TELEHANDER TH336 337 406 407 414 514 417C - CAT - Service

Service Manual
Models
TH336C, TH337C,
TH406C, TH407C,
TH414C, TH514C,
TH417C
S/N MJR00150 & After, S/N THM00150 & After,
S/N DJB00150 & After, S/N SXJ00150 & After,
S/N GAT00150 & After, S/N RCH00150 & After,
S/N MLH00150 & After, S/N JJT00150 & After,
S/N KEK00150 & After, S/N RWW00150 & After,
S/N MWC00150 & After, S/N KKW00150 & After,
S/N RRJ00150 & After, S/N RRW00150 & After
31200799
UENR6251-04
Revised
November 26, 2014
EFFECTIVITY PAGE
October 8, 2012 - A - Original Issue Of Manual

March 12, 2013 - B - Revised pages 1-4, 3-22, 3-23, 7-2, 8-5, 8-9, 8-10, 9-19, 9-20, 9-23 & 9-24.
October 8, 2013 - C - Revised page 2-11, 2-12, 2-14 thru 2-18, 3-27, 3-54, 3-56, 4-6, 4-7, 5-3, 7-1 thru 7-26, 8-5, 8-16,
8-18, 9-5 thru 9-22, 9-43, 9-44.
July 18, 2014 - D - Revised cover and pages 8-6 thru 8-10, 9-29.
November 26, 2014 - E - Revised pages 1-4, 2-3 thru 2-12, 7-3, 9-45, 9-46, 9-50, 9-51.
31200799 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C i

EFFECTIVITY PAGE
ii TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 31200799

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.6 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology - TH336C, TH337C, TH406C & TH407C . . . . 3-4
3.2 Boom System - Two Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Boom System Component Terminology - TH414C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.7 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation . . . . . . . . . . . . . . . 3-20
3.9 Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.10 Boom Sections Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.12 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.14 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation . . . . . . . . . . . . . . . 3-32
3.15 Tandem Extend/Retract Cylinders Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.17 Boom System - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.19 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.20 Boom Sections Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.21 Boom Extend and Retract Chains - TH414C & TH417C . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.22 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.23 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.24 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C i

3.25 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3.26 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.27 Boom Retract Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.5 Mechanical Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Hydraulic Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.8 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.9 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.10 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.11 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.12 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
ii TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.10 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.11 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.12 Boom Ride Control (TH336C, TH337C, TH406C, TH407C- If Equipped) . . . . . . . . . . . 8-25
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Keypad and Display Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.6 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.7 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.8 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.9 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.10 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.11 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.12 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.14 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.15 Platform Load System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.16 Load Stability Indicator (LSI) (CE & AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.19 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.20 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C iii

iv TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

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

All information in this manual is based on the latest
product information available at the time of publication. WARNING indicates a potentially hazardous situation
The manufacturer reserves the right to make changes which, if not avoided, could result in death or serious
and improvements to its products, and to discontinue the injury.
manufacture of any product, at its discretion at any time
without public notice or obligation.
CAUTION
1.3 OPERATION & MAINTENANCE
MANUAL CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
The mechanic must not operate the machine until the
injury.
Operation & Maintenance Manual has been read and
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
An Operation & Maintenance Manual is supplied with
each machine and must be kept in the manual holder
located in the cab. In the event that the Operation &
Maintenance Manual is missing, consult the local
Caterpillar dealer before proceeding.
1-2 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

Safety Practices
1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

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

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

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.3 Platform Hydraulic Performance Specifications . . . . . . . . . . . . . . . . . . . . 2-14
2.4.4 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.5 Engine Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.6 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.7 Transmission Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4.8 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.5 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.5.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.6 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.6.1 10 & 1st 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.6.2 50 & 1st 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.6.3 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.6.4 1000, 1500 & 3000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.6.5 6000 & 12000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.1 50 Hour Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.2 500 Hour Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.1 REPLACEMENT PARTS AND 2.2 THREAD LOCKING COMPOUND

WARRANTY INFORMATION
JLG P/N Loctite® ND Industries Description
0100011 242TM Vibra-TITETM121 Medium Strength (Blue)
1001095650 243TM Vibra-TITETM122 Medium Strength (Blue)
0100019 271TM Vibra-TITETM140 High Strength (Red)
0100071 262TM Vibra-TITETM131 Medium - High Strength (Red)
Loctite® 243TM can be substituted in place of Loctite®

242TM.
Vibra-TITETM 122 can be substituted in place of Vibra-
TITETM 121.
1
MZ6510
Before ordering parts or initiating service inquiries, make

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

2.3 TORQUE CHARTS
2.3.1 SAE Fastener Torque Chart

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

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

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

Values for Magni Coating Fasteners (Ref 4150701)

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


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


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

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

2.3.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Torque TM (Loctite® 242TM or
Tensile Stress Clamp Load (Loctite® 262 or
Size Pitch Torque (Lube) 271TM or Vibra-TITETM
Area See Note 4 (Dry or Loctite® 263TM) 271TM or Vibra-TITETM
111
131)
or 141)
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

2.3.2 Metric Fastener Torque Chart (Continued)

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

Values for Magni Coated Fasteners (Ref 4150701)*

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

Values for Magni Coated Fasteners (Ref 4150701)*

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

2.3.3 Hydraulic Hose Torque Chart Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 4 Nm (3 lb-ft).
18 Nm 18 Nm 38,1 to 44,5 mm 2. Mark a dot on one of the swivel nut flats and another
4
(13 lb-ft) (13 lb-ft) 1.5 to 1.75 in. dot in line on the hex of the adapter it’s connecting
31 Nm 31 Nm 25,4 to 38,1 mm to.
6
(23 lb-ft) (23 lb-ft) 1 to 1.5 in. 3. Use the double wrench method while tightening to
54 Nm 54 Nm 38,1 to 44,5 mm avoid hose twist.
8
(40 lb-ft) (40 lb-ft) 1.5 to 1.75 in. 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
81 Nm 81 Nm 38,1 to 44,5 mm
10 covering the dots indicating that the connection has
(60 lb-ft) (60 lb-ft) 1.5 to 1.75 in.
been properly tightened.
100 Nm 115 Nm 25,4 to 38,1 mm
12
(136 lb-ft) (85 lb-ft) 1 to 1.5 in.
156 Nm 156 Nm 19,0 to 25,4 mm
16
(115 lb-ft) (115 lb-ft) 0.75 to 1.0 in.
230 Nm 230 Nm 19,0 to 25,4 mm
20
(170 lb-ft) (170 lb-ft) 0.75 to 1.0 in.
271 Nm 271 Nm 19,0 to 25,4 mm
24
(200 lb-ft) (200 lb-ft) 0.75 to 1.0 in.
366 Nm 19,0 to 25,4 mm
32 N/A
(270 lb-ft) 0.75 to 1.0 in.
Note: By definition the “Flats Method“ will contain some

variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 4 Nm (3 lb-ft).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.

2.4 SPECIFICATIONS
2.4.1 Travel Speeds
Machine Maximum Travel Speed

4 Speed - 32 kph (19.9 mph)
TH336C, TH337C, TH406C & TH407C
6 Speed - 40 kph (24.9 mph)
TH414C 32 kph (19.9 mph)
TH514C & TH417C 34 kph (21.1 mph)
2.4.2 Hydraulic Cylinder Performance

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

FUNCTION
TH336C TH337C TH406C TH407C TH414C TH514C TH417C
Boom Extend (Boom Level) 4-6 3-7 4-7 5-8 10-13 16-19 22-26
Boom Retract (Boom Level) 4-6 3-7 4-6 5-7 10-15 18-21 15-25
Boom Lift 5-7 6-10 5-7 6-10 14-18 16-19 15-18
Boom Lower 3-5 5-8 3-6 5-9 8-13 9-12 9-12
Quick Coupler Raise 2-5 2-4 2-4 2-5 2-5 3-5 2-5
Quick Coupler Lower 2-5 2-4 2-4 2-4 2-5 3-5 3-6
Level - Full Right to Left N/A N/A N/A N/A 7-15 13-19 7-15
Level - Full Left to Right N/A N/A N/A N/A 7-12 10-16 7-15
Outrigger - Both Down N/A N/A N/A N/A 5-8 6-10 6-10
Outrigger - Both Up N/A N/A N/A N/A 4-9 5-9 5-9
Outrigger - Single Down N/A N/A N/A N/A 3-7 3-6 3-6
Outrigger - Single Up N/A N/A N/A N/A 3-7 4-6 3-6
2.4.3 Platform Hydraulic Performance Specifications
APPROXIMATE TIMES (seconds)

FUNCTION
TH414C TH514C TH417C
Platform Lift 31-60 31-60 39-60
Platform Lower 31-60 31-60 39-60
Platform Extend 19-35 19-35 27-43
Platform Retract 19-49 19-40 27-60
Platform Rotate 180° 14-35 14-35 14-35

2.4.4 Electrical System
Battery
Type, Rating 12 V, Negative (-) Ground, Tapered Top Post, Maintenance Free
Quantity 1 - (2 - If Equipped)
1 - 900 Cold Cranking Amps @ -18° C (0° F)
Cranking Performance
(2 - If Equipped), 1800 Cold Cranking Amps @ -18° C (0° F)
Group/Series BCI Group 31
74.5 kW - 12V, 100 Amps
Alternator
75 kW, 93.1 kW, 92.6 kW & 106 kW - 12V, 120Amps
74.5 kW, 75 kW, 93.1 kW - 12V, R4,2 KW
Starter
92.6 kW & 106 kW - 12V, R4,0 KW
2.4.5 Engine Fan Speed
Fan Type Fan Speed - High Idle Fan Hydraulic Pressure Oil Temperature
Hydraulic 2225 - 2275 RPM 205 - 215 bar (2973 - 3118 psi) 45°- 55°C (113°-131°F)
Belt Driven 2525 - 2575 RPM N/A N/A
2.4.6 Engine Performance Specifications
a. S/N MJR00150 & After, DJB00150 & After00150 & After, GAT00150 & After, MLH00150 & After,
KEK00150 & After, MWC00150 & After, RRJ00150 & After
Description 75 kW 92.6 kW 106 kW

Engine Make/Model CAT C3.4 CAT C4.4 CAT C4.4
Displacement 3,4 liters (207 in³) 4,4 liters (269 in³) 4.4 liters (269 in³)
Low Idle 845 - 855 rpm 795 - 805 rpm 795 - 805 rpm
High Idle 2295 - 2345 rpm 2295 - 2345 rpm 2295 - 2345 rpm
Power 75 kW @ 2200 rpm 92,6 kW @ 2200 rpm 106 kW @ 2200 rpm
410 Nm (302 lb-ft) @ 530 Nm (365 lb-ft) 560 Nm (365 lb-ft) @
Peak Torque
1400 rpm 1400 rpm 1400 rpm
Fuel Delivery Fuel Injection Fuel Injection Fuel Injection
Dry Type, Replaceable Dry Type, Replaceable Dry Type, Replaceable
Air Cleaner Primary and Safety Primary and Safety Primary and Safety
Elements Elements Elements

b. S/N THM00150 & After, SXJ00150 & After, RCH00150 & After, JJT00150 & After, RWW00150 & After,
KKW00150 & After, RRW00150 & After
Description 74,5 kW 93.1 kW

Engine Make/Model CAT C3.4 CAT C4.4
Displacement 3,4 liters (207 in³) 4,4 liters (269 in³)
Low Idle 900 - 1000 rpm 945 - 955 rpm
High Idle 2270 - 2370 rpm 2295 - 2345 rpm
Power 74.5 kW @ 2200 rpm 92,5 kW @ 2200 rpm
Peak Torque 410 Nm (302 lb-ft) @ 1400 rpm 530 Nm (365 lb-ft) @1400 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Dry Type, Replaceable Primary and
Air Cleaner
Safety Elements Safety Elements
2.4.7 Transmission Performance Specifications
a. S/N MJR00150 & After, DJB00150 & After00150 & After, GAT00150 & After, MLH00150 & After,
Engine Power Transmission Stall Speed

4 Speed 1945 rpm 2125 rpm
C3.4 75 kW
6 Speed 1945 rpm 2125 rpm
C4.4 92.6 kW 6 Speed 1810 rpm 1990 rpm
C4.4 106 kW 6 Speed 1900 rpm 2080 rpm
b. S/N THM00150 & After, SXJ00150 & After, RCH00150 & After, JJT00150 & After, RWW00150 & After,
Engine Power Transmission Stall Speed

C3.4 74.5 kW 4 Speed 1872 rpm 2070 rpm
C4.4 93.1 kW 6 Speed 1814 rpm 2004 rpm

2.4.8 Tires
Note: Standard wheel lug nut torque is 360 ±20 Nm (265 ±15 lb-ft) for TH336C, TH337C, TH406C, TH407C &
TH414C machines. Standard wheel lug nut torque for TH514C & TH417C machines is 460 ±20 Nm (340 ±15 lb-ft).
Note: Pressures for foam filled tires are for initial fill ONLY.
a. TH336C, TH337C, TH406C & TH407C
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
Pneumatic 4,0 Bar (58 psi)
Approx 264 kg
Foam Filled
15.5-25 L-2 16 Ply (582 lb)
Approx 4,6 L
Liquid Filled
(155 oz)
15.5/80-24 TR01 16 Ply Approx 6,0 L
Liquid Filled
(200 oz)
15.5/80-24 SGI 14 Ply Approx 6,0 L
Liquid Filled
(200 oz)
460/70R24 XMCL N/A Approx 6,4 L
Liquid Filled
(215 oz)
500/70R24
XMCL N/A Approx 6,5 L
(TH337C & TH407C only) Liquid Filled
(220 oz)
400/80-24 Power CL N/A Approx 6,0 L
Liquid Filled
(200 oz)
440/80-24
Power CL N/A Approx 6,4 L
(TH337C & TH407C only) Liquid Filled
(215 oz)

b. TH414C

Star Rating
15.5/80-24 TR01 16 Ply Approx 6,0 L
Liquid Filled
(200 oz)
15.5-25 L-2 12 Ply Approx 4,6 L
Liquid Filled
(155 oz)
400/80-24 Power CL N/A Approx 6,0 L
Liquid Filled
(200 oz)
440-80-24 Power CL N/A Approx 6,4 L
Liquid Filled
(215 oz)
c. TH514C & TH417C

Star Rating
Foam Filled Approx 264 kg
14-24 TG02 16 Ply (ANSI only) (582 lb)
Approx 4,6 L
Liquid Filled
(155 oz)
Foam Filled Approx 264 kg
14-24 SGG-2A 16 Ply (ANSI only) (582 lb)
Approx 4,6 L
Liquid Filled
(155 oz)

2.5 FLUIDS AND LUBRICANT

CAPACITIES
a. Fluids
S/N MJR00150 & After, DJB00150 & After00150 & After, GAT00150 & After, MLH00150 & After,
Ambient Temperature Range

Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
SAE 0W-20 -22 50 -30 10
SAE 0W-30 -22 86 -30 30
SAE 0W-40 -22 104 -30 40
CAT DEO ULS SAE 5W-30 -13 86 -25 30
Engine Crankcase
API CJ-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
SAE 10W -4 104 -20 40
Hydraulic System CAT HYDO Advanced
SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
SAE 30 32 95 0 35
Transmission and
CAT TDTO SAE 50 50 122 10 50
Transfer Case
SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
Axle Differential* CAT TDTO
SAE 30 -4 104 -20 40
and Wheel End TO-4
Cylinder, Boom
Wear Pad and CAT Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Axle Grease
CAT Extended Life Coolant
Engine Coolant 50/50 Mix
(ELC)
Fuel #2 Diesel Ultra Low Sulfur (S < 15 mg/kg)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (197-0017) required for front axle differential.

S/N THM00150 & After, SXJ00150 & After, RCH00150 & After, JJT00150 & After, RWW00150 & After,
Ambient Temperature Range

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

Engine Crankcase
API CI-4 SAE 5W-40 -13 122 -25 50
SAE 10W-30 -4 104 -20 40
SAE 10W-40 -4 122 -20 50
SAE 15W-40 14 122 -10 50
SAE 10W -4 104 -20 40
Hydraulic System CAT HYDO Advanced
SAE 30 50 122 10 50
SAE 10W 0 95 -18 35
SAE 30 32 95 0 35
Transmission and
CAT TDTO SAE 50 50 122 10 50
Transfer Case
SAE 5W-30 -22 68 -30 20
SAE 0W-20 -40 68 -40 20
Axle Differential* CAT TDTO
SAE 30 -4 104 -20 40
and Wheel End TO-4
Cylinder, Boom
Wear Pad and CAT Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Axle Grease
CAT Extended Life Coolant
Engine Coolant 50/50 Mix
(ELC)
Fuel #2 Diesel Low Sulfur (S < 500 mg/kg)
Air Conditioning Refrigerant R-134a Tetrafluorethane
Note: Friction Modifier (197-0017) required for front axle differential.

2.5.1 Capacities
Engine Crankcase Oil

Capacity with Filter Change
74.5 kW 8,5 liter (9.0 quart)
75 kW 8,0 liter (8.5 quart)
92.6 kW & 106 kW 8,8 liter (9.3 quart)
93.1 kW 9,5 liter (10.0 quart)
Fuel Tank
Capacity 150 liter (39.6 gallon)
Cooling System
System Capacity
75 kW & 16,0 liter (16.9 quart)
74.5 kW, 92.6 kW, 93.1 kW & 106 kW 25,0 liter (26.4 quart)
Transmission System
Capacity with Filter Change 14 liters (14.8 quarts)
Transmission Drop Box
Capacity 2,75 liter (2.9 quart)
Hydraulic System
System Capacity
TH336C, TH337C, TH406C & TH407C 135 liter (35.7 gallon)
TH414C, TH514C & TH417C 145 liter (38.3 gallon)
Reservoir Capacity to Full Mark 90 liter (23.8 gallon)
Auxiliary Hydraulic Circuit Max Flow 80 lpm (21.1 gpm)
Axles
Differential Housing Capacity - Front Axle
TH336C, TH337C, TH406C & TH407C 10,5 liter (11.1 quart)
TH414C, TH514C & TH417C 11,5 liter (12.2 quart)
Differential Housing Capacity - Rear Axle 11,5 liter (12.2 quart)
Friction Modifier (197-0017) - Front Axle Differential 0,35 liter (0.37 quart)
Wheel End Capacity
TH336C, TH337C, TH406C & TH407C 0,8 liter (0.8 quart)
TH414C 0,9 liter (1.0 quart)
TH514C & TH417C 1,5 liter (1.5 quart)
Air Conditioning System (if equipped)
System Capacity 1,35 kg (3.0 lb)

2.6 SERVICE AND MAINTENANCE

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

Differential Oil End Oil Levels Chain & Tension Lug Nut
Level (TH414C & TH417C) Torque
MAM3460

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

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

Transmission Transfer Case Differential Oil End Oil Breather
Oil & Filter Oil
Clean Axle
Magnetic Oil
Plugs
MAM3470

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

Case Oil Level Fan Belt Differential Oil End Oil Levels Breather
Level
Check Boom Check Boom

Wear Pads Chain & Tension
(TH414C & TH417C)
EVERY
500
Change Fuel Change Engine Change Check Wheel Lubrication

Filters Oil and Air Filter Lug Nut Schedule
Filter Elements Torque
Check LSI
Calibration
(CE & AUS)
MAM3480

2.6.4 1000, 1500 & 3000 Hour
EVERY
1000
Change Change Check Change Change Axle

Transmission Transfer Case Air Intake Hydraulic Differential Oil
Oil & Filter Oil System Fluid & Filters
Change Wheel Clean Axle

End Oil Magnetic Oil
Plugs
EVERY
1500
Change
Crankcase
Vent Filter
EVERY
3000
Change Service Deisel Change Exhaust

Fan Belt Particulate After Treatment
Filter Sensor
(75 kW engine only)
MAM3490

2.6.5 6000 & 12000 Hour
EVERY
6000
or
3 Years
Add Engine
Coolant
Extender
EVERY
12000
or
6 Years
Change
Engine Coolant
MAM3500
Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance
Manual for additional information.

2.7 LUBRICATION SCHEDULES
2.7.1 50 Hour Lubrication
a. TH336C, TH337C, TH406C & TH407C
EVERY
50
A
B
A A
B
B B
B
B
B
A
A
A
A A A
A
A A
OAM2411

b. TH414C
EVERY
50
A
B
A
A A
A A
A A A A
B A
B
B B
B B
B
B A
A A
A
A
A
A
A
OAM2202

c. TH514C
EVERY
50
A
B
A A A A
A A A A
A B
B
B B
B B B
B
B B
B A
B
A
A A
A A
A
A
A
OAM2880

d. TH417C
EVERY
50
A
A
B
A A A A
A A A A
B B A
B B B B
A A
B B
B B B
B
A
B
B B
B
B
B B B
B B A
A
A B
A
A A
A A
A
OAM2891

2.7.2 500 Hour Lubrication
a. TH336C, TH337C, TH406C & TH407C
EVERY
500
C C
OAM2421

b. TH414C, TH514C & TH417C
EVERY
500
C C
OAM2212

Section 3
Boom
Contents

3.1 Boom System Component Terminology - TH336C, TH337C, TH406C & TH407C 3-4
3.2 Boom System - Two Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.1 Complete Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.3 Second Section Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.4 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.5 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.6 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.7 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.8 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.4 Boom System Component Terminology - TH414C . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6.2 Second and Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6.3 Third Boom Section and Extend/Retract Cylinder Removal . . . . . . . . . . . 3-15
3.6.4 Third Boom Section and Extend/Retract Cylinder Installation . . . . . . . . . 3-15
3.6.5 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . 3-17
3.7 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.2 Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.7.4 Extend Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation . . . . . . . . 3-20
3.8.1 Extend/Retract Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8.2 Extend/Retract Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.8.3 Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8.4 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.9 Extend/Retract Cylinder Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.9.1 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Boom
3.10 Boom Sections Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.10.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.11 Boom System Component Terminology - TH514C. . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.12 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.13.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.13.2 Second and Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.13.3 Tandem Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13.4 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13.5 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.13.7 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation . . . . . . . . 3-32
3.14.1 Extend/Retract Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.14.2 Extend/Retract Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.14.3 Tilt-Electrical/Auxiliary Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.14.4 Tilt-Electrical/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15 Tandem Extend/Retract Cylinders Removal/Installation . . . . . . . . . . . . . . . . . . . 3-34
3.15.1 Tandem Extend/Retract Cylinders Removal . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.2 Tandem Extend/Retract Cylinders Bleeding Procedure . . . . . . . . . . . . . . 3-35
3.15.3 Tandem Extend/Retract Cylinders Installation . . . . . . . . . . . . . . . . . . . . . 3-36
3.16 Boom System Component Terminology - TH417C. . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17 Boom System - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.18.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.18.2 Second, Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . 3-40
3.18.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.18.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.18.5 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.18.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.18.7 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.18.8 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.18.9 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . 3-44
3.19 Boom Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.20 Boom Sections Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.20.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.21 Boom Extend and Retract Chains - TH414C & TH417C. . . . . . . . . . . . . . . . . . . . 3-49
3.21.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.21.2 Inspection Guidelines - TH414C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3.21.3 Inspection Guidelines - TH417C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3.21.4 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.21.5 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.22 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.22.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.22.2 Boom Wear Pad Installation/Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Boom
3.23 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3.23.1 Quick Coupler Removal (TH336C, TH337C, TH406C & TH407C). . . . . . 3-55
3.23.2 Quick Coupler Installation (TH336C, TH337C, TH406C & TH407C) . . . . 3-55
3.23.3 Quick Coupler Removal (TH414C, TH514C & TH417C) . . . . . . . . . . . . . 3-55
3.23.4 Quick Coupler Installation (TH414C, TH514C & TH417C) . . . . . . . . . . . . 3-55
3.24 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.25 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.25.1 Installation and Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.26 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.26.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.26.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.27 Boom Retract Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY - TH336C, TH337C,
TH406C & TH407C
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the boom system.
The following illustration identifies the components that
are referred to throughout this section.
PIVOT PIN
FIRST
BOOM
SECTION
SECOND
BOOM
SECTION
EXTEND/RETRACT
CYLINDER
TILT
CYLINDER
AUXILIARY HYDRAULIC
CONNECTIONS
QUICK COUPLER
LINK ASSEMBLY
MAM0600
QUICK
COUPLER

Boom
3.2 BOOM SYSTEM - TWO SECTION 3.3.1 Complete Boom Removal

While the boom sections can be separated from each
3.2.1 Boom System Operation other on the machine, it is much safer, more efficient and
more cost- effective to remove the complete boom
The boom operates via an interchange among the
assembly from the machine and place it on suitable
electrical, hydraulic and mechanical systems. Components
supports for separation. Work can then progress at a
involved include the joystick, tilt cylinder, extend/retract
normal working height.
cylinder, lift/lower cylinder, compensating cylinder,
various pivots, supporting hardware and other components. Note: When removing a complete boom assembly use
a hoist or crane with a minimum lift capacity of 2721 kg
3.3 BOOM ASSEMBLY MAINTENANCE (6000 lbs).
1. Remove any attachment from the quick coupler
The boom assembly consists of the first and second assembly. Refer to the Operation & Maintenance
section booms and supporting hardware. Manual.
Note: Before removing the boom or boom section, the 2. Park the machine on a hard, level surface, fully
carriage or any other attachment must be removed from retract the boom, Raise the boom to allow access to
the quick coupler. the lift/lower cylinder and the compensation cylinder
Before beginning, conduct a visual inspection of the pivot pins, place the transmission in (N) NEUTRAL,
machine and work area, and review the task about to be engage the park brake and shut the engine OFF.
undertaken. Read, understand and follow these 3. Place a Do Not Operate Tag on both the ignition key
instructions. switch and the steering wheel.
During service of the boom, perform the following: 4. Properly disconnect the battery.
1. Check wear pads. (Refer to Section 3.22.1, “Wear 5. Open the engine cover. Allow the system fluids to
Pad Inspection.”) cool.
2. Apply grease at all lubrication points (grease fittings). 6. Remove the quick coupler assembly. Refer to
Refer to Section 2.6, “Lubrication Schedule.” Section 3.23.1, “Quick Coupler Removal (TH336C,
3. Check for proper operation by operating all boom TH337C, TH406C & TH407C).”
functions through their full ranges of motion several 7. Remove boom angle sensor arm. Refer to Section
times. 9.12.7, “Boom Angle Sensor.”
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
WARNING
NEVER weld or drill the boom unless approved in
writing by JLG. The structural integrity of the boom 3 2
will be impaired if subjected to any repair involving 1
welding or drilling.
4
6 MAM0640
8. Support the boom by placing a sling around the

boom head. Support the lift/lower cylinder (1) and
remove the lock bolt (2) and then the rod end pin (3).
Lower the lift/lower cylinder onto the frame rails.

Boom
9. Support the compensating cylinder (4) and remove 4. Using suitable slings, balance the boom assembly,
the lock bolt (5) and then the barrel end pin (6). lift and carefully guide the boom into place. Align the
Lower the compensation cylinder onto the lift/lower frame pivot bore with the boom assembly pivot bore.
cylinder. Install boom pivot pin and lock bolt (7). Apply
10. Label, disconnect and cap the tilt and auxiliary Loctite® 242TM and torque to 90 Nm (66 lb-ft).
hydraulic hoses attached to the machine at the tubes
on top of the boom. Plug and cap the hose ends to
prevent dirt and debris from entering the hydraulic
system.
11. Label, disconnect and cap the hoses on the extend/
retract cylinder.
12. Lower the boom to a level position and place a
suitable support under the rear of the boom. 2
Reposition the slings to each end of the boom. 1 3
6 MAM0640
5. With the sling still in place, install the compensating

cylinder (4), pin (6) and lock bolt (5). Apply Loctite®
7
242TM and torque to 90 Nm (66 lb-ft).
MAM0671 6. With the sling still in place, install the rod end of the
lift/lower cylinder (1), pin (3) and lock bolt (2). Apply
13. Remove the lock bolt and pivot pin (7) from rear of Loctite® 242TM and torque to 90 Nm (66 lb-ft).
first boom section.
Note: Raising the boom up or down with the sling may
14. Lift the complete boom off machine and set on level be necessary so the boom, compensating and lift/lower
ground or supports being careful not to damage the cylinder bores can be aligned for easier pin installation.
tubes on the bottom of the boom.
7. Uncap and connect the previously labeled extend/
3.3.2 Complete Boom Installation retract cylinder hoses to the extend/retract cylinder.
Refer to Section 2.3.3, “Hydraulic Hose Torque
Note: Lubrication of the boom wear surfaces with CAT Chart,” for proper hose torque.
Multipurpose Grease is recommended to keep the boom
wear surfaces lubricated properly. Lubrication of the 8. Uncap and connect the previously labeled tilt hoses
boom wear surfaces is also recommended when the and (if equipped) auxiliary hoses to the appropriate
machine is stored, to help prevent rusting. cylinder. Refer to Section 2.3.3, “Hydraulic Hose
Torque Chart,” for proper hose torque.
1. Park the machine on a hard, level surface, place the
9. Install the boom angle sensor arm. Refer to Section
transmission in (N) NEUTRAL, engage the park
9.12.7, “Boom Angle Sensor.”
brake and shut the engine OFF.
10. Start the engine and operate all boom functions
2. Place a Do Not Operate Tag on both the ignition key
several times to bleed any air out of the hydraulic
switch and the steering wheel.
system. Check for fluid leaks. Check the hydraulic
3. Open the engine cover. Allow the system fluids to fluid level in the tank and add fluid as required.
cool.
11. Clean up all debris, hydraulic fluid, etc., in, on, near
Note: Grease the boom pivot bore, compensating and around the machine.
cylinder rod ends, lift/lower cylinder rod end and pins 12. Close and secure the engine cover.
before installing.
13. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.

Boom
3.3.3 Second Section Boom Removal Note: Tag each pad, backing plate, shim and bolts from
each location.
assembly. 1
2. Be sure there is enough room in front of the machine 2
to allow the boom sections to be removed. Park the
machine on a hard, level surface, fully retract the
boom, lower the boom, place the transmission in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
3. Place a Do Not Operate Tag on both the ignition key 1
MAM0620
4. Properly disconnect the battery.
5. Open the engine cover. Allow the system fluids to 12. Remove the retaining rings (1) from the rear of the
cool. extend/retract cylinder.
6. Remove the quick coupler assembly. Refer to 13. Remove the extend/retract cylinder mounting pin (2).
Section 3.23.1, “Quick Coupler Removal (TH336C,
TH337C, TH406C & TH407C).” Note: Tag each spacer and shim from each side of the
extend/retract cylinder.
7. Label, disconnect and cap the tilt hoses and (if
equipped) auxiliary hydraulic hoses attached to the 14. Support the front of the boom by placing a sling
machine at the boom head. Plug and cap the hose behind the boom head. Pull the second boom
ends to prevent dirt and debris from entering the section out of the first boom section approximately
hydraulic system. 15 cm to 20 cm (6 in to 8 in).
8. Place a sling around the tilt cylinder and remove the 15. Pull the tilt hoses and (if equipped) auxiliary
retaining rings and pin at the barrel end of the tilt hydraulic hoses through the rear of the boom.
cylinder. Remove tilt cylinder. 16. Remove the top, side and bottom wear pads from
the front of the first boom section.
7
Note: Tag each pad, backing plate, shim and bolts from
each location.
17. Pull the second boom section halfway out of the first
boom section, reposition the sling, balancing the
second boom section and remove from the first
boom section.
18. Set the second boom section on level ground. Set
the complete boom on suitable stands to begin tear
down.
19. Inspect the boom and welds. Consult the local
Caterpillar dealer if structural damage is detected.
MAM3990
20. Inspect hoses, hardware, wear pads, mounting
9. Disconnect and remove the boom retract sensor (7) points and other components visible with the first
from the rear of the first boom section. boom section. Replace any item if damaged.
10. Label, disconnect and cap the extend/retract 21. Inspect all wear pads for wear. (Refer to Section
hydraulic hoses on the extend/retract cylinder at the 3.22.1, “Wear Pad Inspection.”)
rear of the boom. Plug and cap the hose ends to
prevent dirt and debris from entering the hydraulic 3.3.4 First Boom Section Removal
system.
1. Temporarily connect the battery.
11. Remove the top and side wear pads from the rear of
2. Remove boom angle sensor arm. Refer to Section
the second boom section.
9.12.7, “Boom Angle Sensor.”

Boom
3. Start the machine and raise the first boom section to

gain access to the lift cylinder pin and the
compensation cylinder pin.
WARNING 8
DO NOT activate ANY boom function other than the

boom lift/lower function. Activating the extend/retract,
tilt or auxiliary function could cause hydraulic oil to
spray onto the machine and/or surrounding areas.
4. Properly disconnect the battery. 7

5. Support the first boom section by placing a sling at
the balance point of the section. MAM0670
8. Remove the lock bolt (7) and pivot pin (8) from rear
of first boom section.
9. Lift the first boom section off machine and set on
level ground or supports being careful not to damage
the tubes on the bottom of the boom.
10. Inspect the boom and welds. Consult the local
Caterpillar dealer if structural damage is detected.
11. Inspect hoses, hardware, wear pads, mounting
2 MAM0630
points and other components visible with the first
1 3
boom section. Replace any item if damaged.
6. Support the lift/lower cylinder (1) and remove the 12. Inspect all wear pads for wear. Refer to Section
lock bolt (2) and then the rod end pin (3). Lower the 3.22.1, “Wear Pad Inspection.”
lift/lower cylinder onto the frame rails.
3.3.5 Extend/Retract Cylinder Removal
1. Secure the second boom section on suitable
supports.
2
1
1
6 4
3
5
MAM0640
7. Remove the lock bolt (4) and pin (5) from the barrel
end of the compensating cylinder (6) on the first MAM0660
boom section. Rest the cylinder on the machine

frame. 2. Remove the retaining rings (1) from the rod end
(front) of the extend/retract cylinder (2).
3. Remove the extend/retract cylinder mounting pin (3).

Boom
4. Place a sling around the barrel end of the extend/ 3.3.7 First Boom Section Installation
retract cylinder.
Note: Lubrication of the boom wear surfaces with CAT
5. Pull the extend/retract cylinder out of the second Multipurpose Grease is recommended to keep the boom
boom section approximately half way. wear surfaces lubricated properly. Lubrication of the
6. Support the barrel end of the extend/retract cylinder boom wear surfaces is also recommended when the
and reposition the sling toward the center or machine is stored, to help prevent rusting.
balancing point of the extend/retract cylinder. Note 1. Park the machine on a hard, level surface, place the
the location of the sling for installation. transmission in (N) NEUTRAL, engage the park
7. Remove the extend/retract cylinder and place on brake and shut the engine OFF.
level ground or suitable supports. 2. Place a Do Not Operate Tag on both the ignition key
3.3.6 Extend/Retract Cylinder Installation
3. Open the engine cover. Allow the system fluids to
Note: Grease the boom extend/retract cylinder bore and cool.
pins before installing.
Note: Grease the boom pivot bore, compensating
cylinder rod ends, lift/lower cylinder rod end and pins
before installing.
2
1
1
3
MAM0660
MAM0670
1. Place the sling at the balance point around the

extend/retract cylinder barrel (2). 4. Using suitable slings, balance the first boom section,
lift and carefully guide the boom into place. Align the
2. Install the extend/retract cylinder halfway into the
frame pivot bore with the boom assembly pivot bore.
rear of the second boom section.
Install boom pivot pin and lock bolt (4). Apply
3. Lower the extend/retract cylinder onto a suitable Loctite® 242TM and torque to 90 Nm (66 lb-ft).
stand and reposition the sling toward the end of the
cylinder.
4. Lift and push the extend/retract cylinder the
remainder of the way into the boom section.
5. Align the barrel end of the extend/retract cylinder
with the pin bores in the second boom section.
6. Install the extend/retract cylinder mounting pin (3).
7. Install the retaining rings (1) into the pin bores
making sure the rings seat properly within the bore
grooves.

Boom
3.3.8 Second Boom Section Installation

Note: Lubrication of the boom wear surfaces with CAT
Multipurpose Grease is recommended to keep the boom
wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.
1. If previously removed, install the extend/retract
cylinder into the rear of the second boom section.
8 Refer to Section 3.3.6, 3.3.6. “Extend/Retract
9 10
Cylinder Installation.”
5 7 2. Using suitable slings, balance the second boom
section, lift and carefully guide the boom into place.
3. Install the wear pads, shims and bolts to their proper
6 location at the front inside of the first boom section.
DO NOT tighten the wear pads at this time.
MAM0640
4. Feed the tilt cylinder hoses and if equipped, the
5. With a sling in place, raise the compensation auxiliary hoses through the channel above the
cylinder (5) into place and install the pin (6) and lock extend/retract cylinder.
bolt (7) to the barrel end of the compensating 5. Install the wear pads, shims and bolts previously
cylinder on the first boom section. removed from the rear of the second boom section.
6. With the sling still in place, install the rod end of the DO NOT tighten the wear pads at this time.
lift/lower cylinder (8), pin (9) and lock bolt (10). Apply 6. Uncap and connect the previously labeled extend/
Loctite® 242TM and torque to 90 Nm (66 lb-ft). retract cylinder hoses to the extend/retract cylinder.
Note: Raising the boom up or down with the sling may Refer to Section 2.3.3, “Hydraulic Hose Torque
be necessary so the boom, compensating and lift/lower Chart,” for proper hose torque.
cylinder bores can be aligned for easier pin installation. 7. Uncap and connect the previously labeled tilt hoses
and (if equipped) auxiliary hoses to the appropriate
7. Remove sling.
cylinder. Refer to Section 2.3.3, “Hydraulic Hose
8. Temporarily connect the battery. Torque Chart,” for proper hose torque.
9. Start the machine and lower the first boom section to 8. Install the boom angle sensor arm. Refer to Section
a level position. 9.12.7, “Boom Angle Sensor.”
9. Install the previously removed boom retract sensor.
WARNING Refer toSection 3.27, “Boom Retract Sensor
Adjustment,” for detailed adjustment instructions.
DO NOT activate ANY boom function other than the
10. Adjust and shim each wear pad as needed. Refer to
boom lift/lower function. Activating the extend/retract,
Section 3.22, “Boom Wear Pads.”
tilt or auxiliary function could cause hydraulic oil to
spray onto the machine and/or surrounding areas. 11. Properly connect the battery.
fluid level in the tank and add fluid as required.
and around the machine.
14. Close and secure the engine cover.

Boom

TERMINOLOGY - TH414C
The following illustrations identify the components that
FIRST
BOOM
SECTION
EXTEND CHAINS
(inside boom)
SECOND
BOOM HOSE CARRIER
SECTION (inside boom)
THIRD
BOOM
SECTION
RETRACT CHAIN
(inside boom)
EXTEND/RETRACT CYLINDER
TILT
CYLINDER
QUICK COUPLER
MAM0680

Boom
3.5 BOOM SYSTEM - THREE SECTION 3.6 BOOM ASSEMBLY MAINTENANCE

These instructions must be completed in sequence. The
3.5.1 Boom System Operation second and third boom sections are removed from the
The TH414C three section boom consists of the first, first boom section.The third boom section is removed
second and third assemblies with first and second section from the second boom section or the complete boom
extend chains, and a single first and second section assembly can be removed from the machine.
retract chain. Before beginning, conduct a visual inspection of the
As the extend/retract cylinder, which is anchored at the machine and work area, and review the task about to be
rear of the second boom section, and the front of the third undertaken. Read, understand and follow these
boom section begins to extend, it pushes the third boom instructions.The boom assembly consists of the first,
section out of the second boom section. second and third section booms and supporting
The boom sections are connected by extend and retract hardware.
chains. These chains are routed around sheaves on the Note: Before removing the boom or boom section, the
front and the rear of the second boom section. As the carriage or any other attachment must be removed from
extend/retract cylinder is forced out hydraulically, the the quick coupler.
second and third boom sections are pulled out by the
extend chains. Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
As hydraulic pressure is applied to the retract port on the undertaken. Read, understand and follow these
extend/retract cylinder, the retract chain pulls the second instructions.
and third boom sections back into the first boom section.
During service of the boom, perform the following:
This mechanical linkage formed by the chains and
supporting hardware, extends and retracts the second 1. Check wear pads. (Refer to Section 3.22.1, “Wear
and third boom sections into the first boom section at the Pad Inspection.”)
same rate. 2. Check hose sheaves and chain rollers.
The boom section lifts and lowers via action of the lift 3. Apply grease at all lubrication points (grease fittings).
cylinder. (Refer to Section 2.6, “Lubrication Schedule.”)
4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
boom.
WARNING
writing by JLG. The structural integrity of the boom
will be impaired if subjected to any repair involving

Boom
3.6.1 Boom Removal 11. Label, disconnect and cap any electrical cables if
equipped.
other on the machine, it is much safer, more efficient and 12. Remove the pin from the rod end of each
more cost- effective to remove the complete boom compensation cylinder being careful not to drop the
assembly from the machine and place it on suitable cylinder. Lower each cylinder to a secure position.
supports for separation. Work can then progress at a 13. Remove the pin from the rod end of the lift/lower
normal working height. cylinder being careful not to drop the cylinder. Lower
Note: When removing a complete boom assembly use the cylinder to a secure position.
a hoist or crane with a minimum lift capacity of 6000 lbs. 14. Confirm that the boom assembly is balanced with
the sling and remove the boom assembly pivot pin.
assembly. Refer to Operation & Maintenance 15. Lift the boom assembly from the machine and lower
Manual. onto suitable supports.
2. Park the machine on a hard, level surface, fully
retract the boom, raise the boom assembly to
3.6.2 Second and Third Boom Section
access lift/lower cylinder pin, place the transmission
Removal
in (N) NEUTRAL, engage the park brake and shut 1. Set the complete boom on level ground and by
the engine OFF. repositioning the slings turn boom over on to the top
3. Place a Do Not Operate Tag on both the ignition key side. Set the complete boom on suitable stands to
switch and the steering wheel. begin tear down.
4. Open the engine cover. Allow the system fluids to Note: With the complete boom setting upside down, the
cool. removal and replacing of each boom section, tilt cylinder,
hoses, extend and retract chains and extend/retract
cylinder are made much easier.
6. Remove boom angle sensor arm. Refer to Section
9.12.7, “Boom Angle Sensor.” 2. Label, disconnect and cap the tilt circuit hoses from
the tilt cylinder at the front of the third boom section.
Label, disconnect and cap the auxiliary circuit hoses
from the quick disconnect fittings at the front of the
third boom section. Cap all fittings and openings to
system.
3. Place a sling around the tilt cylinder and remove the
retaining rings and pin at the barrel end of the tilt
cylinder. Remove tilt cylinder.
4. Remove all wear pads, shims and backing plates
from the front inside of the first boom section. Label
1 and tag each set of wear pads being removed.
1
MAM4010 2
7. Disconnect and remove the boom retract sensor (1)

from the rear of the first boom section.
8. Place a sling around the first boom section at the
balance point.
9. Take the weight off the boom assembly.
10. Label, disconnect and cap all hydraulic hoses
attached to the tubes on the bottom of the boom. MAM0690
Cap all fittings and openings to keep dirt and debris
from entering the hydraulic system.

