator by checking level of float in water separator bowl. If water is present, complete steps 4-7.

1. Fuel Shut-off Valve Lever 2. Indicator Ring 3. Drain Plug

4. Turn the fuel shut-off valve lever (1, Figure 11) on the water separator to the OFF position.

5. Place a container underneath the drain plug.

Loosen the plug until water begins draining. Allow water to drain until the indicator ring returns to the bottom of the water separator.

6. Tighten the drain plug and discard fuel/water according to environmental laws. DO NOT pour the fuel/water onto the ground or down a drain.

7. Turn the fuel shut-off valve lever (1) on the water separator to the ON position.

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Maintenance — Checking and Adjusting V-belt Tension Checking and Adjusting V-belt Tension 1. Perform the “Mandatory Procedure” on page 4.

Safety

Air Conditioning V-belt Inspect and service the air conditioning V-belt (X, Figure 13) the same as directed in Checking and Adjusting V-belt Tension.

Shutdown

To adjust the air conditioning V-belt tension 2. Open the engine cover.

1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

2. Open the engine cover.

3 2

3

1 1

Figure 12 – V-belt Tension 2

1. V-belt 2. Adjustment Bolt 3. Alternator

Figure 13 – Air Conditioning V-belt

3. Inspect the V-belt (1, Figure 12) for damage.

Replace if damaged or worn.

1. Air Conditioning V-belt 2. Adjustment Bolt 3. Alternator

4. Press on the V-belt (1) to check deflection. The belt should deflect no more than 8 mm (5/16").

3. Inspect the V-belt (1, Figure 13) for damage.

Replace if damaged or worn.

5. If deflection is more than 8 mm (5/16"): Loosen the adjustment bolt (2) and rotate the alternator (3) outward until V-belt tension is correct. Tighten bolt (2) and re-check V-belt tension.

4. Press on the V-belt (1) to check deflection. The belt should deflect no more than 8 mm (5/16").

5. If deflection is more than 8 mm (5/16"): Loosen the adjustment bolt (2) and rotate the air conditioning compressor (3) outward until V-belt tension is correct. Tighten bolt (2) and re-check V-belt tension.

CAUTION Overtightening the V-belt can cause severe damage to the compressor and the deflection pulley.

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50940008/AP0311

Maintenance — Air Conditioning Maintenance Air Conditioning Maintenance

4. Remove the blue cap (1, Figure 14) from the lowside air conditioning port. Connect the low-pressure air conditioning gauge to the low-side port.

CAUTION

5. Remove the red cap (2) from the high-side air conditioning port. Connect the high-pressure air conditioning gauge to the high-side port.

The air conditioning system must be repaired, serviced and filled with refrigerant only by trained staff and a workshop authorized in air conditioning maintenance.

6. Purge air from the system and add 26 oz. (737 g) of R134a refrigerant.

7. After filling, remove the air conditioning gauges from the ports, and replace the caps back onto the port.

Air Conditioning System Charging 1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

NOTE: Replace the blue cap on the low-side port (1), and the red cap on the high-side port (2).

2. Open the engine cover.

8. Start the machine and turn on the air conditioning system. allowthe machine to run for a couple of minutes at full throttle and check for unusual sounds.

3. Remove the blue cap (1, Figure 14) from the lowside air conditioning port. Connect the low-pressure air conditioning gauge to the low-side port.

9. Cool air should come out of the air vents after a short while.

10. Stop the engine. Remove the ignition key and take it with you.

1

11. Open the engine cover and inspect for damage or malfunctions. Troubleshoot/repair if necessary.

12. Check air conditioning V-belt tension and adjust if necessary.

Air Conditioning Compressor Service For air conditioning compressor service information, refer to the air conditioning compressor service document, part number 50940007.

2

Figure 14 – Air Conditioning System Ports 1. Low-Side Port (Blue Cap) 2. High Side Port (Red Cap)

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Maintenance — Hydraulic System Maintenance Hydraulic System Maintenance

6. Slowly remove the oil fill cap (2, Figure 15). Allow the pressure to escape before completely removing the cap.

WARNING

7. Add hydraulic fluid as required. See “Fluid Capacities/Lubricants” on page 11.

Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed, or gangrene may result.

8. Reinstall the oil fill cap.

Changing Hydraulic Oil and Filter Replace the hydraulic oil if it becomes contaminated, after major repairs, and after 500 hours or one year of use.

Hydraulic Oil

1. Perform the “Mandatory Procedure” on page 4

Checking Hydraulic Oil Level 1. Perform the “Mandatory Procedure” on page 4.

Safety

Safety

Shutdown

2. Open the hood.

Shutdown

3. Slowly remove the oil fill cap (2, Figure 15). Allow the pressure to escape before completely removing the cap.

2. Completely lower the lift arm and attachment.

3. Open the hood.

4. Position a waste oil collection container, capacity 45 liters (11 gallons), underneath the hydraulic oil reservoir.

4. Check the hydraulic oil level by removing the dipstick (1, Figure 15), located on the left in the engine compartment.

1

3

1

Figure 16 – Hydraulic Oil Drain Plug (AL 400 Series shown)

2

1. Drain Plug

Figure 15 – Hydraulic Oil Service (AL 500 Series shown)

IMPORTANT: Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

1. Hydraulic Oil Dipstick 2. Hydraulic Oil Fill Cap 3. Hydraulic Oil Filter Cover

5. Remove the drain plug (1, Figure 16) and allow the oil to completely drain.

5. If hydraulic oil is required, allow the system to cool.

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50940008/AP0311

Maintenance — Planetary Axles Planetary Axles

6. Unscrew the filter cover (3, Figure 15).

Changing Planetary Axle Oil Replace the oil in the axles if it becomes contaminated, after the first 500 hours of service, and after 1500 hours or annually thereafter.

1. Warm the axles up to operating temperature.

2. Perform the “Mandatory Safety Shutdown Procedure” on page 4. The machine must be parked on a level surface.

1

3. Complete the “Changing Axle Wheel-Hub Oil” and the “Changing Axle Center Oil” procedures.

Changing Axle Wheel-Hub Oil Figure 17 – Hydraulic Oil Service (AL 500 series model shown)

NOTE: Removing the tires and raising the machine on jackstands can make hub oil changing easier. See “Raising Machine for Drive System Troubleshooting” on page 161.

1. Hydraulic Oil Filter

1. Rotate the oil drain/fill plugs (1, Figure 18) on the wheel hubs so they are positioned at the top as shown in the figure. Thoroughly clean the area around the plugs and slowly loosen and remove the plugs.

7. Remove the old filter element (1, Figure 17).

8. Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber gasket of the new filter element (1, Figure 17).

9. Install the new filter element (1, Figure 17).

10. Reinstall the drain plug.

1

11. Reinstall the filter cover.

12. Refill the reservoir until the oil is between the two lines on the dipstick (1, Figure 15).

13. Start the engine and operate the hydraulic controls.

14. Stop the engine and check for leaks at the hydraulic oil filter and reservoir drain plug.

15. Check the oil level and add oil if necessary.

Figure 18 – Wheel-Hub Oil Drain Plug Removal Position 1. Wheel-Hub Oil Drain/Fill Plug

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Maintenance — Planetary Axles 2. Position a waste oil collection containers, capacity 0.5 liters (0.5 quarts) each, underneath the wheel hubs to catch oil as it drains.

1

2 1

Figure 20 – Wheel-End Axle Oil Level Check

Figure 19 – Wheel-Hub Oil Drain Position

1. Wheel-Hub Oil Fill

1. Wheel-Hub Oil Drain

5. Add oil through the holes to the level line (2) stamped on the hub and shown in Figure 20. See “Fluid Capacities/Lubricants” on page 11 for the specific oil type and grade.

IMPORTANT: Always dispose of waste oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

6. Thoroughly clean the oil drain/fill plugs. Replace the plugs with new O-rings and tighten to 70 Nm (52 lbf.-ft.).

3. Rotate the oil drain holes (1, Figure 19) on the wheel hubs so they are positioned at the bottom as shown in the figure. Allow the oil to completely drain from the hubs.

4. Rotate the holes on the wheel ends so they are positioned to the side as shown in Figure 20.

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Maintenance — Brake Fluid Reservoir Changing Axle Center Oil NOTE: Remove the optional counterweight, if it is installed.

5. Add oil through the oil fill holes (1, Figure 21) until it reaches the bottom of the holes. See “Fluid Capacities/Lubricants” on page 11 for the specific oil type and grade.

1. Thoroughly clean the area around the axle center fill plugs (1, Figure 21) and slowly loosen and remove the plugs.

6. Thoroughly clean the axle center oil fill plugs (1, Figure 21). Replace the plugs with new O-rings and tighten to 70 Nm (52 lbf.-ft.).

Brake Fluid Reservoir Front Axle

Checking Brake Fluid Reservoir Level 1. Perform the “Mandatory Procedure” on page 4.

Safety

Shutdown

2. Open the engine hood.

3. The brake fluid reservoir (H, Fig. 22) is located against the operator platform at the front of the engine compartment.

1 Rear Axle

G

2 H

Figure 21 – Axle Center Oil Level Check 1. Axle Center Oil Fill 2. Axle Center Oil Drain

2. Position a waste oil collection containers, capacity 2.5 liters (2.6 quarts) front and 3.2 liters (3.4 quarts) rear, underneath the axle centers to catch oil as it drains.

Figure 22 – Brake Fluid Reservoir

IMPORTANT: Always dispose of waste oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

4. Carefully remove the brake fluid reservoir fill cap (G). Be careful not to allow dirt to fall into the reservoir.

3. Thoroughly clean the area around the axle center drain plugs (2, Figure 21) and slowly loosen and remove the plugs. Allow the oil to completely drain from the axle centers.

5. The brake fluid reservoir fluid level should not fall below 1/2 full. Add automatic transmission fluid as required.

4. Thoroughly clean the axle center oil drain plugs.

Replace the plugs with new O-rings and tighten the plugs to 70 Nm (52 lbf.-ft.)

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Maintenance — Wheels and Tires Wheels and Tires

Tires

WARNING

Wheel Fasteners Wheel fastener torque must be checked before initial operation and every two hours thereafter until the wheel mounting hardware torque stabilizes. Torque the wheel fasteners in the order shown (Figure 23). When tires are removed and replaced, this procedure must be repeated. See “Wheels” on page 16 for wheel fastener torque specifications, wheel rim dimensions and wheel offset measurements.

Inflating or servicing tires can be dangerous. When possible, trained personnel should service and mount tires. To avoid possible death or serious injury, follow the safety precautions below.

To keep tire wear even, rotate the tires from front to rear and rear to front.

IMPORTANT: Keep the same size tire on each side of the loader to prevent excessive wear on tires, chains, or other damage. If different sizes are used, tires will be turning at different speeds, causing excessive wear.

The tread bar of all tires should face the same direction.

1 3 6

• Be sure the rim is clean and free of rust. Lubricate the tire beads and rim flanges with a soap solution.

Do NOT use oil or grease.

• Use a clip-on tire chuck with remote hose and gauge, allowing you to stand clear while inflating the tire.

5

• Never inflate beyond 35 psi (2.4 bar) to seat the beads. If the beads have not seated by the time the pressure reaches 35 psi (2.4 bar), deflate the tire, reposition the tire on the rim, lubricate both parts and re-inflate. Inflation pressure beyond 35 psi (2.4 bar) with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury.

4 2 Figure 23 – Wheel Fasteners Tightening Order (AL 500 Series shown)

• After seating the beads, adjust the inflation pressure to the recommended operating pressure.

• Do not weld, braze or otherwise attempt to repair and use a damaged rim.

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Maintenance — Wheels and Tires Checking Tire Pressure Correct tire pressure should be maintained for all tires to enhance operating stability and extend tire life.

NOTE: See tire sidewall for inflation pressures.

Liquid Tire Ballast

WARNING On AL 500 Series machines, liquid ballast must be installed in the rear tires to maintain proper stability and balance.

To prevent corrosion and freezing, use only a good grade of calcium chloride or equivalent fluid as tire ballast.

Mix the liquid tire ballast product according to the manufacturer’s instructions. Fill to the level shown in Figure 24.

Figure 24 – Fluid-Filled Rear Tires Fill Level

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Maintenance — Lubrication Lubrication IMPORTANT: Use of lubricants not corresponding to manufacturer recommendations may invalidate warranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

Refer to Figure 25 and Figure 26 for grease fitting locations. See “Fluid Capacities/Lubricants” on page 11 for proper grease specifications. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any missing or damaged fittings. To minimize dirt build-up, avoid excessive greasing.

7 9 8

8

6

5

2

2

1 1

4 3 Figure 25 – Grease Every 10 Hours (or daily) (AL 500 Series shown) 1. All-Tach® Pins (2) 2. All-Tach® Pivots - Lower (2) 3. Lower Link Pivot - Front 4. Upper Link Pivot - Front 5. Lower Link Pivot - Rear

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6. Loader Pivot 7. Tilt Cylinder - Front 8. LIft Cylinder - Front (2) 9. Upper Link Pivot - Rear

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Maintenance — Lubrication

13 10

13

10 14 15

12 11

12

16

17

18

Figure 26 – Grease Every 10 Hours (or daily) (AL 500 Series shown) 10. Lift Arm- Upper Pivot (2) 11. Tilt Cylinder - Rear Pivot 12. Lift Cylinder - Rear Pivot (2) 13. Articulation Pivot - Upper (2) 14. Steering Cylinder - Front

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15. Articulation Pivot - Lower 16. Driveshaft - Center 17. Driveshaft - Both Ends 18. Steering Cylinder - Rear (2)

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Maintenance — Electrical System Electrical System

Cab and In-Line Fuses (Later Machines)

Fuse Locations

Cab fuses (2, Figure 29) are located in the engine compartment at the right rear corner of the operator’s platform. Open the engine cover to access these fuses.

The main system fuse (1, Figure 27) is located behind the battery connected to the positive (+) battery terminal.

2

1

Figure 29 – Cab Fuse Block (Later Machines) Refer to “Fuse Blocks (s) - Engine Compartment” on page 40.

Figure 27 – Master System Fuse (AL 500 Series shown)

Additional in-line fuses are located in the wire harness under the platform.

1. Master System Fuse

The primary fuse panel (1, Figure 28) is located at the left side of the steering column.

Control Module Fuse

1

Main Fuse

Figure 28 – Steering Column Fuse Panel (AL 500 Series shown)

Glow Plugs and Starter Solenoid Fuses

1. Steering Column Fuse Panel.

Figure 30 – Inline Fuses Under Platform (Later Machines) PRINTED IN U.S.A.

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Maintenance — Electrical System Cab and Engine Compartment Fuses (Early Machines) Additional fuses are located in the engine compartment at the right rear corner of the operator’s platform. All machines will have one fuse panel (1, Figure 31).

Machines with cab will have an additional fuse panel (2). Open the engine cover to access these fuses.

1

2

Figure 31 – Engine Compartment Fuse Panels (Early Machines) 1. Fuse Panel (all machines).

2. Fuse Panel (cab machines only).

Refer to “Fuse Blocks (s) - Engine Compartment” on page 40.

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Maintenance — Electrical System Fuse Panel - Steering Column

12

11

13

10

9

14

8

7

6

15

5

4

16

3

2

1

TOP

Figure 32 – Fuse Panel, Steering Column Fuse No.

Rated Current (Amp)

1 2 3 4 5 6

5 10 5 7.5 5 10

7 8 9 10 11 12 13 14 15 16

5 10 20 10 10 7.5 10 10 5 10

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Protected Circuit Instrument panel, differential lock, cab relay Joystick, control module relay Fuel pump, fuel solenoid hold Horn, beacon Work light switch, work light relays Power-A-Tach® Starter relay Turn signals Ignition switch Rear work light Front work light 12V accessory power outlet High-beam headlights Low-beam headlights Position lights Spare fuse

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Maintenance — Electrical System Fuse Blocks (s) - Engine Compartment NOTE: Early machine have a fuse block located at the right rear corner of the operator’s platform, inside the engine compartment. Later machines do not have this fuse block; fuses are located underneat the operator’s plaform. See “Cab and In-Line Fuses (Later Machines)” on page 37.

On cab-equipped machines a fuse block, also located at the right rear corner of the operator’s platform inside the engine compartment, holds fuses for cab electronics.

Early machines only. These fuses are located inline on later machines. See “Cab and In-Line Fuses (Later Machines)” on page 37.

STANDARD FUSES

CAB FUSES

5

1

6

2 7

3 8 4

Figure 33 – Fuse Panels, Engine Compartment Fuse No.

Rated Current (Amp)

1 2 3 4 5 6 7 8

15 40 25 25 5 5 10 25

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Protected Circuit Drive Module Glow Plugs Control Module Starter Solenoid Dome Light Rear Wiper Motor Front Wiper Motor Heater

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Maintenance — Electrical System Control Modules

• Green steady on — Indicates power to the drive controller

The control modules, located behind the operator’s seat on the right, provide switching, control logic and diagnostic functions.

• Red/green flashing — Indicates an error in the system See “Drive Controller (Plus+1 Module)” on page 172 for more information about the drive controller.

Control Module Error Codes

1

Malfunctioning drive function may indicate a control module error condition.

The following describes control module error codes.

Error codes are indicated by flashing LEDs (3, Fig. 34) located near the electrical connectors at the bottom of the module.

The LED flash pattern for error messages starts with four medium-length flashes, which signal the start of the message, followed by a pause. After the pause, a number of long flashes may occur, indicating the first digit for the code. After another pause, a number of short flashes occur indicating the second digit for the code. After a final pause, the flash pattern then repeats.

3 2

More than one error code may be displayed, one after the other.

Figure 34 – Control Modules

To illustrate, the flash pattern for error code “13” would be: Four medium flashes (message start), pause, one long flash (first digit of error code), pause, three short flashes (second digit of error code), pause. The flash pattern then repeats.

1. Machine Controller 2. Drive Controller 3. LED Lights

Machine Controller

Error Flash Code

Th e mac hine c ontro ller pr ovide s the followin g functions: • Glow plug control

Description

13

Watchdog Ready Error

15

Battery Voltage or Sensor Voltage Error

19

Pump Current Forward Error

• Starter logic

23

Pump Current Reverse Error

• Sends forward/reverse signal to drive controller

27

Motor Current Error

See “Machine Controller” on page 168 for more information about the machine controller.

31

Engine Speed RPM Error

35

FNR Shortcut Error

39

Inching Error

43

Driving Pedal Error

47

Mode Switch-2 Error

55

Brake Pressure Defeat Error (or Parking Brake Error or Brake Light Error)

59

Motor RPM and Direction Error

70

General CAN Receive Error

Drive Controller The drive controller provides computerized control of the drive system, and provides error-reporting functionality.

LED lights inside the cover indicate the following:

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Maintenance — Electrical System Battery

a) 0.5 kg (1 lbs.) of baking soda in 4 L (4 qts.) of water.

WARNING

b) 0.5 L (0.5 qts.) of household ammonia in 4 L (4 qts.) of water.

Before servicing the battery or electrical system, disconnect the negative cable from the negative battery terminal. Alternately, if the machine is equipped with a battery disconnect switch, turn the the battery disconnect switch to the “OFF” position.

Whenever the battery is removed, be sure to disconnect the negative (-) battery terminal connection first.

Using a Booster Battery (Jump-Starting) IMPORTANT: Only complete these steps if the loader cannot be started using the ignition key switch.

Refer to “Electrical System” on page 15 for battery specifications. To access the battery, tilt the operator’s platform. See “Engine Maintenance” on page 20.

If the loader does not start because of a “dead” (discharged) battery, start the loader using a battery jumper cable connected to the battery of another vehicle.

The battery top must be kept clean. Clean it with an alkaline solution (ammonia or baking soda and water).

After foaming has stopped, wipe the battery top with a damp towel. If the terminals and cable connection clamps are corroded or have a build-up, disconnect the cables and clean the terminals and clamps with the same alkaline solution. Thoroughly dry the battery using a clean towel.

NOTE: The loader cannot be tow-started because no direct mechanical connection exists between the wheels and engine. Attempting to tow-start the machine may damage the drive train.

WARNING

WARNING

Do not jump-start a frozen battery, or it may explode. A discharged battery can freeze at -10°C (14°F).

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. ALWAYS charge the battery in a well-ventilated area.

NOTE: Check that the battery disconnect switch is not turned off before jump starting.

Never lay a metal object on top of a battery, because a short circuit can result.

The booster battery must have a nominal voltage of 12Volts. The capacity (Amp-hour rating) of the currentsupplying battery must be approximately equal to that of the discharged battery.

Battery acid is harmful to skin and fabrics. If acid spills, follow these first-aid tips:

WARNING

1. Immediately remove any clothing on which acid spills.

Keep metal parts on your clothing and metal watchbands away from the positive (+) pole of the battery — risk of short circuit.

2. If acid contacts skin, rinse the affected area with running water for 10 to 15 minutes.

3. If acid contacts eyes, flood eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

1. Turn the key switches of both machines to OFF. Be sure the machines are in neutral and NOT touching each other.

4. To neutralize acid spilled on the floor, use one of the following mixtures: 50940008/AP0311

2. Check that battery jumper cables have a sufficient diameter.

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Maintenance — Electrical System Remote Battery Terminal

3. Connect the positive jumper cable to the positive (+) terminal on the discharged battery.

The optional remote battery terminal allows access to the battery terminals for jump-starting purposes.

4. Connect the negative jumper cable to the negative (-) terminal on the discharged battery.

Open the engine hood to access the remote battery terminal. Remove cap (T, Figure 35) for access to the remote connection for the positive battery terminal stud. Stud (U) provides a remote connection to the machine ground.

NOTE: If the machine is equipped with the optional remote battery terminal, connect the cables to the terminal studs on the remote battery terminal. See “Remote Battery Terminal” on page 43.

5. Connect the free end of the positive jumper cable to the positive (+) terminal on the booster battery.

U

6. Connect the free end of the negative jumper cable to a convenient ground on the machine carrying the booster battery.

T

7. Start the machine with the discharged battery. If the engine does not start immediately, stop cranking after 10 seconds and repeat starting procedure after approximately 30 seconds.

WARNING When the engine is running, components in the engine compartment rotate. Before removing the jumper cables, be sure that no loose clothing can become caught in the rotating components.

Figure 35 – Remote Battery Terminal

8. After the engine is running, remove the negative jumper cable connected the booster machine ground.

IMPORTANT: DO NOT allow the booster cable ends to touch when removing them. Arcs and direct short circuits can cause severe damage to the electrical system.

9. Disconnect the jumper cables from the machine with the discharged battery.

10. Remove the positive jumper cable from the booster battery.

11. Close the engine cover and confirm it is latched securely.

12. Allow the machine to run for at least 30 minutes to re-charge the battery.

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Maintenance — Storing the Loader Storing the Loader

After Storage

Before Storage

1. Check the tire air pressure and inflate the tires if they are low.

If the loader is to be stored for a long period, in excess of two months, the following procedures are suggested:

2. Connect the battery.

3. Check the fan belt tension.

1. Wash off entire machine.

4. Check all fluid levels (engine oil, transmission/ hydraulic oil, engine coolant and any attached implements).

2. Fully inflate the tires.

3. Lubricate all grease zerks.

5. Start the engine. Observe all indicators. If all indicators are functioning properly and reading normally, move the machine outside.

4. Check all fluid levels and replenish as necessary.

5. Add stabilizer to the fuel per the fuel supplier’s recommendations.

6. When outside, park the machine and let the engine idle for at least five minutes.

6. Remove the battery, charge fully and store in a cool, dry location.

7. Shut off the engine and walk around machine.

Make a visual inspection looking for evidence of leaks.

7. If the machine will not be operated for a month or longer, apply grease to all exposed hydraulic cylinder rod areas or retract all cylinders so rod exposure is minimized. Apply grease to any remaining rod areas.

8. Protect exposed cylinder rods.

9. Protect against extreme weather conditions such as moisture, sunlight and temperature.

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Maintenance — Maintenance Log Maintenance Log Date

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Hours

Service Procedure

45

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Maintenance — Maintenance Log Date

50940008/AP0311

Hours

Service Procedure

46

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Maintenance — Maintenance Log Date

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Hours

Service Procedure

47

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Maintenance — Maintenance Log Date

50940008/AP0311

Hours

Service Procedure

48

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Operation — Operation Safety CHAPTER 4 — OPERATION Operation Safety

If the machine is equipped with a folding ROPS, never operate the machine without the ROPS fully extended. Only fold the ROPS temporarily if necessary during transport.

