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11890169 service

1. V1020298 Fig 14 1 Hose 15 Tag remove and plug the two lower hydraulic hoses from the oil coolers Disconnect and plug the hose beneath the oil coolers NOTE Drain all the residual oil from hoses and coolers into a suitable container N gt 1020299 Fig 15 1 2 Hose 11 16 Remove the throttle cable u 1020300 17 Tag remove and plug the hydraulic hoses from the front inner side of hydraulic tank NOTE Drain all the residual oil from hoses and coolers into a suitable container V1020301 Fig 17 18 Tag remove and plug the hydraulic hose from the rear inner side of hydraulic tank NOTE Drain all the residual oil from hoses and coolers into a suitable container V1020302 12 19 Disconnect the propeller shafts from the drop box NA m UN N n PS E lt lt V1020303 Fig 19 20 Disconnect the ground wires from
2. 9092 faos MEE een DNE UY LE LL 841 mi00w zoov wzoov 1 msa vL sa S wf L Cylinder repair Disassembly 1 Remove the head from the cylinder body 2 Carefully slide the rod assembly out of the cylinder 3 Remove all seal kit components wipers rod seals o rings and back up rings from the head and piston 4 Inspect all the parts for scratches pitting or polishing Scratches or pitting deep enough to catch the fingernail are unacceptable replace the cylinder Polishing is a sign of uneven loading When this occurs
3. 3 ENT tH D Pe beoe ERE vr e ee e er 3 Installation e e En utes err Hering 11 Extend cylinder repair 16 Boom sections removal overhaul and installation 17 Boom secti n 3 ever En Cede E CP ex ETE E PER 18 Boom section Ze 2 ai a s Rr kn ehe ACTA PE 19 Boom section 1 removal are en nn De PC ehren 21 Boom main pin bearing removal and installation sss 24 Lift cylinder removal and installation while boom is removed 25 Slave cylinders removal while booms are removed 28 Slave cylinders lower supporting point removal and installation 29 Slave cylinders installation while booms are removed 29 Slave cylinders upper supporting point removal and installation while booms are ETT 30 Boom sections 31 Boom section 1 31 Boom section 2 33 Boom section 3 36 Hydraulic hoses removal and installation
4. 20 Rubber and plastics ccoo eine aa eode tar dev a tad 20 Lm 20 Safety when handling oils and 21 Pressure setting and leak detection eee 22 Observe the following safety 22 STANDARD PARTS SERVICE 19 GENERAL 191 Safety equipment without own function group Safety concerns everybody Always follow the instructions in the machine s operator s man ual The operator s manual should always be kept in the cab for easy reference We have spent many hours engineering and producing a machine with a high level of safety and efficiency All this time may be wasted if an individual who is about to perform service on any of our machines does nat read through the safety instruc tions or does not follow them for example does not replace guards climbs on slippery machine parts instead of using a lad der grabs on to hoses instead of the provided handles or uses the wrong tools for the job Always use genuine intended and adapted spare parts to maintain safe and efficient machine function Machines seldom cause accidents Instead people do A safety conscious person and a well maintained machine con stitute a safe efficient and profitable combination Any person who does not follow the safety instructions an
5. 53 Installation rt Loto ett et 54 Boom support V1015075 HYDRAULIC SYSTEM DIGGING HANDLING GRADING EQUIPM MISC EQUIP 94 UNIT LOAD HANDLING 942 Boom load handling Boom extend cylinder and chains removal and installation Removal IMPORTANT Plug all pipes hoses and connections when removing 1 Remove fork carriage or other attachment from the boom 2 Park the machine on a firm level surface with the parking brake set and the wheels chocked 3 Support the boom in a horizontal position with the boom fully retracted Use a stand to support the boom 4 Extend the tilt cylinder as much as needed for future removal of piston rod end 5 Open and remove the rear cover 6 Remove the oil tubes from the rear ofthe boom 7 Remove the extend chain adjustment bolt and the retaining plate from the cylinder support bracket at the rear of the boom 8 Remove the cylinder support bracket 9 Remove the extension oil tubes gt lt YA E AL AT V1014567 Fig 5 10 Secure the upper tilt cylinder end with a sling and disconnect the hoses from the tilt cylinder 11 Remove the retaining ring and drive out the upper pin with a hammer and a driver Lift or pull the tilt cylinder slightly for ward for better access to remove the hydraulic hoses for the auxiliary output if the machine is s
6. 1022339 Fig 15 Never install a fuse with a higher rating than the value given on the decal inside the fuse box There is a risk of fire on the circuit board FU Function FU A Function 1 10 Radio 9 10 Rotating beacon 2 10 Preheater 10 20 Lamps 3 10 A Starter relay fuse 11 15 Wipers 4 10 Position lights 12 15 Light and horn 5 10 Hour recorder 13 20 Cigarette lighter 6 10 Transmission control unit 14 15 Working lights 7 10 Power outlet 15 15 Working lights 8 10 Optional hydraulic func 16 10 Position lights tion 38 Relays Never install relay with a higher rating than value given below V1022341 Fig 16 RE A Function RE A Function 1 30 Starter 17 30 Axle lock 3 30 Neutral 18 30 Hydraulic oil filter pressure 7 30 Forward speed 19 30 Auxiliary 1 9 30 Gear box D 20 30 Auxiliary 2 10 30 Gear box valve D 21 30 Work light 11 30 Reverse speed 23 30 Blink relay 13 30 Low accumulator pressure 25 30 Axle lock 14 30 Pre accumulator 27 30 Plus after key 15 30 Pre accumulator indicator 28 30 Right blink light 16 30 Stop motor 29 30 Left blink light 39 A1346600 ee V1015055 V1015104 V1015105 V1015106 gt 0 38 INSTRUMENT SENSOR WARNING AND INFORMATION SYSTEM 380 General common info a
7. Right engine mount bracket V belt and tension pulley Water pump Fuel pump Alternator Turbo charger Exhaust 11 V1019588 7 Pre heater Coolant out Coolant in 10 Crankshaft pulley 11 Left engine mount bracket Component location plan view Fig 5 First cylinder Second cylinder Third cylinder Fourth cylinder 8 V1019631 Valve cover Air inlet Exhaust Govenor 13 and engine serial number The nameplate is affixed on the top of the engine beside of the oil cap The engine serial number is stamped on the nameplate and on the crankcase side The engine model and engine serial number must be indicated when ordering spare parts Engine Model Spec No Serial No 240 000000 00837765 D4D CDE2 gm kW S Imin co oc 14 DIN ISO 3046 IFN m 100 VOLVO MADE IN GERMANY V1019618 Fig 6 1 Nameplate with engine model and serial number Cylinder numbering The oylinders are numbered beginning at the flywheel end The direction of engine rotation is counter clockwise when facing the flywheel Firing order 040 CDE2 1 3 4 2 Fig 7 A Flywheel side V1019666 14 Repair Instructions p PRELIMINARY DOCUMENT Contents 21 ENGINE 210 General common info about 211 218 Engine and transmission assembly remo
8. Section 2 content structure The primary organization follows function group index for articulated haulers The function groups are based on MEC s company standard with 10 main groups numbered from 0 to 9 There is an additional section on safety The main groups are divided into sub groups which expand in several levels Example of function group for fuel feed pump according to the below 2 Engine with suspension and equipment Level 2 Level 3 Level 4 20 General 21 Engine 22 Lubrication system 23 Fuel system 230 General common information 233 Fuel feed pump filters 2331 Fuel feed pump 2334 Filter cleaners 234 Fuel tank refuelling pump 235 Fuel lines 24 Not used 25 Inlet system Exhaust system 26 Cooling system 27 Engine controls PRELIMINARY DOCUMENT Contents 19 GENERAL 191 Safety equipment without own function group Safety concerns 5 Safety when handling the machine 6 A few simple safety eene eene 6 Safety when lifting and supporting the 8 Safety rules when nennen nennen 9 Before starting any service work nssnsensnennnnnennennnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 9 Service POSIT
9. a tetto eere dE Ee rh EI rre Ree 16 Fig 1 A1520400 ELEC SYSTEM WARNING SYSTEM INFORMATION SYSTEM INSTRUMENTS 30 GENERAL 300 Comprehensive info electrical system Electrical system special instructions for servicing general WARNING No changes may be made to the electrical system without prior approval from MEC Changes may affect machine functions and can result in risks for personal injury or machine damage WARNING Carelessness when working with the electrical system may result in risks of serious personal injuries as well as machine damage When working on the electrical system the following instructions as well as instructions in respective section must be followed carefully WARNING Always remove watches rings bracelets and other metallic objects from the body before starting to work on the electri cal system WARNING Never boost start the machine by connecting directly to the starter motor This may result in uncontrolled machine movements When using another machine to boost start it must not touch the machine that is being started IMPORTANT Incorrect connection may result in permanent damage to electrical electronic components Always ensure use of correct connection point and polarity Never test if a cable connection is supplied with electric power by producing sparks This may permanently damage electrical electronic components
10. 22 Safety rules when 22 Before starting any service work 23 Service POSITIONS ie te Eie oai Aa 23 Service posIitlof 1 oret 23 Service POSION 2 5 Ep etn te RU 24 General niet ete Le 24 Working under raised boom 4 25 Safety when working with 25 Charging batteries icon tte 26 Starting with booster batteries 27 Fire prevention 27 Checklist after a fire or heat 29 CE marking and declaration of conformity sss 30 EU EMC Directive rese in ii Inn 30 Unauthorized modifications of the Roll Over Protective Structure ROPS 30 Some simple rules regarding tyre handling 31 Working on the electrical system of the machine 32 Safety for work on hydraulic systems sse 32 Generale eee dette ate ee ete that eni TE N 32 PreSsure release en nie 32 Health risks associated with paints plastics and 33 Work on painted
11. 37 P TUR 37 Er 39 944 Jibb load handling Boom wear pads adjustment or 41 Boom front wear pads ea te Le eb ud eiut 41 Boom section 2 upper rear wear padS 42 Boom section 3 upper rear wear eene 42 Side rear wear pads all ener 42 Boom chains and chain guide rollers wear inspection 43 BOOM CHAINS isis edet o ico 43 Chain guide Tole Ana ai 45 GChaitilubticatlon er a 45 Boom chains tension nter 46 Boom chain adjustment eene denen 46 945 Lifting frame work with mounting and link arm system Lift cylinder incl mountings Lift cylinder removal and mm 48 uocem Hehe deka and Dias 48 Installation ci A de eet eet ec de 49 Tilting cylinder incl mountings Tilt cylinder removal and nee 51 Removal mita aia 51 Installation e t e A Eae fa 52 Slave cylinder removal and 53
12. NS gt Fig 63 V1014787 V1014788 28 Slave cylinders removal while booms are removed IMPORTANT Plug all pipes hoses and connections when removing 39 Attach a sling to the slave cylinder and fold it slightly forward for better access when removing the locking screw 40 Tag and remove the hydraulic hoses from the slave cylinder Remove the locking screw 41 Drive out the lower pin to the slave cylinder 42 Remove the slave cylinder NOTE Weight of slave cylinder 20 kg 44 Ib Slave cylinders lower supporting point removal and installation 43 Drive the bearing out with a hammer and a driver Use tools handle 11667001 and drive plate 11667060 44 Drive in the new bearing by using the same tools V1014790 Fig 66 Slave cylinders installation while booms are removed 45 Lift the slave cylinder in place and install the pin NOTE Weight of slave cylinder 20 kg 44 Ib LO 9 9 44 Ib V1014785 Fig 67 46 Lock the pins with the locking screws and connect the hydraulic hoses according to previous marking V1014787 29 Slave cylinders upper supporting point removal installation while booms are removed Removal 47 For high boom versions Drive the bearing out with a hammer and a driver Use tools handle 11667001 and drive plate 11667060 For low boom versions Pull the bearing out with a puller V1014797 Fig 69 Installation 48 For bo
13. Turn off the engine before opening engine covers radiator covers and similar Make sure that no tools or other objects that can cause damage are forgotten in the machine When changing oil in the engine hydraulic system or trans mission keep in mind that the oil may be hot and can cause severe burns Working under raised boom Always secure the boom with safety strut before beginning any work Safety when working with batteries Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine In addition batteries give off hydrogen gas when they are loaded supplying electricity or being charged Together with the oxygen in the air hydrogen gas forms a very explosive mixture This combination corrosive acid and explosive gas means a high risk of accidents during all work with batteries used in vehi cles Therefore it is very important that you take great care and follow the rules below when you are working with batteries Fig 8 Do not smoke near batteries Follow these instructions when charging batteries Batteries give off explosive gases Never smoke near bat teries Begin by disconnecting the ground lead when removing a battery In order to reduce the risk of sparks that can cause fire always connect the ground lead last when fitting a bat tery Never tilt a battery to any great extent in any direction Bat tery electrolyte may leak out Donot conne
14. Electrical system special instructions for servicing electrical components batteries WARNING During rapid charging of batteries always remove the cell caps During charging an explosive mixture of oxygen and hydrogen is formed A short circuit open flame or spark near the battery can cause a powerful explosion Always turn off the charging current before disconnecting the charging clamps Ventilate well especially ifthe battery is being charged in a confined area The battery electrolyte contains corrosive sulphuric acid Remove spilled electrolyte from the skin immediately Wash with soap and plenty of water If electrolyte has splashed into the eyes or on any other sensitive body part rinse immediately with plenty of water and contact a physician immediately WARNING The batteries could explode due to the current surge ifa fully charged battery is connected to a completely dis charged battery Since the batteries contain sulphuric acid this could result in personal injuries WARNING Never charge a frozen battery Explosion hazard Never turn off the main electric power or disconnect the battery cables when the engine is running The battery s minus connection must always be discon nected before removing or installing components and con nections in the electrical system Fully charged and otherwise fully functional batteries shall be used when checking or testing in the electrical system If
15. Alternator starter motor Cable to engine preheating When unfused cables have been disconnected it is impor tant to check that they are reconnected and clamped in such a way that they cannot be exposed to chafing Unfused cables must not rest against oil and fuel hoses When fitting any optional equipment make sure that all cables circuits are connected across a fuse and routed and clamped so that there is no risk of chafing Fuel hydraulic and brake systems Check to make sure that there is no chafing damage to fuel hydraulic and brake hoses Welding and grinding Welding and grinding on the machine may only be done in a clean area and not in places that contain combustible liq uids such as fuel tanks hydraulic pipes or similar Work with extra care when welding and grinding near flam mable objects IMPORTANT A fire extinguisher should be easily accessi ble during all welding work Never weld on a painted surface without first removing the paint Welding on a painted surface generates in addition to health hazardous vapours technically inferior welds which may lead to future failures with subsequent acci dents Actions after a fire see Checklist after a fire or heat exposure 15 16 Checklist after a fire or heat exposure If a machine has been damaged by fire or been exposed to intense heat the following precautionary measures according to the following check list must under all circumsta
16. Fig 54 28 Drive in the new bearing by using the same handle 11667001 and drive plate 11667105 O OA V1014795 24 Lift cylinder removal and installation while is removed Removal IMPORTANT Plug all pipes hoses and connections when removing 29 Tag and remove the hoses from the lift cylinder V1014779 Fig 56 30 Secure the lift cylinder with a sling and remove the locking screw for the cylinder pin V1014780 Fig 57 31 Remove the pin with a hammer and a driver Use the holes in the side of the frame for better access V1014781 Fig 58 25 32 Lift the cylinder out from the frame NOTE Weight of lift cylinder 200 kg 440 Ib v1014782 33 Ifthe bearing in the lower lift cylinder support is to be Fig 59 replaced Drive the bearing out with a hammer and driver the bearing must be driven out to the right 34 Reinstall the new bearing with a hammer and drive plate 11667090 The bearing must be driven in from the right hand side of the machine 26 Installation 35 Liftthe cylinder in place and install the pin Use a driver and the hole in the side of the frame for better access NOTE Weight of lift cylinder 200 kg 440 Ib V1014783 Fig 60 36 Connect the hydraulic hoses according to previous mark ing Fig 61 37 Install the locking screw 38 Lower the lift cylinder to it s frame support V1014780 Fig 62 27 RO We 7 Bile iN
17. A 8 e6 910 96 910 96 910 916 91 9 Fig 101 44 V1015087 6 Rotated pins 7 Excessive exterior wear pay special attention to the areas that make contact with the guide rollers most often 8 Measure chain elongation Apply 68 kg 150 Ib of pull to chain Measure the distance between pin centres and refer to the following illustration for maximum allowable wear length Measure at five different locations on each chain If any measurement exceeds the wear limit the chain must be replaced Item Designation Number Original Maximum of pitches length wear length mm inch mm inch A Extend chain 12 304 8 12 313 9 12 36 B Retract chain 16 304 8 12 313 9 12 36 Chain guide rollers 9 10 11 Remove the extend chain guide roller from the front end of the extend cylinder Inspect the guide rollers pins and bushings for wear Any noticeable wear on any of these parts will require its replacement Inspect the lubrication passages and grease fittings to ensure proper flow of grease through the pins Chain lubrication 12 13 14 Once the boom chains have been inspected it is very important to lubricate before installation Use motor oil to lubricate the chains multigrade SAE 20W 50 would be suitable It is impossible to lubricate the boom chains once they are in place Use a towel and or wire
18. MA 14 Fork tilt MA 15 Axle lock MA 16 Axle lock P 1 Frame level joystick P2 Fork tilt joystick SE Temperature sensors monitors SE 3 Hydraulic oil high temperature SE 4 Hydraulic oil low temperature SE Pressure sensors monitors SE 8 Hydraulic oil filter pressure SE 10 Proximity sensor ECU Control unit 24 31 gt 9 30 gt 7 29 gt 2 411 15 9 YE j MA13 dl ses a ue YE YE 14 PCIA m YE EL YE YE P2 M an s p je TOS 1022108 25 Wiring diagram T09 SW Switch SW 8 Hydraulic lock SW 13 Left stabilizer SW 14 Right stabilizer SW 19 SW 20 RE Relays RE 19 Auxiliary 1 RE 20 Auxiliary 2 FU Fuse Fuses in fuse box FU 8 Stabilizer and auxiliary MA Solenoid valves MA 18 Hydraulic lock MA 19 Auxiliary 1 MA 20 Auxiliary 2 MA 21 Left stabilizer up MA 22 Left stabilizer down MA 23 Right stabilizer up MA 24 Right stabilizer down D Diods D 10 26 8 31 gt 3 32 gt Fig 9 p 402 3357 T09 V1022109 27 Wiring diagram T10 SW Switch SW 3 Left combi switch SW 9 Marker lamp FU Fuse FU 4 Left marker lamp FU 10 22 FU 11 Marker lamp FU 16 Right marker lamp LA
19. ementi 33 The following safety instructions must be followed 33 R bber and plastics 5 erede e I Laien 34 Fl ot r ber eiie cr Lebe e reete ic 34 Safety when handling oils and emen 35 Pressure setting and leak detection ene 35 STANDARD PARTS SERVICE 11 STANDARD PARTS 110 General Service For the machine to operate at the lowest possible cost it must receive thorough and complete maintenance Intervals for main tenance and lubrication refer to normal operating and environ mental conditions Maintenance work is described in the Opera tor s manual For other adjustments and repairs an authorized brand name workshop should be used Engine For severe tions ACEA E3 96 CCMC D5 is recommended to give optimum service life Axles and transmission MEC WB 101 For trade names and oil E ES Hubs and dropbox Hydraulic system Steering system Working hydraulics 16 LUBRICANT FUEL OTHER FLUID 160 General Recommended lubricants oils Cil grade Engine oil MEC Diesel Engine Oil MEC VDS 10 0 10 20 30 40 als 32 50 68 86 104 122 Recommended viscosity at varying ambient tem peratures 50 APICF CF 4 API CG 4 SAE 0W 30 SAE 0W 40 API CH 4 ACEA E1 E3 96 SAE 5W 30 SAE 5W 40 ACEA E4 98 DHD 1 SAE 10W 30 SAE 10W 40 SAE 15W 30 SAE 15W 40
20. CE marked Our machines have been specifically tested for electromagnetic interference The CE marking of the machine and the declaration of conformity also cover the EMC directive If other electronic equipment is fitted to this machine the equip ment must be CE marked and tested on the machine with regard to electromagnetic interference Unauthorized modifications of the Roll Over Protective Structure ROPS Never make any unauthorized modifications to the ROPS such as lowering the height of the roof drilling welding on fire extin guisher brackets radio aerial brackets or other equipment Such unauthorized modifications will affect the structural strength of the ROPS cab and will void the certification The Roll Over Protective Structure ROPS has been approved following testing and meets standards according to ISO 3471 1994 and SAE 1040 MAY 94 The cab has also been tested and approved according to FOPS standard as defined by ISO 3449 1997 and ISO 6055 1997 All planned modifications must be reviewed in advance by our Engineering Department in order to determine whether the alter ation can be made without affecting the certification Fig 19 Never stand to the side of the tyre while inflating It is important that all persons in your organisation including management are made fully aware of these rules involving ROPS If anyone in your company discovers that a certain machine was modified in non approve
21. IM Instruments IM 1 Fuel indicator IM 2 Water temperature indicator IM 3 Hour meter IM 4 External hour meter D Diodes D 31 D 32 D 34 14 un OR Bode LONE 9 OR LED17 8 FU5 EX AXP 7 303 IM3 2 1 2 31 10 EC 1 1235 11 IMA 13 6 gt 2 IM2 c 2 LED12 0 031 BE gt 2 430 7 032 BI LED14 gt O D BL LED15 cm LED20 gt 2 1 520 Es 8 LED22 4 2 1 400 C9 YE a 4 LED11 pos 1022103 Fig 3 Wiring diagram 4 LED Indicators LED 16 Blinker light LED 18 Hydraulic oil filter LED 19 High hydraulic oil temperature LED 21 Low hydraulic oil temperature LED 27 Low brake oil pressure D Diodes D 33 D 35 16 355 Fig 4 T04 V1022104 17 Wiring diagram T05 SW Switch SW 4 Left combi switch RE Relays 7 Forward speed 9 Gear box valve D RE 10 Gear box valve C RE 11 Reverse speed FU Fuse Fuses in fuse box FU 6 Combi switch FU 12 Horn SA Sounders SA 1 Front horn 4 Reverse warning MA Solenoid valves 5 Forward speed 6 Reverse speed 8 Gear box valve 9 Gear box valve D MA 10 Gear box valve D Diods
22. Lamp LA 1 Main beam right LA 2 Main beam left LA 3 Full beam right LA 4 Full beam left 5 Rear right marker lamp LA6 Front right marker lamp LA 25 Rear left marker lamp LA 26 Front left marker RE Relay RE 24 Plus after key switch 28 ES FU16 06 O OX LA25 pS FUA gt LA1 Q LA2 0 amp 4 730 13 731 13 50 12 801 12 802 12 803 47 12 13 331 12 39 gt 11 T10 V1022110 Fig 10 29 Wiring diagram T11 SW Switch SW 15 Rotation beacon SW 18 Work lights SW 35 Cab light RE Relays RE 21 Work light FU Fuse Fuses in fuse box FU 13 Cigarette lighter and power outlet FU 14 Rear working lights FU 15 Front working lights FU Fuse Fuses in batte ry compartment FU 19 D FU 22 D LA Lights LA 7 Brake light LA 8 Brake light LA 13 Cab rear work light LA 14 Cab rear work light LA 15 Boom work light LA 16 Boom work light LA 17 Cab front work light LA 18 Cab front work light LA 21 Cab light LA 23 Rotating beacon lamp FC FC 9 PO Plug PO1 Plug 1 PO2 Plug 2 30 LA14 41 gt 5 E FU14 709 y 15 vo RE21 LA15 FU19 87a vo 331 LL y 0 31403 LA17 710 K 15 vo COS LA18 X CN PO rt PO FU22 209 FU13 202 nn 0 LA23 27 705 PU 111 V1022111 Fig 11
23. NOTE Do not apply grease to the chain Grease will coat only the outside of the chain and will seal out the necessary lubricat ing oil 31 Install the front fastening plate and tighten the anchor nut lightly 32 Install the chain guide roller 11 33 Make sure the set screws apply tension on the pin s flat surface NOTE Use Loctite 242 and torque the set screws to 11 Nm 100 Ibf in 34 Secure both chains to the chain block and secure with cotter pins V1014603 35 Install the chain block to the rear end of boom section 3 make sure the block is levelled and parallel to the boom Install the pin and secure set screws with Loctite 242 36 Secure the extension cylinder with 2 slings and lift in a level position Insert the front sheave end to the boom assembly NOTE Cylinder weight 195 kg 430 Ib 1014587 Fig 26 12 37 Pull the extension chain up around the chain guide roller and put the chain in the chain guide channel gt AA fmm SE ES FO gt X SI gt lt gt ALZA Ic 25 gt 0 1014590 Fig 27 Secure the chain to the chain rod s anchor Secure the hex block between rod and anchor with Loctite 242 39 Temporary strap the chain rod to the extension cylinder The straps prevents the rod from falling down from the inder 38 V1014584 Fig 28 40 Lower the extracted e
24. SAE 20W 50 requirements see 10 O 10 20 30 40 14 32 50 68 86 104 Specifications in the Operator s Manual for the respective machine 1006493 MEC Super Trans mission GL 5 30 10 0 10 20 30 40 50 F 22 14 32 50 68 86 104 122 80W 90 80W 140 Hydraulic oil Super Hydraulic Oil ISO 6743 4HV 10 0 10 20 30 40 14 32 50 68 86 104 1007807 ISO VG46 ISO VG68 HV 17 SERVICE 170 General common info about 171 179 Replacement parts For reference when ordering replacement parts or making serv ice inquires record the model and serial numbers of your machine They are stamped on the serial number plate on the left side of the machine Service methods Appropriate service methods and proper repair procedures are essential for safe reliable operation of MC loaders and safety of the individual doing the work This Service Manual provides gen eral directions for accomplishing service and repair work with tested effective techniques Following them will assure reliabil ity There are many variations in procedures techniques tools and parts for servicing machines as well as work skills This manual cannot possibly anticipate all such variations and provide a