Boom
5. Disconnect both tilt hoses and (if equipped) both

auxiliary hoses (1) at the bottom of the first boom
section.Plug the hose ends and cap the tube ends to
system. Pull the disconnected hoses from the rear of
the boom.
6. Loosen and remove the lock nut and jam nut (2) on
the retract chain at the front of the first boom section. 9
MAM0880
3
10
3
10. Loosen and remove the hose stop bracket (9) from
the rear of the second boom section.
MAM0710
11. Pull the disconnected extend chains (10) from the
7. Disconnect both extend/retract hoses (3) at the rear of the boom.
bottom of the first boom section. Plug the hose ends 12. Remove both top and one side wear pads, shims
and cap the tube ends to prevent dirt and debris and backing plates from the rear inside of the
from entering the hydraulic system. Pull the second boom section. Label each set of wear pads
disconnected hoses from the rear of the boom. being removed
13. Place a sling around the second boom section, lift
8 and slowly pull the second and third boom section
approximately half way out of the first boom section.
Lower the second and third boom sections onto a
suitable support.
6
14. Relocate the sling or using two slings for better
5
stability, balance the two boom sections and slowly
7 pull them out of the first boom section being careful
not to damage the hydraulic hoses or chains. Lower
the second and third boom sections onto suitable
supports.
MAM0721
8. Remove the locknuts and jam nuts (4) from the

extend chains (5) at the top of the first boom section.
9. Pull both extend chains (5) back to allow the removal
of two circlips (6), two spacers (7) and clevis bracket
(8).

Boom
3.6.3 Third Boom Section and Extend/ 8. Relocate the sling or using two slings for better
Retract Cylinder Removal stability, balance the third boom section and slowly
pull the third boom section out of the second boom
1. Remove all wear pads, shims from the front inside of
section. Lower the third boom section onto suitable
the second boom section. Label each set of wear
supports.
pads being removed.
9. Loosen and remove the tilt circuit, auxiliary circuit
hoses from the rear of the third boom section.
12
11
11
MAM0740
MAM0870
2. Loosen and remove the retract chain sheave
components (11) from the front of the second boom 10. Remove the retaining rings and pin from the extend/
section. retract cylinder at the front of the third boom section
3. Pull the retract chain (12) free of the sheave brackets (11).
and lay it on the third boom section. 11. Place a sling around the rear of the extend/retract
cylinder, lift and slowly pull the extend/retract
cylinder approximately half way out of the third boom
section. Lower the extend/retract cylinder onto a
suitable support.
10 stability, balance the extend/retract cylinder and
slowly pull the extend/retract cylinder out of the third
boom section. Lower the extend/retract cylinder onto
suitable supports.
3.6.4 Third Boom Section and Extend/

Retract Cylinder Installation
9 MAM0730
Note: During reassembly use Loctite® 242TM on all bolt
threads and use Loctite 545® on all hydraulic fittings
4. At the rear of the boom, loosen and remove all
retract chain sheave components (9). Note: Shim all wear pads. Refer to Section 3.22, “Boom
5. Remove the retaining rings and pin from the extend/ Wear Pads.” You may have to final adjust the wear pads
retract cylinder at the rear of the second boom after the boom assembly is installed on the machine and
section (10). hydraulic power is available.
6. Secure the hydraulic hoses at the rear of the third Note: Coat the interior of all bushings and sheaves with
boom section. CAT ADVANCED 3MOLY-NLGI Grade 2 prior to the
installation of pins and bushings. Wear pads and slide
7. Place a sling around the third boom section, lift and
areas must be lubricated with CAT ADVANCED 3MOLY-
slowly pull the third boom section approximately half
NLGI Grade 2 or an equivalent.
way out of the second boom section. Lower the third
boom section onto a suitable support. 1. Place the third boom section upside down on
suitable supports.

Boom
2. Place a sling around the extend/retract cylinder and 9. With the extend/retract cylinder installed in the third
slowly insert the extend/retract cylinder halfway into boom section, the third boom section is ready to be
the rear of the third boom section. Lower the extend/ installed into the second boom section.
retract cylinder onto a suitable support. 10. Place the second boom section upside down on
3. Relocate the sling and install the extend/retract suitable supports.
cylinder the remainder of way into the third boom 11. Lubricate the inside second boom section on area’s
section. where the third boom section wear pads will slide.
12. Using a suitable sling, balance the third boom
section and carefully slide the hoses and
1 m-1,2 m (3 ft-4 ft) of the third boom section into the
front of the second boom section.
13. Set the third boom section onto a suitable support
and reset the sling under the boom head of the third
1 boom section. Carefully slide the third boom section
into the second boom section.
14. Leave 152 mm-203 mm (6 in-8 in) of the third boom
section out to be able to install the wear pads in the
front of the second boom section.
MAM0870
15. With the sling still under boom head, install the wear
4. Align the rod end of the extend/retract cylinder with pads and spacers in the front of the second boom
the bore in the front of the third boom section and section.
install the pin and retaining rings (1). 16. Install the top wear pads and spacers on the top rear
5. Install the extend/retract hoses to the barrel end of of the third boom section.
the extend/retract cylinder. 17. Install the wear pads and spacers on the bottom and
6. Install the tilt circuit hoses, auxiliary/electrical circuit both sides at the rear of the second boom section.
hoses through the channels at the rear of the third For ease of installation, DO NOT install the top wear
boom section and bolt into place. pads at this time.
18. Lubricate wear pads, inside sheaves, bores and pins
during assembly.
2 19. Push the third boom section the remainder of the
way into the second boom section.
MAM0890
7. Connect the retract chain (2) at the rear of the third

boom section and lay the chain over the boom.
8. Lubricate wear pad paths and lay the extend/retract
cylinder hoses, tilt hoses, auxiliary/electrical hoses MAM0730
behind the third boom section being careful to
protect the hoses against being damaged when 20. Align the barrel end of the extend/retract cylinder
installing the third boom section into the second with the bore on the rear of the second boom section
boom section. and install the pin and retaining rings (3).

Boom
3.6.5 Second and Third Boom Section 10. Install the wear pads, spacers and shims at the front
Installation of the first boom section. Apply Loctite® 242TM and
torque the wear pad mounting bolts to 92-106 Nm
1. Place the first boom section upside down on suitable
(68-78 lb-ft).
supports.
2. Lubricate the inside first boom section on area’s
where the second boom section wear pads will slide.
3. Using a suitable sling, balance the second and third
boom sections and carefully slide 0,9 m-1,22 m
(3 ft-4 ft) into the front of the first boom section.
4. Set the second and third boom sections onto a
suitable support and reset the sling under the boom 2
head of the third boom section. MAM0880
4 1
11. Connect both extend chains (1) at the rear of the

third boom section.
6
7 12. Feed the extend/retract hoses, tilt hoses and
auxiliary/electrical hoses between the second and
5 first boom sections.
13. Connect the extend/retract hoses, tilt hoses and
auxiliary/electrical hoses to the proper tubes on the
bottom of the first boom section.
8 14. Install the hose stop bracket (2).
Refer to Section 3.27, “Boom Retract Sensor
MAM0721
5. Install the clevis bracket (4), two spacers (5) and two
circlips (6), previously removed from the extend 9
chains (7). 3
6. Install both extend chains (7) to the top of the first
boom section
7. Install the locknuts and jam nuts (8) to the extend
chains (7) and allowing the extend chains to hang
out over the rear of the first boom section. Do Not
tighten the lock nuts and jam nuts at this time.
8. Lay the extend/retract cylinder hoses, tilt hoses, MAM0690
auxiliary/electrical hoses behind the second and
third boom sections being careful to protect the 16. Install the lock nut and jam nut (3) on the retract
hoses against being damaged when installing the chain at the front of the first boom section.
second and third boom sections into the first boom 17. Tighten all hose clamps.Connect the auxiliary hoses
section. to the quick disconnects on the side of the boom
9. Carefully slide the hoses and the two boom sections head. Connect the electrical cable to the plug
into the first boom section. Leave 152 mm-203 mm mounted below the auxiliary quick disconnects if
(6 in-8 in) in of the two boom sections out to be able equipped.
to install the wear pad block and the wear pads in
the front of the first boom section

Boom
18. Install the tilt cylinder in the boom head, install the Note: Raising the boom up or down with the sling may
mounting pin and keeper bolt, locking the mounting be necessary so the boom, compensating and lift/lower
pin and tilt cylinder into position. cylinder bores can be aligned for easier pin installation.
19. Connect the tilt cylinder hoses to the proper fittings 7. Uncap and connect the previously labeled extend/
on the tilt cylinder. retract cylinder hoses to the extend/retract cylinder.
8. Uncap and connect the previously labeled tilt hoses
3.6.6 Complete Boom Installation and (if equipped) auxiliary hoses to the appropriate
Note: Lubrication of the boom wear surfaces with CAT cylinder.
Multipurpose Grease is recommended to keep the boom 9. Install the boom angle sensor arm. Refer to Section
wear surfaces lubricated properly. Lubrication of the 9.12.7, “Boom Angle Sensor.”
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting. 10. Start the engine and operate all boom functions
1. Park the machine on a hard, level surface, place the system. Check for fluid leaks. Check the hydraulic
transmission in (N) NEUTRAL, engage the park fluid level in the tank and add fluid as required.
2. Place a Do Not Operate Tag on both the ignition key and around the machine.
cool. 3.7 BOOM CHAIN REMOVAL/
Note: Grease the boom pivot bore, compensating INSTALLATION
before installing.
3.7.1 Retract Chain Removal
The removal of the retract chain can be accomplished
with out the complete tear down of the boom sections.
assembly. Refer to Operation & Maintenance
Manual.
retract the boom, level the boom assembly, place the
4 transmission in (N) NEUTRAL, engage the park
MAM0670
cool.
4. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the 5. Properly disconnect the battery.
Loctite® 242TM and torque to 90 Nm (66 lb-ft).
cylinders, pins and lock bolts. Apply Loctite® 242TM
and torque to 90 Nm (66 lb-ft).
6. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt. Apply Loctite®
242TM and torque to 90 Nm (66 lb-ft).

Boom
4. Install the retract chain lock nut and adjusting nut (2)
at the front of the second boom section below the
boom head.
5. Properly connect the battery.
7. For chain adjustments see Section 3.10.1, “Chain
Adjustments.”
1 3.7.3 Extend Chain Removal

The removal of the extend chains can be accomplished
with out the complete tear down of the boom sections.
MAM1370 Manual.
6. Remove the retract chain lock nut and adjusting nut 2. Park the machine on a hard, level surface, fully
(1). Fasten a rope/wire to the threaded end of the retract the boom, level the boom assembly, place the
shackle end to aid in reinstallation. transmission in (N) NEUTRAL, engage the park
3 cool.
2
5
MAM1380
7. Remove the retract chain lock nut and adjusting nut

(2) from the bottom front of the first boom section. 5
8. Remove the retract chain roller (3) to allow for retract

chain removal.
9. Pull the retract chain (4) from between the second
and third boom sections below the boom head.
MAM0720
10. Unfasten the rope/wire from the retract chain.
6. Remove the extend chain lock nuts and adjusting
3.7.2 Retract Chain Installation nuts (5) from the extend chain at the top of the first
boom section. Fasten a rope/wire to the threaded
1. Fasten the rope/wire left in the boom from the retract
end of the shackle end to aid in reinstallation.
chain removal to the new retract chain and pull the
chain through the boom sections to the approximate
final position. Remove the rope/wire.
2. Install the retract chain lock nut and adjusting nut (1)
at the rear of the third boom section.
3. Install the retract chain roller (3) if previously
removed.

Boom
3.8 EXTEND/RETRACT, TILT AND

6 AUXILIARY CIRCUIT HOSE
REMOVAL/INSTALLATION
Hoses that need replaced and are still in one piece can
7 be removed and replaced without removing sections of
the boom.
3.8.1 Extend/Retract Hose Removal

Manual.
MAM1370 retract the boom, level the boom assembly, place the
7. Remove the hose guard bracket (6) from the rear of brake and shut the engine OFF.
the second boom section. 3. Place a Do Not Operate Tag on both the ignition key
8. Remove the connecting pin (7) from the extend switch and the steering wheel.
chain. 4. Open the engine cover. Allow the system fluids to
9. Pull the extend chain from between the first and cool.
second boom sections at the rear of the machine. 5. Properly disconnect the battery.
10. Unfasten the rope/wire from the extend chain. 6. Label, disconnect and cap both hoses from the
11. Repeat steps 6 through 10 to remove the other extend/retract cylinder at the rear of the boom. Cap
extend chain. all fittings and openings to keep dirt and debris from
entering the hydraulic system.
3.7.4 Extend Chain Installation 7. Fasten a rope/wire to the hose end below the first
1. Fasten the rope/wire left in the boom from the extend boom section.
chain removal to the new extend chain and pull the 8. From the rear of the boom, pull the extend/retract
chain through the boom sections to the approximate hoses from between the first and second boom
final position. Remove the rope/wire. sections.
2. Install the extend chain lock nut and adjusting nut (5) 9. Unfasten the rope/wire from the hose end.
at the top of the first boom section.
Note: Always check hose sheaves for wear and/or
3. Install the extend chain connecting pin (7) at the rear damage. Replace if necessary.
of the third boom section.
4. Repeat steps 1 through 3 to install the other extend 3.8.2 Extend/Retract Hose Installation
chain.
1. Fasten the rope/wire left in the boom from the hose
5. Install the hose guard bracket (6). removal to the new hose end at the rear of boom.
6. Properly connect the battery. 2. Slowly pull the rope/wire from below the first boom
7. Close and secure the engine cover. section until the hose end is visible at the tube
connections.
8. For chain adjustments see Section 3.10.1, “Chain
Adjustments.” 3. Unfasten the rope/wire from the extend/retract hose.
4. Uncap and connect the hoses to the previously
labeled tubes under the first boom section.
labeled fittings at the rear of the extend/retract
cylinder. Refer to Section 2.3.3, “Hydraulic Hose
Torque Chart,” for proper hose torque.

Boom
3.8.3 Tilt/Auxiliary Hose Removal 3.9 EXTEND/RETRACT CYLINDER

1. Label, disconnect and cap both hoses from the tilt REMOVAL/INSTALLATION
cylinder or auxiliary fittings at the front of the boom.
Cap all fittings and openings to keep dirt and debris The extend/retract cylinder hydraulically extends and
from entering the hydraulic system. retracts the third boom section.
Seal kits for the extend/retract cylinders are available
2. Fasten a rope/wire to the hose end at the boom from the local Caterpillar dealer.
head.
3. Label, disconnect and cap both hoses attached to 3.9.1 Extend/Retract Cylinder Removal
the tubes on the bottom of the boom. Cap all fittings
and openings to keep dirt and debris from entering
the hydraulic system.
Manual.
4. Fasten a rope/wire to the hose end below the first
2. Park the machine on a hard, level surface, extend
boom section.
the boom to gain access to the extend/retract
5. Loosen and remove the clamps holding the tilt hoses cylinder pin in the third boom section, level the boom
at the rear of the third boom section. assembly, place the transmission in (N) NEUTRAL,
6. From the rear of the boom, pull the tilt hoses from engage the park brake and shut the engine OFF.
between the first and second boom sections. 3. Place a Do Not Operate Tag on both the ignition key
7. Unfasten the rope/wire from each end of the hose switch and the steering wheel.
assembly.
Note: Always check hose sheaves for wear and/or 1
damage. Replace if necessary.
3.8.4 Tilt/Auxiliary Hose Installation

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.
2. Slowly pull the rope/wire from the boom head until
the hose end is visible at the boom head.
3. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube MAM0980
connections.
4. Remove the cylinder rod eye mounting pin (1) at the
4. Unfasten the rope/wire from each end of the hose. side of the third boom section.
5. Uncap and connect the hoses to the previously 5. Start the machine and SLOWLY retract the extend/
labeled tubes under the first boom section. Refer to retract cylinder and at the same time manually
Section 2.3.3, “Hydraulic Hose Torque Chart,” for retract the third boom section.
proper hose torque.
6. Shut the engine OFF.
labeled fittings at the tilt cylinder or the auxiliary
cool.
fittings. Refer to Section 2.3.3, “Hydraulic Hose
Torque Chart,” for proper hose torque. 8. Properly disconnect the battery.
7. Install and tighten the clamps holding the tilt hoses 9. Loosen and remove the extend/retract cylinder
at the rear of the third boom section. hoses at the rear of the boom assembly. Plug the
hose ends to prevent dirt and debris from entering
10. Remove the cylinder barrel end pin (2). Note the
location of the spacers and washers

Boom
11. Attach a sling or other suitable lifting device to the 3.10 BOOM SECTIONS ADJUSTMENT
extend/retract cylinder and carefully pull the extend/
retract cylinder free of the machine through the rear
of the boom/chassis assembly. 3.10.1 Chain Adjustments
12. Place the extend/retract cylinder in a designated The chains are adjusted by tightening and/or backing off
area for the next operation. the adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
3.9.2 Extend/Retract Cylinder Installation whenever this procedure is performed.
The chains are properly adjusted whenever the following
1. Install the extend/retract cylinder into the rear of the
parameters are met.
boom and line up the barrel end of the cylinder with
the pin bores on the second boom section. Be 1. Start the machine, level the boom and retract the
certain that the wear pads are installed on the extend/retract cylinder completely. Turn engine OFF.
cylinder. Suitably support the boom.
10
9
2
MAM0970
2. Install the mounting pin (2), spacers and washers

through the second boom section bore and cylinder
barrel. Secure with retaining clips.
4 5
labeled fittings at the extend/retract cylinder. Apply 7 6 8 MAM0921
Loctite 545® to the fittings.
4. Manually pull the third and second boom sections 2. At the rear of the boom verify that there is
out until there is access to the extend/retract cylinder approximately 5,0 ± 1,0 mm (0.078 ± 0.016 in) gap
mounting pin bore in the third boom section. between the clevis shoulder and the face of the first
5. Properly connect the battery. boom section (3).
6. Start the machine and extend the extend/retract Note: Use a mirror to help verify the proper gap (3) at
cylinder until the rod eye of the cylinder aligns with the rear of the boom.
the pin bore in the third boom section. Note: If required, remove the boom support, start the
7. Shut the engine OFF. machine and raise the boom to gain access to the retract
8. Install the mounting pin (1) and secure with the chain lock nut (4) and the adjusting nut (5). Loosen the
retaining clips. lock nut, lower and level the boom. Turn engine OFF.
Install boom support.
9. Start the machine and cycle the extend/retract
cylinder checking for leaks or any alignment 3. If adjustment is needed, loosen the lock nut (4) and
problems. tighten the retract chain adjusting nut (5) to ensure a
gap of 5,0 ± 1,0 mm (0.078 ± 0.016 in) between the
clevis shoulder and the face of the first boom section
(3).
4. Tighten the retract chain lock nut (4) to 120 Nm
(86 lb-ft) against the adjusting nut (5).

Boom
5. Tighten the retract chain lock nut (6) to 120 Nm

Note: Ensure that there is a minimum of one full thread
of the clevis showing beyond the face of the lock nut (4).
6. Start the machine and extend the boom completely.
Verify the boom is level and shut the machine OFF.
A
MAM3610
11
7. Tighten both front top extend chain adjusting nuts

(10) evenly to increase tension in the retract chain
(11) until the distance between the bottom of the
bottom of the second boom section and the bottom
of the retract chain is 115 - 117 mm (4.5 - 4.6 in)(A).
8. Start the machine and retract the boom
approximately 0,5 m (197.0 in). Fully retract and
extend the boom several times.
9. Extend the boom fully. Turn OFF engine
10. Measure dimension (A), if adjustment is required,
repeat step seven thru ten.
11. Tighten both extend chain lock nuts (9) to 120 Nm
of the clevis showing beyond the lock nut.
12. Remove the boom support.

Boom

The following illustrations identify the components that
FIRST
BOOM
SECTION
SECOND
BOOM
SECTION
THIRD
BOOM
SECTION
AUXILIARY HOSE
CONNECTIONS
ELECTRIC
CONNECTOR
TILT
CYLINDER TANDEM EXTEND/RETRACT CYLINDER
(LOCATED IN BOOM)
QUICK COUPLER
MZ4120

Boom
3.12 BOOM SYSTEM - THREE SECTION 3.13 BOOM ASSEMBLY MAINTENANCE

These instructions must be completed in sequence. The
3.12.1 Boom System Operation second and third boom sections are removed from the
The TH514C three section boom consists of the first, first boom section.The third boom section is removed
second and third assemblies with a tandem extend/ from the second boom section or the complete boom
retract cylinder connecting the three sections. assembly can be removed from the machine.
As the tandem extend/retract cylinders, which the lower Before beginning, conduct a visual inspection of the
cylinder is anchored at the rear of the first boom section machine and work area, and review the task about to be
and the rear of the second boon section and the top undertaken. Read, understand and follow these
cylinder is connected near the front of the third boom instructions.The boom assembly consists of the first,
section begins to extend, it pushes the second boom second and third section booms and supporting
section out of the first boom section and the third boom hardware.
section out of the second boom section.
Note: Before removing the boom or boom section, the
As hydraulic pressure is applied to the retract port on the carriage, any other attachment and the quick coupler
extend/retract cylinders, the top cylinder pulls the third must be removed from the boom assembly.
boom section into the second boom section and bottom
cylinder pulls the second boom section into the first boom Before beginning, conduct a visual inspection of the
section. machine and work area, and review the task about to be
undertaken. Read, understand and follow these
This hydraulic cylinder linkage formed by the tandem instructions.
extend/retract cylinder, extends and retracts the second
and third boom sections into the first boom section at the During service of the boom, perform the following:
same rate. 1. Check wear pads. (Refer to Section 3.22.1, “Wear
The boom section lifts and lowers via action of the lift Pad Inspection.”)
cylinder. 2. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.6, “Lubrication Schedule.”)
3. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
boom.
WARNING
writing by JLG. The structural integrity of the boom
will be impaired if subjected to any repair involving

Boom
3.13.1 Boom Removal

other on the machine, it is much safer, more efficient and 2
more cost- effective to remove the complete boom 2
2
assembly from the machine and place it on suitable
supports for separation. Work can then progress at a
normal working height.
Note: When removing a complete boom assembly use 2
a hoist or crane with a minimum lift capacity of 5000 lbs.
Manual.
MZ4140
13. Label, disconnect and cap all hydraulic hoses (2)

attached to the tubes on the bottom of the boom.
Cap all fittings and openings to keep dirt and debris
1 from entering the hydraulic system.
14. Disconnect the electrical cables if equipped.
MZ4170
15. Remove the pin from the rod end of each
compensation cylinder being careful not to drop the
2. Park the machine on a hard, level surface, extend cylinder. Lower each cylinder to a secure position.
the boom to allow access to the tandem extend/
16. Remove the pin from the rod end of the lift/lower
retract cylinder mounting pin in the third boom
cylinder being careful not to drop the cylinder. Lower
section (1).
the cylinder to a secure position.
3. Remove the retaining rings and mounting pin (1).
17. Lower the boom assembly, reposition the slings and
4. Raise the boom assembly and retract the extend/ confirm that the boom assembly is balanced and
retract cylinder allowing the third boom section to remove the boom assembly pivot pin.
retract along with the extend/retract cylinder.
18. Lift the boom assembly from the machine and lower
5. Keep the boom assembly raised to access lift/lower onto suitable supports.
cylinder pin, place the transmission in
(N) NEUTRAL, engage the park brake and shut the 3.13.2 Second and Third Boom Section
engine OFF. Removal
6. Place a Do Not Operate Tag on both the ignition key 1. Set the complete boom on level ground and by
switch and the steering wheel. repositioning the slings turn boom over on to the top
7. Open the engine cover. Allow the system fluids to side. Set the complete boom on suitable stands to
cool. begin tear down.
8. Properly disconnect the battery. Note: With the complete boom setting upside down, the
9. Remove the quick coupler assembly. Refer to removal and replacing of each boom section, tilt cylinder,
Section 3.23.3, “Quick Coupler Removal (TH414C, hoses and tandem extend/retract cylinder are made
TH514C & TH417C).” much easier.
10. If equipped, disconnect the boom angle sensor arm.
Refer to Section 9.12.7, “Boom Angle Sensor.”
11. Place a sling around the front of the first boom
section.
12. Take the weight off the boom assembly.

Boom
2. Label, disconnect and cap the tilt circuit hoses from

the tilt cylinder at the front of the third boom section. 10 9
Disconnect the electrical plug connection from the
boom head. Label and remove the electrical plug
from the end of the electrical cable. Label,
disconnect and cap the auxiliary circuit hoses from
the quick disconnect fittings at the front of the third
boom section. Cap all fittings and openings to 8
7
system.
3. Place a sling around the tilt cylinder and remove the
retaining rings and pin at the barrel end of the tilt
cylinder. Remove tilt cylinder.
4. Remove the side and top wear pads, spacers and 6
shims from the front inside of the first boom section.
Label and tag each set of wear pads being removed. MZ4150
4 3 6. Disconnect both extend/retract tubes (6) from the

tandem cylinder at the rear of the boom. Plug the
tube ends and cap the cylinder fittings to prevent dirt
and debris from entering the hydraulic system.
7. Remove the circlip (7), pin (8), shims (9) and spacer
(10) from each side of the rear tandem cylinder rod
end. Note the location and number of shims for
assembly.
5
8. Pull the disconnected hoses and electrical cable
from the rear of the boom.
MZ4130
5. Disconnect both tilt hoses (3) and (if equipped) both

auxiliary hoses (4) at the bottom of the first boom
section. Disconnect the top tandem extend/retract 11
cylinder hose (5) at the bottom of the first boom
section. Plug the hose ends with plastic plugs (use
plastic plugs for the needed clearance when
removing the hoses from between the sections) and
cap the tube ends to prevent dirt and debris from
MZ4160
9. Remove the boom retract sensor (11) from the rear

of the first boom section.
10. Place a sling around the second boom section, lift
and slowly pull the second and third boom section
approximately half way out of the first boom section.
Lower the second and third boom sections onto a
suitable support.

Boom
11. Relocate the sling or use two slings for better 2. Place a sling around the third boom section, lift and
stability, balance the two boom sections and slowly slowly pull the third boom section approximately half
pull them out of the first boom section being careful way out of the second boom section. Lower the third
not to damage the hydraulic hoses. Lower the boom section onto a suitable support.
second and third boom sections onto suitable 3. Relocate the sling or using two slings for better
supports. stability, balance the third boom section and slowly
3.13.3 Tandem Extend/Retract Cylinder section. Lower the third boom section onto suitable
Removal supports.
16 4. Relocate the sling or use two slings for better
stability, balance the third boom section and slowly
section being careful not to damage the hydraulic
hoses. Lower the third boom section onto suitable
supports.
14 5. If required, remove the clamps at the rear of the third

boom section holding the tilt/electrical and auxiliary
hoses.
6. Remove hoses as needed.
3.13.5 Third Boom Section Installation

15
Note: During reassembly use Loctite® 242TM on all bolt
threads and use Loctite 545® on all hydraulic fittings
Note: Shim all wear pads. Refer to Section 3.22, “Boom
12 MZ4200 Wear Pads.” You may have to final adjust the wear pads
13 13
after the boom assembly is installed on the machine and
1. Remove the two hex head bolts and washers (12) hydraulic power is available.
holding each hose guard (13) in place and remove
Note: Coat the interior of all bushings and sheaves with
guards.
CAT ADVANCED 3MOLY-NLGI Grade 2 prior to the
2. Remove the four socket head bolts and washers installation of pins and bushings. Wear pads and slide
(14), clamp plate and shim (15) holding the extend/ areas must be lubricated with CAT ADVANCED 3MOLY-
retract cylinder (16) in place at the rear of the second NLGI Grade 2 or an equivalent.
boom section.
1. Place the second boom section upside down on
3. Place a sling around the tandem extend/retract suitable supports.
cylinder, lift and slowly pull the extend/retract
cylinder approximately half way out of the rear of the 2. Lubricate the inside second boom section on area’s
third boom section. Lower the extend/retract cylinder where the third boom section wear pads will slide
onto a suitable support. with CAT Advanced 3Moly - NLGI 2.
4. Relocate the sling or using two slings for better 3. Using a suitable sling, balance the third boom
stability, balance the extend/retract cylinder and section and carefully slide into the front of the
slowly pull the extend/retract cylinder out of the second boom section.
second boom section. Lower the extend/retract 4. Set the third boom section onto a suitable support
cylinder onto suitable supports. and reset the sling under the boom head of the third
boom section. Carefully slide the third boom section
3.13.4 Third Boom Section Removal into the second boom section leaving room to install
the previously removed wear pads, spacers and
1. Remove one side and top wear pads, spacers and
shims.
shims from the front inside of the second boom
section. Label each set of wear pads being removed.

Boom
5. Install the previously removed wear pads, spacers bolts and washers (3) and torque to 250 Nm
and shims on the front inside of the second boom (185 lb-ft).
section. Apply Loctite® 242TM and torque the wear 9. Apply Loctite® 242TM to the four hex head bolts (6).
pad mounting bolts to 92-106 Nm (68-78 lb-ft).
10. Install each hose guard (7) to the extend/retract
6. With the third boom section installed in the second cylinder trunnion (5). Install the four hex head bolts
boom section, the extend/retract cylinder is ready to and washers (6) and torque to 28 Nm (21 lb-ft).
be installed into the third boom section.
3.13.7 Second and Third Boom Section
3.13.6 Extend/Retract Cylinder Installation Installation
1. Lubricate the inside third boom section on area’s 1. Place the first boom section upside down on suitable
where the extend/retract cylinder wear pad will slide supports.
with CAT Advanced 3Moly - NLGI 2
2. Lubricate the inside first boom section on area’s
2. Apply CAT Multipurpose Grease - NLGI Grade 2 to where the second boom section wear pads will slide.
the trunnion blocks on the extend/retract cylinder
and to the trunnion supports at the rear of the 3. Using a suitable sling, balance the second and third
second boom section. boom sections and carefully slide into the front of
the first boom section.
3. Connect the extend/retract cylinder hose to the tube
connection at the rear of the extend/retract cylinder. 4. Set the second and third boom sections onto a
suitable support and reset the sling under the boom
4. Place a sling around the tandem extend/retract head of the third boom section.
cylinder and slowly insert the extend/retract cylinder
halfway into the rear of the rear of the third boom 8
section. Lower the extend/retract cylinder onto a
suitable support.
5. Relocate the sling and install the extend/retract
cylinder the remainder of way into the second boom
section.
5 4
9
2
MZ4150
5. Carefully slide the second and third boom sections

6 into the first boom section until the extend/retract
3 cylinder rod (8) aligns with the mounting pin bores
(9) in the rear of the first boom section.
7
MZ4190
6. Align the trunnion blocks (1) of the extend/retract

cylinder with each support (2) at the rear of the
second boom section.
7. Apply Loctite® 242TM to the four socket head bolts
(3).
8. Install each clamp plate and shim(4) holding the
extend/retract cylinder (5) in place at the rear of the
second boom section. Install the four socket head

Boom
13 19
11 12
18
10
MZ4130
MZ4210
11. Connect the extend/retract cylinder hose (18) to the
6. Feed the tilt cylinder hoses/electrical cable (10) and tube fitting on the bottom of the first boom section.
auxiliary hoses (not shown) through the top left
12. Connect the tilt hoses and auxiliary hoses (19) to the
(11)(tilt) and top right (12)(auxiliary) of the third
proper tube fittings on the bottom of the first boom
boom section.
section.
7. Feed the remainder of the tilt cylinder hoses/
13. Connect the auxiliary hoses to the quick disconnects
electrical cable (10)(if equipped) and auxiliary hoses
on the side of the boom head.
between the first and second boom sections.
14. Connect the electrical cable to the plug mounted
8. Feed the extend/retract cylinder hose (13) between
below the auxiliary quick disconnects if equipped.
the first and second boom sections.
15. Secure the electrical cable to the tilt hoses on the
bottom of the first boom section.
15 16
17
20
14
MZ4150
9. Install the extend/retract cylinder pivot pin (14), 22

spacers (15), shims (16) and circlips (17).
21
10. Install the previously removed wear pads, spacers
and shims on the front inside of the first boom MZ4220
section. Apply Loctite® 242TM and torque the wear
pad mounting bolts to 92-106 Nm (68-78 lb-ft). 16. Install the tilt cylinder (20) in the boom head, install
the mounting pin (21) and keeper bolt, locking the
mounting pin and tilt cylinder into position.

Boom
17. Connect the tilt cylinder hoses to the proper fittings Note: Grease the boom pivot bore, compensating
on the tilt cylinder. cylinder rod ends, lift/lower cylinder rod end and pins
18. Connect the electrical plug to the previously labeled before installing.
electrical cable.
19. Install the electrical plug (22) on the side of the
boom head.
24
MAM0670
23 4. Using suitable slings, balance the boom assembly,

lift and carefully guide the boom into place. Align the
MZ4230
20. Install the tilt hose and auxiliary hoses clamps (23) Loctite® 242TM and torque to 90 Nm (66 lb-ft).
at the rear of the second boom section.
21. Install both extend/retract cylinder tubes (24) to the cylinders, pins and lock bolts. Apply Loctite® 242TM
proper fittings on the extend/retract cylinder and and torque to 90 Nm (66 lb-ft).
clamp in place on the bottom of the first boom
section. 6. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt. Apply Loctite®
22. Install the previously removed boom retract sensor. 242TM and torque to 90 Nm (66 lb-ft).
Adjustment,” for detailed adjustment instructions. Note: Raising the boom up or down with the sling may
be necessary so the boom, compensating and lift/lower
3.13.8 Complete Boom Installation cylinder bores can be aligned for easier pin installation.
Note: Lubrication of the boom wear surfaces with CAT 7. Uncap and connect the previously labeled extend/
Multipurpose Grease is recommended to keep the boom retract cylinder hoses to the extend/retract cylinder
wear surfaces lubricated properly. Lubrication of the tubes.
boom wear surfaces is also recommended when the 8. Uncap and connect the previously labeled tilt hoses
machine is stored, to help prevent rusting. and (if equipped) auxiliary hoses to the appropriate
1. Park the machine on a hard, level surface, place the tube fittings.
transmission in (N) NEUTRAL, engage the park 9. Install the boom angle sensor arm. Refer to Section
brake and shut the engine OFF. 9.12.7, “Boom Angle Sensor.”
2. Place a Do Not Operate Tag on both the ignition key 10. Properly connect the battery.
switch and the steering wheel. 11. Start the engine and slowly extend boom to allow
3. Open the engine cover. Allow the system fluids to access to the tandem extend/retract cylinder
cool. mounting pin in the third boom section (1).
12. Shut engine OFF.

Boom
MZ4170
13. Align the tandem extend/retract cylinder rod and

install the mounting pin (2) and retaining rings. 3
14. Install the previously removed Quick Coupler. Refer
to Section 3.23.4, “Quick Coupler Installation MZ4240
(TH414C, TH514C & TH417C).”
6. Label, disconnect and cap the hose from the extend/
retract cylinder tube (3) at the rear of the boom. Cap
all fittings and openings to keep dirt and debris from
18. Install previously removed attachment.
3.14 EXTEND/RETRACT, TILT AND

AUXILIARY CIRCUIT HOSE 4
REMOVAL/INSTALLATION MZ4250
7. Disconnect and cap the hose from the extend/retract

Hoses that need replaced can be removed and replaced cylinder tube at the fitting on the bottom of the boom
without removing sections of the boom. (4). Cap all fittings and openings to keep dirt and
debris from entering the hydraulic system.
3.14.1 Extend/Retract Hose Removal
8. From the rear of the boom, pull the extend/retract
1. Remove any attachment from the quick coupler hose from between the first and second boom
assembly. Refer to Operation & Maintenance sections.
Manual.
2. Park the machine on a hard, level surface, fully 3.14.2 Extend/Retract Hose Installation
retract the boom, level the boom assembly, place the 1. Slowly push the new extend/retract hose between
transmission in (N) NEUTRAL, engage the park the first and second boom sections until the hose
brake and shut the engine OFF. end is visible at the tube fitting connection under the
3. Place a Do Not Operate Tag on both the ignition key first boom section.
switch and the steering wheel. 2. Uncap and connect the hose to the previously
4. Open the engine cover. Allow the system fluids to labeled tube under the first boom section.
cool. 3. Uncap and connect the hose to the previously
5. Properly disconnect the battery. labeled tube at the rear of the extend/retract cylinder.
4. Refer to Section 2.3.3, “Hydraulic Hose Torque
Chart,” for proper hose torque.
5. Tighten the clamp holding the extend/retract hose at
the rear of the second boom section.

Boom
3.14.3 Tilt-Electrical/Auxiliary Hose Removal 3.14.4 Tilt-Electrical/Auxiliary Hose

1. Label, disconnect and cap both hoses from the tilt
Installation
cylinder or auxiliary fittings at the front of the boom. 1. Slowly push the new hoses between the first and
Disconnect the electrical plug connection from the second boom sections until the hose ends are visible
boom head. Label and remove the electrical plug at the tube fitting connections under the first boom
from the end of the electrical cable. Cap all fittings section.
and openings to keep dirt and debris from entering 2. Uncap and connect the previously remove hoses to
the hydraulic system. the proper fittings and tighten.
2. Cut nylon ties securing the electrical cable (if 3. Feed the remaining tilt cylinder hoses or auxiliary
equipped) from the tilt hoses. hoses through the top left (tilt) and top right
(auxiliary) third boom section.
4. Uncap and connect the tilt hoses or auxiliary hoses
to the proper fitting at the boom head.
5. Connect the electrical plug to the previously labeled
5 electrical cable.
6. Install the electrical plug on the side of the boom
MZ4260 head.
3. Label, disconnect and cap both hoses attached to 7. Refer to Section 2.3.3, “Hydraulic Hose Torque
the tubes on the bottom of the boom (5). Plug the Chart,” for proper hose torque.
hose ends with plastic plugs (use plastic plugs for 8. Tighten the clamp holding the tilt hoses or auxiliary
the needed clearance when removing the hoses hoses at the rear of the second boom section.
from between the sections) and cap the tube ends to
system.
6
7
MZ4240
4. Loosen the clamps holding the tilt (6) or auxiliary

hoses (7) at the rear of the second boom section.
5. From the rear of the boom, pull the tilt (6) or auxiliary
hoses (7) from between the first and second boom
sections.
6. Pull the tilt (6) or auxiliary hoses (7) from the third
boom section.

Boom
3.15 TANDEM EXTEND/RETRACT

CYLINDERS REMOVAL/
INSTALLATION 4
The tandem extend/retract cylinders hydraulically

extends and retracts the second and third boom sections.
Seal kits for the extend/retract cylinders are available
4
from the local Caterpillar dealer.
3.15.1 Tandem Extend/Retract Cylinders

Removal 5
1. Remove any attachment from the quick coupler 2
Manual.
3
MZ4280
9. Remove the rod end pin (2). Note the location of the
spacers and washers (3).
10. Loosen and remove the extend/retract cylinder hose
1
(4) at the tube fitting on the extend/retract cylinder.
Plug the hose end to prevent dirt and debris from
MZ4270 11. Loosen and remove both tubes (5) at the end of the
extend/retract cylinder.
2. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park 12. Remove both clamps under the first boom section
brake. Extend the boom to allow access to the holding the extend/retract cylinder tubes.
tandem extend/retract cylinder mounting pin in the
third boom section (1).
3. Remove the retaining rings and mounting pin (1).
4. Raise the boom assembly and retract the extend/
retract cylinder allowing the third boom section to 6
retract along with the extend/retract cylinder.
5. Lower the boom assembly to a level position and MZ4260
shut the engine OFF.

13. Label, disconnect and cap the tilt circuit and the
6. Place a Do Not Operate Tag on both the ignition key auxiliary circuit hoses (6) at the bottom of the first
switch and the steering wheel. boom section. Cap all fittings and openings to
7. Open the engine cover. Allow the system fluids to prevent dirt and debris from entering the hydraulic
cool. system.
8. Properly disconnect the battery. 14. Pull the tilt hoses and/or auxiliary hoses from
between the first and second boom sections. Secure
the hoses away from the extend/retract cylinder.

Boom
3.15.2 Tandem Extend/Retract Cylinders

Bleeding Procedure
9
This procedure must be followed to assure no air is
trapped within the tandem extend/retract cylinders. An
10 auxiliary pump and reservoir must be used to properly fill
the tandem extend/retract cylinders.
12
Port Thread Sizes:
13 V1 & V2 - 1 1/16-12 SAE UNF/2B
7 C1 - M16x1,5
C2 - M30x2
9 Note: Use only metal plugs on ports utilized during the

7 procedure.
8
Note: Clean the area around each port before starting
the bleeding procedure.
11 5 4 (NOT SHOWN)
8 MZ4460
1
15. Remove the two hex head bolts and washers (7) 3
holding each hose guard (8) in place and remove
guards. 2
MZ5190
16. Remove the four socket head bolts and washers (9),
clamp plate and shim (10) holding the extend/retract Note: Allow adequate space for both cylinder rods when
cylinder (11) in place at the rear of the second boom extended.
section.
1. Connect the auxiliary pump to the V2 port (1) on the
17. Place a sling around the tandem extend/retract (rear) load control valve (2). Plug the V1 port (3).
cylinder, lift and slowly pull the extend/retract Plug C1 Port (tube end)(4). Remove the plug on the
cylinder approximately half way out of the rear of the top port C2 (5).
boom assembly. Lower the extend/retract cylinder
onto a suitable support. 1

stability, balance the extend/retract cylinder and
slowly pull the extend/retract cylinder free of the MZ5270
machine. Lower the extend/retract cylinder onto 6

suitable supports.
2. Slowly fill the bottom tandem cylinder (6) using the
V2 port (1) until the cylinder rod is fully extended.
Note: Fill each cylinder using a maximum of 10-20 bar
(145-290 psi).
Note: Approximately 38 liters (10 gal) of hydraulic oil is
required to fill the bottom cylinder.
7 5
4 (NOT SHOWN)
1
MZ5270
3. Plug the V2 port (1). Connect the auxiliary pump to

the C2 port (5) on the top cylinder (7). Remove plug
from C1 port (tube end)(4) and connect to reservoir.