WARNING

ALWAYS fasten the Seat belt when operating the machine. Repair or replace any damaged Seat belt and buckle parts before operation.

Before operating the machine, read and understand the operator’s manual provided with the machine. Follow warnings and instructions for operation. Failure to follow instructions can result in injury or death. Read and understand all safety and instructional decals before operation.

Position the load as low as possible while traveling. Never make turns with the load raised higher than the axles, or tipping may occur, which could result in severe injury or death.

Do not operate the machine unless all guards and shields are in place. Know how to stop the machine before starting.

If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which only protects the operator while in the operator’s seat.

Trying to escape from a tipping machine can result in death or serious personal injury.

Use only approved accessories and attachments.

Check for correct function after adjustments or maintenance.

If any warning indicators illuminate when the engine is running, turn off the engine immediately.

Correct the problem before re-starting the engine.

Travel cautiously, under complete control at all times. Avoid sudden changes of direction while traveling.

Never adjust the operator’s seat or the steering column when the engine is running.

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Operation — Controls and Switches Controls and Switches 18

3

6b

22

6b

23

22

21

1

16 18

21

22

4

2

21

9 5 10 6a 8

14

7 19

15

Located Behind Joystick

20

14

11

Located Inside Engine Compartment

13

12

17

NOTE: Controls 11, 12, 13 and 17 are located on the steering column, below instrument panel 2.

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Operation — Controls and Switches No.

Item

Description

1

Steering knob

Use to turn steering wheel.

2

Instrument panel

Contains warning indicators, operation indicators, and gauges.

3

Steering wheel

Turn to control travel direction.

4

Accelerator pedal

Press to control engine/travel speed.

5

Multi-purpose joystick

Use to control lift arm/attachment maneuvering and loader drive direction.

6a

Auxiliary hydraulics control lever

Use to activate auxiliary hydraulics control circuit.

On early machines, the control lever is located next to the joystick.

Use to activate auxiliary hydraulics control circuit.

6a

Auxiliary hydraulics control buttons

7

Parking brake lever

Use to engage parking brake.

8

Operator’s seat

Adjust operator’s seat position (page 57).

9

Brake/inch pedal

Press to control gradual travel and braking.

10

Steering column tilt

Use to adjust steering column tilt (page 58).

11

Hazard light switch

Press to activate hazard lights.

12

Work light switch

Press switch to ON position to activate work lights.

13

Rotating beacon switch (option)

Press switch to ON position to activate rotating beacon.

On later machines, auxiliary hydraulics flow is controlled using buttons on the front of the joystick.

Use switch to connect/disconnect the battery and electrical circuit.

14

Battery disconnect switch (option; standard EU only)

On early machines, the battery disconnect switch is located on the operator’s platform under the seat.

On later machines, the battery disconnect switch is located inside the engine compartment.

15

Seat belt

Always fasten seat belt before operating loader.

16

Control lever

Controls road lights, directional indicators and horn.

17

Power-A-Tach® lock/unlock (option)

Use to lock/unlock attachment.

18

Drive direction switch

Use to control forward/reverse drive direction.

19

Seat plate

Seat plate according to ISO 7096 (located on seat).

20

Hand throttle

Controls engine speed independently from the accelerator pedal. Does not control travel speed.

Toggles between slow/fast travel speed. Indicators 11 and14 illuminate to show selection.

21

Slow/fast speed toggle switch

On early machines, this switch is located on the top right of the joystick.

On later machines, this switch is located on the top left of the joystick.

Engages differential lock when depressed. Indicator 5 illuminates when the differential lock is engaged.

22

Differential lock momentary or slow/fast selection switch

On early machines, this switch is located on the front of the joystick.

On later machines, this switch is located on the top right of the joystick.

23

Auxiliary Electrical circuit momentary switch (option)

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On early machines, this switch controls electrical power flow to wiring harness connection. Reserved for electrically powered attachments.

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Operation — Instrument Panel and Indicators Instrument Panel and Indicators 17

16

1

2 3

15

4

14 13

5

18 19 12

6

7

11 20 21 10

8 9

No.

Indicator

Description

1

Forward travel

Drive direction thumb switch on joystick is in forward position – the machine will move forward when the travel pedal is pressed when this lamp is lit.

2

Pre-heat

Illuminates when the ignition key is in the “I” (Run) position. Goes out when the glow plugs have heated sufficiently to start the engine.

3

Engine oil temperature warning

See page 56.

4

Hydraulic oil filter

See page 56.

5

Differential lock

Differential lock engaged.

6

Right turn/hazard lights

Right turn signal engaged. Hazard lights.

7

Parking brake

Parking brake engaged.

8

Road lights

Road lights upper beam engaged.

9

Rearward travel

Drive direction thumb switch on joystick is in Reverse position – the machine will move in reverse when the travel pedal is pressed when this lamp is lit.

10

Alternator

Alternator not charging.

11

Slow speed

Low-speed drive engaged.

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Operation — Instrument Panel and Indicators No.

Indicator

Description

12

Left turn/hazard lights

Left turn signal engaged. Hazard lights.

13

Fuel level

Displays the amount of fuel in the tank.

14

Fast speed

High-speed drive engaged.

15

Hydraulic oil temperature

See page 56.

16

Engine oil pressure

Engine oil pressure too low.

17

Hourmeter

Displays hours of operation.

18

Low fuel

Fuel level too low.

19

Engine rpm

Displays engine rpm.

20

Voltmeter

Displays system voltage level.

Start-up - 3 bars illuminate, if battery is fully charged.

During operation - 4-5 bars illuminate.

Alternator overheat - 6 bars illuminate.

21

Engine oil temperature

Displays temperature level.

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Operation — Cab Controls (Cab only) Cab Controls (Cab only) Cab Environment Controls To operate the cab heater and air circulation fan: 1. Move lever (1, Figure 1) down to increase heat; up to reduce heat.

1

2. Turn the fan control (2, Figure 1) clockwise to increase circulation fan speed; counter-clockwise to decrease circulation fan speed.

2 Figure 1 -- Cab Environment Controls 1. Heat control 2. Fan control

Air Conditioning Control (option) Optional air conditioning is controlled by a knob located on the windshield wiper control panel. To operate the air condition system: 1. Rotate the air conditioning control knob clockwise to turn on the air conditioning system. The knob has three positions, from off at the “0” position, to full speed at the “3” position.

2. Rotate the air conditioning control knob counterclockwise to the “0” position to turn off the air conditioning system.

ON MAXIMUM

OFF

IMPORTANT: Do not operate the air conditioning and the cab heater at the same time because this will exceed the capacity of the electrical system and discharge the battery.

Figure 2 -- Air Conditioning Control

Cab Windshield Wiper Controls

Press the icon side of the wiper switches to the first detent to activate the wiper blades (Figure 3). Press the icon side of the switches past the detent to activate the washer fluid.

1. Activates the front wiper and washer.

1

2. Activates the rear wiper and washer.

2

Figure 3 -- Wiper Controls 1. Front wiper control 2. Rear wiper control

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Operation — Cab Controls (Cab only) Cab Dome Light The dome light is located on the cab ceiling. Push button (1, Figure 4) to turn the light on/off.

1 Figure 4 -- Cab Dome Light

Cab Defrost Turn the vents (1, Figure 5), located on the left and right side of the cab, toward the window to defrost the window.

1 Figure 5 -- Vent

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Operation — Warning Indicators Warning Indicators

IMPORTANT: If any of the following indicators illuminate when the engine is running, turn off the engine immediately. Correct the problem before restarting the engine. During normal operation these indicators should be OFF.

3 1

4

5

2

Figure 6 - Warning Indicators No.

Indicator

Description

1

Engine coolant temperature warning

Temperature is too hot.

2

Voltmeter

Alternator overheat - 6 bars illuminate.

3

Engine oil pressure

Pressure is too low.

4

Hydraulic oil temperature

Temperature is too hot.

5

Hydraulic oil filter

Hydraulic oil filter service required.

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Operation — Operator’s Seat and Ignition Switch Operator’s Seat and Ignition Switch

Seat belt

WARNING

Seat Adjustment

WARNING

Always fasten the seat belt securely and properly.

Never operate the machine without the seat belt fastened around the operator.

Never adjust the operator’s seat when the engine is running.

IMPORTANT: Inspect the seat belt for damage before use. Replace if damaged.

Adjust the operator’s seat so all controls are easy to reach and the pedals can be completely depressed with your back against the seat (Figure 7).

Keep the seat belt (5, Figure 7) clean. Use only soap and water to wash seat belt. Cleaning solvents can damage seat belt.

Ignition Key Switch

5

3

1

O

I

5

II 4 2 Figure 7 -- Operator’s Seat Adjustment 1. Forward/rearward lever 2. Weight adjustment knob 3. Recline lever 4. Height adjustment knob 5. Seat belt

Figure 8 -- Ignition Key Switch

“O” position: All power off. Key can be inserted/ removed.

1. Forward/rearward adjustment: Pull the lever up, adjust the seat and release the lever. Check that the seat is locked in place.

“I” position: Run position.

2. Weight adjustment: While sitting in the seat, rotate the knob until the desired tension is reached.

“II” position: Start position. Holding the switch in this position starts the engine.

3. Recline adjustment: Pull the front lever up, recline the seat back as desired and release the lever.

Check that the seat is locked in place.

NOTE: Switch must be returned to “O” position between starting attempts to reset the start safety interlock.

4. Height adjustment: Rotate knob until the desired seat height is reached.

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50940008/BP0311

Operation — Steering Column Steering Column

Control Lever

Steering Column Adjustment

The control lever on the steering column controls the following functions:

WARNING Never adjust the steering column when the engine is running.

1 3

Adjust the steering column for visibility, usability and comfort.

2

Figure 10 -- Control Lever 1. Horn 2. Lights 3. Turn signals

1. Push the control lever in to activate the horn (1, Figure 10).

2. Twist the end of the control lever to activate the position lights (2).

3. Push the control lever forward or rearward to activate the turn signals (3).

1

4. Push the control lever downward to activate “high” beam (driving light).

5. Pull the control lever upward to activate “low” beam (dipped-beam light). .

Figure 9 -- Steering Column Adjustment 1. Push the adjustment lever (1, Figure 9) downward.

1

2. Adjust the steering column to the desired position.

2

3. Release the adjustment lever.

3

4. Check that the steering column is locked in place.

Figure 11 -- Road Light 1. “High” beam (driving light) 2. “Low” beam (dipped-beam light) 3. Marker/turn signal

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Operation — Hand Throttle Hand Throttle

Lift Arm Down-Stop

The hand throttle, located to the right of the operator’s seat, controls engine speed independently from the accelerator pedal. The hand throttle does not control travel speed.

The lift arm down-stop is designed to limit lift arm downward travel. This feature is useful when changing tires sizes, or when driving the machine over long distances.

1. Loosen the throttle lock ring (1, Figure 12).

1. Empty the bucket (if applicable).

2. Press the red throttle release button (2).

3. Pull/push the throttle control knob (3) and the throttle release button as a unit.

C

2

C B

3 A

1

Figure 13 – Lift Arm Down-Stop 2. Position the lift arm above the down-stop hole (C, Figure 13) position where you want to limit travel, and also high enough to allow removal of the downstop lock bar (B).

Figure 12 -- Hand Throttle

3. Perform the “Mandatory Procedure” on page 4.

NOTE: The throttle can be quickly placed into the idle position by firmly pushing against the throttle release button (2). For normal operation, move the throttle release button (2) and the throttle control knob (3) as a unit to prevent undue wear on the throttle mechanism.

Shutdown

4. Remove the lock pin (A), and pull the lock bar (B) from the machine.

5. Slide the lock bar (B) all the way through the desired down-stop holes (C).

4. For fine adjustments, rotate the throttle control knob (3).

6. Replace the lock pin (A) into the lock bar (B).

5. Tighten the throttle lock ring (1) to lock the throttle in position.

PRINTED IN U.S.A.

Safety

59

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Operation — Lift/Tilt Lock Lift/Tilt Lock

AL 500 Series Machines

AL 400 Series Machines

1. Remove the quick-release pin (1, Figure 15), and lift the cylinder stop channel (2) off the machine.

1. Remove the spring pins (1, Figure 14), and remove the lock bar (2) from the machine.

2 1 2

1

1

1

1

2

2

1

3 4 Figure 15 – AL 500 Series Lift Arm Lock Figure 14 – AL 400 Series Lift Arm Lock

2. Tilt the attachment/hitch back as required and place the cylinder stop channel (2) under tilt indicator (1) and over the tilt cylinder to brace the tilt cylinder in the extended position.

2. Tilt the attachment/hitch as required to align holes in tilt bracket (3) with holes in lift arms (4). Slide the lock bar (2) all the way through the locking holes (3) in the lift arm, the tilt cylinder linkage and the front frame.

3. Replace the quick-release (1) into the cylinder stop channel so it passes under the tilt cylinder rod.

3. Replace the spring pins (1) into the ends of the lock bar.

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Chassis — Tilting the Platform CHAPTER 5 — CHASSIS Tilting the Platform

STEP 3

WARNING

2

Always close the cab doors (if applicable) and open the engine cover before tilting the platform.

Stay clear from underneath the platform as it is tilted. Always secure the tilt support when platform is tilted.

STEP 1

Remove the left rear platform locking hardware (2).

Complete Mandatory Safety Shutdown Procedure. See “Mandatory Safety Shutdown Procedure” on page 4.

IMPORTANT: Use care to not drop nut between the fender and hydraulic tank.

STEP 2

STEP 4

1 3

Open the engine hood (1).

Remove the left front platform locking bolt (3).

IMPORTANT: The hood MUST be opened BEFORE tilting the platform or damage to the hood will result! On later machines, hood must be opened to unlock platform tilt.

STEP 5

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If equipped with cab, close the cab doors.

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Chassis — Lowering the Platform Lowering the Platform

STEP 6

STEP 1

4

1

5 Release the safety bar (1) from the locked, tilted position.

NOTE: It may be necessary to lift the platform to aid in releasing the safety bar from the locked position.

4

Lower platform.

NOTE: On later machines, the hood must be opened to unlock platform tilt.

Insert the steering lock bar (4) into platform (5) to provide leverage for tilting the platform.

STEP 2

STEP 7

2

6

2 Tilt the platform until the safety bar (6) clicks into the locked, tilted position.

Remove the steering lock bar (2) from platform. Stow lock bar.

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Chassis — Lowering the Platform STEP 3

3

Install and tighten left rear locking bolt (3) to 302 lb-ft (410 N•m).

STEP 4

4

Install and tighten left front locking bolt (4) to 302 lb-ft (410 N•m).

STEP 5

5

Close engine hood (5).

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Chassis — Repairing or Replacing Platform Switch Repairing or Replacing Platform Switch 400 Series 41249 and Before 500 Series 51241 and Before The platform switch automatically shifts the drive pump to neutral when the platform is opened. Complete the following steps to repair or replace the platform switch: NOTE: Do not manually operate the switch. Only access the switch to repair or replace.

STEP 1 Tilt the platform. See “Tilting the Platform” on page 61.

STEP 2

1 1

Repair or replace platform switch (1).

STEP 3 Lower the operator’s platform back into the operating position. See “Lowering the Platform” on page 62.

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Chassis — Hood Removal Hood Removal

STEP 3

STEP 1

1

5

Remove hinge pins (5) from the hood and remove hood from the machine.

Open the engine hood (1) and support it.

STEP 2

3

4

2 Remove bolts (2) and nuts (3) from the hood safety cables (4).

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65

50940008/AP0311

Chassis — Hood Installation Hood Installation

STEP 3

5

STEP 1

1 Close engine hood (5).

Install engine hood on the machine and install the hinge pins (1).

STEP 2

3

4

2

Install safety cables (4) using bolts (2) and nuts (3) removed during disassembly.

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Chassis — Center/Steering Bearing Removal Center/Steering Bearing Removal

STEP 4

6

STEP 1

5

Perform the “Tilting the Platform” procedure on page 61, including the “Mandatory Safety Shutdown Procedure” on page 4.

STEP 2

Remove the snap ring (5) from the rod end pin (6) and remove the pin from the steering cylinder.

1

Move the rod end away from the machine.

STEP 5

1

8

Install jack stands (1) on both sides under the rear frame as shown.

STEP 3

4

3

7

Remove the two caps (7) from the top link (8).

2

STEP 6

9 Remove the eight mounting nuts (2) from the drive shaft (3). Remove the drive shaft from the front axle assembly (4).

Remove the two mounting bolts (9) from the top link.

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Chassis — Center/Steering Bearing Removal STEP 7

STEP 9

3

Use a floor jack to lift the rear frame to relieve tension in the articulation top link.

2

4

3

Slide a steel rod (2) through the tie-down eyelets (3) located under the rear frame. Position two jack stands (4) against the steel bar next to the eyelets as shown.

Lower frame onto jack stands.

STEP 8

WARNING

8

Remove the panel from the bottom of the rear frame before using a jack to support the rear frame as shown in the photo. Use caution when setting the rear frame onto the jack stand(s). The rear frame can alternately be supported by an overhead hoist, or by threading a rod through the hoist point brackets (24), and using two jackstands against the rod and against the point brackets.

Remove the top link (8) from the machine.

STEP 10

10

Remove the pivot mounting bolt (10) from the machine.

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Chassis — Center/Steering Bearing Removal STEP 13

STEP 11

14

15

11 200 Series shown; 400/500 Series similar

200 Series shown; 400/500 Series similar

Install a floor jack (11) under the front frame as shown.

Use a floor jack. Lift the front frame (14) from the rear frame (15). Install jack stands under the front frame.

NOTE: Photo may not exactly match installation.

NOTE: Photo may not exactly match installation.

STEP 12

13

STEP 14

12

16

Remove six mounting bolts (12) from the pivot bearing retaining ring bracket (13). Remove retaining ring bracket.

Remove the pivot bearing (16) from the machine.

NOTE: Photo may not exactly match installation.

STEP 15

18 17

Remove the retaining ring (17) from both bearings in the top link (18).

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Chassis — Center/Steering Bearing Installation Center/Steering Bearing Installation

STEP 16

STEP 1

19

1

20

2

Use a press (19) and a 2-5/8 inch (67 mm) bearing driver (20) to remove the bearings from the top link.

Use a press (1) and a 2-5/8 inch (67 mm) bearing driver (2) to install the two new bearings into the top link.

STEP 2

4 3

Install the retaining ring (3) into both bearings in the top link (4).

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Chassis — Center/Steering Bearing Installation STEP 5

STEP 3

5

Use a floor jack. Lift the front frame and remove the jack stands.

Install the pivot bearing (5) into the rear frame.

NOTE: Photo may not exactly match installation.

NOTE: Photo may not exactly match installation.

STEP 4

6

STEP 6

7

8

Install the pivot bearing retaining ring bracket (6) with the six mounting bolts (7). Tighten the bolts to 33 lb-ft (45 N•m).

Lower the floor jack and align the front frame with the pivot bearing (8). Install the front frame into the pivot bearing.

NOTE: Photo may not exactly match installation.

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Chassis — Center/Steering Bearing Installation STEP 10

STEP 7

9

10

Apply Loctite® 262 or equivalent to the pivot mounting bolt (9). Install and tighten the bolt to 302 lb-ft (410 N•m).

Install the top link (10) on the machine.

STEP 11

STEP 8 Remove the floor jack from the front frame.

11

STEP 9

Apply Loctite ® 262 or equivalent to the two top mounting bolts (11). Install the two bolts and tighten to 302 lb-ft (410 N•m).

STEP 12 Use a floor jack. Lift the rear frame to align the top link with the rear and front frames.

12

Install the two caps (12) onto the top link.

STEP 13 Remove the two jack stands from the rear of machine.

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Chassis — Center/Steering Bearing Installation STEP 14

STEP 15

13

15

17

14

16

Install the drive shaft (15) on the front axle assembly (17 ) us ing th e eight nuts ( 16) rem oved duri ng disassembly. Tighten nuts to 33 lb-ft (45 N•m).

Install the rod end of the cylinder into place. Install the pin (13) and install the snap ring (14).

STEP 16 Lower the platform. See “Lowering the Platform” on page 62.

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Chassis — Lift Arm Removal Lift Arm Removal

STEP 3

5

STEP 1 Remove the attachment plate hydraulic system. See “Attachment Plate Hydraulics Removal” on page 77.

5

STEP 2

1

4

4 3

Remove bolts and nuts (4). Remove pins (5) from lift cylinder rod ends.

3

2

STEP 4

1 6

6 4 9

7

8 Remove and plug hydraulic hoses (6). Disconnect work light (7). Remove bolts and nuts (8). Support lift arm with the proper lifting strap and appropriate lifting device. Removes pins (9).

Remove the bolts and nuts (1). Remove and plug the hydraulic hoses (2) from the tilt cylinder. Support the cylinder with the proper lifting strap (4) and appropriate lifting device. Remove pins (3). Remove tilt cylinder.

STEP 5

10

Remove lift arm (10).

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Chassis — Lift Arm Installation Lift Arm Installation

STEP 2

5

STEP 1

5

1

6

6

Align the lift cylinders with lift arm. Install pins (5).

Install the retaining bolts (6) and nuts and tighten to 33 lb-ft (45 N•m). Remove lifting straps.

2 7

2

3 4

STEP 3

4

7 8

Using the proper lifting strap (7) and appropriate lifting device, install the tilt cylinder (8).

STEP 4

Using proper lifting straps (1), move lift arm into place.

Install upper mounting pin (2). Install retaining bolts and nuts (3) and tighten to 33 lb-ft (45 N•m). Install hydraulic hoses (4).

9

10

Reconnect work light

11 9 10 Install pins (9) on tilt cylinder. Install retainer bolts and nuts (10) and tighten to 33 lb-ft (45 N•m). Install and tighten hydraulic hoses (11) on tilt cylinder. Remove lifting strap.

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Chassis — Lift Arm Installation STEP 5 Install the attachment plate hydraulic system. See “Attachment Plate Hydraulics Installation” on page 78.

STEP 6 Start the machine and bleed air out of the tilt cylinder by cycling the cylinder through full extension and retraction three times.

STEP 7 Check the hydraulic fluid level and fill as required. See “Fluid Capacities/Lubricants” on page 11.

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Chassis — Attachment Plate Hydraulics Removal Attachment Plate Hydraulics Removal

STEP 3

STEP 1

1

4

2

3 1 Remove bolts and nuts (4).

Disconnect attachment plate cylinder hoses (1). Cap and plug all fittings.

STEP 4

WARNING

STEP 2

Securely, safely and carefully support the hitch plate to prevent it from falling when the upper attachment plate pin is removed. The attachment plate if very heavy and can cause serious injury if it is allowed to fall.

3

STEP 5

2 5

Remove the auxiliary hoses (2) from the attachment plate. Cap and plug all fittings. Remove the retaining bolt and nut (3).

Remove upper attachment plate pin (5).

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Chassis — Attachment Plate Hydraulics Installation Attachment Plate Hydraulics Installation

STEP 3

STEP 1

1

4

9

2

3

Connect hoses (9) to the attachment plate cylinder.

Align attachment plate (1) with lift arm (2) and install the lower attachment plate pin (3) on both sides. Install two retaining bolts (4) and tighten to 33 lb.-ft. (45 N•m).

STEP 2

1

5 7

6 8 Align attachment plate (1) with stabilizer (5) and install upper attachment plate pin (6). Install retaining bolt (7) and tighten to 33 lb.-ft. (45 N•m). Install auxiliary hoses (8) to the attachment plate.

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Engine — Engine Removal CHAPTER 6 — ENGINE Engine Removal

STEP 2

Engine Removal Preparation 40

STEP 1 Remove the engine hood. See “Hood Removal” on page 65.

39 38

STEP 2

4

Tilt the platform. See “Tilting the Platform” on page 61.

STEP 3

42

Remove the battery. See “Battery Removal” on page 183.

41

STEP 4 Remove the radiator/oil cooler. See “Radiator/Oil Cooler Removal” on page 89.

43

STEP 5 Remove the air cleaner from the engine.