25. be sure all hoses are in good con dition and all fittings are tight 2 Use pressure gauge with a range that is high enough to measure the specified pressure 3 Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury General part replacement Replace O rings seals and gaskets whenever they are dis turbed Never mix new and old seals or O rings regardless of condition Always lubricate new seals and O rings with 10W30 oil before installation Replace all used elastic locknuts with new parts When replacing parts use the correct tool Cleaning prior to repair Clean the exterior of all parts before repairing Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user Certain types of fluids damage rubber parts and or cause skin irritation The following precautions must be observed to insure hydraulic cleanliness 1 AON Flush hose and tube assemblies with a solvent compatible with hose assemblies Blow out excess solvent with shop air Cap hydraulic fittings and protect threads until installation Cap hoses and tube assemblies until installation Flush hydraulic reservoir fuel tank and chain case hous ings with a suitable solvent to remove any foreign debris Protect system components from airbor
26. current rating that the battery can generate Start cables with regards to cracks oxidation and other defects That battery cables are intact and connections are con nected securely That the machines do not touch each other WARNING When using start cables the positive and negative connec tion must not come into contact Risk of personal injury Connect start cables as follows B 4 V1003824 Fig 4 Connecting start cables Connect the first start cable A to the battery s plus termi nal 1 on the machine to be started Connect the other end of the cable A to the battery s plus terminal 2 on the assisting machine Connect the other start cable B to the battery s minus ter minal 3 on the assisting machine Connect the other end of the cable B to the frame 4 on the machine to be started Check that good electric contact is obtained Auxiliary start Check that the start cables are connected securely and correctly figure Start the engine in the assisting machine Start the engine in the machine to be started If the engine does not start within 30 seconds wait for at least two min utes before the next start attempt Remove the start cables as follows B 1 V1003825 Fig 5 Removing start cables Remove the cable B from the frame 1 on the machine that has been started with auxiliary start Remove the other end of the start cable B from the bat tery s minus t
27. directive If other electronic equipment is fitted to this machine the equip ment must be CE marked and tested on the machine with regard to electromagnetic interference Unauthorized modifications of the Roll Over Protective Structure ROPS Never make any unauthorized modifications to the ROPS such as lowering the height of the roof drilling welding on fire extin guisher brackets radio aerial brackets or other equipment Such unauthorized modifications will affect the structural strength of the ROPS cab and will void the certification The Roll Over Protective Structure ROPS has been approved following testing and meets standards according to ISO 3471 1994 and SAE 1040 MAY 94 The cab has also been tested and approved according to FOPS standard as defined by ISO 3449 1997 and ISO 6055 1997 All planned modifications must be reviewed in advance by our Engineering Department in order to determine whether the alter ation can be made without affecting the certification It is important that all persons in your organisation including management are made fully aware of these rules involving ROPS If anyone in your company discovers that a certain machine was modified in a non approved manner your company must notify the customer and manufacturer if writing regarding which machine it was and how it was modified NOTE Modifications or removal of material which affects sound i e noise insulating material noise damp
28. injuries and even deaths Therefore it is very important that you read and follow the instructions in the Operator s Manual Never use a machine for which the Operator s Manual is missing Learn the meaning of all the warning plates symbols and operating instructions before operating the machine 19 20 A few simple safety rules General Remedy faults or defects which affect the safety as soon as possible Always wear a hard hat safety glasses gloves protective shoes and other protective articles when required Do not remain in front of or behind the machine while the engine is running To avoid unnecessary climbing on the machine use either a long handled rubber scraper or brush for cleaning the out sides of the windows When servicing the machine and for instance when chang ing bulbs a ladder may be necessary Make sure that stepping surfaces service areas handles and anti slip surfaces are free from oil diesel fuel dirt and ice and that they are changed if they are damaged or miss ing Check at regular intervals that all anti slip items are securely fitted If this is not the case they should be secured or replaced When you are entering or leaving the machine always face the machine and use the steps and hand holds Always use both hands and one foot or both feet and one hand Do not jump Before operating Read the Operator s Manual before you operate the machine Follow the operating instructions
29. speed is in direct relation with engine speed NOTE The pressure regulator valve is mounted behind the filter adapter housing Input shaft and directional clutches description The turbine shaft driven from the turbine transmits power to the forward High 4 or reverse clutch These clutches consists of a drum with internal splines and a bore to recieve a hydraulic actuated piston The piston is oil tight by teh use of sealing rings The steel discs with external splines and friction discs with internal splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch To engage the clutch the solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows the to drive as one unit When the clutch is released a return s
30. the part must be checked for roundness Use the following recommenda tions for different cylinder sizes Cylinders more out of round than shown in table should be replaced Cylinder size bore Maximum out of roundness inches mm inches mm lt 7 lt 178 0 003 0 076 gt 7 gt 178 0 005 0 127 Assembly NOTE Torque all hardware to the specifications listed in the General Information section of this manual unless otherwise specified 5 Lubricate all components with clean hydraulic fluid NOTE To avoid cutting the seals do not use sharp edged tool during replacement After installing the seals wait at least one hour before assembling the cylinder to allow the seals to elasti cally restore their original shape 6 Install the new components from the seal kits 7 Lubricate the seals in the head and carefully slide it onto the rod dust seal end first Slide the spacer onto the rod if equipped Install the o ring and piston on the end of the rod Torque the piston nut according to table Description Piston nut torque Extend cylinder 410 475 Nm 300 350 Ibf ft Lift cylinder 2170 2710 Nm 1600 2000 Ibf ft Tilt cylinder 1900 2300 Nm 1400 1700 Ibf ft Frame level cylinder 1525 1865 Nm 1125 1375 Ibf ft Slave cylinder 510 610 Nm 375 450 Ibf ft Stabilizer cylinder 1085 1355 Nm 800 1000 Ibf ft 8 Lubricate the seals on the piston and the head 9 Carefully sli
31. water and seek immediate medical attention Starting with booster batteries When starting with booster batteries the following must be observed Check that the booster batteries or other power source have the same voltage as the standard batteries WARNING Batteries may explode due to the current surge if a fully charged battery is connected to a completely discharged battery Personal injuries may be sustained Follow these steps 1 2 3 9 Move the gear selector to neutral Apply the parking brake Check that the booster batteries or other power source have the same voltage as the standard batteries Do not disconnect the cables to the standard batteries Connect on the booster battery to on the battery nearest the starter motor Connect the other start cable from on the booster bat tery to the machine chassis such as on the frame member close to the starter motor Start the engine with the ignition key in the cab Once the engine has started remove the start cable between the chassis and the booster battery negative ter minal Then remove the start cable between the positive terminals Refit the terminal caps on the battery terminals Fire prevention measures General There is always a risk of fire Find out which type of fire extinguisher to use where it is located and how to use it The fire extinguisher in the machine should be located for quick access or in an extern
32. 31 Wiring diagram T12 MO Motors Front wiper 4 Front washer pump 5 Rear wiper MO 6 Rear washer pump MO 7 Roof wiper motor SW Switches SW 17 Rear wiper 32 800 445 801 10 45 gt 10 46 5 32 GR 10 48 gt 303 OR A 804 5 4 2 4 10 47 5 V1022112 Fig 12 33 Wiring diagram T13 LA Lights LA9 Front right blink light LA 10 Front left blink light LA 11 Rear right blink light LA 12 Rear left blink light SW Switches SW 7 Direction switch RE Relays RE 23 Blink relay RE 28 Right blink relay RE 29 Left blink relay D Diodes D 16 Right blink light RE 17 Light blink left 34 10 43 gt 10 42 gt Fig 13 LA9 Q LA11 LA10 LA12 113 1022113 35 372 Electrical distribution box fuse relay circuit breaker Fuse Main fuses The main fuses are located inside the engine compartment V1022340 Function FU A unction 1 OA After Key 4 Key switch OA Signal light and output 5 Horn and work light power OA Starter motor 36 Fuses FU6 c 4 5
33. Em 36 FUSES e E Hee Metu erbe e CUN 38 Relay REII VS ie 39 38 INSTRUMENT SENSOR WARNING AND INFORMATION SYSTEM 380 General common info about 383 387 Eontroliswitchesi ndi ai dm e lee 40 Parking brake SE Ee eSI 40 40 Front WIDOr tore i sh act 40 TOP MEE 40 Top Washer za eed mme c tud d EN 40 41 En 41 PAZ ANG 41 nece MINOR RS 41 RIght StabiliZOr Heike ine 41 Frame levels e e mii 41 ee ale eR ete mus 41 Indicator lights eere reti eta T E RERUM nee 42 ELEC SYSTEMS 37 CABLE FUSE RELAY 370 General common info about 371 Cable coulors 379 The cable colours used in wiring diagrams are indicated in the table below Cod Cod e Colour e Colour BL Blue R Red BN Brown SB Black GN Green VO Violet GR Grey W White OR Orange Y Yellow Pink Electrical symbols and designations Designation Explanation designation AL Alternator with charging regulato
34. Hub hub reduction Hub reductions ninaa inii Fig 1 1 Fill plug 2 Sight glass 3 Drain plug V1021910 POWER TRANSMISSION 43 GEARBOX 430 General Transfer case oil filling NOTE The transfer case is a separate sealed unit and does not share oil with the transmission Op no 1 Putthe machine in service position 1 see TH60 TH80 191 Safety rules when servicing 2 Clean the area around the sight glass on the transfer case Inspect the oil level it should be in the middle of the sight glass 3 Fill if necessary with oil according to specifications see section TH60 TH80 160 Recommended lubricants oils Clean the area around the fill plug before it is removed 4 Reinstall the fill plug 45 PROPELLER SHAFT 451 Propeller shaft complete Specification All propeller shafts consists of two universal joint and a slip yoke assembly Both of the universal joints and the slip yoke assem must be lubricated every 250 h there are 3 grease nipples on each shaft Do not lubricate with a high pressure grease gun Maximum grease gun pressure 15 bar 217 psi Grease with lithium base with EP additives and consistency NLGI No 2 Torque Propeller shaft Nm Ibf ft Front propeller shaft 71 10 52 7 Rear propeller shaft 71 10 52 7 46 FRONT AXLE REAR AXLE 460 General common info about 461 468 Drive axles oil filling Op no 1 Put
35. Oil cooler Engine D4D component location Component location right hand side 6 7 A Fig 2 la 1b 10 Oil filler Oil dipstick Coolant in Thermostat Coolant out 1 late models la 1b early models Component location left hand side 1b late models 177 4 Engine lifting eyes Inlet manifold Exaust manifold Starter motor 1a 1b early models Component location rear side 1a 1b late models Fig 3 la 1b Oil filler Oil dipstick Coolant temperature sensor Turbo charger Start Solenoid N u Governor Accelerator Flywheel Sump 11 Component location front Fig 4 o 12
36. Service Brake Service brake inspection 52 HYDRAULIC BRAKE SYSTEM 520 General common info about 520 522 Service brake bleeding Pressure settings accumulator system Accumulator pressure 55 PARKING BRAKE 550 General common info about 551 554 Hydraulic cylinder Parking brake manual release Reset the parking brake E uw V1014929 Fig 1 2 Oil level plug ice er c 20 4 S V1020350 Fig 2 BRAKE 51 WHEEL BRAKE 510 General common info about 511 519 Service Brake The service brakes are a hydraulically actuated multi plate oil bath type housed inside the axle housing on either side of the differential They are designed to provide long trouble free serv ice life by utilizing the oil in the axle to cool the brake assembly and by using the gear reduction at the hub to reduce the braking effort Service brake inspection 1 Putthe machine in Service position 1 see TH60 TH80 191 Safety rules when servicing 2 Remove the oil level plugs 2 One is on the front sid
37. Transmission regulator pressure neutral port 31 12 76 bar 185 psi at 600 rpm 19 31 bar 280 psi at 2000 rpm Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 Forward High clutch port 44 Forward clutch port 45 Reverse clutch port 46 Clutch activated 16 5 19 3 bar 240 280 psi at 1800 rpm Clutch released 0 0 2 bar 0 3 psi at 1800 rpm Lubrication pressure port 33 at 1850 rpm 2 9 4 0 bar 42 58 psi at 49 l min 13 pump flow Safety valve cracking pressure 8 27 10 20 bar 120 148 psi measured at port 32 with converter out shut off Filter bypass valve set at 2 1 3 5 bar 30 50 psi Transmission out pressure port 32 at 49 l min 13 2 9 6 41 bar 42 93 psi pump flow 1850 rpm and max 8 27 bar 120 psi at no load governed speed Pump flow at 2000 rpm in neutral 53 l min minimum 14 gpm NOTE All pressures and flows to be measured with oil tempera ture of 82 93 180 200 F Transmission overview Basically the T12000 transmission is composed of five main assemblies 1 Converter pump drive section and pressure regulating valve Input shaft and directional clutches Range clutches Output section Transmission solenoids O14 WP Converter pump drive and pressure regulating valve description Engine power is transmitted from the engine to the impeller COVer This element is the pump porti
38. a nega tive effect on the electrical system 1003611 Fig 3 Example of bolted joint as grounding point Several cables are often interconnected at the same grounding point which means that several functions and systems can be affected by the quality of the grounding point It s very important that the electrical connection at a grounding point is correct that is there is no paint or dirt on the contact surface between the cable terminal and grounding point chassis ground there is no corrosion on the contact surface between the cable terminal and grounding point bolts and nuts are securely tightened Unprotected grounding points should always be provided with corrosion protection A defect at a grounding point can have effects in systems and functions that at first glance don t appear to have anything to do with that grounding point This malfunctions can be very difficult to find Auxiliary start WARNING Never boost start the machine by connecting directly to the starter motor This may result in uncontrolled machine movements When using another machine to boost start it must not touch the machine that is being started Auxiliary start with start cables Check the following before connecting That the ignition is OFF in both machines That the machine cannot start to move when started That the machines have the same system voltage That the start cables are dimensioned for the max
39. a return oil filter positioned on the right hand side of the machine Venting is through a breather filter with a built in counter pressure One gear pump provide all hydraulics with oil The pump is positioned on the transmission When the steering or brakes are used these systems are in priority The working pump also serves the servo system with oil Functions are controlled by a five spool control valve The con trol valve is of the closed centre type This means that no oil passes through the control valve in neutral position Pressure build up general The figures in the text below refer to the Hydraulic diagram A TH60 TH80 990 Hydraulic diagram A The pump 1 placed on the transmission pumps oil to the pres sure regulator 2 When the hydraulic pressure exceeds 20 bar 290 psi and there is no LS signal the oil will be directed to the tank The pressure will remain on 20 bar 290 psi This is the stand by pressure The pressure limiting valve 3 drains the LS pressure to tank when the maximum system pressure 240 bar 3480 psi is reached The oil goes to the priority valve 6 which priorities brakes steering and servo pressure Tilt up and boom lift uses maximum system pressure 240 bar 3480 psi other working hydraulic functions are maximized to 175 bar 2538 psi by pressure limiting valve 19 Pressure build up brakes The figures in the text below refer to the Hydraulic diagram A TH60 TH80 990 Hydraulic
40. brush to remove any grease or dirt that may prevent the penetration of new oil into the joints Apply small amounts of motor oil to each joint Rotate the joint to ensure full penetration of oil Wipe any excess oil from the chain NOTE Do not apply grease to the chain Grease will coat only the outside of the chain and will seal out the necessary lubricat ing oil 45 Fig 102 V1021811 1015091 Fig 103 1 Spacer position when not in use 2 Spacer position when used 46 Boom chains tension inspection The boom chains are contained completely within the boom sections and are not visible from the exterior Measuring the distance between the top brackets of section 2 and 3 will indi cate the chain tension 1 2 Fully retract the boom Raise the boom to full height to allow all sections to fully retract Lower the boom until the attachment is approximately 50 mm 2 in from the ground Set the parking brake and turn off the engine Measure the distance between the top brackets of section 2 and 3 If the distance is less than 28 mm 1 125 in then the chain requires adjustment See Boom chain adjustment page 46 for further instructions Boom chain adjustment Op no 1 Retract the boom until the distance between the brackets on top of boom section 2 and 3 measure approximately 30 mm 1 25 in Remove the spacers and mounting hardware from the top bracket of boom section 3 and reinstall them in
41. equipment to perform the service work correctly Repair or change broken or damaged tools and equipment Service positions Before you begin service work the machine must be placed on level ground and prepared as shown below If work has to be carried out on the machine before it has cooled there is a risk of burns Therefore take care when working with hot liquids and machine parts Service position 1 V1021707 Remove the attachment from the attachment bracket Fully retract the boom Fully lower the boom so that the boom supports to the machine frame Park the machine on firm level ground Apply the parking brake Turn off the engine Remove the ignition key Allow the machine to cool down If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns w A 9 Attach a black and yellow label to the steering wheel with the message forbidden to start the engine 10 Unfasten seat belt and exit the machine using the handles 11 Block the wheels 23 Fig 13 Service position 2 24 Service position 2 9 10 11 V1025265 Remove the attachment from the attachment bracket Fully retract the boom Place a support under the boom Park the machine on firm level ground Apply the parking brake Turn off the engine Remove th
42. excessive pressures Interrupt the pressure increase as soon as the specified pressure has been reached changes in small increments when setting pressure adjustment devices whose sensitivity is not known This is especially important with regard to the servo circuit which is pressurized as soon as the engine is started Check and calibrate the pressure checking equipment reg ularly and replace damaged components 35 Description p PRELIMINARY DOCUMENT Contents 20 GENERAL 200 General engine installation and its function Engine specifiCatiofis ene da 4 Engine weight tee e ine edd lakes ete tt dee e e eee n b d dd tes 6 Engine CapacitleS cita a aide 6 Engine tightening torques oconoccccccnnoccccccconconcnccnnnnnnnncccnnn nennen eene enne 7 Enigine 040 component location eene ee emen 8 Component location right hand side sssssssenn emen 8 Component location left hand side 9 Component location rear side 10 Component location front 11 Component location plan view 12 Nameplate and engine serial number eene 13 Cylinder numbering 13 ENGINE WITH MOUNTING AND EQUIPMENT 20 GENERAL 200 General engine installatio
43. in the Opera tor s Manual and carry out the measures which are detailed in the manual before operating A few important rules are given below Make a control lamp test before starting the engine by turn ing the ignition key to position 1 see the Operator s Man ual Carry out all safety checks prescribed in the Operator s Manual WARNING Never operate the machine if you are tired or under the influence of alcohol medicine or other drugs Before starting the engine indoors make sure that the extraction capacity of the ventilation system is sufficient The machine is provided with a diesel engine and the exhaust gases may be dangerous to your health Make sure the ventilation is sufficiently good and avoid running L50385 1 Fig 9 Read the Operator s Manual plates and instructions before you start operating the machine Fig 10 Use th tion the engine for a longer time than necessary particularly when the ventilation is unsatisfactory Read all plates and instructions which are fitted on the machine and given in the Operator s Manual before you begin to operate or service the machine Each of the instructions contain important information about safety handling and service of the machine Use the lap type seat belt during all operation Always sit in the seat facing the front of the machine when starting the engine The machine must be operational before putting it to work that is all faults which may
44. point use suitable breathing protection If the work area cannot be sand blasted remove the paint in another way for example with a paint remover solvent NOTE When using paint removers solvents use an air extractor breathing protection and protective gloves High speed grinding machines and grinding discs also heat the paint and must only be used if there s an air extractor on the grinding machine Use breathing protection as well Rubber and plastics WARNING When heated rubber and plastics can give off gases which are dangerous to health and the environment The following safety instructions must be followed Do not weld or cut near polymer materials rubber and plastics without first protecting them from the heat Never burn polymer materials when scrapping them Becareful when handling machines that have been exposed to fire or other intense heat Also refer to Check list after a fire or other heat exposure Always use protective gloves protective glasses goggles and breathing protection Fluor rubber WARNING Risk of serious corrosive injuries WARNING When hydrogen fluoride rubber is heated there is a risk of hydrogen fluoride gas build up already at approx 320 C 610 F When inhaled the gas is extremely corrosive to respiratory tracts Certain seals designed to withstand high operating temperatures for example in engines transmissions axles brakes hydrau
45. pump drive and pressure regulating valve description Input shaft and directional clutches description Range clutches and output section description sss Range cl tches ia Output Section ED Transmission controls description sss nnnm POWER TRANSMISSION 40 GENERAL 400 General common info about 410 436 Transmission specifications Transmission Type Power transmission Designation T1200 Torque converter ratio 2 1 Number of gears forward reverse 414 Pump flow t 33 4 r s 2000 rpm 53 litres 14 US gal per minute Gear shifting system Electro hydraulic Filter External spin on Speed range forward reverse Gear Forward reverse 1st 3 1 mph 5 1 kph 2nd 6 8 mph 11 kph 3rd 13 7 mph 22 kph 4th 21 1 mph 34 kph Transmission ratio Gear Forward reverse 1st 4 47 2nd 2 05 3rd 1 00 4th 0 66 Drop box specifications Type Shaft drop box Drop box ratio 1 1 42 TRANSMISSION HYDRAULIC CONTROL 420 General Transmission temperatures and pressures specifications Temperatures Operating temperature 70 120 C 158 248 F Max allowed temperature neutral port 31 120 C 248 F a Measured at temperature check port converter out port 71 Pressures
46. removal and installation page 51 WARNING Risk of injuries caused by crushing 1 Remove fork carriage or other attachment from the boom 2 Park the machine on a firm level surface with the parking brake set and the wheels chocked 3 Support the boom a horizontal position with the boom fully retracted Use a stand to support the boom 17 Boom section 3 removal NOTE Use 8 screw or a threaded rod with a length of approximately 100 mm 4 in to get a hold of the pads as the securing bolts are removed 4 Remove all wear pads from rear end of boom section 3 Two on top one on each side and one at the bottom V1014617 Fig 38 5 Secure boom section 2 to section 1 with a rod to keep them together while extracting boom 3 V1014612 Fig 39 6 Attach a sling to the front end of section 3 and extract approximately 3 m 120 in NOTE Total length of boom section 3 5 1 m 200 in 7 Attach a second sling to the boom and extract it fully from the boom NOTE Weight of boom section 3 557 kg 1230 Ib 8 Putthe boom section 3 on stands or a suitable fixture V1014615 Fig 40 18 Boom section 2 removal 9 Remove the securing rod from boom section 1 and 2 Remove the retaining plates and the rear upper wear pads from boom section 2 V1014667 10 Remove the rear wear pads at the sides from boom section 2 one at each side V1014668 11 Use a pair of clamps t