Boom
Note: Use a reservoir with a minimum capacity of 70 3.15.3 Tandem Extend/Retract Cylinders
liter (18 gal). Installation
7 5 1. Using two slings for better stability, balance the
extend/retract cylinder and slowly push the extend/
retract cylinder approximately half way into the rear
of the boom assembly. Lower the extend/retract
cylinder onto a suitable support.
MZ5280
2. Align the trunnion blocks (12) of the extend/retract
4. Slowly fill the top tandem cylinder (7) using the C2 cylinder (11) with each support (13) at the rear of the
port (5) until the cylinder rod is fully extended. second boom section.
Note: Approximately 24 liters (6 gal) of hydraulic oil is 3. Apply Loctite® 242TM to the four socket head bolts
required to fill the bottom cylinder. (9).
5. Both tandem extend/retract cylinder rods are now 4. Install each clamp plate and shim(10) holding the
fully extended. extend/retract cylinder (11) in place at the rear of the
5 second boom section. Install the four socket head
4 (NOT SHOWN) 1 bolts and washers (9) and torque to 250 Nm
(185 lb-ft).
5. Apply Loctite® 242TM to the four hex head bolts (7).
3 6. Install each hose guard (8) to the extend/retract
2 MZ5280
cylinder (11). Install the four hex head bolts and
6. Plug C2 port (5). Connect C1 port (4) to the V1 port washers (7) and torque to 28 Nm (21 lb-ft).
(3) using a tee fitting and hose. Connect the open
end tee fitting to the auxiliary pump. Connect the V2
port (1) to reservoir.
1
6
MZ4260
3
MZ5290
7. Install the tilt hoses and auxiliary hoses (6) between
the first and second boom sections.
7. Slowly fill the tandem extend/retract cylinders using
the V1 port (3) until both cylinder rods are fully
retracted. Keep the cylinders pressurized for 2
approximately two minutes.
8. Remove the fittings and hose from the V1 (3) & V2
(1) ports and install plugs.
13 3
9. For tandem extend/retract cylinder installation, refer
to Section 3.15.3, “Tandem Extend/Retract Cylinders
Installation.”
10. After tandem extend/retract cylinder installation, 16
start machine and cycle the tandem extend/retract 14
cylinder twice at maximum idle and maximum stroke.
Keep the cylinders pressurized for approximately 12
one minute. 15
MZ4280
11. Shut engine OFF. Verify the tandem extend/retract
cylinder is leak free. Check hydraulic fluid level and 8. Align the rod end of the tandem extend/retract
add if necessary. cylinder and the mounting bore at the rear of the first
boom section. Install the rod end pin (14), spacers
and shims (15). Secure with the retaining clips.

Boom
9. Connect both tubes (16) to the appropriate locations

at the end of the extend/retract cylinder.
10. Install both clamps under the first boom section
holding the extend/retract cylinder tubes.
17
MZ4170
13. Start the engine and slowly extend boom to allow

access to the tandem extend/retract cylinder
mounting pin in the third boom section (17).
14. Shut engine OFF.
15. Align the tandem extend/retract cylinder rod and
install the mounting pin (17) and retaining rings.

Boom

the operator/mechanic be familiar with the name and
location of the major assemblies of the boom system. The
following illustration identifies the components that are
referred to throughout this section.
FOURTH BOOM HOSE CARRIER

SECTION
THIRD BOOM
SECTION
SECOND BOOM
SECTION
AUXILIARY
QUICK
CONNECTS
RETRACT CHAINS (THREE)
EXTEND/RETRACT CYLINDER
REAR VIEW
TILT CYLINDER
QUICK COUPLER
EXTEND CHAINS
(TWO PAIR) FIRST BOOM
SECTION
BOTTOM VIEW
MZ5670

Boom
3.17 BOOM SYSTEM - FOUR SECTION 2. Park the machine on a firm, level surface. Be sure
BOOM there is enough room in front of the machine to allow
the boom sections to be removed. Fully retract the
boom then raise the boom to access the rod end pin
3.17.1 Boom System Operation of lift cylinder. Place the transmission in
The four section boom consists of the first, second, third (N) NEUTRAL, engage the park brake and shut the
and fourth assemblies with double third and fourth engine OFF.
section extend chains, a double third section retract 3. Place a Do Not Operate Tag on both the ignition key
chains and a single fourth section retract chain. switch and the steering wheel.
As the extend/retract cylinder, which is anchored at the 4. Open the engine cover. Allow the system fluids to
front of the second boom section, and the rear of the first cool.
boom section begins to extend, it forces the second boom
5. Label, disconnect and cap both hoses from the
section out of the first boom section.
Extend/Retract cylinder.
The first, second, third and fourth boom sections are
6. Label, disconnect and cap both hoses from the tilt
connected by extend and retract chains. These chains
hoses and auxiliary hoses from tubes at the bottom
are routed around sheaves on the second and third boom
rear of the first boom section. Cap all fittings to
sections. As the second and third boom sections are
forced out, the extend chain pulls the fourth boom section
system.
out of the third boom section.
7. Remove the Extend/Retract cylinder support at the
As hydraulic pressure is applied to the retract port on the
top front of the first boom section.
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chain 8. Support the Extend/Retract cylinder and remove the
pulls the third and fourth boom sections back into the clip and pin from rod end of extend/retract cylinder.
second boom section. Remove the clip and pin from barrel end of extend/
retract cylinder and remove the extend/retract
This mechanical linkage formed by the chains and
cylinder.
supporting hardware, extends and retracts the third and
fourth boom sections at the same rate. 9. Disconnect the boom angle indicator rod from the
switch at the inside left rear corner of the main boom
The first boom section does not extend or retract, but lifts
section and frame.
and lowers via action of the lift cylinder.
10. Support the front of the boom by placing a sling
3.18 BOOM ASSEMBLY MAINTENANCE behind the boom head. Support the Lift/Lower
cylinder and remove the lock bolt and then the rod
These instructions must be completed in sequence. The end pin. Lower the Lift/Lower cylinder onto the frame
second, third and fourth boom sections are removed from rails.
the first boom section.The third and fourth boom sections 11. Remove the lock bolt and pin from Compensation
are removed from the second boom section.The fourth cylinder on each side of first boom section. Remove
boom section is removed from the third boom section. the lock bolt and pivot pin from rear of first boom
Before beginning, conduct a visual inspection of the section.
machine and work area, and review the task about to be 12. Lower the boom to a level position and place a
undertaken. Read, understand and follow these suitable support under the boom head. Reposition
instructions. the slings to each end of the boom.
13. Lift the complete boom off machine and set on level
3.18.1 Boom Removal ground or supports being careful not to damage the
1. Remove any attachment from the quick coupler tubes on the left side of boom.
assembly.
Note: If replacing the innermost boom section, remove
the quick coupler assembly. Refer to Section 3.23.3,
“Quick Coupler Removal (TH414C, TH514C &
TH417C).”

Boom
3.18.2 Second, Third and Fourth Boom 4. At the bottom front of the first boom section, remove
Section Removal the jam nuts and nuts and washers from the two
extend chain clevises. Remove clips and pins from
the two clevises and remove clevis from each chain.
5. At the bottom front of the second boom section
1 remove the jam nuts and nuts and washers from the
two extend chain clevises. Remove clips and pins
from the two clevises and remove clevis from each
chain.
MZ5680
1. Set the complete boom on level ground and by

repositioning the slings turn boom over on to the top
side. Set the complete boom (1) on suitable stands
to begin tear down.
MAM4020
Note: With the complete boom setting upside down, the
removal and replacing of each boom section, tilt cylinder, 6. Disconnect and remove the boom retract sensor (3)
hoses, extend and retract chains and hose carrier are from the rear of the first boom section.
made much easier. 7. At the rear of the boom, label, disconnect and cap
2. At the boom head attach a sling through rod end of both Tilt hoses and both Auxiliary hoses from the
tilt cylinder. Label, disconnect and cap both hoses bulkhead on the hose carrier. Cap all fittings to
from Tilt cylinder. Plug the cap all fittings to prevent prevent dirt and debris from entering the hydraulic
dirt and debris from entering the hydraulic system. system.
Remove the clip from barrel end of tilt cylinder pin. 8. Remove the clip and pin from both retract chain
Remove the tilt cylinder pin and lift the Tilt cylinder clevises that are attached to the rear of the third
out of the boom head. section boom. The pins can be removed through the
3. Use a suitable sling around the third section boom to access holes at the bottom left and right sides of the
take any pressure off of wear pads to make pad first section boom. Do not remove the clevises.
removal easier. 9. Remove the clip and pin from the retract chain clevis
that is attached to the rear of the fourth boom
section. Do not remove the clevis.
10. Pull the second section boom out 152 mm to
203 mm (6 in to 8 in) and remove all the wear pads
from the front inside of the first section boom. Label
MZ5690 all parts for installation.
11. Pull the third boom section out 152 mm to 203 mm
2 2 (6 in to 8 in). Remove the top left and right side wear
pads from the second boom section. Loosen the
Note: Before removing the extend chains, measure the bottom rear wear pad bolts and remove the shims
distance (2) between the face of the jam nut to the end of from the second boom section to gain the necessary
the chain clevis on all four extend chains. This clearance to be able to remove the second boom
measurement will be used when reassembling the section from the first boom section. Label all parts
boom. for installation.

Boom
12. Using a sling around the front of the second boom

section, lift and slide the three boom sections 75% of
the way out of the first boom section. Set the boom
head down on a suitable support, then center the
sling to be able to balance the three boom sections
being removed. Carefully pull the three boom
sections the remainder of the way out of the first 3
boom section and set the three boom sections down
on suitable supports.
13. Remove the clip and pin holding each retract chain
from the inside of the first boom section. Clean and
inspect chains. Replace if damaged.
14. Label, disconnect and cap the Tilt and Auxiliary
hydraulic hoses from tubes at bottom front of first
boom section. Plug all fittings to prevent dirt and
debris from entering hydraulic system. Clean and
inspect the hoses. Replace if damaged. MZ5700
15. Inspect the boom and welds. Consult your local

authorized service distributor if structural damage is 4. Place a sling around the front of the third boom
detected. section. Lift and slide the two boom sections 75% of
the way out of the second boom section. Set the
16. Inspect hoses, hardware, wear pads, mounting boom head down on a suitable support, then center
points, chains and other components visible with the the sling to be able to balance the two boom
first boom section. Replace any item if damaged. sections being removed. Carefully pull the two boom
(Refer to Section 3.21, “Boom Extend and Retract sections (3) the remainder of the way out of the
Chains - TH414C & TH417C,” and Section 3.22.1, second boom section and set the two boom sections
“Wear Pad Inspection.”) down on suitable supports.
Note: It is recommended that if any chain or hose is 5. Remove the lock bolts, keeper and pin from both
damaged that ALL chains or hoses are replaced. sheaves at bottom rear of the second section boom.
Remove the sheaves.
3.18.3 Third and Fourth Boom Section
6. Remove the clip and pin holding retract chain from
Removal
bottom front of second boom section. Clean and
1. With the three boom sections setting on suitable inspect chain. Replace if damaged.
supports remove bolts, keeper and pin from both 7. Inspect the boom and welds. Consult your local
sheaves on the bottom front of the second boom authorized service distributor if structural damage is
section. Remove sheaves. Remove all wear pads on detected.
the front inside of the second boom section. Label all
parts for installation. 8. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
2. Remove the bolts, keeper and pin from center first boom section. Replace any item if damaged.
sheave on the bottom rear of the third boom section. (Refer to Section 3.21, “Boom Extend and Retract
Remove the sheave. Chains - TH414C & TH417C,” and Section 3.22.1,
3. Remove the top left and right side rear wear pads on “Wear Pad Inspection.”)
the third boom section. Loosen the bottom rear wear 9. It is recommended that if any chain or hose is
pad bolts and remove the shims from the third boom damaged that ALL chains or hoses are replaced.
section to gain the necessary clearance to remove
the third boom section from the second boom
section. Label all parts for installation.

Boom
3.18.4 Fourth Boom Section Removal 7. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
1. With the two boom sections setting on suitable
first boom section. Replace any item if damaged.
supports remove the bolts, keeper and pin from
(Refer to Section 3.21, “Boom Extend and Retract
sheave on the front of the third boom section.
Chains - TH414C & TH417C,” and Section 3.22.1,
Remove the sheaves. Remove all wear pads, from
“Wear Pad Inspection.”)
the front inside of the third boom section. Label all
parts for installation. 8. It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced.
2. Remove the top left and right side rear wear pads on
the fourth boom section. Loosen the bottom rear
wear pad bolts and remove the shims from the fourth
3.18.5 Hose Carrier Removal
boom section to gain the necessary clearance to be 1. Label, disconnect and cap both auxiliary hydraulic
able to remove the fourth boom section from the hoses in the boom head. Cap all fittings to prevent
third boom section. Label all parts for installation. dirt and debris from entering hydraulic system.
3. Loosen and remove the two bolts holding the rear of 2. With fourth boom section setting on suitable
the hose carrier to the top of the third boom section. supports loosen and remove the six bolts (three per
Lift and push rear of hose carrier into the fourth side) on the fourth boom section.
boom section.
MZ5720
3. Pull the hose carrier (5) halfway out of fourth boom

section by hand and set on a suitable support. Place
a sling around the center of the hose carrier to be
MZ5710
able to balance the hose carrier while being
removed. Carefully slide the hose carrier the
4. Place a sling around the front of the fourth boom remainder of the way out of the fourth boom section
section (4). Lift and slide the fourth boom section 3/4 and set down on suitable supports.
of the way out of the third boom section. Set the
boom head down on a suitable support, then center 3.18.6 Hose Carrier Installation
the sling to be able to balance the fourth boom
section being removed. Carefully pull the fourth 1. Install the hose carrier into the fourth boom section.
boom section the remainder of the way out of the Using a suitable sling, place the sling under the
third boom section and set the fourth boom section center of the hose carrier and guide the front of hose
down on suitable supports. carrier into the rear of the fourth boom section. Set
the rear of the hose carrier on a suitable support.
5. Remove the clip and pin holding both extend chains
Remove the sling and slide the remainder of the
from bottom of third and fourth boom sections. Clean
hose carrier into the fourth boom section by hand.
and inspect chains. Replace if damaged.
2. Apply Loctite® 242TM to the hose carrier bolts. Install
6. Inspect the boom and welds. Consult your local
the bolts through the three holes on each side of the
authorized service distributor if structural damage is
fourth boom section. Install the front two bolts first.
detected.
Install the middle two next. Then the rear two bolts
last. Torque to all six bolts to 90 Nm (66 lb-ft).

Boom
3.18.7 Fourth Boom Section Installation

7
MZ5740
5. Apply Loctite® 242TM to the sheave mounting bolts,

Install the sheave (7), pin, lock plate and bolts at the
bottom front of the third boom section. Torque bolts to
90 Nm (66 lb-ft). Grease the sheave using the grease
fitting in the pin. Spin the sheave by hand to ensure
the sheave spins freely on the pin and to distribute
MZ5710 grease evenly. Pull both extend chains from the fourth
boom section around the front and over the sheave.
1. Apply Loctite® 242TM to the wear pad mounting bolts. Install both chain clevises, pins and clips.
Install the bottom, left right and top wear pads. Do 6. Retract the fourth boom section the remainder of the
not shim or tighten the side and top wear pad bolts way into the third boom section and install the wear
at this time. Install both extend chains (6) on bottom pads at the rear of third and fourth boom sections.
rear of fourth boom section. Lay extend chains the
length of fourth boom section. 7. Apply Loctite® 242TM to the wear pad mounting bolts
and install the bottom left and right side wear pads,
2. Grease the inside third boom section on area’s backing plates, shims and bolts. Shim the top wear
where the fourth boom section wear pads will slide. pads on the rear of the fourth boom section. Shim
3. Using a suitable sling, balance the fourth boom the top left and right wear pads on the rear of the
section and carefully slide 914 mm to 1219 mm fourth boom section. Torque bolts to 90 Nm (66 lb-ft).
(3 ft to 4 ft) into the front of the third boom section. Torque grease fitting bolts to 45 Nm (33 lb-ft).
Set the fourth boom section head onto suitable
support and reset sling under the boom head of the 3.18.8 Third and Fourth Boom Section
fourth boom section. Carefully slide the fourth boom Installation
section into the third boom section. Leave
1. At the rear of the third boom section apply Loctite®
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom
242TM to the wear pad mounting bolts and install the
section out to be able to install wear pads in front of
bottom rear wear pads, washers and bolts. Torque to
the third boom section.
90 Nm (66 lb-ft). Install the bottom rear left and right
4. With the sling still under boom head install the top side wear pads, backing plate and bolts (do not shim
wear pads. Lower the fourth boom section and install or tighten bolts). Install the top rear wear pads,
the bottom, left and right side wear pads. Do not backing plates and bolts (front bolts are drilled and
shim or tighten bolts at this time. tapped for grease fittings. do not shim or tighten
Note: Grease wear pads, inside sheaves, bores and bolts). Install both extend chains on the bottom rear
pins during assembly. of the third boom section. Lay extend chains the
length of third boom section.
2. Grease the inside second boom section on areas
where the third boom section wear pads will slide.
3. Install retract chain, pin and clip to bottom front
inside of the second boom section.
Note: Keep the retract chain centered on bottom of the
third boom section while installing the third boom section
into the second boom section.

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

boom sections and carefully slide 914 mm-1219 mm
(3 ft - 4 ft) into the front of the second boom section.
Set the third and fourth boom sections onto a
suitable support and reset the sling under the boom
1
head of the fourth boom section. Carefully slide the
third and fourth boom sections into the second boom
section. Leave 152 mm-203 mm (6 in - 8 in) of the
third boom section out to be able to install the wear
pads in the front of the second boom section.
5. With the sling still under boom head, Apply Loctite®
242TM to the wear pad mounting bolts and install the MZ5760
top wear pads, washers and bolts in the front of the
second boom section. Torque to 90 Nm (66 lb-ft). 8. Install the retract chain sheave (1), pin, keeper and
Lower the third and fourth boom section and apply bolts to bottom rear of third boom section. Apply
Loctite® 242TM to the wear pad mounting bolts and Loctite® 242TM and torque to 90 Nm (66 lb-ft). Grease
install bottom wear pads, backing plates, shims, and the sheaves using the grease fitting in the pin. Spin
the allen head cap bolts in the front of the second the sheaves by hand to ensure the sheaves spin
boom section. Torque to 90 Nm (66 lb-ft). Install both freely on the pin and to distribute grease evenly.
left side and right side front wear pads, backing
plates, shims and bolts in the front of the second 2 2
boom section. Torque to 90 Nm (66 lb-ft).
Note: Grease wear pads, inside sheaves, bores and
pins during assembly.
8 9
MZ5770
MZ5750
9. Install both retract chain sheaves (2), pin, keeper
6. Install both sheaves (8), pins, lock plates and bolts at and bolts to bottom rear of second boom section.
the bottom front of the second boom section. Apply Apply Loctite® 242TM and torque to 90 Nm
Loctite® 242TM and torque bolts to 90 Nm (66 lb-ft). (66 lb-ft). Grease the sheaves using the grease
Grease the sheaves using the grease fitting in the fitting in the pin. Spin the sheaves by hand to ensure
pin. Spin the sheaves by hand to ensure the sheaves the sheaves spin freely on the pin and to distribute
spin freely on the pin and to distribute grease evenly. grease evenly.
Pull both extend chains from the third boom section
around the front and over the sheaves. Install both 3.18.9 Second, Third and Fourth Boom
chain clevises, pins and clips (9). Section Installation
7. Apply Loctite® 242TM to the wear pad mounting bolts Note: Light lubrication of the boom wear surfaces with a
and install the bottom left and right side wear pads, factory authorized grease is recommended to keep the
backing plates, shims and bolts.Shim the top wear boom wear surfaces lubricated properly. Light lubrication
pads on the rear of the third boom section. Shim the of the boom wear surfaces is also recommended when
top left and right wear pads on the rear of the third the machine is stored, to help prevent rusting.
boom section.Torque bolts to 90 Nm (66 lb-ft).
Torque grease fitting bolts to 45 Nm (33 lb-ft). 1. Apply Loctite® 242TM to the wear pad mounting bolts.
At the rear of the second boom section, install the
bottom rear wear pads, washers and bolts. Torque to
90 Nm (66 lb-ft). Install the bottom rear left and right
side wear pads, backing plate and bolts (do not shim

Boom
or tighten bolts). Install top rear wear pads, backing the front of the second boom section. Torque to
plates and bolts (front bolts are drilled and tapped for 90 Nm (66 lb-ft).
grease fittings. do not shim or tighten bolts). Note: Shim ALL side wear pads as needed to maintain
a minimum gap (1.6 mm - 1/16 in) the horizontal
direction or a snug fit. The number of shims can vary at
each shim point.
7. Install the bottom left and right side wear pads,
3 3 backing plates, shims and bolts at the rear of the
second boom section.Shim the top wear pads on the
rear of the second boom section. Shim the top left
5
and right wear pads on the rear of the second boom
4 section. Apply Loctite® 242TM and torque bolts to
90 Nm (66 lb-ft).
8. Retract the second, third and fourth boom sections
MZ5780
the remainder of the way into the first boom section.
2. Grease the inside first boom section on area’s where
the second boom section wear pads will slide.
3. Install the retract chains (3), pins and clips to bottom
front inside of the first boom section.
4. Install both tilt hoses (4) and both auxiliary hoses (5)
to the tubes mounted at the bottom front of the first
boom section. Make sure both sets of hoses are run
7
through the opening at the bottom front of the first
boom section and run down the inside center of the
boom section
Note: Keep the retract chains, tilt and auxiliary hoses
centered in the first boom section while installing the
second boom section into the first boom section.
6
5. Using a suitable sling, balance the second, third and
fourth boom sections and carefully slide
914 mm - 1219 mm (3 ft - 4 ft) into the front of the
first boom section. Set the second, third and fourth
boom sections onto a suitable support and reset
sling under the boom head of the fourth boom MZ5730
section. Carefully slide the second, third and fourth
boom sections into the first boom section. Leave 9. Attach the retract chain (6), pin and clip to the clevis
152 mm - 203 mm (6 in - 8 in) of the second boom at the rear of the fourth boom section.
section out to be able to install wear pads in front of
10. Attach the retract chains (7), pins and clips to the
the first boom section.
clevises at the rear of the third boom section.
6. With sling still under boom head, Apply Loctite®
242TM to the wear pad mounting bolts. Install the top
wear pads, washers and bolts in the front of the first
boom section. Torque to 90 Nm (66 lb-ft). Lower the
second, third and fourth boom sections and apply Note: Installing the clevis pins in the third boom section
Loctite® 242TM to the wear pad mounting bolts, Install can only be done when the first boom section and the
bottom wear pads, backing plates, shims, and bolts second boom section access holes are aligned.
in the front of the first boom section. Torque to
90 Nm (66 lb-ft). Install both left side and right side
front wear pads, backing plates, shims and bolts in

Boom
18. Remove the caps from the fittings on the Tilt cylinder
9 and the plugs from the Tilt hoses from the hose
carrier. Install both Tilt hoses and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
19. Using suitable slings, lift complete boom off supports
and set on level ground. It will be necessary to place
MZ5690 a block under the rear of the boom to keep the tilt
8 and auxiliary tubes from being damaged
20. Turn the boom over being careful not to damage the
12. Attach both extend chain clevises (8) through the
Tilt and Auxiliary tubes mounted on the side and rear
holes in the bottom front of the first boom section.
of boom.
Install the washers, adjustment nut and jam nut to
the clevises. 21. After boom is turned upright, place a suitable
support under the rear of the boom.
13. Attach both extend chain clevises (9) through the
holes in the bottom front of the second boom 22. Attach a sling around a balance point on the Extend/
section. Install the washers, adjustment nut and jam Retract cylinder and carefully set on top of the first
nut to the clevises. boom section.
Note: Adjust all four extend chains using the Note: Grease Extend/Retract cylinder barrel end bore
measurement taken in the beginning of the tear down and rod end bore and pins before installing.
procedure. Depending on the extent of the parts being 3
replaced, the above measurement is to be used as a 1
starting point ONLY. 6
14. Pull the rear of the hose carrier over the rear of the 5
fourth boom section and set onto the rear of the third
boom section. Using the two bolts, washers and
nuts, bolt the rear of the hose carrier to the rear of
the third boom section. Apply Loctite® 242TM and
torque the two bolts to 90 Nm (66 lb-ft). 2
15. Remove the caps from the fittings on the hose

carrier bulkhead and the plugs from the tilt and
auxiliary hoses. Install all four hoses and tighten until 4
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
16. Remove the caps from the Auxiliary hoses in the
MZ5790
boom head and install the Auxiliary hoses from the
front of the hose carrier to the Auxiliary bulkhead. 23. Align the Extend/Retract cylinder barrel end (1) with
Tighten each hose wrench-tight. Mark the hose bore at rear of the first boom section (2). Install the
fitting then tighten each hose firmly 1 to 1 1/2 flats. pin and retaining clip (3).
Bolt the auxiliary hose bulkhead to the side of the
boom head and torque the two bolts to 90 Nm 24. Align the Extend/Retract cylinder rod end with bore
(66 lb-ft). at front of the second boom section (4). Install the
pin and retaining clip (5).
17. Using a suitable sling through the rod end of the Tilt
cylinder, lower the Tilt cylinder into boom head. Align 25. Install Extend/Retract cylinder support (6). Apply
the Tilt cylinder barrel end bore with the boom head Loctite® 242TM and torque bolts to 90 Nm (66 lb-ft).
bore and install the Tilt cylinder pin and retaining
clip.
Note: Grease Tilt cylinder barrel end bore and pin
before installing.

Boom
3.18.10 Complete Boom Installation

10
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly. Light lubrication
of the boom wear surfaces is also recommended when
the machine is stored, to help prevent rusting.
1. Park the machine on a hard, level surface. Make
sure park brake is set, key is removed from the
ignition and “Do Not Operate” tag is placed in clear
view in the cab.
8
MZ5810
12 11
5. Remove the caps from Extend/Retract cylinder

fittings and plugs from Extend/Retract cylinder
hoses. Attach each hose to the Extend/Retract
cylinder fittings (10) and tighten until wrench-tight.
7 8 9 MZ5800 Mark the hose fitting then tighten each hose firmly 1
to 1 1/2 flats.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the 6. Remove the caps from both Tilt tubes (11) and
frame pivot bore with the boom assembly pivot bore. Auxiliary tubes (12) and plugs from both Tilt hoses
Install boom pivot pin (7). Apply Loctite® 242TM and and both Auxiliary hoses. Attach both sets of hoses
torque lock bolts to 90 Nm (66 lb-ft). to the Tilt tubes and the Auxiliary tubes and tighten
until wrench-tight. Mark the hose fitting then tighten
3. With the sling still in place, install both each hose firmly 1 to 1 1/2 flats.
Compensation cylinders, pins and lock bolts (8).
Apply Loctite® 242TM and torque to 90 Nm (66 lb-ft). 7. Connect the boom angle indicator rod to the switch
at the inside left rear corner of the main boom
4. With the sling still in place, install the rod end of the section and frame. Refer to Section 9.12.7, “Boom
Lift/Lower cylinder, pin and lock bolt (9). Apply Angle Sensor,” for adjustment information.
Loctite® 242TM and torque to 90 Nm (66 lb-ft).
Note: Raising the boom up or down with the sling several times. Check for leaks, and check the
maybe necessary so the boom, Compensation and Lift/ hydraulic fluid level in the reservoir; add fluid if
Lower cylinder bores can be aligned for easier pin required.
installation. 9. Clean up all debris, hydraulic fluid, etc., in, on, near
Note: Grease the boom pivot bore, compensation and around the machine.
before installing.

Boom
3.19 BOOM CHAIN REMOVAL/ 1. If adjustments are needed: Start the machine, level
INSTALLATION the boom and extend the boom 0,91m to 1,2m
(3 ft to 4 ft). Turn OFF engine.
The removal of the extend and/or retract chain can only
be accomplished with the complete tear down of the
boom.
3.20 BOOM SECTIONS ADJUSTMENT
3.20.1 Chain Adjustments

The chains are adjusted by tightening and/or backing off
the adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.
Fully retract and level the boom.
A 3
MY3670
B 1
D MY3660 4
The boom is properly adjusted whenever the following

parameters are met. 2 2
A. 797 ±3mm (31.0 ±0.12in)
MY3680
B. 499 ±3mm (19.9 ±0.12in)
C. 229 ±3mm (9.0 ±0.12in)
2. Loosen the locknuts on the extend and retract
D. 20mm (0.80in)
chains.
3. Adjust extend chains (1) and retract chains (2) to
ensure a gap of (D) between the face of the second
boom section and the shoulder of the third boom
section. The retract chains (2) are accessible from
the side of the boom.
4. Adjust extend chains (3) and retract chain (4) to
ensure a gap of (C) between the face of the third
boom section and the center of the tilt cylinder pin on
the fourth boom section. The retract chain (4) is
accessible from the rear of the boom.

Boom
5. Adjust extend chains (1 & 3) and retract chain(s) 3.21 BOOM EXTEND AND RETRACT
(2 & 4) to ensure a gap of (A & B) for the overall
CHAINS - TH414C & TH417C
boom section adjustment.
6. Tighten the extend and retract chain lock nuts to 120
Nm (86 lb-ft) against the adjusting nut. 3.21.1 Boom Chain Inspection

of the clevis showing beyond the lock nut. WARNING
7. Start the machine and slowly extend and retract the Worn pins, stretched or cracked links or corrosive
boom three times. environments can cause chain failure. A chain failure
8. Retract the extend/retract cylinder completely. Turn could result in uncontrolled boom movement, loss of
OFF engine. load or machine instability.
9. Verify boom section dimensions. Repeat steps 1 thru Under normal operating conditions the boom chains will
7 if necessary. need to be inspected every 250 hours of operation. The
10. Start the machine, lower the out riggers if necessary retract chains need to be exposed and inspected every
1000 hours of operation. Refer to the Service Manual for
and extend the boom to maximum extension, then
the proper procedure. Environmental conditions and
retract 51 to 76 mm (2 to 3 in). Shut machine off. dynamic impulse/shock loads can drastically affect
normal operating conditions and require more frequent
inspection intervals.
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
E F
• Moisture - Corrosive rusting reduces chain
strength by pitting and cracking.
MY5290 • Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of
11. Measure the distance between the top of both cold storage results in moisture from
extend chains and the bottom of the second and condensation.
third boom sections at the center of each section. • Chemical Solutions or Vapors - Corrosive attack
12. The distance between the top of the extend chains on the chain components and/or the mechanical
and the bottom of the third boom section (E) should connections between the chain components.
measure 120 mm ± 2 mm (4.724 in ± 0.078 in). Cracking can be (and often is) microscopic.
Going from microscopic cracking to complete
13. The distance between the top of the extend chains failure can be either abrupt or may require an
and the bottom of the second boom section (F) extended period of time.
should measure 180 mm ± 2 mm (7.0 in ± 0.078 in).
• Abrasives - Accelerated wearing and scoring of
14. Loosen the locknuts on the extend chains and adjust the articulating members of the chain (pins and
if necessary. Tighten locknuts to 120 Nm (86 lb-ft). plates), with a corresponding reduction in chain
15. Start the machine and cycle the extend/retract strength. Due to the inaccessibility of the bearing
cylinder to verify the boom extends and retracts surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
properly.
the naked eye.
Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
limit of a leaf chain.

Boom
• High velocity movement of load, followed by Edge Wear

sudden, abrupt stops.
• Carrying loads in suspension over irregular
surfaces such as railroad tracks, potholes, and
rough terrain. 1 2
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
The above load cycles and environmental conditions
MZ1463
make it impossible to predict chain life. It is therefore
necessary to conduct frequent inspections until Check the chain for wear on the link plate edges
replacement life can be predicted. caused by running back and forth over the sheave.
The maximum reduction of material should not
The boom chain’s normal life expectancy can be
exceed 5%. Measure and compare to a normal link
expressed as a maximum percent of elongation. This is
plate height by measuring a portion of chain that
generally 3%. As the chain flexes back and forth over the
does not run over the sheave. If the measured plate
sheave, the bearing joints (pins and inside link plates)
height (1) is 5% less than the normal plate height
gradually incur wear due to articulation.
(2), discard and replace the chain.
3.21.2 Inspection Guidelines - TH414C Elongation
It is important to measure the chain in the section
a. Retract Chain that moves over the sheaves because it receives the
1. Park the machine on a firm, level surface, raise the most frequent articulation. Measuring the chain near
boom to a horizontal (level) position, place the its clevis terminals could give an inaccurate reading.
transmission in (N) NEUTRAL, engage the park The ends of the chains, near the clevis terminal, will
not have flexed as frequently, if at all, as the middle
brake switch.
of the chains.
2. Fully extend the boom until the retract chain is taut.
It is best to measure in 12 pin increments from pin
Shut the engine off.
center to pin center. For example, if the links are
3. The retract chain will be visible for inspection with 25 mm (1 in) from pin center to pin center, the
the vehicle in this state. distance should be 305 mm (12 in). If the links are
19 mm (.75 in) apart, the distance after 12 pins
4. While doing the chain inspection, check all chain
should be 229 mm (9 in).
clevis ends, pins for distortion or cracking and
sheaves for bearing wear or grooving from the chain. 4
b. Extend Chains 3
1. Park the machine on a firm, level surface, raise the

boom to a horizontal (level) position, place the
brake switch.
2. Fully retract the boom. Shut the engine off.
3. Both extend chain clevises and pins will be visible for
inspection with the vehicle in this state.
4. Limited visual inspection of the extend chains is
possible. For complete extend chain inspection, the
extend chains must be removed from the boom. For MY1360
extend chain removal, refer to Section 3.7.3, “Extend
Chain Removal,” and Section 3.7.4, “Extend Chain If the distance measured (3) is 3% greater than the
Installation.” normal length (4), discard and replace the chain.
5. Inspect the extend and retract chains every 250
hours of operation.
6. Inspect the chains for the following conditions:

Boom
3.21.3 Inspection Guidelines - TH417C Elongation

1. Park the machine on a firm, level surface, raise the It is important to measure the chain in the section
boom to a horizontal (level) position, place the that moves over the sheaves because it receives the
transmission in (N) NEUTRAL, engage the park most frequent articulation. Measuring the chain near
brake switch. its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will
2. Fully extend the boom until the extend chain is taut. not have flexed as frequently, if at all, as nearer the
Shut the engine off. middle of the chains.
3. The extend chains will be visible for inspection with
the vehicle in this state. a. Extend Chains (fourth to third section)
4. While doing the chain inspection, check all chain 4
clevis ends for distortion or cracking and sheaves for
bearing wear or grooving from the chain. 3
5. Inspect the retract chains every 1000 hours of
operation. Refer to the Service Manual for proper
procedure.
6. Inspect the chains for the following conditions:
Edge Wear
Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The maximum reduction of material should not
exceed 5%. This can be compared to a normal link
plate height by measuring a portion of chain that MY1360
does not run over the sheave.
When the original length (3) of 305 mm (12.00 in)
a. Extend Chains (fourth to third section) per foot of extend chain between the fourth and third
The extend chains between the fourth and third boom sections has elongated from wear to a length
boom sections measures 18 mm (.713 in) (1). If the (4) of 313 mm (12.36 in), the chain should be
measurement of the worn chain is less than 17 mm discarded and replaced.
(.677 in) (2), the chain should be replaced. Measure across a span of 16 pins at the center of
the extend chain. Measure from pin center to pin
b. Extend Chains (third to second section) center. Because the retract chain is inside the boom
you will not be able to measure the chain.
The maximum measurement allowed is
313 mm(12.36 in). If the measurement is more than
2 1 313 mm (12.36 in), the chain should be replaced.
b. Extend Chains (third to second section)

When the original length (3) of 317 mm (12.5 in) per
MZ1463 foot of extend chain between the third and second
boom sections has elongated from wear to a length
The extend chains between the third and second (4) of 325 mm (12.8 in), the chain should be
boom sections measures 29,6 mm (1.2 in) (1). If the discarded and replaced.
measurement of the worn chain is less than Measure across a span of 10 pins at the center of
28,6 mm (1.1 in) (2), the chain should be replaced. the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom
you will not be able to measure the chain.
The maximum measurement allowed is
325 mm(12.8 in). If the measurement is more than
325 mm (12.8 in), the chain should be replaced.

Boom
Distorted or Battered Link Plates Cracked Plates

Inspect the chains very carefully, front and back as
85 well as side to side, for any evidence of cracked
plates. If any one crack is discovered, the chain
should be replaced in its entirety.
It is important, however to determine the cause of
the crack before installing a new chain so the
condition does not repeat itself.
The types of cracks are:
MZ1466
• Fatigue Cracking -
Distorted or battered link plates (5) on a leaf chain can Fatigue cracks (1) are a 1
result of repeated
cause tight joints and prevent flexing.
cyclic loading beyond MZ1467
Turning or Protruding Pins the chain’s endurance
limit.
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces • Stress Corrosion
between pin and link plates. When chain is allowed Cracking - The
to operate in this condition, a pin or series of pins, outside link plates 2
can begin to twist out of a chain, resulting in failure. are particularly MZ1468
susceptible to stress
corrosion cracking (2).
• Corrosion Fatigue Cracking - Corrosion
7 fatigue cracks are very similar to fatigue
6
cracks in appearance. Corrosion fatigue is the
8 combined action of an aggressive
MZ1465
environment and cyclic stress.
Other Modes of Failure
Examine the pin head rivets to determine if the
“VEE” flats are still in correct alignment (6). Chain • Ultimate Strength Failure -
with rotated/displaced heads (7) or abnormal pin These types of failures are
protrusion (8) should be replaced immediately. caused by overloads far in 3
excess of the design load. MZ1469
DO NOT attempt to repair the chain by welding or Either fractured plates (3) or 4
driving the pin(s) back into the chain. Once the press enlarged holes (4) can
fit integrity between outside plates and pins has occur. If either of these
been altered, it cannot be restored. MZ1470
failures occurs, the chain
Any wear pattern on the pin heads or the sides of the should be replaced immediately.
link plates indicates misalignment in the system. • Tight Joints
This condition damages the chain as well as - All joints in
increases frictional loading and should be corrected. the chain
should flex
freely. Tight
joints (5) 5 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.

Boom
3.21.4 Expose Chains for Inspection 3.21.5 Chain Lubrication

After inspection and before being returned to service,
c. Retract Chain chains must be lubricated with CAT Multipurpose
1. Park the machine on a firm, level surface. Place the Grease-NLGI Grade 2.
transmission in (N) NEUTRAL, engage the park The lubricant must penetrate the chain joint to prevent
brake switch and raise the boom to a horizontal wear. Applying lubricant to the external surfaces will
(level) position. prevent rust, but the chains should be articulated to
2. Fully extend the boom until the retract chain is taut. make sure the lubricant penetrates to the working
surfaces between the pins and links.
Shut the engine OFF.
The retract chain will be visible for inspection with the To prepare the chain for lubrication, the chain plates
should be brushed with a stiff brush or wire brush to
machine in this state.
clear the space between the plates so that lubricant can
While doing the chain inspection, check all chain clevis penetrate to the working surfaces.
ends for distortion or cracking and sheaves for bearing
Lubricant may be applied with a narrow paint brush or
wear or grooving from the chain. directly poured on, but the chain should be well flooded
If during the inspection, if any chain is found to be with lubricant and the boom should be extended and
damaged or stretched, the chain must be replaced. It is retracted to be sure that the lubricant penetrates to the
recommended that when any chain is replaced, that all working surfaces. All surplus lubricant should be wiped
the chains and clevises be replaced at the same time. away from the external surfaces. DO NOT use a solvent
for this wiping operation.
d. Extend Chains Regular application of lubricant is necessary to make
sure that all working surfaces are adequately lubricated.
The extend chains are only partially visible through the In extremely dusty conditions, it may be necessary to
rear of the boom with all the sections retracted. It is lubricate the chains more often. Refer to Section 2.6,
possible to see a section of the extend chain as the boom “Service and Maintenance Schedules,” and Section 2.7,
is slowly extended. If there is ANY question that one or “Lubrication Schedules,” for detailed information.
both extend chains are damaged, the extend chains
Lubrication of chains on vehicles working consistently in
should be removed, inspected and replaced if necessary.
extreme hot or cold conditions requires special
Refer to Section 3.21, “Boom Extend and Retract Chains consideration. Contact the Caterpillar dealer for
- TH414C & TH417C.” guidance.
Note: DO NOT attempt to repair a chain. Replace a
stretched or damaged chain with a new part. Always
replace both the chain and the clevis. It is recommended
that when any chain is replaced, that all chains and
clevis’ be replaced at the same time.

Boom
3.22 BOOM WEAR PADS • The bottom wear pads must be shimmed equally on
each side.
The boom wear pads are flat rectangular plastic blocks 5
with metal inserts.
3.22.1 Wear Pad Inspection

1 1
Ma2070
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to • Maintain a total boom section clearance of
back), they should be replaced. Replace pads as a set if 1,8 - 3,3 mm (0.070 to 0.130 in) both the horizontal
and vertical directions.
worn or damaged.
A
3.22.2 Boom Wear Pad Installation/

Lubrication
B
The boom has been factory lubricated for proper wear pad
break-in and will normally require minor further
lubrication. However, after replacing any wear pad(s), or MY3620
after prolonged periods of inoperation, lubrication of the

• The length of the wear pad bolt depends on the
boom wear surfaces with CAT Multipurpose Grease is number of shims, spacers and washers being used.
recommended to keep the boom wear surfaces
• The thickness of each threaded wear pad insert is
lubricated properly. Lubrication of the boom wear
7,9 mm (0.312 in)(A).
surfaces is also recommended when the machine is
stored, to help prevent rusting. • The bolt length should be determined by measuring
the distance from the face of the insert to the face of
The following wear pad procedure must be followed to the boom (B) including any spacer, shim(s) and
insure the proper wear pad installation: washer(s).
• The wear pad inserts and mounting bolts MUST be • Bolt thread engagement in the wear pad insert
clean before mounting bolts are installed. should be 5,4 - 8,5 mm (0.215 - 0.335 in).
• Apply Loctite® 242TM to all wear pad mounting bolts. • One or two hardened washers are to be used on
each wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers.
4 • Use only one hardened washer if mounting bolts are
recessed.
• Wear Pad Bolt Torque:
3 M8-25, 28 Nm (20.6 lb-ft)
M8-35, 28 Nm (20.6 lb-ft)
2
M10-20, 55 Nm (40.6 lb-ft)
M10-25, 55 Nm (40.6 lb-ft)
M10-30, 55 Nm (40.6 lb-ft)
M10-35, 55 Nm (40.6 lb-ft)
M10-50, 55 Nm (40.6 lb-ft)
MAM1390
M12-20, 97 Nm (71.5 lb-ft)
M12-25, 97 Nm (71.5 lb-ft)
• A spacer (2) with holes must be used before any M12-30, 97 Nm (71.5 lb-ft)
shim (3) is used. M12-35, 97 Nm (71.5 lb-ft)
• A shim (3) must inserted between the spacer (2) and M12-45, 97 Nm (71.5 lb-ft)
wear pad support plate, block or boom section (4). • Lubricate the face and pockets of each wear pad
• The number of shims can vary at each shim point. after being installed.