Loosen clamps and remove hoses (4 and 41). If equipped, loosen clamps and remove hoses (38, 39 and 40). If equipped, remove clamp (42) securing remote battery terminal cable (43) to the engine.

STEP 6 Remove the piston/drive hydraulic pump. See “Piston/Drive Hydraulic Pump Removal” on page 150.

STEP 3

STEP 1

10

2

9 1

8 Remove nuts (8) from the exhaust pipe (9). Rotate and remove the pipe from the engine (10).

Remove bolts (1) from the hood upright latch bracket (2).

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Engine — Engine Removal STEP 7

STEP 4

11 12

17 16

Remove the coolant temperature switch connector (11) and low coolant switch connector (12).

Remove bolts (16) from the alternator (17). Rotate alternator for access to wire terminals.

STEP 5

STEP 8

14

13 14 13

18

If equipped, label the heater hoses (13). Remove hose clamps (14). Remove heater hoses (13).

Remove wire harnesses (18) from the alternator.

Remove the alternator from the machine.

STEP 6

STEP 9

15

19

13

20

Remove wire harnesses (19) from the starter solenoid (20).

If equipped, remove tie strap (15). Position cab heater hoses (13) as needed.

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Engine — Engine Removal STEP 13

STEP 10

28

22 29

23 30

28

21

29

Loosen clamps (28) and remove fuel lines (29) from the fuel filter housing (30).

Remove wire connectors (21) from the fuel solenoid and glow plugs. Remove the wire connector (22) from the engine oil pressure switch (23).

STEP 14 STEP 11

32 24 44

31

Remove throttle cables (31) from bracket (44) and fuel pump linkage (32).

If equipped with tail lights, remove the wire connector (24).

STEP 15 STEP 12

27

33

25

26 Support the engine using an appropriate lifting device (33).

Remove wire connector (25) from the hydraulic oil temperature sender. Remove and plug hydraulic line (26). Remove engine oil filter (27) for more clearance when removing engine.

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Engine — Engine Removal STEP 19

STEP 16

37

34

Remove the engine (37) from the machine.

Remove rear engine mounting bolts (34).

STEP 17

35

Remove the top six front engine mounting bolts (35).

STEP 18

36

Lift the engi ne and mo ve the eng ine r earwar d approximately 1 inch (25 mm). Remove two P-clamps (36) that hold the battery cable to the engine.

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Engine — Engine Installation Engine Installation

STEP 3

4

STEP 1

1

1 2

Apply Loctite ® 262 or equivalent to the engine front mounting bolts. Install front engine mounting bolts (4) and tighten bolts to 33 lb-ft (45 N•m).

Install lifting chains (1) on the engine lifting brackets as shown. Install engine (2) into the machine.

STEP 4

STEP 2

3 5

Install rear engine mounting bolts, rubber isolators, and lock nuts (5). Tighten bolts to 155 lb-ft (210 N•m).

Install and tighten P-clamps (3).

STEP 5

Remove the lifting device from the engine.

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50940008/AP0311

Engine — Engine Installation STEP 9

STEP 6

7 14 44

6

Install the throttle cable (6) through bracket (44) and onto fuel pump linkage (7).

If equipped, install the wire harness (14) to the tail light connector.

STEP 7

STEP 10

10

16

8

17 10

9 8

15

Install fuel lines (8) on the filter housing (9) and tighten clamps (10).

Install the wire harness (15) to glow plugs and fuel solenoid wire connectors. Install the wire connector (16) to the engine oil pressure switch (17).

STEP 8 STEP 11

11

18

13

12 Install the engine oil filter (11). Install the hydraulic line (12). Install the wire harness (13) on the hydraulic oil temperature sender.

50940008/AP0311

Install wire harnesses (18) to the starter solenoid.

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Engine — Engine Installation STEP 15

STEP 12

24 22 25 19 If equipped, install the tie strap (24). Install cab heater hoses (22) to the bracket (25).

Install wire harnesses (19) on the alternator.

STEP 13

STEP 16

26 21

27

20

Install bolts (20). Install and tighten the alternator (21).

Install the wire harness to the coolant temperature switch (26) and low coolant switch (27).

STEP 14

STEP 17

23 22

29

23 22

28

If equipped, install cab heater hoses (22) and tighten clamps (23).

Install nuts (28). Install the exhaust pipe (29). Tighten nuts to 18 lb-ft (25 N•m).

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Engine — Engine Installation Engine Installation Completion

STEP 18

STEP 1

40

Install the air cleaner on the engine.

STEP 2 Install the radiator/oil cooler. See “Radiator/Oil Cooler Installation” on page 92.

39 38 4

STEP 3 Install the battery. See “Battery Installation” on page 184.

42

41

STEP 4 Lower the platform. See “Lowering the Platform” on page 62.

STEP 5 Install the engine hood. See “Hood Installation” on page 66.

43

STEP 6 Install the upper and lower radiatior hoses (4 and 41). If equipped, install heater hoses (38, 39 and 40). If equipped, secure remote battery terminal cable (43) with bracket (42).

Install piston/drive hydraulic pump. See “Piston/Drive Hydraulic Pump Installation” on page 152.

STEP 19

34 35

Install the hood latch upright bracket (34). Install bolts and nuts (35). Do not tighten at this time.

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Engine — Drive Coupling Removal Drive Coupling Removal

Drive Coupling Installation

STEP 1

STEP 1

Remove the Piston/Drive Hydraulic pump. See “Piston/ Drive Hydraulic Pump Removal” on page 150.

WARNING 1

Support the engine before removing the engine mounting bracket. Serious injury or damage to the engine can result if the engine is allowed to fall.

STEP 2 NOTE: New bolts purchased from Mustang have locking compound already applied.

4

7

Apply Loctite® 262 or equivalent to bolts.

2

Install coupler and bolts (1).Tighten bolts to 33 lb-ft (45 N•m).

7

1

STEP 2

3

3

7 Remove the six upper bolts (1). Remove engine mounting bolts (7). Remove the engine mounting bracket (2). Remove the two lower bolts (3) and remove the drive coupler cover (4).

7

4

STEP 3

2

NOTE: New bolts purchased from Mustang have locking compound already applied.

6

Apply Loctite® 262 or equivalent to bolts (2). Use the two lower bolts (2) to install the drive coupler cover (3).

Install the six upper bolts (4). Tighten all the bolts to 33 lb-ft (45 N•m).

5

Install engine mounting bolts (7), rubber isolators, and lock nuts. Tighten bolts to 155 lb-ft (210 N•m).

STEP 3

Remove the eight bolts (5) and remove the drive coupler assembly (6).

PRINTED IN U.S.A.

NOTE: New bolts purchased from Mustang have locking compound already applied.

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Engine — Starter Removal Apply Loctite® 262 or equivalent to bolts.

Starter Installation

Install the piston/drive hydraulic pump. See “Piston/ Drive Hydraulic Pump Installation” on page 152.

Tighten bolts to 90 lb-ft (122 N•m).

STEP 1 Install the starter on the engine. Tighten the two starter mounting bolts (3) to 64 lb-ft (87 N•m).

Starter Removal

STEP 2

STEP 1 Tilt the platform. See “Tilting the Platform” on page 61.

3

STEP 2

2

Remove the ba t tery. See “Battery Removal” on page 183.

1

STEP 3

Install the battery cable and charging system wires (1).

Install the wire connector (2) on the starter solenoid.

3

STEP 3

2

Install the ba t tery. See “Battery Installation” on page 184.

1

Lower the platform. See “Lowering the Platform” on page 62.

Remove nut (1) and remove cables from the starter.

Remove the wire connector (2). Remove the starter bolts (3).

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Cooling System — Radiator/Oil Cooler Removal CHAPTER 7 — COOLING SYSTEM Radiator/Oil Cooler Removal

NOTE: Cooling system capacity is approximately 6.8 qts. (6.4 L).

STEP 1

IMPORTANT: Always dispose of coolant according to environmental laws.

Disconnect the ground cable from the battery or turn off the master disconnect switch, if equipped.

Close the radiator drain plug after the radiator has drained completely.

STEP 2

STEP 5

Remove the engine hood. See “Hood Removal” on page 65.

STEP 3

3

2

3

5

Remove the hydraulic oil reservoir plug (5) and drain the hydraulic oil. Install the reservoir plug.

1

NOTE: The reservoir capacity is approximately 10.6 gal. (40 L).

Loosen front bolts and nuts (1) from the engine access panel (2). Remove the nuts (3). Remove the access panel.

IMP O RTANT: Al way s d is po se o f h yd r aul ic oil according to environmental laws.

STEP 4

STEP 6

6 6

4

7

Loosen hose clamps (6) and remove the hose (7).

Open the radiator drain plug (4) and drain coolant into a clean container.

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Cooling System — Radiator/Oil Cooler Removal STEP 9

STEP 7

8

9

13

Remove filter housing mounting bolts (8). Remove the housing (9).

STEP 8

11

12

14

10

Loosen the hose clamp (13) and remove the lower hose from the radiator. Remove and plug the hydraulic hose (14) from the oil cooler.

Loosen the hose clamp (10) and remove the upper hose from the radiator (11). Remove the hydraulic hose (12). Plug the hose and cap the cooler port.

IMP O RTANT: Al way s d is po se o f h yd r aul ic oil according to environmental laws.

STEP 10

15 15 Remove the two lower radiator/oil cooler mounting bolts (15).

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Cooling System — Radiator/Oil Cooler Removal STEP 14

STEP 11

20

16

Remove four bolts that hold the engine fan (20) and water pump pulley on the engine. Remove the fan, pulley and belt.

Remove the two upper radiator/oil cooler mounting bolts (16).

NOTE: Photo may not exactly match installation.

STEP 15 STEP 12

17

21

18

Using an appropriate lifting device, lift and remove the radiator/oil cooler (21) from the machine.

Remove the radiator reservoir hose (17) and reservoir (18).

IMPORTANT: Be careful not to damage the foam on both side of the radiator when removing the radiator from the machine. It may be necessary to catch the foam at the bottom of the radiator when the radiator is removed.

STEP 13

19

Loosen the alternator bolts (19).

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Cooling System — Radiator/Oil Cooler Installation Radiator/Oil Cooler Installation

STEP 4

STEP 1

40

Install the foam at the bottom of the radiator. Make sure the foam at the sides of the radiator is in place in the engine compartment.

STEP 2

19 1 Install the fan V-belt (40), adjust tension and tighten bolt (19). See “Checking and Adjusting V-belt Tension” on page 27.

STEP 5 Using an appropriate lifting device, lift the radiator/oil cooler (1) into place.

5

STEP 3

4

2

Install the radiator reservoir (4) and hose (5).

3

STEP 6

Install the water pump pulley (2) and engine fan (3).

Tighten the bolts to 7 lb-ft (10 N•m).

6

Install the two upper radiator/oil cooler mounting bolts and nuts (6). Tighten to 33 lb-ft (45 N•m).

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Cooling System — Radiator/Oil Cooler Installation STEP 9

NOTE: Photo may not exactly match installation.

STEP 7

11 10

7 7

Install the upper radiator hose (10) and upper cooler hose (11). Tighten the hose clamps.

STEP 10

Install the two lower radiator/oil cooler bolts (7). Tighten to 18 lb-ft (25 N•m).

13

STEP 8

12

Install the air filter housing (12) with bolts (13).

8

STEP 11

1

14

15 2

15

3

9

Install the lower radiator hose (8) and tighten the hose clamp. Install the lower cooler hydraulic hose (9).

Install the intake hose (14) and hose clamps (15).

STEP 12 Connect the ground cable to the battery or turn on the master disconnect switch, if equipped.

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Cooling System — Radiator/Oil Cooler Installation STEP 13 Install the engine hood. See “Hood Installation” on page 66.

STEP 14

16 18

18

17

Install the engine access panel (16). Tighten bolts and nuts (17). Tighten nuts (18). Fill cooling system. Refer to “Fluid Capacities/Lubricants” on page 11 for proper coolant type and quantity information.

STEP 15 Fill the hydraulic system. Refer to “Fluid Capacities/ Lubricants” on page 11 for proper hydraulic oil type and quantity information.

STEP 16 Run the engine and check for leaks.

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Axles — Front Axle Removal CHAPTER 8 — AXLES Front Axle Removal

STEP 3

6

5

STEP 1

2

1 5 3

Remove the two cap screws (5) from the parking brake drum (6). Remove drum from front axle hub.

Remove the eight mounting nuts (1) from the driveshaft (2). Remove driveshaft (2) from front axle assembly (3).

STEP 4

NOTE: Parking brake must be released before the parking brake drum is disassembled.

STEP 2

7 12

8

Remove brake tension spring (7) from parking brake (8). Save for use during installation.

4

Remove hoses (4). Cap the fitting and plug the hose.

Remove hydraulic brake line hose (12) from the front of the brake assembly. Cap the fitting and plug the hose.

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Axles — Front Axle Removal STEP 8

STEP 5

10 14

9

Remove parking brake cable (9) from parking brake arm (10).

Using a hydraulic jack (14), raise the center of the axle until wheels are about 2 inches (50 mm) off the ground.

STEP 6

STEP 9

12 11

15

13 Install two jack stands (15) under the front frame, one on each side. Lower the frame onto the stands.

Rotate 90° and remove spring washer (11) from parking brake cable (12). Pull the cable through the backing plate (13). Reposition cable as needed. Save spring washer for use during installation.

STEP 10

STEP 7

5

6 16

5 Remove lug nuts (16) from wheels. Remove wheels from axle.

Reinstall parking brake drum (6) and hand tighten cap screws (5).

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Axles — Front Axle Removal STEP 11

Position a floor jack under the axle and apply slight upward pressure.

STEP 12

17

17

Remove axle mounting bolts (17) on each side.

STEP 13

Lower the floor jack and remove the axle.

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Axles — Front Axle Installation Front Axle Installation

STEP 4

STEP 1

2

Carefully roll the axle under the machine with a floor jack.

Install wheels onto the axle. Install lug nuts (2) and tighten to 202 lb-ft (315 N•m).

STEP 2

STEP 5

Raise the axle into position.

Use a hydraulic jack to lift the center of the axle.

STEP 3

STEP 6

1

1

Align the four bolt holes in the axle with the holes in the frame. Install bolts (1) and nuts on each side. Tighten to 302 lb-ft (410 N•m).

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Remove jack stands and lower the machine.

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Axles — Front Axle Installation STEP 10

STEP 7

12

3

10 9

Install hoses (3) on front axle. Install hydraulic brake line hose (12) to the front of the brake assembly.

Replace parking brake cable (9) onto parking brake arm (10).

STEP 8

STEP 11

6

5

7 8

5 Remove the two cap screws (5) from the parking brake drum (6). Remove drum from front axle hub.

Replace brake tension spring (7) onto parking brake (8).

STEP 9

STEP 12

5

6

12 11 5

13

Reinstall parking brake drum (6) and securely tighten cap screws (5).

Rotate 90° and route the cable through the backing plate (13). Replace replace spring washer (11) on parking brake cable (12).

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Axles — Rear Axle Removal Rear Axle Removal

STEP 13

STEP 1 Remove the hydrostatic motor. See “Hydrostatic Motor Removal” on page 153.

4

NOTE: The driveshaft is removed hydrostatic motor removal procedure.

during

the

STEP 2

Install driveshaft on front axle assembly. Install nuts (4) and tighten to 33 lb-ft (45 N•m).

1

Use a floor jack (1) to raise the center of the axle until wheels are about 2 inches (50 mm) off the ground.

STEP 3

3

4

2

3

Slide a steel rod (2) through the tie-down eyelets (3) located under the rear frame. Position two jack stands (4) against the steel bar next to the eyelets as shown.

Lower frame onto jack stands.

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Axles — Rear Axle Removal STEP 7

STEP 4

3

6 7 Use floor jack to carefully lower the axle until the hydraulic hose (6) can be removed. Cap fitting and plug hose. Remove axle (7).

Remove lug nuts (3) from wheels. Remove wheels.

STEP 5

4 Position floor jack (4) under the axle and apply slight upward force.

STEP 6

5

Remove axle mounting bolts and nuts (5) on each side of the machine.

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Axles — Rear Axle Installation Rear Axle Installation

STEP 3

STEP 1

4 5

1

Install wheels (4). Install lug nuts (5) and tighten to 232 lb-ft (315 N•m).

2

STEP 4 Carefully roll the axle under the machine with a floor jack. Install hydraulic hose (1). Raise axle (2) into position. Align the four bolt holes in axle with the holes in frame.

STEP 2

6

3

Use a floor jack (6) to lift the center of the axle.

STEP 5

Install bolts and nuts (3) on each side of the machine.

Tighten axle mounting bolts and nuts to 302 lb-ft (410 N•m).

7 Remove jack stands (7) and lower the machine.

STEP 6 Install the hydrostatic motor. See “Hydrostatic Motor Installation” on page 155.

NOTE: The The driveshaft is installed during the hydrostatic motor installation procedure.

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Hydraulics — Work Hydraulics Troubleshooting CHAPTER 9 — HYDRAULICS Work Hydraulics Troubleshooting NOTE: The following table contains general hydraulics troubleshooting information. For more in-depth diagnostics information, refer to the hydraulics troubleshooting flow charts, starting on page 107.

Problem

Possible Cause

Corrective Action

Work hydraulics do not work or work only at a low performance level.

Low hydraulic fluid level.

Add hydraulic fluid. See “Checking Hydraulic Oil Level” on page 29.

Hydraulic fluid is not warm.

Allow longer warm-up

Hydraulic cylinder damaged.

Repair/replace cylinder. See “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Control valves damaged.

Repair/replace control valve.

See “2-Spool Control Valve Removal” on page 126 or “3Spool Control Valve Removal” on page 128. Also refer to the parts manual for control valve parts information.

Engine speed is too low.

Adjust engine speed.

Dirty/restricted air filter(s).

Replace air filter(s). See “Air Cleaner” on page 22.

Incorrect fuel grade.

Change the fuel; see “Fluid Capacities / Lubricants” on page 11 for proper fuel grade.

Oil leaking past tilt cylinder seals.

See “Work Cylinder Leakage Test” on page 124. Repair/ replace cylinder if required. Also see “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders.

Repair/replace as required.

Attachment tilts down with tilt control in neutral.

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Hydraulics — Work Hydraulics Troubleshooting Problem

Possible Cause

Corrective Action

Lift arm does not raise/lower.

Lift spool in control valve not actuated or leaking.

Repair/replace control valve.

See “2-Spool Control Valve Removal” on page 126 or “3Spool Control Valve Removal” on page 128. Also refer to the parts manual for control valve parts information.

Oil leaking past lift arm cylinder piston seals.

See “Work Cylinder Leakage Test” on page 124. Repair/ replace cylinder if required. Also see “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Refer to flowchart on page 107 for more detailed lift arm hydraulics troubleshooting.

Attachment tilt not working properly.

Tilt spool in control valve not actuated or leaking.

Repair/replace control valve.

See “2-Spool Control Valve Removal” on page 126 or “3Spool Control Valve Removal” on page 128. Also refer to the parts manual for control valve parts information.

Oil leaking past tilt cylinder piston seals.

See “Work Cylinder Leakage Test” on page 124. Repair/ replace cylinder if required. Also see “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Refer to flowchart on page 107 for more detailed attachment tilt hydraulics troubleshooting.

Hydraulic system overheating.

50940008/AP0311

Hydraulic oil cooler is dirty.

Clean hydraulic oil cooler.

Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Load too high.

Reduce the load.

Auxiliary hydraulics control lever not in neutral.

(NOTE: following serial numbers only: 400 Series 41249 and Before 500 Series 51241 and Before)

Check that auxiliary hydraulics control lever is in neutral. See page 50 for auxiliary hydraulics control lever location.

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Hydraulics — Work Hydraulics Troubleshooting Problem

Possible Cause

Corrective Action

Lift and/or tilt functions too slow, inconsistent or jerky.

Low engine speed.

Increase engine speed.

Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Oil leaking past cylinder piston seals.

See “Work Cylinder Leakage Test” on page 124. Repair/ replace cylinder if required. Also see “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Hydraulic pump malfunction.

Repair/replace hydraulic pump.

Refer to flowcharts on page 115 for more detailed hydraulic pump troubleshooting.

Oil leading past lift cylinder seals.

See “Work Cylinder Leakage Test” on page 124. Repair/ replace cylinder if required. Also see “Hydraulic Cylinder Disassembly/Assembly” on page 141.

Oil leaking past lift spool in control valve.

Repair/replace control valve.

See “2-Spool Control Valve Removal” on page 126 or “3Spool Control Valve Removal” on page 128. Also refer to the parts manual for control valve parts information.

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders.

Repair/replace as required.

Spool in control valve not actuated or leaking.

Repair/replace control valve.

See “2-Spool Control Valve Removal” on page 126 or “3Spool Control Valve Removal” on page 128. Also refer to the parts manual for control valve parts information.

Hydraulic oil leaking past seals.

Repair/replace as required.

Lift arm does not maintain raised position with multi-purpose joystick centered (neutral).

Auxiliary hydraulics do not function.

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Hydraulics — Hydrostatic Drive System Hydrostatic Drive System Problem

Possible Cause

Corrective Action

No response from either hydrostatic drive or the lift/tilt systems.

Hydraulic oil viscosity too heavy.

Allow longer warm-up; replace with proper grade hydraulic oil, see “Fluid Capacities / Lubricants” on page 11 for proper oil grade.

Refer to flowchart on page 109 for more detailed hydrostatic drive system troubleshooting.

Drive will not operate in either direction.

Parking brake is engaged

Disengage parking brake.

Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Brake/inch pedal stuck or malfunctioning.

Repair/replace as required.

Refer to flowchart on page 109 for more detailed hydrostatic drive system troubleshooting.

Hydrostatic (drive) system noisy.

Hydraulic oil viscosity too heavy.

Allow longer warm-up, See “Fluid Capacities / Lubricants” on page 11 for proper oil grade.

Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Refer to flowchart on page 109 for more detailed hydrostatic drive system troubleshooting.

Sluggish acceleration.

Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Refer to flowchart on page 109 for more detailed hydrostatic drive system troubleshooting.

Hydrostatic drive overheating.

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Hydraulic oil level is too low.

Add hydraulic oil; check for leaks. See “Checking Hydraulic Oil Level” on page 29.

Drive system continuously overloaded.

Decrease load on drive system.

Lift/tilt and/or auxiliary system continuously overloaded.

Decrease load on lift/tilt and/or auxiliary system(s).

Oil cooler fins restricted.

Clean oil cooler fins.

Hydraulic oil filter restricted.

Replace filter.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Hydraulics Troubleshooting Diagnostic Flow Charts Use the flow charts in this section to help pinpoint the specific causes of hydraulic system malfunctions.

Work Hydraulics Diagnostics

Check the Following and Correct as Necessary:

AL 400 Series Serial Numbers 41249 and Below

- Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

- Connections Tight/OK? 11 - Controller Error Codes?

- Operator in Seat?

-------------------------------------------------------AL 400 Series Serial Numbers 41249 and below AL 500 Series Serial Numbers 51241 and below

START

AL 500 Series Serial Numbers 51241 and Below

8

Repair/Replace Control Valve

-Joystick Safety Lock Released?

AL 400 Series Serial Numbers 41250 and Up

9

Repair/Replace Hydraulic Plumbing, Cylinders, As Required

Also See Steering Diagnostics Work Hydraulics Operating Properly ?

5 Any Steering Function ?

YES

Any Work Hydraulics Function ?

NO

Go To Operator Presence Diagnostics

YES

NO

Cylinder Movement Direction Correct?

AL 500 Series Serial Numbers 51242 and Up

END

4 7 8

1 2

YES

Repair/Replace Pumps/Pump Connection Parts As Required

NO NO

NO

Any Travel Drive Function ?

YES NO

Connection Between Drive/Work Pump OK ?

YES

1 Repair/Replace Work Pump

YES

NO Work Hydraulics Lack Power ?

NO

Work Hydraulics Action Slow ?

Engine/ Pump Coupling OK ?

YES

NO

7

NO

NO

Work Pressure OK with Tilt Cylinder Deadheaded ?

BOTH Lift and Tilt Hydraulics Do Not Cycle Properly

Work Pressures Not OK with Either Lift and Tilt Cylinders Dead-Headed

Lift Hydraulics Cycle Properly Under Load ?