47. the boom Park the machine on firm level ground Apply the parking brake Turn off the engine Remove the ignition key Allow the machine to cool down Aria If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns Attach a black and yellow label to the steering wheel with the message forbidden to start the engine Unfasten seat belt and exit the machine using the handles Block the wheels 11 Fig 3 V1014530 12 V1014530 176 Emergency measures Hydraulic cylinder Parking brake manual release Op no 1 Place the machine in service position see section Safety rules when servicing page 22 Release the parking brake by giving a hammer blow to the external ring of the check unit Reset the parking brake 3 Reset the parking brake by starting the machine and intro duce pressure into the braking system Check that at end of the piston stroke the check unit is actually engaged onto the rod Recovering and towing WARNING Before starting any recovery or towing work make sure that the parking brake is applied and the wheels are blocked to prevent the machine from rolling Extreme caution must be observed in connection with towing to prevent accidents and personal injuries WARNING If the engine cannot be started the brake and steering func tions will be severely limited In such cases towing should on
48. 00 7 V A1398400 leal 0904500 Position monitor closing i e lever position Designation Symbol Explanation designation IL Position monitor opening i e return filter monitor A1399800 SE Level monitor i e coolant level Pressure monitor i e air filter Single terminal switch with manual on and off i e activation of air conditioning Sw Single terminal switch with manual on and automatic off i e horn A0905900 Summary of codes in wiring diagrams AL Alternators IM Instruments and information display unit BA Batteries LA Lights DI Diodes LC Control lights FC Fuses MA Solenoid valves FH Fuses MO Motors FU Fuses on circuit board PO Power outlets sockets GC Grounding point cab R Rheostats GE Grounding point engine RE Relays GF Grounding point front RF Flasher relays GFSM Grounding point starter motor SA Audible signals GR Grounding point rear SE Sensors and monitors HE Heating heating coil Sw Switches Wiring diagram T01 BA Battery BA 1 Battery AL Alternator AL 1 Alternator SW Switch SW 1 Start Key switch SW 2 Battery disconnect switch SW6 Seat switch RE Relays RE 1 Starter relay RE Neutral relay FU Fuse Fuses in fuse box FU 3 Starter relay FU Fuse Fuses in batte ry compartment FU 17 Starter motor fuse RE 20 Sta
49. 1 Put the machine in service position 1 see TH60 TH80 191 Safety rules when servicing Run the hydraulic system until the oil temperature is 38 C 50 100 F 122 F WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 3 Open the rear cover to get access to the hydraulic main valve Connect the pressure gauge to pressure nipple ACCM1 The nipple is located to the right side at the intake mani fold no picture yet Start the engine and run at 2500 rpm Roll the fork all the way up and hold at relief Read the pressure gauge Correct maximum pressure is 210 5 Bar 3046 72 PSI Replace cartridge ifthe correct pressure cant be achieved Remove the pressure gauge and close the rear cover Fig 4 Parking brake lever V1014530 55 PARKING BRAKE 550 General common info about 551 554 Hydraulic cylinder Parking brake manual release 1 Place the machine in service position see section TLH6 TH80 191 Safety rules when servicing 2 Release the parking brake by giving a hammer blow to the external ring of the check unit Reset the parking brake 3 Reset the parking brake by starting the machine and intro duce pressure into the braking system Check that at end of the piston stroke the check unit is actually engaged onto the rod PRELIMINARY DOCUMENT Contents 60 GENERAL 600 Comprehensive info steering Steering system spe
50. 10 Install the lock screw for the lower and reconnect the hydraulic hoses 11 Install the upper pin and it s lock screw V1014787 54 Limited Owner Warranty Aerial Platform Sales Corp warrants its equipment to the original purchaser against defects in material and or workmanship under normal use and service for one 1 year from date of registered sale or date the unit left the factory if not registered MEC Aerial Platform Sales Corp further warrants the structural weldments of the main frame and scissor arms to be free from defects in material or workmanship for five 5 years from date of registered sale or date unit left the factory if not registered Excluded from such warranty is the battery s which carries a ninety 90 day warranty from described purchase date Warranty claims within such warranty period shall be limited to repair or replacement MEC Aerial Platform Sales Corp s option of the defective part in question and labor to perform the necessary repair or replacement based on MEC Aerial Platform Sales Corp s then current flat rate provided the defective part in question is shipped prepaid to MEC Aerial Platform Sales Corp and is found upon inspection by MEC Aerial Platform Sales Corp to be defective in material and or workmanship MEC Aerial Platform Sales Corp shall not be liable for any consequential incidental or contingent damages whatsoever Use of other than factory authorized parts misuse imprope
51. 12 Reset the parking brake eene tentent ennt nnne tnn nhe Enn tenente adn 12 Recovering and towirig o ee edite E eese shade ee dusted 12 12 Recovering mtt dues 12 VOI 12 After TECOVering lOWing unit sungen D E PUDE REM decile 13 Retracting and lowering the boom without hydraulic 14 Jump starting AD reete eto then aetema 16 Auxiliary start with start cables sese emnes 16 19 GENERAL 190 General Boom and Chassis 5 nennen nennen nennen 18 Main chassis nemo bee tee 18 gol A io 18 Outriggers if 18 teet acl cee 18 Attachment ui he fund a A steely 18 Cylinder anchor points Heel aaa andrea 18 191 Safety equipment without own function group Safety concerns 18 Safety when handling the machine 19 A few simple safety 20 Safety when lifting and supporting the
52. 17 2 US gal per minute Oil filter filtering size 0 012 mm 0 0005 in Pressure relief valve opening pressure 1 00 MPa 10 bar 145 psi Oil filter bypass valve opening pressure Pressure regulating valve opening pressure 0 25 MPa 2 5 bar 36 psi 0 40 MPa 4 bar 58 psi Fuel system Type Direct injection Cold starting device Preheating element in inlet manifold Fuel feed pump Make Dana Type Gear pump Feed pressure 0 5 MPa 5 bar 72 psi Feed pressure after fuel filter minimum at 1500 rpm 0 28 MPa 2 8 bar 41 psi Relief valve opening pressure 0 6 MPa 6 bar 87 psi Bypass valve opening pressure 0 050 MPa 0 5 bar 7 psi Fuel flow minimum at 220 rpm 9 litres 2 4 US gal per minute Injection pump Make Bosch Timing setting 5 btdc Injectors Quantity 4 Bore 0 203 mm 0 008 in Opening pressure 22 MPa 220 bar 3190 psi Adjusting pressure 22 MPa 220 bar 3190 psi Max pressure 160 MPa 1600 bar 23200 psi Check leakage 20 MPa 200 bar 2900 psi for 10 sec Schweitzer Designation S200 Air cleaner with connections air pre heater Type of air cleaner Two stage Preheating coil In induction manifold Cooling system Type Liquid cooled with integrated oil coole
53. 20 Ib WY NJ 5 Putthe cylinder on a work bench or similar level surface tilt cylinder overhaul see TH60 TH80 900 Cylinder repair PS V1014614 Fig 114 51 Installation 6 Secure the tilt cylinder with a sling and lift into the boom section Cylinder weight 55 kg 120 Ib 7 Lower the cylinder and install the pin for the piston rod end TITA 9 Secure the pin with lock screw II 8 Connect hydraulic hoses to the tilt cylinder gt V1014613 Fig 115 9 Install the pin and the retaining ring to the cylinder support V1014571 Fig 116 52 Slave cylinder removal and installation Removal 1 Put the machine in service position 1 See TH60 TH80 191 Safety rules when servicing 2 Secure the slave cylinder with a sling NOTE Plug all tubes hoses and connections while removing 3 Remove the upper lock screw and pin 4 Tag and remove the hydraulic hoses from the slave cylin der and remove the lower lock screw V1014787 Remove the lower pin with a hammer and driver Lift the cylinder out from the machine and put it on a work bench Weight of slave cylinder 20 kg 44 Ib 7 TH60 TH80 900 Cylinder repair for instructions to repair the cylinder V1014788 Fig 118 53 Installation 8 Secure the slave cylinder with a sling and lift into the machine Weight of slave cylinder 20 kg 44 Ib 9 Install the lower pin V1014788
54. 21 224 Lubrication system description 4 35 Lubrication and oil system secrctari ii a a E 35 Lubrication general description 444srnesnnnnnnnnnnnennnnnnnennnnnnnnnnnnnn nenn rra 35 Wiring diagram lube oil circuit ee eect emen 36 23 FUEL SYSTEM 230 General common info about 233 238 Fuel system general 37 Fuel system design structure tenente nennen denn ne 37 FUE e eta det o eh ah any 37 F eltilter o tU Leer 37 Draining water from the fuel water 38 233 Fuel pump filter strainer Fuel feed pump a HE 38 236 Injection pump regulator pump companion Injection system una nee 38 Commencement of 38 237 Injector delivery pipe 38 Governor external Me Wii in ee anne 39 Injector InjGctloDiTloZzle HEN 39 25 INLET SYSTEM EXHAUST SYSTEM 250 General common info about 251 258 Engine air intake filter rue rennen 26 COOLING SYSTEM 260 General common info about 261 269 Cooling System cirio ne dees deeded 40 Cooling system general description ccccccceceeeeeeeeeeeeeceneecaeceeeeeeeeeeeeteteetstnsisaeeess 40 Draini
55. 242 and tighten to a torque of 54 Nm 39 Ibf ft Side rear wear pads all 10 Loosen the side wear pad securing bolts Add the clear 11 42 ance between wear pad and boom section from each side add the measurements from corresponding side pads together lower left and lower right and upper left and upper right Install enough shims so the total clearance doesn t exceed 3 mm 0 125 in Install shims as required to produce an equal gap between the boom sections at either side One side may require more shims then the other Secure the bolts with Loctite 242 and tighten to a torque of 54 Nm 39 Ibf ft Boom chains and chain guide rollers wear inspection Boom chains 1 Remove extend cylinder and the chains from the boom Refer to the removal section in instruction entitled Boom extend cylinder and chains removal and installation page 3 Carefully inspect individual links for the following conditions If any of the following conditions exist the chain must be replaced When replacing chains always replace the chain anchor pins as well 2 Broken missing or cracked plates i V1015081 Fig 95 e e V1015082 3 Excessive surface rust and pitting Fig 96 4 Binding links links that no longer rotate freely i v o V1015083 Fig 97 5 Loose or broken pins 1 V1015084 Fig 98 43 V1015085 Fig 99 V1015086 Fig 100
56. 27 General description of air cleaner 1 Primary element 2 Secondary element 3 Inlet tube 4 Housing cover 39 26 COOLING SYSTEM 260 General common info about 261 269 Cooling system Cooling system general description The cooling circuits of the DAD engine are closed forced circu lation cooling continuous flow cooling is not permitted V1019531 Fig 84 V1019531 General cooling system circuit Thermostat housing 8 Coolant pump 9 Lubrication oil cooler 10 Cylinder cooling 11 Cylinder head cooling 12 Line from engine to radi 13 ator Radiator 14 Ru N 40 Line from radiator to engine Ventilation line from cylinder head to expansion tank Expansion tank Line from expansion tank to engine Coolant return from heater Coolant supply to heater V belt version M 26x1 5 Coolant supply to heater Poly v belt version 18x1 5 Fig 85 V1019797 V1019797 Draining cooling system Draining For draining the cooling system undo screw at the Left hand side of the crankcase and catch coolant in a suitable container and dispose of There after tighten screw again 41 Electrical and Information System 9p Description PRELIMINARY DOCUMENT Contents 30 GENERAL 300 Comprehensive info electrical system Electrical system special instructions for servicing 5 Electrical system special instruct
57. 50385 1 Fig 1 Read the Operator s Manual plates and instructions before you start operating the machine seat belt needs to be washed Use a mild soap solu tion when washing and allow the belt to dry while it is fully pulled out before rolling it up Make sure the belt is fitted in a correct way Change the belt immediately if it is worn damaged or if the machine has been involved in an accident where the belt had to take some strain Changes to the belt or its mountings must never be made The seat belt is intended for one adult person only Keep the belt rolled up when not in use Fig 3 Do not overload lifting or supporting equip ment When the engine is running Respect the warning lamps The red lamps require immedi ate action or consideration see instructions in the Opera tor s Manual under the instrument panels section Apply the parking brake and make sure that the attachment attachment bracket is resting on the ground before you leave the machine Unless you are putting the machine in a service position Place gearshift lever and control levers in neutral positions before you leave the machine Empty and place the attachment in transporting position before transport operating on a public road Stop the engine before you leave the machine unattended When there is risk of overturning The cab constitutes the protection for the operator and it meets the requirements for Roll O
58. 7 Fig 78 62 Install the lower rear wear pads on boom section 2 while the clamps still are in place V1014671 Fig 79 34 63 Remove the clamps and install the side wear pads Control the play between sections install shims if necessary 1014668 64 Install the upper rear wear pads to section 2 and secure with corresponding hardware NOTE Torque hardware to 27 Nm 20 Ibf ft NOTE These rear upper wear pads on boom section 2 can not be shimmed If the play between sections is higher than stated then the lower rear pads on section 2 has to be shimmed V1014667 35 Boom section 3 installation 65 Install the lower rear wear pad to section 3 66 Secure boom section 3 with 2 slings and lift in a level posi tion Insert boom section 3 as long as possible with both slings attached 67 Remove the inner sling and fully insert section 3 into sec tion 2 V1014615 Fig 82 68 Install the rear end wear pads to boom section 3 Two on IA top and one at each side Control the play between sections use shims if necessary 1014617 Fig 83 36 Hydraulic hoses removal and installation NOTE Plug all tubes hoses and connections when removing Removal 1 Putthe machine in service position 1 See TH60 TH80 191 Safety rules when servicing 2 Remove the hoses from tilt cylinder and the auxiliary fittings if so equipped Open the rear cover Remove t
59. 7110 Nm 5277 Ibf ft 7 Unplug and connect the hydraulic hose to the rear inner side of the hydraulic tank 23 8 Unplug and connect the hydraulic hoses to the front inner side of the hydraulic tank V1020301 Fig 51 9 Unplug and connect the two lower hydraulic hoses to the oil 1 2 coolers Connect hose beneath the oil coolers 5 lol o9 V1020299 Fig 52 1 Hose 2 Hose 10 Unplug and connect the upper left hydraulic hose to the oil cooler N 1020298 Fig 53 1 Hose 24 11 Connect the throttle cable DA V1020300 12 Connect the fuel return line to the engine Fig 55 View from above 1 Fuel return hose 13 Unplug and connect the hoses for fuel filter and water sep 1 arator V1020296 Fig 56 1 Water separator 2 Fuel filter 25 14 Fig 57 1 Air cleaner Breather 3 Filter bracket 4 Oil filter 15 V1020294 Fig 58 1 Hoses to tra
60. D5 Reverse speed D6 Forward speed SE Sensor SE 1 Transmission oil temperature 18 1 0 701 2 vo I j 13 208 205 R 15 R 10 1 lt 52 20 radio i SE1 7 GN Fig 5 05 1022105 Wiring diagram T06 SW Switch SW 12 4 wheels steer 2 wheels crab steering MA Solenoid valves MA 2 4 wheel steer MA 3 Crab steer 20 Fig 6 T06 1022106 21 Wiring diagram T07 SW Switch SW 10 Parking brake RE Relays RE 13 Low accumulator oil pressure RE 14 Preaccumulator RE 15 Preaccumulator indicator RE 16 Stop motor RE 24 Park brake light MA Solenoid valves MA 4 Park brake MA 17 Preaccumulator switch D Diods D7 Low accumulator pressure D8 Horn D9 Preaccumulator D 14 SE Sensor SE 5 Low accumulator pressure 22 302 s 1553 7 80 303 3 6125 62 25 3 20 gt 430 321 se 87 gu da 318 amp 306 OR d 31 304 8 a JA D9 301 IL 1 07 1022107 Fig 7 23 Wiring diagram T08 RE Relays RE 17 Axle lock RE 18 Hydraulic oil filter pressure RE 25 Axle lock relay FU Fuse Fuses in fuse box FU 7 Control unit MA Solenoid valves MA 11 Frame level MA 12 Frame level MA 13 Fork tilt
61. Front axle Type Drive steer axle Differential gear ratio 1 3 875 Hub reduction gear ratio 1 6 00 Total gear ratio 1 23 25 Steering angle 45 Axle track width over flanges 2180 mm 85 8 in Capacities front axle including dif ferential 8 7 lit 2 3 US gal Weight front axle dry 470 kg 1036 lb Front axle capacities Front axle Capacities including differential and hubs 11 7 lit 3 1 US gal Hub hub reduction Hub reduction Hub reduction Hub reduction gear ratio 1 6 00 Number of satelites 4 Oil volume per hub 1 5 1 0 40 US gal 463 Rear axle 1 Rear axle specification Rear axle Type Drive steer axle Differential gear ratio 1 3 875 Hub reduction gear ratio 1 6 00 Total gear ratio 1 23 25 Steering angle 45 Axle track width over flanges 2180 mm 85 8 in Capacities front axle including dif 8 7 lit 2 3 US gal ferential Weights front axle dry 457 kg 1007 Ib Rear axle capacities Rear axle Capacities including differential 11 7 lit 3 1 US gal and hubs Hub hub reduction Hub reduction Hub reduction Hub reduction gear ratio 1 6 00 Number of satelites 4 Oil volume per hub 1 51 0 40 US gal PRELIMINARY DOCUMENT Contents 51 WHEEL BRAKE 510 General common info about 511 519
62. IONS vi aati cenae a Ne I ata 10 Service position 1 2 EE 10 Service position 11 11 Working under raised boom nennen nnns 12 Safety when working with batteries 12 Charging batteri6S 13 Starting with booster emen 13 Fire prevention 14 Checklist after a fire or heat 16 CE marking and declaration of conformity 16 EU EMC Directive etre cedi hdd her d ehe d dd ed edd ied 16 Unauthorized modifications of the Roll Over Protective Structure ROPS 17 Some simple rules regarding tyre handling s 17 Working on the electrical system of the machine 18 Safety for work on hydraulic eene 19 CIC EM 19 Press re rele se u aneinander ad 19 Health risks associated with paints plastics and 20 Work on painted nennen 20 The following safety instructions must be followed
63. NOTE Torque the bolts diagonally to 110 Nm 81 Ibf ft Ensure the bracket is set evenly without any binding 1014569 Fig 35 1 Chain adjustment bolt 2 Retaining plate 0 4551 16 48 Install the bolt to the extension chain hex block and tighten lightly 49 Install the retaining plate and secure the bolts with Loctite 242 NOTE Torque diagonally to 245 Nm 180 Ibf ft 50 Install the oil tubes at the rear of boom 51 Reinstall the rear cover See further instructions in Boom chain adjustment page 46 for setting the tension of chains Extend cylinder repair For repair of the extend cylinder its necessary to remove the cylinder from the boom assembly See section removal in Boom extend cylinder and chains removal and installation page 3 See TH60 TH80 900 Cylinder repair for instructions to repair the cylinder Fig 37 1 Boom support V1015075 Boom sections removal overhaul and installation Tools 11667001 Handle 11667060 Drive plate 11667085 Drive plate 11667090 Drive plate 11667105 Drive plate To be able to perform this instruction it s necessary to perform the instructions in the following instructions first See section removal in Boom extend cylinder and chains removal and installation page 3 removing the hoses see section removal in Hydraulic hoses removal and installation page 37 and tilt cylin der removal see Tilt cylinder
64. SERVICE MANUAL TH60 TH80 PRELIMINARY DOCUMENT Information purpose The organization of the information refers to the following Information type Specifications Functional description Methods Troubleshooting Description Specifications give the values which are necessary for the work that is to be done Functional descriptions give an introduction to how respective system is built up the included parts and connection to function events sequences and activation deactivation Checking reconditioning removing mounting etc Method des criptions show a safe and reliable work procedure for the work that is to be performed on the machine Troubleshooting should systematically lead to determination of the malfunction cause and correct service action within the shortest possible time Content organization and user s instructions The following tables account for the division of information according to the new organization for VCE s service manuals FOREWORD In each binder there is a Foreword which describes the content of the binder and gives a reference number Each booklet has its own reference number and can be updated and replaced individually In case of an update the Fore word in the binder in question is also replaced SECTION S SAFETY Common information for all function groups Separate information in respective section S 0 9 Separate information under respective fun
65. a 145 bar 2100 psi The remaining pressure in the system must be lowered so called depressurization releasing pressure before hose connections plugs etc are opened in the hydraulic system or brake system WON Lower attatchment s to the ground Turn off the engine and remove the ignition key Release the system pressure by moving the control levers forward and rearward several times with full strokes All pressurised vessels must be opened very carefully so that any residual pressure is released Check tightening of leaking couplings and connections should only be done after all the pressure in the system has been completely released All pressurized tanks vessels shall be opened carefully so that any residual pressure is released Check tightening of leaking couplings and connections may only performed after the system is completely depres surized In case of hydraulic hose leaks that show up as very fine jets remember the high pressure the jet can easily penetrate your hand for example and cause serious injuries To check for leaks use a steel plate or stiff board never use your hands Health risks associated with paints plastics and rubber Work on painted surfaces No welding or torch cutting is allowed on painted surfaces All paint is broken down when heated and forms a wide variety of substances that may be irritating and very hazardous to health after prolonged or repeated e
66. ad gasket according to table V1010616 Fig 68 Piston projection Identification of cylinder head gasket 0 33 0 55 mm 1 hole 0 56 0 65 mm 2 holes 0 66 0 76 mm 3 holes 1 hole 1 2 mm 2 holes 1 3 mm 3 holes 1 4 mm Cylinder head Fitting cylinder head Prior to fitting the cylinder head onto crankcase the sealing sur faces for the cylinder head gasket must be clean and free from oil Pay attention to dowel sleeves Lightly oil the cylinder head bolts NOTE It is absolutely necessary to observe the bolt tightening O O LS order in the adjacent schematic V1010614 Fig 69 Cylinder head gasket marking 1 Marking number of holes 30 151 step 30 Nm 2nd step 80 Nm 3rd step 90 Tightening order V1019693 Fig 70 Exhaust manifold side at upper end of figure 31 040 V1022196 Fig 71 Position of valves D4D 1 3 5 and 7 are exhaust valves DAD 2 4 6 and 8 are inlet valves V1019691 Fig 72 V1010648 Fig 73 32 214 Valve mechanism Valves The engine is provided with one inlet and one exhaust valve per cylinder The valves guides are shrunk in the cylinder head The valve seat inserts are also shrunk in the cylinder head The valves are turned by eccentr
67. aids are flammable Store such items in cool and adequately ventilated areas Remember that such aids must not be used in combination with electric preheating of induction air Cleanliness Cleanliness is a decisive factor for operational reliability of the machine s systems Therefore keep the servicing area clean Oil or water make floors and steps slippery and are also dangerous in combination with electrical systems or tools Oily clothes or clothes drenched in grease constitute a serious fire hazard Check daily that the machine and equipment such as underbody skid plates are free from dirt and oil This reduces the risk of fire and makes it easier to detect defec tive components or loose parts IMPORTANT If a high pressure washer is used when cleaning work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature Protect electrical cabling in a suitable manner Keep the machine especially clean when operating in envi ronments with fire hazards such as saw mills garbage dumps etc In such environments suitable equipment to reduce the risk of accumulation of material and spontane ous combustion should be fitted for example muffler guard radiator screen heavy duty cyclone pre cleaner etc Electrical system 28 Check electrical cables with regard to chafing damage and make sure that they cannot be damaged in su
68. ain with a feeler gauge Reinstall the valve cover Tighten the bolts to 11 Nm 8 Ibf ft 215 Engine transmission camshaft Camshaft Camshaft The camshaft is mounted on 5 bearings The running surface of bearings and came are induction hardened Each bearing runs in a bearing bush pressed into the crankcase There is one inlet exhaust and injection pump cam per cylinder The axial stop for the camshaft is located in the timing chest cover 216 Crank shaft connecting rod vibration damper fly wheel Crankshaft The forged crankshaft of the 040 engine series is provided with integrated balance weights The drive gear for the timing gears and the flywheel flange are shrunk on Connecting rod The connecting rod of forged steel is fitted at the big end bearing bore with a balance weight in order to compensate the manufac turing tolerances with regard to weight and position of the centre of gravity 33 Piston The piston of the D4D CDE2 engine are made of special alumin ium alloy The piston bowl has a small amount of eccentricity to 4 the piston axis The piston must be so installed that the flywheel symbol on the piston top faces the flywheel Piston cooling V1019649 Fig 76 1 Fly wheel symbol The piston is cooled by spraying lube oil against the inside of the piston top The 2 hole piston cooling nozzles made of plastic are fitted in the main bearing pedestals V1019653 Fig 77 V1019653 34 Th