Boom
Boom Section Wear Pad Pathway Lubrication: 2. Coat the quick coupler pivot pin with CAT Thread
• Clean and lightly grease all wear pad pathways with Lubricant. Insert the quick coupler pivot pin (2)
CAT Multipurpose Grease. through the boom head and the lever assembly.
• Clean and lightly grease the hose carrier guide bar 3. Align the quick coupler with the lever assembly and
pathway with CAT Multipurpose Grease. insert the coupler pin (1) and replace the lock bolt
assembly. Apply Loctite® 242TM and torque to
3.23 QUICK COUPLER 90 Nm (66 lb-ft).
4. If equipped, reconnect the hydraulic quick coupler
Note: The following procedures covers all styles of
device hoses to the quick disconnect fittings on the
quick couplers.
left side of the boom head.
3.23.1 Quick Coupler Removal 3.23.3 Quick Coupler Removal
(TH336C, TH337C, TH406C & TH407C) (TH414C, TH514C & TH417C)
1. Lower attachment to ground, tilt forward to access
1. Lower attachment to ground, tilt forward to access
coupler pin, set park brake and turn off engine.
coupler pin, set park brake and turn off engine.
2. If equipped with a hydraulic quick coupler device,
2. If equipped with a hydraulic quick coupler device,
refer to Operation & Maintenance Manual.
refer to Operation & Maintenance Manual.
VIIEW LOOKING DOWN
1 5
2
4
3
MAM1340
MAM0750 3. Remove the lock bolt (3) holding the rod end tilt
cylinder pin to the quick coupler assembly. Remove
3. Remove the lock bolt (1) holding the coupler pin to the rod end pin (4).
the tilt cylinder lever assembly. Remove the coupler
pin. 4. Support the quick coupler assembly. Remove the pin
from the quick coupler assembly (5).
4. Support the quick coupler assembly. Remove the
pivot pin (2) from the quick coupler assembly. 5. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
5. Inspect the above pin for nicks or surface corrosion. If damaged or if it cannot be repaired the pin must be
Use fine emery cloth to fix minor nicks or corrosion. replaced.
If damaged or if it cannot be repaired the pin must be
replaced.
3.23.4 Quick Coupler Installation
6. Inspect the coupler and lever assembly pins for nicks (TH414C, TH514C & TH417C)
or surface corrosion. Use fine emery cloth to fix
1. Assemble the quick coupler to the boom head. Line
minor nicks or corrosion. If damaged or if it cannot
up the quick coupler between the mounts on the
be repaired the pin must be replaced.
boom head. The quick coupler should be centered in
the boom head.
3.23.2 Quick Coupler Installation
(TH336C, TH337C, TH406C & TH407C) 2. Coat the quick coupler pivot pin with CAT Thread
Lubricant. Insert the quick coupler pivot pin (5)
1. Assemble the quick coupler to the boom head. Line through the quick coupler and boom head.
up the quick coupler between the mounts on the
boom head. The quick coupler should be centered in 3. Align the quick coupler with the rod end tilt cylinder
the boom head. and insert the coupler pin (4) and replace the lock
bolt assembly (3). Apply Loctite® 242TM and torque to
90 Nm (66 lb-ft).
Boom
4. If equipped, reconnect the hydraulic attachment 3.25 BOOM PROP (IF EQUIPPED)
hoses to the quick disconnect fittings on the left side
of the boom head.
3.24 FORKS
WARNING
A raised boom can fall if a hydraulic component is
Forks should be cleaned and inspected prior to being removed. Remove any load, retract the boom and
attached to carriage. If the following criteria is not met, install the boom prop or a suitable supporting stand
forks must be removed from service immediately. before working under a raised boom.
Daily Inspection
3.25.1 Installation and Removal Procedures
1. Inspect forks (8) for cracks, paying special attention
to heel (9) and mounting tubes (10).
a. Prop Installation
2. Inspect forks for broken or bent tips (11) and twisted
blades (12) and shanks (13). 1. Park the machine on a firm, level surface. Place the
Yearly Inspection brake switch.
1. Straightness of the upper face of blade (12) and the 2. Raise the boom to an angle of approximately 20
front face of shank (13) should not exceed 0.5 degrees. Stop engine.
percent of the length of blade or height of shank.
2. Angle (14) between upper face of blade and front switch and the steering wheel.
face of shank should not exceed 93 degrees.
4. Before installing the boom prop, inspect the prop for
3. Thickness of blade (15) and shank (16) should not damage. Do not use if the prop is damaged or if the
be reduced to 90 percent of original thickness. o-rings are damaged or missing.
Note: Contact the local Caterpillar dealer with the fork
part number to find the manufactured dimensions of the
fork blade.
4. Ensure fork length (17) is adequate for intended
loads.
5. Fork markings should be legible, re-stamp if
required.
6. Compare fork tips (18) when mounted on a carriage. 1 2
Maximum difference in height of fork tips is 3 percent
3
of the length of the blade (15).
10
3
9
14 11
12
MAM1281
13 5. Install boom prop (1) onto lift/lower cylinder rod
8
directly behind the lift/lower cylinder pin boss (2).
16
6. Install o-rings (3). Align lift cylinder lock so o-rings
are on bottom side of lift/lower cylinder rod.
7. Start engine and SLOWLY lower boom until there is
a clearance of 0.25 in (6 mm) between bottom end of
15 18
boom prop and the top of the lift/lower cylinder
barrel.
17 MH6460

Boom
3.26 EMERGENCY BOOM LOWERING

PROCEDURE
NOTICE
EQUIPMENT DAMAGE. DO NOT operate with the
boom prop in place. Damage to the boom prop and/or
WARNING
the lift/lower cylinder could occur. To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting
8. Shut OFF engine.
the lift cylinder. If circumstances prevent retraction of
the extend/retract cylinder first, lower the lift cylinder
b. Prop Removal
the minimum amount necessary and resume
1. If needed, start machine and slowly raise the boom retraction of the extend/retract cylinder as soon as
until the boom prop is clear of the lift/lower rod end. possible.
2. Remove the o-rings (3) and boom prop (1) from the
cylinder. Return the boom prop to the proper location 3.26.1 Equipment and Supplies Required
and secure. Auxiliary Hydraulic Power Supply:
3. Lower boom, shut engine OFF. • Portable hydraulic unit or another machine with
an auxiliary hydraulic power supply with a capac-
ity to hold up to 35 L (9 gal) of hydraulic oil from
the machine during lowering process.
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.5, “Fluids and Lubricant
Capacities.”
Hoses:
• Two Hydraulic Hoses - Approximately 3,0 m
(10 ft) each, with a minimum I.D. of
9,5 mm (0.375 in) and a minimum rating of
275,8 bar (4000 psi).
Fittings:
• Two -8 ORFS Caps
• Two -8 ORFS Plugs
Adaptors:
• Two -8 ORFS Adaptors
Note: Machine extend/retract and lift/lower hoses are -8
ORFS. The adaptor size may vary depending on the
hose ends of the auxiliary hydraulic power supply.

Boom
3.26.2 Lowering Procedure b. Lower the boom as follows:

1. Place a suitable receptacle under the main control
a. Retract the boom as follows:
valve.
1. Place a suitable receptacle under the main control 2. Label and disconnect the lift/lower cylinder hoses
valve. (6 & 7) from the main control valve. Install plugs in
2. Label and disconnect the extend/retract cylinder hoses to prevent fluid loss. Cap all fittings and
hoses (4 & 5) from the main control valve. Install openings to keep dirt and debris from entering the
plugs in hoses to prevent fluid loss. Cap all fittings hydraulic system.
Note: Loss of hydraulic oil is limited to the amount
trapped within each hose.
Note: Loss of hydraulic oil is limited to the amount
3. Using the hoses and fittings specified, connect the
trapped within each hose.
hoses between the auxiliary hydraulic power supply
3. Using the hoses and fittings specified, connect the and the hoses removed from the main control valve
hoses between the auxiliary hydraulic power supply lift/lower section of the affected machine. Hose (7) is
and the hoses removed from the main control valve the supply (lower) and hose (6) is the return.
extend/retract section of the affected machine. Connect the hoses in the proper order to ensure that
Retract hose (5) is the supply and extend hose (4) is the boom is lowered, not raised.
the return. Connect the hoses in the proper order to 4. Use the auxiliary power supply to lower the boom.
ensure that the cylinder is retracted, not extended.
5. Loosen and remove the jumper hoses and reconnect
6 the lift/lower cylinder hoses.
4
6. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.”
5 Dispose of used oil at an approved recycling facility.
7 and around the machine.
MAM1270
VIEW FROM RIGHT SIDE
4. Use the auxiliary power supply to retract the extend/

retract cylinder.
5. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.
6. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.

Boom
3.27 BOOM RETRACT SENSOR 4. Loosen the turn the lock nuts (5) to achieve the
ADJUSTMENT proper clearance between the face of the sensor (3)
and the side of the inner boom section (4) if required.
a. TH336C, TH337C, TH406C & TH407C 5. Torque the locknuts to 18 - 22 Nm (13 - 16 lb-ft).
c. TH514C
1
6
2
MAM3990
8
1. Level and fully retract the boom.
2. Measure the distance between the face of the MAM4000
sensor (1) and the top of the inner boom section (2).
3. A distance of 2 - 4mm (0.08 - 0.15 in) is required.
2. Measure the distance between the face of the
4. Use the appropriate shim(s) to achieve the proper sensor (6) and the side of the inner boom section
clearance between the face of the sensor (1) and the (7).
top of the inner boom section (2) if required.
b. TH414C 4. Loosen the turn the lock nuts (8) to achieve the
proper clearance between the face of the sensor (6)
3 and the side of the inner boom section (7) if required.
5. Torque the locknuts to 18 - 22 Nm (13 - 16 lb-ft).
4
d. TH417C
5
10
MAM4010
1. Level and fully retract the boom. 11

sensor (3) and the side of the inner boom section MAM4020
(4).

Boom

sensor (9) and the side of the inner boom section
(10).
4. Loosen the turn the lock nuts (11) to achieve the
proper clearance between the face of the sensor (9)
and the side of the inner boom section (10) if
required.
5. Torque the locknuts to 18 - 22 Nm (13 - 16 lb-ft).
Note: If adding Boom Retract Switch follow the software
instructions below.
1. Access the machine setup menu using the cab
display or the analyzer.
2. Enter Access code for level 1 Access.
3. Navigate to Boom Retract Switch.
4. Navigate to “Yes”.
Note: If switch is being installed on a platform machine,
the boom retract switch will default to “Yes”.

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

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

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

8.11.1, “General Cylinder
Removal Instructions.”
2. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.22, “Boom
Wear Pads.”
3. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.

and/or wear. Refer to Section 2.7,
“Lubrication Schedules.”
Replace worn pins as needed.
2. Worn bearing(s). 2. Replace bearing(s) and

lubricate at regular intervals
Refer to Section 2.7,
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/ Refer to Section 2.7,
or wear. “Lubrication Schedules.”
2. Worn bushing(s). 2. Replace bushing(s) and

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

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

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

Boom

6. Drooping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s).
boom extend or retract adjusted.
functions.
2. Chain(s) stretched or binding. 2. Replace chains as needed.
Refer to Section 3.10, “Boom
Sections Adjustment.”
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.22, “Boom Wear
Pads.”
4. Contaminated, corroded or 4. Remove contamination and/or

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

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

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

pivot pin noise and/or wear. Refer to Section 2.6, “Service
and Maintenance Schedules.”
Refer to Section 8.11.1,
“General Cylinder Removal
Instructions.”
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals.
Refer to Section 2.7,
8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.22, “Boom Wear
Pads.”
2. Rapid cycle times with heavy 2. Reduce cycle times.

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

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

abrasive conditions.

Boom

9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”
10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.21, “Boom Extend
and Retract Chains - TH414C &
TH417C.”- Replace chains as
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. Refer

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

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

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

Boom
This Page Intentionally Left Blank

Section 4
Cab and Covers
Contents

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column/Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Service Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Mechanical Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Mechanical Throttle Pedal Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.7 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.8 Window Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.9 Heater/Air Conditioning System (if Equipped) . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.10 Cab Heater/Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.11 Air Conditioning (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Cab and Covers
4.1 OPERATOR CAB AND COVERS

COMPONENT TERMINOLOGY
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
LSI INDICATOR
(CE & AUS)
FRAME LEVEL
INDICATOR INSTRUMENT PANEL
ACCESSORY
STEERING CONTROL LEVER
WHEEL
LONGITUDINAL
LEVEL INDICATOR
(AUS)
LOAD CHART
12 VOLT POWER
TRANSMISSION OUTLET
CONTROL LEVER
(if equipped
BOOM JOYSTICK
& TRANSMISSION
CONTROL
RIGHT CONSOLE SWITCHES
FRONT CONSOLE
SWITCHES
POWER/EMERGENCY
STOP SWITCH
(if equipped for platform):
IGNITION
SWITCH
SERVICE BRAKE MAM0543

PEDAL
ACCELERATOR
PEDAL PARK BRAKE

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

WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all
safety precautions as outlined in the “Safety Practices” 1. Park the machine on a firm, level surface, fully
section of this manual. retract the boom, lower the boom, place the
4.2.1 Operator Cab Safety brake and shut the engine OFF.
WARNING 3. Open the engine covers. Allow the system fluids to
The protection offered by this ROPS/FOPS will be cool.
impaired if subjected to any modification or structural 4. Properly disconnect the battery.
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using 1
fasteners of correct size, grade, and torqued to their 3
specified value.
WARNING
DO NOT weld, grind, drill, repair or modify the cab in
any way. Any modification or damage to cab structural
components requires cab replacement.
Refer to the appropriate parts manual for ordering
information.
4.2.2 Serial Number Plate 2
The cab serial number plate is located on the left side of MAH0430
the cab, below the seat. Information specified on the

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

1. Install the steering wheel (3) onto the splined
steering column shaft.
2. Secure the steering wheel with the nut (2).
3. Press the center button (1) onto the steering wheel.
5. Close and secure the engine covers.

Cab and Covers
4.3.2 Steering Column/Orbitrol Valve b. Steering Column and Orbitrol Valve Installation
1. Install the steering column to its original orientation
a. Steering Column and Orbitrol Valve Removal
in the cab.
1. Park the machine on a firm, level surface, level the 2. Have an assistant hold the orbitrol valve in its
machine, fully retract the boom, lower the boom, original orientation from outside the cab. Install the
place the travel select lever in the (N) NEUTRAL steering column to the valve with the previously
position, engage the parking brake and turn the removed hardware.
engine OFF.
3. Install the accessory control lever, and if equipped,
2. Place a Do Not Operate Tag on both the ignition key transmission control lever. Connect the control
switch and the steering wheel. lever(s) harness connector to the main cab harness
3. Open the engine cover. Allow the system fluids to and install the steering wheel assembly.
cool. 4. Uncap and connect the previously labeled hydraulic
4. Properly disconnect the battery. hoses to the orbitrol valve.
5. Remove the lower dash panel in the cab. 5. Carefully examine all connections one last time
6. Remove the protective cover from the front of the before engine start-up. Rectify any faulty conditions.
cab. 6. Properly connect the battery.
2
7. Start the engine and check the operation of steering
system. Check for hydraulic fluid leaks. Check the
3
hydraulic fluid level in the tank and add fluid as
required.
8. Install the protective cover to the front of the cab.
9. Install the lower dash panel in the cab.
4 key switch and the steering wheel.
5 c. Steering Test
6
Conduct a pressure check of the steering hydraulic
circuits at the main control valve. Refer to Section 8.4.1,
1 “Pressure Checks and Adjustments.”
MAM3930
4.3.3 Service Brake
7. Label, disconnect and cap the hydraulic hoses
attached to the orbitrol valve (1). a. Brake Valve Removal
8. Remove the steering wheel (2). Refer to Section Refer to Section 8.10.3, “Service Brake Valve,” for
4.3.1, “Steering Wheel.” removal information.
9. Disconnect and remove the accessory control lever
(3), and if equipped, transmission control lever (4). b. Brake Valve Installation
Disconnect the control lever(s) harness from the
Refer to Section 8.10.3, “Service Brake Valve,” for
main cab harness.
installation information.
10. Have an assistant hold the orbitrol valve from the
outside of the cab. Remove the four bolts (5)
securing the orbitrol valve to the cab.
11. Remove the steering column (6) through the dash
panel opening.
Note: DO NOT disassemble the orbitrol valve. The
orbitrol valve is not serviceable and must be replaced in
its entirety, if defective.

Cab and Covers
c. Service Brake Pedal Removal 4. Install the pedal tension spring (7).
1. Park the machine on a firm, level surface, level the 5. Be sure the brake pedal has the correct range of motion.
machine, fully retract the boom, lower the boom, If the pedal requires adjustment, refer to Section
place the travel select lever in the (N) NEUTRAL 4.3.3, e. “Service Brake Pedal Adjustment.”
position, engage the parking brake and turn the 6. Properly connect the battery.
engine OFF.
cool. e. Service Brake Pedal Adjustment
4. Properly disconnect the battery. 1. Loosen the pedal adjustment bolt. The adjustment
bolt cannot contact the linkage during adjustment.
2. Remove the master cylinder dust cover to gain
access to the master cylinder plunger.
3. Rotate the master cylinder push rod clockwise until
the push rod bottoms in the plunger. Rotate the push
rod a quarter turn counterclockwise and tighten the
adjustment bolt locknut. There should be
9 10 0,6-1,2 mm (0.2-0.8 in) of axial play between the
push rod and plunger.
8
4. Screw in the adjustment bolt (10) by hand until the
bolt makes contact with the linkage. Turn the bolt an
additional one turn and secure with the locknut.
8 5. Verify that the pedal height is no less than
134 mm (5.3 in) from cab floor (mat included).
6. Verify that the master cylinder plunger is flush with
master cylinder body.
7. Install the master cylinder dust cover.
7 MAM0220
4.3.4 Electronic Throttle Pedal

5. Remove the tension spring (7) from the brake pedal.
6. Remove the clips securing the brake pedal and a. Electronic Throttle Pedal Removal
linkage to the service brake valve.
1. Park the machine on a firm, level surface, level the
7. Remove the connecting plates (8) between the pedal machine, fully retract the boom, lower the boom,
and the lever assembly (9). place the travel select lever in the (N) NEUTRAL
8. Remove the two snap rings. position, engage the parking brake and turn the
engine OFF.
9. Remove the pedal and lever assembly keeping note
of location of all washers, bushings, etc. 2. Place a Do Not Operate Tag on both the ignition key
d. Service Brake Pedal Installation 3. Properly disconnect the battery.
1. Install the brake pedal and lever assembly (9) onto 4. Remove the tension spring from the pedal.
their mounting posts with the previously used
washers, bushings etc.
2. Install the two snap rings.
3. Install the connecting plates (8) between the pedal
and the lever assembly with the previously used
clips.

Cab and Covers
4
3
2
MAM0230
5. Disconnect the sensor linkage from the

pedal (1). MAM4040
6. Remove the snap ring (2) securing the throttle pedal 4. Remove the tension spring (3) from the pedal.
to the mounting post. 5. Disconnect the nut securing the throttle cable end
7. Remove the throttle pedal assembly from the cab. (4) to the throttle pedal.
6. Remove the snap ring (5) securing the throttle pedal
b. Electronic Throttle Pedal Installation to the mounting post.
1. Position the throttle pedal in its mounting location 7. Remove the throttle pedal assembly from the cab.
within the cab.
2. Secure the throttle pedal into position with the b. Mechanical Throttle Pedal Installation
previously used snap ring. 1. Position the throttle pedal in its mounting location
3. Install the pedal tension spring. within the cab.
4. Install the sensor linkage to the pedal. 2. Secure the throttle pedal into position with the
5. Properly connect the battery. previously used snap ring.
6. Close and secure the engine cover. 3. Install the throttle cable to the throttle pedal.
7. Remove the Do Not Operate Tag from the ignition 4. Refer to Section b, “Mechanical Throttle Pedal Cable
key switch and the steering wheel. Installation,”for detailed cable installation and
adjustments.
4.3.5 Mechanical Throttle Pedal 5. Install the pedal tension spring.
a. Mechanical Throttle Pedal Removal
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF. 4.3.6 Mechanical Throttle Pedal Cable
2. Place a Do Not Operate Tag on both the ignition key a. Mechanical Throttle Pedal Cable Removal
switch and steering wheel, stating that the machine
should not be operated. 1. Disconnect the throttle cable from the throttle pedal
(4).
2. Loosen the lock nuts (6) on the base of the throttle
pedal.

Cab and Covers
6. Adjust throttle pedal stop (10) to 10-12mm

7 (0.39-0.47 in).
7. Connect the throttle cable (7) to the engine.
8. Tighten the lock nuts (8) on the throttle cable engine
bracket.
9. Secure the throttle cable with nylon ties as needed.
10. Start the machine and verify low idle (900-100 RPM)
and high idle (2300-2400 RPM). Adjust if required.
4.3.7 Joystick Assembly
a. Joystick Assembly Removal

MAM4030 place the travel select lever in the (N) NEUTRAL
8 position, engage the parking brake and turn the
3. Disconnect the throttle cable (7) from the engine. engine OFF.
4. Loosen the lock nuts (8) on the throttle cable engine 2. Place a Do Not Operate Tag on both the ignition key
bracket. switch and the steering wheel.
5. Cut all cable nylon ties securing the throttle cable. 3. Properly disconnect the battery.
6. Remove the throttle cable noting the routing location
of the throttle cable.
b. Mechanical Throttle Pedal Cable Installation

6
1. Install the throttle cable following the routing location
of the previously removed cable.
C
9 10
B
MAM0370
A 4. Remove the bolts securing the boom joystick to the

cab (6).
5. Lift the joystick from its mounting position.
6. Label and disconnect the electrical connectors
6 attached to the joystick.
MAM4050 7. Remove the joystick assembly.
2. Connect the throttle cable to the throttle pedal (4).
b. Joystick Assembly Installation
3. Hand tighten the lock nuts (6) on the base of the
throttle pedal. 1. Connect the previously labeled electrical connectors
to the joystick.
4. Adjust the throttle cable to 12-14mm
(0.47-0.55 in)(A) and tighten locknuts (6). 2. Install the bolts securing the joystick to the cab.
5. Adjust throttle pedal stop (9) to 4-6mm 3. Properly connect the battery.
(0.15-0.23 in).
Cab and Covers
4. Test the joystick functions.

4.3.8 Window Wiper Assembly

Refer to Section 9.11, “Window Wiper/Washer
Windshield Wiper Motor,” for removal and installation
information.
4.3.9 Heater/Air Conditioning System 7

(if Equipped)
a. Heater Assembly Removal 7 MAM3940

EARLY PRODUCTION
machine, fully retract the boom, lower the boom, 11. Remove the small cab floor plate (7).
place the travel select lever in the (N) NEUTRAL 12. Remove the four bolts securing the intake box to the
position, engage the park brake and shut the engine heater box.
OFF.
13. Label and disconnect the electrical connections to
2. Place a Do Not Operate Tag on both the ignition key the heater assembly.
cool.
CAUTION
The cooling system is under pressure. NEVER
remove the radiator cap while the cooling system is
hot. Wear safety glasses. Turn the radiator cap to the
first stop and allow pressure to escape before
removing the cap completely.
8
5. Place a suitable container beneath the radiator. MAM0250
Slowly turn the radiator cap to the first stop, and

14. Disconnect the cable (8) for the heater control knob
allow any pressure to escape. Remove the radiator
from the water valve.
cap.
15. Support the heater assembly from under the cab
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Remove the 16. Remove the bolts securing the heater assembly to
drain plug and allow the coolant to drain. the cab. Remove the heater assembly.
7. Transfer the coolant to a container with a cover, and
b. Heater Assembly Installation
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility. 1. Position the heater assembly to its original orientation
8. Tighten the radiator drain plug. under the cab. Secure with the previously used
hardware.
9. From under the cab, remove the protective cover to
the heater assembly. 2. Connect the cable for the heater control knob to the
water valve.
10. Remove the cab floor mat.
3. Connect the previously labeled electrical connectors
to the heater assembly.

Cab and Covers
4. Replace the heater assembly filter if needed, refer to 4.3.10 Cab Heater/Air Conditioning Controls
Section 4.3.9, c. “Heater Assembly Filter
Replacement.” a. Cab Heater Controls Removal
5. Fill the cooling system completely with coolant, 1. Park the machine on a firm, level surface, level the
allowing time for the coolant to fill the engine block. machine, fully retract the boom, lower the boom,
The cooling system capacity is listed in Section 2.5, place the transmission in (N) NEUTRAL, engage the
“Fluids and Lubricant Capacities.” park brake and shut the engine OFF.
6. Properly connect the battery. 2. Place a Do Not Operate Tag on both the ignition key
7. Start the engine, run it briefly at low idle and check switch and the steering wheel.
the machine for any visual sign of fluid leakage. 3. Open the engine cover. Allow the system fluids to
Note: STOP the engine immediately if any leakage is cool.
noted, and make any necessary repairs before 4. Properly disconnect the battery.
continuing. 5. Remove the plastic side cover in the cab to gain
8. Wait for the engine to cool and check the coolant access to the control cables and electronics. If
level. Add coolant as required to bring the coolant to necessary, remove the seat for more accessibility.
the proper level.
9. Install the protective cover to the heater assembly.
12
10. Install the intake box to the heater box.
11. Install the small cab floor plate.
12. Install the plastic side cover in the cab.
11
13. Install the cab floor mat.
11
15. Remove the Do Not Operate Tag from the ignition 10 MAM0310
6. Label and disconnect the control cables (10)
c. Heater Assembly Filter Replacement attached to the control knob mechanisms.
7. Label and disconnect the electrical connectors (11)
1. Remove the cab floor mat.
attached to the control box.
2. Remove the small cab floor plate (7).
8. Depress the side clips (12) and push the control box
3. Remove the four bolts securing the intake box (8) to through the dash panel.
the heater box.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
9
The controls are not serviceable. Replace controls if
found to be defective.
c. Installation and Testing

1. Install the control box into the dash panel until the
side clips firmly hold the box.
MAM0930 2. Connect the previously labeled electrical connectors
to the appropriate locations.
4. Remove the heater assembly filter (9) and replace 3. Connect the previously labeled control cables to the
with a new filter. appropriate control knob mechanisms.
5. Install the intake box to the heater box. 4. Verify the water valve on the bottom of the heater
6. Install the small cab floor plate. assembly opens completely.
7. Install the cab floor mat. 5. Properly connect the battery.

Cab and Covers
6. Turn the ignition key to the ON position and check 2. Block all four wheels to help prevent the machine
the control functions. from moving. Assure that there is sufficient overhead
7. Start the machine and allow engine to warm to and side clearance for cab removal.
operating temperature. Check heat control at 3. Open the engine cover. Allow the system fluids to
different levels. cool.
8. Install the plastic side cover. If necessary, install the 4. Properly disconnect the battery.
seat. 5. Place a funnel at the base of the radiator to channel
9. Close and secure the engine cover. the drained coolant into the container. Remove the
10. Remove the Do Not Operate Tag from the ignition drain plug and allow the coolant to drain.
key switch and the steering wheel. 6. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
4.3.11 Air Conditioning (if Equipped) coolant at an approved recycling facility.
If the air conditioning system requires servicing, contact 7. Tighten the radiator drain plug.
the local Caterpillar dealer or certified air conditioning 8. Label and disconnect the cab heater hoses. Refer to
service center. Refer to Section 2.5, “Fluids and Lubricant Section 4.3.9, “Heater/Air Conditioning System (if
Capacities,” for refrigerant type and capacity. Equipped).”
9. Remove the protective cover from the front of the
4.4 CAB REMOVAL cab.
WARNING 2 3
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
Note: To help ensure safety and optimum performance,

replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the local Caterpillar
dealer with any questions about the suitability or condition
of a cab.
Note: Remove and label cab components as needed
before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts MAM0420
to the replacement cab after the replacement cab is
securely mounted on the machine. 10. Label, disconnect and cap all hydraulic hoses
attached to the steering orbitrol valve (2). Cap all
1. Park the machine on a firm, level surface. Allow
fittings and openings to keep dirt and debris from
sufficient overhead and side clearance for cab
removal. Level the machine, fully retract the boom,
lower the boom, place the travel select lever in the 11. Label, disconnect and cap all hydraulic hoses
(N) NEUTRAL position, engage the park brake and attached to the service brake valve (3). Cap all
shut the engine OFF. fittings and openings to keep dirt and debris from
12. Disconnect the cab ground strap.

Cab and Covers
13. Remove the hydraulic oil reservoir. Refer to Section 22. Inspect and replace other machine parts that are
8.7.3, “Hydraulic Oil Reservoir Removal/Installation.” exposed with the cab removed. Repair or replace as
14. Remove the fuel tank. Refer to Section 7.6.2, “Fuel required.
Tank.”
15. Label and disconnect the cab harness connectors.
Move the harnesses clear of the cab to prevent
damage during cab removal.
5
MAM1240
5
16. Install four lifting eye bolts with a minimum lifting

capacity of 363 kg (800 lb) in the existing lifting holes
at the top corners of the cab (4).
17. Use a hoist or overhead crane and sling with a
minimum lifting capacity of 363 kg (800 lb) attached
to the four eye bolts. DO NOT attempt to lift the cab
at this point.
18. Remove the four bolts (5) securing the cab to the
frame.
19. Remove the mirrors and all other cab components
as needed, if not previously removed.
20. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift the
cab and remove it from the frame. Readjust the
position of the sling as needed to help balance the
cab during removal.
21. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
no personnel enter the cab while it is being removed
from the machine.

Cab and Covers
4.5 CAB INSTALLATION Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
1. Block all four wheels to help prevent the machine fluid leakage. STOP the engine immediately if any
from moving. Assure that there is sufficient overhead leakage is noted, and make any necessary repairs
and side clearance for cab installation. before continuing.
2. Attach a sling with a minimum lifting capacity of 16. Wait for the engine to cool and check the coolant
363 kg (800 lb) through the lifting eyes of the cab. level. Add coolant to the overflow bottle as required
3. Use a hoist or overhead crane and sling attached to to bring the coolant to the proper level.
the cab. Carefully begin to align the cab with the 17. Install the protective cover to the front of the cab.
mounting holes in the frame. Stop and check that
18. Install the mirrors and all other cab components as
wiring, hydraulic hoses, cables, etc., will not be
needed, if removed.
pinched or damaged as the cab is positioned.
Readjust the position of the sling as needed to help 19. Unblock the wheels.
balance the cab during installation. 20. Close and secure the engine cover.
4. Install the four cab to frame mount bolts, washers and 21. Remove the Do Not Operate Tag from the ignition
nuts to 150 Nm (111 lb-ft). key switch and the steering wheel.
5. Connect the previously labeled cab harness
connectors to their appropriate locations.
6. Install the fuel tank. Refer to Section 7.6.2, “Fuel
Tank.”
7. Install the hydraulic oil reservoir. Refer to Section
8.7.3, “Hydraulic Oil Reservoir Removal/Installation.”
8. Reconnect the cab ground strap.
9. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
10. Reconnect any remaining electrical connections to
their appropriate locations.
11. Reconnect the heater hoses to the cab heater. Refer
to Section 4.3.9, “Heater/Air Conditioning System (if
Equipped).”
12. Fill the cooling system completely with coolant,
allowing time for the coolant to fill the engine
block.The cooling system capacity is listed in
Section 2.5, “Fluids and Lubricant Capacities.”
14. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
15. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Axle Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Mechanical Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.1 Mechanical Park Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5.2 Mechanical Park Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5.3 Mechanical Park Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Hydraulic Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.1 Park Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.7 Brake Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.8 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.9 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.10 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.11 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-13
5.11.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-13
5.12 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.1 AXLE, DRIVE SHAFT AND WHEEL

locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.
IF EQUIPPED WITH
MECANICAL PARK BRAKE
REAR AXLE
ASSEMBLY
MECHANICAL PARK REAR STEERING

BRAKE CYLINDER
TRANSMISSION REAR AXLE WHEEL

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

FRONT AXLE HUBS
ASSEMBLY
MAM3300
IF EQUIPPED WITH
HYDRAULIC PARK BRAKE
TH414C, TH514C & TH417C REAR AXLE
ONLY ASSEMBLY
HYDRAULIC PARK REAR STEERING

BRAKE CYLINDER
REAR AXLE WHEEL

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

ASSEMBLY HUBS
MAM3301

5.4 AXLE REPLACEMENT

WARNING
5.4.1 Axle Removal
safety precautions as outlined in the “Safety Practices”
section of this manual.
WARNING
5.2 AXLE SERIAL NUMBER An improperly supported machine can fall. Safely
raise and adequately support the machine so that it
The front and rear axle serial number plate is located on will remain stable and in place before attempting to
the inside of each axle on the right side of the center remove an axle.
section. Information on the serial number plate is required
The front and rear axle assemblies differ in that the front
in correspondence regarding the axle.
axle assembly is equipped with a parking brake
Supply information from the axle serial number plate mechanism and a limited slip feature; the rear axle has
when communicating about an axle assembly or axle neither. The following steps outline a typical axle removal
components. procedure, suitable for either the front or the rear axle
assembly.
5.3 AXLE SPECIFICATIONS AND Cleanliness is extremely important. Before attempting to
MAINTENANCE INFORMATION remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on electrical
For axle, oil specifications and maintenance information, components. If using a steam cleaner, seal all openings
refer to Section 2, “General Information and before steam cleaning.
Specifications.”
Note: Clear the work area of all debris, unnecessary
Detailed axle service instructions are provided in the
personnel, etc. Allow sufficient space to raise the
following publications:
machine and to remove the axle.
If equipped with mechanical park brake:
• Axle Disassembly/Assembly Manual machine, fully retract the boom, lower the boom,
(P/N 31200453) place the travel select lever in the (N) NEUTRAL
TH336C, TH337C, TH406C, TH407C & TH414C position, engage the parking brake, straighten all
• Axle Disassembly/Assembly Manual wheels and shut the engine OFF.
(P/N 31200455) TH514C & TH417C 2. Place a Do Not Operate Tag on both the ignition key
• Parts Manual (P/N 31200730) switch and steering wheel.
TH336C, TH337C, TH406C & TH407C 3. Open the engine cover. Allow the system fluids to
• Parts Manual (P/N 31200729) cool.
TH414C, TH514C & TH417C
If equipped with hydraulic park brake:
5. Remove the bolts securing the fender assembly to
• Axle Disassembly/Assembly Manual the axle.
(P/N - N/A -) TH414C, TH514C & TH417C
• Parts Manual (P/N 31200729)
TH414C, TH514C & TH417C

10. Support the axle that is being removed with a suitable

MECHANICAL PARK BRAKE SHOWN jack, hoist or overhead crane and sling. DO NOT
raise the axle or the machine.
11. Remove both wheel and tire assemblies from the
axle that is being removed. Refer to Section 5.11.1,
“Removing Wheel and Tire Assembly from
Machine.”
2 Note: The wheel and tire assemblies must be re-installed
later with the directional tread pattern “arrows” facing in
1 the direction of forward travel.
2 12. Remove the drive shaft assembly. Refer to Section
MZ2491
5.10.3, “Drive Shaft Removal.”
TH336C, TH337C, TH406C & TH407C FRONT 3 13. TH414C, TH514C & TH417C Only: On the front
axle, remove the lower position cylinder mount pin
for the front cylinder. Tap the cylinder mount pin out,
MECHANICAL PARK BRAKE SHOWN
and move the cylinder to prevent it from interfering
with axle removal. If a new axle will be installed,
remove the frame level mounting plate from the axle.
14. Remove the bolts and locknuts securing the axle to
the frame.
15. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
2 axle. DO NOT raise or otherwise disturb the
machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
1
2 removing it from beneath the machine. Place the
MZ2501 axle on a suitable support or holding stand.
TH414C, TH514C & TH417C FRONT AXLE
3
5.4.2 Axle Installation
6. If the axle will be disassembled after removal, place
a suitable receptacle under the axle (1) and wheel 1. Before proceeding, ensure that the machine will
hubs (3) drain plugs. Remove the drain plugs and remain in place during axle installation. Block the
allow the oil to drain into the receptacle. Transfer the front and rear of both tires on the axle that is already
used oil into a suitable covered container, and label installed on the machine.
the container as “Used Oil.” Dispose of the used oil 2. If applicable, raise the machine using a suitable jack
at an approved recycling facility. or hoist. Place suitable supports beneath the frame
7. Label, disconnect and cap the steering and brake and lower the machine onto the supports, allowing
lines at the axle. Wipe up any spilled oil. enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
8. Block the front and rear of both tires on the axle that
is not being removed. Ensure that the machine will 3. Using a suitable jack, hoist or overhead crane and
remain in place during axle removal before sling, remove the axle from its support or holding
proceeding. stand. Balance the axle and prevent it from tipping,
turning or falling while positioning it beneath the
9. Raise the machine using a suitable jack or hoist.
machine. DO NOT raise or otherwise disturb the
Place suitable supports under both sides of the
machine while installing the axle. Keep the axle
frame and lower the machine onto the supports.
supported and balanced on the jack, hoist or
Ensure that the machine will remain in place during
overhead crane and sling throughout the installation
axle removal.
procedure.
4. Position the axle under the frame, and align the axle
housings with the holes in the frame.

5. Apply Loctite® 271™to each mounting bolt. onto Machine.”

6. Install the axle mounting bolts and nuts. Tighten and 14. Carefully remove the jack, hoist or overhead crane
torque as required: and sling supporting the axle.
15. Carefully raise the machine using a suitable jack or
Front Axle Rear Axle hoist. Remove the supports from beneath the frame
Machine and lower the machine to the ground.
Bolts Torque Bolts Torque
TH336C, TH337C, 780-820 Nm 550 Nm 16. Remove the blocks from the front and rear of both
TH406C, TH407C (575-605 lb-ft) (406 lb-ft) tires on the other axle.
TH414C, TH514C, 550 Nm 550 Nm Note: ALWAYS use new o-rings when servicing the
TH417C (406 lb-ft) (406 lb-ft) machine.
17. Install new o-rings into the fittings. Lubricate the
7. TH414C, TH514C & TH417C Only: Install the frame o-rings with clean hydraulic oil.
level mount to the front axle (if necessary). Move the 18. Uncap and connect the steering and brake lines at
cylinder into position on the axle cylinder anchor. their axle fittings.
Insert a cylinder mount pin through the cylinder and
cylinder anchor. Secure the cylinder mount pin. 19. Check the hydraulic reservoir oil level.
8. Apply multi purpose grease through the self tapping 20. Start the engine. Turn the steering wheel several
lube fitting to lubricate the self align bearing and the times lock to lock, operate the frame tilt function
cylinder mount pin. several times in both directions and check the
function of the brakes. Check for hydraulic leaks, and
9. Install the drive shaft assemblies. Refer to Section tighten or repair as necessary.
5.10.5, “Drive Shaft Installation.”
21. Apply Loctite® 243TM to all mounting bolts.
10. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle 22. Install the fender assembly. Torque the mounting
according to the alignment marks made earlier. If bolts to 241 Nm (178 lb-ft).
installing a new axle, note the position of the 23. Properly connect the battery.
driveshaft yoke at the transmission. Align the 24. Close and secure the engine cover.
driveshaft yoke on the axle in the same plane as the
yoke on the transmission. 25. Remove the Do Not Operate Tag from the ignition
11. Tighten the axle oil drain plug (1), loosen and
remove the axle oil fill plug (2). Refer to Section 2.5, Note: The service brake circuit will need to bled after
“Fluids and Lubricant Capacities,” for proper oil and axle installation. Refer to Section 8.10.4, “Service Brake
capacities. Bleeding.”
5.5 MECHANICAL PARK BRAKE

3
5.5.1 Mechanical Park Brake Removal

position, engage the parking brake, straighten all
wheels and shut the engine OFF.
MT0220
12. Rotate wheel hubs 90 degrees so the drain plug switch and steering wheel.
becomes the fill plug (3). Refer to Section 2.5, 3. Open the engine cover. Allow the system fluids to
“Fluids and Lubricant Capacities,” for proper oil and cool.
capacities. 4. Properly disconnect the battery.
13. Install the wheel and tire assemblies. Refer to 5. Remove park brake cable from park brake lever.
Section 5.11.2, “Installing Wheel and Tire Assembly

5.5.3 Mechanical Park Brake Adjustment

1. Chock all wheels to prevent machine from moving.
MY3690
5
5 4
6. Remove bracket (4) from park brake.

7. Remove the bolts (5) securing the park brake to the
axle. Remove the park brake off the brake disc.
MZ5260
5.5.2 Mechanical Park Brake Installation 2. Place the park brake in the disengaged position.
1. Slide park brake onto brake disc and secure with the Depress the release lever (7) and push the park
previously used hardware. DO NOT tighten the bolts brake lever (8) downward.
at this time.
10
MZ2550
2. Use a feeler gauge to measure the distance (6)

between locknuts and spacers. Set the gap to
1 ±0.5 mm (0.040 ± 0.020 in) before tightening the MAM1350
two bolts. Torque bolts to 115 Nm (85 lb-ft).
3. Adjust lock nuts (9) to remove any slack in the park
3. Install bracket onto park brake. Install park brake
brake cable (10).
cable
4. Sitting in the operators seat, adjust the park brake
cable by turning the adjuster knob (8) clockwise to
5. Close and secure the engine cover. increase park brake force. Turn the adjuster knob
6. Remove the Do Not Operate Tag from the ignition counterclockwise to decrease park brake force.
5.6 HYDRAULIC PARK BRAKE
For detailed hydraulic park brake removal, Refer to
Section 5.3, “Axle Specifications and Maintenance
Information.”

5.6.1 Park Brake Test 8. If J4-11 (connector on the UGM) is HIGH when
operator presses the Enter button, the analyzer will
The following procedure is used in order to determine if
provide the following information: WARNING: DRIVE
the parking brake is functional. This procedure is not
WILL BE ENGAGED for a period of 2 seconds and
intended to measure the maximum brake performance.
then display the following information: FORWARD
Note: Refer to Section 9.4.1, “Keypad,” for additional TO START (first line) NEUTRAL TO PAUSE (second
information. line).
Note: The hand held Analyzer can also be used if 9. If the control system receives a valid drive
desired. FORWARD signal in this test mode, the transmission
neutralize state will be overridden (act as the park
1. Verify the machine is on a dry, level surface and the brake is not set) and drive will be engaged. If the
test area is clear of personnel and obstacles. control system receives a valid drive NEUTRAL
2. Engage the park brake and start the machine. signal in this test mode, the transmission neutralize
3. Access Level 3 on the display screen. state will be engaged (normal operation).
4. Select PARK BRAKE TEST from the calibration 10. Gradually increase the engine speed to high idle.
menu. The machine should not move.
5. The operator will be asked: PERFORM PARK 11. Reduce engine speed to low idle. Move transmission
BRAKE TEST? To begin the test, press the Enter to the neutral position.
button.
Note: Pressing the ESC button will return the operator
back to the CALIBRATIONS menu.
WARNING
If the machine begins to move during the PARK
Note: If there is an active fault pertaining to a drive BRAKE TEST, reduce engine speed to low idle and
direction or gear selection inputs, the analyzer will not apply the service brakes.
permit the test to be run and show PARK BRAKE TEST
FAILED. Note: If the machine moved during the PARK BRAKE
TEST, refer to Section 5.5.3, “Mechanical Park Brake
6. With the park brake test now running, the analyzer Adjustment,” and re-test.
will prompt the operator to SET PARK BRAKE.
Note: If J4-5 (connector on the UGM) goes LOW or J4-
Note: If J4-5 (connector on the UGM) is LOW when the 11 (connector on the UGM) goes LOW or an active fault
operator presses the Enter button, the control system pertaining to the drive direction or gear selection inputs
will respond with a PARK BRAKE TEST FAILED become active in this test mode, the test will be stopped
message and any concluding button press will return the and the control system will respond with a PARK BRAKE
analyzer back to CALIBRATION: PARK BRAKE TEST TEST FAILED message and any concluding button
menu screen. press will return the analyzer back to
7. If J4-5 (connector on the UGM) is HIGH when the CALIBRATION:PARK BRAKE TEST menu screen.
operator presses the Enter button, the analyzer will 12. If the ESC or Enter button is pressed at this stage,
prompt the operator to Shift To Second Gear. the control system will stop the test and respond with
Note: If J4-11 (connector on the UGM) is LOW or J4-11 a PARK BRAKE TEST COMPLETE message and
is HIGH and one of the other gear select inputs is HIGH any concluding button press will return the analyzer
when the operator presses the Enter button, the control back to CALIBRATION: PARK BRAKE TEST menu
system will respond with a PARK BRAKE TEST FAILED screen.
message and any concluding button press will return the 13. With the PARK BRAKE TEST complete, engage the
analyzer back to CALIBRATION: PARK BRAKE TEST park brake, shut engine OFF.
menu screen.