YES

6 Repair/Replace Drive Pump

YES NO

3

YES

107

NO

7 Repair/Replace Cylinder

10 Work Pressure OK with Tilt Cylinder Deadheaded ?

Go To Hydraulic Pump Diagnostics

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Repair/Replace Coupling

NO

Tilt Hydraulics Cycle Properly Under Load ?

YES

Repair/Replace Cylinder

2 YES

NO

4 7 8 Repair/Replace Hydraulic Plumbing, Cylinders, As Required

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Work Hydraulics Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

1 2

Reference Information

Additional Information

See “Gear/Work Hydraulic Pump Removal” on page 149.

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Pump(s) have to be removed to access pump coupling components.

3

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

Additional diagnostics specific to the pump(s) is required.

4

Refer to the parts manual for main relief valve parts information.

5

See “Operator Presence Diagnostics” on page 113.

Additional diagnostics specific to the operator presence control is required.

6

See “Drive Coupling Removal” on page 87.

Refer to the parts manual for drive coupling parts information.

7

See “Hydraulic Cylinder Disassembly/Assembly” on page 141.

General cylinder service information.

8

See “Steering Control Valve Removal” on page 156.

Refer to the parts manual for steering control valve parts information.

9

See “Steering Hydraulics Diagnostics” on page 109.

Work and steering hydraulics are integrated at points. Additional diagnostics may be required.

10

See “Work Pressure Test” on page 124 See: • “Fuse Locations” on page 37.

11 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Steering Hydraulics Diagnostics Check the Following and Correct as Necessary: - Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

8 - Connections Tight/OK? - Controller Error Codes?

- Operator in Seat?

- Steering Lock Bar in Lock Position?

-------------------------------------------------------AL 400 Series Serial Numbers 41249 and below AL 500 Series Serial Numbers 51241 and below

START

7

-Joystick Safety Lock Released?

Also See Work Diagnostics

END

Steering Operating Properly ?

YES

Lift Arm Function ?

NO

YES

Steering Functions At All ?

YES

RETURN TO START NO

Steering Valve/Steering Column Coupling OK?

YES RETURN TO START

Repair Cylinder/ Hydraulic Plumbing

NO

4 5 6

3

Steering Cylinder and/or Steering Cylinder Hydraulic Plumbing OK ?

NO

Work System Pressure OK ?

YES

4 Repair Coupling

NO

Repair/Replace Steering Valve

NO

YES

Is Steering Action Slow ?

NO

Is Increased Steering Effort Required ?

3 Piston/Gear Pump Coupling OK ?

YES

NO

YES

Go To Hydraulic Pump Diagnostics

NO

1 2 Repair Coupling

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Steering Hydraulics Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

1 2

Reference Information

Additional Information

See “Gear/Work Hydraulic Pump Removal” on page 149.

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Pump(s) have to be removed to access pump coupling components.

3

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

Additional diagnostics specific to the pump(s) is required.

4

Refer to the parts manual for main relief valve parts information.

5

See “Hydraulic Cylinder Disassembly/Assembly” on page 141.

General cylinder service information.

6

See “Steering Control Valve Removal” on page 156.

Refer to the parts manual for steering control valve parts information.

7

See “Work Hydraulics Diagnostics” on page 107.

Work and steering hydraulics are integrated at points. Additional diagnostics may be required.

See: • “Fuse Locations” on page 37.

8 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Drive Hydraulics Diagnostics

Check the Following and Correct as Necessary: - Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

8 - Filter Blocked?

- Connections Tight/OK? - Controller Error Codes?

- Operator in Seat?

- Steering Lock Bar in Lock Position?

-------------------------------------------------------AL 400 Series Serial Numbers 41249 and below AL 500 Series Serial Numbers 51241 and below

START

-Joystick Safety Lock Released?

Drive Operating Properly ?

END

YES

4 Refer to Axle Service Manual (if necessary)

NO

Disengage Brake

1 3 Drive System Error Code and/or Pump Hydraulics Diagnostics (as necessary)

YES

Parking Brake Dash Indicator Light On ?

YES

Parking Brake On ?

5 Go To Motor Hydraulic Diagnostics (if necessary)

Disengage Inching

NO

NO

NO

1 Go To Drive System Electrical Diagnostics

YES

Parking Brake Indicator Light On ?

Drive Operates in Both Directions ?

NO

YES

Drive Operates Slowly ?

YES

Is Inching Engaged ?

YES

NO

NO YES

Indicator Lights Work When Drive Direction Switch Engaged ?

NO

YES

Any Drive Movement At All ?

5 Go To Motor Hydraulic Diagnostics (if necessary)

NO

3 PLUS+1 Service Tool Error Codes/ Diganostics

Go To Pump Hydraulics Diagnostics

2

7 Repair/Replace Coupling(s)

NO

Coupling(s) OK ?

NO

Work Hydraulics Operate ?

YES

YES

Charge Pump Pressure OK ?

6

NO

Repair/Replace Pump

YES

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Drive Hydraulics Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

1

2

Reference Information

Additional Information

See “Drive System Electrical Diagnostics” on page 119.

Additional diagnostics specific to electronics controlling the drive system is required.

See “Gear/Work Hydraulic Pump Removal” on page 149.

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Pump(s) have to be removed to access pump coupling components.

3

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

Additional diagnostics specific to the pump(s) is required.

4

See “Axles” chapter, starting on page 95.

Refer to ZF planetary axle service document, part number 918363.

5

See “Hydrostatic Motor Diagnostics” on page 117.

Refer to the parts manual for hydraulic motor parts information.

6

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Refer to piston/drive pump service document, part number 918358.

7

See “Charge Pump Pressure Test” on page 122.

See: • “Fuse Locations” on page 37.

8 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Operator Presence Diagnostics

Check the Following and Correct as Necessary:

7

- Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

- Connections Tight/OK? - Controller Error Codes?

- Operator in Seat?

START

1

Work Hydraulics Operate Properly (lift/tilt) ?

2 Go To Hydraulic Piston/Drive Pump Diagnostics (as necessary)

Repair/Replace Seat Switch/ Control Valve

END

YES

NO YES

3 Go To Work Hydraulics Function Diagnostics (as necessary)

NO

Seat Switch and/or Control Valve Repair/Replace Required ?

Engine Loads when Joystick Moved (lift/tilt operation) ?

NO

YES

Sit in Seat

NO

Operator In Seat ?

6 Repair/Replace Lift/Tilt Lock Valve(s)

YES

5 4 Repair/Replace Seat Switch/ Electrical Connections

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NO

113

Machine Controller "SEAT SWITCH" and "LIFT/TILT SOL" Lit When Operator In Seat and Joystick Moved (lift/tilt operation) ?

YES

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Operator Presence Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

Reference Information

Additional Information

1

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

Additional diagnostics specific to the drive pump may be required.

2

Refer to the parts manual for seat switch and/or control valve parts information.

3

See “Work Hydraulics Diagnostics” on page 107.

4

Refer to the parts manual for seat switch and/or related electrical parts information.

5

See “Machine Controller LED/Indicator Assignments” on page 168.

6

See “Lift/Tilt Lock Valves” on page 135. Also refer to the parts manual for lift/tilt lock valve parts information.

Additional diagnostics specific to the work hydraulics may be required.

See: • “Fuse Locations” on page 37.

7 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Hydraulic Piston/Drive Pump Diagnostics

Check the Following and Correct as Necessary: - Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

- Connections Tight/OK? - Controller Error Codes?

- Operator in Seat?

START

3

Pump Operation Meets Specifications ?

11

5

Go To Motor Hydraulics Diagnostics

4

Refer to Axle Service Manual (if necessary)

2

Repair/Replace Pump if Indicated by Motor/Axle Diagnostics

END

YES

NO

7 Check Service Tool Drive System Error Code(s)

Operates in Forward and Reverse ?

NO

YES

9 YES

Any Pressure at A & B Ports ?

NO

Go To Drive Electrical Diagnostics (as necessary)

Check Service Tool Drive System Error Code(s)

10

Charge Pump Pressure Meets Specification ?

1

7

YES

NO

8

Repair/Replace Differential Lock Valve or Hydraulic Plumbing

YES

9 6

Repair/Replace Pump

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NO

Any Pressure at Charge Pump ?

YES

Differential Lock Valve Leaking to Tank ?

115

6

Repair/Replace Pump

NO

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Hydraulic Piston/Drive Pump Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

Reference Information

Additional Information

See “Drive System Electrical Diagnostics” on page 119.

Additional diagnostics specific to electronics controlling the drive system is required.

See “Gear/Work Hydraulic Pump Removal” on page 149.

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Refer to the parts manual for pump internal components. Also refer to piston/drive pump service document, part number 918358. Also, pump(s) have to be removed to access pump coupling components, if necessary.

3

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

Additional diagnostics specific to the pump(s) is required.

4

See “Axles” chapter, starting on page 95.

Refer to ZF planetary axle service document, part number 918363.

5

See “Hydrostatic Motor Diagnostics” on page 117.

Refer to the parts manual for hydraulic motor parts information.

6

See “Piston/Drive Hydraulic Pump Removal” on page 150.

Refer to piston/drive pump service document, part number 918358.

7

See drive controller error codes; “Drive Controller Error Codes” on page 172.

Also refer to “Electrical Status Error Reporting Screen” on page 177.

8

Refer to the parts manual for differential lock valve and hydraulic plumbing parts information.

9

See “Charge Pump Pressure Test” on page 122.

10

See “Drive Pressure Test” on page 123.

1

2

See: • “Fuse Locations” on page 37.

11 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Hydrostatic Motor Diagnostics START

Check the Following and Correct as Necessary:

5

- Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

- Connections Tight/OK? - Controller Error Codes?

- Operator in Seat?

Drive NOT Operating but Pump Operating to Specifications ?

NO

END

YES

1 Repair / Replace Motor

3 Remove Motor from Axle (hydraulics still plumbed)

NO

Drive Motor Rotates When Drive Engaged ?

YES

YES

4

Can Motor be Rotated

by Hand (engine off) ?

NO

2 Refer to Axle Service Manual

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Hydrostatic Motor Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

Reference Information

Additional Information

1

See “Hydrostatic Motor Removal” on page 153.

Refer to series 51 and 51-1 bent-axis motor service document, part number 918359.

2

See “Axles” chapter, starting on page 95.

Refer to ZF planetary axle service document, part number 918363.

3

Perform the steps in “Hydrostatic Motor Removal” necessary for hose removal (STEP 7).

See “Hydrostatic Motor Removal” on page 153.

4

Rotate motor as follows: 1) Thread bolt and nut into the motor shaft. 2) Jam nut against the motor shaft to lock the bolt onto the motor shaft. 3) Use a wrench on the bolt to try to rotate the motor shaft.

5

See “Hydraulic Piston/Drive Pump Diagnostics” on page 115.

See: • “Fuse Locations” on page 37.

6 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Drive System Electrical Diagnostics

Check the Following and Correct as Necessary: - Fuses?

- Oil Level?

- Obstructions in Hydraulic System?

- Filter Blocked?

- Connections Tight/OK? - Controller Error Codes?

4 - Operator in Seat?

START

Drive System Switches / Indicators Operate Properly ?

YES

END

NO

1 Parking Brake Indicator Lit When Parking Brake Lever is DOWN ?

Depress Platform Switch (lower platform)

YES

NO

3

Repair/Replace Parking Brake Switch

2

Repair/Replace Platform Switch

Repair/Replace Joystick Switch

NO AL 400 Series Serial Numbers 41249 and Below

2

AL 500 Series Serial Numbers 51241 and Below

NO

Parking Brake Indicator Lit When Parking Brake Lever UP ?

YES

YES

NO

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Platform Switch Depressed ?

With Parking Brake Lever DOWN, Drive Direction Indicators Operate When Drive Direction Switch Engaged ?

YES

1 Repair/Replace Parking Brake Switch

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Hydraulics — Hydraulics Troubleshooting Diagnostic Flow Charts Drive System Electrical Diagnostics (Continued) NOTE: The table below refers to the flow chart on the previous page.

Item No.

Reference Information

Additional Information

1

Refer to the parts manual for parking brake switch parts information.

2

Refer to the parts manual for joystick parts information.

3

See “Repairing or Replacing Platform Switch” on page 64.

Refer to the parts manual for platform switch parts information.

See: • “Fuse Locations” on page 37.

4 • “Engine Oil Level Check” on page 20.

• “Drive Controller Error Codes” on page 172 and “Machine Controller Logic” on page 169.

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Hydraulics — Drive System Pressure Tests Drive System Pressure Tests Drive System Components The following figure shows general drive system component locations

F B

C

D

A

E

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A

“A” Port Test Fitting

B

“B” Port Test Fitting

C

Drive/Piston Pump

D

Work/Gear Pump

E

Drive Motor

F

Charge Pressure Port Test Fitting

121

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Hydraulics — Drive System Pressure Tests Charge Pump Pressure Test

IMPORTANT: Start with a pressure gauge rated for a higher pressure than required, and move to lowerpressure gauges as needed. Gauges will be damaged if the pressure exceeds the capacity of the gauge.

This test determines the condition of the charge pump.

STEP 1 Start the machine and allow it to warm to operating temperature (120° F / 49° C). Set the throttle to low idlle (1000 rpm).

STEP 2 Tilt the platform according to “Tilting the Platform” on page 61.

Connect a pressure gauge rated for 414 bar (6000 psi) to test fitting (F). Start the machine. With the engine at low idle, shift the drive into forward and check the pressure on the gauge.

NOTE: It may be necessary to switch to a pressure gauge rated for 39 bar (1000 psi) to accurately measure charge pressure.

Alternate Charge Pump Pressure Test Procedure

F

B

STEP 2 Charge pump pressure can be read indirectly from either port (A) or port (B), depending upon which port exhibits the lower pressure as follows: IMPORTANT: Start with a pressure gauge rated for a higher pressure than required, and move to lowerpressure gauges as needed. Gauges will be damaged if the pressure exceeds the capacity of the gauge.

Connect pressure gauges rated for 414 bar (6000 psi) to the test fitting. Start the machine. With the engine at low idle, shift the drive into forward and check the pressures on the gauges. The gauge displaying the lower pressure is connected to the port that can be used for measuring charge pump pressure indirectly.

A

NOTE: It may be necessary to switch to a pressure gauge rated for 34.5 bar (500 psi) to accurately measure charge pressure.

F

IMPORTANT: DO NOT shift from forward into reverse with the 39 bar (1000 psi) gauge installed or damage to the gauge will result.

B

STEP 3 Pressure should be no lower than 32 ± 1.5 bar (464 ± 22 psi).

A

NOTE: Higher engine rpms and cooler hydraulic oil pressures will result in higher charge pressure readings. Pressures above 41 bar (600 psi) could indicate a malfunctioning relief valve.

Primary Charge Pump Pressure Test Procedure STEP 2 Charge pump pressure can be read directly from port (F) as follows:

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Hydraulics — Drive System Pressure Tests Drive Pressure Test

STEP 3

This test determines the condition of the drive/piston pump.

Start the machine and allow it to warm to operating temperature (120° F / 49° C).

STEP 1

STEP 4

Tilt the platform according to “Tilting the Platform” on page 61.

Carefully drive the machine against an immovable object, such as a tree.

STEP 2

STEP 5 Drive the machine against the object and record the pressure on gauge.

B

NOTE: Pressure will ramp up at either the (A) or (B) ports depending upon whether the drive is in forward or reverse.

STEP 6 Check the pressures at both low and high idle.

Pressure should be 400 ± 15 bar (5800 ± 218 psi). in both forward and reverse.

A

NOTE: The higher value represents relief pressure for the drive system. Using the travel pedal, it should be possible at high idle to ramp pressure all the way up to relief pressure if the tires do not slip. Inability to reach relief pressure can indicate a malfunctioning relief valve, internal leakage in the system, or other drive circuit problems.

IMPORTANT: A malfunctioning relief valve or other internal problems could cause pressure to exceed relief pressure, If the pressure spikes higher than relief pressure, stop the pressure check and shut down the engine immediately. Exceeding relief pressure can cause serious damage to the hydraulic system.

B

A

IMPORTANT: Start with a pressure gauge rated for a higher pressure than required, and move to lowerpressure gauges as needed. Gauges will be damaged if the pressure exceeds the capacity of the gauge.

On the drive/piston pump, connect pressure gauges rated for 414 bar (6000 psi) to test fittings (A) and (B).

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Hydraulics — Work System Pressure Tests Work System Pressure Tests

STEP 4

Work Pressure Test

Later Machines

This test determines the condition of the work/pump.

STEP 1 Tilt the platform according to “Tilting the Platform” on page 61.

STEP 2

A

Early Machines

IMPORTANT: Start with a pressure gauge rated for a higher pressure than required, and move to lowerpressure gauges as needed. Gauges will be damaged if the pressure exceeds the capacity of the gauge.

Connect a pressure gauge rated for 414 bar (6000 psi) to test fitting (A) inside the front of the steering console pedestal.

Operate the auxiliary hydraulic flow without connecting an attachment. This will cause the work system circuit to reach full pressure.

NOTE: Early machines require removal of the front panel on the control column base to access test fitting (A).

STEP 5

STEP 3

Work Cylinder Leakage Test

Start the machine and allow it to warm to operating temperature (120° F / 49° C). Set the throttle to low idlle (1000 rpm).

This test determines the condition of the cylinder piston and seals.

Pressure should be 207 ± 7 bar (3000 ± 100 psi).

STEP 1 Start the machine and allow it to warm to operating temperature.

STEP 2 Use the joystick to fully retract the cylinder to be tested.

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Hydraulics — Steering Circuit Pressure Test Steering Circuit Pressure Test

STEP 3 Disconnect the hose from the base of the cylinder.

This test checks for correct steering circuit pressure.

STEP 4 IMPORTANT: Hydraulic oil loss may occur. Provide a means to catch oil where the hose was disconnected from the base of the cylinder.

With an assistant holding a container to catch oil at the point the hose was removed from the base of the cylinder, use the joystick to try to retract the cylinder farther. Only a small amount of oil, or no oil at all, should drain from the port at the base of the cylinder.

Draining oil indicates worn seals and/or piston.

NOTE: Incorrect steering circuit pressure may indicate other hydraulic system problems. Refer to “Hydraulics Troubleshooting Diagnostic Flow Charts” on page 107.

STEP 1 Tilt the platform according to “Tilting the Platform” on page 61.

STEP 2

A

Insert a run tee (Mustang P/N 176526) in between the hydraulic hose and 90° fitting indicated in the figure at (A).

NOTE: A test fitting (Mustang P/N 50300055) can additionally be inserted to allow connecting a Mustang pressure test kit (Mustang P/N 184476).

IMPORTANT: Start with a pressure gauge rated for a higher pressure than required, and move to lowerpressure gauges as needed. Gauges will be damaged if the pressure exceeds the capacity of the gauge.

Connect a pressure gauge rated for 414 bar (6000 psi) to the test fitting.

STEP 3 Start the machine and allow it to warm to operating temperature.

STEP 4 Turn the steering in one direction all the way to the stop to dead-head the cylinder.

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Hydraulics — 2-Spool Control Valve Removal 2-Spool Control Valve Removal

STEP 5 Quickly read the pressure reading and slightly return the steering so it is not against the stop.

IMPORTANT: Hydraulic oil temperature rises sharply when steering is dead-headed against the stop. Do not keep the steering in the dead-headed position against the stop for long periods or damage to hydraulic components can result.

Steering pressure should be 195 ± 5 bar (2825 ± 70 psi)

400 Series 41250 and Up 500 Series 51242 and Up STEP 1 Tilt the platform. See “Tilting the Platform” on page 61.

STEP 2 Remove the battery. See “Battery Removal” on page 183.

NOTE: Remove the battery to allow better access to the 2-spool control valve hydraulic hoses.

STEP 3

1

Remove protective boot (1) from joystick.

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Hydraulics — 2-Spool Control Valve Removal STEP 6

STEP 4

2

6

3 12

NOTE: If equipped with cab, seat deck liner will need to be modified to access cover (4).

Loosen set screw (6) in joystick base. Loosen jam nut (12) and remove joystick.

STEP 7

7

7

4

3

7

7

3

7

Remove torx screws (3). Remove covers (2) and (4).

Remove and plug hydraulic hoses (7) from control valve.

STEP 5 STEP 8

8

8

5

Disconnect electrical connector (5).

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Remove the lower mounting bolts and nuts (8) from the control valve.

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Hydraulics — 3-Spool Control Valve Removal NOTE: Photo may not exactly match installation.

3-Spool Control Valve Removal

STEP 9

400 Series 41249 and Before 500 Series 51241 and Before 9

STEP 1

9

Tilt the platform. See “Tilting the Platform” on page 61.

STEP 2 Remove the battery. See “Battery Removal” on page 183.

NOTE: Remove the battery to allow better access to the 3-spool control valve hydraulic hoses.

STEP 3

Remove upper mounting bolts and nuts (9). Remove control valve from machine.

1

2

Remove protective boots (1) and (2) from the joystick and auxiliary control lever.

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Hydraulics — 3-Spool Control Valve Removal STEP 4

STEP 5

4 6 3

5

3

7

3 Remove electrical connectors (6) and (7).

Remove torx screws (3). Remove covers (4) and (5).

STEP 6

6

12

Loosen set screw (6) in joystick base. Loosen jam nut (12) and remove joystick.

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Hydraulics — 3-Spool Control Valve Removal STEP 10

STEP 7

12

12

9

Loosen the auxiliary control lever jam nut (9). Remove the lever.

Remove the lower mounting bolts (12) from the control valve.

NOTE: Photo may not exactly match installation.

STEP 8

10

STEP 11

10

13 13 Label, remove and plug the five upper hydraulic hoses (10) from control valve.

Remove upper mounting bolts (13). Remove control valve from machine.

STEP 9

11

Label, remove and plug the three lower hydraulic hoses (11) from control valve.

NOTE: Photo may not exactly match installation.

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Hydraulics — 2-Spool Control Valve Installation 2-Spool Control Valve Installation

STEP 3

4

400 Series 41250 and Up 500 Series 51242 and Up

4

STEP 1

4

4

1

4

Install the seven hydraulic hoses (4).

2

STEP 4

Install control valve (2) onto machine. Install upper mounting bolts and nuts (1).Tighten to 18 lb-ft (25 N•m).

11

STEP 2

12

3

3

Loosen set screw (11) in joystick base. Loosen jam nut (12) and remove joystick.

STEP 5

Install lower mounting bolts and nuts (3). Tighten to 18 lb-ft (25 N•m).

NOTE: Photo may not exactly match installation.

6

Connect electrical connector (6).

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Hydraulics — 2-Spool Control Valve Installation STEP 9

STEP 6

Lower the platform. See “Tilting the Platform” on page 61.

7

STEP 10 Start the engine and bleed the air out of the hydraulic control valve by cycling through the joystick function three times.

8

Check the hydraulic reservoir fluid level and fill as needed. Refer to “Fluid Capacities/Lubricants” on page 11.

STEP 11 Start the machine and bleed the air out of the hydraulic control valve by cycling through the joystick function three times.

9

8 8

Install covers (7) and (9). Install torx screws (8).

STEP 7

10

Install boot (10) on the joystick.

STEP 8 Install the battery. See “Battery Installation” on page 184.

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Hydraulics — 3-Spool Control Valve Installation 3-Spool Control Valve Installation

STEP 3

4

400 Series 41249 and Before 500 Series 51241 and Before STEP 1

1

Install lower hydraulic hoses (4).

2

NOTE: Photo may not exactly match installation.

2

STEP 4

5

5

Install control valve (1) onto machine. Install upper mounting bolts (2).Tighten to 18 lb-ft (25 N•m).

STEP 2

Install upper hydraulic hoses (5).

3

3

STEP 5

Install lower mounting bolts (3). Tighten to 18 lb-ft (25 N•m).

NOTE: Photo may not exactly match installation.

6

Install the auxiliary control lever. Tighten jam nut (6).

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Hydraulics — 3-Spool Control Valve Installation STEP 8

STEP 6

11

10 12

12

Loosen set screw (11) in joystick base. Loosen jam nut (12) and remove joystick.

11

STEP 7

12

12 8 Install covers (10) and (11). Tighten torx screws (12).