69. al box that can be locked Fire fighting equipment installed in or on the machine must be maintained in working order Such equipment should be regarded as a complement to the operator s own efforts in case of a fire The equipment should not be considered as a replacement of the operator s own fire fighting efforts Fire extinguishers mounted on the machine or used when working on the machine must fulfil certain requirements See the Operator s Manual At the slightest sign of fire if the situation allows it and keeping in mind your own safety take the following action 27 Fig 17 Smoking and open flames are absolutely for bidden when filling fuel or any time diesel fuel is in contact with the open air drive the machine away from the danger area lower attachment s to their bottom position so that the attachment rests on the ground stop the engine by turning the ignition key to the 0 posi tion leave the cab turn off the battery disconnect switch start fighting the fire and call the fire department if neces sary Smoking or open flames are absolutely forbidden close to the machine when filling fuel or at any time the fuel system is in contact with the open air Diesel fuel is flammable and must not be used for cleaning Use an approved solvent instead Remember that certain solvents can cause skin rashes and are usually flammable Avoid inhaling solvent vapour Engine starting
70. and discard them The safety instructions in the following checklist must be fol lowed under all circumstances if a machine has been exposed to a fire or other intense heat Safety when handling oils and fuel When changing oil in the engine hydraulic system or trans mission Remember that the oil may be hot and can cause burns Engine hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes for example in eyes and throat and on skin Therefore take special care to keep such oils away from these sensitive body parts When emptying draining oils or fuel steps must be taken to avoid unnecessary spills In places where a container for collecting the liquid cannot be used use a pump or connect a hose to ensure safe handling Oil released or spilled on the ground will harm the environment and could also cause a fire Waste oil fluids must always be taken care of by a com pany authorized for such work Remember the fire hazard 21 22 Pressure setting and leak detection WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries Observe the following safety precautions Lever and pedal movements should be made slowly in order to avoid sudden or unexpected machine movements and excessive pressures Interrupt the pressure increase as soon as the specified pressure has been reached Make changes in small increments wh
71. ansmission 19 Fig 39 1 Rear mounting Fig 40 1 20 Front mounting 1020278 1020279 Engine and transmission installation to hydraulic tank engine frame assembly To perform this procedure see previous instructions in Transmis sion installation on removed engine page 18 Op no 1 Secure the engine and transmission assembly with lift slings WARNING Risk of injuries caused by crushing NOTE Weight for engine and transmission case approximately 710 kg 1565 Ib 2 Install the rear engine transmission mounting brackets NOTE Torque for mounting brackets 185 Nm 136 Ibf ft 3 Install the hydraulic pump NOTE Inspect the hydraulic pump gasket and replace if necessary 4 Install the front engine mounting brackets NOTE Torque for mounting brackets 185 Nm 136 Ibf ft Front end frame mounting bracket nuts 5 Install front end frame mounting bracket from inside into the hydraulic tank and engine frame assembly temporary secure the bracket with corresponding nuts The bracket can not be installed afterwards 6 Liftthe engine and transmission into the hydrau lic tank and engine frame assembly NOTE Inspect the rubber mounts before they are reinstalled They must be in good condition and in the same thickness 7 Install the four engine mounting bolts Tighten the front and rear bolts NOTE Torque to 175 N
72. ar Shuttle valve Pressure limiting valve max pressure steering 159 bar Priority valve steering and brake Pressure regulator steering 175 bar Pressure regulator brake 210 bar MA 17 Solenoid valve accumulator charging Strainer Pressure regulator pilot pressure and parking brake MA 4 Solenoid valve parking brake MA 18 Solenoid valve pilot pressure Parking brake cylinder Accumulator SE 5 Switch for charging accumulator Steering unit Foot brake valve Pressure limiting valve 175 bar Non return valve Steering selector Crab steering 4 wheel Front steering cylinder Rear steering cylinder Pressure and flow compensator Valve spool Pressure relief valve 190 bar tilt down Pressure relief valve 250 bar tilt up Proportional solenoid valve Slave cylinder for self level Tilt cylinder Load retainer and line rupture valve Extend cylinder Lift cylinder Pressure compensator Solenoid valve frame level Front cylinder frame level Rear cylinder frame level Frame level Extra hydraulic outlet Oil cooler Oil filter Hydraulic oil tank Stabilizer Solenoid valve Joystick OLEOZOLA
73. at can cause fire always connect the ground lead last when fitting a bat tery Never tilt a battery to any great extent in any direction Bat tery electrolyte may leak out Do not connect a discharged battery in series with a fully charged battery The current surge can cause the batteries to explode not allow metal objects such as tools rings wrist watches to come in contact with battery terminals Risk of fire and personal injury Always cover the top of the battery with a rag or other non conducting material when you work close to the batteries Always refit the terminal caps on the batteries Batteries contain substances dangerous to health and the environment Discarded batteries must therefore be dis posed of according to local and or national regulations Charging batteries Explosion hazard When a battery is being charged an explosive mixture of oxygen and hydrogen is formed A short circuit open flame or spark near the battery can cause a powerful explosion Always turn off the charging current before disconnecting the charging clamps Ventilate well especially if the battery is charged in a confined space Corrosive sulphuric acid The battery electrolyte contains corrosive sulphuric acid Elec trolyte spilled on bare skin must be removed immediately Wash with soap and plenty of water If electrolyte gets into your eyes or any other sensitive body part rinse immediately with plenty of
74. ater a solution or suspension of calcium hydroxide that is slaked lime in water After the work has been completed wash the protective gloves in lime water and discard them The safety instructions in the following checklist must be fol lowed under all circumstances if amachine has been exposed to a fire or other intense heat Safety when handling oils and fuel When changing oil in the engine hydraulic system or trans mission Remember that the oil may be hot and can cause burns Engine hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes for example in eyes and throat and on skin Therefore take special care to keep such oils away from these sensitive body parts When emptying draining oils or fuel steps must be taken to avoid unnecessary spills In places where a container for collecting the liquid cannot be used use a pump or connect a hose to ensure safe handling Oil released or spilled on the ground will harm the environment and could also cause a fire Waste oil fluids must always be taken care of by a com pany authorized for such work Remember the fire hazard Pressure setting and leak detection WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries Observe the following safety precautions e Lever and pedal movements should be made slowly in order to avoid sudden or unexpected machine movements and
75. ator Never install pads that are worn close to or below the chamfer The boom will be damaged if the wear pads are worn below the chamfer NOTE Top pad Always inspect that the clearance between top wear pads and section doesn t exceed 3 mm 0 125 in If so install shims to produce a gap smaller than stated Side pads Always inspect that the total clearance between sec tions doesn t exceed 3 mm 0 125 in If so install shims to pro duce a gap smaller than stated and as equal as possible on both sides 56 Install the front inner side and front bottom wear pads in boom section 1 Install the outer boom guide pads 57 sure that the chain guide wheel still is in place in the rear end of boom section 2 With the wheel in place the boom section will roll smoothly in place when installing Install all the front inside wear pads in boom section 2 while the boom still is on stands or fixture 58 Secure boom with 2 slings and lift in a level position Insert boom section 2 into section 1 as long as possible with both slings attached 33 59 Remove the inner sling and insert the boom until approxi mately 0 5 m 20 in remains 60 Lower the outer end of section 2 and install the upper wear 7 pads in boom section 1 Control the play install shims if necessary Fully insert boom section 2 V1014676 Fig 77 61 Use a pair of clamps to unload the chain guide wheel and remove the wheel and pin V101467
76. black and yellow label to the steering wheel with the message forbidden to start the engine Unfasten seat belt and exit the machine using the handles Block the wheels NOTE No work should be performed on the machine until you have sufficient knowledge and skills to do so General Machines that operate in contaminated areas polluted environments and or areas hazardous to health should be specially equipped In addition local safety regulations apply when servicing such machines See also Checklist after a fire or heat exposure page 16 When washing the machine with a high pressure washer do not aim the water jet directly at non slip surfaces that are glued on 11 Fig 6 Protective equipment Fig 7 Battery charging 12 If anyone is to take over the job that you have started make sure that this person is informed as to how much of the work has been done and how much remains Never wear loose objects such as a scarf or jewellery that could get caught and cause personal injury when you are working on the machine scii Never step on parts of the machine that are not pre pared or intended for this such as an open and raised engine hood cover Always wear a hard hat protective goggles gloves work shoes and other necessary safety items that your work requires Always turn off the engine when servicing the machine unless instructions on signs and plates or in this manual state otherwise
77. bout 383 387 Control switches Control switches are located on the dashboard with the excep tion of the Frame level switch witch is located on the right arm rest near the Control lever Parking brake set Two position switch Engage the parking brake NOTE WARNING Steering mode Three position switch top is Four wheel Round mode middle is Two wheel mode bottom is Crab mode See section Steering oper ating instructions TH60 TH80 050 Steering operating instructions Front wiper Two position Switch Turns on main wiper on the front window of enclosed cabs Top wiper Two position Switch Turns on wiper on the top window of enclosed cabs Top washer Two position momentary Switch Sprays window wash solution onto the top window of enclosed cabs 1015106 V1015121 gt V1015054 s FN lt 5 a N N v101 a N AN N V1015056 s V1015057 Creep mode Two position momentary Switch Shifts transmission into highest gear Use this drive mode when moving close to your landing area where slow controlled movements is necessary Work lights Two position Switch Turns on work lights on machines so equipped Hazard lights Two position Switch Turns on flashing hazard lights on machines so eqipped Left stabilizer Three position momentary switch Raises and lowers the left stabi lizer on machine so equipped Right stabilizer Three po
78. cables as follows Connect the first start cable A to the battery s plus termi nal 1 on the machine to be started Connect the other end of the cable to the battery s plus terminal 2 on the assisting machine Connect the other start cable B to the battery s minus ter minal 3 on the assisting machine Connect the other end of the cable B to the frame 4 on the machine to be started Check that good electric contact is obtained Auxiliary start Check that the start cables are connected securely and correctly figure Start the engine in the assisting machine Start the engine in the machine to be started If the engine does not start within 30 seconds wait for at least two min utes before the next start attempt Fig 8 Removing start cables 1 1003825 Remove the start cables as follows Remove the cable B from the frame 1 on the machine that has been started with auxiliary start Remove the other end of the start cable B from the bat tery s minus terminal 2 on the assisting machine Remove the cable A from the battery s plus terminal 3 on the assisting machine Remove the other end of the start cable A from the bat tery s plus terminal 4 on the machine that has been started with auxiliary start 17 18 19 GENERAL 190 General Boom and Chassis inspection Main chassis retract the boom raise it and support it with a suitable stand
79. can cause severe burns Nicos V1020290 6 Drain the oil from hydraulic tank 1020291 Drain the coolant from the radiator WARNING Exhaust system components get very hot and can cause severe burns V1020424 8 Remove the exhaust pipe from the exhaust manifold 1 Exhaust pipe 4 AN E ud Fig 9 an Fig 10 1 Air cleaner 2 Breather 3 Filter bracket 4 Oil filter 9 Remove the front dirt guard Remove the air cleaner the hydraulic tank breather and the remote engine lubrication filter from the filter bracket Remove the filter bracket NOTE Plug all tubes hoses and connections while removing 11 Tag remove and plug hoses for fuel filter and water sepa rator WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1020296 Fig 11 1 Water separator 2 Fuel filter 12 Tag remove and plug the hydraulic hose from the pumps pressure side Tag remove and plug hoses from the transmission NOTE Drain all the residual oil from hoses and coolers into a suitable container V1020294 13 Disconnect the fuel return line from the engine 1020297 Fig 13 View from above 1 Fuel return hose 10 14 Tag remove and plug the upper left hydraulic hose from the oil cooler NOTE Drain all the residual oil from hoses and coolers into a suitable container
80. cause an accident must be rem edied Do not operate the machine for long periods without venti lation or with a fully closed cab without having the fan run ning there is risk of lack of oxygen Only step on slip protected surfaces and hold onto the available hand holds and railings Lap type seat belt If the seat belt needs to be washed Use a mild soap solu tion when washing and allow the belt to dry while it is fully pulled out before rolling it up Make sure the belt is fitted in a correct way Change the belt immediately if it is worn damaged or if the machine has been involved in an accident where the belt had to take some strain Changes to the belt or its mountings must never be made The seat belt is intended for one adult person only Keep the belt rolled up when not in use When the engine is running Respect the warning lamps The red lamps require immedi ate action or consideration see instructions in the Opera tors Manual under the instrument panels section Apply the parking brake and make sure that the attachment attachment bracket is resting on the ground before you leave the machine Unless you are putting the machine in a Service position Place gearshift lever and control levers in neutral positions before you leave the machine Empty and place the attachment in transporting position before transport operating on a public road Stop the engine before you leave the machine unattended When there i
81. ch a way This applies particularly to unfused electrical cables which are red For example electrical cables between Batteries Battery starter motor Alternator starter motor Cable to engine preheating coil When unfused cables have been disconnected it is impor tant to check that they are reconnected and clamped in such a way that they cannot be exposed to chafing Unfused cables must not rest against oil and fuel hoses When fitting any optional equipment make sure that all cables circuits are connected across a fuse and routed and clamped so that there is no risk of chafing Fuel hydraulic and brake systems Check to make sure that there is no chafing damage to fuel hydraulic and brake hoses Welding and grinding Welding and grinding on the machine may only be done in a clean area and not in places that contain combustible liq uids such as fuel tanks hydraulic pipes or similar Work with extra care when welding and grinding near flam mable objects IMPORTANT fire extinguisher should be easily accessi ble during all welding work Never weld on a painted surface without first removing the paint Welding on a painted surface generates in addition to health hazardous vapours technically inferior welds which may lead to future failures with subsequent acci dents Fig 18 Fire extinguisher Actions after a fire see Checklist after a fire or heat exposure Checklis
82. ch is energized via the start relay RE 1 in the battery box V1019912 Fig 6 Starter motor and fittings 1 Solenoid 2 Starter motor 35 LIGHTING 350 General common info about 351 356 Lighting specifications Lightning bulbs Watt Socket Travel lights asymmetrical Main upper beam 55W H7 Dipped lower beam 55W H3 Parking lights 5W BA 155 Marker lights 5W BA 155 Stop lights 21W BA 15s Direction lights 21W BA 15s Work light 55W H3 Rotating beacon 21W H3 Cab light 21W BA 15s Electrical and Information System Cable and Fuses PRELIMINARY DOCUMENT Contents 37 CABLE FUSE RELAY 370 General common info about 371 379 Cable COGS EE 5 Electrical symbols and designations nn eene 6 Wiring diagram TON is 10 Wiring diagram T02 nn a do aad etae e na 12 Wiring diagram L0 14 Wiring diagram 04 a cd ii 16 Wiring diagram TOS ci nl 18 Wiring diagram TOB comicidad 20 Wiring diagram A dd 22 Wiring diagram TO8 ido a ee an na 24 Wiring diagram T09 2 ne A and 26 Wiring diagram editi kein ine d e uoa 28 Winna diadan T 11 edet eren 30 Wiring diagram 32 Wiring diagram T 19 eter tte e e ID PORE ee 34 372 Electrical distribution box fuse relay circuit breaker Fuse MAIN TUS CS IR ODER e
83. cifications uusessnnnennnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnnn nn Pressure build up steering uusuosmsn nsnonsennnnsnonnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nennen STEERING 60 GENERAL 600 Comprehensive info steering Steering system specifications Steering system ype Powered orbitol Number of steering wheel 3 5 revolution total Steering angle 45 degree steering angle Turning radius between walls 3 9 meters 12 ft 11 in Pressure build up steering The figures in the text below refer to the Hydraulic diagram A TH60 TH80 990 Hydraulic diagram A The oil flow continues into the pressure regulator 7 which reduce the steering pressure to 175 bar 2538 psi if other functions requires higher system pressure If no other functions are used then the LS pressure limits the steering pressure to 159 bar 2306 psi by pressure limiting valve 5 The steering valve is of the type orbitrol The steering valve delivers a LS signal through the shuttle valves 4 The LS signal affects the priority valve 6 and the pressure regulator 2 PRELIMINARY DOCUMENT PRELIMINARY DOCUMENT Hydraulic System Description p PRELIMINARY DOCUMENT Contents 90 GENERAL 900 General Hydraulic system Pressure build up general nennen nennen Pre
84. corrosive to respiratory tracts Certain seals designed to withstand high operating temperatures for example in engines transmissions axles brakes hydraulic motors and pumps may be made of fluor rubber which will form hydrogen fluoride and hydrofluoric acid when exposed to intense heat This acid is highly acidic and corrosive It cannot be rinsed or washed off the skin and causes very severe burn and corrosive injuries that take a very long time to heal As a rule injured tissue must be removed surgically The acid may remain on machine parts for a very long time sev eral years after a fire NOTE may take several hours after contact with the acid before any symptoms become apparent If swelling redness or burning sensations appear and contact with heated fluor rubber is suspected contact a physician imme diately If a machine or a component for a machine has been exposed to fire or other intense heat it shall be handled by spe cially trained personnel Thick protective neoprene rubber gloves and tight fitting protec tive goggles must be used during all handling of machines after a fire WARNING Never burn painted parts or parts made of plastics or rubber after they have been discarded This work must be done by a licensed waste management plant Decontamination The area around a heated part that is suspected of being made of fluor rubber must be decontaminated by thorough and ample washing with lime w
85. cription Lube oil pump Oil cooler Bypass valve oil cooler Oil filter Bypass valve oil filter Pressure regulating valve Exhaust turbocharger Remark Opening pressure p 2 1 0 35 bar With bypass valve 5 Opening pressure p 2 5 0 5 bar Opening pressure p 4 0 0 4 bar Fig 79 V1019700 36 Fig 80 V1019532 General fuel system circuit 23 FUEL SYSTEM 230 General common info about 233 238 Fuel system general The D4D engine operate according to the direct injection princi The piston bowl has a small amount of eccentricity to the piston axis The fuel is injected via single injection pumps The maximum pressure reaches up to 1350 bar 19580 PSI e 6 hole nozzles Compression 19 1 Max injection pressure 1350 bar 19580 PSI Fuel system design structure Fuel system The fuel is delivered by the fuel feed pump 3 from tank 1 via the filter 5 to the supply duct of the single injection pumps inte grated in the crankcase From the single injection pumps the fuel is supplied through the injection lines 8 to the injectors 9 At the end of the supply duct is fitted the pressure holding valve 10 5 bar 72 PSI Some parts might look different or have another location Fuel tank Line to fuel feed pump Fuel feed pump Line to fuel filter Fuel filter Line to injection pumps Injection pump Delivery pipe to injector Injector Banjo bolt with pressure
86. ct a discharged battery in series with a fully charged battery The current surge can cause the batteries to explode Donotallow metal objects such as tools rings wrist watches to come in contact with battery terminals Risk of fire and personal injury Always cover the top of the battery with a rag or other non conducting material when you work close to the batteries Always refit the terminal caps on the batteries Batteries contain substances dangerous to health and the environment Discarded batteries must therefore be dis posed of according to local and or national regulations Charging batteries Explosion hazard When a battery is being charged an explosive mixture of oxygen and hydrogen is formed A short circuit open flame or spark near the battery can cause a powerful explosion Always turn off the charging current before disconnecting the charging clamps Ventilate well especially if the battery is charged in a confined space Corrosive sulphuric acid The battery electrolyte contains corrosive sulphuric acid Elec trolyte spilled on bare skin must be removed immediately Wash with soap and plenty of water If electrolyte gets into your eyes or any other sensitive body part rinse immediately with plenty of water and seek immediate medical attention Starting with booster batteries When starting with booster batteries the following must be observed Check that the booster batteries or other power s
87. ction group General information concerning Personal safety and machine safety Ina service manual divided according to the binder system section S is included in Binder 1 Warnings appear continuously in all information where required VARNING WARNING SYMBOL This symbol appears at various points throughout the service manual in conjunction with a warning text Its appearance means Warning stay alert Your safety is involved Ignoring the risks can result in an accident serious injury or death SECTION 0 SPECIFICATIONS Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group All specifications are given in section 0 This section also includes transport ins tructions and tools Ina service manual divided according to the binder system section 0 is included in Binder 1 Under general there are speci fications concerning the entire section Under respective function group there are specifications that con cern the function In certain cases the specifica tions are repeated for methods where it is suitable DESCRIPTION AND FUNCTION DESCRIPTION Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group Section 0 specifications In section 0 there i
88. cylinder liners i e crankcase and liners form one casting Cylinder head design structure The cylinder heads of the DAD are made of grey cast iron and designed as block type heads The combustion air enters verti cally and the exhaust air is discharged laterally Inlet and outlet are located on one side of the cylinder head Determining cylinder head gasket Op no 21102 Tools 9998678 Measuring tool Dial gauge The thickness of the cylinder head gasket is responsible for the correct piston crown clearance of the engine Piston crown clearance 0 65 mm essentially influence the combustion and thus Power Fuel consumption Exhaust emission Measuring piston projection A dial gauge with a fixture measuring tool is needed to meas ure the piston projection 1 Install the dial gauge into measuring tool 999 86 78 and place on cylinder block with spacer washers NOTE Put the spacer washers on the block and not on the liner edges 2 Setthe dial gauge in the level of the crankcase surface to Zero 29 3 Position the dial gauge within the checking point area Turn the crankshaft to find the highest position of the piston Read the height from the dial gauge the checking points must be kept within the specified area V1010617 Fig 67 Checking point area 4 Measure all pistons in the same way Make note of each value and use the highest piston projection value to deter mine the cylinder he
89. d who ignores the warnings in this manual must make sure that their work method is safe Otherwise there is a great risk of serious accidents and injuries perhaps even fatali ties WARNING WARNING SYMBOL This symbol is shown at various points throughout the manual The appearance of it means Warning stay alert Your safety is involved Get to know the capacities and limitations of your machine Safety when handling the machine MEC is only responsible if the machine has been used in a correct way and been maintained in accordance with instructions in Service Man uals and the Operator s Manual for the machine prescribed service and prescribed inspections have been carried out at the stated points in time the recommended lubricants according to the manual have been used no security seals have been broken by other than author ised persons all alterations and repairs have been carried out in the way prescribed by MEC only MEC s genuine spare parts accessories or attach ments which meet MEC s requirements have been used WARNING The machine operator must have sufficient skills knowl edge and instructions before operating the machine An untrained operator may cause serious damage injuries and even deaths Therefore it is very important that you read and follow the instructions in the Operator s Manual Never use a machine for which the Operator s Manual is missing Lea