5.7 BRAKE INSPECTION

appropriate Axle Disassembly & Assembly Manual, refer
to Section 5.3, “Axle Specifications and Maintenance
Information.”
5.8 STEERING ANGLE ADJUSTMENT

appropriate Axle Disassembly & Assembly Manual, refer
to Section 5.3, “Axle Specifications and Maintenance
Information.”

5.9 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

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

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

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

housings and fill to correct level.
Refer to Section 2.5, “Fluids and
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

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

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

unbalanced. needed.


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

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

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

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

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

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

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

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

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

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

damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.


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

needed. Refer to Section 5.5,
“Mechanical Park Brake.”
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

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

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

internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.7, “Brake
Inspection.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 5.7, “Brake
reduced. Inspection.”
2. Brake (hydraulic) system not 2. Refer to Section 8.10.4,

operating properly. “Service Brake Bleeding.”
3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).

5.10 DRIVE SHAFTS TO AXLE
5.10.1 Drive Shaft Inspection

Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive 2
TO TRANSMISSION
looseness, missing parts, cracks or other damage. Worn 1
or damaged drive shafts and cross and bearing
assemblies may cause an excessive amount of vibration
or noise. 3
MT0350
Note: To ensure optimum performance, the driveshaft 4
assemblies are specially balanced as a unit at the 7. Remove the four bolts (1) and two straps (2)
factory. When servicing any flange yoke, slip yoke or securing the bearing cross to the transmission
drive shaft tube, order a complete assembly if output shaft flange.Discard the bolts.
components are bent or damaged. Refer to the 8. Remove the four bolts (3) and two straps (4)
appropriate parts manual for ordering information. securing the bearing crosses to the axle.
Note: Any bolt removed from the drive shaft assembly 9. Remove the drive shaft assembly.
MUST be replaced. Do Not re-torque.
10. Repeat the above procedure on the rear drive shaft.
5.10.2 Drive Shaft Maintenance 5.10.4 Drive Shaft Cleaning and Drying
Refer to Section 2.5, “Fluids and Lubricant Capacities,” 1. Disassemble and clean all parts using an approved
for information regarding the lubrication of the grease cleaning fluid. Allow to dry.
fittings on the drive shafts. 2. Remove any burrs or rough spots from all machined
surfaces. Re-clean and dry as required.
5.10.3 Drive Shaft Removal
5.10.5 Drive Shaft Installation
machine, fully retract the boom, lower the boom, 1. Raise the drive shaft assembly into position. The slip
place the transmission in (N) NEUTRAL, engage the yoke end of the drive shaft mounts toward the axle. If
park brake and shut the engine OFF. reinstalling a drive shaft previously removed, align
the flange yokes according to the alignment marks
made during removal.
switch and steering wheel.
3. Open the engine cover. Allow the system fluids to Note: Yokes at both ends of the drive shaft must be in
cool. the same plane to help prevent excessive vibration.
4. Properly disconnect the battery. 2. Apply Loctite® 243TM to all mounting bolts.
5. Block the wheels. 3. Install the two straps (2) and four new bolts (1)
securing the bearing crosses to the transmission.
6. The drive shaft assembly is a balanced assembly.
Torque capscrews to 38 Nm (lb-ft).
Mark the yoke and axle, transmission and the shaft
and slip yoke so that these components can be 4. Install the two straps (4) and four new bolts (3)
returned to their original positions when reinstalled. securing the bearing crosses to the axle. Torque
Yokes at both ends of the drive shaft must be in the capscrews to 38 Nm (lb-ft).
same plane to help prevent excessive vibration. 5. Repeat the above procedure on the rear drive shaft.
8. Unblock the wheels.

5.11 WHEELS AND TIRES 3. Loosen but DO NOT remove the lug nuts on the
wheel and tire assembly to be removed.
4. Place a suitable jack under the axle pad closest to
WARNING the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
Mismatched tire sizes, ply ratings or mixing of tire sufficient room to lower the machine onto the
types (radial tires with bias-ply tires) may compromise support and to remove the wheel and tire assembly.
machine stability and may cause machine to tip over.
5. Lower the machine onto the support.
It is recommended that a replacement tire to be the same 6. Remove lug nuts and washers in an alternating
size, ply and brand as originally installed. Refer to the pattern.
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended 7. Remove the wheel and tire assembly from the
that replacement tires have the following characteristics: machine.
• Equal or greater ply/load rating and size of original. 5.11.2 Installing Wheel and Tire Assembly
• Tire tread contact width equal or greater than onto Machine
original. 5
• Wheel diameter, width and offset dimensions equal
to the original.
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc.,
without written factory recommendations, may result in
unsafe condition regarding stability.
MZ6020
Foam filled tires have a positive effect on the weight,
stability and handling characteristics of the machine, Note: The wheel and tire assemblies must be installed
especially under load. The use of hydrofill as a tire-fill with the directional tread pattern “arrows” facing in the
substance is not recommended because of possible direction of forward travel.
environmental impact.
1. Position wheel onto studs on wheel end of axle.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire 2. Install wheel washers onto studs.
does not provide an airtight seal. Check tire inflation 3. Start all lug nuts by hand to prevent cross threading.
pressures when the tires are cold. When mounting a tire Apply one drop of lubrication oil.
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly. 3
1 5
5.11.1 Removing Wheel and Tire Assembly
from Machine
8 7
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission in (N) NEUTRAL, engage the park 6 2
brake and shut the engine OFF. 4
2. Place a Do Not Operate Tag on both the ignition key OAH0990
switch and steering wheel, stating that the machine
should not be operated.

4. Tighten lug nuts in an alternating pattern as

indicated in the previous figure. TH336C, TH337C, TH414C, TH514C &
TH406C& TH407C TH417C
TH336C, TH337C, TH406C, TH407C & TH414C
340-380 Nm (251-280 lb-ft)
TH514C & TH417C
440-480 Nm (324-354 lb-ft)
5. Remove machine from supports.
key switch and the steering wheel. 1
5.12 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted
after exhausting all other options. Make every effort to
repair the machine and move it under its own power.
1. Fully retract the boom. Position attachment
approximately 610 mm (24 in) above the ground.
Note: If total loss of power has occurred, refer to 2
Section 3.26, “Emergency Boom Lowering Procedure.” MAM2720
6. Secure the machine to a suitable towing vehicle.

WARNING a. For towing or retrieval from front of machine,
attach towing equipment to lifting points (1).
Do not attempt to tow a machine that is loaded or the
boom/attachment is raised more than approximately b. For towing or retrieval from rear of machine,
610 mm (24 in). attach towing equipment to the retrieval hitch (2).
2. Remove load from the machine.

3. Place the transmission in (N) NEUTRAL, engage the WARNING
park brake and shut the engine OFF. Use a vehicle of sufficient capacity to tow the
4. Block all four wheels. machine. Tow vehicle must be capable of providing
braking for both vehicle and machine.
WARNING 7. Clear the area of any unnecessary personnel.

8. Have an operator seated in the machine operator
Block all four wheels when preparing the machine for cab.
towing to prevent any unexpected movement.
9. Remove the blocks from all four wheels.
5. Remove the front and rear drive shafts. Refer to 10. Disengage the machine park brake.
Section 5.10, “Drive Shafts.”
11. Tow the machine to a secure location.
Note: Tow the machine at a very slow speed.
12. After towing is complete, engage the park brake.
13. Block all four wheels.
14. Reinstall the front and rear drive shafts. Refer to
Section 5.10, “Drive Shafts.”
15. Repair machine as necessary.

Section 6
Transmission
Contents

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

Transmission
6.1 TRANSMISSION ASSEMBLY

locations of the major assemblies of the transmission.
The following illustration identifies the components that
SHIFT SOLENOID
SHIFT SOLENOIDS
REAR DRIVE
SHAFT YOKE
TRASFER CASE
OIL DRAIN PLUG
TRANSMISSION
OIL DRAIN PLUG
SHIFT SOLENOIDS
TRANSMISSION OIL
FILTER
TRANSMISSION OIL
DIPSTICK
SHIFT SOLENOID
TRANSMISSION OIL
FILL TUBE AND
BREATHER
FRONT DRIVE
SHAFT YOKE
MZ6190

Transmission
6.4 TRANSMISSION REPLACEMENT

WARNING Cleanliness is of extreme importance. Before attempting
DO NOT service the machine without following all to remove the transmission, thoroughly clean the exterior
safety precautions as outlined in Section 1, “Safety of the transmission to help prevent dirt from entering
Practices,” of this manual. during the replacement process. Avoid spraying water or
cleaning solution onto or near the transmission shift
Note: These instructions cover only the routine solenoids and other electrical components.
maintenance, removal, installation and troubleshooting
of the transmission. Refer to the local Caterpillar dealer 6.4.1 Transmission Removal
and the applicable Transmission Service Manual for
assistance with comprehensive transmission diagnosis,
repair and component replacement. WARNING
NEVER lift a transmission alone; enlist the help of at
6.2 TRANSMISSION SERIAL NUMBER least one assistant or use a suitable hoist or overhead
crane and sling with a minimum lifting capacity of
454 kg (1000 lb).
place the transmission in (N) NEUTRAL, engage the
park brake and shut the engine OFF.
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery(s).
5. Drain the hydraulic oil reservoir. Refer to Section
8.7.1, “Hydraulic Oil Reservoir Draining.”
6. If not previously removed, remove the implement
pump. Refer to Section 8.8.1, “Pump Replacement.”
1
MZ6200
7. Refer to Section 7.9, “Engine Replacement,” for
detailed removal instructions.
The transmission serial number plate (1) is located on the
8. Thoroughly clean the transmission and surrounding
front of the transmission case behind the oil dipstick.
area, including all hoses and fittings, before
Information contained in the serial number is required in
proceeding.
correspondence with the transmission manufacturer.
9. Place a suitable receptacle under the transmission/
6.3 SPECIFICATIONS AND transfer case drain plugs. Remove the transmission
drain plug, and allow the transmission oil to drain
MAINTENANCE INFORMATION
into the receptacle.
For transmission, oil specifications and maintenance 10. Remove the transmission transfer case drain plug,
information, refer to Section 2, “General Information and and allow the transfer case oil to drain into the
Specifications.” receptacle.
Detailed transmission parts and service information can 11. Transfer the used transmission oil into a suitable,
be found in SIS Web. covered container, and label the container as “Used
Oil.” Dispose of used oil at an approved recycling
facility. Clean and reinstall the transmission and
transfer case drain plugs.

Transmission
19. Remove any external transmission components as

required. Cover all transmission openings.
6.4.2 Transmission Installation
2
WARNING
NEVER lift a transmission alone; enlist the help of at
3 least one assistant or use a suitable hoist or overhead
MZ6380 crane and sling.
12. Remove the access cover (3) from the engine bell Note: Apply Loctite® 243TM to all transmission bolts
housing (2). This will allow access to remove the six before installation.
torque convertor flex plate bolts and washers from
the engine flywheel. 1. Use a suitable hoist or overhead crane, secure the
transmission with a lifting strap or chain to the
13. Turn the engine over slowly by hand and align each
transmission lifting bracket (6).
of the torque convertor flex plate bolts to be
accessed. Remove them one at a time. 2. Install the air cleaner mounting bracket (5) with the
previously removed hardware.
5 3. Install the transmission to the engine and secure
6 with the ten bolts and washers (4) previously
removed. Torque to 55 Nm (41 lb-ft).
4. Remove the hoist or overhead crane and sling.
5. Turn the engine over slowly by hand and align and
install each of the torque convertor flex plate bolts
and washers to the engine flywheel through the
access opening on the engine bell housing. Install
them one at a time. DO NOT fully tighten until all of
the bolts are in place.
4 6. Torque each flex plate bolt to 26 Nm (19 lb-ft).
7. Install the hydraulic pump. Refer to Section 8.8.1,
“Pump Replacement.”
MZ6390 8. Refer to Section 7.9.3, “Engine/Transmission
14. Remove the ten bolts and washers (4) holding the Installation,”for detailed engine/transmission
transmission to the engine. installation instructions.
15. Remove the air cleaner mounting bracket (5). 6.4.3 After Transmission Service or
16. Use a suitable hoist or overhead crane, secure the Replacement
transmission with a lifting strap or chain to the
In general:
transmission lifting bracket (6).
1. Check the transmission oil level and add oil as
Note: The lifting bracket (6) is NOT included with the required.
transmission.
2. Disconnect and clean all transmission hoses. When
17. Carefully remove the transmission from the machine. possible, remove transmission lines from the
Avoid causing damage to the transmission or machine for cleaning.
surrounding parts.
3. Install a new hydraulic filter.
18. Lift the transmission clear of the machine, and lower
4. Check the torque on the drive shaft yoke capscrews.
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.

Transmission
5. When an overhauled or repaired transmission is 6.5 TORQUE CONVERTOR DIAPHRAGM

installed, thoroughly clean the oil cooler lines to and
from the transmission.
6.5.1 Torque Convertor Diaphragm
Removal
position, engage the parking brake, and shut the
8 engine OFF.
7 2. Place a Do Not Operate Tag on both the ignition key
Note: In order to remove the engine drive plate, the
engine and transmission must be separated.
MAM0780
3. Refer to Section 6.4.1, “Transmission Removal,” and
6. Reassemble all components and check the level of Section 7.9.1, “Engine Removal.”
hydraulic oil in the hydraulic oil reservoir. If required 4
fill with clean, fresh oil until oil level is visible in the 3
lower gauge window (7). DO NOT overfill.
7. Run the engine for two minutes at idle to help prime the
transmission oil lines. 2
8. Recheck the level of the fluid in the hydraulic oil 1
reservoir with the engine running at idle.
9. Add oil as necessary until oil level is visible in the
upper gauge window (8). Recheck the oil level when
it reaches operating temperature 83-94° C
(180-200° F).
10. Recheck all drain plugs, lines, connections, etc., for
MAL1950
leaks, and tighten where necessary.
4. Remove the six bolts holding the diaphragm to the
6.4.4 Transmission Torque Converter Stall flywheel.
Test 5. With the drive plate and torque converter removed,
1. Start the machine and bring engine to normal loosen and remove the six bolts (1) holding the
operating temperature. support ring (2) and diaphragm (3) to the torque
converter (4).
Engine - 75° ± 5° C (167° ± 40° F)
6. Replace diaphragm if damaged.
Hydraulic Oil - 60° ± 5° C (140° ± 40° F)
Torque Converter - 80° ± 5° C (176° ± 40° F) 6.5.2 Torque Convertor Diaphragm
2. Ensure that the transmission neutralizer switch is in Installation
the OFF position. 1. Install the new diaphragm on the torque converter
3. With the engine at high idle and the service brake and install the six bolts. Torque as required.
fully depressed, shift the transmission into 4th gear 2. Mount the diaphragm/converter assembly to the
forward. transmission. Torque as required.
4. With the transmission in the stall condition, the 3. Refer to Section 6.4.1, “Transmission Removal,” and
torque converter speed output should be 0 rpm. Section 7.9.2, “Engine Installation,” for the
5. Record the stall speed at a steady state condition remainder of the installation.
after 10 seconds in the stall state. 4. Remove the Do Not Operate Tags from both the
6. Shift the transmission back to neutral after ignition key switch and the steering wheel.
completion of the test.

Transmission
6.6 TROUBLESHOOTING
The transmission should be checked, serviced and
This section provides an easy reference guide covering repaired only by experienced service technicians who are
the most common problems that may occur during aware of all safety instructions and particular component
operation of the transmission. features.
Note: Contact the local Caterpillar dealer if internal
transmission repair is required during the warranty
period.

1. Transmission will not engage 1. Oil level too high or low. 1. Fill hydraulic reservoir to correct
or will not shift properly. level. Refer to Section 2.5,
“Fluids and Lubricant
Capacities.”
2. Transmission control lever not 2. Refer to Section 9.8, “Electrical

functioning properly and/or a System Schematics.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.
3. Transmission valve body 3. Refer to Section 9.8, “Electrical

solenoids not functioning System Schematics.”
properly.
4. Pilot operated shift valves not 4. Clean the valve spool and
operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section 6.6,

“Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.

Transmission

2. Low or no pump flow or 1. Low oil level. 1. Fill hydraulic reservoir to correct
pressure. level. Refer to Section 2.5,
Capacities.”
2. Transmission filled with incorrect 2. Drain hydraulic reservoir and fill

oil, or oil contaminated. to correct level. Refer Section
2.5, “Fluids and Lubricant
Capacities.”
3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump

assembly.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill hydraulic reservoir to correct
level. Refer to Section 2.5,
Capacities.”
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and

open. housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic
Circuits.”
2. Low engine rpm causes 2. Adjust the engine rpm to

converter stall. specifications. Refer to
Transmission Service Manual.
3. Pump output pressure is low. 3. Refer to Section 6.6,

“Low or no pump flow or
pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.6,

“Transmission overheating (oil
above 120° C (248° F)).”

Transmission

5. Transmission overheating 1. Low oil level. 1. Fill hydraulic reservoir to correct
(oil above 120° C (248° F)). level. Refer to Section 2.5,
Capacities.”
2. Clogged radiator. 2. Remove debris from the

radiator.

oil, or oil contaminated. to correct level. Refer to Section
Capacities.”
4. Excessive “roading.” 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump

assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat.
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill hydraulic reservoir to correct
from transmission. level. Refer to Section 2.5,
Capacities.”

oil. to correct level. Refer to Section
Capacities.”
3. Incorrect clutch engagement. 3. Refer to Section 9.12.1,

“Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as

needed.
5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).

Refer to Section 6.4.1,
“Transmission Removal.”
6. Loose diaphragm (flex plate) 6. Tighten capscrews.

mounting capscrews.

Transmission

7. Oil leaking from transmission. 1. Hose fittings loose. 1. Tighten fittings.
2. Oil leaking at valve bodies 2. Replace gaskets and/or tighten

(possible valve body gaskets capscrews to 9,5 Nm (7 lb-ft).
damaged or missing and/or
mounting capscrews not tight).
3. Housing capscrews loose. 3. Tighten capscrews to 46 Nm

(34 lb-ft).
4. Oil leaking at pump (possible 4. Replace o-rings and/or tighten

pump to housing o-rings capscrews to 115 Nm (85 lb-ft).
missing or damaged, and/or
pump mounting capscrews not
tight).
5. Oil leaking at converter bell 5. Replace converter and/or input

(possible converter leak and/or shaft seal.
input shaft seal damage).
6. Oil leaking at output shaft 6. Replace output shaft seal.

(output shaft seal damaged).
7. Housing damaged. 7. Replace housing as needed.

Transmission

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.4.3 Radiator Assembly Removal—75 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.4.4 Radiator Assembly Removal—74.5, 92.6, 106 and 93.1 kW . . . . . . . . . . 7-12
7.4.5 Radiator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.6.4 Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.7.1 Exhaust System Removal—75 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.7.2 Exhaust System Installation—75 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.7.3 Exhaust System Removal—74.5 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.7.4 Exhaust System Installation—74.5 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.7.5 Exhaust System Removal— 92.6 & 106 kW. . . . . . . . . . . . . . . . . . . . . . . 7-20
7.7.6 Exhaust System Installation— 92.6 & 106 kW . . . . . . . . . . . . . . . . . . . . . 7-20
7.7.7 Exhaust System Removal—93.1 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.7.8 Exhaust System Installation—93.1 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Engine
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7.8.1 Air Cleaner Assembly Removal—75 kW. . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.8.2 Air Cleaner Assembly Installation—75 kW . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.8.3 Air Cleaner Assembly Removal—74.5 kW . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.8.4 Air Cleaner Assembly Installation—74.5 kW. . . . . . . . . . . . . . . . . . . . . . . 7-24
7.8.5 Air Cleaner Assembly Removal— 92.6 & 106 kW . . . . . . . . . . . . . . . . . . 7-25
7.8.6 Air Cleaner Assembly Installation— 92.6 & 106 kW . . . . . . . . . . . . . . . . . 7-25
7.8.7 Air Cleaner Assembly Removal—93.1 kW . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.8.8 Air Cleaner Assembly Installation—93.1 kW. . . . . . . . . . . . . . . . . . . . . . . 7-26
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.9.1 Engine/Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.9.2 Transmission Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.9.3 Engine/Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Engine
7.1 INTRODUCTION
WARNING
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices,”of
this manual.
WARNING
Engine fuel lines are pressurized. DO NOT attempt repairs
unless specific training has been completed.
7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: Detailed engine service instructions (covering
disassembly, inspection, internal repair, assembly,
adjustment and troubleshooting information) are
provided in appropriate engine service manual. A
gradual running-in (break-in) of a new engine is not
necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
temperature is at least 60° C (140° F). Extended light-
load operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.

Engine
7.1.2 Component Terminology

locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.
S/N MJR00150 & AFTER 75 kW
S/N DJB00150 & AFTER
S/N GAT00150 & AFTER
S/N MLH00150 & AFTER
S/N KEK00150 & AFTER
S/N MWC00150 & AFTER
S/N RRJ00150 & AFTER
TURBO CHARGER
WATER
PUMP
ALTERNATOR
MAM3700
SECONDARY
FUEL FILTER
PRIMARY FUEL
FILTER
OIL FILTER
STARTER
MAM3710
FUEL INJECTOR
PUMP

Engine
S/N THM00150 & AFTER 74,5 kW

S/N SXJ00150 & AFTER
S/N RCH00150 & AFTER
S/N JJT00150 & AFTER
S/N RWW00150 & AFTER
S/N KKW00150 & AFTER
S/N RRW00150 & AFTER
TURBO CHARGER
WATER
PUMP
ALTERNATOR
MZ7000
PRIMARY
FUEL FILTER
SECONDARY
FUEL FILTER
FUEL INJECTOR
PUMP
STARTER
OIL FILTER
MZ7010

Engine
S/N MJR00150 & AFTER 92,6 kW

S/N DJB00150 & AFTER 106 kW
S/N GAT00150 & AFTER
S/N MLH00150 & AFTER
CLOSE CIRCUIT
BREATHER
TURBO CHARGER
WATER
PUMP
ALTERNATOR
MZ6230
AC COMPRESSOR
(IF EQUIPPED)
PRIMARY
FUEL FILTER
SECONDARY
FUEL FILTER
FUEL INJECTOR
PUMP
STARTER
MZ6240
OIL FILTER

Engine
S/N THM00150 & AFTER 93,1 kW

S/N SXJ00150 & AFTER
S/N RCH00150 & AFTER
S/N JJT00150 & AFTER
TURBO CHARGER
WATER
PUMP
ALTERNATOR
MAM3650
SECONDARY
FUEL FILTER
PRIMARY FUEL
FILTER
FUEL
INJECTOR
PUMP
STARTER
MAM3660
OIL FILTER

Engine
7.2 ENGINE SERIAL NUMBER 74.5 & 93.1 kW Engine—THM00150, SXJ00150,

RCH00150, JJT00150, RWW00150, KKW00150,
The engine serial number is stamped on the engine block RRW00150 and After
and is included on a decal attached to the side of the
• Service Manual (P/N KENR6217)
radiator. Information contained in the serial number is
required in correspondence with the engine • Operation and Maintenance Manual
manufacturer. (P/N SEBU8180-01)
• System Operation Testing and Adjusting
7.3 SPECIFICATIONS AND (P/N RENR9965)
MAINTENANCE INFORMATION • Disassembly & Assembly (P/N KENR6216-01)
For engine, coolant and oil specifications, and • Specifications (P/N RENR9961-01)
maintenance information, refer to Section 2, “General • Electric Schematic (P/N RENR9964-02)
Information and Specifications.”
• Troubleshooting (P/N SENR9969-05)
Detailed engine service instructions are provided in the
following publications: • Parts Manual (SEBP4124)
75 kW Engine—MJR00150, DJB00150, 92.6 & 106 kW Engine—MJR00150, DJB00150,

GAT00150, MLH00150, KEK00150, MWC00150, GAT00150, MLH00150 and After
RRJ00150 and After • Service Manual (P/N KENR9133)
• Service Manual (P/N UENR0651) • Operation and Maintenance Manual
• Operation and Maintenance Manual (P/N SEBU8606-01)
(P/N SEBU8727) • System Operation Testing and Adjusting
• System Operation Testing and Adjusting (P/N KENR9119-01)
(P/N UENR0620) • Disassembly & Assembly (P/N KENR9120-01)
• Disassembly & Assembly (P/N UENR0621) • Specifications (P/N KENR9118-01)
• Specifications (P/N UENR0619) • Electric Schematic (P/N KENR9122-01)
• Electric Schematic (P/N KENR9132) • Troubleshooting (P/N KENR9111-01)
• Troubleshooting (P/N UENR0611) • Parts Manual (P/N SEBP6149)
• Parts Manual (P/N SEBP6150)
74.5 kW Engine—THM00150, SXJ00150,
RCH00150, JJT00150, RWW00150, KKW00150,
RRW00150 and After
• Service Manual (P/N KENR6217)
• Operation and Maintenance Manual
(P/N SEBU8327)
• System Operation Testing and Adjusting
(P/N RENR9965)
• Disassembly & Assembly (P/N KENR6216-01)
• Specifications (P/N RENR9961-01)
• Electric Schematic (P/N RENR9964-02)
• Troubleshooting (P/N SENR9969-05)
• Parts Manual (SEBP4124)

Engine
7.4 ENGINE COOLING SYSTEM
1
7.4.1 Surge Tank Cap
Verify a 1 Bar (14.5 psi) surge tank cap is being used. An
incorrect or malfunctioning cap can result in the loss of
coolant and a hot running engine.
7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If engine seems to take a long time to warm up,
thermostat may be stuck in open position and
requires replacement. MZ6260
TYPICAL THERMOSTAT. LOCATION MAY VARY PER ENGINE
• If engine runs hot, check temperature of upper
radiator hose. 7. Remove capscrews securing thermostat housing (1)
to the engine.
• If hose is not hot, thermostat may be stuck in
closed position. 8. Remove the thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let
• If engine has overheated, performance may
any debris into the thermostat opening.
suffer, indicating other damage including a
leaking cylinder head gasket, cracked cylinder Note: ALWAYS use the correct thermostat and install a
head or block, and/or other internal engine new gasket. NEVER operate the engine without a
damage. thermostat, or engine damage will result.
a. Thermostat Removal b. Thermostat Installation

1. Park the machine on a firm, level surface, level the 1. Install the engine thermostat, thermostat gasket and
machine, fully retract the boom, lower the boom, thermostat housing. Secure with the previously
place the transmission in the (N) NEUTRAL position, removed capscrews.
engage the parking brake, and shut the engine OFF. 2. Properly connect the battery.
2. Place a Do Not Operate Tag on both the ignition key 3. Open the surge tank cap, and fill system completely
switch and steering wheel. with CAT extended life coolant (ELC). Add coolant at
3. Open engine cover. Allow the system fluids to cool. a maximum rate of 1.3 gallons per minute (5 liters
4. Properly disconnect the battery. per minute) to full cold level with coolant.
5. Slowly turn surge tank cap to the first stop and allow 4. Add coolant to the surge tank until 1/4 to 1/2 full.
any pressure to escape. Remove surge tank cap. This overfilling will compensate for any air trapped in
cooling system. Replace and tighten surge tank cap.
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the 5. Run engine to operating temperature. Visually check
drain plug and slowly remove to allow the coolant to for leaks with engine running. Check coolant level in
drain. Transfer the coolant into a properly labeled surge tank and fill, or drain, as necessary.
container. Dispose of properly if coolant needs to be 6. Close and secure the engine cover.
replaced. Replace the radiator drain plug. 7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

Engine
7.4.3 Radiator Assembly 6. Remove air cleaner assembly, Refer to Section

Removal—75 kW 7.8.1, “Air Cleaner Assembly Removal—75 kW.”
MJR00150, DJB00150, GAT00150, MLH00150, 7. Place a suitable receptacle under transmission drain
KEK00150, MWC00150, RRJ00150 and After plug. Remove the transmission drain plug, and allow
the transmission oil to drain into the receptacle.
Before considering radiator assembly replacement for
other than obvious damage, conduct a cooling system 8. Transfer used transmission oil into a suitable,
pressure test check the coolant specific gravity, coolant covered container, and label container as “Used Oil.”
level, fan belt tension, excess debris that would hinder Dispose of used oil at an approved recycling facility.
engine cooling and dash panel temperature indicator. Clean and reinstall the transmission drain plug
• If there is excessive debris in and around the 9. Drain the hydraulic oil reservoir. Refer to Section
engine cover grill, use the reversing fan option to 8.7.1, “Hydraulic Oil Reservoir Draining.”
clear the area and allow proper air flow. 10. Slowly turn surge tank cap to first stop and allow any
• If engine runs hot, check temperature of upper pressure to escape. Remove the surge tank cap.
radiator hose. 11. Place a suitable container beneath radiator drain.
• If hose is not hot, thermostat may be stuck in the
closed position.
• If engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
1. Park machine on a firm, level surface, level machine,
fully retract the boom, lower boom, place travel select
lever in (N) NEUTRAL position, engage parking
brake, and shut engine OFF. 5
8
switch and steering wheel. 7
7
3. Open engine cover. Allow the system fluids to cool.
9
MAM3910
2
12. Place a funnel at base of radiator to channel drained
coolant into a container. Open drain plug (5) and
slowly remove to allow coolant to drain. Transfer the
coolant into a properly labeled container. Dispose of
properly if coolant needs to be replaced. Close the
radiator drain plug.
3 13. Label and disconnect both transmission cooler
hoses (7). Cap all fittings and openings to prevent
dirt and debris from entering the hydraulic system.
14. Label and disconnect the outer hydraulic cooler hose
(8). Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system.
MZ6210
15. Loosen and remove radiator assembly mounting
bolts, washers and (if equipped) shims (9). Note the
4
number of shims being used and there location.
5. Remove the hood (2), end cover (3) and belly pans
(4) from the engine compartment.

Engine
10 11 12
13
MAM3920
15 14
20. Loosen and remove clamps (14) securing fuel inlet

MAM3900
hose to radiator shroud.
16. Loosen and remove the outer air intercooler tube 21. Loosen and disconnect fuel hoses (15) from radiator
(10) from the radiator assembly. assembly. Plug and cap hoses and fittings to prevent
dirt and debris from entering fuel system.
17. Loosen and remove the inner air intercooler tube
(11) from the radiator assembly.
18. Loosen and remove the top radiator hose (12) from
the radiator assembly.
19. Loosen and remove the bottom radiator hose (13) 18
from the radiator assembly.
MAM3690
22. Loosen and remove radiator assembly mounting

bolt, washer and (if equipped) shims (18). Note
23. Carefully lift the radiator assembly out of
engine compartment.
Note: Fuel Cooler, Fan Shrouding, Fan Guard and
Fan Assembly can be removed and/or disassembled
after radiator assembly is removed and placed in a
secure location.

Engine
7.4.4 Radiator Assembly Removal—74.5, 5. Remove the hood (2), end cover (3) and belly pans
92.6, 106 and 93.1 kW (4) from the engine compartment.
MJR00150, DJB00150, GAT00150, MLH00150, 6. Place a suitable receptacle under transmission drain
KEK00150, MWC00150, RRJ00150, THM00150, plug. Remove the transmission drain plug, and allow
SXJ00150, RCH00150, JJT00150, RWW00150, the transmission oil to drain into the receptacle.
KKW00150, RRW00150and After 7. Transfer used transmission oil into a suitable,
Before considering radiator assembly replacement for covered container, and label container as “Used Oil.”
other than obvious damage, conduct a cooling system Dispose of used oil at an approved recycling facility.
pressure test check the coolant specific gravity, coolant Clean and reinstall the transmission drain plug
level, fan belt tension, excess debris that would hinder 8. Drain the hydraulic oil reservoir. Refer to Section
engine cooling and dash panel temperature indicator. 8.7.1, “Hydraulic Oil Reservoir Draining.”
• If there is excessive debris in and around the 9. Slowly turn surge tank cap to first stop and allow any
engine cover grill, use the reversing fan option to pressure to escape. Remove the surge tank cap.
clear the area and allow proper air flow.
10. Place a suitable container beneath radiator drain.
• If engine runs hot, check temperature of upper
radiator hose.
6
• If hose is not hot, thermostat may be stuck in the
closed position.
• If engine has overheated, performance may 9
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
fully retract the boom, lower boom, place travel select
lever in (N) NEUTRAL position, engage parking 7
brake, and shut engine OFF. 5
9
switch and steering wheel. 7
MAM3730
2
9
7
3
5
9 8
MAM3630
7
11. Place a funnel at base of radiator to channel drained

coolant. Open drain plug (5) and slowly remove to
MZ6210
allow coolant to drain into a properly labeled
4 container. Dispose of properly if coolant needs to
be replaced. Close drain plug.

Engine
12. Label and disconnect electrical connectors at 16. Loosen and remove the outer air intercooler tube
hydraulic reversing fan valve (6). Remove grommet (10) from the radiator assembly.
from fan shroud and pull wire harness/connectors 17. Loosen and remove the inner air intercooler tube
through fan shroud opening and place on engine. (11) from the radiator assembly.
13. Label and disconnect both transmission cooler 18. Loosen and remove the top radiator hose (12) from
hoses (7). Cap all fittings and openings to prevent the radiator assembly.
dirt and debris from entering the hydraulic system.
19. Loosen and remove the bottom radiator hose (13)
14. Label and disconnect the outer hydraulic cooler hose from the radiator assembly.
(8). Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system. Note: Not all models equipped with fuel cooler assembly.
15. Loosen and remove two radiator assembly mounting 20. Loosen and disconnect the fuel outlet hose (14) from
bolts, washers and (if equipped) shims (9). Note the radiator assembly. Plug and cap hose and fitting to
number of shims being used and there location. prevent dirt and debris from entering the fuel
system.
15 21. Loosen and disconnect fuel inlet hose (15) from
14 17 radiator assembly. Loosen and remove four clamps
securing fuel inlet hose to radiator shroud. Plug and
10 18 cap hose and fitting to prevent dirt and debris from
entering fuel system.
16 11 22. Loosen and disconnect hydraulic hose (16) from
radiator assembly. Plug and cap hose and fitting to
12 prevent dirt and debris from entering fuel system.
23. Loosen and remove air inlet tube (17).
24. Loosen and remove two radiator assembly mounting
bolts, washers and (if equipped) shims (18). Note
13
25. Carefully lift assembly out of engine compartment.
18
Note: Fuel Cooler, Fan Shrouding, Fan Guard, Fan
Assembly, Fan Reversing Valve Assembly can be
MZ6280 removed and/or disassembled after radiator assembly is
removed and placed in a secure location.
17
7.4.5 Radiator Assembly Installation
18 1. Place assembly in engine compartment at original
orientation. Secure with previously used hardware.
11 2. (if equipped) Uncap and connect previously labeled
10
fuel hoses to fuel cooler tube connections. Secure
16 fuel inlet hose with previously removed clamps.
3. Uncap and connect the previously labeled hoses to
12 the radiator, transmission cooler and oil cooler.
4. (if equipped) Connect electrical connecter to
reversing valve.
13
5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling.”
6. Fill transmission. Refer to Section 2.5.1, “Capacities.”
18 7. Open surge tank cap and fill the radiator completely
MAM3620 with coolant. Replace and tighten cap. Refer to
Section 2.5, “Fluids and Lubricant Capacities,” for

Engine
proper capacities. 7.5 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter,
9. Run engine to operating temperature. Visually check alternator and primary wiring, is described in Section 9.8,
for leaks with engine running. Check all fluid levels “Electrical System Schematics.”
for correct levels.
10. (if equipped) Check reversing fan for proper 7.6 FUEL SYSTEM
operation. Refer to Section 3, page 3-27 for
detailed instructions.
7.6.1 Diesel Fuel
11. Install the end cover, hood and belly pans on the
engine compartment. Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high quality, clean diesel fuel.
13. Remove the Do Not Operate Tag from the ignition Low cost, inferior fuel can lead to poor performance and
key switch and the steering wheel. expensive engine repair.
Note: Due to the precise tolerances of diesel injection
systems, keep the fuel clean, and free of dirt and water.
Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
nozzles. Use #2 diesel fuel with a minimum Cetane rating
of 40. #2 diesel fuel gives the best economy and
performance under most operating conditions. Fuels
with Cetane numbers higher than 40 may be needed in
high altitudes or extremely low ambient temperatures to
help prevent misfiring and excessive smoking.
Inform the owner/operator of the machine to use #2
diesel fuel, unless ambient temperatures are below
0° C (32° F). When temperatures are below 0° C (32° F),
a blend of #1 diesel and #2 diesel fuels (known as
“winterized” #2 diesel) may be used.
Note: #1 diesel fuel may be used, however, fuel
economy will be reduced.
Use a ultra low sulfur content fuel with a cloud point (the
temperature at which wax crystals form in diesel fuel) at
least 10° below the lowest expected fuel temperature.
The viscosity of the fuel must be kept above
1.3 centistrokes to provide adequate fuel system
lubrication.
7.6.2 Fuel Tank

Note: The fuel tank is a one piece unit. It is located on the
rear of the cab. If it is determined that the fuel tank must be
removed, the fuel must be drained before tank removal.
Always dispose of fuel properly.
a. Fuel Tank Removal
position, engage the parking brake, and shut the
engine OFF.

Engine
2. Place a Do Not Operate Tag on both the ignition key c. Cleaning and Drying
If contaminated fuel or foreign material is in the tank, the
3. Open engine cover. Allow system fluids to cool. tank can usually be cleaned.
4. Properly disconnect battery. To clean the fuel tank:
Note: If replacing tank, remove all internal and external 1. Have a dry chemical (Class B) fire extinguisher near
components from old tank, and retain for use on the the work area.
replacement tank. 2. Remove fuel or oil tank drain plug, and safely drain
Note: Have a dry chemical (Class B) fire extinguisher fuel into an approved container. Dispose of fuel
near the work area. properly.
3. Clean fuel tank with a high pressure washer, or flush
tank with hot water for five minutes and drain water.
Dispose of contaminated water properly.
4. Add a diesel fuel emulsifying agent to tank. Refer to
manufacturer’s instructions for correct emulsifying
agent-to-water mixture ratio. Refill tank with water,
and agitate mixture for 10 minutes. Drain tank
completely. Dispose of contaminated water properly.
5. Refill fuel tank with water until it overflows.
Completely flush tank with water. Empty fuel tank,
and allow it to dry completely.
1
d. Assembly
Fuel level indicator can be removed and reused on new
tank. Dispose of old tank according to local regulations
2 concerning hazardous materials disposal regulations.
MAM0321
e. Inspection
5. Remove lower cover (1) of fuel tank.
1. Inspect fuel tank thoroughly for any cracks, slices,
6. Remove hydraulic oil reservoir. Refer to Section leaks or other damage.
8.7.3, “Hydraulic Oil Reservoir Removal/Installation.”
2. With fuel tank removed from machine, plug all
7. Remove fuel tank drain plug, and drain fuel into an openings except one elbow fitting. Install elbow
approved container. Dispose of fuel properly. fitting, and apply approximately 7-10 kPa
8. Label, disconnect and cap fuel lines of fuel tank. (1-1.5 psi) of air pressure through elbow. Check
Disconnect fuel sender. reservoir for leaks by applying a soap solution to
9. Support fuel tank with a floor jack or suitable exterior and look for bubbles to appear at cracked or
supports. Remove bolts securing fuel tank support damaged area.
(2) to cab.
f. Fuel Tank Installation
10. Lower fuel tank and support bracket away from cab
being careful to minimize fluid spillage. 1. If necessary, install fuel tank to support bracket with
previously used hardware.
11. If replacing fuel tank, remove bolts and washers
securing support bracket to fuel tank. 2. Using a floor jack, lift fuel tank and support bracket
to their original orientation on cab. Install with
b. Disassembly previously used hardware. Remove floor jack.
The fuel tank is a one-piece unit and cannot be 3. Install fuel tank to machine with previously used
disassembled. The fuel level indicator can be removed and hardware. Remove floor jack.
reused on the new replacement tank. Dispose of the old 4. Connect previously labeled fuel hoses to their
tank according to local regulations concerning hazardous appropriate locations. Secure with clamps. Connect
materials disposal. fuel sender.

Engine
5. Fill fuel tank according to specifications.Refer to 7.6.4 Fuel Cooler

Note: Not all models equipped with fuel cooler assembly.
6. Check fuel tank for leaks.
7. Install hydraulic oil reservoir. Refer to Section 8.7.3, a. Fuel Cooler Removal
“Hydraulic Oil Reservoir Removal/Installation.” 1. Park machine on a firm, level surface, level machine,
8. Install lower cover of fuel tank. fully retract boom, lower boom, place transmission in
9. Properly connect battery. (N) NEUTRAL position, engage parking brake, and
shut engine OFF.
2. Place a Do Not Operate Tag on both ignition key
11. Remove Do Not Operate Tag from ignition key switch switch and steering wheel.
and steering wheel.
7.6.3 After Fuel System Service 4. Properly disconnect the battery.
1. Drain and flush the fuel tank if it was contaminated.
75kW
2. Vent air from fuel system in accordance with
instructions found in appropriate Engine Operation &
Maintenance Manual.
3. Fill fuel tank with fresh, clean diesel fuel as required.
MAM3920
74,5kW
92,6kW
106kW
1
93,1kW
MZ6290
5. Temporarily clamp both fuel lines (1) before

removing the fuel cooler.

Engine
7.7 ENGINE EXHAUST SYSTEM

Note: Emission Sensitive Exhaust. Assembly must be
replaced exactly as removed. Contact your local
Caterpillar dealer before removing the muffler system.
3 2
7.7.1 Exhaust System Removal—75 kW
MJR00150, DJB00150, GAT00150, MLH00150,
KEK00150, MWC00150, RRJ00150 and After
4
2
4 fully retract boom, lower boom, place travel select
brake, and shut engine OFF.
5
MZ6300
4. Properly disconnect battery.
6. Loosen fuel hose clamps (2) noting the orientation. 5. Remove belly pan.
7. Loosen the hood mounting bracket bolt (3).
8. Loosen and remove the four fuel cooler mounting
bolts (4). Remove the fuel cooler (5).
9. Safely drain any fuel into a suitable container.
Dispose of fuel properly.
1 7
b. Fuel Cooler Installation
1. Apply Loctite® 242TM to all mounting bolts. 6
2
2. Install fuel cooler to the mounting brackets with the
previously removed bolts. Torque to 28 Nm (21 lb-ft). 8
3. Tighten the hood mounting bracket bolt. Torque to 5
28 Nm (21 lb-ft).
4. Install previously removed fuel lines and secure with
clamps. Torque clamps to 5 Nm (44 lb-in).
5. Remove both clamps on each fuel line.
9
6. Start the machine and verify no fuel leakage.
7. Shut machine OFF.
1
9. Remove the Do Not Operate Tag from the ignition 3 4
MAM3740
6. Loosen and remove tail pipe clamps (1) securing tail

pipe (2) to exhaust pipe (3).
7. Loosen and remove clamp (4) securing exhaust pipe
(3) to exhaust pipe (5).