STEP 9

13 14 9

Install electrical connectors (8) and (9).

Install boots (13 and 14) on the joystick and auxiliary control lever.

STEP 10 Install the battery. See “Battery Installation” on page 184.

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Hydraulics — Lift/Tilt Lock, Power-A-Tach® System and Auxiliary STEP 11 Lower the platform. See “Lowering the Platform” on page 62.

STEP 12 Start the engine and bleed the air out of the hydraulic control valve by cycling through the joystick function three times.

Check the hydraulic reservoir fluid level and fill as needed. Refer to See “Fluid Capacities/Lubricants” on page 11.

STEP 13 Start the machine and bleed the air out of the hydraulic control valve by cycling through the joystick function three times.

Lift/Tilt Lock, Power-A-Tach® System and Auxiliary Hydraulics Valve Locations 400 Series 41250 and Up 500 Series 51242 and Up Lift/Tilt Lock Valves The lift and tilt lock valves lock-out the lift arm lift and tilt functions whenever the operator seat is not occupied.

Malfunctioning lift and/or tilt lock valves can result in inoperative lift and/or tilt functions.

The tilt (23) and lift (21) lock valves are fastened to the underside of the operator’s platform, under the operator’s seat, next to the Power-A-Tach ® system hydraulic valve (22) and auxiliary hydraulic valve (20).

23

21

22

20

Power-A-Tach® System Hydraulic Valve The Power-A-Tach ® system valve (22) contols the Power-A-Tach® system cylinder, if equipped to lock attachments into the attachment plate.

The Power-A-Tach® system valve (22) is fastened to the underside of the operator’s platform, under the operator’s seat between the locking valves (21 & 23) and the auxiliary hydraulic valve (20).

Auxiliary Hydraulic Valve The auxiliary hydraulic valve diverts hydraulic flow into the auxiliary hydraulics circuit.

The auxiliary hydraulic valve (20) is fastened to the underside of the operator’s platform, under the operator’s seat next to the lift and tilt lock valves (20 & 21) and the Power-A-Tach® hydraulic valve (22).

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Hydraulics — Lift Cylinder Removal Lift Cylinder Removal

STEP 3

STEP 1

CAUTION

2

3

Securely support the lift arm so when the lift cylinder is removed, the lift arm cannot fall.

STEP 2

3 1 1

2

Place an absorbant mat under the cylinder to catch any dripping oil. Remove and plug hydraulic lines (1).

4

Remove the retaining bolts and nuts (2). Using the proper lifting strap and appropriate lifting device, remove pins (3) and lift cylinder (4).

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Hydraulics — Lift Cylinder Installation Lift Cylinder Installation

STEP 3

STEP 1

5 4 4

1

Using the proper lifting strap and appropriate lifting device, lift the cylinder (1) into place.

Install hydraulic hoses (4) on cylinder (5). Remove lifting strap from cylinder.

STEP 4 Start the machine and bleed the air out of the cylinder by cycling the cylinder through full extension and retraction three times.

STEP 2

STEP 5 Check the hydraulic fluid level and fill as needed. See “Hydraulic System Maintenance” on page 29.

3 2

3

2

Install cylinder pins (2). Install retaining bolts and nuts (3). Tighten bolts and nuts to 33 lb-ft (45 N•m).

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Hydraulics — Tilt Cylinder Removal Tilt Cylinder Removal

Tilt Cylinder Installation

STEP 1

STEP 1

CAUTION

1 2

Support the attachment connection plate so that it doesn’t fall when the tilt cylinder is removed.

STEP 2

3

5

2

Install a lifting strap (1) on the tilt cylinder (2). Use an appropriate lifting device to lift the cylinder into place.

1

STEP 2

5

3

4

3

2

4

5 4

3

Install the pins (3). Install bolts and nuts (4) tighten to 33 lb.-ft. (45 N•m). Install two hydraulic hoses (5) on the tilt cylinder (2). Remove lifting strap.

Remove and plug two hydraulic hoses (1) from the tilt cylinder (2). Remove bolts and nuts (3). Install a lifting strap (4) on the tilt cylinder. Use an appropriate lifting device to support the cylinder. Remove pin (5).

Place an absorbant mat under the cylinder to catch any dripping oil. Remove cylinder.

NOTE: Cylinder plugs will need to be removed to move rod for alignment with pin.

STEP 3 Start the machine and bleed the air out of the cylinder by cycling the cylinder through full extension and retraction three times.

STEP 4 Check the hydraulic fluid level and fill as needed. See “Hydraulic System Maintenance” on page 29.

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Hydraulics — Steering Cylinder Removal Steering Cylinder Removal

Steering Cylinder Installation

STEP 1

STEP 1 Position steering cylinder in machine.

Tilt the platform. See “Tilting the Platform” on page 61.

STEP 2

STEP 2

1

2 1

2 2 Place a drain pan under the steering cylinder (1) and remove and plug hydraulic hoses (2).

IMPORTANT: Dispose of hydraulic oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste oil onto the ground or down a drain.

1 2

STEP 3

4

Install pins (1).Install snap rings (2).

STEP 3

3

4

3

3 3

4 Install hydraulic hoses (3) on cylinder (4).

Lower the platform. See “Lowering the Platform” on page 62.

Remove snap rings (3). Remove pins (4). Remove cylinder.

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Hydraulics — Steering Cylinder Installation STEP 4 Start the machine and bleed the air out of the cylinder by cycling the cylinder through full extension and retraction three times.

STEP 5 Check the hydraulic fluid level and fill as needed. See “Hydraulic System Maintenance” on page 29.

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly Hydraulic Cylinder Disassembly/ Assembly

Cylinder Disassembly

Except for some configuration differences, hydraulic cylinder disassembly, repair and assembly procedures will be mostly the same for all cylinders.

Refer to the parts manual for specific part and part orientation information for specific cylinders.

When backup rings are used with o-ring seals, always note the position of the backup ring (above or below the o-ring) when removing the seals for reassembly reference.

WARNING When disassembling hydraulic cylinders, NEVER use pneumatic or hydraulic pressure to aid in removing the piston and rod assembly from the cylinder barrel. Ignoring this warning may result in severe injury or death.

STEP 1

One-piece teflon piston seals can be difficult to install on the piston. Soaking the seals in hot 130°-140° F (54°-60° C), clean hydraulic oil for a short time prior to installation will make the seals more resilient and easier to install on the piston.

2

1

Before installing the piston and rod assembly into the barrel, lubricate the piston seals and wear rings liberally with clean hydraulic fluid. Using an engine piston ring compressor to compress the piston seals tightly for a short period of time will often aid in the assembly procedure.

3

G0908021

Refer to the following pages for the disassembly / assembly procedures: • “Cylinder Disassembly” on page 141.

• “Cylinder Assembly” on page 145.

Clamp the base end of the cylinder (1) in a vice (2).

Position a wooden block (3) under the cylinder as shown.

STEP 2 2

1

G0908023

Loosen and remove the head gland (1) from the cylinder (2).

IMPORTANT: Protect the polished surface finish on the cylinder rod at all times by covering the polished surface with impact-resistant material.

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 6

STEP 3

1 2 2 1 G0908022

G0908019

Remove the rod assembly (1) from the cylinder base (2).

Remove the piston (1) from the cylinder rod (2).

STEP 7

STEP 4 2 2 1

3

1 G0908018

Remove the head gland (1) from the cylinder rod (2).

G0908018

Remove the cylinder base from the vice and clamp the rod end (1) in the vice (2). Support the rod on a wooden block (3).

STEP 8 1

STEP 5

2

2 1

G0908016

G0908020

Remove and discard the wear ring (1) from the piston (2).

Remove the nut (1) from the cylinder rod (2).

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 12

STEP 9 2

2 1

1

G0908015

G0908010

Remove and discard the o-ring (1) from the piston (2).

Remove and discard the o-ring and backup ring (1) from the head gland (2). Note the position of the backup ring and the o-ring.

STEP 10

STEP 13 1

2 2 1 G0908014

Remove and discard the outer seal (1) from the piston (2).

G0908009

Remove and discard the o-ring (1) from the head gland (2).

STEP 11

STEP 14 2 1

1 2 G0908013

Remove and discard the inner o-ring (1) from the piston (2).

G0908008

Remove and discard the wiper ring (1) from the head gland (2).

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 18

STEP 15

Inspect all parts for damage, wear and scoring.

Replace as needed.

STEP 19 1

Remove the bearing (1) from the rod end (2). Discard the wear bearing if replacement is needed.

2

G0908007

Remove and discard the rod seal (1) from the head gland (2).

STEP 16

1

G0908012

If required, remove the snap ring (1).

STEP 17 1

2 G0908011

Remove and discard the bearing (1) from the rod end (2).

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly Cylinder Assembly

STEP 3

STEP 1 1 2 1

G0908007

Install a new seal (1) in the head gland (2).

2 G0908011

If needed, install a new bearing (1) in the rod end (2).

NOTE: Lubricate all new seals with clean hydraulic fluid or petroleum jelly.

STEP 2

STEP 4

Install the snap ring (1) into the rod end (2).

1

2 G0808008

Install a new wiper ring (1) in the head gland (2).

STEP 5 2

1 G0908009

Install a new o-ring (1) on the head gland (2).

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 9

STEP 6 2

1

2

1

G0908010

G0908015

Install a new backup ring and o-ring (1) on the head gland (2) in the same positions as the ones that were removed.

Install a new o-ring (1) on the piston (2).

STEP 10 1

STEP 7

2

2

1

G0908016

Install a new wear ring (1) on the piston (2).

G0908013

Install a new inner o-ring (1) on the piston (2).

STEP 11 2

STEP 8

1

2

1

G0908017

Clamp the cylinder rod (1) in a vice (2).

G0908014

Install a new outer seal (1) on the piston (2).

50940008/AP0311

IMPORTANT: Protect the polished finish on the cylinder rod at all times.

146

PRINTED IN U.S.A.

Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 15

STEP 12

2

1 2 1

3

G0908018

G0908021

Install the head gland (1) onto the cylinder rod (2).

Remove the cylinder rod from the vice and clamp the cylinder base (1) in the vice (2). Support the base on a wooden block. (3)

STEP 13 1

STEP 16

2

1

2

G0908019

Install the piston (1) onto the cylinder rod (2).

G0908022

Insert the rod assembly (1) into the cylinder base (2).

STEP 14

2

1

G0908020

Use Loctite® 271 or equivalent on the threads. Install the nut (1) on the cylinder rod (2) and tighten to 350 lb.ft. (475 N•m).

PRINTED IN U.S.A.

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Hydraulics — Hydraulic Cylinder Disassembly/Assembly STEP 17

2 1

G0908023

Install and tighten the head gland (1) into the cylinder base (2).

IMPORTANT: Protect the polished surface on the cylinder rod at all times.

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Hydraulics — Gear/Work Hydraulic Pump Removal Gear/Work Hydraulic Pump Removal

Gear/Work Hydraulic Pump Installation

STEP 1 STEP 1

1 1

2 Remove the hydraulic oil reservoir plug (1) and drain the hydraulic oil. Install the reservoir plug.

Install a new O-ring (1) on the pump (2).

NOTE: The reservoir capacity is approximately 10.6 gal. (40 L).

STEP 2

IMPORTANT: Dispose of hydraulic oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste oil onto the ground or down a drain.

5 3

STEP 2 Tilt the platform. See “Tilting the Platform” on page 61.

4

STEP 3

5

Place a drain pan under the pump.

STEP 4

Apply Loctite ® 262 or equivalent to pump mounting bolts (3).

2

Using pump mounting bolts (3), install pump (4) onto machine and tighten bolts to 33 lb-ft (45 N•m). Install hoses (5).

3

STEP 3 Lower the platform. See “Lowering the Platform” on page 62.

4

STEP 4

2 Remove hydraulic hoses (2). Remove pump mounting bolts (3) and remove pump (4).

Fill the hydraulic reservoir with the proper hydraulic oil.

See “Fluid Capacities/Lubricants” on page 11.

NOTE: Make note of the port size difference for proper orientation during installation.

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Hydraulics — Piston/Drive Hydraulic Pump Removal STEP 5 Start the engine and let it run for five minutes. Check for leaks.

Piston/Drive Hydraulic Pump Removal STEP 1

Shut off the engine.

Check the hydraulic reservoir level. See “Hydraulic System Maintenance” on page 29.

1

Remove the hydraulic oil reservoir plug (1) and drain the hydraulic oil. Install the reservoir plug.

NOTE: The reservoir capacity is approximately 10.6 gal. (40 L).

IMPORTANT: Dispose of hydraulic oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste oil onto the ground or down a drain.

STEP 2 Tilt the platform. See “Tilting the Platform” on page 61.

STEP 3 Remove the battery. See “Battery Removal” on page 183.

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Hydraulics — Piston/Drive Hydraulic Pump Removal STEP 7

STEP 4

2

2

11

Label and disconnect harness connectors (2).

STEP 5

3

4

Label, disconnect, and plug small hydraulic hoses (3 and 4).

Using the appropriate lifting device, support the pump.

Remove two mounting bolts (11). Slide pump forward until shaft is clear of drive splines and remove the pump from the machine.

NOTE: Gear/work hydraulic pump removed for picture purposes only.

STEP 6

5 10

6 7 12 9

Label, disconnect, and plug large hydraulic hoses (5 through 12).

NOTE: Remove fittings and sending unit for easier access to mounting hardware.

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Hydraulics — Piston/Drive Hydraulic Pump Installation Piston/Drive Hydraulic Pump Installation

STEP 3

8

STEP 1

9 1 Install hydraulic hoses (8 and 9).

Apply anti-seize to the splines on the pump shaft.

Using the appropriate lifting device, lift the pump into place. Install the pump into the machine. Apply Loctite® 262 or equivalent and install two pump mounting bolts (1). Tighten bolts to 92 lb-ft (125 N•m).

STEP 4

10

STEP 2

11

2 3 7 6

In st al l wi r e ha rn es s c o nne c tor s (1 0) on p um p directional solenoids (11).

4 5

STEP 5 Install the battery. See “Battery Installation” on page 184.

Install large hydraulic hoses (2 through 7). Install fittings and sending unit, if removed.

STEP 6 Lower the platform. See “Lowering the Platform” on page 62.

STEP 7 Fill the hydraulic oil reservoir with the proper hydraulic oil. See “Fluid Capacities/Lubricants” on page 11.

STEP 8 Start the engine and run for 5 minutes, checking for leaks. Operate the drive system to work air out of the hydraulic system.

STEP 9 Check the hydraulic reservoir level and fill as needed.

See “Hydraulic System Maintenance” on page 29.

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Hydraulics — Hydrostatic Motor Removal Hydrostatic Motor Removal

STEP 4

STEP 1

1 12

Remove the hydraulic oil reservoir plug (1) and drain the hydraulic oil. Install the reservoir plug.

Remove the speed sensor connection (12) from the bottom of the hydrostatic motor.

NOTE: The reservoir capacity is approximately 10.6 gal. (40 L).

STEP 5

IMPORTANT: Dispose of hydraulic oil according to environmental laws or take to a recycling center for proper disposal. DO NOT pour waste oil onto the ground or down a drain.

5

STEP 2

4

Tilt the operator platform. See “Tilting the Platform” on page 61.

STEP 3

2

3

Remove drive shaft mounting nuts (3) and remove drive shaft (4) from axle housing (5).

2

STEP 6 Place a drain pan under the motor.

Remove the wire harnesses (2) from the hydrostatic motor solenoids.

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Hydraulics — Hydrostatic Motor Removal STEP 7

STEP 8

7 6

6

6

Remove motor mounting bolts (7). Remove motor.

Remove O-ring from axle housing.

Label, remove and plug hydraulic hoses (6).

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Hydraulics — Hydrostatic Motor Installation Hydrostatic Motor Installation

STEP 3

STEP 1

2 5

4

1

Install drive shaft (4). Install nuts (5). Tighten nuts to 18 lb-ft (25 N•m).

STEP 4

Apply anti-seize to the motor splines. Install O-ring in axle housing. Install motor (1) onto the axle housing.

Apply Loctite® 262 or equivalent and install the motor mounting bolts (2). Tighten to 92 lb-ft (125 N•m).

6

NOTE: If installing a new motor, install new hydraulic fittings. Torque the fittings to 66 lb-ft (90 N•m).

6

STEP 2

3

Connect wire harness (6) to motor solenoid.

STEP 5

3

3

Install hydraulic hoses (3).

12

Connect the speed sensor harness (12) to the bottom of the hydrostatic motor, as shown.

STEP 6 Fill the hydraulic reservoir with the proper hydraulic oil.

See “Fluid Capacities/Lubricants” on page 11.

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Hydraulics — Steering Control Valve Removal STEP 7

Steering Control Valve Removal

Start the engine and run for 5 minutes, checking for leaks. Operate the drive system to work air out of the hydraulic system.

400 Series 41250 and Up 500 Series 51242 and Up

Shut off engine.

STEP 1

STEP 8 Check hydraulic reservoir level and fill as needed. See “Hydraulic System Maintenance” on page 29.

Perform the shutdown procedure. See “Mandatory Safety Shutdown Procedure” on page 4.

STEP 2

1 1

2

Remove torx screws (1) and cover (2).

STEP 3

3

3

4

Remove torx screws (3) from the steering column access panel (4) and remove panel.

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Hydraulics — Steering Control Valve Removal STEP 4

5

5

6

Label, disconnect and plug hydraulic hoses (5).

Remove fitting (6).

STEP 5

7

7

8 7

7

Lift steering column boot (8) and remove four mounting bolts (7). Remove the steering control valve from machine.

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Hydraulics — Steering Control Valve Removal Steering Control Valve Removal

STEP 4

400 Series 41249 and Before 500 Series 51241 and Before 4

4

STEP 1

Label, disconnect and plug hydraulic hoses (4).

STEP 5

5

Turn machine all the way to right as shown.

STEP 2

6

Perform the shutdown procedure. See “Mandatory Safety Shutdown Procedure” on page 4.

STEP 3

1

Remove torx screws (5) from the steering column access panel (6) and remove panel.

3

STEP 6

2 Remove wire harness connector (1) from horn (2).

Remove nut (3) and remove horn.

7

8 Lift steering column boot (7) and remove mounting bolts (8). Remove the steering control valve from machine.

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Hydraulics — Steering Control Valve Installation Steering Control Valve Installation

STEP 3

4

400 Series 41250 and Up 500 Series 51242 and Up

4

STEP 1

1 5 1 1

Install access panel (5) and torx screws (4).

1

STEP 4

6 6 Install steering control valve and bolts (1). Tighten the bolts to 33 lb-ft (45 N•m).

STEP 2

7 2

2

3

Install cover (7) and torx screws (6).

STEP 5 Start machine. Check steering operation and check for leaks.

STEP 6

Install hydraulic hoses (2) and fitting (3).

PRINTED IN U.S.A.

Bleed air out of steering control valve by turning steering wheel fully to the right and then fully to the left three times.

159

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Hydraulics — Steering Control Valve Installation Steering Control Valve Installation

STEP 3

400 Series 41249 and Before 500 Series 51241 and Before 4

4

STEP 1

Install hydraulic hoses (4).

STEP 4

1 Install valve and bolts (1). Tighten the bolts to 33 lb-ft (45 N•m).

7 STEP 2

5

3 6

2

Use nut (5) to secure horn (6). Install wire harness connector (7).

STEP 5 Install steering access panel (2) and torx screws (3).

Tighten the screws.

Start machine. Check steering operation and check for leaks.

STEP 6 Bleed air out of steering control valve by turning steering wheel fully to the right and then fully to the left three times.

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Hydraulics — Raising Machine for Drive System Troubleshooting Raising Machine for Drive System Troubleshooting

STEP 4

WARNING Use extreme caution when raising the machine for drive system troubleshooting. Never allow anyone under a raised machine. Lowering the lift arm or a falling machine can result in death or serious personal injury.

1

STEP 1 Park the machine where it can be lifted with the appropriate equipment. Make sure the lifting equipment is in good working order and is of sufficient capacity.

Secure the steering lock bar (1) in the transport position using the cotter pins provided.

STEP 5 FRONT SUPPORT POINTS

WARNING Do not lift machine without the proper equipment.

For machine weights, see “Weights and Capacities” on page 14.

1

STEP 2 Per for m the s hutdown procedur e acc ording to “Mandatory Safety Shutdown Procedure” on page 4.

STEP 3 Close the engine cover.

If the machine is equipped with a cab, close the cab doors.

Jack up the front wheels of the machine below the center (differential) of the front axle. Position two jackstands under both sides of the front frame behind the front wheels as shown and carefully lower the machine onto jackstands (1)

CAUTION To prevent injury and equipment damage, always close and lock the cab doors (if applicable) and close the engine cover before lifting the machine.

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Hydraulics — Raising Machine for Drive System Troubleshooting STEP 6 REAR SUPPORT POINTS

3

2 1

Jack up the rear wheels of the machine below the center (differential) of the rear axle.

Slide a steel rod (2) through the tie-down eyelets (3) located under the rear frame. Position two jackstands against the steel bar to next to the inside of the eyelets as shown. Carefully lower the machine onto jackstands (1).

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Hydraulic Schematics — AL 400 Series Hydraulic Schematic – SN 41250 and Up AL 400 Series Hydraulic Schematic – SN 41250 and Up

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Hydraulic Schematics — AL 400 Series Hydraulic Schematic – SN 41249 and Before AL 400 Series Hydraulic Schematic – SN 41249 and Before AUXILIARY COUPLERS

BRAKE RESERVOIR

MALE FEMALE

240 BAR (3480 PSI)

L

TILT CYLINDER

FRONT BRAKE

R

LIFT CYLINDERS

POWER-A-TACH CYLINDER STEER CYLINDER

190 BAR (2755 PSI)

MASTER CYLINDER

C1

C2

S1

S2

REAR DIFFERENTIAL LOCK

L

POWER-A-TACH VALVE CHECK VALVE

A3

69 BAR (1000 PSI)

T

B3

A2

B2

A1

L

B1

7.75 L (2 GAL.) PER MIN.

103 BAR (1500 PSI)

P

4.8 BAR (70 PSI)

STEERING CONTROL UNIT

214 BAR (3100 PSI)

P CF

P

LS

T

FRONT DIFFERENTIAL LOCK

R R

T

EF

DIFFERENTIAL LOCK VALVE

HPCO

C1

C2

ORF 1

PC1 PC08-30 SV08-30 SVI

P

P1

T1

T

OIL COOLER

MAIN CONTROL VALVE

A

L1

HYROSTATIC PUMP - 45 CC (2.75 in3)

A P

RETURN FILTER

C2

ELECTRIC PRESSURE SWITCH - 2.5 BAR (36 PSI)

C1 M3

BYPASS PRESSURE - 2.5 BAR (36 PSI) CHARGE PRESSURE - 0.5 BAR (7.3 PSI)

min. disp.

M3

M5

MA

M4

A

L2 B

B

M4

M

flow out A

GEAR PUMP 20 CC (1.22 in3)

cw

LOW IDLE - 1000 RPM L4 HIGH IDLE - 3000 RPM L3 RATED - 2800 RPM

B

HYDROSTATIC MOTOR 60 CC MAX (3.66 in3) 27 CC MAX (1.65 in3)

MB L2

50940008/AP0311

L1

S

164

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Hydraulic Schematics — AL 500 Series Hydraulic Schematic – SN 51242 and Up AL 500 Series Hydraulic Schematic – SN 51242 and Up

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Hydraulic Schematics — AL 500 Series Hydraulic Schematic – SN 51241 and Before AL 500 Series Hydraulic Schematic – SN 51241 and Before AUXILIARY COUPLERS

BRAKE RESERVOIR

MALE FEMALE

240 BAR (3480 PSI)

L

LIFT CYLINDERS

TILT CYLINDER

FRONT BRAKE

R

POWER-A-TACH CYLINDER STEER CYLINDER

190 BAR (2755 PSI)

MASTER CYLINDER

C1

C2

S1

S2

REAR DIFFERENTIAL LOCK

L

POWER-A-TACH VALVE CHECK VALVE

A3

69 BAR (1000 PSI)

T

B3

A2

B2

A1

L

B1

P CF

LS

T

FRONT DIFFERENTIAL LOCK

R R

7.75 L (2 GAL.) PER MIN.

103 BAR (1500 PSI)

P

2.1 BAR (30 PSI)

STEERING CONTROL UNIT DISPLACEMENT

214 BAR (3100 PSI)

P

T

EF C1

C2

ORF 1

PC1 PC08-30

160 CC (9.76 in3)

DIFFERENTIAL LOCK VALVE

HPCO

SV08-30 SVI

P

P1

T1

T

OIL COOLER

MAIN CONTROL VALVE

A

L1

HYDROSTATIC PUMP - 45 CC (2.75 in3)

A P

RETURN FILTER

C2

ELECTRIC PRESSURE SWITCH - 2.5 BAR (36 PSI)

C1 M3

BYPASS PRESSURE - 2.5 BAR (36 PSI) CHARGE PRESSURE - 0.5 BAR (7.3 PSI)

min. disp.