90. d manner your company must notify the customer and manufacturer if writing regarding which machine it was and how it was modified NOTE Modifications or removal of material which affects sound e noise insulating material noise damping or noise absorbing material may not be performed Further making new holes openings in the cab or engine compartment is not allowed as this may increase the sound level in the cab Some simple rules regarding tyre handling WARNING A tyre fitted on a split rim may explode causing severe injury or even death Inflating e Never stand to the side of the tyre while inflating Never stand to the side of the tyre while inflating which is fitted on a split rim Use a self locking outlet with a hose long enough to allow you to stand outside of the hazard zone during inflation see the illustration Make sure that the hazard zone is clear when the tyre is inflated The machine must be unladen when checking tyre pres sure Spare tyres should only be filled with enough air to allow the rim parts to be held in place Secure a loose wheel with an inflation cage cable or chains before inflating Before removing the inflation cage check that the tyre is properly fitted to the rim Adjustments should be made before the wheel is inflated Donotattempt to adjust side rings or lock rings when the tyre is inflated Tyres used at less than 8096 of normal pressure and rims or tyres suspec
91. de the rod assembly into the cylinder 10 Secure the head to the cylinder 1 2 3 V1020098 Inlet Pressure plate Shaft journals Bushings Shaft seal One piece shaft amp gear 91 WORKING HYDRAULICS SERVO HYDRAULICS 913 Pump working hydraulics Hydraulic pump specifications NOTE Values are settings and theoretical values not to be used for testing Hydraulic pump Type Gear pump Designation CPB 032 R2 AX AL Displacement Cu in rev 3 14 cc rev 51 49 Capacity 2500 rpm 128 73 l min US 33 98 GPM Theoretical Continuous Pressure 25 MPa 250 bar 3600 PSI Intermittent Pressure 27 5 MPa 275 bar 4000 PSI Peak Pressure 31 MPa 310 bar 4500 PSI Minimum speed at 2500 PSI 600 rpm Rotational direction Clockwise Weight 20 90 Ibs 9 48 kgs Hydraulic pump description The pump is a fixed displacement gear pump The principle for such a pump is described in the picture below Fig 3 Rear view 1 Counterbalance valve 1025174 94 UNIT LOAD HANDLING 940 General common info about 941 945 Retracting and lowering the boom without hydraulic power Tools Minimess hose NOTE In case of loss of hydraulic power it can be necessary to retract and lower the boom manually NOTE The boom must be retracted first and then lowered Low ering the boom while its still extended may cause fo
92. dents Instead people do A safety conscious person and a well maintained machine con stitute a safe efficient and profitable combination Any person who does not follow the safety instructions and who ignores the warnings in this manual must make sure that their work method is safe Otherwise there is a great risk of serious accidents and injuries perhaps even fatali ties WARNING WARNING SYMBOL This symbol is shown at various points throughout the manual The appearance of it means Warning stay alert Your safety is involved Get to know the capacities and limitations of your machine Safety when handling the machine MEC is only responsible if the machine has been used in a correct way and been maintained in accordance with instructions in Service Man uals and the Operator s Manual for the machine prescribed service and prescribed inspections have been carried out at the stated points in time the recommended lubricants according to the manual have been used no security seals have been broken by other than author ised persons all alterations and repairs have been carried out in the way prescribed by MEC only MEC s genuine spare parts accessories or attach ments which meet MEC s requirements have been used WARNING The machine operator must have sufficient skills knowl edge and instructions before operating the machine An untrained operator may cause serious damage
93. diagram A The oil flow continues to the pressure regulator 8 which reduces the brake accumulator charge to 210 bar 3045 psi The pressure switch SE 5 16 reads the pressure in the accu mulator circuit and energizes MA 17 9 when pressure is between150 182 bar 2176 2640 psi MA 17 9 then changes position and drains the LS circuit the pump pressure decreases if no other functions are in operation When the pres sure is between149 128 bar 2161 1856 psi the power to MA 17 is cut and the pressure increases again The MA 17 is also energized when the ignition key is in start position Pressure build up servo system The figures in the text below refer to the Hydraulic diagram A TH60 TH80 990 Hydraulic diagram A The oil flow continues through strainer 10 into pressure regula tor 11 which reduce the servo pressure to 30 bar 435 psi When the seat sensor is activated the MA 18 13 will be ener gized and the servo circuit will be pressurized The servo pressure is also used to release the spring applied parking brake 14 via the MA 4 12 Pressure build up steering The figures in the text below refer to the Hydraulic diagram A TH60 TH80 990 Hydraulic diagram A The oil flow continues into the pressure regulator 7 which reduce the steering pressure to 175 bar 2538 psi if other func tions requires higher system pressure If no other functions are used then the LS pressure limits the steering p
94. dvice or cautions for each one Accordingly anyone who intends to depart from the instructions in this manual must first consider personal safety and then machine integrity NOTE recommends the use of enviromentally sound waste storage and disposal practises Never drain fluids on the ground or into a sewer or catch basin Use suitable collection containers then store and or dispose of waste products in an approved and safe manner Check and obey all federal state and or local regulations regarding waste storage disposal and recycling Disclaimer MEC reserves the right to make changes to and to add improvements upon its products at any time without public notice or obligation MEC also reserves the right to discontinue manufacturing any product at its discretion at any time Bearings Removal Bearings should never be removed unless absolutely necessary Always use the recommended puller to reduce the risk of bear ing or related component damage When bearings or bushing are removed check that the bearings is free from discoloration nicks scuffing and signs of overheat ing Ifin doubt replace the bearing or bushing Cleaning Bearings acceptable for service should be cleaned in a suitable solvent and immersed in a clean lubricating oil until needed Installation Be sure bearings are installed with care during servicing main tenance and repair All bearings on this machine are installed as a press fit W
95. e and one is on the rear side of the axles 3 Apply the brakes and while they are applied measure the distance between the disc using a feeler gauge The mini mum distance S between the discs is 4 5 mm 0 177 in If the brakes are worn beyond the wear limit the brake discs must be replaced 4 Repeat steps 1 3 on the other axle 52 HYDRAULIC BRAKE SYSTEM 520 General common info about 520 522 Service brake bleeding NOTE The service brakes operate on hydraulic system pres sure and fluid There is no fluid reservoir to fill or maintain Perform this procedure in the following order Right rear brake left rear brake right front brake left front brake 1 Put machine in service position 1 see TH60 TH80 191 Safety rules when servicing 2 Ensure that the hydraulic oil is at the proper level in the main hydraulic tank 3 Start the engine and leave it running throughout the proce dure 4 fita clear hose over the brake bleed valve so the oil can be directed into a drain pan f 5 an assistant depress the brake pedal while the bleed valve is opened Watch for air in the oil as it flows through the clear hose 6 Once the oil flows free of air close the bleed valve 7 Test brakes for proper function V1020327 Fig 3 1 Bleed nipple 2 Hose Pressure settings accumulator system Tools 11666020 Manometer 0 250 bar 14290262 Adapter Tema Minimess 14290266 Hose Accumulator pressure
96. e ignition key Allow the machine to cool down Bis If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns Attach a black and yellow label to the steering wheel with the message forbidden to start the engine Unfasten seat belt and exit the machine using the handles Block the wheels NOTE No work should be performed on the machine until you have sufficient knowledge and skills to do so General Machines that operate in contaminated areas polluted environments and or areas hazardous to health should be specially equipped In addition local safety regulations apply when servicing such machines See also Checklist after a fire or heat exposure page 29 When washing the machine with a high pressure washer do not aim the water jet directly at non slip surfaces that are glued on Fig 14 Protective equipment Fig 15 Battery charging e If anyone is to take over the job that you have started make sure that this person is informed as to how much of the work has been done and how much remains Never wear loose objects such as a scarf or jewellery that could get caught and cause personal injury when you are working on the machine aodio Never step on parts of the machine that are not pre pared or intended for this such as an open and raised engine hood cover Always wear a hard hat protective goggles gloves work shoes and o
97. e main oil gallery supplies Crankshaft Camshaft Valve tappets Roller tappets 16 15 11 17 1 Fig 78 Lubrication oil circuit 22 LUBRICATING SYSTEM 220 General common info about 221 224 Lubrication system description The lube oil is supplied by the lube oil pump trough the oil cooler to the oil filter Both components are mounted to the lube oil cooler housing which is flanged to the crankcase Downstream of the filter the lube oil flows into the main gallery and secondary gallery From here the oil is ducted to the lubrication points The secondary oil gallery supplies Exhaust turbocharger Lubrication and oil system Lubrication general description 12 9 13 14 10 8 5 2 42 43 41 3 V1025247 35 AR e e ARRON ark N tem Oil sump 7 Intake line 8 Lubricating oilpump 9 Lubricating oil cooler 10 Heat exchanger 11 bypass valve Relief valve 12 Lube oil replacement 13 filter Oil pressure sensor 14 Oil filter control valve 15 inside filter Main oil pipe 16 Crankshaft main 17 bearing Crankshaft big end bearing Camshaft bearing Line to piston cooling spray nozzle Piston cooling spray nozzle Valve lifter with rocker arm shot lubrication Pushrod oil supply for rocker arm lubrication Rocker arm Return line to oil sump Oil line to turbocharger Turbocharger Oil line from turbocharger Wiring diagram lube oil circuit Des
98. ed in or on the machine must be maintained in working order Such equipment should be regarded as a complement to the operator s own efforts in case of a fire The equipment should not be considered as a replacement of the operator s own fire fighting efforts Fire extinguishers mounted on the machine or used when working on the machine must fulfil certain requirements See the Operator s Manual At the slightest sign of fire if the situation allows it and keeping in mind your own safety take the following action drive the machine away from the danger area lower attachment s to their bottom position so that the attachment rests on the ground stop the engine by turning the ignition key to the 0 posi tion leave the cab turn off the battery disconnect switch start fighting the fire and call the fire department if neces sary Smoking or open flames are absolutely forbidden close to the machine when filling fuel or at any time the fuel system is in contact with the open air Diesel fuel is flammable and must not be used for cleaning Use an approved solvent instead Remember that certain solvents can cause skin rashes and are usually flammable Avoid inhaling solvent vapour Engine starting aids are flammable Store such items in cool and adequately ventilated areas Remember that such aids must not be used in combination with electric preheating of induction air Cleanliness 14 Cleanl
99. en setting pressure adjustment devices whose sensitivity is not known This is especially important with regard to the servo circuit which is pressurized as soon as the engine is started e Check and calibrate the pressure checking equipment reg ularly and replace damaged components Service and p PRELIMINARY DOCUMENT Contents 11 STANDARD PARTS 110 General LI C TA 5 16 LUBRICANT FUEL OTHER FLUID 160 General Recommended lubricants oils 6 17 SERVICE 170 General common info about 171 179 Replacement parts ettet dee Haan ar 7 Service methods ad anes 7 EE E 7 BONOS E 7 ti rear nern female 7 Cleaning ee ee 7 Installation m t Pe ute trea 8 Hoses and tubes ei 8 Inspeetion n 8 lacu nk ee eee ee eed ee ee 8 Pressure test oostre dt add 8 General part 9 Cleaning prior to Fepalt eec Are air 9 173 Maintenance Service POSITIONS r i oe DH HE PATATE E FTO 10 Service alee A 10 SEIVICE POSIUON 2 11 176 Emergency measures Hydraulic cylinder Parking brake manual release
100. erminal 2 on the assisting machine Remove the cable A from the battery s plus terminal 3 on the assisting machine Remove the other end of the start cable A from the bat tery s plus terminal 4 on the machine that has been started with auxiliary start Joystick ECU specifications General Weight 0 2 kg 0 44 Ib Operating temperature 40 to 70 C Voltage supply 9 34 Current consumption idle 60 mA 28 Vdc 40 mA 14 Vdc Data interface Mechanical encoder VREF output 4 9 5 1 Vdc 30 mA 28 V Outputs Current PWM outputs number 2 double Type current mode Current closed loop PWM mode Voltage open loop Min threshold 50 mA Max load 3000 mA Dither frequency 25 333 Hz Resolution 1mA Inputs Voltage inputs number 2 Signal range 0 5 Resolution 5 mV Digital inputs number 2 Signal high 4 Vgar Signal low 0 1 Joystick ECU description The joystick ECU controls two joysticks P1 and P2 P1 is forthe Frame level and P2 is for the Fork tilt The Solenoid valves MA 11 12 MA 13 and MA 14 are pulse modulated PWM Frame level P1 Press the joystick to the left to tilt the machine left MA 11 is acti vated Press the joystick to the right to tilt the machine right MA 12 is activated ECU pin 7 fead 4 9 5 1 Vdc 30mA 28 V T
101. ernator connections when the engine is running This may damage both alter nator and charging regulator IMPORTANT Make sure that the alternator plus connec tion is not connected to the frame This will damage the alternator and may also damage the regulator Electrical system special instructions for servicing actions when working on machine 1 For electric welding on the machine the battery cables must be disconnected and the connectors must be unplugged from the control units NOTE See instructions for electric welding in MC60 70 191 Safety during electric welding 2 During blasting work on the machine work very carefully to prevent damage to electrical cabling and components 3 Never aim the jet directly at electrical components when using a high pressure washer This is especially important when using a combination of warm water and degreaser agent 4 Before drilling or making any holes pin point the exact position of any electrical components in the area IMPORTANT Drilling and other modifications to the cab structure are forbidden The reason is that the ROPS pro tection may not function as intended if the cab structure is modified Grounding points chassis ground The machine s grounding points are very important parts of the electrical system as all sub systems voltage levels are referred to the machine s grounding points as 0 volt If there s contact problem at a grounding point chassis ground it will have
102. g the engine by turn ing the ignition key to position 1 see the Operator s Man ual Carry out all safety checks prescribed in the Operator s Manual WARNING Never operate the machine if you are tired or under the influence of alcohol medicine or other drugs Before starting the engine indoors make sure that the extraction capacity of the ventilation system is sufficient The machine is provided with a diesel engine and the exhaust gases may be dangerous to your health Make sure the ventilation is sufficiently good and avoid running the engine for a longer time than necessary particularly when the ventilation is unsatisfactory Read all plates and instructions which are fitted on the machine and given in the Operator s Manual before you begin to operate or service the machine Each of the instructions contain important information about safety handling and service of the machine Usethe lap type seat belt during all operation Always sit in the seat facing the front of the machine when starting the engine The machine must be operational before putting it to work that is all faults which may cause an accident must be rem edied Do not operate the machine for long periods without venti lation or with a fully closed cab without having the fan run ning there is risk of lack of oxygen Only step on slip protected surfaces and hold onto the available hand holds and railings Lap type seat belt L
103. g the parking brake and placing suitable wedges on both sides of the wheels which are not to be raised off the ground Always use a jack with sufficient lifting capacity and posi tion the jack according to instructions for the work that is to be done Make sure that the jack is correctly positioned and is at the correct angle to the lifting point on the machine Take care to position supports under the machine in a safe way Safety rules when servicing This section covers general safety rules in connection with checking and service work Other rules as well as information and warning texts are given in this manual and also in the Operator s Manual If changes are made that affect the machine safety the person making the changes is responsible for them Therefore the following applies When installing a two way radio mobile telephone etc installation must be performed according to the manufac turer s instructions in order to eliminate interference with electronic systems and components that are necessary for machine functions When retrofitting equipment in or on the cab do not drill weld or cut the cab structure as this will reduce the opera tors protection in case the machine rolls over Fig 12 Service position 1 Before starting any service work Service work performed incorrectly can be dangerous Make sure that you have sufficient knowledge correct informa tion the right tools and the proper
104. ghten lightly NOTE Do not torque the extension chain tension bolt at this time The retraction chain adjustment nut must be inspected first 16 Install the retaining plate and secure the bolts with Loctite 242 NOTE Torque bolts diagonally to 245 Nm 180 Ibf ft 17 Install the rear oil tubes between the extend tubes and hoses Adjust the boom chains see Boom chain adjustment page 46 for further instructions 18 Install the rear cover V1015096 944 Jibb load handling Boom wear pads adjustment or replacement See the following sections to determine ifthe pads need to be shimmed or replaced NOTE Each boom wear pad is chamfered at each end This is designed as a wear indicator Never install pads that are worn close to or below the chamfer The boom will be damaged if the wear pads are worn below the chamfer NOTE Wear pad securing bolt length is important Be sure that the bolts are returned to the same location from which they were removed NOTE All bolts should be secured with Loctite 242 and tight ened to a torque of 54 Nm 39 Ibf ft NOTE All pads must be greased while installed Use NLGI Grade 2 grease Shims are available in the following thicknesses 1 1 0 mm 0 039 in 2 3 0 0 125 in 3 5 0 mm 0 197 in 4 10 00 mm 0 39 in Only for boom section 1 bottom front end and boom section 2 upper rear end Boom front wear pads all 1 Extend the boom approximately 3 m 10 ft and lo
105. he jack according to instructions for the work that is to be done Make sure that the jack is correctly positioned and is at the correct angle to the lifting point on the machine Take care to position supports under the machine in a safe way Safety rules when servicing This section covers general safety rules in connection with checking and service work Other rules as well as information and warning texts are given in this manual and also in the Operator s Manual If changes are made that affect the machine safety the person making the changes is responsible for them Therefore the following applies When installing a two way radio mobile telephone etc installation must be performed according to the manufac turer s instructions in order to eliminate interference with electronic systems and components that are necessary for machine functions When retrofitting equipment in or on the cab do not drill weld or cut the cab structure as this will reduce the opera tors protection in case the machine rolls over Before starting any service work Service work performed incorrectly can be dangerous Make sure that you have sufficient knowledge correct informa tion the right tools and the proper equipment to perform the service work correctly Repair or change broken or damaged tools and equipment Fig 4 Service position 1 10 Service positions Before you begin service work the machine must be placed o
106. he oil tubes from the rear of the boom 5 Remove the extend chain adjustment bolt and the retaining plate from the cylinder support bracket at the rear of the boom Fig 85 1 Chain adjustment bolt 2 Retaining plate 37 IA 1014609 ERS V1014611 38 6 Remove the cylinder support bracket Pull out the upper part ofthe hydraulic hoses 7 Remove the horseshoe tubes from the supply tubes at the bottom of the boom 8 Pull the horseshoe tubes out as far as needed to access the hose fittings Remove the horseshoe tubes 9 Pull the hoses out from the boom from the rear end gt VA 1014609 Installation 10 11 14 Push the hoses into the boom and connect them to the horseshoe tubes at the bottom front end of the boom section 1 Attach the horseshoe tubes to the supply tubes and pull all slack in the hoses to the rear of the boom Feed the hydraulic hoses through the channels at the rear of the boom until they come out the front of boom section 3 Attach the hoses to tilt cylinder and auxiliary fittings if so equipped Install the cylinder support bracket and secure the bolts with Loctite 242 NOTE Torque the bolts to 110 Nm 81 Ibf ft Ensure the bracket is set evenly without any binding 39 1014569 91 1 Extension chain bolt 2 Retaining plate 0 4551 40 15 Install the extension chain tension bolt and ti
107. hen possible always install the bearing into the rotating part first Use the proper tools or a press when installing a bearing or bushing In the absence of the proper tools or a press heat the bearings and or casing in hot oil to assist in the installation Hoses and tubes Inspection Ifthe hose end connections are damaged always replace hoses and tubes Damaged dented crushed or leaking hose fittings restrict oil flow and the operation of the parts being served Fit tings showing signs of movement from their original position have failed and must be replaced Be sure hoses are in good condition If in doubt replace them Replace hoses if the following occur chafed outer cover concealed corrosion of wire reinforcement ballooning replace immediately kinked crushed stretched or deformed Installation When installing a new hose loosely connect each end and take the designed position before tightening the connection Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing If a hose is replaced on a moving part be sure it does not foul by moving the part through its complete range of travel Be sure any hose which has been installed is not kinked twisted or exposed to any sharp edges Free moving unsupported hoses must never touch each other or related work surfaces This causes chafing reducing hose life Pressure testing 1 Prior to pressure testing
108. ic actuation through the rocker arms NOTE The coloured mark on the spring must show to the bot tom Rocker arm lubrication is integrated in the lube oil circuit The oil is supplied via tappets and push rods Valve clearance adjustment The valve clearance must be checked and adjusted at specified intervals see operation manual To do this the engine oil tem perature must be 20 80 68 176 F Adjustment 1 Remove the valve cover 2 Turn crankshaft until both valves in cylinder 1 are overlap ping Overlapping means that the exhaust valve is about to close and the inlet valve is about to open 3 Adjust clearance of valves marked in black in figure Inlet valve 0 30 mm 0 0118 in Outlet valve 0 50 mm 0 0197 in Mark respective rocker arm with chalk to show that adjust ment has been done NOTE The valve clearance should be increased by 0 1 mm 0 004 in when the cylinder head gasket has been replaced Adjust to normal valve clearance after 50 hours of operation 4 Tighten the lock nut to 20 Nm 14 8 Ibf ft Check the adjustment again with a feeler gauge Fig 74 Fig 75 V1019654 1019692 V1019654 5 Turn crankshaft one full revolution 360 Now adjust clear ance of valves marked black in figure 6 Tighten the lock nut to 20 Nm 14 8 Check the adjustment ag
109. ic main valve manifold 1025175 Fig 5 Section of valve manifold 1 Pressure port PM 9 Attach the other end of the minimess hose to the nipple on the lift cylinder valve block The boom will lower very slowly NOTE The extend cylinder counterbalance valve must be replaced after the setting has been altered to retract the boom Contact a workshop authorized by MEC V1025176 Fig 6 Lift cylinder valve block 1 Nipple 15 Fig 7 Connecting start cables 16 4 1003824 Jump starting Auxiliary start WARNING Never boost start the machine by connecting directly to the starter motor This may result in uncontrolled machine movements When using another machine to boost start it must not touch the machine that is being started Auxiliary start with start cables Check the following before connecting That the ignition is OFF in both machines That the machine cannot start to move when started That the machines have the same system voltage That the start cables are dimensioned for the max current rating that the battery can generate Start cables with regards to cracks oxidation and other defects That battery cables are intact and connections are con nected securely That the machines do not touch each other WARNING When using start cables the positive and negative connec tion must not come into contact Risk of personal injury Connect start