Engine
8. Remove and retain all hardware (6) securing 7.7.3 Exhaust System Removal—74.5 kW
heatshield (7). Remove heatshield
THM00150, SXJ00150, RCH00150, JJT00150,
9. Remove clamps (8 & 9) that secure exhaust pipe (5). RWW00150, KKW00150, RRW00150 and After
10. Remove exhaust pipe. 1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place travel select
7.7.2 Exhaust System Installation—75 kW lever in (N) NEUTRAL position, engage parking
MJR00150, DJB00150, GAT00150, brake, and shut engine OFF.
MLH00150, KEK00150, MWC00150, 2. Place a Do Not Operate Tag on both ignition key
RRJ00150 and After switch and steering wheel.
Note: Keep all clamps loosened until entire exhaust 3. Open engine cover. Allow the system fluids to cool.
system is in place. 4. Properly disconnect battery.
11. Install exhaust pipe (5). 5. Remove belly pan.
12. Secure with new clamps (8 & 9). Do Not Tighten.
13. Install exhaust pipe (3).
14. Secure with new clamp (4). Do Not Tighten.
27
15. Install the tail pipe (2).
16. Secure with new clamps (1). Do Not Tighten.
B 26
24
A
23
MZ6330
25
TH336C, TH337C, TH406C & TH407C—
Use mounting holes “A”. MZ6321
TH414C, TH514C & TH417C—

Use mounting holes “B”. 6. Loosen and remove tail pipe clamp (23) at
muffler (24).
17. Adjust exhaust and tail pipes for proper clearance
then tighten all clamps. Torque to 12 Nm (9 lb-ft). 7. Loosen and remove two clamps (25 & 26) securing
tail pipe (27) to muffler (24).
18. Re-Install the heatshield (7) with hardware (6)
removed earlier. 8. Remove tail pipe from muffler.
19. Properly connect battery.
20. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
21. Install the belly pan.

Engine
29
27
31
32
26
24
30
23
31 28 MZ6900
25
MZ6321
9. Loosen and remove clamp (28) and hardware (29) 3. Install the tail pipe (27) to the muffler (24) with
securing exhaust pipe (30). previously used clamp (23). Do Not Tighten.
10. Remove hardware (31) securing muffler and 4. Install clamps (25 & 26). Do Not Tighten.
carefully lower muffler from machine.
11. Remove exhaust pipe.
7.7.4 Exhaust System Installation—74.5 kW B
THM00150, SXJ00150, RCH00150,

JJT00150, RWW00150, KKW00150,
RRW00150 and After
Note: Keep all clamps loosened until entire exhaust
system is in place.
1. Install muffler (24) and with hardware (31) A
removed earlier. Do Not Tighten
MZ6330
2. Install exhaust pipe (30). Secure with new clamp.
Do Not Tighten. TH336C, TH337C, TH406C & TH407C—
Use mounting holes “A”.
TH414C, TH514C & TH417C—
Use mounting holes “B”.
5. Adjust muffler, exhaust and tail pipes for proper
clearance then tighten all clamps. Torque to
12 Nm (9 lb-ft).

Engine
7.7.5 Exhaust System Removal—

92.6 & 106 kW
22
MJR00150, DJB00150, GAT00150, MLH00150 and After 15
18
fully retract boom, lower boom, place travel select 15 20
5. Remove belly pan.
19 MZ6310
16 17 19 21
14 9. Label, loosen and disconnect three muffler

sensors (15). Only two sensors shown. One is
located behind muffler.
10. Loosen and remove muffler ball clamp (16).
13 11. At bottom of muffler, loosen muffler hangars (17).
12. Remove cotter keys (18), pins (19) and carefully
lower muffler from machine.
Note: Remove exhaust pipe between muffler and back
pressure valve as an assembly.
11 13. Loosen and remove V-band clamp (20) securing
exhaust pipe (21) to back pressure valve (22).
10
14. Remove exhaust pipe assembly.
12
7.7.6 Exhaust System Installation—
MZ6321 92.6 & 106 kW
MJR00150, DJB00150, GAT00150, MLH00150
6. Loosen and remove the tail pipe clamp (10) at and After
muffler (11).
7. Loosen and remove two clamps (12 & 13) securing
system is in place.
tail pipe (14) to muffler (11).
8. Remove tail pipe from muffler. 1. Install muffler and secure with hangars, pins and
cotter keys. Do not tighten hangars.
2. Install exhaust pipe between the muffler and back
pressure valve. Secure with new clamps (16 & 20).
Do Not Tighten.
3. Tighten and torque muffler hangars (17) to
47-63 Nm (35-63 lb-ft).
4. Tighten and torque V-band clamp (20) to 11-13 Nm
(8-9.5 lb-ft).
5. Tighten and torque ball clamp (16) to 33-37 Nm
(24-26.5 lb-ft).

Engine
6. Install the pipe (14) to muffler (11) with previously 7.7.7 Exhaust System Removal—93.1 kW
used clamp (10). Do Not Tighten.
THM00150, SXJ00150, RCH00150, JJT00150 and After
7. Install clamps (12 & 13). Do Not Tighten.
fully retract boom, lower boom, place travel select
4. Properly disconnect battery.
5. Remove belly pan.
A
MZ6330
27
8. TH336C, TH337C, TH406C & TH407C—
12 Nm (9 lb-ft). 26
24
15
15 23
25
MZ6340
MZ6321
10. Install previous labeled sensor connectors (15). 6. Loosen and remove tail pipe clamp (23) at
Torque to 1,5-1,7 Nm (13.2-15 in-lb). muffler (24).
11. Properly connect the battery. 7. Loosen and remove two clamps (25 & 26) securing
12. Start engine and check for exhaust leaks at all tail pipe (27) to muffler (24).
exhaust connections. Adjust or repair as needed. 8. Remove tail pipe from muffler.

Engine
29
27
31
32
26
24
30
23
31 28 MZ6900
25
MZ6321
9. Loosen and remove clamp (28) and hardware (29) 3. Install the tail pipe (27) to the muffler (24) with
securing exhaust pipe (30). previously used clamp (23). Do Not Tighten.
10. Remove hardware (31) securing muffler and 4. Install clamps (25 & 26). Do Not Tighten.
carefully lower muffler from machine.
11. Remove exhaust pipe.
7.7.8 Exhaust System Installation—93.1 kW

THM00150, SXJ00150, RCH00150, JJT00150 and After
system is in place.
1. Install muffler (24) and with hardware (31)
removed earlier. Do Not Tighten
A
2. Install exhaust pipe (30). Secure with new clamp.
Do Not Tighten. MZ6330
TH336C, TH337C, TH406C & TH407C—

12 Nm (9 lb-ft).

Engine
7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly

Installation—75 kW
NOTICE MJR00150, DJB00150, GAT00150, MLH00150,

KEK00150, MWC00150, RRJ00150 and After
NEVER run the engine with only the inner safety 1. Install air cleaner assembly (19) to air cleaner
element installed. mounting plate and secure with previously
used hardware.
Note: Refer to the appropriate machine Operation
& Maintenance Manual for the correct element 2. Place loosened clamp (17) over air intake hose (18)
change procedure. and install the hose on the air cleaner assembly.
Tighten clamps.
7.8.1 Air Cleaner Assembly 3. Connect previously labeled wire connections to air
Removal—75 kW pressure switch (20).
MJR00150, DJB00150, GAT00150, MLH00150, 4. Properly connect battery.
KEK00150, MWC00150, RRJ00150 and After 5. Close and secure engine cover.
1. Park machine on a firm, level surface, level machine, 6. Remove Do Not Operate Tag from ignition key switch
fully retract the boom, lower boom, place travel select and steering wheel.
3. Open engine cover. Allow system fluids to cool.
19 20
17
22
18
21
MAM3750
5. Loosen and remove clamp (17) securing air intake

hose (18) to air cleaner (19). Remove air intake hose.
6. Label and disconnect air pressure switch (20).
7. Remove the two bolts (21) securing the air cleaner
strap (22) to the air cleaner (19). Remove the air
cleaner assembly.

Engine
7.8.3 Air Cleaner Assembly 7.8.4 Air Cleaner Assembly

Removal—74.5 kW Installation—74.5 kW
THM00150, SXJ00150, RCH00150, JJT00150, THM00150, SXJ00150, RCH00150, JJT00150,
RWW00150, KKW00150, RRW00150 and After RWW00150, KKW00150, RRW00150 and After
1. Park machine on a firm, level surface, level machine, 1. Install air cleaner assembly (3) to air cleaner
fully retract the boom, lower boom, place travel select mounting plate and secure with previously
lever in (N) NEUTRAL position, engage parking used hardware.
brake, and shut engine OFF. 2. Place loosened clamp (4) over the air inlet hose (5)
2. Place a Do Not Operate Tag on both ignition key and install hose on the air cleaner assembly.
switch and steering wheel. Tighten clamp.
3. Open engine cover. Allow system fluids to cool. 3. Place loosened clamps (1) over air intake hose (2)
4. Properly disconnect the battery. and install the hose on the air cleaner assembly.
Tighten clamps.
4. Connect previously labeled wire connections to air
pressure switch (6).
1 5. Properly connect battery.
6. Close and secure engine cover.
7. Remove Do Not Operate Tag from ignition key switch
2 and steering wheel.
8 6
5
3
MZ6350
5. Loosen and remove clamps (1) securing air intake

6. Remove clamp (4) securing air inlet hose (5)
between air cleaner assembly and engine. Pull air
inlet hose off air cleaner.
cleaner assembly.

Engine
7.8.5 Air Cleaner Assembly Removal— 7.8.6 Air Cleaner Assembly Installation—
92.6 & 106 kW 92.6 & 106 kW
MJR00150, DJB00150, GAT00150, MLH00150 MJR00150, DJB00150, GAT00150, MLH00150
and After and After
brake, and shut engine OFF. 2. Place loosened clamp (4) over the air inlet hose (5)
2. Place a Do Not Operate Tag on both ignition key and install hose on the air cleaner assembly.
switch and steering wheel. Tighten clamp.
Tighten clamps.
1 5. Properly connect battery.
6. Close and secure engine cover.
8 6
5
3
MZ6350

cleaner assembly.

Engine
7.8.7 Air Cleaner Assembly 7.8.8 Air Cleaner Assembly

Removal—93.1 kW Installation—93.1 kW
THM00150, SXJ00150, RCH00150, JJT00150 and After THM00150, SXJ00150, RCH00150, JJT00150 and After
brake, and shut engine OFF. 2. Place loosened clamp (12) over the air inlet
2. Place a Do Not Operate Tag on both ignition key hose (13) and install hose on the air cleaner
switch and steering wheel. assembly. Tighten clamp.
Tighten clamps.
9 6. Close and secure engine cover.
9
16
12
13
11 MAM3640 14
15

cleaner assembly.

Engine
7.9 ENGINE REPLACEMENT 8. Remove the hood (1), end covers (2) and belly pans
(3) from the engine compartment.
7.9.1 Engine/Transmission Removal 9. Remove the heater and cooling hoses attached to
the engine.
10. Label, disconnect and cap/plug all hydraulic
WARNING connections on the engine/transmission.
NEVER lift engine/transmission alone; enlist the help Note: The engine/transmission harness is routed and
of at least one assistant. Use a suitable hoist or attached to the engine/transmission using hold-down
overhead crane and sling with a minimum lifting clamps and plastic wire ties at various places on the
capacity of 2000 lb (454 kg). engine. Before removing engine/transmission, ensure
that the harness has been completely separated
Note: The radiator assembly must be removed from the (disconnected) from the engine/transmission. Move the
machine before engine/transmission removal. Refer to harness clear of the engine/transmission, and with the
Section 7.4.3, “Radiator Assembly Removal—75 kW.” help of an observer, ensure that the engine/transmission
Several additional components must be removed before clears the harness during removal.
engine/transmission removal. They will be addressed in
the following procedures. 11. Label and disconnect all electrical wire connections
on the engine/transmission.
fully retract boom, lower boom, place travel select 12. Label and disconnect all hoses on the engine and
lever in (N) NEUTRAL position, engage parking transmission. Plug and/or cap all fittings and
brake, and shut engine OFF. openings to keep dirt and debris from entering the
hydraulic system.
switch and steering wheel. 13. Label, disconnect and cap fuel lines.
3. Open engine cover. Allow system fluids to cool. 14. Label and remove all clamps securing any fuel line
on engine.
4. Properly disconnect and remove the battery(s).
15. Remove exhaust pipe from exhaust manifold. Refer
5. Properly drain hydraulic oil system. Refer to Section to Section 7.7, “Engine Exhaust System.”
8.7, “Hydraulic Reservoir,” for detailed instructions.
Note: Emission Sensitive Exhaust. Assembly must be
6. Properly drain the transmission. Refer to Section
replaced exactly as removed.
6.4.1, “Transmission Removal,” for detailed
instructions. 16. Remove air cleaner assembly. Refer to Section 7.8,
7. Mark position of cover to help with cover adjustment “Air Cleaner Assembly.”
when being reinstalled. 17. Remove the drive shaft assemblies.Refer to Section
5.10.3, “Drive Shaft Removal.”
18. Secure the engine with a lifting strap or chain from
1 the appropriate lifting points. Use a suitable hoist or
overhead crane.
Note: Not all engines are equipped with lifting brackets.
19. Loosen and remove the four engine/transmission
mounting bolts and washers securing the engine to
the frame.
2
2 20. Slightly lift and pull the engine/transmission out of
the machine. Have an assistant ensure that the
2 engine/transmission clears all frame components
during removal.
21. Place engine/transmission on a flat, level surface.
MZ6210

Engine
7.9.2 Transmission Removal/Installation 7.9.3 Engine/Transmission Installation

1. Refer to Section 6.4, “Transmission Replacement,” 1. Attach a lifting chain to front and rear engine lift
for detailed transmission removal and brackets, and lift engine/transmission clear of ground.
installation instructions.
Note: Apply Loctite® 243TM to engine mount bracket
2. Engine Disassembly, Inspection and Service bolts before installation.
Engine disassembly, internal inspection, service, repair 2. Lift engine/transmission and slowly push and lower
and assembly procedures are covered in the CAT service into engine compartment. Have an assistant ensure
manual. Several special engine service tools are required to that engine/transmission clears frame, hose and
properly service the CAT engine. Contact the local harness components during engine/transmission
Caterpillar dealer for further information. installation. Position engine/transmission brackets
Note: If engine is being replaced, there may be external over frame mounts.
components that will be required to be transferred from 3. Align motor mount holes and install front mounting
original engine to replacement engine depending upon who bolts and washers.
you purchase new engine from and configuration of your
replacement engine. Refer to appropriate CAT user manual 4. Align motor mount holes and install rear mounting
for detailed procedures that cover transfer of original engine bolts and washers.
components to replacement engine. 5. Lower the engine onto the mounts and remove the
lifting chains.
6. Install flat washer, lock washer and nut on front two
mounting bolts.
7. Torque engine/transmission mounting bolts to
mounts to 241 Nm (178 lb-ft).
8. Install air cleaner. Refer to Section 7.8, “Air Cleaner
Assembly.”
9. Install exhaust pipe. Refer to Section 7.7, “Engine
Exhaust System.”
10. Install radiator assembly. Refer to Section 7.4.3,
“Radiator Assembly Removal—75 kW.”
11. Install the drive shaft assemblies. Refer to Section
5.10.5, “Drive Shaft Installation.”
12. Connect and secure all the previously labeled
hydraulic hoses, fuel lines and electrical wire
connections on the engine and transmission.
13. Install heater and cooling hoses to the engine and
tighten clamps (if equipped).
14. Install hood (1), end covers (2) and belly pans (3)
from engine compartment. and adjust if necessary.
15. Install and properly connect battery(s).
16. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
Note: Have an assistant stand by with a Class B
fire extinguisher.
17. Check for proper fluid levels prior to startup. Refer to

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.1 TH336C, TH337C, TH406C & TH407C . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6.2 TH414C, TH514C & TH417C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.4 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.1 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.1 Auxiliary Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.2 Auxiliary Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.10 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.10.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.10.2 Reversing Fan Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.10.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.10.4 Service Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.10.5 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.10.6 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.10.7 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.11 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.11.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.11.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.11.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.11.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.12 Boom Ride Control (TH336C, TH337C, TH406C, TH407C - If Equipped) . . . . . . 8-25
8.12.1 General Accumulator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.12.2 Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.12.3 Pre-Charging Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.12.4 Checking Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
location of the hydraulic components of the machine. The
LIFT/LOWER COMPENSATION
EXTEND/RETRACT HYDRAULIC FLUID CYLINDERS
CYLINDER RESERVOIR CYLINDER
(TH414C/514C/417C)
TILT CYLINDER
MAIN CONTROL
VALVE
MAM0850
IMPLEMENT
PUMP COMPENSATION
OUTRIGGER CYLINDER
LEVELING CYLINDER (TH336C/337C/406C)
CYLINDER (TH414C/514C/417C)
(TH414C/514C/417C) (BEHIND TIRE ON RIGHT SIDE)

Hydraulic System
8.2 SAFETY INFORMATION 8.3 SPECIFICATIONS

Refer to Section 2.4, “Specifications,” for hydraulic
WARNING system specifications.
DO NOT service the machine without following all 8.4 HYDRAULIC PRESSURE DIAGNOSIS
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
8.4.1 Pressure Checks and Adjustments
Petroleum-based hydraulic fluids are used in this
When diagnosing trouble in the hydraulic system, use the
machine. The temperature of hydraulic fluid increases
hydraulic testing information in Section 8.5.1, “Hydraulic
during the operation of various hydraulic functions. A
Pressures.”
heated petroleum-based hydraulic fluid presents a fire
hazard, especially when an ignition source is present. In general, follow the steps below whenever conducting
pressure checks and performing adjustments:
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully 1. Park the machine on a firm, level surface. Engage
examine any deterioration and determine whether any the park brake, place the travel select lever in (N)
further use of the component would constitute a hazard. NEUTRAL, level the boom and turn the engine OFF.
If in doubt, replace the component. 2. At the proper test port, install a pressure gauge
Whenever you disconnect a hydraulic line, coupler, fitting capable of measuring at least 10% more pressure
or other component, slowly and cautiously loosen the part than that which the circuit being checked operates
involved. A hissing sound or slow seepage of hydraulic under.
fluid may occur in most cases. After the hissing sound 3. Start the engine. Operate machine functions several
has ceased, continue removing the part. Any escaping oil times to allow hydraulic oil to reach operating
should be directed into an appropriate container. Cap or temperature. The hydraulic oil temperature should
otherwise block off the part to prevent further fluid be between 38-49° C (100-120° F). If a temperature
seepage. gauge or thermometer is unavailable, the hydraulic oil
Hydraulic system maintenance will, at times, require that reservoir should be warm to the touch.
the engine be operated. Always follow safety precautions. 4. Refer to Section 8.5.1, “Hydraulic Pressures,” for
A major cause of hydraulic component failure is testing procedures.
contamination. Keeping the hydraulic fluid as clean as 5. Fully depress the accelerator pedal if required. Place
possible will help avoid downtime and repairs. Sand, grit and hold the joystick in the position needed to
and other contaminants can damage the finely machined operate the particular machine function being
surfaces within hydraulic components. If operating in an checked. Continue holding the joystick in position
exceptionally dirty environment, change filters and until pressure readings are taken.
inspect the fluid more often. When servicing the system,
6. Check the pressure gauge reading. It should read as
cap or plug hydraulic fittings, hoses and tube assemblies.
specified in the Pressure Readings column of the
Plug all cylinder ports, valves and the hydraulic reservoir,
charts found in Section 8.5.1, “Hydraulic Pressures.”
and pump openings until installation occurs. Protect
If the reading is not as specified, turn the engine
threads from contamination and damage.
OFF and check other components in the system.
Some hydraulic functions are actuated by interfacing with Verify that all related hydraulic components and
electrical system components (switches, solenoids and electrical switches, sensors, solenoids, etc. are
sensors). When the hydraulic system is not functioning operating correctly.
properly, check the electrical aspect of the malfunctioning
7. Adjust the appropriate relief valve by turning the
circuit also.
adjustment screw. Turning clockwise will increase
Some hydraulic functions are actuated by interfacing with the pressure; turning the screw counterclockwise will
electrical system components (switches, solenoids and decrease the pressure.
sensors). When the hydraulic system is not functioning
8. Start the engine and check the pressure again. Turn
properly, check the electrical aspect of the malfunctioning
the engine OFF. If there is pressure reading in the
circuit also. Refer to Section 9.8, “Electrical System
gauge, bleed it off then disconnect or remove the
Schematics,” in this manual.
pressure gauge from the machine.

Hydraulic System
8.5 HYDRAULIC CIRCUITS b. Adjusting Hydraulic Pressures

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

Hydraulic System
c. Pressure Specifications
Hydraulic Test Port Procedure Adjustment Pressure

Circuit Location Range
Connect gauge to LS1 port, select 2 wheel
steer, run engine at high idle, turn steering
wheel one direction to lock. Hold and check 168-178 Bar
1 Steer Pressure LS1 (A) N/A
pressure. 2467-2582 psi
Note: Do not operate any other function
while checking pressure.
Connect one gauge to LS1 port, and
connect one gauge to P port, select 2 wheel
steer, run engine at high idle, turn steering
LS1 (A)& wheel one direction to lock. Hold and check 18,5-23,5 Bar
2 Pump Margin pressure. 1
P (B) 269-340.8 PSI
The margin pressure is the difference
between the pressures measured at the
LS1 Port and the P Port.
225-235 Bar
Connect gauge to LS1 port, level boom and
3 Load Sense LS1 (A) 2 3263-3408
bottom boom retract.
PSI
245-255 Bar
Maximum Pump Connect gauge to P port, level boom and
4 P (B) 3 3553-3698
Pressure bottom boom retract.
PSI
Stand-By Connect gauge to P port, check pressure at 15-35 Bar
5 P (B) N/A
Pressure Low idle with no function. 218- 508 PSI
Connect gauge to PR port, check pressure 25-30 Bar
6 Pilot Pressure PR (C) N/A
with no function. (362-435 PSI)
Auxiliary Auxiliary Connect gauge to Auxiliary Coupling, check 215 Bar
7 N/A
Pressure Port pressure at coupling. 3118 PSI
Note: All pressure check are to be performed at High Idle unless noted.
A
3
2
MZ6400 MZ6410

8-6
8.6
8.6.1
8 7 6 5 4 3 2 1
TH336C & 406C 110/80 TH336C & 406C 125/85 COMPENSATION

TELE TH337C & 407C 130/90
TH337C & 407C 115/80 65/45
70/50
TILT
LIFT
H H
A4
B4
C2 C1
V1
V2
M C2 C1 AUX 1
330 Bar 300 Bar (STANDARD)
300 Bar
260 Bar Ratio 4.2:1 Ratio 7.3:1
Ratio 4:1
Ratio 4:1
C1
C2
70 Bar 70 Bar
V2 V1
V2 V1
Hydraulic System
G H G
D
LS1 (P STEER) B1 A1 B2 A2 B3 A3 B4 A4
DLS TPr
(LS STEER) P2
Pr
LS2
0.8
100
P1
0.4
F G TDi F
30 Bar
HYDRAULIC SCHEMATICS
100
P 0.7 l/min
GAUGE 231
E Bar
3.5 10
T2
Bar T1
C D A A B A
280 B 280 280 280
280 Bar Bar Bar
Bar Bar
3 MAIN CONTROL VALVE
E E
TH336C, TH337C, TH406C & TH407C
STEERING
SELECT VALVE
Refer to Hydraulic Schematic Package (P/N 31200831)
A B
R L
240 240
Bar Bar
LS
P
D D
180
Bar
STEERING VALVE
(ORBITAL) P T
MASTER CYLINDER
19Bar
REAR STEER
FRONT STEER
2.2
REVERSE & DEMAND FAN 260Bar
0.6 0.6 8 BAR
16.8cc NORM OPEN
C C
DRIVE RATIO
1:1.088 WITH ENGINE
P T
M/C
BOOSTED BRAKE ACTUATION
B B
19cc
FILL
CAT: 207 bar
8 Bar
3.45 Bar
beta(10)=1000
A A
ENGINE:FAN PUMP
DRIVE RATIO
1:1.0588
8 7 6 5 4 3 2 1
MZ6420E
TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

8.6.1
8 7 6 5 4 3 2 1
H H
IN MCV
ZONE E5
1.5 L
A1 B1
T2 H
C D
B4 A4 AUX QC
T P
M1
M P1 P2
G G
M/C
OPTIONAL
Y
300 bar
R.4:1 LS INTEGRAL TRAILER BRAKE QRC
TRAILER BRAKE
70 bar AUX 1 & AUX QC B
F F
(OPTION)
TRAILER
A1 B1
E P A G
RIDE CONTROL
(OPTION)
A B
TRAILER BRAKING

E A B E
LS2
TOW HITCH
B4 A4 AUX QC
A B
P1 P2
D D
A B P2 T2
AUX 2
TRAILER SERVICES
REAR AUX
TH336C, TH337C, TH406C & TH407C (Continued)
LS2
2.5 2.5 AUX 1

M/C
1
H
C C
P2 T2 T P AUX 1, AUX QC & AUX 2

TRAILER SERVICES (OPTION)
TRAILER BRAKING AND HYDRAULIC HITCH
M/C
B LS INTEGRAL TRAILER BRAKE QRC B
TRAILER BRAKE
B
E P A G
A A
8 7 6 5 4 3 2 1
MZ6430E
Hydraulic System
8-7
8-8
8 7 6 5 4 3 2 1
8.6.1
H H
IN MCV
ZONE E5
1.5 L
A1 B1
T2 H
C D
B4 A4 AUX QC
T P
M1
M P1 P2
Hydraulic System
G G
M/C
OPTIONAL
Y
300 bar
R.4:1 LS INTEGRAL TRAILER BRAKE QRC
TRAILER BRAKE
70 bar AUX 1 & AUX QC B
F F
(OPTION)
TRAILER
A1 B1
E P A G
RIDE CONTROL
(OPTION)
A B
TRAILER BRAKING
E A B E
LS2
TOW HITCH
B4 A4 AUX QC
A B
P1 P2
D D
A B P2 T2
AUX 2
TRAILER SERVICES
REAR AUX
TH336C, TH337C, TH406C & TH407C (Continued)
LS2
2.5 2.5 AUX 1

M/C
1
H
C C
P2 T2 T P AUX 1, AUX QC & AUX 2

TRAILER SERVICES (OPTION)
TRAILER BRAKING AND HYDRAULIC HITCH
M/C
B LS INTEGRAL TRAILER BRAKE QRC B
TRAILER BRAKE
B
E P A G
A A
8 7 6 5 4 3 2 1
MZ6440E

8.6.2
8 7 6 5 4 3 2 1
90/60 TILT COMP

TH 514
NOTE 2 110/63 TH 417 130/80
TH 414 80/60 TH 514 90/45 TH 514 150/75
TH 414 TH 414
75/45 125/75
TH 417 TH 417
C2 C1
H C2 C1 H
M C2 C1
M C2 M1 C1
300 Bar
Ratio 4:1 300 Bar TH514 300 Bar
Ratio 4:1 TH417 350 Bar 330 Bar
Ratio 4:1 Ratio 4.2:1
70 Bar STABILIZERS LEVELING
70 Bar
70 Bar TH 414 125/55 TH 414 100/45
V2 V1 TH 514 TH 514
V2 V1 140/65 TH 417 110/45
TH 417
V2 V1
LIFT A2 B2
TELE B2
A2
TH 414 TELE (LEFT) (RIGHT)
TH 514 NOTE 2
TH 417 AUX
G TELE NOTES 1 & 2 NOTES 1 & 2 G
D 70 Bar Max 70 Bar Max
LS1 (P STEER) 60 Bar Min 60 Bar Min
B1 A1 B2 A2 B3 A3 B4 A4
DLS TPr
(LS STEER) P2
Pr
LS2
0.8
100 350 100 350

100 Bar Bar Bar Bar
P1
V2 V1 V2 V1 V2 V1
0.4
TDi LS
F A B A B A B F
100
30 Bar
TH414C, TH514C & TH417C
P 0.7 l/min
P
GAUGE 231
Bar P in
10 0.6
T2 S
T1 B
A A A
280 B 280 280 280
1.5
280 Bar Bar Bar
Bar Bar
SX14NGE SAE MAIN CONTROL VALVE

T 1.0

E E
STEERING VALVE LEVELING STABILIZERS
SELECT VALVE
NOTE 1 NOTE 1
A B
R L
240 240
Bar
Bar MOTOR 1.2
SAHR OPTION
T (SH2 A5) 250
bar
LS
P
D C D D
SAHR OPTION
MASTER CYLINDER (SH2 D3)
180
Bar B
STEERING VALVE
(ORBITAL)
P T
19Bar
REAR STEER
SEE NOTE 3
FRONT STEER
2.2
SOS SAMPLE POINT 260Bar

8 BAR
0.6 0.6 NORM OPEN 20 12.5 BAR
bar NORM OPEN
A
F
PUMP DATA P T
C C
MCN CC PART #
STANDARD AXLE
2.8 BAR PUMP SPEED AT: 414C 45 1001121054 G
LOW IDLE - 870 RPM 514C 63 1001121053
HIGH IDLE - 2555 RPM
417C 63 1001121053
BOOSTED BRAKE ACTUATION
NOTE 1, DEAD ENGINE BOOM LOWER KIT OPTION

3.45 BAR NOTE 2: LMI SYSTEM OPTION
E NOTE 3: SAHR AXLE OPTION ONLY
BRAKE BOOST AND SAHR PRESSURE LIMITED TO 20 BAR
5 BAR
beta 5(c)=1000
B B
FILL
TH414C, TH417C, TH514C
BELT DRIVEN FAN
A A
8 7 6 5 4 3 2 1
MAM3590C
Hydraulic System
8-9
8-10
8 7 6 5 4 3 2 1
8.6.2
REVERSE & DEMAND FAN
H B4 A4 AUX QC H
16.8cc
V1 V2
P1 P2
NON-REVERSING OPTION
C1 C2
Hydraulic System
G A4 G
B4
19cc
AUX 1
FILL PLATFORM OPTION AUX 1 & AUX QC
225 bar
8 Bar
F F
SAHR PARK BRAKE VALVE
3.45 Bar VALVE SHOWN WITH THE BRAKE DISENGAGED.
BRAKE DISENGAGEMENT PRESSURE 18-30 BAR
beta(10)=1000
ENGINE: FAN PUMP

DRIVE RATIO R
1:1.0588
MAIN CONTROL VALVE F
PILOT PRESSURE 0.2 Bar
(LIMITED TO 20 BAR)
(SHT 1 C3)
E BRAKE E
MASTER CYLINDER N
WITH PILOT P TANK E
LIMITED TO 20 BAR
(SHT 1 C3) B
TH414C, TH514C & TH417C (Continued)
FRONT AXLE
3
D D
2 1
SUPPLY (STEERING SYSTEM) A
2.8 BAR
0.7MM
C C
G TANK
REAR AXLE
B B
STEERING LS LINE C D STEERING LS LINE
(ORBITAL) A P (MAIN CONTROL VALVE)
SAHR BRAKE OPTION

A A
8 7 6 5 4 3 2 1
MAM3600C

Hydraulic System
8.7 HYDRAULIC RESERVOIR 8.7.2 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter.
3. Fill the reservoir with oil until oil level is visible in the
1 lower gauge window (3). Refer to Section 2.5,
“Fluids and Lubricant Capacities.”
4. Install the lower cover of the reservoir.
4 7. Start machine and check all hydraulic functions for
proper operation. Check for any hydraulic oil leaks.
3 Shut machine OFF and check hydraulic oil level. If oil
is warm, oil level should be visible in the upper
gauge window (4). Add hydraulic oil if necessary.
2
MAM0180
8.7.3 Hydraulic Oil Reservoir Removal/
The hydraulic reservoir (1) is located on the rear of the Installation
cab.
If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
8.7.1 Hydraulic Oil Reservoir Draining
reservoir is removed. Always dispose of hydraulic oil
1. Park the machine on a firm, level surface, level the properly.
place the transmission in (N)NEUTRAL, engage the a. Reservoir Removal
2. Place a Do Not Operate Tag on both the ignition key machine, fully retract the boom, lower the boom,
switch and the steering wheel. place the transmission in (N) NEUTRAL, engage the
3. Open the engine cover. Allow the system fluids to park brake and shut the engine OFF.
cool. 2. Place a Do Not Operate Tag on both the ignition key
4. Properly disconnect the battery. switch and the steering wheel.
5. Remove the lower cover of the reservoir. 3. Open the engine cover. Allow the system fluids to
cool.
6. Open the filler cap on the hydraulic oil reservoir.
Remove the drain plug (2) on the bottom of the 4. Properly disconnect the battery.
hydraulic oil reservoir. 5. Remove the lower cover of the reservoir.
7. Transfer the used hydraulic oil into a suitable 6. Drain the hydraulic oil reservoir. Refer to Section
covered container, and label as "Used Oil". Dispose 8.7.1, “Hydraulic Oil Reservoir Draining.”
of used oil at an approved recycling facility. Clean
and reinstall the drain plug. Torque drain plug to 7. Label, disconnect and cap all hydraulic hoses
35 Nm (25 lb-ft). attached to the hydraulic oil reservoir. Cap all fittings
8. Wipe up any hydraulic fluid spillage in, on, near and the hydraulic system.
around the machine and the work area.
8. Remove the bolts securing the hydraulic oil reservoir
to the frame.
9. Remove the hydraulic oil reservoir.

Hydraulic System
b. Disassembly e. Inspection
Dispose of the old reservoir according to local regulations 1. Inspect the hydraulic oil reservoir thoroughly for any
concerning hazardous materials disposal. cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
7-10 kPa (1-1.5 psi) of air pressure through the
elbow. Check the reservoir for leaks by applying a
2
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
f. Reservoir Installation
1. Place the hydraulic oil reservoir into its original
orientation.
3
2. Secure the hydraulic oil reservoir to the frame with
MAM1110 the previous mounting hardware.
1. Remove the adapters (2) from the bottom of the 3. Uncap and connect the previously labeled hydraulic
tank. hoses to their appropriate locations. Be sure all lines
are free of kinks and sharp bends.
2. Remove the screws securing the hydraulic manifold
(3) to the tank. 4. Install hydraulic filter bracket and hydraulic filter.
3. Pull the hydraulic manifold out of the hydraulic tank. 5. Fill the reservoir with oil until oil level is visible in the
lower gauge window. Refer to Section 2.5, “Fluids
c. Assembly and Lubricant Capacities.”
1. Install the hydraulic manifold in the hydraulic tank 6. Check the hydraulic oil reservoir for leaks.
using a new o-ring. Torque the six screws to 7. Install the lower reservoir cover.
2,25 ±0,25 Nm (19.9 ±2 lb-in). 8. Properly connect the battery.
2. Install the adapters to the bottom of the tank. Torque 9. Close and secure the engine cover.
to 23±3 Nm (17±2 lb-ft).
10. Start machine and check all hydraulic functions for
d. Cleaning and Drying proper operation. Check for any hydraulic oil leaks.
Shut machine OFF and check hydraulic oil level. If oil
If contaminated hydraulic oil or foreign material is in the is warm, oil level should be visible in the upper
tank, the tank can usually be cleaned. gauge window. Add hydraulic oil if necessary.
To clean the hydraulic oil reservoir: 11. Remove the Do Not Operate Tag from the ignition
1. Have a dry chemical (Class B) fire extinguisher near key switch and the steering wheel.
the work area.
2. Remove the hydraulic oil reservoir drain plug, and
8.7.4 Hydraulic Filter Replacement
safely drain any hydraulic oil into a suitable
a. Hydraulic Filter Removal
container. Dispose of hydraulic oil properly.
3. Clean the hydraulic oil reservoir with a high-pressure 1. Park the machine on a firm, level surface, level the
washer, or flush the tank with hot water for five machine, fully retract the boom, lower the boom,
minutes and drain the water. Dispose of place the transmission in (N) NEUTRAL, engage the
contaminated water properly. park brake and shut the engine OFF.
cool.

Hydraulic System
8.8 ENGINE IMPLEMENT PUMP
8.8.1 Pump Replacement
a. Pump Removal
4
cool.
MAM3980 4. Properly disconnect the battery.
4. Thoroughly clean the filter and surrounding area, 5. Drain the hydraulic reservoir. Refer to Section 8.7.1,
including all hoses and fittings before proceeding. “Hydraulic Oil Reservoir Draining.”
5. Place a pan or container below the hydraulic filter. 6. Remove the engine compartment belly pan.
6. Loosen and remove the hydraulic filter (4). 7. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
7. Transfer any used hydraulic oil into a suitable
covered container, and label as "Used Oil". Dispose Note: Cap all hoses as you remove them to prevent
of used oil at an approved recycling facility. unnecessary fluid spillage.
8. Properly dispose of the used hydraulic filter. 8. Label, disconnect and cap the hydraulic hoses
attached to the pump.
b. Hydraulic Filter Installation 6
1. Clean any excess hydraulic oil from the hydraulic 7
filter base.
2. Apply a light coating of clean hydraulic oil to the
rubber seal on the new hydraulic filter.
3. Install the hydraulic filter and hand tighten until the
filter come in contact with the base. Tighten the filter 4
at least 1/4 turn to verify the filter is sealed to the
filter base.
4. Start machine and check for any hydraulic oil leaks. 5
Shut machine OFF and check hydraulic oil level. If oil
is warm, oil level should be visible in the upper MZ6450
gauge window. Add hydraulic oil if necessary.
5. Close and secure the engine cover. 9. Remove the two bolts and two lockwashers (4)
securing the pump (5) to the adapter plate (6).
6. Remove the Do Not Operate Tag from the ignition Remove the o-ring (7) located between the plate and
key switch and the steering wheel. the pump. Wipe up any hydraulic oil spillage.
10. If necessary, remove the four bolts securing the
adapter plate to the transmission. Remove the
adapter plate.
11. If a new pump will be installed, remove all hose
fittings from the pump.
Note: DO NOT disassemble the operating pump. The
pump is pre-set from the manufacturer.

Hydraulic System
b. Pump Installation 8.9 AUXILIARY PUMP (PLATFORM

1. Apply Loctite® 243TM to all mounting bolts. EQUIPPED MODELS ONLY)
2. If the adapter plate was removed, place into position
with a new, oiled o-ring on the engine. Secure with 8.9.1 Auxiliary Pump Description
the previously used hardware. The auxiliary pump works as a safety back up for the
3. Place the pump and a new, oiled o-ring into position platform in case of engine stalling. The pump will allow
on the adapter plate. Align the pump shaft with the the platform to lower without the engine running.
internal gear, so that the machined teeth mesh
together. 8.9.2 Auxiliary Pump Replacement
4. Align the bolt holes with the pump mount holes.
Secure the pump to the adapter plate with the two a. Auxiliary Pump Removal
bolts and washers. Torque as required. 1. Park the machine on a firm, level surface, level the
5. Uncap and connect the previously labeled hydraulic machine, fully retract the boom, lower the boom,
hoses to their appropriate locations. place the transmission in (N) NEUTRAL, engage the
6. Fill the hydraulic reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling.” 2. Place a Do Not Operate Tag on both the ignition key
8 3. Open the engine cover. Allow the system fluids to

cool.
4. .Properly disconnect the battery.
MZ6460
7. Prime the pump by filling the case with fresh, filtered

hydraulic oil from a clean container through the 45°
elbow fitting (8) port.
MAM1290
8. Remove the fitting noting the orientation. Fill the
pump, install and tighten the 45° elbow fitting. 5. Thoroughly clean the auxiliary pump (1) and
9. Check all routing of hoses and tubing for sharp surrounding area, including all hoses and fittings,
bends or interference with any rotating members. before proceeding.
10. Inspect for leaks and check all fluid levels. The 6. Place a suitable container to catch hydraulic fluid
hydraulic reservoir oil level must be to the middle of drainage beneath the frame.
the sight gauge. 7. Label, disconnect and cap the hydraulic hoses
11. Install the belly pan. attached to the auxiliary pump. Slowly turn hose
fittings to allow any trapped pressure in the hydraulic
12. Properly connect the battery. system to escape. Call all fittings to prevent dirt and
13. Close and secure the engine cover. debris from entering the hydraulic system.
14. Start machine and verify proper operation. 8. Wipe up any hydraulic fluid spillage in, on, near and
15. Remove the Do Not Operate Tag from the ignition around the machine and work area.
key switch and the steering wheel. 9. Label and disconnect the electrical connections to
the auxiliary pump.
c. Implement Pump Test 10. Support the valve and remove the bolts securing the
Refer to Section 8.4.1, “Pressure Checks and pump to the engine pod.
Adjustments.” 11. Remove the pump.

Hydraulic System
b. Auxiliary Pump Installation a. Main Control Valve Removal

1. Install the pump to its original orientation and secure 1. Park the machine on a firm, level surface, level the
in place with the previously used hardware. machine, fully retract the boom, lower the boom,
2. Connect the previously labeled electrical place the transmission in (N) NEUTRAL, engage the
connections to the pump. park brake and shut the engine OFF.
3. Uncap and connect the previously labeled hydraulic 2. Place a Do Not Operate Tag on both the ignition key
hoses to the auxiliary pump. switch and the steering wheel.
4. Properly connect the battery. 3. Open the engine cover. Allow the system fluids to
cool.
5. Test the pump functions.
5. Thoroughly clean the main control valve and
7. Remove the Do Not Operate Tag from the ignition surrounding area, including all hoses and fittings,
key switch and the steering wheel. before proceeding.
6. Place a suitable container to catch hydraulic fluid
8.10 CONTROL VALVES
drainage beneath the frame.
7. Drain the hydraulic oil reservoir. Refer to Section
8.10.1 Main Control Valve 8.7.1, “Hydraulic Oil Reservoir Draining.”
The main control valve is mounted at the rear of the 8. Label, disconnect and cap all the hydraulic hoses,
machine inside the frame. tubes and wires at the main control valve. Slowly
6 turn hose fittings to allow any trapped pressure in
5 2
4 the hydraulic system to escape.
3
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
10. Support the valve and remove the four bolts securing
the main control valve to the frame. Remove the
main control valve.
b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods.
2. Disassemble each section assembly as required.
MZ6400
Some sections include a pre-adjusted relief valve that
The main control valve assembly consists of working regulates pressure in a specific circuit.
sections with their own valve assemblies, each providing
Note: DO NOT adjust any of the relief valve assemblies.
a specific hydraulic function. Those functions are:
Tampering with a relief valve will irrevocably alter
Inlet Section (2), Auxiliary (3), Tilt (4), Extend/Retract (5)
pressure in the affected circuit, requiring recalibration or a
and Lift/Lower (6).
new relief valve.
Disassemble each Valve Section

1. Carefully separate the load sense outlet section (5) from
the next section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining section.
4. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
valve section if equipped.