M3

M5

MA

M4

A

L2 B

B

M4

M

flow out A

GEAR PUMP 20 CC (1.22 in3)

cw

L4 LOW IDLE - 1000 RPM L3 RATED - 2800 RPM

B

HYDROSTATIC MOTOR 60 CC MAX (3.66 in3) 27 CC MAX (1.65 in3)

MB L2

L1

S

CHARGE PRESSURE - 32 BAR (464 PSI) RELIEF SETTING - 400 BAR (5800 PSI) MAX CHARGE PUMP - 12 CC (0.73 IN3)

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Drive Control System— Machine and Drive Controllers CHAPTER 10 — MACHINE/DRIVE CONTROLLERS Machine and Drive Controllers

• For information about the machine controller, see: “Machine Controller” on page 168.

The machine controller provides operator control logic.

• For information about the drive/PLUS+1 controller, see: “Machine Controller” on page 168.

The drive controller (PLUS+1 module) provides computerized control of the drive system, and provides error-reporting functionality.

The drive controller receives inputs from the throttle sensor, inching sensor, engine RPM sensor, and pump RPM sensor. Additionally, the machine control module sends forward/neutral/reverse drive and hi/low gear input data to the drive controller.

NOTE: Applying the park brake shifts the drive into neutral. The drive is shifted into low gear when the engine is started.

3

2 1

1. Drive Controller 2. LED LIghts 3. Machine Controller

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Drive Control System— Machine Controller Machine Controller The machine controller provides operator control logic.

Machine Controller LED/Indicator Assignments The machine controller input/output indicators can be used for system troubleshooting.

AL 400 Series: SN 41250 and up AL 500 Series: SN 51242 and up

AL 400 Series: SN 41249 and before

2 3

1

AL 500 Series: SN 51241 and before

4 1

2 3

10

4

26

5

20

6

21

7

7

8

6

9

9

10

8

11

22

12

11

13

23

14

24

15

13

16

25

17

15

18

16

19

19 18 17

LED

Description

1

12 volt power is coming in to controller

2

High drive speed indicator signal sent to instrument panel

3

Low drive speed indicator signal sent to instrument panel

4

Glow plug indicator signal sent to instrument panel

5

Signal sent to auxiliary hydraulics circuit solenoid

6

Signal sent to auxiliary engine start relay

7

Signal sent to drive speed range toggle (high/low -- indicator is ON in low speed)

8

Signal sent to drive pump travel direction solenoid (forward)

9

Signal sent to drive pump travel direction solenoid (reverse)

10

Signal sent to glow plug relay (timed)

11

Signal sent to fuel solenoid to start fuel flow

12

Operator’s platform switch in closed position (platform down) -- (Early serial number machines only)

13

Later serial number machines: parking brake switch in closed position (brake on) Early serial number machines: parking brake switch in open position (brake off)

14

Auxiliary hydraulics circuit control lever in neutral position -- (Early serial number machines only)

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Drive Control System— Machine Controller LED

Description

15

Drive speed switch on joystick closed (depressed)

16

Drive direction switch on joystick in reverse position

17

Drive direction switch on joystick in forward position

18

NOT USED

19

Ignition switch in “ON/START/RUN” position

20

Signal sent to auxiliary hydraulics flow solenoid (forward direction) -- (Later serial number machines only)

21

Signal sent to auxiliary hydraulics flow solenoid (reverse direction) -- (Later serial number machines only)

22

Signal sent to lift/tilt lock solenoids (lift/tilt activation; all safety requirements met) -- (Later serial number machines only)

23

Reverse direction auxiliary hydraulics joystick button closed (depressed) -- (Later serial number machines only)

24

Seat switch in closed position (operator in seat) -- (Later serial number machines only)

25

Forward direction auxiliary hydraulics joystick button closed (depressed) -- (Later serial number machines only)

26

Signal sent to fuel solenoid to maintain fuel flow

Machine Controller Logic Functions controlled by the machine controller follow specific logic as described in the following table. Numbers in the table refer to the numbered LEDs in the previous table.

NOTE: Not all possible logic function states are shown in the table.

Function

Glow Plug

“IN” LEDs

“OUT” LEDs

Notes

When the ignition switch is in the (1) -- Ignition switch in "ON" position (10) -- Signal sent to glow plug relay “ON” position and engine temperature is below 50° F (10° C), glow (no LED) Engine temperature is (4) -- Signal sent to glow plug indica- plug and glow plug indicator are below 50° F (10° C) tor on instrument panel activated for a period of time determined by engine temperature (1) -- Ignition switch in "START" position

The engine will start only if:

Later serial number machines: (6) -- Signal sent to engine starter Later serial number machines: (13, 24) -- (24) Seat switch indicates The operator seat is occupied and/ operator in seat and/or (13) parking (11) -- Signal sent to fuel solenoid for or the parking brake is on brake engaged Engine Start 1.5 seconds to start fuel flow Early serial number machines: Earlier serial number machines: (26) -- Signal sent to fuel solenoid to The operator seat platform is down (12, 13, 14) -- (24) ROPS tilt switch maintain fuel flow and/or the parking brake is on and/ indicates operator platform is down or the auxiliary hydraulics lever is in and/or (13) parking brake engaged neutral (centered) position and/or (14) auxiliary hydraulics lever is in forward/reverse position (1) -- Ignition switch in "START" position (16, 17) -- Joystick drive direction Engine Start switch is in (17) forward or (16) Disabled reverse position

Engine will not start if the joystick drive direction switch is not in the neutral position NO "OUT" SIGNALS

Earlier serial number machines: (14) -- Auxiliary hydraulics lever is in forward/reverse position PRINTED IN U.S.A.

169

Early serial number machines: Additionally, engine will not start if auxiliary hydraulics lever is not in neutral (centered) position

50940008/AP0311

Drive Control System— Machine Controller Function

“IN” LEDs

“OUT” LEDs

(1) -- Ignition switch in "RUN" position

Notes

The engine will run only if:

Later serial number machines: Later serial number machines: (13, 24) -- (24) Seat switch indicates The operator seat is occupied and/ Engine Run operator in seat and/or (13) parking (26) -- Signal sent to fuel solenoid to or the parking brake is on Safety brake engaged maintain fuel flow Early serial number machines: The operator seat platform is down and/or the parking brake is on

Earlier serial number machines: (12, 13) -- (24) ROPS tilt switch indicates operator platform is down and/ or (13) parking brake engaged

Lift/Tilt Safety

Later serial number machines only

(1) -- Ignition switch in "RUN" position

(22) -- Signal sent to lift/tilt lock soleThe lift/tilt functions are enabled noids (24) -- Seat switch indicates operator only with the ignition in the “RUN” in seat position and the operator seat occupied Later serial number machines

(1) -- Ignition switch in "RUN" position (24) -- Seat switch indicates operator Auxiliary in seat (20) -- Signal sent to Forward auxilHydraulics iary hydraulics solenoid Flow (For- (25) -- Forward direction auxiliary hydraulics joystick button is pressed ward) (23) -- Reverse direction auxiliary hydraulics joystick button is pressed (for continuous flow)

Forward auxiliary hydraulics flow is activated if the ignition switch is in the “RUN” position, the operator seat is occupied and the forward direction auxiliary hydraulics joystick is pressed Continuous forward hydraulics flow is activated if the reverse direction hydraulics joystick button is then pressed, and both buttons are held for two seconds. Forward hydraulics flow will then continue after the buttons are released Continuous forward hydraulics flow is deactivated if either button is momentarily pressed

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Drive Control System— Machine Controller Function

“IN” LEDs

“OUT” LEDs

Notes Later serial number machines

(1) -- Ignition switch in "RUN" position (24) -- Seat switch indicates operator Auxiliary in seat Hydraulics (21) -- Signal sent to Reverse auxilFlow (23) -- Reverse direction auxiliary iary hydraulics solenoid (Reverse) hydraulics joystick button is pressed (25) -- Forward direction auxiliary hydraulics joystick button is pressed (for continuous flow)

Reverse auxiliary hydraulics flow is activated if the ignition switch is in the “RUN” position, the operator seat is occupied and the reverse direction auxiliary hydraulics joystick is pressed Continuous reverse hydraulics flow is activated if the forward direction hydraulics joystick button is then pressed, and both buttons are held for two seconds. Reverse hydraulics flow will then continue after the buttons are released Continuous reverse hydraulics flow is deactivated if either button is momentarily pressed Early serial number machines Auxiliary hydraulics flow is activated if the ignition switch is in the “RUN” position, the operator’s platform is down and the auxiliary hydraulics lever is in the forward or reverse position

(1) -- Ignition switch in "RUN" position Auxiliary (12) -- ROPS tilt switch indicates Hydraulics operator platform is down Flow

No Output

(14) -- Auxiliary hydraulics lever in forward/reverse position

Continuous hydraulics flow is activated when the auxiliary hydraulics control lever is moved past the forward/reverse position into the detent Hydraulics flow is deactivated when the auxiliary hydraulics lever is moved to the neutral (centered) position

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Drive Control System— Drive Controller (Plus+1 Module) Drive Controller (Plus+1 Module) Drive controller input/output values can be monitored using the PLUS+1 service tool and provides useful dr ive system troubleshooting information. See "PLUS+1 Service Tool/Module Communication Connection", starting on page 173.

To illustrate, the flash pattern for error code “13” would be: Four medium flashes (message start), pause, one long flash (first digit of error code), pause, three short flashes (second digit of error code), pause. The flash pattern then repeats.

Error Code

Description

LED lights inside the cover indicate the following:

13

Watchdog Ready Error

• Green steady on — Indicates power to the controller and/or proper operating condition

15

Battery Voltage or Sensor Voltage Error

19

Pump Current Forward Error

23

Pump Current Reverse Error

• Red/green flashing — Indicates an error in the system

Drive Controller Error Codes Malfunctioning drive function may indicate a control module error condition.

The following describes external control module error codes. Error codes are indicated by flashing LEDs (3, Fig. 1) located near the electrical connectors at the bottom of the module.

27

Motor Current Error

31

Engine Speed RPM Error

35

FNR Shortcut Error

39

Inching Error

43

Driving Pedal Error

47

Mode Switch-2 Error

55

Brake Pressure Defeat Error (or Parking Brake Error or Brake Light Error)

59

Motor RPM and Direction Error

70

General CAN Receive Error

NOTE: drive controller external error codes provide basic error reporting functionality. Additional error code detail can be accessed through the “Electrical Status” screen in the service tool. See “Electrical Status Error Reporting Screen” on page 177.

The LED flash pattern for error messages starts with four medium-length flashes, which signal the start of the message, followed by a pause. After the pause, a number of long flashes may occur, indicating the first digit for the code. After another pause, a number of short flashes occur indicating the second digit for the code. After a final pause, the flash pattern then repeats.

More than one error code may be displayed, one after the other.

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Drive Control System— Service Communication Kit and PLUS+1 Service Communication Kit and PLUS+1 GUIDE Service Tool Software

STEP 2 Connect the two harnesses in the kit together.

STEP 3

The 203907 service communication kit provides a physical connection between the drive controller and a computer. The kit also provides diagnostic and calibration software and instructions for it’s use.

NOTE: For additional information about the PLUS+1 service tool, its features and functionality, visit the Sauer-Danfoss website at: http://www.sauerdanfoss.com.

PLUS+1 Service Tool/Module Communication Connection Remove the cover from the two-pin service connector on the PLUS+1 module. Plug the harness into the service connector.

STEP 1

STEP 4 Turn the ignition key on the loader to the “1” (Run) position to activate the PLUS+1 module.

STEP 5

Remove the screw and the strap securing the PLUS+1 module service cover on the loader. Remove the cover.

Double click the “PLUS+1 GUIDE Service Tool 4.1” icon on the desktop to launch the PLUS+1 service tool software.

NOTE: Service Tool software installation is required before the service tool can be used.

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Drive Control System— Plus+1 Service Tool Navigation/Overview STEP 6 Plug the USB cable on the “CAN HS” cable into a USB port on the computer that has the PLUS+1 GUIDE Service Tool software installed.

4. After the service tool starts, select “Gateway > CG150>Sauer Danfoss CG150 #0 (Channel0)” from the “Communication” menu.

The first time the USB cable is plugged into the computer, a “Found New Hardware Wizard” window displays.

1. Select the “Install the software automatically” radio button and click “Next”.

Plus+1 Service Tool Navigation/ Overview The “Diagnostic Navigator” is located in the left pane of the service tool window. Selecting items in this pane provides access to functions and data points inside the PLUS+1 module on the machine.

a 2. The system will find and install the proper software located on the PLUS+1 module. b

c

3. Click “Finish” when the “Completing the Found New Hardware Wizard” message displays.

a. The “*ConnDiagram*” PDF document resides inside the PLUS+1 module. This document shows a diagram of the pin assignments for the two 12-pin input/output connectors on the module. b. The “Log Functions” section allows: •

Real-time access to drive system inputs and outputs, allowing for monitoring the drive system while the machine.

•

Detailed error information access – includes both active errors and error history.

c. The “Parameter Functions” section allows: • 50940008/AP0311

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Pedal calibration/re-calibration.

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Drive Control System— Software Log Monitoring Screen •

Selected drive adjustments.

•

Error history reset.

system

parameter

8. Electrical system current supplied to the forward drive solenoid on the drive pump (mA).

9. Electrical system current supplied to the reverse drive solenoid on the drive pump (mA).

Software Log Monitoring Screen The “Software” screen is useful for troubleshooting d r i v e s y s te m p r o b l e m s . I t p r o v i d e s a c c e s s t o transmission controls status values.

10. Electrical system current supplied to the pressure compensation over-ride solenoid on the drive motor (mA).

To access the “Software” screen, select “Diagnostic Navigator”: “Log Functions > System > Software.”

1

5 8 2 9

3

10

4

6 7 NOTE: The figure shows the “Software” screen with the machine engine running and the drive system in neutral.

1. Drive/piston pump speed (in RPMs).

NOTE: Pump speed should the same as engine speed (RPMs).

2. “Start Protection” indicates if drive system is disabled because required conditions are not met; drive is disabled when “ON” is displayed.

3. Drive direction indication; “Forward”, “Neutral” and “Reverse”.

4. Indicates error condition.

5. High/Low gear indication; “Mode 2” = high gear; “Mode 4” = low gear.

6. Electrical system voltage supplied to the drive controller.

7. Voltage supplied to sensors through the drive controller.

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Drive Control System— Electrical Inputs/Outputs Monitoring Screen Electrical Inputs/Outputs Monitoring Screen The “Electrical Inputs/Outputs” screen is useful for troubleshooting. It provides access to: • Input values from the machine controller and various sensors.

• Output values to the drive pump and drive motor solenoid valves.

To access the “Electrical Inputs/Outputs” screen, select “Diagnostic Navigator”: “Log Functions > System > Electrical.”

1

9. Feedback loop for the reverse solenoid on the drive/ piston pump. The left value displays signal strength sent to the solenoid; the right value displays signal strength returned from the solenoid. Good circuit condition is indicated by closely matching values in these two fields.

10.Feedback loop for the pressure compensation override solenoid on the drive motor. The left value displays signal strength sent to the solenoid; the right value displays signal strength returned from the solenoid. Good circuit condition is indicated by closely matching values in these two fields.

8 2

8. Feedback loop for the forward solenoid on the drive/ piston pump. The left field displays signal strength sent to the solenoid; the right fields displays signal strength returned from the solenoid. Good circuit condition is indicated by closely matching values in these two fields.

9 10

3 4 5 6

7

NOTE: The figure shows the “Electrical Inputs/ Outputs” screen with the machine engine running and the forward drive direction selected in the drive system with low gear selected.

1. Drive direction indication; “Forward”, “Neutral” and “Reverse”.

2. High/Low gear indication; “Mode 2” = high gear; “Mode 4” = low gear.

3. Indicates pedal position; 500 mV is the target “Neutral” pedal position.

4. Indicates drive/piston pump speed (RPMs).

NOTE: Engine and pump speed should be the same.

5. Indicates hydraulic motor speed (RPMs).

6. Electrical system voltage supplied to the drive controller.

7. Voltage supplied to sensors through the drive controller.

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Drive Control System— Electrical Status Error Reporting Screen Electrical Status Error Reporting Screen

4. The “Error Counter” field displays the number of reported errors for a given drive system location.

NOTE: This counter persists unless it is cleared using the “System Definition” screen. See “System Definition Error Count/Timestamp Reset Screen” on page 178.

The “Electrical Status” screen is used to view detailed drive system error information.

Error information is displayed highlighted in red. Fields that display error information are highlighted in green when no error conditions exist.

To access the “Electrical Status” screen, select “Diagnostic Navigator”: “Log Functions > Status > Electrical.”

1

2

3

5. The “Last Occurrence Timestamp” field displays the time the most recent error occurred.

NOTE: Time displayed in this field is derived from the hour meter time counter.

6. The “Error Counter” field displays the number of current active/uncleared errors.

4 5

7. The “Hour Meter” field displays accumulated operation time in minutes.

NOTE: The hour meter value accumulates only when the drive controller is supplied with power.

Because of this, it may not accurately reflect engine or machine run time.

6

7

1. The “Error Mode” field indicates the operational condition of the machine based upon reported errors.

Errors effecting safety and/or machine handling limit machine operation in order to prevent accidents, injuries and/or damage to the machine. “SAFE” means the drive has been disabled; “LIMITED” means the drive operates with limited speed and power.

2. The “Error Status” field shows the occurrence of an error next to the location in the drive system the error occurred.

NOTE: The “Error Status” field can display an “ERROR” condition even if the Error Type field displays a corrected condition. To clear the corrected error in the “Error Status” field, turn the ignition “Off”, and then back on to the run or start positions. This temporarily cuts power to the drive module and clears the corrected error.

3. The “Error Type” field displays error type detail, such as “out of Range”, “Value too low”, etc.

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Drive Control System— System Definition Error Count/Timestamp System Definition Error Count/ Timestamp Reset Screen The “System Definition” screen is used to reset error counters and timestamps. See “Electrical Status Error Reporting Screen” on page 177.

To access the “Electrical Status” screen, select “Diagnostic Navigator”: “Parameter Functions > Error history reset.”

To reset error counters and timestamps: 1. Change “0” to “1” in the “Reset Error History” field.

2. Click the download button of the screen.

located near the top

3. Change “1” back to “0” in the “Reset Error History” field.

4. Click the download button of the screen.

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located near the top

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Drive Control System— Drive Controller Pedal Calibration Parameters Drive Controller Pedal Calibration Parameters

NOTE: Adjust this value only in increments of 100 and then test. Extreme changes to this value will reduce the effective control range of the drive pedal.

Poor or no control response will result if the pedals are out of calibration.The PLUS+1 module must be recalibrated whenever:

2. This field indicates the maximum expected drive pedal fully depressed or full travel position.

• The articulated loader speed control or brake/inch pedal mechanical components are removed for service or replacement.

NOTE: Adjust this value only in increments of 100 and then test. Extreme changes to this value will reduce the effective control range of the drive pedal.

• The electronic pedal sensor is removed for service or replacement.

3. These fields indicate the tolerance modifiers for the expected minimum and maximum values (1 and 2).

Numbers in these fields set a range above and below minimum and maximum values (1 and 2) that will be accepted during the calibration process.

• The PLUS+1 module is replaced.

Driving Pedal Parameter Screen

NOTE: Adjust these values only in increments of 10, and then test. Extreme changes to this value will reduce the effective control range of the drive pedal.

The “Driving” screen is used to change minimum and maximum values used in pedal calibration.

NOTE: Minimum/maximum pedal calibration values needs to be changed only if pedal calibration is not possible because actual pedal travel falls outside the indicated minimum and maximum position values.

Values on this screen are expressed in digits instead of volts.

Actual pedal position can be determined in real-time using the pedal position input field on the “Electrical Inputs/Outputs” monitoring screen (item 3, page 176).

To convert pedal mV values to digits, multiply mV by 2 (example: 500 mV X 2 = 1000 digits.

To access the “Driving” screen, select “Diagnostic Navigator”: “Parameter Functions > Inputs > Driving.”

NOTE: Changes made in this screen do not take effect until the download button is clicked. This button is located near the top of the screen.

Pump Profiling Screen/Drive “Creep” Adjustment The “Pump Profiling Automotive” screens are used to adjust machine “creep”.

“Creep” occurs when the machine moves if the drive is shifted to forward or reverse while engine speed is below 1200 RPM. There are two “Pump Profiling Automotive” screens: one for low- (Mode 4), and one for high-speed (Mode 2) travel modes.

3

1

To access the “Pump Profiling Automotive” screens:

2

• For high-speed, select “Diagnostic Navigator”: “Parameter Functions > Pump > Mode 2 Profiling Automotive.”

1. This field indicates the minimum expected drive pedal neutral position.

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Drive Control System— Pump Profiling Screen/Drive “Creep” • For low-speed, select “Diagnostic Navigator”: “Parameter Functions > Pump > Mode 4 Profiling Automotive.”

1

2

Values in fields (1 and 2) determine output to the drive pump based on pedal input and engine speed.

1. This field indicates the pump profiling threshold in the forward drive direction. Lowering the value in this field will prevent creep; increasing the value will increase creep speed.

NOTE: Adjust this value only in increments of 10 and then test. Extreme changes to this value can disable the drive or cause immediate, aggressive uncontrolled drive activation.

2. This field indicates the pump profiling threshold in the reverse drive direction. Lowering the value in this field will prevent creep; increasing the value will increase creep speed.

NOTE: Adjust this value only in increments of 10 and then test. Extreme changes to this value can disable the drive or cause immediate, aggressive uncontrolled drive activation.

NOTE: Changes made in this screen do not take effect until the download button is clicked. This button is located near the top of the screen.

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Drive Control System— Pedal Calibration Procedure Pedal Calibration Procedure

•

Perform this procedure if the status of either the brake/ inch, or speed control pedals is shown to be out of calibration in the Pedal Data window. See “Pedal Calibration Data” on page 182.

To calibrate the brake/inch pedal: “Diagnostic Navigator”: “Parameter Functions > Inputs > Inching > Setup Status.”

IMPORTANT: If pedal mechanical components, the electronic pedal sensor and/or the PLUS+1 module is replaced, calibration must be forced because the pedals may be out-of-calibration, even though they will register as being in-calibration. See “Forcing Pedal Parameter Calibration” on page 182.

If calibrating the brake/inch pedal: 1. Tilt the operator platform up as directed in the operator’s manual and lock the platform in the tilted position using the platform tilt support.

4. Press the pedal down all the way. The top status flag changes to yellow and displays a “Calibr. started” message. The “Max Value” field displays a numeric value for the depressed pedal calibration point.

2. Remove spring clip (Z) from push rod (X). Remove push rod (X) from the brake valve.

Z

X

5. Release the pedal, and if necessary, pull the pedal back until it reaches its maximum released travel point. The top status flag changes to green and displays a “All points calibr.” message, and the bottom status flag also changes to green and displays a “Calibration complete” message. The “Min Value” field displays a numeric value for the released pedal calibration point.

Brake Valve with Push Rod Removed

3. Access the Setup Status window by clicking on the following links: •

To calibrate the speed control pedal: “Diagnostic Navigator”: “Parameter Functions > Inputs > Driving > Setup Status.”

6. If calibrating the brake/inch pedal. a. Replace the push rod back into the brake valve.

Connect the push rod to the brake pedal with the spring clip. b. Tilt the operator platform down.