110. in frame Temporary remove the vertical front end support and lower the boom section 1 until the upper support for the slave cyl inders facing the holes in the main frame Disconnect the upper joint to the slave cylinders attached to the boom section 1 by first removing the lock screw and then drive the pin out with a hammer and a driver Reposition the boom section 1 in it s horizontal position by using the front end support previously removed 21 Fig 50 Fig 51 22 V1014767 1014766 22 Remove the locking screws to the boom pin Remove the height indicator plate from the boom 24 Ny E A 7 DEN 2 V1014768 25 26 Secure the boom with two lift slings and lift until the rear boom main pin is unloaded Drive the main pin out from the boom joint There is a threaded hole in one end of the main pin to attach a puller if extra force is needed Lift the boom section 1 and place on stands or a suitable fixture NOTE Weight of boom section 1 750 kg 1655 Ib Remove the front inner side and bottom wear pads Remove the outer boom guide pads Remove the thrust washers located at the bearings in the frame 23 Boom main pin bearing removal and installation NOTE When the bearings are removed clean and control that the bearing surfaces are in good condition 27 Drive out the bearing Use tools handle 11667001 and drive plate 11667085
111. iness is a decisive factor for operational reliability of the machine s systems Therefore keep the servicing area clean Oil or water make floors and steps slippery and are also dangerous in combination with electrical systems or Fig 10 Fire extinguisher tools Oily clothes or clothes drenched in grease constitute a serious fire hazard Check daily that the machine and equipment such as underbody skid plates are free from dirt and oil This reduces the risk of fire and makes it easier to detect defec tive components or loose parts IMPORTANT If a high pressure washer is used when cleaning work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature Protect electrical cabling in a suitable manner Keep the machine especially clean when operating in envi ronments with fire hazards such as saw mills garbage dumps etc In such environments suitable equipment to reduce the risk of accumulation of material and spontane ous combustion should be fitted for example muffler guard radiator screen heavy duty cyclone pre cleaner etc Electrical system Check electrical cables with regard to chafing damage and make sure that they cannot be damaged in such a way This applies particularly to unfused electrical cables which are red For example electrical cables between Batteries Battery starter motor
112. ing or noise absorbing material may not be performed Further making new holes openings in the cab or engine compartment is not allowed as this may increase the sound level in the cab Some simple rules regarding tyre handling WARNING A tyre fitted on a split rim may explode causing severe injury or even death 17 Inflating e Never stand to the side of the tyre while inflating Never stand to the side of the tyre while inflating which is fitted on a split rim Use a self locking outlet with a hose long enough to allow you to stand outside of the hazard zone during inflation see the illustration Make sure that the hazard zone is clear when the tyre is inflated The machine must be unladen when checking tyre pres sure Spare tyres should only be filled with enough air to allow the rim parts to be held in place Secure a loose wheel with an inflation cage cable or chains before inflating Before removing the inflation cage check that the tyre is properly fitted to the rim Adjustments should be made before the wheel is inflated Do not attempt to adjust side rings or lock rings when the Fig 11 tyre is inflated Never stand to the side of the tyre while inflating Tyres used at less than 80 of normal pressure and rims or tyres suspected of being damaged should not be inflated with the wheel attached to the machine Fitting of tyres and rims Handling of tyres should be performed by authorised
113. ions for servicing electrical components batteries 6 Electrical system special instructions for servicing electrical components alternator and charging reg lator aan nn 7 Electrical system special instructions for servicing actions when working on machine 7 Grounding points chassis ground eene nnne 7 Auxillary Start eee esaet e inea up ao pact a um tem dort eremo bees 8 Auxiliary start with start cables sss eem rra 8 Joystick ECU Specifications nnne 10 General 10 ih Re pe ob it d ated cate elu eM ab 10 gelu EE 10 Joystick ECU a 11 Frame level P1 eee Ad ad 11 ForktilE P2 eire e erbe nein aes 11 31 BATTERY 311 Battery Battery Satety eme omen eie ned diana 12 Battery specifications ceca Dee e ne a un 13 Battery description inpr t ein eed eee 13 Battery Charging Lee dt ede e 14 33 STARTING SYSTEM 330 General common info about 331 334 Starter motor specifikation 15 Starter motor description x etie in 15 35 LIGHTING 350 General common info about 351 356 Lighting specificati ns
114. irements which are given in the EU Machine Safety Direc tive If changes are made that affect the safety of the machine the person making the changes is responsible for the same As proof that the requirements are met the machine is supplied with an EU Declaration of Conformity issued by MEC for each individual machine This EU declaration also covers attachments manufactured by MEC The documentation is a valuable document which should be kept safe and retained for at least 10 years The document should always accompany the machine when is sold If the machine is used for other purposes or with other attach ments than described in this manual safety must be maintained at all times and in each individual case The person carrying out such action is also responsible for the action which in some cases may require a new CE marking and the issue of a new EU Declaration of Conformity EU EMC Directive The electronic equipment of the machine may in some cases cause interference with other electronic equipment or the equip ment may be adversely affected by external electromagnetic interference which may constitute safety risks The EU EMC directive on Electromagnetic conformity provides a general description of what demands can be made on the machine from a safety perspective where permitted limits have been determined and given according to international standards A machine or device which meets the requirements should be
115. lic motors and pumps may be made of fluor rubber which will form hydrogen fluoride and hydrofluoric acid when exposed to intense heat This acid is highly acidic and corrosive It cannot be rinsed or washed off the skin and causes very severe burn and corrosive injuries that take a very long time to heal As a rule injured tissue must be removed surgically The acid may remain on machine parts for a very long time sev eral years after a fire NOTE It may take several hours after contact with the acid before any symptoms become apparent If swelling redness or burning sensations appear and contact with heated fluor rubber is suspected contact a physician imme diately If a machine or a component for a machine has been exposed to fire or other intense heat it shall be handled by spe cially trained personnel Thick protective neoprene rubber gloves and tight fitting protec tive goggles must be used during all handling of machines after a fire WARNING Never burn painted parts or parts made of plastics or rubber after they have been discarded This work must be done by a licensed waste management plant Decontamination The area around a heated part that is suspected of being made of fluor rubber must be decontaminated by thorough and ample washing with lime water a solution or suspension of calcium hydroxide that is slaked lime in water After the work has been completed wash the protective gloves in lime water
116. ly be performed in an emergency situation by experi enced and trained personnel and only for the shortest pos sible distance see towing If possible transport the machine on a trailer General If possible the engine should be running while recovering towing the machine to ensure satisfactory braking and steering performance Recovering Use a towbar heavy gauge cable or chain connected to the towing eyes at the front or rear of the machine to tow the machine to a suitable place or passable road Towing Lower the boom to convenient towing height If the machine has to be towed to a workshop after recov ery use a towbar or heavy gauge towing cable connected to the front towing eyes A towbar must always be used if the machine that is to be towed has no brake function The towing vehicle or machine must always be at least as heavy as the towed machine and have sufficient engine and braking power to tow and brake both machines on uphill and downhill grades Always tow the shortest possible distance Maximum towing speed under all conditions is 10 km h Place the transmission in neutral and release the parking brake See section Hydraulic cylider parking brake manual release Hydraulic cylinder Parking brake manual release page 12 if the machine does not work under it own power After recovering towing The following safety measures should be taken before removing the towbar heavy gauge cable or chain af
117. m 129 Ibf ft 8 Remove the lift slings 9 Reinstall the radiator hoses and fan blade guard Engine and transmission assembly installation to main frame Op no To be able to perform this procedure first see instructions in page 20 NOTE The weight of engine transmission installation including radiator and hydraulic tank is 1000 kg 2200 Ib WARNING Risk of injuries caused by crushing 1 Putthe complete engine transmission and hydraulic tank assembly on a level and stable subframe For example EUR pallets or similar 21 2 Lift and push the complete assembly into it s position in the main frame Adjust the height to install the hydraulic tank frame to the machine main frame V1020306 Fig 45 3 Tighten the nuts from under the machine NOTE Torque to 1050 Nm 775 Ibf ft NOTE Strap all wires and hydraulic hoses to prevent them from rubbing against any sharp edges V1020307 Fig 46 4 Connect the engine wiring harness to it s connecting 1 point at the main frame N Fig 47 1 Engine wiring harness 22 Z SE m 373 2 N DJI A y KPT CO MON d 5 Fig 48 1 Ground point sun o O GND Se V1020303 Fig 49 V1020302 5 Connect the ground wires to the engine block 6 Connect the propeller shafts to the drop box NOTE Always use new bolts according to MEC Parts NOTE Torque to
118. maintenance valve Leak off fuel line Return line to fuel tank Maintain maximum possible distance Fuel filter Fuel filters must be replaced according to instructions in the operators manual The filters must also be changed whenever there is excessive water in the fuel system or when the engine shows noticeable and sudden loss in power 37 Fig 81 V1019735 1 Over pressure relief valve 2 Bypass valve 38 V1019735 Draining water from the fuel water separator The presence of water in fuel will cause the engine to run rough and to smoke excessively If the water is not drained it may cause engine damage The main fuel filter incorporates a fuel water separator Drain this daily if water contamination is sus pected If water contamination is not suspected its good prac tice to drain the fuel water separator weekly as condensation inside the tank will cause some water to be present 233 Fuel pump filter strainer Fuel feed pump The fuel feed pump is designed as a rotary pump which is driven via the Poly V belt The pump is provided with a two way valve The over pressure relief valve 1 is designed as a plunger valve and opens at 5 5 bar 80 PSI This valve simultaneously limits the system pressure to 9 5 bar 138 PSI The bypass valve 2 is a ball valve When the fuel lines have run empty the fuel system can be primed with a hand pump This prevents an excessive engine starting procedure Starter protecti
119. n level ground and prepared as shown below If work has to be carried out on the machine before it has cooled there is a risk of burns Therefore take care when working with hot liquids and machine parts Service position 1 w A 10 11 1021707 Remove the attachment from the attachment bracket Fully retract the boom Fully lower the boom so that the boom supports to the machine frame Park the machine on firm level ground Apply the parking brake Turn off the engine Remove the ignition key Allow the machine to cool down warnine If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns Attach a black and yellow label to the steering wheel with the message forbidden to start the engine Unfasten seat belt and exit the machine using the handles Block the wheels Fig 5 Service position 2 Service position 2 ONOORWN 9 10 11 1025265 Remove the attachment from the attachment bracket Fully retract the boom Place a support under the boom Park the machine on firm level ground Apply the parking brake Turn off the engine Remove the ignition key Allow the machine to cool down If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns Attach a
120. n and its function Engine specifications General Make Deutz Designation D4D CDE2 Type Dry sleeve Product number EG 00619224 Aspiration standard Turbo Number of cylinders 4 Bore 101 mm 3 98 in Engine RPM governed 2500 RPM Stroke 126 mm 4 96 in Displacement 4 038 dm3 246 5 in3 Number of valves 8 Rotation direction CCW Compression ratio 19 0 1 Firing sequence 1 3 4 2 Low idle 900 rpm High idle 2565 rpm Weight dry 380 kg 840 Ib Performance ISO 9249 DIN 6271 net 68 kW 91 hp Max flywheel output at 2000 rpm SAE J1349 gross 70 kW 94 hp SAE J1349 net 68 kW 91 hp DIN 79929 net 68 kW 91 hp ISO 9249 DIN 6271 net 385 Nm 284 Ibf ft Max torque at 1500 rpm SAE J1349 gross 389 Nm 237 Ibf k SAE J1349 net 385 Nm 284 Ibf ft 385 Nm 284 Ibf ft DIN 79929 net Valve mechanism Valve arrangement Overhead valves Valve clearance inlet valve 0 30 mm 0 0118 in exhaust valve 0 50 mm 0 0196 in Lubrication system Type Forced feed circulation lubrication Lube pump type Gear driven Oil pressure gt 1100 rpm 0 45 MPa 4 5 bar 65 psi Oil pressure minimum warm engine low idling 0 08 MPa 0 8 bar 12 psi Oil temperature normal 80 C 176 F Oil temperature max 125 C 257 F Oil flow at 2500 rpm 65 litres
121. nces be fol lowed Asa precaution seal rings O rings or axle shaft seals should always be handled as if they were made of fluor rubber see also section Fluor rubber warnine Avoid splashing when washing a machine damaged by fire For this reason never use high pressure washing equipment Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to con tact with melted polymers First wash thoroughly with plenty of lime water a solution or a suspension of calcium hydroxide i e slaked lime Use thick protective gloves made of rubber and wear gog gles that are certain to protect your eyes Seek medical attention if your skin may have come in con tact with burnt fluor rubber The skin should be treated with Hydrofluoric Acid Burn Jelly or similar Symptoms may not appear until several hours after contact with burnt fluor rubber Discard protective gloves rags and other items that may have come into contact with burnt fluor rubber CE marking and declaration of conformity Only applies to machines marketed within the EU EEA This machine is CE marked This means that when delivered the machine meets the applicable Essential Health and Safety Requirements which are given in the EU Machine Safety Direc tive If changes are made that affect the safety of the machine the person making the changes is responsible for the same As proof that the req
122. nd of the cylinder until the front end sheave clears the chain block Insert until the sheave end passes the chain block Lift the extracted end of the cylin der to a level and insert the complete cylinder into boom 3 Feed the extension chain into the boom sections while inserted cut the straps as the chain rod goes into the boom assembly Secure the threaded block to the outer rod end Do not use Loctite 242 since this block must be adjustable when the chain is tensioned NOTE Lubricate the chain with multigrade SAE 20W 50 oil while installed NOTE Do not apply grease to the chain Grease will coat only the outside of the chain and will seal out the necessary lubricating oil 41 Remove the sling Fig 29 13 42 Secure the cylinder to boom section 2 and secure the bolts with Loctite 242 NOTE Torque the bolts diagonally to 460 Nm 338 Ibf ft V1014576 43 Install hose guide rollers For tilt cylinder to the right and for auxiliary to the left if machine is so equipped 44 Push the hoses forward and reconnect them at the front end tilt cylinder and auxiliary output ANA V1014566 45 Reinstall the upper pin to the tilt cylinder and secure the pin with the retaining ring 1014571 Fig 32 14 46 Reinstall the oil extension tubes to extend cylinder 1014567 47 Install the cylinder support bracket and secure the bolts with Loctite 242
123. ne contaminants Plug all cylinder valve reservoir tank and pump openings until installation Use clean filtered motor oil when filling the system See Recommended lubricants oils page 6 Fig 1 10 173 Maintenance Service positions Before you begin service work the machine must be placed on level ground and prepared as shown below If work has to be carried out on the machine before it has cooled there is a risk of burns Therefore take care when working with hot liquids and machine parts Service position 1 N gt A 10 11 V1025264 Remove the attachment from the attachment bracket Fully retract the boom Fully lower the boom so that the boom supports to the machine frame Park the machine on firm level ground Apply the parking brake Turn off the engine Remove the ignition key Allow the machine to cool down If work must be done on the machine before it has cooled down beware of hot fluids and hot components that can cause severe burns Attach a black and yellow label to the steering wheel with the message forbidden to start the engine Unfasten seat belt and exit the machine using the handles Block the wheels Fig 2 Service position 2 5 10 11 V1025265 Remove the attachment from the attachment bracket Fully retract the boom Place a support under
124. ned in the hydraulic system or brake system 1 Lower attatchment s to the ground 2 Turn off the engine and remove the ignition key 3 Release the system pressure by moving the control levers forward and rearward several times with full strokes All pressurised vessels must be opened very carefully so that any residual pressure is released Check tightening of leaking couplings and connections should only be done after all the pressure in the system has been completely released All pressurized tanks vessels shall be opened carefully so that any residual pressure is released Check tightening of leaking couplings and connections may only performed after the system is completely depres surized In case of hydraulic hose leaks that show up as very fine jets remember the high pressure the jet can 19 20 easily penetrate your hand for example and cause serious injuries check for leaks use a steel plate or stiff board never use your hands Health risks associated with paints plastics and rubber Work on painted surfaces No welding or torch cutting is allowed on painted surfaces All paint is broken down when heated and forms a wide variety of substances that may be irritating and very hazardous to health after prolonged or repeated exposure The following safety instructions must be followed Remove all paint by sand blasting at least 10 cm 4 in around the welding or cutting
125. ng cooling system aa 41 41 TR ENGINE WITH MOUNTING AND EQUIPMENT 21 ENGINE 210 General common info about 211 218 Engine and transmission assembly removal from main frame Op no 21073 1 Put the machine in service position 1 see TH60 80 191 Safety rules when servicing 2 Remove the gas spring at it s upper ball joint and remove the hinges from the engine hood V1020287 1 Hinge 2 Gas spring 3 Remove the engine hood WARNING If the battery s plus terminal is short circuited to the minus terminal or to the chassis there is a risk of explosion or fire Therefore always protect the battery terminals INN T A IL Br 2 de y 1020288 WARNING The battery electrolyte contains corrosive sulphuric acid Electrolyte spilled on bare skin should be removed immedi ately Wash the affected area with soap and plenty of water If electrolyte gets into your eyes or any other sensitive body part rinse immediately with plenty of water and seek imme diate medical attention 4 Open the battery hatch Tag and disconnect the battery ter minals start with negative terminal to prevent sparks and short circiuts Remove the cable support from the hatch and remove the complete hatch including the battery from the machine Fig 4 5 Remove the rear dirt guard WARNING Y F Hot oil and hot engine coolant
126. nly if the engine will be replaced tag and remove the engine wiring harness and all hoses connected to the engine Plug all hose ends Engine and transmission removal cont NOTE Weight of the engine and transmission is approximately 710 kg 1565 Ib 5 Secure the engine and transmission with lift slings and a hoist device 15 6 Remove all slack in the lift equipment and remove the four engine mountings 7 Lift the engine and transmission out of the hydraulic tank engine frame assembly V1020273 8 Putthe engine and transmission on a suitable and safe sur face for example stands Transmission removal from removed engine Op no 42183 See page 15 for information how to remove the engine and transmission from the hydraulic tank engine frame assembly V1020274 Fig 29 1 Secure the transmission with at least 2 slings to keep it level while lifting V1020262 Fig 30 16 2 Remove the cover at the bottom of the engine close to the transmission housing V1020263 3 Remove the bolts 8 pcs that hold the flexplates to the fly wheel Use tool 999 86 76 to rotate the engine step by step V1020265 4 Remove all slack in the lift slings and remove the bolts between the transmission housing and the engine block NOTE Weight of transmission approximately 290 kg 640 Ib Fig 33 17 1020309 Fig 34 V1020262 Fig 35 18 5 Liftand place the transmission
127. nsmission 2 Hose from pump I 6 BE KIN 18 Y lt MN Al Av 7 20 wae V1020293 Fig 59 26 Install the filter bracket Install the remote engine lubrica tion filter the hydraulic tank breather and the air cleaner Unplug the hoses and connect to the transmission casing and the pump pressure side Install the front dirt guard Make sure the drain plug is tightened and refill the hydrau lic tank See operators manual for instructions and TH60 TH80 Recommended lubricants oils for specifications Make sure the drain plug is tightened and refill the radiator with coolant See operators manual for instructions and specifications NOTE Make sure the filler caps are reinstalled in their orig inal positions The cap for expansion tank is marked 50 kPa Inspect engine oil level See operators manual for instruc tions and TH60 TH80 Recommended lubricants oils for specifications Inspect transmission oil level See operators manual for instructions and 7H60 TH90 Recommended lubricants oils for specifications NN A Fig 61 1 Exhaust pipe V1020289 2 Install the rear dirt guard 1 WARNING If the battery s plus terminal is short circuited to the minus terminal or to the chassis there is a risk of explosion or fire Therefore always protect the battery terminals WARNING The battery electrolyte contains corrosive sulphuric acid Elec
128. nstal lation must be performed according to manufacturer s instructions in order to eliminate interference with electronic systems and components intended for the function of the machine Safety for work on hydraulic systems The hydraulic systems in our TL 70 90 work at very high pressures up to approx 25 MPa 250 bar 3626 psi In order to prevent serious personal injuries it s important that the systems are maintained correctly and that all per sons who come into contact with the machines are very careful and very alert to any defects Those who follow the simple rules below have laid a good foun dation for accident prevention General Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer A hydraulic hose that swells for example at a connection indicates that it s about to burst Replace the hose as soon as possible Pay attention to leaks from hydraulic hoses and connections Repair the leakage before the part bursts Scrapped accumulators Empty the accumulators gas and remove the gas valve Plug the oil port NOTE It is dangerous to disconnect the gas valve when the accumulator is pressurized WARNING If the pressure is not released before opening the system oil under high pressure will jet out resulting in serious per sonal injuries Pressure release When the engine has been stopped there remains an accu mulated pressure in the system 14 5 MP
129. o P1 pin 2 ECU pin 15 fead To P1 pin 1 ECU pin 8 Input signal 0 5 v 4 5 V To P1 pin 3 Fork tilt P2 Press the joystick forward for tilting the fork tilt up MA 13 is acti vated Press the joystick backwards for tilting the fork tilt down MA 14 is activated ECU pin 7 fead 4 9 5 1 Vdc 30mA 28 V To P2 pin 2 ECU pin 15 fead To P2 pin 1 ECU pin 16 Input signal 0 5 v 4 5 V To P2 pin 3 11 12 31 BATTERY 311 Battery Battery safety The following WARNING is intended to supplement and does not replace the warnings and information provided on the battery by the battery manufacturer See also TH60 TH80 191 Safety when working with batteries WARNING Batteries contain corrosive acid Handle batteries accord ing to instructions in Section 3 and Section Safety WARNING The batteries could explode due to the current surge if a fully charged battery is connected to a completely dis charged battery Since the batteries contain sulphuric acid this could result in personal injuries WARNING During rapid charging of batteries always remove the cell caps During charging an explosive mixture of oxygen and hydrogen is formed A short circuit open flame or spark near the battery can cause a powerful explosion Always turn off the charging current before disconnecting the charging clamps Ventilate well especially ifthe battery is being charged in a confined area The batter