Hydraulic System
5. Keep all parts being removed from individual valve

sections tagged and kept together.
c. Main Control Valve Parts Cleaning

Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.
d. Main Control Valve Parts Inspection

5
Inspect all parts and internal passageways for wear,
damage, etc. If inner surfaces of any component DO NOT
display an ultra-smooth, polished finish, or are damaged
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to
the polished surfaces within the component, and wear of 5 MZ6400
and/or harm to other parts.
5. Install the nuts on the tie rods (5) and torque to
e. Main Control Valve Assembly 25Nm (18.5 lb-ft).
Note: ALWAYS replace seals, o-rings, gaskets, etc., f. Main Control Valve Installation
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean 1. Install the main control valve onto the frame, aligning
hydraulic oil. the bolts with the holes in the end sections of the
main control valve. Slide the main control valve into
Assemble each Valve Section position, and tighten the bolts.
1. Reassemble any check valves, compensator valves, 2. Prime the main control valve by filling the inlet
anti-cavitation valves or shock valves from each openings with fresh, filtered hydraulic oil from a
individual valve sections if equipped. clean container, before attaching the hoses.
2. Install the end caps on each end of the valve section. 3. Use new oiled o-rings as required. Uncap and
connect all hoses, clamps, etc. to the main control
Assemble the Main Control Valve. valve.
4. Check the routing of all hoses, wiring and tubing for
1. If removed, install all four tie rods into the end main
sharp bends or interference with any rotating
control valve section.
members, and install tie wraps and/or protective
2. Stand the end main control valve section on end. conduit as required. Tighten all tube and hose
3. Install the proper o-rings and load sense shuttle on clamps.
the inner face of the end main control valve section. 5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
Align the next valve section over the three tie rods “Hydraulic Oil Reservoir Filling.”
and slide onto the end main control valve section.
4. Using the proper o-rings and load sense shuttle,
7. Start the engine and run at approximately one-third
repeat step three for the remaining valve sections
to one-half throttle for about one minute without
and lastly the inlet end valve section.
moving the machine or operating any hydraulic
functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
around the machine, work area and tools.

Hydraulic System
g. Main Control Valve Test b. Reversing Fan Installation

Conduct a pressure check of the hydraulic system in its 1. Apply Loctite® 243TM to all mounting bolts.
entirety. Adjust pressure(s) as required. Refer to Section 2. Install the reversing fan valve (6) with the previously
8.5.1, “Hydraulic Pressures.” removed mounting bolts, washers and nuts (8).
Torque as required.
8.10.2 Reversing Fan Valve
3. Connect the previous labeled connectors (7) to the
a. Reversing Fan Removal proper solenoids (7).
4. Connect the previous labeled four hydraulic hoses to
the fittings on the side and bottom of the reversing
fan valve.
park brake and shut the engine OFF. 5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
conduit as required. Tighten all tube and hose
3. Open the engine cover. Allow the system fluids to clamps.
cool.
6. If required, fill the hydraulic oil reservoir. Refer to
4. Properly disconnect the battery. Section 8.7.2, “Hydraulic Oil Reservoir Filling.”
8
8. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
functions.
10 9. Inspect for leaks and check the level of the hydraulic
MAM3550
7 6 9 7 c. Reversing Fan Test
1. Disconnect solenoid connector HV747 (9).
5. Label and disconnect the electrical connectors (7)
on each end of the reversing fan valve (6). 2. Start the machine and warm the hydraulic system to
operating temperature.
6. Thoroughly clean the reversing fan valve and
surrounding area, including all hoses and fittings, 3. Shut off the machine and install a digital or a
before proceeding. 34,5 bar (500 psi) gauge to test port (10) on the
reversing fan manifold.
7. Place a suitable container to catch hydraulic fluid
drainage beneath the reversing fan valve. 4. Start the machine, run the engine at idle and bottom
the appropriate hydraulic function. Refer to Section
8. Label, disconnect and cap the four hydraulic hoses
2.4.5, “Engine Fan Speed,” for the correct pressure
attached to the back and bottom of the reversing fan
rating.
valve.
9. Loosen and remove the two mounting bolts, washers
and nuts (8) from the reversing fan valve.

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

1. Install the service brake valve to its original
a. Service Brake Valve Removal
orientation in the cab. Secure with the previously
1. Park the machine on a firm, level surface, level the used hardware.
machine, fully retract the boom, lower the boom, 2. Install the service brake pedal linkage to the valve
place the transmission in (N) NEUTRAL, engage the rod.
3. Uncap and connect the previously labeled hydraulic
2. Place a Do Not Operate Tag on both the ignition key hoses to the service brake valve.
4. Check the routing of all hoses, and tubing for sharp
3. Open the engine cover. Allow the system fluids to bends or interference with any rotating members,
cool. and install tie wraps and/or protective conduit as
4. Properly disconnect the battery. required. Tighten all tube and hose clamps.
5. Remove the protective cover from the front of the 5. Properly connect the battery.
cab. 6. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
9. Install the lower dash panel in the cab.
10. Install the protective cover to the front of the cab.
1
MAM0560 8.10.4 Service Brake Bleeding

Carefully bleed the brake lines as soon as the brake valve
6. Label, disconnect and cap all hoses attached to the
is installed in the machine. Air in the system will not allow
service brake valve (1).
the brakes to apply properly. There are two brake bleeder
7. Remove the lower dash panel in the cab. locations on the front axle. Work with an assistant to
8. Disconnect the service brake pedal linkage from the perform this procedure.
valve rod. 1. Place the travel select lever in (N) NEUTRAL,
9. Remove the two nuts securing the service brake engage the park brake, and start the engine.
valve to the cab.
10. Remove the valve through the front of the cab.
Note: DO NOT disassemble the service brake valve. 2 2
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
MAM0210

Hydraulic System
2. Remove the plastic cap from the left brake bleeder 8.10.7 Steer Select Valve
(2). Attach one end of a length of transparent tubing
over the brake bleeder. Place the other end of this
tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
must be below the oil level in the container.
3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
brakes. Carefully open the bleeder. Have the
assistant depress the brake pedal. Close the brake
bleeder when air bubbles no longer appear in the oil.
Release the brake pedal. Remove the tubing from
the brake bleeder.
4. Repeat steps 2 and 3 for the right brake bleeder. 4
MAM0300
8.10.5 Service Brake Test
TH406C FRAME SHOWN
1. Install a digital or a 70 bar (1000 psi) gauge to the
test port on the brake valve (behind the front cover of The machine can be used in the front-wheel, four-wheel
the cab). or crab steering mode. The steer select valve (4) controls
the direction of hydraulic fluid flow to the steering cylinder
2. Start the machine and apply pressure to the service mounted on each axle. The steer select valve is attached
brake pedal. A maximum pressure of 44 bar inside the frame near the front axle.
(638 psi) should be achieved.
Verify the correct operation of the steer select valve
3. If further testing is required, refer to Section 8.5.1, solenoids before considering replacement of the valve.
“Hydraulic Pressures.” Refer to Section 9.8, “Electrical System Schematics.” The
housing of the steer select valve is not serviceable and
8.10.6 Steering Orbitrol Valve must be replaced if defective.
3 a. Steer Select Manifold and Valve Removal

MZ0370 switch and the steering wheel.
The steering orbitrol valve (3) is located at the base of the cool.
steering wheel shaft, concealed by the lower dash cover. 4. Properly disconnect the battery.
The valve is not serviceable and must be replaced in its 5. Label, disconnect and cap the hydraulic hoses and
entirety if defective. For detailed information refer to the electrical plugs connected to the steering select
Section 4.3.2, “Steering Column/Orbitrol Valve.” valve.
6. Remove the bolts holding the steer select valve to
the mounting plate on the frame.
7. Remove the steer select valve from the machine.
Wipe up any hydraulic fluid spillage in, on, near and
around the machine.
b. Steer Select Manifold and Valve Disassembly,

Cleaning, Inspection and Assembly

Hydraulic System
1. Place the steer select assembly on a suitable work d. Steering Test

surface.
Refer to Section 8.5.1, “Hydraulic Pressures.”
2. Separate the steer select solenoids from the spool.
1. Conduct a pressure check of the steering hydraulic
Discard the o-rings.
circuit.
3. Clean all components with a suitable cleaner before
2. Check each steering mode for proper function.
inspection.
4. Inspect the solenoid cartridges for proper operation. 8.11 HYDRAULIC CYLINDERS
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination. 8.11.1 General Cylinder Removal
Instructions
5. Inspect internal passageways of the steer select
valve for wear, damage, etc. If inner surfaces of the 1. Remove any attachment from the machine. Park the
manifold DO NOT display an ultra-smooth, polished machine on a firm level surface and fully retract the
finish, or components are damaged in any way, boom. Allow sufficient work space around the
replace the manifold or appropriate part. Often, dirty hydraulic cylinder being removed. Support the boom
hydraulic fluid causes failure of internal seals and if the lift/lower cylinder is being removed. Place the
damage to the polished surfaces within the travel select lever in (N) NEUTRAL, engage the park
secondary function manifold. brake, shut the engine OFF and chock wheels.
Note: ALWAYS replace seals, o-rings, gaskets, etc., 2. Place a Do Not Operate Tag on both the ignition key
with new parts to help ensure proper sealing and switch and the steering wheel.
operation. Lubricate seals and o-rings with clean 3. Open the engine cover. Allow the system fluids to
hydraulic oil. cool.
6. Install the solenoids in the steer select housing. 4. Label, disconnect and cap or plug hydraulic hoses in
relation to the cylinder.
c. Steer Select Valve and Manifold Installation 5. Attach a suitable sling to an appropriate lifting device
1. Install the steer select valve to the mounting plate and to the cylinder. Make sure the device used can
under the left front side of the frame using the two actually support the cylinder.
bolts. 6. Remove the lock bolt and/or any retaining clips
2. Connect all the hydraulic hoses, fittings, solenoid securing the cylinder pins. Remove the cylinder pins.
wire terminal leads, etc., to the steer select valve 7. Remove the cylinder.
3. Check the routing of all hoses, wiring and tubing for 8. Wipe up any hydraulic fluid spillage in, on, near and
sharp bends or interference with any rotating around the machine, work area and tools.
conduit as required. Tighten all hose clamps.
5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
MZ0400
Hydraulic System
a. General Cylinder Disassembly Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
1. Clean the cylinder with a suitable cleaner before
disassemble these parts, remove any accessible seals
disassembly. Remove all dirt, debris and grease
from the area of the bonded parts. Wipe off any hydraulic
from the cylinder.
oil, then heat the part(s) uniformly to break the bond. A
2. Clamp the barrel end of the cylinder in a soft-jawed temperature of 149-204° C (300-400° F) will destroy the
vise or other acceptable holding equipment if bond. Avoid overheating, or the parts may become
possible. distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
WARNING white, powdery residue on threads and other parts, which

must be removed by brushing with a soft brass wire brush
Significant pressure may be trapped inside the cylinder. prior to reassembly.
Exercise caution when removing a counterbalance valve 9. Remove the piston head from the rod and carefully
or a pilot-operated check valve from a cylinder. slide the head gland off the end of the rod.
Note: Avoid using excessive force when clamping the 10. Remove all seals, back-up rings and o-rings from the
cylinder in a vise. Apply only enough force to hold the piston head and all seals, back-up rings and o-rings
cylinder securely. Excessive force can damage the from the head gland.
cylinder tube. Note: The head gland bearing will need to be inspected
3. If applicable, remove the counterbalance valve from to determine if replacement is necessary.
the side of the cylinder barrel. DO NOT attempt to salvage cylinder seals, sealing rings
Note: DO NOT tamper with or attempt to adjust the or o-rings. ALWAYS use a new, complete seal kit when
counterbalance valve cartridge. If adjustment or rebuilding hydraulic components. Consult the parts
replacement is necessary, replace the counterbalance catalog for ordering information.
valve with a new part.
b. Cylinder Cleaning Instructions
4. Extend the rod as required to allow access to the
base of the cylinder. 1. Discard all seals, back-up rings and o-rings. Replace
with new items from seal kit to ensure proper
Note: Protect the finish of the rod at all times. Damage cylinder function.
to the surface of the rod can cause seal failure.
2. Clean all metal parts with an approved cleaning
5. Using a pin spanner wrench, unscrew the head solvent such as trichlorethylene. Carefully clean
gland from the tube. A considerable amount of force cavities, grooves, threads, etc.
will be needed to remove the head gland. Carefully
Note: If a white powdery residue is present on threads
slide the head gland down along the rod toward the
or parts, it can be removed by using a soft brass wire
rod eye, away from the cylinder barrel.
brush. Wipe clean with Loctite® Cleaner prior to
Note: When sliding the rod and piston assembly out of reassembly.
the barrel, prevent the threaded end of the barrel from
damaging the piston. Keep the rod centered within the
barrel to help prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.

Hydraulic System
c. Cylinder Inspection 7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
1. Inspect internal surfaces and all parts for wear,
8.11.4, “Cylinder Torque Specifications” for torque
damage, etc. If the inner surface of the cylinder
specifications for the head gland.
barrel does not display a smooth finish, or is scored
or damaged in any way, replace the barrel. 8. If applicable, install new counter balance valve into
block on the cylinder barrel.
2. Remove light scratches on the piston, head gland,
rod or inner surface of the cylinder barrel with a 400-
e. General Cylinder Installation
600 grit emery cloth. Use the emery cloth in a rotary
motion to polish out and blend the scratch(es) into 1. Grease the bushings at the ends of the hydraulic
the surrounding surface. cylinder. Using an appropriate sling, lift the cylinder
3. Check the piston rod assembly for run-out. If the rod into it’s mounting position.
is bent, it must be replaced. 2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
d. General Cylinder Assembly Instructions 3. Connect the hydraulic hoses in relation to the labels
1. Use the proper tools for specific installation tasks. or markings made during removal.
Clean tools are required for installation. 4. Before starting the machine, check fluid level of the
2. Install new seals, back-up rings and o-rings on the hydraulic fluid reservoir and if necessary fill to full
piston and new seals, back-up rings, o-rings and mark with oil.
bearing on the head gland. 5. Start the machine and run at low idle for about one
Note: The extend/retract cylinder has a spacer that minute. Slowly activate hydraulic cylinder function in
MUST be installed over the rod AFTER the head gland both directions allowing cylinder to fill with hydraulic
oil.
and BEFORE the piston head.
6. Inspect for leaks and check level of hydraulic fluid in
3. Fasten the rod eye in a soft-jawed vise, and place a reservoir. Add hydraulic fluid if needed. Shut the
padded support under and near the threaded end of engine OFF.
the rod to prevent any damage to the rod.
Note: Protect the finish on the cylinder rod at all times. around the machine, work area and tools.
Damage to the surface of the rod can cause seal failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the 8.11.2 Cylinder Pressure Checking
cylinder rod. Apply Loctite® 243TM and install the set
Attach a 345 bar (5000 psi) gauge to the test port on the
screw in the piston head. Refer to Section 8.11.4,
P1 port on the hydraulic manifold to check the system
“Cylinder Torque Specifications” for torque
pressure. For more information, refer to Section 8.4.1,
specifications for the piston head and the set screw.
“Pressure Checks and Adjustments.”
Note: Avoid using excess force when clamping the
Note: If a hydraulic cylinder pressure is greater than the
cylinder barrel in a vise. Apply only enough force to hold
main control valve pressure, increase the main control
the cylinder barrel securely. Excessive force can
valve pressure by adjusting the main relief. Generally,
damage the cylinder barrel.
one half turn clockwise will be adequate to check an
5. Place the cylinder barrel in a soft-jawed vise or other individual circuit. Activate the circuit and if pressure is
acceptable holding devise. obtained turn the main relief counter clockwise one half
turn. Re-check the main relief setting and adjust if
Note: When sliding the rod and piston assembly into the
necessary.
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.

Hydraulic System
8.11.3 Steering Cylinders

The steer cylinder is attached to each axle center
housing. The steer cylinder is covered in the appropriate
manufacturer’s axle literature.Detailed axle service
instructions (covering the axle, differential, brakes and
wheel-end safety, repair, disassembly, reassembly,
adjustment and troubleshooting information) are
provided in the appropriate Axle Disassembly &
Assembly Manual.
Machine
Manual P/N
(Mechanical Park Brake)
TH336C, TH337C, TH406C,
31200453
TH407C & TH414C
TH514C & TH417C 31200455
Machine
Manual P/N
(Hydraulic Park Brake)
TH414C, TH514C & TH417C 31200XXX
FRONT AXLE STEER CYLINDER
MAM2710
REAR AXLE STEER CYLINDER

Hydraulic System
8.11.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston Set Screw

TH336C, TH337C, TH406C & TH407C 400 Nm (295 lb-ft) 1540 Nm (1136 lb-ft) 10 Nm (7 lb-ft)
TH414C 400 Nm (295 lb-ft) 2460 Nm (1814 lb-ft) 10 Nm (7 lb-ft)
TH514C & TH417C 400 Nm (295 lb-ft) 3420 Nm (2522 lb-ft) 10 Nm (7 lb-ft)
b. Extend/Retract Cylinder

TH336C,TH337C,
300-350 Nm (221-258 lb-ft) 540-590 Nm (398-435 lb-ft) 20-25 Nm (15-18 lb-ft)
TH406C,TH407C
TH414C 320-370 Nm (236-273 lb-ft) 815-865 Nm (601-638 lb-ft) 20-25 Nm (15-18 lb-ft)
Top: 380-430 Nm (280-317 lb-ft)
TH514C 1070-1120 Nm (789-826 lb-ft) 20-25 Nm (15-18 lb-ft)
Bottom: 480-530 Nm (354-391 lb-ft)
TH417C 320-370 Nm (236-273 lb-ft) 815-865 Nm (601-638 lb-ft) 20-25 Nm (15-18 lb-ft)
c. Tilt Cylinder
Model Head Piston

All machines 1500 Nm (1106 lb-ft) 3000 Nm (2212 lb-ft)
d. Compensation Cylinder
Model Head Piston

TH336C, TH337C, TH406C & TH407C 800 Nm (590 lb-ft) 1100 Nm (811 lb-ft)
TH414C & TH417C 1000 Nm (737 lb-ft) 1100 Nm (811 lb-ft)
TH514C 1200 Nm (885 lb-ft) 1000 Nm (737 lb-ft)
e. Frame Level Cylinder

f. Outrigger Cylinder


Hydraulic System
8.12 BOOM RIDE CONTROL (TH336C,

TH337C, TH406C, TH407C
- IF EQUIPPED)
8.12.1 General Accumulator Information

The accumulator is a 275 bar (3988 psi) piston type
accumulator. MAM1430
2 4 3
The pneumatic accumulator is operated by compressed
gas. Gas and hydraulic oil occupy the same container. 5. Disconnect and cap or plug the hydraulic tube (2) at
When oil pressure rises, incoming oil compresses the the accumulator (3).
gas. When oil pressure drops, the gas expands, forcing 6. Remove the two straps (4) securing the accumulator
the oil out into the lift side of the lift/lower cylinder. to the lift/lower cylinder.
The gas is separated from the oil by a piston. This
prevents the mixing of gas and oil and keeps gas out of 7. Remove the accumulator.
the hydraulic system. 8. Wipe up any hydraulic fluid spillage in, on, near and
1 b. Accumulator Installation
6
MAM1440
The accumulator must be “pre-charged” with gas before

use in the hydraulic system. This is done by filling the gas
chamber with dry nitrogen to a pressure of 35 bar
(507 psi). The schrader valve is located under the
protective cap (1) at the top of the accumulator. The MAM1460
schrader valve is used for pre-charging and testing the 5

accumulator. A B
1. Secure the accumulator (5) to the lift/lower cylinder

a. Accumulator Removal
with the two straps (6) to the proper dimensions:
1. Remove any attachment from the machine. Park the A. 57,0 ± 10 mm (2.25 ± 0.375 in)
machine on a firm level surface and fully retract the B. 200,0 ± 10 mm (7.875 ± 0.375 in)
boom. Raise the boom to allow sufficient work space 2. Uncap and connect the hydraulic tube to the
around the lift/lower cylinder to allow the accumulator.
accumulator to be removed. Support the boom.
Place the travel select lever in (N) NEUTRAL, 3. Remove the boom support.
engage the park brake, shut the engine OFF and 4. Properly connect the battery.
chock wheels. 5. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key 6. Remove the Do Not Operate Tag from the ignition
switch and the steering wheel. key switch and the steering wheel.
3. Open the engine cover. Allow the system fluids to 7. Refer to Section 8.12.3, “Pre-Charging
cool. Accumulator,” for Accumulator pre-charging
4. Properly disconnect the battery. instructions.

Hydraulic System
8.12.2 Accumulators
This section covers the charging of the accumulator 9
system.
10
The accumulator is located and mounted under the lift/
lower cylinder. The internal parts of the accumulator are
not serviceable. If the internal piston is leaking, or the
seals on the top or bottom cap are leaking, the 5
accumulator requires replacement.
The accumulator pre-charge pressure will vary 4 7
depending on the ambient temperature that the
accumulator was pre-charged at and the actual operating
temperature of the accumulator. 8
6 MAM1450
8.12.3 Pre-Charging Accumulator
1. Thoroughly clean the top of each accumulator (4).
Note: Replacement accumulators are not pre-charged
2. Make sure the nitrogen supply is shut off.
when shipped.
3. Attach the accumulator fill kit (5) to the nitrogen
bottle.
WARNING 4. Remove the protective cap from the gas valve on the
NEVER fill an accumulator with oxygen! An explosion accumulator.
could result if oil and oxygen are mixed under pressure. 5. Back the “T” handle (6) on the accumulator fill kit all
Only fill accumulator with dry nitrogen. the way out (counter-clockwise). Attach the schrader
adaptor (7) to the gas valve on the accumulator.
Pre-charged the accumulator with nitrogen gas only. Tighten securely.
Nitrogen gas is free of water vapor and oxygen which
makes it harmless to internal parts and will not react if 6. Turn the gas valve/bleed valve (8) on the
mixed with oil under pressure. accumulator fill kit all the way in.
7. Turn the “T” handle (6) all the way in to open the
NOTICE valve core on the accumulator.
8. Open the valve (9) on the nitrogen bottle.
Never fill an accumulator with air. Air contains moisture
which can cause corrosion. This corrosion may damage 9. Slowly adjust the regulator (10) on the nitrogen
seals and ruin the accumulator. bottle to read 35 bar (507 psi).
10. Close the main valve (9) on the nitrogen bottle.
Never charge an accumulator to a pressure more than
specified. The proper pressure for the accumulator is 11. Back the “T” handle (6) on the accumulator fill kit all
35 bar (507 psi). the way out (counter-clockwise).
12. Let the pre-charge on the accumulator set for 10-15
Note: Make sure the nitrogen bottle, as well as the
minutes. This will allow the gas temperature to
charging and gauge assembly used is compatible with
stabilize. If the desired pre-charged range is
the schrader valve assembly on the accumulator. The
exceeded, turn the “T” handle (6) all the way in. With
nitrogen bottle and all components must be rated for a
the main valve (9) closed on the nitrogen bottle, turn
pressure at least as high as the nitrogen source. It is
the gas valve/bleeder valve (8) out to bleed pressure
strongly recommended that the nitrogen bottle has a
off the accumulator. Turn the valve all the way in and
high pressure regulator.
check the pressure reading on the regulator gauge.
You will require an accumulator fill kit to properly charge 13. When the correct pressure is reached, back the “T”
the accumulators. Refer to the parts manual or contact handle (6) on the accumulator fill kit all the way out
the local Caterpillar dealer. (counter-clockwise). Bleed the pressure from the
Use the following steps to properly pre-charge each hose by turning the gas valve/bleed valve out to
accumulator: relieve the pressure.

Hydraulic System
14. Turn the gas valve/bleed valve (8) all the way in and
remove the schrader adapter (7) from the valve on
the accumulator.
15. Reassemble the protective cap onto the gas valve
on the accumulator.
8.12.4 Checking Pre-Charge
a. Gas Leaks
2 1
MAM1440
1. If an external leak is suspected, apply soapy water to

the gas valve (1) and the seams of the gas bottle (2).
If bubbles form, the accumulator has to be replaced.
2. If an internal leak is suspected, check for foaming oil
in the hydraulic reservoir and/or no accumulator
action. If any of these signs are evident, the
accumulator has to be replaced.

Hydraulic System

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Keypad and Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5.1 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5.2 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.6.1 Resetting the Anti theft Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.6.2 Hardware Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.6.3 Confirm Machine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.6.4 Review Service History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.6.5 Set Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.6.6 Cabin Joystick Telescope: X-Axis/Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.7 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.7.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.7.2 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.8 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.8.1 Cab Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.8.2 Cab Roof, Ride, Float and Boom Extend LImit . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.3 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8.4 Transmission and Reverse Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.5 Front Frame and Boom Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8.6 Rear Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.8.7 C4.4 - 93.1 kW, 74.5 kW, Battery & Platform . . . . . . . . . . . . . . . . . . . . . . 9-24
9.8.8 Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.8.9 LMIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.8.10 C4.4 - 92.5 kW, 106 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.8.11 C3.4 - 74.5 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.8.12 CAT Product Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.9 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.9.1 Constant Power Circuit from Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.9.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

Electrical System
9.10 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32

9.10.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.10.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.10.3 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.11 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.11.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.11.2 Rear and Roof Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.11.3 Windshield/Rear Window/Roof Window Washer Reservoir . . . . . . . . . . . 9-35
9.12 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.12.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.12.2 Transmission Oil Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.12.3 Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.12.4 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.12.5 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.12.6 Front and Rear Axle Steering Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.12.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.12.8 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.13 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.13.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.13.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.14 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.15 Platform Load System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.16 Load Stability Indicator (LSI) (CE & AUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.16.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.16.2 LSI Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.16.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.16.4 LSI-CAN Check PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.16.5 500 Hour - LSI UGM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.17 Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.17.1 Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.17.2 Analyzer Software Version P4.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.18.1 Indicator Cross Reference Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.19 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.20 Engine Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
9.20.1 92.5 kW & 106 kW - S/N MJR00150, DJB00150, GAT00150 & MLH00150 9-83
9.20.2 74.5 kW - S/N MJR00150, DJB00150, GAT00150, MLH00150, KEK00150,
MWC00150 & RRJ00150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-90

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
location of the electrical components of the machine. The
9.1.1 General Overview
LOAD STABILITY
INDICATOR
ALTERNATOR
DISPLAY
JOYSTICK
PANEL
POWER
DISTRIBUTION
BOARD
UGM
CONTROLLER
STARTER
IGNITION KEY MAM3510 MZ6240

SWITCH
BOOM ANGLE
SENSOR
LOAD STABILITY
SENSOR (ON AXLE)
MAM0850

Electrical System
9.2 SPECIFICATIONS 9.4.2 Display Screen

The display screen is located in the center of the
Electrical system specifications are listed in Section 2,
instrument panel and can display the following
“General Information and Specifications.”
information with activation of the menu screen.
9.3 SAFETY INFORMATION
WARNING MENU:
HELP: PRESS ENTER
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
9.4 KEYPAD AND DISPLAY SCREEN

OAM2610
9.4.1 Keypad a. Help - Displays active fault code. Depress OK button

1 2 3
again and use keypad arrows to cycle through the
last 25 fault codes. Active fault codes are denoted
with an asterisk. Refer to Section 9.18.1, “Indicator
Cross Reference Table,” for the complete list of
codes.
b. Operator Tools - Speed, Temperature and Oil

Pressure units and Steer Mode can be modified by
OAM2600 the operator. Customer Service level access code is
Depress the C and OK buttons on the keypad to access required to view other items.
the menu.
1. C (Clear or Escape): Use in conjunction with display c. Personalities - Customer or Service level access
screen. Returns user interface one level during code required.
navigation. If at top of the menu, depress and hold
for one second to exit. d. Access Level - Code entry determines access level.
• Operator (Level 3) - No code required.
2. Up/Down Arrows: Use in conjunction with display
screen. Navigate menu selections and change • Customer (Level 2) - Refer to Section 9.5,
“Software Level 2 Accessibility.”
adjustable values.
• Service (Level 1) - Manufacturer service
3. OK (Enter): Use in conjunction with display screen. representative only.
Confirms user interface inputs.
e. Diagnostics - View diagnostic information.
f. System Test - Performs test of all system inputs and

outputs.
g. Machine Setup - Service level access code required.
h. Calibrations - Customer or Service level access code

required.

Electrical System
9.5 SOFTWARE LEVEL 2 ACCESSIBILITY

The following parameters can be altered in the 2nd level of access to the machine’s software.
Refer to Section 9.17.2, “Analyzer Software Version P4.5,” for detailed software information.
9.5.1 Operator Tools
Setting/
Menu Visible Comment
Submenu
Enter Current
Code: 0000
Change Access Levels Requires the existing code to be entered before a
Anti-theft Code? 1,2 new one
Enter New
Code: 0000
Transfer From
Display->UGM
Transfer From
UGM->display
Initiates Transfer Of Non-volatile Memory Settings
Perform Hardware Transfer Status: Access Levels
Between The Cabin Display And Ugm; Displays
Exchange? In Progress… 1,2
Progress And Final Status For The Technician
Transfer Status:
Cycle Power Now
Transfer Failed:
Cycle Power Now
Service
Confirm Machine Complete? Access Levels Records that preventive maintenance has been
Service? Yes: Enter, 1,2 performed
No: ESC
Review Service History Access Levels Displays the engine operating hours for the past
Service History? 1:0h 0m 1,2 fifteen service confirmations
Set Service Access Levels Increment/decrement the engine operating hours
Interval:500h N/A 1,2 before the next service interval
Access Level 1;
Machine
Review LMI LMI History Displays the engine operating hours for the past
Setup’s
Shutoff History 1:0H 0M fifteen LMI shutoff (cancel) incidents
MARKET is CE
or AUSTRALIA
Selects units for vehicle speed display; default to
Vehicle Speed KPH Access Levels
KPH when Machine Setup’s MARKET is CE or
Units: Kph MPH 1,2,3
AUSTRALIA; default to MPH when MARKET is ANSI
Selects units for temperature display; default to
Temperature: Celsius Access Levels CELSIUS when Machine Setup’s MARKET is CE or
Celsius Fahrenheit 1,2,3 AUSTRALIA; default to FAHRENHEIT when
MARKET is ANSI

Electrical System
Select units for oil pressure display; default to BAR

Oil Pressure: BAR Access Levels
when Machine Setup’s MARKET is CE or
Bar PSI 1,2,3
AUSTRALIA; default to PSI when MARKET is ANSI
Selects the cabin joystick resource that will be used
Cabin Joystick: X-AXIS Access Levels
to control telescope; fork tilt is controlled by the
Telescope: X-AXIS ROLLER 1,2,3
opposite
Steer Mode: Automatic Access Levels
Selects steering mode preference
Automatic Manual 1,2,3
Access Level 1;
Revise Engine Set Engine On Used to update engine on data log for service
Mechanical
Hours? Hours: 0H (rebuild or replacement); mechanical engine only
Engine
The technician will press the UP / DOWN arrow keys
Perform LSI-CAN
to select YES. When set to YES and ENTER button
System Check? is pressed, the control system will provide the
No following directions
The following directions will be displayed and when
Remove Weights the operator presses the ENTER button, the control
And Attachments. system will advance to the next menu screen
Access Levels
1,2; Machine Display when Machine Setup’s MODEL is TH414C,
Setup’s LOAD TH417C, or TH514C; the following directions will be
Fully Deploy displayed and when the operator presses the
MONITORING
Stabilizers ENTER button, the control system will advance to
is LSI-CAN or
LSI-CAN SYSTEM the next menu screen
LSI-CAN + LMI;
CHECK:
CALIBRATION The following directions will be displayed and when
Telescope In And LSI-CAN the operator presses the ENTER button, the control
Fully Lift Up. SYSTEM system will advance to the next menu screen
CHECK
completed The following directions will be displayed and when
**** Stop **** the operator presses the ENTER button, the control
Wait 1 Minute system will advance to the next menu screen
The technician will press the ENTER button to start
the control system comparative check of the LSI
Press Enter To System load sensor raw counts; PASS (within +/- 20
Start Test: Pass counts) or FAIL will be indicated; the ESC button will
used to exit
Displays UGM operating hours and minutes when
LSI Suspend Log
Review LSI the LSI-CAN suspended vehicle operation; ON
NN: XXH YYM - Access Level 1
Suspended Log? during passive mode and OFF otherwise (last ten
On events)
Fan Reverse Access Level 1, Sets the length of time that the fan will be reversed
Timer: 2sec 2sec To 10sec 2, or 3; (cycling or demand)
Hydraulic
Variable Speed
Fan Reverse Fan or
5min To 60min Sets the interval between cycling fan reversals
Interval: 20min Reversing Fan
configured
Access Level 1, Selects the tyre fitted for proper vehicle speed
Tyre Selection:
2, or 3 calibration (refer to Vehicle Speed Calculation)

Electrical System
Default Gear Access Levels

1, 2, 3, 4 Sets the default transmission gear at power-up
Selection: 2 1,2,3
When YES, the UGM shall not transmit CANbus
ECM Tool
messages. This will allow maximum bandwidth for
ECM Service Tool Access? Access Level 1 Caterpillar and Deutz service tools during re-
Access? Yes: Enter, programming. Power cycle is required to resume
No: ESC normal operation.
9.5.2 Personalities
Function Description Default Value
Main Lift Allows the owner to adjust the Max Lift Up and Max Lift Down 1400 mA (up)
function speeds 1600 mA (down)
Soft Lift Allows the owner to adjust the derate value when the boom 40%(TH336C & TH406C)
enters the soft lift zone 45% (TH337C & TH407C)
35% (TH414C)
Telescope Allows the owner to adjust the Max Tele In and Max Tele Out 1300 mA
function speeds
Fork Tilt Allows the owner to adjust the Max Fork Tilt Up and Max Fork 1150 mA
Tilt Down function speeds
Platform Level Allows the owner to adjust the Max Platform Level Up and Max 800 mA
Platform Level Down function speeds
Platform Rotate Allows the owner to adjust the Max Platform Left and Max 1000 mA
Platform Right function speeds
Platform Lift Allows the owner to adjust the Max Platform Lift Up and Max 1020 mA (up)
Platform Lift Down function speeds 960 mA (down)
Platform Allows the owner to adjust the Max Platform Tele In and Max 1000 mA (in)
Telescope Platform Tele Out function speeds 1080 mA (out)
Outriggers Allows the owner to adjust the Max Outrigger Up and Max 1000 mA
Outrigger Down function speeds
Frame Level Allows the owner to adjust the Max Frame Level Left and Max 1000 mA
Frame Level Right function speeds
Bucket Lift Allows the owner to adjust the Max Bucket Up and Max Bucket 1400 mA (up)
Down function speeds 1600 mA (down)
Bucket Allows the owner to adjust the Max Bucket Tele In and Max 1300 mA
Telescope Bucket Tele Out function speeds
Bucket Tilt Allows the owner to adjust the Max Bucket Tilt Up and Max 1400 mA (up)
Bucket Tilt Down function speeds 1600 mA (down)
Auxiliary Allows the owner to adjust the Accel, Decel, and Max Function 1500 mA
Function Coil A and Max Function Coil B function speeds

Electrical System
9.5.3 Calibration
Menu SubMenu Visible Comment

Calibrate Tilt Use by technicians to calibrate the tilt sensor (integral
Sensor? to UGM); press ENTER to confirm; ESC to exit
Displayed when Machine Setup’s STABILIZERS is
Tilt Calibration
Access Levels EQUIPPED and at least one stabilizer is not deployed;
Set Stabilizers
1,2; press ENTER or ESC to exit
Calibrations: Machine Setup’s
Tilt Sensor
Tilt Sensor PLATFORM Displayed while control system averages readings
Calibrating...
OPTION is
Calibration ENABLED Calibration offset was within +/- 8.0 degrees; press
Complete ENTER or ESC to exit
Calibration offset was outside +/- 8.0 degrees; press
Calibration Failed
ENTER or ESC to exit

Electrical System
Calibrate Boom Used by technicians to calibrate the boom angle

Angle Sensor? sensor; press ENTER to confirm; ESC to exit
Press Enter At Technician must lower boom to mechanical stop, press
Lowest Position. ENTER to confirm
Boom Angle:
Displayed while control system averages readings
Calibrating...
Lift Up. Press Technician must raise boom to mechanical stop, press
Enter At Top. ENTER to confirm.
Boom Angle:
Displayed while control system averages readings
Calibrating... Access Levels
1,2;
Calibration:
Platform Not Calibration was successful; press ESC key to exit
Complete
Attached
Calibration: The platform was attached when the calibration was
Remove Platform initiated; press ESC key to exit
The minimum or maximum boom angle sensor counts
Calibration: were improper for this vehicle; press ESC key to exit;
Calibrations: Failed press LEFT or RIGHT for the BOOM ANGLE RAW
Boom Angle COUNTS display
DTC 2344, 2345, 2346, 2353, or 6621 was active and
Calibration: calibration could not succeed; press ESC key to exit;
Sensor Fault press LEFT or RIGHT for the BOOM ANGLE RAW
COUNTS display
Access Levels
1,2;
Machine Setup’s
Boom Angle Raw: MODEL is Displays the raw ADC counts for the CANbus boom
Counts: xxxx TH414C, angle sensor after a SENSOR FAULT or FAILED event
TH417C, or
TH514C; platform
is not attached
Access Levels
1,2;
Displays the raw ADC counts for the boom angle
Boom Angle Raw: Machine Setup’s
sensor from UGM J7-4 after a SENSOR FAULT or
Counts: xxxx MODEL is
FAILED event
TH406C or
TH407C

Electrical System
Used by technicians to calibrate the platform load

Platform Type: sensing system; use LEFT, RIGHT, UP, DOWN to
350-extendable select 350-EXTENDABLE or 450-FIXED; press
ENTER to continue or ESC to exit
Displayed when Machine Setup’s STABILIZERS is
Stabilizers
Access Levels EQUIPPED and at least one stabilizer is not deployed;
Not Deployed
1,2; press ENTER or ESC to exit
Confirm Platform Machine Setup’s Use LEFT, RIGHT, UP, DOWN to select YES; press
Calibrations:
Is Empty: No LOAD SENSING ENTER to continue or ESC to exit
LSS
is WARN ONLY or
Calibration PLATFORM Displayed while control system averages readings
In Progress CUTOUT
The 350-EXTENDABLE was 850-1300LBS empty; the
Calibration
450-FIXED was 176-375LBS empty; calibration was
Complete
successful; press ESC to exit
Calibration The platform was outside weight limits or the reading
Failed could not be recorded in the LSS Module
Press Enter To
Access Level 1; Used by technicians during the manufacturing process
Use Stabilizers
Machine Setup’s to move the stabilizers before the boom is fitted and
Calibrations: *Warning* MODEL is the boom angle sensor is calibrated; interlocks that
Stabilizers Safeties Offline TH414C, prevent stabilizer movement while the boom is
TH417C, or elevated are ignored; press ENTER to continue or
Press ESC Button
TH514C ESC to exit
When Test Done
UP and DOWN select NO or YES; press ENTER while
Confirm Boom Access Level 1; YES to energize boom ride valves with the vehicle
Calibrations: Ride Test: No stationary; interlocks that prevent boom ride while
Machine Setup’s
Boom Ride stationary are ignored
BOOM RIDE is
Test
Press Enter YES
Press ENTER to complete test
When Test Done

Electrical System
Used by customers (mining) as part of a daily safety

verification that the vehicle cannot drive through the
Perform Park
parking brake in second gear; interlocks that prevent
Brake Test?
gear engagement while the parking brake is set are
ignored; press ENTER to continue or ESC to exit
Prompt user to apply the park brake; brake must
Set Park Brake remain applied during test unless shifter returns to
neutral
Shift To Second
Prompt user to select second gear
Calibrations: Gear
Access Levels
Park Brake
1,2,3 Prompt user that the vehicle will engage the
Test Warning: Drive
transmission (attempt to drive through park brake)
Will Be Engaged
during the next step
Forward To Start
Prompt user to select forward direction for evaluation
Neutral To Pause
Park Brake Test
The evaluation was successful; press ESC to exit
Complete
The CABIN JOYSTICK – FNR SWITCH FAULT
Park Brake Test
(23115) fault was active and the test could not
Failed
proceed; press ESC to exit
Confirm Trans UP and DOWN select NO or YES; default to NO at
Service: No power-up
Calibrations:
Access Levels 1,2 When YES, allow Direction Selection despite faults
Trans Service Confirm Trans
detected so a technician can diagnose or transport a
Service: Yes
vehicle
Perform Fan Used by technicians at the factory for noise testing;
Speed Test? press ENTER to begin or ESC to exit
Access Levels
Calibrations: UP and DOWN keys directly adjust fan speed valve
1,2; Hydraulic
Fan Speed current with 50mA increments (3000mA maximum);
Fan Speed Valve Variable Speed
Test default is 0mA (highest fan speed) to start test; fan
0 Ma Fan Configured
reversing is prevented once test begins; selected fan
speed valve current is retained until power is cycled
9.6 OPERATOR TOOLS 6. Enter the current anti theft code.

Note: If a machine does not have an anti theft code set,
9.6.1 Resetting the Anti theft Code the default code is “00000”.
To reset the anti theft code: 7. Enter the new code.
1. Turn the engine to the ON position.
9.6.2 Hardware Exchange
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode. After the replacement of either the display or UGM
(Controller) the machine software will indicate a
3. Scroll to "Access Level Code". Enter the code
Hardware Exchange fault. To correct this fault:
"33271" to go into access level 2.
4. Scroll to and select the "Operator Tools” screen.
2. Press the “C” and “OK” buttons on the dash
5. Scroll to and select the “Change Anti Theft Code”
simultaneously to enter the analyzer mode.
screen.

Electrical System
3. Scroll to “Access Level Code”. Enter the code 6. Enter a new service interval.
“33271” to go into access level 2.
4. Scroll to and select the “Operator Tools” screen. 9.6.6 Cabin Joystick Telescope: X-Axis/
Roller
5. Scroll to and select the “Perform Hardware
Exchange” screen. To change the joystick telescope function on the joystick:
6. Scroll to and select the proper screen for hardware 1. Turn the engine to the ON position.
exchange. The screen will show either 2. Press the "C" and "OK" buttons on the dash
“DISPLAY -> UGM” or “UGM -> DISPLAY”. The new simultaneously to enter the analyzer mode.
component should be listed second.
9.6.3 Confirm Machine Service
4. Scroll to and select the "Operator Tools" screen.
To log the machine service into the software:
5. Scroll to and select the "Cabin Joystick Telescope"
1. Turn the engine to the ON position. screen.
2. Press the “C” and “OK” buttons on the dash 6. Select either X-AXIS or ROLLER.
When changing the joystick function, ensure the correct
3. Scroll to “Access Level Code”. Enter the code joystick operation decal is installed. Contact the local
“33271” to go into access level 2. Caterpillar dealer.
4. Scroll to and select the “Operator Tools” screen.
5. Scroll to and select the “Confirm Machine Service”
screen.
6. If service is complete, press ENTER for YES.
Otherwise, press ESC for NO.
9.6.4 Review Service History

To view the last 15 machine service instances:
2. Press the "C" and "OK"I’ll buttons on the dash
5. Scroll to and select the "Review Service History"
screen.
6. Scroll through the screens to view the last 15 times
the machine was serviced.
9.6.5 Set Service Interval

To set the machine recommended service interval:
2. Press the "C" and "OK" buttons on the dash
5. Scroll to and select the "Set Service Interval" screen.