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Drive Control System— Pedal Calibration Procedure Forcing Pedal Parameter Calibration

Pedal Calibration Data

When the PLUS+1 module is replaced, pedals will automatically be out-of-calibration.

Pedal calibration data can be accessed through the “Diagnostic Navigator”: “Log Functions > Calibration > Pedal Data.”

When pedal mechanical components and/or the electronic pedal sensor are replaced, however, they will register as being in-calibration even though they will not be.

a

After replacing pedal mechanical components and/or the electronic pedal sensor, pedal calibration must be manually forced as follows: 1. The Set Defaults window can be accessed through the “Diagnostic Navigator”: “Parameter Functions > Inputs > Driving > Set Defaults.” b

The Pedal Data window displays the current pedal calibration data and status. Status values for both the brake/inch (Inching) and speed control (Driving) pedals are displayed:

A

a. This status flag displays calibration point status:

real-time

pedal

2. Use the up and down arrows (A) to select “1” in the Calibrate Driving field.

•

A red “No point calibr” flag indicates the pedal requires calibration.

3. Click the module.

•

A yellow “Calibr. started” flag indicates pedal calibration is under way.

•

A green “All points calibr.” flag indicates the pedal is properly calibrated.

button to send the “1” value to the

b. This status flag indicates pedal calibration status.

4. Use the up and down arrows (A) again to select “0” in the Calibrate Driving field.

5. Click the module.

•

A red “Go to Zero” flag indicates that at least one of the pedal reference points is out of calibration.

•

A green “Calibration completed” flag indicates the pedal is properly calibrated.

button again to send the “0” value to the

6. Proceed to “Pedal Calibration Procedure” on page 181.

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Electrical System — Battery Removal CHAPTER 10 — ELECTRICAL SYSTEM Battery Removal

STEP 3

STEP 1 Tilt the platform. See “Tilting the Platform” on page 61.

STEP 2

3

Remove battery hold-down and bolt (3).

1

22

STEP 4

Remove the negative (1) and positive (2) battery cables.

WARNING Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following:

4

Remove the battery (4) from the machine.

When you disconnect the battery cables, always disconnect the negative (-) battery cable first.

When you connect the battery cables, always connect the negative (-) battery cable last.

Do not short circuit the battery posts with metal items.

Do not weld, grind or smoke near a battery.

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Electrical System — Battery Installation Battery Installation

WARNING

STEP 1

Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: When you disconnect the battery cables, always disconnect the negative (-) battery cable first.

When you connect the battery cables, always connect the negative (-) battery cable last.

1

Do not short circuit the battery posts with metal items.

Install the battery (1) onto the machine.

STEP 2

Do not weld, grind or smoke near a battery.

STEP 4 Lower the platform. See “Lowering the Platform” on page 62.

2

Install battery hold-down and bolt (2).

STEP 3

3

4

Install the negative (3) and positive (4) battery cables.

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Electrical Schematics — AL 400 Series (Serial Numbers 41250 and up) Complete Electrical Schematic AL 400 Series (Serial Numbers 41250 and up) Complete Electrical Schematic

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

NOTE: AL400 and AL500 Series machines use the same wiring harnesses and schematics, but not all features are available on AL400 Series machines.

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Electrical Schematics — AL 400 Series (Serial Numbers 41250 and up) Steering Column Electrical Schematic AL 400 Series (Serial Numbers 41250 and up) Steering Column Electrical Schematic

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

NOTE: AL400 and AL500 Series machines use the same wiring harnesses and schematics, but not all features are available on AL400 Series machines.

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Electrical Schematics — AL 400 Series (Serial Numbers 41250 and up) Chassis Electrical Schematic AL 400 Series (Serial Numbers 41250 and up) Chassis Electrical Schematic

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

NOTE: AL400 and AL500 Series machines use the same wiring harnesses and schematics, but not all features are available on AL400 Series machines.

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Electrical Schematics — AL 400 Series (Serial Numbers 41250 and up) Engine Electrical Schematic AL 400 Series (Serial Numbers 41250 and up) Engine Electrical Schematic

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

NOTE: AL400 and AL500 Series machines use the same wiring harnesses and schematics, but not all features are available on AL400 Series machines.

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Electrical Schematics — AL 400 Series (Serial Numbers 41250 and up) FOPS, Power-A-Tach® and Tail Light Electrical Schematic AL 400 Series (Serial Numbers 41250 and up) FOPS, Power-A-Tach® and Tail Light Electrical Schematic

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

NOTE: AL400 and AL500 Series machines use the same wiring harnesses and schematics, but not all features are available on AL400 Series machines.

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Electrical Schematics — AL 500 Series (Serial Numbers 51242 and up) Complete Electrical Schematic (Includes Air Conditioning Option) AL 500 Series (Serial Numbers 51242 and up) Complete Electrical Schematic (Includes Air Conditioning Option)

LB DBL BL W O Y GY BR

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

50940008/AP0311

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

190

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Electrical Schematics — AL 500 Series (Serial Numbers 51242 and up) Steering Column Electrical Schematic (Includes Air Conditioning Option) AL 500 Series (Serial Numbers 51242 and up) Steering Column Electrical Schematic (Includes Air Conditioning Option)

LB DBL BL W O Y GY BR

PRINTED IN U.S.A.

191

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

50940008/AP0311

Electrical Schematics — AL 500 Series (Serial Numbers 51242 and up) Chassis Electrical Schematic (Includes Air Conditioning Option) AL 500 Series (Serial Numbers 51242 and up) Chassis Electrical Schematic (Includes Air Conditioning Option)

LB DBL BL W O Y GY BR

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LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

PRINTED IN U.S.A.

Electrical Schematics — AL 500 Series (Serial Numbers 51242 and up) Engine Electrical Schematic (Includes Air Conditioning Option) AL 500 Series (Serial Numbers 51242 and up) Engine Electrical Schematic (Includes Air Conditioning Option)

LB DBL BL W O Y GY BR

PRINTED IN U.S.A.

193

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

50940008/AP0311

Electrical Schematics — AL 500 Series (Serial Numbers 51242 and up) FOPS, CAB, Power-A-Tach® and Tail Light Electrical Schematic (Includes Air Conditioning AL 500 Series (Serial Numbers 51242 and up) FOPS, CAB, Power-A-Tach® and Tail Light Electrical Schematic (Includes Air Conditioning Option)

LB DBL BL W O Y GY BR

50940008/AP0311

194

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN

BK RD PK LGN GN DGN V PU T

BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

PRINTED IN U.S.A.

Electrical Schematics — AL 400 Series (Serial Numbers 41249 and below), AL 500 Series (Serial Numbers 51241 and below) Complete Electrical Schematic AL 400 Series (Serial Numbers 41249 and below), AL 500 Series (Serial Numbers 51241 and below) Complete Electrical Schematic Steering Column Deutsch 12-Pin Connector 111 T/GN

GN GY Y

1 3

113 T/W

112 O/W

2

LB

4

114 PU/O

LB/BK

5

115 PU/W 22 LG/PU

RD/GN

6

GN/GY

7

101 DBL/BK

GY/BL

8 9

116 DBL/BR

10

110 BR/W

GY/Y BL/W W/Y

Plus 1 Communication Connector

117 GY/Y

11

32 Y/DGN

12

EMPTY

1 2

Driving Pedal Sensor

AUXILIARY HYDRAULICS SWITCH

D

87A 30

W

Y/RD

W/BL R

W/RD O/W

O RD

3

2

6

5

O/BK

5A

RD/O

10A

W/RD

BR Y/RD

LB/BK LB

7

7

BK

1

8

1 10

9

Y/RD

PK/BL

BR

BR

1 3

2

4

0

BR

10A

BL/Y

2

90 DBL/Y

LB/RD GY/RD

3

RD/BK BL

5 6

43 O

BL/BK

42 DGN

BR

7 8

RD/O

9

20 BR

10

EMPTY

GN/W

11

4 DBL

V/Y PK/BK

12 13

37 DGN/BK 31 O/BK

BR/Y

14

40 GY

W/GN GY/W

15 16

14 PU 34 Y

PK/W

17

25 BR/O

RD/Y

18

78 GY/BK

ROPS TILT

6

5 7

0 1 2 8

V

Y/BK

RD/Y

13 10A

3 4

93 O/T

Y/BK

30

O

86

87 85

16

Y/GN

BR/BK

118 PK/W

ELEC AUX 6

98 W/DBL

0 BK

7 8

JOYSTICK

7

87

PK

1

O/LB

2

85

85

109 BK/GN

8

91 DGN/O

9

92 DGN/W

10

44 PK

11

95 W

12

120 DBL/RD

86

30 87

87

BR

Y

40A

-

Y/BK

10 31

30 7

L 5

3 R

0 00

V/BK BR

15 8

Hyd. Quick Attach

7

3

1 2

P

H P G

11

MOTOR SPEED SENSOR

145 W/O

12

PUMP SPEED SENSOR

109 BK/GN

1

MOTOR DISPLACEMENT IN

139 W/R 137 DBL/T

2

12V POWER

3

FORWARD OUTPUT SIGNAL

138 LB/Y

4

REVERSE OUTPUT SIGNAL

5

NOT USED

6

NOT USED

7 8

MOTOR DISPLACEMENT OUT BRAKE PRESSURE DEFEAT

9

146 Y/PU

10

NOT USED NOT USED

11

12V POWER

12

12V POWER

DIODE PACK

E

F

C

D

147 LGN

1

110 BR/W

78 GY/BK

M

Ø 1.5

1

123 W/BR

Ø 1.5

2

124 Y/RD

BR Ø 1.5

3

0 BK

ENGINE

ENGINE BLOCK GROUND

9 10

93 O/T

85

131 GY/W

86

WASHER BOTTLE RELAY

87A

2 RD/W

B 125 BK/RD

M HEATER

6

129 O/BR

A 1

P

3

SET

H

M

M

2

FRONT WIPER SWITCH 125 BR/Y

130 Y/BR 6

133 T/RD

7

134 Y/DBL

9

4 3 6 5

8

H

M P

3 7

5

2

REAR WIPER SWITCH

128 DBL/PK

42 DGN

CAB

DOME LIGHT

RT HEADLIGHT LT TAIL LIGHT HIGH BEAM 6

POSITION LOW BEAM

BACKUP ALARM RT TURN SIGNAL

5

O BK 114 PU/O

4

113 T/W

3

111 T/GN

2

112 O/W

1

Brake

69 DBL

4

O BK 115 PU/W

3 2

113 T/W

1

A

LT Turn Signal Position

LT TAIL LIGHT LT HEADLIGHT Brake

DIODE PACK HIGH BEAM 6

LOCK POSITION

B LOW BEAM

D

5VDC SENSOR GROUND INCHING PEDAL SENSOR

144 W/BK

FUEL PUMP

5A

C

9 10

95 W

B

5A

124 Y/RD

REVERSE INPUT SIGNAL +5VDC

142 BR/BK 143 PK/DGN

GLOW PLUGS

Deutsch 3 Pin Connector

49 2

IG

BAT ALTERNATOR

A

ACCESSORY POWER OUTLET

RD/Y BR

L

FUEL SQL.

BATTERY

REAR WORK LIGHTS

PRINTED IN U.S.A.

2

STARTER

RESET

A

7 8

TEMP SENDER

+

119 DBL/W

Y

A

123 W/BR

FORWARD INPUT SIGNAL

92 DGN/W 141 BK/Y

Diff Lock Solenoid

1 RD

43 O

UNLOCK

DRIVING PEDAL SENSOR

6

EMPTY

BATTERY DISCONNECT

10A

92 DGN/W

B

1

105 T

7

B

5

SOLENOID

25A

5

POWER-A-TACH

2

OIL PRESSURE SWITCH

FUSE

25A

84 O/DBL

D

1

Brake Pressure Defeat

BREAKER

A

1

1

A

25A

FRONT WORK LIGHTS

2

2

BREAKER

87

BEACON

B

Diode Pack C

CAB RELAY

A

1

2-Speed SOL

30

B

2

COOLANT TEMP SWITCH

SIGNAL

A

Forward SOL

Hydraulic Pump

Y

CAN -

140 BK/W 91 DGN/O

Hydraulic Pump

60A

94 PK/BK 84 O/DBL

4

B

2

LOW FUEL

B

A

HYDRAULIC FILTER SWITCH

GLOW PLUG

CONTROL MODULE

CAN +

149 T

HYDRAULIC TEMP SWITCH

Reverse SOL

FUEL SENDER

B

86 87A

87A 30

12V POWER

3

3 4 5

A

BR

B

STARTER

12V GROUND

2

PPU Motor

87

ELEC AUX

0 1 8

7

1 3 4

30

6

5

8

10A

6

PARKING BRAKE

2 RD/W

RD

6 L

V

GY/BK

5A

15

Y

4 56a

O/W

GY

10A

6

30

86 87A

O/LB

GN/BK

14

87A

1 56b

RD

GN

Steering Column Selector Switch 9

BR/BK

RD

21 DGN/BL

Packard 2-Pin Connector HORN V/BK

W

12 7.5A

4 DBL

5

BRAKE

PK/BL

LB/BK LB

10A

11

RD

4

5

85

86 87A

1

148 LB

BEACON

GY/BK GN/BK

W/BK

4

106 DBL/GN 108 Y/W 98 W/DBL

85

0 BK 139 W/RD

69 DBL

C

O/W

BL

10A

3

1 2

WARNING FLASHERS

10

RD

2

3

9

9

RD

2

99 Y/BK 100 Y/O

DIFF LOCK 5

8

20A

3

SPEED SELECT 4

91 DGN/O 92 DGN/W

4

REV

PPU Motor

1 RD

5A

2 RD/W

1

Deutsch 2-Pin Connector

9

6

1

2

102 RD/BK

RD/Y V V

5

+

6

O

GY/W

5A 7.5A

4

RD

FWD

139 W/RD

85

BR

30

1

Deutsch 18-Pin Connector

PLUS-1 MODULE

104 PK/DBL

BL

Y/BK

87

86

87

87A

Y/GN

BL/BK

W/BK

GND

86 85

DIFF LOCK

F

81 RD/Y

3

O

87

119 DBL/W

10A

E

87

PK W/GN GY/Y LB RD/BK BR

PK/BK

RD/GN

V/Y GY/RD GN BL/W W/Y BR/Y LB/RD Y LB/BK GY/BL GN/W

PK/W GN/GY

RD/BK RD/BK BL/Y

5A 2

87A 30

30

BL

1

86

87A

30

Inching Pedal Sensor D

012

12 14 16 18 20 22 24 26 11 13 15 17 19 21 23 25

O

85

86

1 RD

9

107 O/GN

127 DBL/O

7

10

85

116 GY/Y

5

8

50

F

116 DBL/BR

3

6

BK

97 T/DBL

1

4

E

O

BR

2

+15

LIGHT

Ignition Switch 15

LT TURN SIGNAL

5

O BK 115 PU/O

4

113 T/W

3

111 T/GN

2

112 O/W

1

195

69 DBL

4

O BK 114 PU/O

3 2

113 T/W

1

LT Turn Signal Position

132 O/RD

LB DBL BL W O Y GY BR BK RD PK LGN GN DGN V PU T

LIGHT BLUE DARK BLUE BLUE WHITE ORANGE YELLOW GREY BROWN BLACK RED PINK LIGHT GREEN GREEN DARK GREEN VIOLET PURPLE TAN

50940008/AP0311

Electrical Schematics — AL 400 Series (Serial Numbers 41249 and below), AL 500 Series (Serial Numbers 51241 and below) Complete Electrical Schematic NOTES

50940008/AP0311

196

PRINTED IN U.S.A.

Troubleshooting — Engine CHAPTER 11 — TROUBLESHOOTING Engine Problem Engine does not turn over

Engine turns over but will not start

PRINTED IN U.S.A.

Possible Cause

Corrective Action

Drive direction switch in forward/ reverse

Place drive direction switch in neutral

Tripped circuit breaker

Reset circuit breaker

Blown fuse

Replace fuse

Dead battery

Charge or replace battery

Auxiliary hydraulics control lever not in neutral (Applies only to early machines equipped with auxiliary hydraulics control lever).

Place the auxiliary hydraulics control lever into the neutral position

Battery disconnect switch in the open position or malfunctioning

Place the battery disconnect switch into the closed position.

Repair or replace if necessary

Engine cranking speed too slow

Check battery and charge/ replace as necessary; tighten battery terminals. Check that engine oil is at operating temperature. On early machines equipped with an auxiliary hydraulics control lever, make sure the lever is in the neutral position.

Fuel tank empty

Fill up the tank and vent the fuel system if necessary

Fuel filter plugged or restricted, paraffin separation in winter

Change the fuel filter; use winter grade diesel fuel

Fuel line leakage

Tighten all the threaded connections and clamps

Engine cranking speed too slow

Check battery and charge/ replace as necessary; tighten battery terminals

Glow plug module malfunction

Check connection and voltage; replace as necessary

Fuel shut-off solenoid not energizing

Check electrical connections/ voltage to shut-off solenoid

Fuel filter restricted

Replace filter

Fuel pump malfunction

Troubleshoot fuel pump. See engine service manual. Replace if necessary

197

50940008/AP0311

Troubleshooting — Engine Problem Engine overheating

Engine running but loader will not drive

50940008/AP0311

Possible Cause

Corrective Action

Crankcase oil level incorrect

Adjust oil level

Cooling air circulation restricted

With engine off, remove restriction

Fan shroud improperly positioned

Adjust fan shroud so it is evenly spaced away from the fan blade tips

Improper oil grade or oil excessively dirty

Change engine oil; see “Fluid Capacities/Lubricants” on page 11 for proper oil grade

Exhaust restricted

Allow exhaust to cool; remove restriction

Air filter restricted

Replace filter(s)

Low coolant level

Add coolant

Loose fan belt

Tighten fan belt

Dirty radiator

Clean radiator

Thermostat malfunction

Replace thermostat

Parking brake is engaged

Release the parking brake

Parking brake switch malfunction

Replace the parking brake switch

On early machines equipped with a platform switch, platform not bolted down

Secure platform

On early machines equipped with a platform switch: platform switch malfunction

Repair or replace platform switch, see “Repairing or Replacing Platform Switch” on page 64

Blown fuse

Check circuit and replace fuse

Joystick drive direction slider switch malfunction

Replace joystick handle

Drive system component malfunction

Check drive controller error code, see “Electrical Status Error Reporting Screen” on page 177

198

PRINTED IN U.S.A.

Troubleshooting — Indicator Lamps / Seals and Hoses Indicator Lamps / Seals and Hoses Indicator Lamps Indicator Activated Engine oil pressure

Hydraulic oil temperature

Possible Cause

Corrective Action

Engine oil pressure too low

Stop engine immediately; check oil level and add oil if necessary; check oil pump

Engine oil level too low

Add oil

Oil pump malfunction

Manually check engine oil pressure and inspect engine oil pump for failures. See engine service manual

Temperature is too hot

Check cooling system for debris in radiator Check hydraulic oil level

Hydraulic oil filter

Hydraulic oil filter service required

Replace filter

Water temperature

Coolant level too low

Add coolant

Air filter plugged

Replace air filter

Engine overheating

Check cooling system

Battery voltage

Alternator not charging properly

Adjust V-belt tension; check alternator

Low fuel

Low fuel

Add fuel

Seals and Hoses Problem Oil, coolant or fuel leakage

Hydraulic fluid leakage

PRINTED IN U.S.A.

Possible Cause

Corrective Action

Loose hose connection(s)

Tighten hose connections

Damaged seals or hoses

Change seals/hoses as necessary

Loose fittings

Tighten hydraulic connections

Seals, hoses or lines damaged

Change seals, hoses or lines as necessary

199

50940008/AP0311

Troubleshooting — Hydraulic System Hydraulic System NOTE: Also see “Work Hydraulics Troubleshooting” on page 103 and “Hydraulics Troubleshooting Diagnostic Flow Charts” on page 107.

Problem Hydraulics do not work or work only at a low performance level

Attachment tilts down with tilt control in neutral

Lift arm does not raise/lower

Attachment tilt not working; Lift arm works properly 50940008/AP0311

Possible Cause

Corrective Action

Low hydraulic fluid level

Add hydraulic fluid

Hydraulic fluid is not warm

Allow longer warm-up

Engine to pump coupling or hydraulic pump damaged

Check hydraulic system pressures. Check pump coupler for wear. inspect hydraulic pump for wear; analyze hydraulic oil sample. Repair/replace as necessary

Pressure limiting valves set too low or damaged

Check hydraulic system pressures. inspect pressure limiting valve. Repair/replace as necessary

Hydraulic cylinder damaged

Disassemble cylinder and inspect for wear/damage parts.

Repair/replace as necessary.

Replace seals

Control valve damaged

Inspect control valve. Repair/ replace as necessary. Replace seals.

Engine speed is too low

Adjust engine speed. See “Accelerator pedal” on page 51 See “Hand throttle” on page 51

Dirty/restricted air filter(s)

Replace air filter(s)

Incorrect fuel grade

Change the fuel; see “Fluid Capacities/Lubricants” on page 11for proper fuel grade

Oil leaking past tilt cylinder seals (internal or external)

Remove cylinder. Repair/replace as necessary. Replace seals

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Repair as required

Lift spool in control valve not actuated or leaking

Inspect control valve. Repair/ replace as necessary. Replace seals

Hydraulic oil leaking past cylinder piston seals

Remove cylinder. Repair/replace as necessary. Replace seals.

Tilt spool in control valve not actuated or leaking

Inspect control valve. Repair/ replace as necessary. Replace seals

200

PRINTED IN U.S.A.

Troubleshooting — Hydraulic System Problem

Possible Cause

Corrective Action

Lift arm does not raise, tilt works properly

Lift spool in control valve not actuated or leaking

Inspect control valve. Repair/ replace as necessary. Replace seals

Hydraulic system overheating

Hydraulic oil cooler is dirty

Clean hydraulic oil cooler

Hydraulic oil level is too low

Add hydraulic oil

Load too high

Reduce the load Check that auxiliary hydraulics control lever is in neutral. See “Auxiliary hydraulics control lever” on page 51

Lift and/or tilt functions too slow

Lift and/or tilt functions inconsistent/ jerky

Lift arm does not maintain raised position with multi-purpose joystick centered (neutral)

Auxiliary hydraulics do not function

PRINTED IN U.S.A.

Low engine speed

Increase engine speed

Low hydraulic oil level

Add oil; check for leaks

Hydraulic oil leaking past cylinder piston seals

Remove cylinder. Repair/replace as necessary. Replace seals.

Hydraulic pump malfunction

Check system pressures.

Inspect pump for wear. Repair/ replace as necessary.

Air in hydraulic system

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system

Low hydraulic oil level

Add oil; check for leaks

Cylinder(s) malfunction

Inspect cylinder. Repair/replace as necessary

Oil leaking past lift cylinder seals (internal or external)

Check work system pressure.

Inspect cylinder. Repair/replace as necessary.

Oil leaking past lift spool in control valve

Inspect control valve. Repair/ replace as necessary. Replace seals

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Check system pressures.

Inspect hydraulic components.

Repair/replace as necessary.

Spool in control valve not actuated or leaking

Inspect control valve. Repair/ replace as necessary. Replace seals

Hydraulic oil leaking past seals

Replace failed seals. Check for failed parts and replace as necessary.

Auxiliary hydraulic connections improperly connected

Correct hydraulic connections

201

50940008/AP0311

Troubleshooting — Hydrostatic Drive System Hydrostatic Drive System NOTE: Also see “Work Hydraulics Troubleshooting” on page 103 and “Drive Hydraulics Diagnostics” on page 111.