130. o equipped V1014571 Fig 6 12 Remove the hose guide rollers Also remove the rollers to the left for auxiliary output hoses if machine is so equipped V1014566 Fig 7 13 Pull out the hoses enough to get access to the cylinder retaining plates and remove them V1014576 Fig 8 14 Attach a sling to the clevis end of the cylinder and reinstall the retaining plate Extract the cylinder out from the boom until the entire extension chain rod is visible V1014581 Fig 9 15 Remove the pin that attaches the extension chain to the rod Remove the rod and put the chain on top of the boom V1014584 Fig 10 16 Extract the cylinder until the front chain guide roller stops at the chain block Lower the extracted end of the cylinder until the front chain guide roller clears the chain block and extract the cylinder until the chain guide roller passes the chain block Keep the front end of the cylinder inside the boom assem bly and pull the extension chain through the chain guide roller me m oe i de EM ha V1014590 Fig 11 17 Attach a second sling to the cylinder and lift in a level posi tion NOTE Cylinder weight 195 kg 430 Ib 18 the cylinder on suitable supports V1014587 Fig 12 19 Remove the set screws for the chain block pin 20 Drive the chain block pin out with a hammer and a driver m 21 Lift the chain block ou
131. o unload the wear pads mounted on the bottom of boom section 2 Remove the bottom wear pads V1014671 19 12 Reinstall the chain guide wheel and it s pin and then loosen the clamps The chain guide wheel will ease the extraction of the boom section 2 V1014677 13 Attach a sling to boom section 2 and extract approximately 7 gt 0 5 m 20 in 14 Give some slack to the sling and remove the upper front wear pads from boom section 1 15 Extract boom section 2 approximately 3 m 120 in NOTE Total length of boom section 2 4 85 m 190 in V1014676 Fig 45 16 Attach a second sling to the boom and lift in a level posi tion NOTE Weight of boom section 2 470 kg 1040 Ib 17 Put the boom section 2 on stands or a suitable fixture and remove the front inner and outer wear pads A total number of 8 pads V1014682 Fig 46 20 Boom section 1 removal It is necessary to remove the front end support to the lift cylinder before the boom section 1 is removed 19 1014764 20 V1020380 Fig 49 18 Secure the lift cylinder with a sling and remove the front end pin Secure the front end of boom section 1 with a sling and lift until the front end of the lift cylinder clears from the support bracket at the boom section 1 Lower the lift cylinder and support it to the front end of the main frame Remove the hydraulic oil tubes along the boom and lay them on the ma
132. on NOTE Do not reduce the line cross section and connection to fuel feed pump as this may results in engine power loss 236 Injection pump regulator pump companion Injection system The engine is provided with single injection pumps Commencement of delivery The setting of the commencement of delivery COD influence Fuel consumption Power Exhaust emissions of the engine The commencement of delivery is set without tolerance It is indicated in C A degrees BTDC of the piston see nameplate and is dependent on application power and speed setting respectively optimization of the engine 237 Injector delivery pipe Governor The governor is mechanical variable speed governor with cen trifugal measuring element NOTE All governor settings may only be conducted by trained specialists Governor external view Injector Injection nozzle The injection nozzles have a replacement interval at 3000 oper ating hours 25 INLET SYSTEM EXHAUST SYSTEM V1019793 Fig 82 V1019793 250 General common info about 251 258 1 Beginning of torque cont Engine air intake fi 1 High iini ngine air intake filter 5 Stop lever The air cleaner prevents dust and other impurities from entering the engine The air passes through the primary filter and then through the secondary filter See operators manual for maintenance Fig 83 V10149
133. on a suitable surface 6 Onlyifthe engine is to be replaced then all necessary hardware must be transferred to the replacement engine Such as Electrical wiring harness Starter Radiator fan blade and hoses Fuel hoses Lubrication hoses for remote oil filter Engine mounting brackets 7 Only if the transmission is to be replaced then all nec essary hardware must be transferred to the replacement transmission Such as Hydraulic pump Rear engine transmission brackets Transmission installation on removed engine Op no 42184 NOTE Make sure that the engine is securely supported on stands or on a solid work bench before attaching the transmis sion NOTE Weight of transmission approximately 290 kg 640 Ib 1 Secure the transmission with at least 2 lift slings to keep it level while lifting Lift the transmission and align it to the engine 2 Install the bolts that hold the transmission case to the engine block NOTE Torque 75 Nm 55 Ibf ft Fig 38 V1020263 V1020265 V1020263 Install the bolts 8 pcs that hold the flexplates to the fly wheel Use Use tool 999 86 76 to rotate the engine step by step NOTE Torque 35 Nm 26 Ibf ft Install the cover at the bottom of the engine Remove the lift slings Only if the engine has been replaced reinstall all removed hardware from the original engine Only if transmission has been replaced reinstall all removed hardware from the original tr
134. on is same as the engine rotation when the forward clutch is engaged A front axle disconnect is optional and is located on the output shaft The drive to the front axle can be disconnected or con nected by manual shifting Transmission controls description The transmission is controlled by the direction and range sole noids The solenoids are mounted on the left side of the trans mission case When the selected direction and range solenoids are energised oil under pressure will flow through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct oil under pres sure through a drilled passage way in the shaft to the desired clutch Power Transmission Repair Instructions p PRELIMINARY DOCUMENT Contents 43 GEARBOX 430 General Transfer case oll TMG ec siio Herner eat 45 PROPELLER SHAFT 451 Propeller shaft complete Sp cification s panen TEE TOQUE tina RN HEN tte eee 46 FRONT AXLE REAR AXLE 460 General common info about 461 468 Drive axles ea ea a are ui Planetary reduction hubs oil filling mH 461 Front axle Frontaxle specification degere Aalen Front axle e ORE iR Hub hub reduction HUD reduction 5 ir A i LEE EP 463 Rear axle 1 c ea estie e d tei dei icis EP QE Rear axle capacities ceto edid ee eae
135. on of the hydraulic torque conver tre and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its centre and discharges it at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter this element recieves fluid at its outer diameter and discharges it at its centre The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and tur bine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication is function of the blading impeller tur bine and reaction member and the converter output speed tur bine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefor we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydrauloc pump is connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump
136. or overhead sling Check the entire frame Check all mounting points carefully cab engine boom axles etc along with any towing attachments or mounting points Cab Check carefully do not repair by welding Outriggers if equipped Lowe the outriggers until they touch the ground Inspect each carefully Check the pads pins cylinders and weldments Boom Extend the boom fully then set the attachment carriage on the ground Check each boom section thoroughly Attachment carrier Check the carriage and attachment Cylinder anchor points Check all cylinder anchor points and pins for signs of wear and stress 191 Safety equipment without own function group Safety concerns everybody Always follow the instructions in the machine s operator s man ual The operator s manual should always be kept in the cab for easy reference We have spent many hours engineering and producing a machine with a high level of safety and efficiency All this time may be wasted if an individual who is about to perform service on any of our machines does not read through the safety instruc tions or does not follow them for example does not replace guards climbs on slippery machine parts instead of using a lad der grabs on to hoses instead of the provided handles or uses the wrong tools for the job Always use genuine intended and adapted spare parts to maintain safe and efficient machine function Machines seldom cause acci
137. ource have the same voltage as the standard batteries WARNING Batteries may explode due to the current surge if a fully charged battery is connected to a completely discharged battery Personal injuries may be sustained Follow these steps 1 Move the gear selector to neutral 2 Apply the parking brake 3 Check that the booster batteries or other power source have the same voltage as the standard batteries 4 Do not disconnect the cables to the standard batteries 13 9 Connect on the booster battery to on the battery nearest the starter motor Connect the other start cable from on the booster bat tery to the machine chassis such as on the frame member close to the starter motor Start the engine with the ignition key in the cab Once the engine has started remove the start cable between the chassis and the booster battery negative ter minal Then remove the start cable between the positive terminals Refit the terminal caps on the battery terminals Fire prevention measures General Fig 9 Smoking and open flames are absolutely for bidden when filling fuel or any time diesel fuel is in contact with the open air There is always a risk of fire Find out which type of fire extinguisher to use where it is located and how to use it The fire extinguisher in the machine should be located for quick access or in an external box that can be locked Fire fighting equipment install
138. per sonnel only Thetyre should be deflated before removal from the machine Never install a tyre on a rim that has not been recom mended for that tyre Never assemble rim parts for different dimensions or use damaged or faulty parts Exercise caution if using reconditioned wheel details Weld ing errors faulty heating or soldering may have weakened the parts and may cause the detail to break Make sure the lock ring groove in the rim is cleaned from foreign matter and rust before fitting the lock ring Use lubricant recommended by the tyre manufacturer when fitting onto the rim Repairing tyres and rims Never cut weld nor heat the wheel parts in any manner Exercise caution when using bead breakers and hydraulic jacks Remain outside the hazard zone when removing for eign objects from the tyres A bead breaker that releases can cause severe personal injury and may result in death Working on the electrical system of the machine Onlyuse test instruments with a light emitting diode never a test light with a light bulb for example during trouble shooting of the electrical system The high firing voltage of the bulb can destroy expen sive electronic components When installing a two way radio mobile phone etc instal lation must be performed according to manufacturer s instructions in order to eliminate interference with electronic systems and components intended for the function of
139. pring will push the piston back and oil will drain back via the solenoid the bleed valve or holes in the clutch piston into the transmission pump These bleed valves will only allow quick escape of oil when the pressure to the piston is released The T12000 transmission 3 speed version has one reverse clutch and one forward clutch This in combination with the 3 range clutches results in the transmission having 3 forward and 3 reverse speeds The T12000 transmission 4 and 6 speed versions have one reverse clutch and two forward clutches forward and High 4 This in combination with the 3 range clutches results in teh transmission having 4 forward for the 4 speed or 6 forward for the 6 speed and 3 reverse speeds The engagement of the directional clutches forward and reverse are modulated This means that clutch pressure is built up gradually This will enable the unit to make forward revers shifts while the vehicle is still moving and will allow smooth engagement of drive The modulation is done hydraulically Range clutches and output section description Range clutches Once a directional clutch is engaged power is transmitted to the range clutches 1st 2 or 3rd Operation and actuation of the range clutches is similar to the directional clutches The engage ment of the range clutches is not modulated Output section With a range clutch engaged power is finally transmitted to the output shaft Output rotati
140. r Coolant pump type Belt driven centrifugal pump Thermostat type Piston thermostat Thermostat begins to open at 83 C 181 4 F Thermostat fully open at 95 C 203 F Pressure valves opens at 0 05 MPa 0 5 bar 7 3 psi Thermostat Type Piston thermostat Quantity 1 Begins to open at 83 C 181 F Fully open at 95 C 203 F Pressure 0 05 MPa 0 5 bar 7 3 psi Coolant pump Type Belt driven centrifugal Flow at 2200 rpm 158 litres 41 7 US gal per minute Working pressure max 0 05 MPa 0 5 bar 7 3 psi Cold start Cold start aid standard Engine air pre heater Cold start aid optional Engine water heater Engine weights Engine dry 380 kg 838 Ib Engine hood 20 kg 44 Ib Cooler 27 kg 60 Ib Engine capacities Engine oil including filter 12 liter 3 2 US gallon Cooling system 14 liter 3 7 US gallon Fuel tank 122 liter 32 2 US gallon Engine tightening torques Engine mounting to engine 185 Nm 136 Ibf ft Engine mounting to frame 173 15 Nm 127 11 Ibf ft Propeller shaft to gearbox 61 81 Nm 45 60 Ibf ft Oil dipstick late models Oil drain plug Oil pressure switch Shut off solenoid Injection pumps solenoids Alternator Cooling fan
141. r A0800200 BA Battery 1399300 DI gt Di A0800800 igde FC FH Fuse FU A0904300 GC GE GF Grounding point GFSM GR 2119600 BEN Heating coil i e heated seat cushion HE 0801000 Op Cigarette lighter socket A1399500 D Instrument IM A1398900 4 Display A1399000 Pd Light continuous light i e low beam light A0905400 LA b4 Light flashing light i e direction indicators A0905600 Control light continuous light i e engine oil pressure high beam indication LC A0905500 A0905700 69 Control light flashing light i e central warning light direction indicators v 0800900 Light emitting diode Designation Symbol Explanation designation 2 0905200 Solenoid valve for control of air Pressure sensor i e control pressure hydraulics MA Solenoid valve for control of oil A0905300 Solenoid i e hold solenoid for bucket lockout A0800100 Electric motor i e fan motor MO A0905100 Starter motor A0800000 PO dx Voltage outlet socket A1399400 R Rheostat i e instrument lighting A1399100 87A 87 Relay RE No control current on 86 85 contact position 30 87A 85 Control current on 86 85 contact position 30 87 RE 0906400 H Audible signal i e buzzer A1399600 SA SEES Audible signal i e horn A1399700 Temperature sensor i e engine oil temperature A0904700 Level sensor i e fuel level SE A09046
142. r maintenance or modification of the equipment voids this warranty The foregoing warranty is exclusive and in lieu of all other warranties express or implied All such other warranties including implied warranties of merchantability and of fitness for a particular purpose are hereby excluded No Dealer Sales Representative or other person purporting to act on behalf of MEC Aerial Platform Sales Corp is authorized to alter the terms of this warranty or in any manner assume on behalf of MEC Aerial Platform Sales Corp any liability or obligation which exceeds MEC Aerial Platform Sales Corp s obligations under this warranty Aerial Platforms Sales Corp 1775 Park Street Suite 77 Selma CA 93662 USA Ph 1 866 379 7278 559 263 9626 Fax 559 263 9631 www mecawp com
143. ressure to 159 bar 2306 psi by pressure limiting valve 5 The steering valve is of the type orbitrol The steering valve delivers a LS signal through the shuttle valves 4 The LS signal affects the priority valve 6 and the pressure regulator 2 Hydraulic pressure specifications Function at High idle Checking points Pressure according to MPa PSI hydraulic diagram Servo pressure PS port 3 0 5 435 73 30 5 Ap LS pressure Pump pressure PM LS port LS port 2 0 2 290 29 20 2 on manifold Pump pressure Boom and tilt PM port 24 0 5 3480 73 240 5 up Pressure regulator for brake ACC1M port 21 0 5 3046 73 210 5 accumulator Max pressure Pressure in brake accumulator ACC1M port 15 0 18 2 2176 2640 150 SE5 pressure 182 Pressure in brake accumulator ACC1M port 14 9 12 8 2161 1856 149 SE5 Min pressure 128 Precharge pressure in brake Port on accumulator 4 83 0 24 700 35 48 3 42 4 accumulator 70 F Steering pressure limiting valve LS port 15 9 0 5 2306 73 159 5 Steering pressure regulator PM port 17 5 2538 175 Pressure limiting valve for Boom PM port 17 5 2538 175 down Tilt down Extend and Extra hydraulic outlet Frame level Hydraulic diagram complete Pump Pressure regulator Pressure limiting valve max pressure 240 b
144. rged after three months Therefor always store batteries as cool as possible 13 14 Battery charging WARNING During battery charging hydrogen gas is formed Hydrogen gas is flammable and may be explosive A short circuit open flame or spark near the battery can cause a powerful explosion Therefore ventilate well Never smoke near bat teries WARNING The battery electrolyte contains corrosive sulphuric acid Electrolyte spilled on bare skin should be removed immedi ately Wash the affected area with soap and plenty of water If electrolyte gets into your eyes or any other sensitive body part rinse immediately with plenty of water and seek imme diate medical attention Batteries must only be charged using a battery charger Check the battery terminal connections and make sure that they are adequately tightened and free from corrosion and dirt Check the battery voltage when the batteries are at rest that is before starting Each battery must be at least half charged IMPORTANT Always disconnect the electric power to the bat tery charger before the charging clamps are removed 33 STARTING SYSTEM 330 General common info about 331 334 Starter motor specifikation Starter motor Voltage 12 VDC Power rating 3 kW Number of gear teeth 9 Starter motor description See TLH6 TH90 370 Wiring diagram T01 The starter motor MO 1 has a built in solenoid whi
145. rn the meaning of all the warning plates symbols and operating instructions before operating the machine A few simple safety rules General e Remedy faults or defects which affect the safety as soon as possible Always wear hard hat safety glasses gloves protective shoes and other protective articles when required Do not remain in front of or behind the machine while the engine is running To avoid unnecessary climbing on the machine use either a long handled rubber scraper or brush for cleaning the out sides of the windows When servicing the machine and for instance when chang ing bulbs a ladder may be necessary Make sure that stepping surfaces service areas handles and anti slip surfaces are free from oil diesel fuel dirt and ice and that they are changed if they are damaged or miss ing e Check at regular intervals that all anti slip items are securely fitted If this is not the case they should be secured or replaced When you are entering or leaving the machine always face the machine and use the steps and hand holds Always use both hands and one foot or both feet and one hand Do not jump Before operating Read the Operator s Manual before you operate the machine Follow the operating instructions in the Opera tor s Manual and carry out the measures which are detailed in the manual before operating A few important rules are given below Make a control lamp test before startin
146. rt key fuse MO Motor MO 1 Starter motor 325 OR 609 GFSM GC GE GF 353 553 58 100 radio T 5 210 30 15 300 30 i P 600 pe BL 7 lt 231 rey GN swe 611 86 Fig 1 122 lt 60 7 T01 V1022101 Wiring diagram T02 SW Switch SW5 Coolant level switch RE Relays RE2 Preheating relay FU Fuse Fuses in fuse box FU2 Preheater relay FU Fuse Fuses in batte ry compartment FU 18 Preheater fuse HE Heating coils HE 1 Preheater SE Temperature sensors monitors SE2 Coolant temperature SE 9 Fuel indicator SE Pressure sensors monitors SE6 Engine oil pressure SE7 Air filter pressure MA Solenoid valves MA 1 Engine governor MA 7 Fuel stop valve 12 JD JF SE6 9 gt Bea SE7 3 1 1 El ye 1022102 Fig 2 13 Wiring diagram R Resistor R 1 Battery charging light FU Fuse Fuses in fuse box FU5 Hour meter LED Indicators LED 11 Preheater lamp LED 12 Water temp LED 13 Engine oil pressure LED 14 Air filter pressure LED 15 Transmission oil pressure LED 17 Battery charging light LED 20 Axle lock LED 22 High beam SA Sounders SA 3 Warning buzzer
147. rward insta bility resulting in machine tip over NOTE If the boom already is in a horizontal position it must be retracted with a winch 1 Secure the risk zone around the machine from unauthorized persons Remove load and secure the machine Block the wheels Secure the boom with a suitable stand or packing Open the rear hatch on the machine Y Loosen the lock nut on the extend cylinder counterbalance valve Turn the socket head screw clockwise until the boom retracts 10 V1025175 Fig 4 Section of main valve manifold 1 Pressure port PM V1025176 Fig 5 Lift cylinder valve block 1 Nipple 11 WARNING Risk of injuries from crushing There is no working clearance between the boom and frame when the boom is lowered 7 Support the front end of the boom with a suitable lifting device and remove the stand or packing 8 Attach a minimess hose to the pressure nipple port PM on the hydraulic main valve manifold 9 Attach the other end of the minimess hose to the nipple on the lift cylinder valve block The boom will lower very slowly NOTE The extend cylinder counterbalance valve must be replaced after the setting has been altered to retract the boom Contact a workshop authorized by MEC Hydraulic System Repair Instructions p PRELIMINARY DOCUMENT Contents 91 WORKING HYDRAULICS SERVO HYDRAULICS 914 Servo hydraulic system Pressure limiting valve Pres
148. s a general description ofthe machine Under general there are des criptions and functional des criptions concerning the entire section Function descriptions for respec tive section are found in function group order in separate booklets Ex Section 2 FUG 20 27 Des criptions engine SECTION 1 SERVICE AND MAINTENANCE Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group In section 1 there is a brief description of the rules that apply to service and mainte nance work Complete instructions for performing ser vice and maintenance are included in the Operator s Manual as well as service and maintenance manual Not described METHODS Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group Not described Describes removing and moun ting of components as well as repairs adjustments and checks that can be performed on the machine RECONDITIONING OF COMPONENTS Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group Reconditioning of components and inclu ded parts are described in separate ser vice manuals Component manuals are available for the engine
149. s risk of overturning The cab constitutes the protection for the operator and it meets the requirements for Roll Over Protective Structure ROPS according to the testing standard for this See further under CE marking A condition for the protection is that the operator is wearing the seat belt and that he or she remains in the cab if the machine should roll over 21 Fig 11 Do not overload lifting or supporting equip ment 22 Falling objects The cab is dimensioned to meet the standards required against objects falling onto the cab roof in accordance with stated testing methods FOPS See further under CE marking Emergency exits from cab Rear window Safety when lifting and supporting the machine NOTE The jack must always be relieved of weight bearing with axle stands under the raised axle before the wheel is removed When lifting or supporting machine parts use equipment with a lifting capacity that equals at least the weight of the part in question Alllifting devices such as straps slings ratchet blocks must comply with governing national regulations for lifting devices We will not accept any responsibility if any lifting devices tools or work methods are used other than those described in this publication e Ifa jack is to be used make sure that the ground or floor is even and is sufficiently firm or strong to support the expected load Prevent the machine from rolling by applyin
150. sition momentary switch Raises and lowers the right stabi lizer on machine so equipped Frame level Three position momentary switch Allows the operator to level the frame before elevating the boom Heater fan Two position switch Turns on the heater fan on machine so equipped 41 1015052 D lt a a R lt gt e A c lt a o lt a 5 3 e V1015046 A1345700 io A1346100 2 a a o A1345400 Vv lt a a gt BK o N Indicator lights Hydraulic oil filter Hydraulic oil temperature Brake pressure Parking brake engaged Oil temperature Oil pressure Water temperature Transmission oil temerature Air filter Glow on plug only at start up Charging system Turn signal High beam lights Hazard lights Power Transmission Description p PRELIMINARY DOCUMENT Contents 40 GENERAL 400 General common info about 410 436 Transmission Drop box specifications assie eee nl 42 TRANSMISSION HYDRAULIC CONTROL 420 General Transmission temperatures and pressures Transmission OVerVvieW cast ee etae eae E Fe E Ta RN ge Ld Converter
151. ssure build up Pressure build up servo system uunsssssnnnennnesnnnnnnnennnnnnnnennnnnn nenn Pressure build up Hydraulic pressure specifications sse Hydraulic diagram complete ooooccocococccococccoccconcnocnnonnnnnoncnnnonnnnnnnnnnnnannannnnnns Cylinder repalr eee Lec Re di o e F ch Disassemblyi xii teet C eee Te ata ERR een tpe M 91 WORKING HYDRAULICS SERVO HYDRAULICS 913 Pump working hydraulics Hydraulic pump Hydraulic pump description 94 UNIT LOAD HANDLING 940 General common info about 941 945 Retracting and lowering the boom without hydraulic power HYDRAULIC SYSTEM DIGGING HANDLING GRADING EQUIPM MISC EQUIP 90 GENERAL 900 General Hydraulic system description The machine is equipped with a load sensing hydraulic system LS system This system is equipped with a fixed displacement gear pump The boom and attachment tilt functions are flow sharing in case the flow demand is greater than what the pump can deliver the flow is divided proportionally according to the operator s lever movements The hydraulic oil tank is common to hydraulic system and steer ing system It is provided with
152. sure settings limiting id tH de HYDRAULIC SYSTEM DIGGING HANDLING GRADING EQUIPM MISC EQUIP 91 WORKING HYDRAULICS SERVO HYDRAULICS 914 Servo hydraulic system Pressure limiting valve Pressure settings limiting valve Tools 11666020 Manometer 0 250 bar 14290262 Adapter Minimess 14290266 Hose Servo pressure 1 Putthe machine in service position 1 see TH60 TH80 191 Safety rules when servicing 2 the hydraulic system until the oil temperature is 38 50 100 F 122 F WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 3 Open the rear cover to get access to the hydraulic valve 4 Connect the pressure gauge to pressure nipple PS The nipple is located to the left side of the main valve 5 Start the engine and run at 2500 rpm Lower the boom until stroke end and keep it under pressure 6 Read the pressure gauge Correct maximum pressure is 30 5 Bar 435 72 PSI 7 The servo pressure is not adjustable Replace cartridge and measure the servo pressure again to verify is correct 8 Remove the pressure gauge and close the rear cover Hydraulic System Diagrams p PRELIMINARY DOCUMENT Contents 94 UNIT LOAD HANDLING 942 Boom load handling Boom extend cylinder and chains removal and
153. t after a fire or heat exposure If a machine has been damaged by fire or been exposed to intense heat the following precautionary measures according to the following check list must under all circumstances be fol lowed Asa precaution seal rings O rings or axle shaft seals should always be handled as if they were made of fluor rubber see also section Fluor rubber Dowsing Avoid splashing when washing a machine damaged by fire For this reason never use high pressure washing equipment Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to con tact with melted polymers First wash thoroughly with plenty of lime water a solution or a suspension of calcium hydroxide i e slaked lime Use thick protective gloves made of rubber and wear gog gles that are certain to protect your eyes e Seek medical attention if your skin may have come in con tact with burnt fluor rubber The skin should be treated with Hydrofluoric Acid Burn Jelly or similar Symptoms may not appear until several hours after contact with burnt fluor rubber Discard protective gloves rags and other items that may have come into contact with burnt fluor rubber 29 30 CE marking and declaration of conformity Only applies to machines marketed within the EU EEA This machine is CE marked This means that when delivered the machine meets the applicable Essential Health and Safety Requ
154. t cylinder Remove the rear end lock screw and the pin Lift the cylinder out from the machine and put it on a work bench Weight of lift cylinder 200 kg 440 Ib 7 TH60 TH80 900 Cylinder repair for instructions to repair the cylinder V1014780 Fig 108 Installation 8 Secure the lift cylinder with at least two slings and lift into the machine Weight of lift cylinder 200 kg 440 Ib 9 Install the rear end pin Use a driver and the holes the frame for better access 1014783 Fig 109 49 10 Connect the hoses according to previous marking and install the lock screw Fig 110 11 Position the front end of lift cylinder and install the front end pin Secure the lock screw with Loctite 242 V1014823 Fig 111 50 Tilting cylinder incl mountings Tilt cylinder removal and installation Put machine in service position 1 see TH60 TH80 191 Safety rules when servicing Removal 1 Secure the tilt cylinder with a sling and remove the retaining ring from the upper cylinder support IMPORTANT Plug all pipes hoses and connections when removing 2 Liftor pull the cylinder slightly forward for better access to the hydraulic hose connections Remove the hoses V1014571 3 Remove the locking screw and drive the pin out from the ms 9 tilt cylinder a 2 4 gt V1014613 Fig 113 4 Lift the tilt cylinder out from the boom Cylinder weight 55 kg 1
155. t from the boom section 2 ZY O Y V1014596 N Fig 14 22 Remove the set screws for the chain guide roller pin V1014603 23 Drive the pin out with a hammer and a driver E 9s li ae ISS 1014604 24 Remove the pin and chain guide roller V1014606 25 Remove the retraction chain adjustment nut and it s fasten ing plate K p V1014599 Fig 18 26 Attach rope to the chain rod end A nut with a welded washer can be of great help The rope is used as guide when the new chain is installed NX ME a 27 Liftup the chain block and pull out the retraction chain at the rear end of the boom assembly 28 sure that the is kept in between the boom sec tions 1 and 2 lz ARAS Ta Lr Y Bali 1014602 10 Y 1014605 Fig 21 pm V1014599 V1014606 Installation Inspect and make sure that both chains and chain guide rollers are in good condition according to instructions in Boom chains and chain guide rollers wear inspection page 43 29 Attach the retraction chain to the rope between the boom sections 1 and 2 30 Lightly lubricate the chain with motor oil as it is inserted and pull until the chain anchor comes out the front end NOTE Lubricate the chain with multigrade SAE 20W 50 oil while installed
156. ted of being damaged should not be inflated with the wheel attached to the machine Fitting of tyres and rims Handling of tyres should be performed by authorised per sonnel only The tyre should be deflated before removal from the machine Never install a tyre on a rim that has not been recom mended for that tyre Never assemble rim parts for different dimensions or use damaged or faulty parts Exercise caution if using reconditioned wheel details Weld ing errors faulty heating or soldering may have weakened the parts and may cause the detail to break Make sure the lock ring groove in the rim is cleaned from foreign matter and rust before fitting the lock ring Use a lubricant recommended by the tyre manufacturer when fitting onto the rim 31 32 Repairing tyres and rims Never cut weld nor heat the wheel parts in any manner Exercise caution when using bead breakers and hydraulic jacks Remain outside the hazard zone when removing for eign objects from the tyres A bead breaker that releases can cause severe personal injury and may result in death Working on the electrical system of the machine Onlyuse test instruments with a light emitting diode never a test light with a light bulb for example during trouble shooting of the electrical system The high firing voltage of the bulb can destroy expen sive electronic components When installing a two way radio mobile phone etc i
157. ter recovering towing 1 Park the machine on a level surface 2 Apply the parking brake 3 Block the wheels to prevent the machine from rolling 13 T 60 Q Fig 4 Rear view 1 14 Counterbalance valve V1025174 Retracting and lowering the boom without hydraulic power Op no Tools Minimess hose NOTE In case of loss of hydraulic power it can be necessary to retract and lower the boom manually NOTE The boom must be retracted first and then lowered Low ering the boom while its still extended may cause forward insta bility resulting in machine tip over NOTE If the boom already is in a horizontal position it must be retracted with a winch 1 Secure the risk zone around the machine from unauthor ized persons Remove load and secure the machine Block the wheels Secure the boom with a suitable stand or packing Open the rear hatch on the machine a NM Loosen the lock nut on extend cylinder counterbalance valve Turn the socket head screw clockwise until the boom retracts WARNING Risk of injuries from crushing There is no working clearance between the boom and frame when the boom is lowered 7 Support the front end of the boom with a suitable lifting device and remove the stand or packing 8 Attach a minimess hose to the pressure nipple port PM on the hydraul
158. th high and low boom versions Drive in the new bearing by using the tools handle 11667001 and drive plate 11667060 30 Boom sections installation 49 Grease the thrust washers use the adhesitivity from the grease and fix them on the inner side of the main frame 220 1014802 Boom section 1 installation 50 Secure boom section 1 with two lift slings and lift into place in the main frame Drive the main pin in and secure with locking screws 1014803 Fig 71 51 Lower the boom till the upper supports for the slave cylin ders are in line with the holes in the main frame Attach the slave cylinders and drive the pins in Secure the pins with locking screws l V1014821 Fig 72 C 31 52 Raise the boom to a suitable height and install the front end of the lift cylinder V1014822 53 Drive the pin in and secure the lock screw with Loctite 242 C 54 Support the boom in a level position V1014823 Fig 74 55 Reinstall the oil supply tubes along the boom section 1 V1014825 32 Fig 76 V1014682 Boom section 2 installation NOTE All wear pads should be tightened to a torque of 54 Nm 39 Ibf ft if nothing else is stated All bolts should be secured with Loctite 242 All pads must be greased with a NLGI Grade 2 grease NOTE Preferably install new wear pads in all positions when reinstalling Each boom wear pad is chamfered at each end This is designed as a wear indic
159. the machine 18 Safety for work on hydraulic systems The hydraulic systems in our TL 70 90 work at very high pressures up to approx 25 MPa 250 bar 3626 psi In order to prevent serious personal injuries it s important that the systems are maintained correctly and that all per sons who come into contact with the machines are very careful and very alert to any defects Those who follow the simple rules below have laid a good foun dation for accident prevention General Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer Ahydraulic hose that swells for example at a connection indicates that it s about to burst Replace the hose as soon as possible Pay attention to leaks from hydraulic hoses and connections Repair the leakage before the part bursts e Scrapped accumulators Empty the accumulators gas and remove the gas valve Plug the oil port NOTE It is dangerous to disconnect the gas valve when the accumulator is pressurized A WARNING If the pressure is not released before opening the system oil under high pressure will jet out resulting in serious per sonal injuries Pressure release When the engine has been stopped there remains an accu mulated pressure in the system 14 5 MPa 145 bar 2100 psi The remaining pressure in the system must be lowered so called depressurization releasing pressure before hose connections plugs etc are ope
160. the batteries are not fully charged they shall be charged or replaced During battery charging the cable connections shall always be removed from the battery When replacing batteries connected in series these shall have the same capacity for example 170 Ah The batter ies should be of the same age equivalent The reason for this is that the charging current needed to charge the battery to a certain voltage changes with the age of the battery Only batteries may used for assisted auxiliary starts Starter units and or batteries connected in series may cause excessive voltage and may seriously damage elec trical components Electrical system special instructions for servicing electrical components alternator and charging regulator Before any alternator or regulator tests are performed the batteries and electrical cabling must be checked for insula tion loose connections and corrosion Check the alternator belts All defects according to the above must be corrected before starting any electrical testing Check the alternator belt and if needed make any neces sary adjustments repairs before troubleshooting At correct belt tension the belt should give when pressure is applied to it IMPORTANT Always connect cabling in a safe manner and make sure that cables are free from rust dirt A discon nected cable may cause damage to both alternator and charging regulator IMPORTANT Never disconnect the alt
161. the engine block Y E y A 7 LT Lan DN II WE gt A i EN V1020304 Fig 20 1 Ground point 21 Disconnect the engine electrical harness CN1 from it s con 1 necting point at the main frame Y NOTE The weight of engine transmission installation including radiator and hydraulic tank is 1000 kg 2200 Ib S B ua V1020305 Fig 21 1 Engine wiring harness 22 Use EUR pallets on top of each other or similar as a sub frame to put under the hydraulic tank assembly Lift until the subframe slightly lifts the tank assembly V1020306 Fig 22 23 Loosen the nuts holding the tank assembly to the main frame Adjust the height so the bolt brackets come loose 1020307 Fig 23 24 Lift and pull out the hydraulic tank assembly V1020271 14 V1020271 Engine and transmission removal from the hydraulic tank assembly Op no To be able to remove the engine and transmission from the hydraulic tank assembly its necessary to perform the proce dures shown in Engine and transmission assembly removal from main frame page 5 WARNING Risk of injuries caused by crushing 1 Put the engine frame assembly on a level and solid sur face Remove the radiator hoses and the fan blade guard Remove the suction hose between hydraulic tank and hydraulic pump 4 O
162. the gap between boom 2 and 3 Tighten the hardware until the spacers are snug between the brackets The screw must be installed through both the brackets and the spacer 4 The extension chain adjusting bolt is located at the rear of the 1 boom Loosen the extension chain adjusting bolt while the retraction chain nut is tightened V1015092 Fig 104 1 Extension chain adjusting bolt 5 The retraction chain adjustment nut is located beneath the first boom section Tighten the retraction chain adjustment nut to 35 Nm 25 Ibf ft Tighten the extension chain adjusting bolt to 70 Nm 50 Ibf ft Remove the spacers from between the brackets and install them in their original position facing forward on boom section 3 V1015093 Fig 105 2 Retraction chain adjustment nut 47 Fig 106 1014694 V1014779 Fig 107 48 945 Lifting frame work with mounting and link arm system Lift cylinder incl mountings Lift cylinder removal and installation Removal 1 Put the machine in service position 2 See TH60 TH80 191 Safety rules when servicing 2 Secure the lift cylinder with at least two slings NOTE Plug all tubes hoses and connections while removing WARNING Be careful when removing the cylinder risk of crushing injuries 3 Remove the front end lock screw and 4 Tag and remove the hydraulic hoses from the lif
163. the machine in service position 1 See TH60 TH80 191 Safety rules when servicing 2 Clean area around the oil level plug on the transfer case 2 1 2 then remove the plug The oil should be in level with the bottom of the threads E 9 10 Ld gr 3 5 V1014929 Fig 2 V1014929 1 Fill plug 2 Oil level plug 4 Clean the area around the fill plug before removing it to add oil Fill if necessary with oil according to the MEC specifi cations shown in TH60 TH80 160 Recommended lubri cants oils Fill to the bottom of the threads NOTE Use of oil with the wrong specifications will cause brake noise and may prematurely wear the brake components Clean and install the plug Planetary reduction hubs oil filling 1 2 Fig 3V1014937 Put the machine into service position 1 See TH60 TH80 191 Safety rules when servicing To properly check the oil level the plug must be on the hor izontal centerline of the hub Clean the area around the plug on the hub then remove the plug Fill if necessary with oil according to specification shown in TH60 TH80 160 Recommended lubricants oils to the bottom of the threads Clean and install the plug Repeat the procedure for the other three planetary reduc tions hubs 461 Front axle Front axle specification
164. ther necessary safety items that your work requires Always turn off the engine when servicing the machine unless instructions on signs and plates or in this manual state otherwise Turn off the engine before opening engine covers radiator covers and similar Make sure that no tools or other objects that can cause damage are forgotten in the machine When changing oil in the engine hydraulic system or trans mission keep in mind that the oil may be hot and can cause severe burns Working under raised boom Always secure the boom with safety strut before beginning any work Safety when working with batteries Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine In addition batteries give off hydrogen gas when they are loaded supplying electricity or being charged Together with the oxygen in the air hydrogen gas forms a very explosive mixture This combination corrosive acid and explosive gas means a high risk of accidents during all work with batteries used in vehi cles Therefore it is very important that you take great care and follow the rules below when you are working with batteries 25 Fig 16 Do not smoke near batteries 26 Follow these instructions when charging batteries Batteries give off explosive gases Never smoke near bat teries Begin by disconnecting the ground lead when removing a battery In order to reduce the risk of sparks th
165. transmission dropbox axles as well as air conditioning Not described TROUBLESHOOTING Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group Section 3 electrical and information sys tem Section 3 summarizes alltypes of diagnostic information Description of troubleshooting methodo logy All warnings and error codes troubleshoo ting using error codes All control units 5 control units are descri bed Description of software and all software functions All parameters that can be set in the soft ware are specified All malfunction symptoms are listed with reference to respective section function group In respective section under General there is a brief des cription of troubleshooting with reference to section 3 in appli cable cases Basic checks for engine Sec tion 2 and Transmission Sec tion 4 are described Control units ECU for engine E ECU and transmission T ECU are described in section 2 and 4 respectively Performance check for engine is described in section 2 Symptom troubleshooting and methods are described under respective function SERVICE TOOLS Common information for all function groups Separate information in respective section S 0 9 Separate information under respective function group
166. trolyte spilled on bare skin should be removed immedi ately Wash the affected area with soap and plenty of water If electrolyte gets into your eyes or any other sensitive body part rinse immediately with plenty of water and seek imme diate medical attention 22 Install the battery hatch and connect the battery terminals Connect negative terminal as the last one 23 Install the exhaust pipe to the exhaust manifold Make sure that the exhaust pipe is in a horizontal position and no stress is put to the flexible section 27 24 Put the engine hood in place NY ali 1 Y 1020288 25 Reinstall the hinges and connect the gas spring at it s upper ball joint 1020287 Fig 64 V1020287 1 Hinges 2 Gas spring 26 Bleed the fuel system if required See operators manual for instructions 27 Start the engine and control all functions Inspect for any liquid leakage Run the engine till it s operating tempera ture Turn off the engine and allow to cool down WARNING Open the radiator cap carefully ifthe engine is warm High pressure in the radiator may cause hot coolant to jet out 28 Inspect all fluid levels and refill if necessary See operators manual for instructions 28 Fig 66 1 9998678 2 Dial gauge 3 Spacer washers CS V1010615 211 Cylinder head Cylinder design structure The D4D with a bore about 101 mm has a crankcase with inte grated
167. uirements are met the machine is supplied with an EU Declaration of Conformity issued by MEC Construc tion Equipment for each individual machine This EU declaration also covers attachments manufactured by MEC The documentation is a valuable document which should be kept safe and retained for at least 10 years The docu ment should always accompany the machine when it is sold If the machine is used for other purposes or with other attach ments than described in this manual safety must be maintained at all times and in each individual case The person carrying out such action is also responsible for the action which in some cases may require a new CE marking and the issue of a new EU Declaration of Conformity EU EMC Directive The electronic equipment of the machine may in some cases cause interference with other electronic equipment or the equip ment may be adversely affected by external electromagnetic interference which may constitute safety risks The EU directive Electromagnetic conformity provides a general description of what demands can be made on the machine from a safety perspective where permitted limits have been determined and given according to international standards A machine or device which meets the requirements should be CE marked Our machines have been specifically tested for electromagnetic interference The CE marking of the machine and the declaration of conformity also cover the
168. val from main frame 5 Engine and transmission removal from the hydraulic tank assembly 15 Transmission removal from removed engine 16 Transmission installation on removed engine 18 Engine and transmission installation to hydraulic tank engine frame assembly 20 Engine and transmission assembly installation to main frame 21 211 Cylinder head Cylinder design Structure eene nter 29 Cylinder head design nennen nennen nee 29 Determining cylinder head gasket sssssssss eene 29 Measuring piston projection nennen 29 Cylinder head Fitting eylinder headi iioc dam eee de aet iq tab p tag ede d 30 Tighitening Orders cedars cond das 31 214 Valve mechanism 32 Valve clearance adjustment eese 32 Adjustment cesado 32 215 Engine transmission camshaft Camshaft SCILICET 33 216 Crank shaft connecting rod vibration damper fly wheel Crankshaft 33 COME Cng TO mid 33 lj RL hen RR RE LEE Nr 34 Piston 34 22 LUBRICATING SYSTEM 220 General common info about 2
169. ver Protective Structure ROPS according to the testing standard for this See further under CE marking A condition for the protection is that the operator is wearing the seat belt and that he or she remains in the cab if the machine should roll over Falling objects The cab is dimensioned to meet the standards required against objects falling onto the cab roof in accordance with stated testing methods FOPS See further under CE marking Emergency exits from cab Rear window Safety when lifting and supporting the machine NOTE The jack must always be relieved of weight bearing with axle stands under the raised axle before the wheel is removed When lifting or supporting machine parts use equipment with a lifting capacity that equals at least the weight of the part in question All lifting devices such as straps slings ratchet blocks must comply with governing national regulations for lifting devices We will not accept any responsibility if any lifting devices tools or work methods are used other than those described in this publication e Ifa jack is to be used make sure that the ground or floor is even and is sufficiently firm or strong to support the expected load Prevent the machine from rolling by applying the parking brake and placing suitable wedges on both sides of the wheels which are not to be raised off the ground Always use a jack with sufficient lifting capacity and posi tion t
170. wer onto a suitable stand or packing placed under the third section 2 Loosen the wear pad securing bolts for the bottom pads Install enough shims so the clearance doesn t exceed 3 mm 0 125 in When adjusting the side wear pads install the shims as required to produce an equal gap between the boom sec tions at either side One side may require more shims than the other The total clearance must not exceed 3 mm 0 125 in 3 Secure the bolts with Loctite 242 and tighten to a torque of 54 Nm 39 Ibf ft 41 Boom section 2 upper rear wear pads The upper wear pads of boom section 2 can not be shimmed If they are worn beyond the specified clearance they must be replaced V1015097 Fig 94 4 Lower and retract the boom to the fully stowed position 5 Remove the upper wear pad retaining brackets and hard ware from the boom Insert a M8 screw length approximately 100 mm 4 in into the wear pads Use the screw as a handle remove the wear pads Install the new pads in the same manor and then remove the M8 screw once the pads are in place Install the retain ing brackets using the original hardware NOTE Torque hardware to 27 Nm 20 Ibf ft Boom section 3 upper rear wear pads 8 Loosen the wear pad retaining bolt and install enough shims so the clearance between wear pad and boom sec tion doesn t exceed 3 mm 0 125 in Secure the bolts with Loctite
171. xposure The following safety instructions must be followed Remove all paint by sand blasting at least 10 cm 4 in around the welding or cutting point use suitable breathing protection If the work area cannot be sand blasted remove the paint in another way for example with a paint remover solvent NOTE When using paint removers solvents use an air extractor breathing protection and protective gloves High speed grinding machines and grinding discs also heat the paint and must only be used if there s an air extractor on the grinding machine Use breathing protection as well 33 34 Rubber and plastics WARNING When heated rubber and plastics can give off gases which are dangerous to health and the environment The following safety instructions must be followed Do not weld or cut near polymer materials rubber and plastics without first protecting them from the heat Never burn polymer materials when scrapping them Becareful when handling machines that have been exposed to fire or other intense heat Also refer to Check list after a fire or other heat exposure Always use protective gloves protective glasses goggles and breathing protection Flour rubber WARNING Risk of serious corrosive injuries WARNING When hydrogen fluoride rubber is heated there is a risk of hydrogen fluoride gas build up already at approx 320 C 610 F When inhaled the gas is extremely
172. y electrolyte contains corrosive sulphuric acid Remove spilled electrolyte from the skin immediately Wash with soap and plenty of water If electrolyte has splashed into the eyes or on any other sensitive body part rinse immediately with plenty of water and contact a physician immediately Battery specifications System voltage 12 V Battery Parts no 11301737 Quantity 1 Ground connection Minus Battery capacity 170 Ah Battery disconnect switch connected on Minus side CCA 900 A Charge level Voltage Fully charged battery 12 7V Half charged battery 12 4V Discharged battery 11 6 V and lower Battery electrolyte density Fully charged battery 1 28 kg dm Battery should be recharged at 1 25 kg dm Battery description The machine is equipped with one battery that gives a total of 12 V with 170 Ah capacity The battery is located in the compart ment in back of the engine The battery should be in good condition when troubleshooting the electrical system If needed charge the battery with a battery charger see Battery charging When a battery is at rest there is a certain spontaneous dis charge which accelerates with increase in storage temperature A fully charged battery stored in a temperature of 20 C 4 F loses insignificant charge during a three month period If the same battery is stored at 20 C 86 F it is only half cha

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