Problem No response from either hydrostatic drive or the lift/tilt systems

Possible Cause Hydraulic oil viscosity too heavy

Corrective Action Allow longer warm-up; replace with proper grade hydraulic oil, see “Fluid Capacities/ Lubricants” on page 11 for proper oil grade Also see “Work Hydraulics Troubleshooting” on page 103 and “Drive Hydraulics Diagnostics” on page 111

Drive will not operate in either direction

Parking brake is engaged

Disengage parking brake

Low hydraulic oil level

Add oil

Low or no charge pressure

Check charge pressure. Check relief pressure. Adjust or replace

Hydrostatic pump(s) relief valves malfunction

Check relief pressure. Adjust or replace

Brake/inch pedal stuck or malfunctioning

1. Check/release brake/inch pedal 2. Check drive error code

Throttle pedal sensor linkage

Check/repair throttle pedal linkage Check drive controller error codes, see “Drive Controller Error Codes” on page 172 and “Electrical Status Error Reporting Screen” on page 177

Electrical connections Hydrostatic (drive) system noisy

50940008/AP0311

Check/inspect electrical connection and harness

Hydraulic oil viscosity too heavy

Allow longer warm-up, see “Fluid Capacities/Lubricants” on page 11 for proper oil grade

Low hydraulic oil level

Add oil

Air in hydraulic system

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system

Drive motor(s) or hydrostat pump(s) internal damage/ leakage

Check drive pressure. Inspect drive motor/hyrostat pump.

Repair/replace as necessary.

202

PRINTED IN U.S.A.

Troubleshooting — Hydrostatic Drive System Problem Sluggish acceleration

Possible Cause

Corrective Action

Low hydraulic oil level

Add oil

Low hydrostat system charge pressure

Check charge pressure. Check relief pressure. Adjust or replace

Drive motor or hydrostat pump internal damage/ leakage

Check drive pressure. Repair/ replace as necessary

Brake/inch pedal engaged, stuck or malfunctioning

Release/repair the brake/inch pedal

Engine running rough.

Bad or wrong fuel

Drive system continuously overloaded

Improve operation procedure

Lift/tilt or auxiliary system continuously overloaded

Improve operation procedure

Drive motor(s) or hydrostatic pump(s) internal damage/ leakage

Check drive pressure. Repair/ replace as necessary

Oil cooler fins restricted

Clean oil cooler fins

Hydraulic oil filter restricted

Replace filter

Brake/inching pedal out of calibration

“Pedal Calibration Procedure” on page 181

Problem

Possible Cause

Corrective Action

Electrical system does not function

Battery disconnect switch is in OFF position

Turn battery disconnect switch to ON

Battery terminals or cables loose or corroded

Clean battery terminals and cables and retighten

Battery malfunction

Test battery; recharge/ replace as necessary

Blown main fuse

Replace main fuse

Instrument display does not activate with key switch on

Blown fuse

Check circuit and replace fuse

Battery terminals/cables loose/ corroded

Clean battery terminals and cables and tighten

Fuel gauge does not work

Fuel gauge sender malfunction

Replace fuel gauge sender

Loose wiring/terminal connections

Check wiring connections

Blown fuse

Check circuit and replace fuse

Hydrostatic drive overheating

Brake not effectively stopping machine

Electrical

PRINTED IN U.S.A.

203

50940008/AP0311

Troubleshooting — Hydrostatic Drive System Problem Engine temperature gauge does not work

Hourmeter does not work

Starter does not engage when key switch turned to START

Work/road lights malfunction

50940008/AP0311

Possible Cause

Corrective Action

Temperature sender malfunction

Replace temperature sender

Loose wiring/terminal connections

Check wiring connections

Blown fuse

Check circuit and replace fuse

Loose wiring/terminal connections

Check wiring connections

Alternator malfunction

Repair/replace alternator

Poor electrical connections to starter

Check connections

Battery terminals/cables loose/ corroded

Clean battery terminals and cables and tighten

Starter relay malfunction

Troubleshoot relay. Repair/ replace as necessary.

Battery malfunction

Test battery; recharge/ replace as necessary

Starter solenoid malfunction

Troubleshoot starter solenoid.

Repair/replace as necessary.

Starter or pinion malfunctioning

Repair/replace as needed

Drive direction switch in forward/ reverse

Place drive direction switch in neutral

Various

See also “Engine does not turn over” on page 197

Single light not working — Light bulb burned out, faulty wiring

Check and replace light bulb as needed, check wiring connections

No lights — blown fuse

Check circuit and replace fuse

Defective light switch or poor ground

Check ground wire connections; replace light switch

204

PRINTED IN U.S.A.

INDEX A Accelerator Pedal . . . . . . . . . . . . . . . . . . . .51 Air Cleaner Dust Valve . . . . . . . . . . . . . . .22 Air Conditioning Maintenance . . . . . . . . .28 Charging . . . . . . . . . . . . . . . . . . . . . . .28 Compressor Service . . . . . . . . . . . . . . .28 Air Filter Restriction Indicator . . . . . . . . .22 Alternator . . . . . . . . . . . . . . . . . . . . . . .52, 56 Attachment Plate Hydraulics Installation . . . . . . . . . . . . .78 Hydraulics Removal . . . . . . . . . . . . . .77 Auxiliary Hydraulic Valve . . . . . . . . . . .135 Auxiliary Hydraulics Control Lever . . . . .51 Axle, Front Installation . . . . . . . . . . . . . . . . . . . . . .98 Removal . . . . . . . . . . . . . . . . . . . . . . . .95 Axle, Rear Installation . . . . . . . . . . . . . . . . . . . . .102 Removal . . . . . . . . . . . . . . . . . . . . . . .100 Axles Change Oil . . . . . . . . . . . . . . . . . . . . . .30

Control Valve Installation, 2-Spool . . . . . . . . . . . . . 131 Installation, 3-Spool . . . . . . . . . . . . . 133 Removal, 2-Spool . . . . . . . . . . . . . . . 126 Removal, 3-Spool . . . . . . . . . . . . . . . 128 Controller, Drive . . . . . . . . . . . . . . . . . . . . 41 Controller, Machine . . . . . . . . . . . . . . . . . 41 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Radiator . . . . . . . . . . . . . . . . . . . . . . . 11 Cooling System . . . . . . . . . . . . . . . . . . . . 23 Check Coolant Level . . . . . . . . . . . . . 23 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Drain/Flush . . . . . . . . . . . . . . . . . . . . . 24 Cylinders Cylinder Disassembly/ Assembly . . . . . . . . . . . . . . . . 141, 149 Lift Cylinder Installation . . . . . . . . . 137 Lift Cylinder Removal . . . . . . . . . . . 136 Steering Cylinder Installation . . . . . . 139 Steering Cylinder Removal . . . . . . . 139 Tilt Cylinder Installation . . . . . . . . . 138 Tilt Cylinder Removal . . . . . . . . . . . 138

B

D

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Installation . . . . . . . . . . . . . . . . . . . . .184 Removal . . . . . . . . . . . . . . . . . . . . . . .183 Battery Disconnect Switch . . . . . . . . .42, 51 Beacon Switch . . . . . . . . . . . . . . . . . . . . . .51 Biodegradable Oil . . . . . . . . . . . . . . . . . . .11 Booster Battery . . . . . . . . . . . . . . . . . . . . .42 Brake/inch Pedal . . . . . . . . . . . . . . . . . . . .51 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Differential Lock . . . . . . . . . . . . . . . . . . . 52 Dome Light . . . . . . . . . . . . . . . . . . . . . . . . 55 Drive Controller . . . . . . . . . . . . . . . 168, 172 Error Codes . . . . . . . . . . . . . . . . . . . . 172 PLUS+1 GUIDE Service Tool Software . . . . . . . . . . . . . . . . . . . . . 173 Drive Controller Pedal Calibration Plus+1 Service Tool . . . . . . . . . . . . . 179 Drive Coupling Installation . . . . . . . . . . . . . . . . . . . . . 87 Removal . . . . . . . . . . . . . . . . . . . . . . . 87 Drive Direction Switch . . . . . . . . . . . . . . . 51 Dust Valve . . . . . . . . . . . . . . . . . . . . . . . . 22

C Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Environment Controls . . . . . . . . . . . . .54 Windshield Wiper Controls . . . . . . . . .54 Center/Steering Bearing Installation . . . . . . . . . . . . . . . . . . . . . .70 Removal . . . . . . . . . . . . . . . . . . . . . . . .67 Contents and Use of this Manual . . . . . . . . .1 Control Lever . . . . . . . . . . . . . . . . . . . .51, 58 Control Modules . . . . . . . . . . . . . . . . . . . .39 PRINTED IN U.S.A.

E Electrical System . . . . . . . . . . . . . . . . . . . 37 Fuse Locations . . . . . . . . . . . . . . . . . . 37 Engine Installation . . . . . . . . . . . . . . . . . . . . . 83 Removal . . . . . . . . . . . . . . . . . . . . . . . 79 205

50940008/AP0311

Index Engine Access Panel . . . . . . . . . . . . . . 20, 21 Engine Cooling System . . . . . . . . . . . . . . 23 Engine Maintenance Change Fuel Filter . . . . . . . . . . . . . . . 25 Change Oil and Filter . . . . . . . . . . . . . 20 Check Oil . . . . . . . . . . . . . . . . . . . . . . 20 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine Oil Pressure . . . . . . . . . . . . . . 53, 56 Engine Oil Temperature . . . . . . . . . . . 52, 56

F Fast Speed . . . . . . . . . . . . . . . . . . . . . . . . . 53 Filter Changes . . . . . . . . . . . . . . . . . . . . . . 19 Forward Travel . . . . . . . . . . . . . . . . . . . . . 52 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Add . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . 53 Fuel Shut-off Valve Lever . . . . . . . . . . . . 26 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 25 Functional Check . . . . . . . . . . . . . . . . . . . 19 Fuse Locations . . . . . . . . . . . . . . . . . . . . . 37 Fuse Panel, Steering Column . . . . . . . . . . 37 Fuse Panel(s), Engine Compartment . . . . 38

G Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

H Hand Throttle . . . . . . . . . . . . . . . . . . . 51, 59 Hazard Light Switch . . . . . . . . . . . . . . . . . 51 Hazard Lights . . . . . . . . . . . . . . . . . . . . . . 52 Hood Installation . . . . . . . . . . . . . . . . . . . . . 66 Removal . . . . . . . . . . . . . . . . . . . . . . . 65 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . 53 Hydraulic Drive System Components . . 121 Hydraulic Oil . . . . . . . . . . . . . . . . . . . 11, 29 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic Oil Filter . . . . . . . . . . . . . . . 52, 56 Hydraulic Oil Pressure . . . . . . . . . . . . . . . 53 Hydraulic Oil Temperature . . . . . . . . . . . . 56 Hydraulic System Change Oil . . . . . . . . . . . . . . . . . . . . . 29 Check Oil Level . . . . . . . . . . . . . . . . . 29 Control Valve Removal . . . . . . . . . . . . . . . . . . . 126 Drive Motor Installation . . . . . . . . . . 155 PRINTED IN U.S.A.

Drive Motor Removal . . . . . . . . . . . 153 Gear/Work Pump Installation . . . . . 149 Gear/Work Pump Removal . . . . . . . 149 Hydrostatic Motor Installation . 159, 160 Piston/Drive Pump Installation . . . . 152 Piston/Drive Pump Removal . . . . . . 150 Pressures . . . . . . . . . . . . . . . . . . . . . 121 Charge Pump Pressure Test . . . . 122 Steering Circuit Pressure Test . . 125 Work Cylinder Leakage Test . . . 124 Steering Control Valve Removal . . . . . . . . . . . . . . . . 156, 158 Hydraulics Schematics . . . . . . . . . . . . . . . . . . . . 163 Hydraulics Valve Location Auxiliary Hydraulic Valve . . . . . . . . 135 Lift/Tilt Lock Valves . . . . . . . . . . . . 135 Power-A-Tach® Valve . . . . . . . . . . 135

I Ignition Key Switch . . . . . . . . . . . . . . . . . 57 Inner Filter Element . . . . . . . . . . . . . . 22, 23 Instrument Panel . . . . . . . . . . . . . . . . . . . 51 Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1

J Jump-Starting . . . . . . . . . . . . . . . . . . . . . . 42

L Leakage Check . . . . . . . . . . . . . . . . . . . . . 19 Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lift Arm Installation . . . . . . . . . . . . . . . . . . . . . 75 Removal . . . . . . . . . . . . . . . . . . . . . . . 74 Lift/Tilt Lock Valves . . . . . . . . . . . . . . . 135 Locking Mechanism . . . . . . . . . . . . . . . . 60 Low Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 53 Lubrication . . . . . . . . . . . . . . . . . . . . . 19, 35

M Machine and Drive Controllers . . . . . . . 167 Machine Controller . . . . . . . . . . . . 167, 168 LED/Indicator Assignments . . . . . . 168 Logic . . . . . . . . . . . . . . . . . . . . . . . . 169 Machine Orientation . . . . . . . . . . . . . . . . . 2 Machine/Drive Controllers . . . . . . . . . . 167 206

50940008/AP0311

Index Main System Fuse . . . . . . . . . . . . . . . . . . . 37 Maintenance Engine Air Cleaner . . . . . . . . . . . . . . . 22 Engine Maintenance . . . . . . . . . . . . . . 20 Engine Oil . . . . . . . . . . . . . . . . . . . 20 Maintenance Log . . . . . . . . . . . . . . . . . . . 45 Maintenance Schedule Check, Clean and Inspect . . . . . . . . . . 18 Functional Check . . . . . . . . . . . . . . . . 19 Leakage Check . . . . . . . . . . . . . . . . . . 19 Lubrication and Filter Changes . . . . . . 19 Maintenance Log . . . . . . . . . . . . . . . . 45 Multi-purpose Joystick . . . . . . . . . . . . . . . 51

O Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Biodegradable Oil . . . . . . . . . . . . . . . . 11 Engine Oil . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic Oil . . . . . . . . . . . . . . . . . . . 11 Oil Dipstick . . . . . . . . . . . . . . . . . . . . . . . . 20 Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . 21 Operator’s Seat . . . . . . . . . . . . . . . . . . . . . 51 Outer Filter Element . . . . . . . . . . . . . . . . . 22

P Parking Brake . . . . . . . . . . . . . . . . . . . . . . 52 Parking Brake Lever . . . . . . . . . . . . . . . . . 51 Platform Lowering . . . . . . . . . . . . . . . . . . . . . . . 62 Tilting . . . . . . . . . . . . . . . . . . . . . . . . . 61 Platform Switch Repair/Replace . . . . . . . . . . . . . . . . . . 64 Plus+1 Module . . . . . . . . . . . . . . . . 167, 172 Plus+1 Service Tool Driving Pedal Parameter Screen . . . . 179 Electrical Inputs/Outputs Monitoring Screen . . . . . . . . . . . . . 176 Electrical Status Error Reporting Screen . . . . . . . . . . . . . . . . . . . . . . . 177 Pedal Calibration . . . . . . . . . . . . 179, 181 Plus+1 Service Tool Navigation . . . . . . . . . . . . . . . . . . 174 Pump Profiling Screen/Drive “Creep” Adjustment . . . . . . . . . . . . 179 Software Log Monitoring Screen . . . 175 System Definition Error Count/ Timestamp Reset Screen . . . . . . . . 178 50940008/AP0311

Power-A-Tach® Hydraulic Valve . . . . . 135 Power-A-Tach® Lock/Unlock . . . . . . . . . 51 Pre-Heat . . . . . . . . . . . . . . . . . . . . . . . . . . 52

R Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . 24 Radiator Drain Valve . . . . . . . . . . . . . . . . 24 Radiator/Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . 92 Removal . . . . . . . . . . . . . . . . . . . . . . . 89 Rearward Travel . . . . . . . . . . . . . . . . . . . 52 Right Turn . . . . . . . . . . . . . . . . . . . . . . . . 52 Road Lights . . . . . . . . . . . . . . . . . . . 52, 204

S Safety Symbol . . . . . . . . . . . . . . . . . . . . . . 1 Signal Words . . . . . . . . . . . . . . . . . . . . 1 Schematics Electrical . . . . . . . . . . . . . . . . . . . . . 195 Hydraulic . . . . . . . . . . . . . . . . . . . . . 163 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Slow Speed . . . . . . . . . . . . . . . . . . . . . . . 52 Specifications Dimensions . . . . . . . . . . . . . . . . . . . . 12 Weights and Capacities . . . . . . . . . . . 14 Starter Installation . . . . . . . . . . . . . . . . . . . . . 88 Removal . . . . . . . . . . . . . . . . . . . . . . . 88 Steering Bearing Installation . . . . . . . . . . . . . . . . . . . . . 70 Removal . . . . . . . . . . . . . . . . . . . . . . . 67 Steering Column . . . . . . . . . . . . . . . . . . . 51 Control Lever . . . . . . . . . . . . . . . . . . . 58 Steering Column Adjustment . . . . . . . . . . 58 Steering Wheel . . . . . . . . . . . . . . . . . . . . . 51 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Preparing . . . . . . . . . . . . . . . . . . . . . . 44 Removing . . . . . . . . . . . . . . . . . . . . . . 44

207

PRINTED IN U.S.A.

Index T Tilting the Platform . . . . . . . . . . . . . . . . . . 20 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Troubleshooting . . . . . . . . . . . . . . . . . . . 197 Drive Hydraulics Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . 111 Drive System Electrical Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . 119 Electrical . . . . . . . . . . . . . . . . . . . . . . 203 Engine . . . . . . . . . . . . . . . . . . . . . . . . 197 Hydraulic Piston/Drive Pump Diagnostics Flow Chart . . . . . . . . . 115 Hydraulic System . . . . . . . . . . . 200, 202 Diagnostics Flow Charts . . . . . . . 107 Hydrostatic Drive . . . . . . . . . . . . 106 Work Hydraulics . . . . . . . . . 103, 126 Hydrostatic Drive System . . . . . . . . . 202 Hydrostatic Motor Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . 117 Indicator Lamps . . . . . . . . . . . . . . . . 199 Operator Presence Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . 113 Seals and Hoses . . . . . . . . . . . . . . . . 199 Steering Hydraulics Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . 109 Work Hydraulics Diagnostics Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . 107 Turning Knob . . . . . . . . . . . . . . . . . . . . . . 51

V V-belt Tension . . . . . . . . . . . . . . . . . . . . . . 27 Air Conditioning . . . . . . . . . . . . . . . . . 27 Checking and Adjusting . . . . . . . . . . . 27 Volt Meter . . . . . . . . . . . . . . . . . . . . . . . . . 56 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 53

W Warning Indicators . . . . . . . . . . . . . . . . . . 56 Water Separator Fuel Shut-off Valve Lever . . . . . . . . . 26 Wheel Fasteners . . . . . . . . . . . . . . . . . . . . 33 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Windshield Washer . . . . . . . . . . . . . . . . . . 11

PRINTED IN U.S.A.

208

50940008/AP0311

TORQUE SPECIFICATIONS Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M10X1.0

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (10 mm)

M12X1.5

15 (20)

18 (25)

18 (25)

18 (25)

0.5 in. (12 mm)

M14X1.5

26 (35)

33 (45)

26 (35)

26 (35)

0.6 in. (14 mm)

M16X1.5

33 (45)

41 (55)

30 (40)

37 (50)

0.6 in. (16 mm)

M18X1.5

41 (55)

52 (70)

33 (45)

52 (70)

0.7 in. (18 mm)

M22X1.5

48 (65)

92 (125)

44 (60)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

74 (100)

107 (145)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

118 (160)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (48 mm)

G1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4 in. (9.73 mm)

G1/4A

26 (35)

26 (35)

22 (30)

26 (35)

0.5 in. (13.16 mm)

G3/8A

33 (45)

52 (70)

33 (45)

37 (50)

0.7 in. (16.66 mm)

G1/2A

48 (65)

66 (90)

41 (55)

48 (65)

0.8 in. (20.96 mm)

G3/4A

66 (90)

133 (180)

74 (100)

103 (140)

1.0 in. (26.44 mm)

G1A

111 (150)

229 (310)

118 (160)

140 (190)

1.3 in. (33.25 mm)

G1 1/4A

177 (240)

332 (450)

155 (210)

266 (360)

1.7 in. (41.91 mm)

G1 1/2A

214 (290)

398 (540)

192 (260)

398 (540)

1.9 in. (47.80 mm)

Thread

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE) Sealing washer

Elastic seal

O-ring

Non-return valve with elastic seal

Identification aid outside Ø

M12X1.5

15 (20)

26 (35)

26 (35)

26 (35)

0.5 in. (12 mm)

M14X1.5

26 (35)

41 (55)

33 (45)

33 (45)

0.6 in. (14 mm)

Thread

M16X1.5

33 (45)

52 (70)

41 (55)

41 (55)

0.6 in. (16 mm)

M18X1.5

41 (55)

66 (90)

52 (70)

52 (70)

0.7 in. (18 mm)

M20X1.5

41 (55)

92 (125)

59 (80)

74 (100)

0.8 in. (20 mm)

M22X1.5

48 (65)

100 (135)

74 (100)

92 (125)

0.9 in. (22 mm)

M27X2.0

66 (90)

133 (180)

125 (170)

100 (135)

1.0 in. (27 mm)

M33X2.0

111 (150)

229 (310)

229 (310)

155 (210)

1.3 in. (33 mm)

M42X2.0

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (42 mm)

M48X2.0

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (48 mm)

G1/8A

26 (35)

41 (55)

33 (45)

33 (45)

0.5 in. (13.16 mm)

G1/4A

33 (45)

59 (80)

44 (60)

44 (60)

0.7 in. (16.66 mm)

G3/8A

48 (65)

85 (115)

55 (75)

74 (100)

0.8 in. (20.96 mm)

G1/2A

66 (90)

133 (180)

125 (170)

107 (145)

1.0 in. (26.44 mm)

G3/4A

111 (150)

229 (310)

229 (310)

192 (260)

1.3 in. (33.25 mm)

G1A

177 (240)

332 (450)

243 (330)

266 (360)

1.7 in. (41.91 mm)

G1 1/4A

214 (290)

398 (540)

310 (420)

398 (540)

1.9 in. (47.80 mm)

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M5

4.1 (5.5)

6 (8)

7 (10)

4 (5)

5 (7)

M6

7 (10)

10 (14)

13 (17)

6.3 (8.5)

9 (12)

M8

18 (25)

26 (35)

31 (42)

15 (20)

22 (30)

M10

33 (45)

48 (65)

59 (80)

30 (40)

44 (59)

M12

64 (87)

81 (110)

108 (147)

51 (69)

74 (100)

M14

100 (135)

133 (180)

170 (230)

81 (110)

118 (160)

M16

155 (210)

203 (275)

258 (350)

125 (170)

184 (250)

M18

207 (280)

302 (410)

354 (480)

181 (245)

254 (345)

M20

302 (410)

420 (570)

509 (690)

251 (340)

361 (490)

M22

406 (550)

575 (780)

686 (930)

339 (460)

487 (660)

M24

524 (710)

738 (1000)

878 (1190)

435 (590)

620 (840)

M27

767 (1040)

1092 (1480)

1305 (1770)

642 (870)

922 (1250)

M30

1047 (1420)

1482 (2010)

1770 (2400)

885 (1200)

1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

10.9

Threads according to DIN 7984

12.9

8.8

10.9

M8X1.0

18 (25)

27 (37)

32 (43)

16 (22)

24 (32)

M10X1.0

37 (50)

55 (75)

65 (88)

32 (43)

48 (65)

M10X1.25

36 (49)

52 (71)

61 (83)

31 (42)

46 (62)

M12X1.25

64 (87)

96 (130)

111 (150)

55 (75)

81 (110)

M12X1.5

61 (83)

92 (125)

107 (145)

53 (72)

77 (105)

M14X1.5

100 (135)

148 (200)

173 (235)

89 (120)

129 (175)

M16X1.5

155 (210)

229 (310)

266 (360)

133 (180)

195 (265)

M18X1.5

232 (315)

332 (450)

391 (530)

199 (270)

284 (385)

M20X1.5

325 (440)

465 (630)

538 (730)

277 (375)

391 (530)

M22X1.5

435 (590)

620 (840)

723 (980)

369 (500)

524 (710)

M24X2.0

546 (740)

789 (1070)

922 (1250)

465 (630)

664 (900)

M27X2.0

811 (1100)

1143 (1550)

1328 (1800)

679 (920)

959 (1300)

M30X2.0

1106 (1500)

1586 (2150)

1844 (2500)

959 (1300)

1364 (1850)

®

Mustang Manufacturing Co., Inc. P.O. Box 179, West Bend, 53095-0179 USA www.mustangmfg.com

50940008/AP0311

918275/AP0311

© 2011 MUSTANG MANUFACTURING COMPANY, INC. All Rights © 2011 GEHL Company.

AllReserved. rights reserved.

PRINTED IN USA

Printed in U.S.A.