Electrical System
9.7 FUSES AND RELAYS
9.7.1 Engine Compartment

The starter relay (1), glow plug relay (2),fuel shutoff
relay(3) are located beside the battery mounted on the
frame in the engine compartment.
3 2 1
MAM3560

Electrical System
9.7.2 Power Distribution Board

The power distribution board is located in the cab. For
access, remove the screws securing the small side panel
to the cab.
MZ2090
Fuse/Relay Function Amp Rating
F1 Right Headlight Low 7.5
F2 Rear Wiper 15
F3 Right Headlight High 7.5
F4 Left Headlight Low 7.5
F5 Left Headlight High 7.5
F6 Radio 10
F7 Front Wiper 20
F8 A/C 7.5
F9 Key 2 15
F10 Key 1 15
F11 Fan 20

Electrical System
Fuse/Relay Function Amp Rating
F12 Lights Bat 1 15
F13 Lights Bat 2 15
F14 Left Marker Lights 7.5
F15 Boom Worklights 15
F16 Brake Lights 15
F17 Front Worklights 15
F18 Flasher 15
F19 Right Marker Lights 7.5
F20 Beacon 15
F21 Rear Worklights 15
F22 Controller 25
F23 Display/Joystick 10
F24 Fuel 15
F25 Power Socket 15
F26 Seat 15
F27 Key Bat 15
F28 DPF Soot Sensor 15
F29 Reverse Alarm 15
F30 Aux Function Power 15
K1 Reverse Travel
K2 1/2 Aux
K3 Flasher
K4 Ignition Power 1
K5 Ignition Power 2
K6 Work Lights
K7 Ignition Power 3
K8 Fuel
K9 Fuel Enable

9.8
9-16
9.8.1
1 2 3 4 5 6 7 8
GRN 055-1
YEL 061-11 6mm² YEL 061-11-1 2.5mm² YEL 061-11-1 2.5mm² Sheet_04-[4,F]
S113 YEL 061-11-2 2.5mm² YEL 061-11-2 2.5mm² Sheet_04-[4,F]
BLK 000-48 4mm² BLK 000-49 6mm² BLK 000-32 2.5mm² BLK 000-32 2.5mm² Sheet_04-[6,F]
YEL 061-5 4mm² S112 BLK 000-33 2.5mm² BLK 000-33 2.5mm² Sheet_04-[6,F]
X35
Sheet_03-[1,B] SHLD CAN CABLE 1 SHLD CAN CABLE 1-5 GRN 050-2
4
S1091 SHLD CAN CABLE 1-8 ORG 053-2
5
H Sheet_03-[1,B] BLK CAN CABLE L 1 BLK CAN CABLE L 1-5 WHT 034-2-1 H
1
S1090 BLK CAN CABLE L 1-8 S213 WHT 032-1-1
2
Sheet_03-[1,B] RED CAN CABLE H 1 RED CAN CABLE H 1-5 S214 GRN 049-11
3
S1089 RED CAN CABLE H 1-8 YEL 062-3-6
8
4
3
2
1
CO01-J8
S28
9
Sheet_03-[1,B] SHLD CAN CABLE 1-4 SHLD CAN CABLE 1-3 CO01-J1 BLK 000-44 1.5mm²
7
S15 SHLD CAN CABLE 1-5 ORG 053-2 WHT 034-2 YEL 063-25
13 APU PUMP RELAY STAB DEPLOYED 2 7 6
Sheet_03-[1,B] BLK CAN CABLE L 1-4 BLK CAN CABLE L 1-3 WHT 049-5 WHT 032-1
21 PLATFORM ATTACHED STAB DEPLOYED 1 20
S14 BLK CAN CABLE L 1-5 GRN 055-1 GRN 049-11 YEL 063-25 Sheet_04-[4,D]
23 HYD QUICK CONNECT BOOM EXTEND LIMIT 8
PLATFORM STAB/ERS (SH10 B6 & SH8 E3)

Sheet_03-[1,B] RED CAN CABLE H 1-4 RED CAN CABLE H 1-3 BLK 058-7 LGR 070-8 LGR 070-8-1 BLK 000-44 1.5mm² Sheet_04-[4,F]
POWER
POWER
STEER RETURN FUNCTION ENABLE
GRN 055-1-2
GRN 055-1-3
8 15
GROUND
GROUND
S04 RED CAN CABLE H 1-5 ORG 049-5 YEL 075-2 S03 LGR 070-8-2 YEL 062-3-6 Sheet_04-[2,F]
35 STEER PRESSURE PLATFORM MODE 2
LGR 076-1 YEL 061-5 4mm²
2 HYD QC OFF 35 1
SHLD CAN CABLE 1-2 WHT 049-5
GRN 055-1-1 1.5mm²

4 19 2
Sheet_03-[1,B] SHLD CAN CABLE 1-10 S21 SHLD CAN CABLE 1-3 SWITCH, PRES, STEERING LGR 070-8-1
5 34 3
BLK CAN CABLE L 1-2 YEL 062-5 YEL 062-5
6 MICROPROCESSOR PWR 14 4
Sheet_03-[1,C] BLK CAN CABLE L 1-10 S25 BLK CAN CABLE L 1-3 SN89-1 GRN 070-3-2 GRN 070-3-2
7 33 5
RED CAN CABLE H 1-2 ORG 049-5 GRN 070-3 GRN 070-3-3 GRN 070-3-3
1 10 32 6
Sheet_03-[1,C] RED CAN CABLE H 1-10 S43 RED CAN CABLE H 1-3 S38 BLK 000-48 4mm²
11 31 7
BLK 058-7 GRN 070-3-1 1.5mm² GRN 055-1-2
1 17 30 8
SHLD CAN CABLE 1-2 8 BAR BLK 000-61 LGR 049-14
SN89-2 19 VEH SPD GND 28 16
SHLD CAN CABLE 1-6 S44 SHLD CAN CABLE 1-1
20 27 11
BLK CAN CABLE L 1-2 TO ENG SPD SN HARN YEL 075-2-3 2.5mm²
G 22 26 10 G
BLK CAN CABLE L 1-6 S45 BLK CAN CABLE L 1-1 RED CAN CABLE H 2-1
X772 15 25 12
PLATFORM BOOM (SH8 C1)

Electrical System
RED CAN CABLE H 1-2 YEL 085-3 BRN 052-3 BLK CAN CABLE L 2-1
1 24 FAN REVERSE CYCLING 23 13
RED CAN CABLE H 1-6 S47 RED CAN CABLE H 1-1 YEL 085-4 SHLD CAN CABLE 2-1
2 25 17 14
WHT 085-2 YEL 085-4 GRN 055-1-3
3 26 +5V 16 9
BLK 000-62 YEL 075-2-3 2.5mm² YEL 062-4 2.5mm²
4 27 10 15
WHT 085-2 YEL 075-2-1 YEL 075-2-1 YEL 075-2-2
16 ENG SPD SIG PLATFORM MODE 1 X36
BLK 000-62 YEL 075-2 S31
9 ENG SPD GND 9
Sheet_04-[4,D] Twisted Pair (RX) YEL 062-4 2.5mm² Sheet_04-[7,E]
30 RX 6
Sheet_04-[4,D] Twisted Pair (TX) YEL 062-3 YEL 075-2-2 Sheet_04-[2,E]
29 TX MICROPROCESSOR PWR 3
YEL 085-3
28 VBAT 5
GRY 048-1 WHT 065-7
12 GLOW PLUGS/CLUTCH LOCK REAR AXLE STEER CENTER 12
GRY 048-25 GRY 048-3 LGR 049-10
F 14 ENGINE TEMP JOYSTICK LOCK 11
GRY 048-23 GRY 048-11 GRN 078-1
E 34 AIR FILTER BOOM ANGLE 4
THROTTLE PEDAL GRY 048-22 GRN 070-1 YEL 063-6 YEL 062-3 Sheet_04-[2,F]
D 3 STAB AND LEVEL SPEED TRAILER SERVICES PWR 29
YEL 057-1-2 RED CAN CABLE H 1-1 GRN 050-2 Sheet_04-[5,C]
C 1 SPARE OUTPUT CAN 1 HIGH 13
BLK 058-8-2 GRY 048-12-1 GRY 048-12 GRY 048-12 BLK CAN CABLE L 1-1
B 32 ALTERNATOR EXCITE CAN 1 LOW 24
GRY 048-21-2 S55 GRY 048-12-2 SHLD CAN CABLE 1-1
A 31 CAN 1 SHIELD NC
WHT 065-6 GRN 050-1 Sheet_04-[5,C]
SN749 33 FRONT AXLE STEER CENTER 21
BLK 058-6 LGR 070-8-2 Sheet_04-[5,C]
18 ANGLE SENSOR GND TRANS FORWARD 22
BRN 052-3 Sheet_03-[6,H]
CO01-J7
BRN 052-4 Sheet_03-[6,H]
CO01-J2
S179
GRN 050-1 GRY 048-24 TO
F 13 DUMP VALVE ENG OIL PRESSURE 8 F
S180
LMIS
6 CAN 2 120 OHM 7
HARNESS
S181
PWR YEL 057-1-1 RED CAN CABLE H 2
A 12 CAN 2 HIGH 3 (SH12 D3)
GRD BLK 058-8-1 S752 BLK CAN CABLE L 2
B 14 CAN 2 LOW 4 X386 X387
SIGNAL GRY 048-21-1 S751 SHLD CAN CABLE 2 YEL 062-19-2
C 17 CAN 2 SHIELD 5 1 1
S750 JUMPER FITTED
BLK 000-46-2
SN88 18 CAN 2 120 OHM 6 2 2 TO ALL MACHINES
SENSOR, POSITION, THROTTLE PEDAL WHT 084-1 RED CAN CABLE H 2-3 RED CAN CABLE H 2-4 WITHOUT LMIS
23 VEH SPD SIG 2 3 3
(ELECTRONIC ENGINE ONLY) BLK CAN CABLE L 2-3 S1105 BLK CAN CABLE L 2-4
27 1 4 4
SHLD CAN CABLE 2-3 S1106 SHLD CAN CABLE 2-4
28 CO01-J12 5 5
GRN 025-1 S1107 LGR 047-13-2
8 TILT UP VALVE 6 6
GRY 048-21 GRN 070-7 WHT 075-1 WHT 075-11
7 9 AUX A VALVE 7 7
BLK 058-8 GRN 026-1 WHT 075-10 WHT 075-11
4 19 TILT DOWN VALVE 8 8
YEL 057-1 GRN 003-1 LGR 047-5-2
6 11 LIFT UP VALVE 9 9
GRY 048-14 GRY 048-14 WHT 032-1-2
37 26 STARTER RELAY 10 10
GRN 047-1 GRN 047-1 WHT 034-2-2
35 24 HYDRAULIC FILTER 11 11
SHLD CAN CABLE 1-6 GRN 070-2
34 20 AUX B VALVE 12 12
BLK CAN CABLE L 1-6 GRN 004-1
33 22 LIFT DOWN VALVE
RED CAN CABLE H 1-6 GRN 013-1
32 34 TELE IN VALVE
GRY 048-22 GRN 014-1
11 35 TELE OUT VALVE X773
Cab Harness Electrical Schematic
GRY 048-23 WHT 084-1

10 29 1
GRY 048-1 CONTROLLER, GRD MODULE BLK 000-61
20 30 2 TO VEH SPD SN HARN
GRY 048-3 BLU 052-2-1-1
14 2 HORN
RED CAN CABLE H 2-2

GRY 048-11
E 18 32 E
BLK CAN CABLE L 2-2

GRY 048-12-1 YEL 062-19-2
19 31
SHIELD CAN CABLE 2-2

ORG 078-3 BLU 047-10 Sheet_03-[2,A]
TO 17 33
GRY 048-24 GRN 069-1 YEL 062-19-1 YEL 062-19 Sheet_04-[4,F]
ENGINE 15 5 FRAME LEVEL RIGHT VALVE
S209
Refer to Electrical Schematic Package (P/N 31200832)
WHT 099-5 ORG 065-1 WHT 075-6 Sheet_03-[2,A]

HARNESS 1 Sheet_03-[5,C] 4 ALL WHEEL STEER VALVE
GRY 048-25 GRN 033-1 WHT 075-5 Sheet_03-[3,A]
(SH10 E1/E4) 12 3 RIGHT STAB UP VALVE
ELECTRICAL SYSTEM SCHEMATICS
YEL 063-39 GRN 031-1 WHT 075-8 Sheet_03-[2,A]

13 10 LEFT STAB UP VALVE
[2,C]
WHT 099-1 GRN 068-1 WHT 075-7 Sheet_03-[2,A]
16 Sheet_03-[4,G] 7 FRAME LEVEL LEFT VALVE
[2,C]
GRN 032-2 BLK 000-46-1 BLK 000-46 Sheet_03-[2,C]
21 21 LEFT STAB DOWN VALVE
[2,C]
WHT 099-4 GRN 034-1 BLK 000-46-2
22 Sheet_03-[5,C] 15 RIGHT STAB DOWN VALVE S210
ORG 065-2
WHT 099-2
23 Sheet_03-[5,C] 16 CRAB STEER VALVE
WHT 099-3 GRY 047-2
24 Sheet_03-[5,C] 25 FUEL LEVEL
KEY PAD
GRN 070-3
3 1 1/2 AUX SW86
BLK 000-46-1
25 1
BLK 000-40 WHT 075-7
26 5 CLEAR
BRN 074-6-1 WHT 075-8
2 4 UP ARROW
TRAN TEMP
AUX RTN
TELE RTN
LIFT RTN
TILT RTN
HYD QC OFF
PLAT COUPLED
STAB RTN
BOOM RETRACT
2 WHEEL STEER
ALTERNATOR D+
PARK BRAKE
LSI CUTOUT LAMP (ONLY ON MODELS UNDER 10M)
FAN REVERSE DEMAND
CLUTCH LOCK
ENGINE START
FRAME LEVEL LEFT
LOAD MOMENT CUTOUT
FUEL RELAY/ECM IGN
APU ENABLE
FRAME LEVEL RIGHT
REVERSE ALARM RELAY
PRE HEAT
TRANS DECLUTCH
LSI CUTOUT LAMP GND (ONLY ON MODELS UNDER 10M)
CRAB STEER
CRAB STEER LED
2 WHEEL STEER LED
ALL WHEEL STEER
ALL WHEEL STEER LED
LOAD MOMENT SHUT OFF
LOAD MOMENT SHUT OFF LED
JOYSTICK LOCK LED
BUCKET MODE
BUCKET MODE LED
BLK 000-43 1.5mm² LGR 047-5-2 WHT 075-5
29 3 DN ARROW
BLK 000-42 1.5mm² LGR 047-13-2 WHT 075-6
28 2 OK
BLK 000-41 LGR 047-11
27 20
TWISTED CABLE 2 WHT LGR 076-3
30 13 BUCKET
11
14
4
2
6
1
3
10
13
5
7
8
9
12
7
5
3
4
18
21
11
22
23
2
6
8
9
10
12
16
17
14
15
20
24
25
30
31
32
34
28
27
35
29
33
26
1
19
13
TWISTED CABLE 2 BLK LGR 047-20
31 18
BRN 073-9 LGR 049-10
9 11 JOYSTICK
GRY 048-16 LGR 047-5-1
CO01-J3
D 36 19
D
CO01-J4
Sheet_03-[3,C] YEL 062-9-5 1.5mm² S211 LGR 047-13-1
5 12 LMI CANCEL
GRY 048-18 S212 LGR 047-8
8 14
BLU 008-3
LGR 076-2
LGR 065-3
LGR 077-1
LGR 064-2
LGR 068-2
LGR 053-1
LGR 069-2
LGR 064-1
LGR 065-4
LGR 047-7
LGR 047-6
LGR 065-5
LGR 047-8
LGR 047-5
LGR 076-3
BRN 052-4
GRY 048-9
ORG 078-3
WHT 058-4
WHT 058-3
WHT 058-2
WHT 058-1
WHT 058-5
WHT 130-1
WHT 131-1
WHT 132-1
WHT 133-1
LGR 065-5
LGR 049-14
LGR 047-13
LGR 047-20
LGR 047-11
GRY 048-15
GRY 048-13
GRN 049-13
WHT 075-10
X32 8 AW STEER
GRY 048-12-2
GRY 134-4
YEL 134-21
PNK 134-23
LGR 047-6
16
LGR 065-3
10 2W STEER
LGR 047-7
15
GRN 025-1 LGR 065-4
1 9 CRAB STEER
GRN 070-7 YEL 062-19-1
10 7
GRN 026-1 BLU 047-10
2 6
GRN 003-1
4 17
GRN 070-2
11 BACK LIGHT
GRN 004-1
5
GRN 013-1
8
TO REAR GRN 014-1
7
HARNESS WHT 058-4
12
(MAIN VALVE) WHT 058-3
9 X33
(SH9 G1/F5) WHT 058-2 BLU 008-3-1
6 6
WHT 058-1 GRY 047-2
3 1
BLK 058-6 GRN 055-1-1 1.5mm²
13 16
RED CAN CABLE H 2-2 GRN 070-3-1 1.5mm²
14 [7,E] 5
BLK CAN CABLE L 2-2 WHT 065-7
C 15 [7,E] 4 C
SHIELD CAN CABLE 2-2 GRN 078-1
16 [7,E] 3
GRN 049-13
X34 19
BLU 071-5 1.5mm²
11
BLU 071-3-1
9
BLU 071-4-1
SW87 10
BLU 075-9-3 BLU 071-2 1.5mm²
8 8
BLK 000-30-15 BLK 000-13
7 2
BLU 071-1 1.5mm²
6 7
BLU SENSOR CABLE 1
5 14
RED SENSOR CABLE 1
4 12
LGR 076-2 BLK SENSOR CABLE 1
1 13
YEL 063-38-3 SHLD SENSOR CABLE 1
2 18
LGR 076-1 BLU 071-9
HYD QUICK CONNECT

3 17
BLU 071-3-3
BLU 071-3-1
BLU 071-4-6
BLU 071-4-1
BLU 071-8 1.5mm²

SW20 15
BLU 075-9-2 YEL 062-12
8 20
BLK 000-30-16
7 21
BLU 052-2-1-1
S27
S26
6 22
5 23
4 24
GRN 081-1
1
YEL 063-6
2
GRY 134-4
YEL 134-21
TRAILER SERVICES
PNK 134-23
GRN 082-1 HORN
B 3 B
1 TO J4-31
1 TO J4-3
T861
T862
SWITCH, SERVICE BRAKE PRESS
1
2
LGR 064-1
1
D1
X111-1
AH108
Sheet_04-[2,B]
Sheet_04-[2,B]
Sheet_04-[2,B]
YEL 062-9-6
1
12.5 BAR
X111-2
Sheet_04-[3,F] BLU 071-12
Sheet_04-[3,G] BLU 075-9-4
Sheet_03-[3,C] YEL 062-9-4
Sheet_04-[5,G] BLK 000-19-2
Sheet_04-[5,F] BLK 000-21 1.5mm²
Sheet_04-[6,F] BLK 000-22
Sheet_04-[6,F] BLK 000-23
Sheet_04-[3,F] BLU 071-11
Sheet_04-[3,F] BLU 071-13
Sheet_04-[3,F] BLU 071-14
Sheet_04-[5,F] BLK 000-20 1.5mm²
Sheet_04-[3,F] BLU 071-16
Sheet_03-[2,A] BLU 047-3
Sheet_03-[4,H] BLU 071-3-4
Sheet_03-[1,H] BLU 071-3
Sheet_03-[1,H] BLU 071-4
Sheet_03-[2,A] BLU 071-4-5
Sheet_03-[4,H] BLU 071-4-2
Sheet_04-[4,F] BLU 008-3-1
Sheet_04-[4,F] BLU 071-2 1.5mm²
Sheet_04-[6,F] BLK 000-13
Sheet_04-[4,F] BLU 071-1 1.5mm²
Sheet_03-[8,B] BLU SENSOR CABLE 1
Sheet_03-[8,B] RED SENSOR CABLE 1
Sheet_03-[8,B] BLK SENSOR CABLE 1
Sheet_03-[8,B] SHLD SENSOR CABLE 1
Sheet_03-[2,H] BLU 071-9
Sheet_03-[6,H] BLU 071-8 1.5mm²
Sheet_04-[3,D] YEL 062-12
Sheet_04-[6,F] BLK 000-15 1.5mm²
Sheet_04-[6,F] BLK 000-24 1.5mm²
Sheet_04-[6,F] BLK 000-16 1.5mm²
Sheet_04-[6,F] BLK 000-17 1.5mm²
SW76
BLU 052-2
YEL 062-9-2
LGR 077-1
4
BLK 000-19-1
TWISTED CABLE 2 BLK

TWISTED CABLE 2 WHT
BLU 071-5 1.5mm²
BLK 18AWG
WHT 18AWG
3
A
B
SW77
C
YEL 062-15 1.5mm² BLU 052-2-3
2
SHLD CAN CABLE 1-8 BLU 052-2-1 S29
1 NC
GRN 070-4
WHT 058-5
GRN 069-1
ORG 065-1
GRN 033-1
GRN 031-1
GRN 068-1
GRN 032-2
GRN 034-1
ORG 065-2
BLU 071-16
WHT 065-6
BLU 071-4-6
BLK 000-20 1.5mm²
BLU 071-14
BLU 071-13
BLU 071-3-3
BLU 071-11
BLK 000-23
BLK 000-22
BLK 000-21 1.5mm²
BLK 000-19-2
YEL 062-9-4
BLU 075-9-4
BLU 071-12
BLU 052-2-4
E
SWITCH, BRAKE PEDAL
X54
D
5
2
6
8
4
9
7
3
1
11
12
32
31
30
29
28
27
26
25
24
23
18
22
20
34
16
15
19
10
13
37
36
35
33
21
17
14
RED CAN CABLE H 1-8

G
BLK CAN CABLE L 1-8
F
1
1
TO FRONT CHASSIS HARNESS
LB858-
LB858+
N/O
N/C
J (SH8 C8/F8)
BLU 052-2-4
H
Sheet_04-[3,F]
Sheet_03-[3,C] YEL 062-9-6
Sheet_04-[3,B] GRN 082-1
Sheet_04-[5,F] GRY 048-18
Sheet_03-[3,C] YEL 062-9-5 1.5mm²
Sheet_03-[2,D] YEL 063-38-3
Sheet_04-[4,F] GRY 048-16
Sheet_04-[3,G] BLU 075-9-2
Sheet_04-[3,G] BLU 075-9-3
Sheet_04-[3,B] GRN 081-1
Sheet_03-[3,D] BLK 000-30-16
Sheet_03-[3,D] BLK 000-30-15
Sheet_04-[3,F] BRN 073-9
Sheet_04-[5,F] YEL 063-39
YEL 061-10-3 Sheet_04-[7,G] PARK BRAKE
C
BLK 000-31-1 Sheet_03-[2,C]
BLK 000-19-4
B
YEL 080-1
WHT 130-1
WHT 131-1
WHT 133-1
WHT 132-1
YEL 062-2 Sheet_03-[3,C]

A
Sheet_04-[3,A]
Sheet_04-[3,A]
A LSI CUT-OUT LAMP

A
X81
1
2
3
4
5
6
X1102
ONLY USED ON
Sheet_03-[2,H] LGR 064-2
Sheet_04-[8,D] GRY 048-15
Sheet_03-[8,E] LGR 068-2
Sheet_03-[4,B] LGR 053-1
Sheet_03-[8,E] LGR 069-2
Sheet_04-[8,D] GRY 048-13
Sheet_03-[8,B] WHT 075-1
Sheet_04-[4,F] BLU 008-3
MODELS UNDER 10M
Sheet_04-[5,F] BLK 000-41

Sheet_04-[5,F] BLK 000-42 1.5mm²
Sheet_04-[5,F] BLK 000-43 1.5mm²
Sheet_04-[6,G] BRN 074-6-1
Sheet_04-[5,F] BLK 000-40
Sheet_03-[6,H] BLU 052-2-3
Sheet_04-[4,F] GRY 048-9
Sheet_04-[5,C] GRN 070-1
Sheet_04-[5,C] GRN 070-4
Sheet_04-[5,G]
Sheet_03-[3,C] YEL 062-9-2
Sheet_04-[2,B]
1 2 3 4 5 6 7 8
MAM3760G

9.8.1
1 2 3 4 5 6 7 8
POSITION 1 JUST FRONT

POSITION 2 FRONT AND REAR
TURN CAB WORKLIGHTS DRIVING LIGHTS REAR WIPER ROOF WIPER
BLU 071-20-1 1.5mm²
6
BLU 071-27 1.5mm²
H HAZARD 2 H
GENERIC BLU 071-25 1.5mm²
FOG LIGHT TRANSMISSION NEUTRALIZER BEACON LIGHT 1 CLEANFIX/FAN REV BOOM WORKLIGHTS HORN
HEST LAMP YEL 061-8-1 1.5mm²
3
8
BLU 071-4-2 1.5mm²
5
BLU 071-3-4 1.5mm²
4
YEL 071-29-1 1.5mm²
7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
4
6
7
8
1
2
3
4
5
6
7
8
1
4
5
6
7
8
1
2
3
5
1
2
3
4
5
6
7
8
2
3
4
5
6
8
1
2
3
4
5
6
7
8
1
2
3
7
1
2
3
4
5
6
7
8
1
1
SW62
SW61
SW74
SW58
SW57
SW56
SW63
SW70
LB860-
SW864
LB860+
SW823
SW940
WIPE
BRN 074-2 1.5mm²
2
BRN 074-3 1.5mm²
3
TURN/WIPER COLUMN SWITCH
BLU 072-1
BLU 071-9
LGR 064-2
BRN 052-3
BRN 052-4
YEL 062-6-2 1.5mm²
YEL 062-7-2
YEL 062-9-7
BLU 075-9-9
BLU 075-9-7
YEL 062-9-3
BLU 075-9-5
BLU 052-2-3
BLU 075-9-6
YEL 062-7-1
BLU 075-9-12
5
BLK 000-30-9
BLK 000-30-8
YEL 062-9-12
YEL 062-9-13
BLK 000-30-5
YEL 063-26-1
BLK 000-30-6
BLK 000-30-2
YEL 063-26-2
BLK 000-30-4
BLU 075-9-16
BLU 075-9-13
BLU 075-9-14
WHT 099-1
BLK 000-30-12
BLK 000-30-10
BLK 000-30-13
BLK 000-30-19
BRN 074-6-2
BLU 075-9-8
YEL 062-7-4
6
BLK 000-30-11
YEL 061-6 1.5mm²

YEL 061-7 1.5mm²
BLU 051-2 1.5mm²

BLU 051-3 1.5mm²
BLU 071-8 1.5mm²
BLU 071-3 1.5mm²

BLU 071-4 1.5mm²
BRN 074-1 1.5mm²
1
BLU 071-26 1.5mm²

BLU 071-27 1.5mm²
YEL 062-11 1.5mm²

BLU 071-28 1.5mm²
BRN 074-13 1.5mm²
BRN 074-10 1.5mm²

BRN 074-11 1.5mm²
YEL 051-3-1 1.5mm²

YEL 051-3-2 1.5mm²
YEL 051-3-3 1.5mm²
YEL 061-8-2 1.5mm²

BRN 074-5-5 1.5mm²
YEL 074-9-3 1mm²

BRN 074-13-1 1.5mm²
YEL 079-29-2 1.5mm²

BRN 074-5 1.5mm²
4
YEL 074-9-4 1.5mm²
S837
Sheet_02-[7,B] BLU 071-3 1.5mm²
BRN 074-5-5 1.5mm²

BRN 074-13-1 1.5mm²
BRN 074-11-1 1.5mm²

BRN 074-11-1 1.5mm²
Sheet_04-[3,G] YEL 079-29-2 1.5mm²
Sheet_02-[7,B] BLU 071-4 1.5mm²
Sheet_04-[4,G] YEL 061-8-2 1.5mm²
Sheet_04-[3,F] BLU 071-28 1.5mm²
Sheet_04-[3,D] YEL 062-11 1.5mm²
Sheet_04-[3,G] YEL 063-26-2 WHT 099-1
G Sheet_02-[1,E] G
Sheet_02-[8,B] BLU 071-9
Sheet_02-[4,D] LGR 064-2
YEL 062-6 1.5mm²

YEL 062-6-1 1.5mm²
Sheet_04-[3,G] YEL 063-26-1
Sheet_04-[8,G] BLU 072-1
Sheet_04-[6,G] BRN 074-6-2
Sheet_04-[3,G] BLU 071-20-1 1.5mm²
Sheet_04-[3,F] YEL 062-6 1.5mm²
Sheet_04-[1,B] BRN 074-3 1.5mm²
Sheet_04-[1,A] BRN 074-2 1.5mm²
Sheet_04-[1,A] YEL 062-6-1 1.5mm²
Sheet_04-[3,G] YEL 071-29-1 1.5mm²
Sheet_02-[7,B] BLU 071-3-4 1.5mm²
Sheet_02-[7,B] BLU 071-4-2 1.5mm²
Sheet_04-[8,C] BRN 074-5 1.5mm²
Sheet_04-[4,G] YEL 061-8-1 1.5mm²
Sheet_04-[4,F] BLU 071-25 1.5mm²
Sheet_04-[3,F] YEL 051-3-3 1.5mm²
Sheet_02-[8,B] BLU 071-8 1.5mm²
Sheet_04-[3,F] YEL 051-3-1 1.5mm²
Sheet_04-[7,H] BLU 051-2 1.5mm²
Sheet_04-[8,G] BLU 051-3 1.5mm²
F Sheet_04-[3,F] YEL 051-3-2 1.5mm² F
Sheet_04-[3,F] YEL 061-6 1.5mm²
Sheet_04-[4,F] BLU 071-26 1.5mm²
Sheet_04-[3,F] YEL 061-7 1.5mm²
Sheet_04-[8,G] BRN 074-10 1.5mm²
Sheet_04-[8,G] BRN 074-11 1.5mm²
Sheet_04-[7,G] YEL 074-9-4 1.5mm²
S95
Sheet_04-[3,G] BLU 075-9 BLU 075-9-12
BLU 075-9-10 BLU 075-9-13
BLU 075-9-14
BLU 075-9-17
BLU 075-9-16
BLU 075-9-10 BLU 075-9-5
S96 BLU 075-9-6
BLU 075-9-7
BLU 075-9-8
BLU 075-9-9
Sheet_04-[3,D] YEL 062-7 YEL 062-7-1
S17 YEL 062-7-2
YEL 062-7-3
Sheet_04-[8,H] BRN 074-1 1.5mm²

E E
Sheet_04-[8,H] BRN 074-13 1.5mm² LGR 069-2 1
Sheet_04-[7,G] YEL 074-9-3 1mm² YEL 063-38-1
2
YEL 062-7-4 LGR 068-2 3
Sheet_02-[3,A] BLU 052-2-3
4
YEL 062-7-5
5
Sheet_02-[8,B] BLK SENSOR CABLE 1
6
FRAME LEVEL
Sheet_02-[8,B] BLU SENSOR CABLE 1 BLK 000-30-3

7
Sheet_02-[8,B] RED SENSOR CABLE 1 BLU 075-9-11 8
Sheet_02-[8,B] SHLD SENSOR CABLE 1 SW46
Sheet_02-[5,D] LGR 069-2
Sheet_02-[5,D] LGR 068-2 BRN 073-11 1.5mm² HI

1
Sheet_04-[3,G] BLU 075-9-11 BLK 000-37 1.5mm² GND
2
Cab Harness Electrical Schematic (Continued)
Sheet_04-[1,A] BRN 073-11 1.5mm² BRN 073-12 1.5mm² LOW M

3
Sheet_04-[5,F] BLK 000-37 1.5mm² BRN 073-10 1.5mm² MED
4
Sheet_04-[1,A] BRN 073-12 1.5mm² WH66-1
Sheet_04-[1,A] BRN 073-10 1.5mm²
HVAC FAN
Sheet_04-[1,A] BRN 073-15 1.5mm² BRN 073-15 1.5mm² 1

Sheet_04-[1,A] BRN 073-16 1.5mm² BRN 073-16 1.5mm² 2
Sheet_02-[6,G] BRN 052-3 WH66-2
AC
D Sheet_02-[4,D] BRN 052-4 D
YEL 063-38-1 BLK 000-30-15 BLK 000-30-19

Sheet_04-[3,D] YEL 063-38 YEL 063-38 BLK 000-30-3 S19 BLK 000-30-2
YEL 063-38-2 S41 BLK 000-30-18 BLK 000-30-1 1.5mm² BLK 000-30-4
Sheet_02-[1,B] YEL 063-38-3 S23 BLK 000-30-16 BLK 000-30-5
Sheet_02-[1,C] BLK 000-30-15 BLK 000-30-14 1.5mm² BLK 000-30-6
Sheet_02-[1,B] BLK 000-30-16 BLK 000-30-20
YEL 062-9-14 YEL 062-9-13
Sheet_02-[6,A] YEL 062-9-4 YEL 062-9-4 YEL 062-9-12
Sheet_02-[4,A] YEL 062-9-2 YEL 062-9-2 YEL 062-9-7
YEL 062-9 1.5mm² YEL 062-9 1.5mm² YEL 062-9-3
Sheet_02-[1,D] YEL 062-9-5 1.5mm² Sheet_02-[1,D] YEL 062-9-5 1.5mm² S02 YEL 062-9-6
Sheet_02-[1,A] YEL 062-9-6 BLK 000-30-14 1.5mm² BLK 000-30-13 BLK 000-30-9
S22
Sheet_04-[6,F] BLK 000-30 1.5mm² BLK 000-30 1.5mm² BLK 000-30-7 1.5mm² BLK 000-30-10
YEL 062-9-15 S24 BLK 000-30-8 BLK 000-30-11
Sheet_02-[2,A] YEL 062-2 YEL 062-2 BLK 000-30-12
1
Sheet_04-[5,F] YEL 061-9 1.5mm² YEL 061-9 1.5mm² EMS
SW51-2
Sheet_04-[7,E] YEL 061-4 YEL 061-4
1 X950 X950
Sheet_02-[1,D] WHT 099-2 WHT 099-2 WHT 099-2 WHT 099-4
SW51-1 1 1 7
YEL 062-7-5 YEL 062-7-5 YEL 062-7-5-2
C 2 2 8 C
BLK 000-31-3 Sheet_02-[1,D] WHT 099-3 WHT 099-3 WHT 099-3 S953
3 3 1
Sheet_04-[6,F] BLK 000-31 BLK 000-31 S18 BLK 000-31-4 Sheet_02-[1,E] WHT 099-5 WHT 099-5 WHT 099-5 YEL 062-7-5-1
4 4 4
Sheet_02-[2,A] BLK 000-31-1 BLK 000-31-1 Sheet_02-[1,D] WHT 099-4 WHT 099-4 WHT 099-4 WHT 099-2
5 5 3
BLK 000-46 BLK 000-30-20
DPF
6 6 2
BLK 000-31-2 BLU 075-9-17
GENERIC
7 7 11
Sheet_04-[4,F] YEL 075-3 WHT 099-3
8 8 5
Sheet_02-[8,F] WHT 075-1 YEL 062-7-5-4
9 9 6
Sheet_02-[1,G] RED CAN CABLE H 1-10
12
Sheet_02-[1,G] BLK CAN CABLE L 1-10 WHT 099-5
9
Sheet_02-[1,G] SHLD CAN CABLE 1-10 YEL 062-7-5-3
10
Sheet_04-[4,F] YEL 062-16
SW854
Sheet_02-[1,H] RED CAN CABLE H 1
Sheet_02-[1,H] BLK CAN CABLE L 1
GD84
Sheet_02-[1,H] SHLD CAN CABLE 1 YEL 075-3
1
Sheet_02-[5,D] LGR 053-1 BLK 000-31-2
2
WHT 075-1
3
Sheet_02-[8,E] BLK 000-46 BLK SENSOR CABLE 1
4
Sheet_02-[8,D] WHT 075-5 BLU SENSOR CABLE 1
5
Sheet_02-[8,D] WHT 075-6 RED SENSOR CABLE 1 LSI DISPLAY
AH99 CONT 6
Sheet_04-[4,F] YEL 75-4 YEL 075-4-2 SHLD SENSOR CABLE 1
NC1
Sheet_02-[1,H] RED CAN CABLE H 1-4 S32 RED CAN CABLE H 1-10
B AH99- 7 B
Sheet_02-[1,H] BLK CAN CABLE L 1-4 WHT 058-9 BLK CAN CABLE L 1-10
8
Sheet_02-[1,H] SHLD CAN CABLE 1-4 SHLD CAN CABLE 1-10
BUZZER
AH99 PULSE NC2
Sheet_02-[7,B] BLU 071-4-5
Sheet_04-[3,G] BLU 071-20-2

Sheet_02-[8,D] WHT 075-7
BLK 000-31-3
YEL 062-7-3
BLK 000-30-18
LGR 053-1
YEL 063-38-2
SHLD CAN CABLE 1
BLK CAN CABLE L 1
RED CAN CABLE H 1
YEL 062-16
Sheet_04-[3,F] BLU 047-9

Sheet_02-[8,D] WHT 075-8
JS75
8
7
6
5
4
3
2
1
6
5
4
3
2
1
SW67
BLU 047-10
WHT 058-9
WHT 075-5
BLK CAN CABLE L 1-4

RED CAN CABLE H 1-4
YEL 075-4-1
WHT 075-6
SHLD CAN CABLE 1-4

WHT 075-8
BLU 047-9
WHT 075-7
BLU 071-20-2
BLU 071-4-5
BLK 000-31-4
BLU 047-3
APU ENABLE ON
GD85
9
8
7
6
5
4
3
2
1
11
13
14
17
16
15
24
23
22
21
20
19
18
10
12
DISPLAY
NC
(PLATFORM ONLY) S T
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
YEL 062-9-14
YEL 062-9-15
NC
NC
NC
NC
GND
VISP
F2
F1
CAN L1
CAN L2
CAN H1
CAN H2
VCC
GND
12V KEY
PWR
CAN HI
OUT BUZZER
CAN SHIELD 1
GND KEY PAD

CAN LOW
A A
CAN SHIELD 2
PLUGGED
Sheet_04-[2,B]
HIGH BEAM W/L

CONT AUX HYD 1/2 AUX HYD
CLEAR KEY PAD

ENTER KEY PAD
Sheet_04-[2,B]
TRAILER TURN W/L

120 OHM CAN 1
BACKLIGHT KEY PAD
CURSER UP KEY PAD

CONTROLLER, JOYSTICK, ITT
CURSER DOWN KEY PAD
LEFT DIRECTION IND W/L

Sheet_02-[8,C] BLU 047-10
Sheet_02-[7,B] BLU 047-3
RIGHT DIRECTION IND W/L

CAB 2 OF 3
1 2 3 4 5 6 7 8
MAM3770G
Electrical System
9-17
MAM3780G
F
B
C
A
G
H
YEL 063-25 Sheet_02-[8,H]

YEL 062-12 Sheet_02-[8,B]
SW97-7 BRN 073-15 1.5mm² YEL 062-7 Sheet_03-[1,E]
SW97-6
1
1
YEL 073-8 1.5mm² YEL 063-38 Sheet_03-[2,D]

YEL 062-9 Sheet_03-[3,C]
SW68-5 BRN 073-16 1.5mm² YEL 062-11 1.5mm² Sheet_03-[1,H]
C
SW68-4 BRN 073-10 1.5mm²
L
SW68-3 YEL 073-7 1.5mm² Twisted Pair (TX) Sheet_02-[3,G]
FAN
B
SW68-2 BRN 073-11 1.5mm² Twisted Pair (RX) Sheet_02-[3,G]
H
SW68-1
SWITCH, HVAC CONTROL
BRN 073-12 1.5mm²

M
GRN 082-1 Sheet_02-[1,B]
GRN 081-1 Sheet_02-[1,B]
YEL 062-17-1
WH69 YEL 062-17-2 YEL 062-17
D2 S13
BRN 074-3-2-1 1.5mm² BRN 074-3-2 1.5mm² YEL 075-2-2 Sheet_02-[7,G]
P 1
BRN 074-3-1 1.5mm² S20
L 2
YEL 062-6-1 1.5mm²
12v 3
M BRN 074-2 1.5mm²
H 4
5
BLK 000-38 1.5mm² YEL 062-3-2
G 6
WIPER, FRONT MOTOR
S16
YEL 062-3-1 YEL 062-3 YEL 062-3 Sheet_02-[6,G]
YEL 062-3-4 1.5mm² YEL 062-3-6 YEL 062-3-6 Sheet_02-[8,H]
YEL 062-3-5 1.5mm²
SW1162
YEL 062-9-14
2
2
1 Sheet_03-[3,A]
YEL 134-21
2 Sheet_02-[4,B]
GRY 134-4
3 Sheet_02-[4,B]
PNK 134-23
4 Sheet_02-[4,B]
5
6
7 BLU 075-9-4 Sheet_02-[7,A]
8
YEL 062-17-1
YEL 062-17-2
YEL 062-3-1
YEL 075-2-2
YEL 062-9-15
9 Sheet_03-[3,A] BLU 075-9-11 Sheet_03-[8,E]
BLU 052-2-4
FNR SWITCH
10 Sheet_02-[3,A]
9
8
7
6
5
4
3
2
1
11
FC03-XP
11
12
10
BRN 073-11 1.5mm² Sheet_03-[8,D]
YEL 062-6-1 1.5mm² Sheet_03-[5,G]

BRN 073-12 1.5mm² Sheet_03-[8,D]
BRN 073-10 1.5mm² Sheet_03-[8,D]
BRN 073-16 1.5mm² Sheet_03-[8,D]
BRN 073-15 1.5mm² Sheet_03-[8,D]
BRN 074-2 1.5mm² Sheet_03-[4,H]

BRN 074-3 1.5mm² Sheet_03-[4,H]
12
BLU 063-2
FAN 14
YEL 073-8 1.5mm² BLU 075-9-16 [7,B]
ANALYZER AC IN 9
BLU 071-16 Sheet_02-[6,A] BLU 075-9-3 Sheet_02-[1,C]
PORT RIGHT SIDE LIGHT 13
BLU 075-9-1 BLU 075-9-1 BLU 075-9 Sheet_03-[1,F]
LEFT SIDE LIGHT 12
BLU 071-14 Sheet_02-[6,A] S94
RIGHT LO BEAM 11
BLU 071-13 Sheet_02-[6,A]
RIGHT HIGH BEAM 10
BRN 073-9 Sheet_02-[1,D] BLU 075-9-2 Sheet_02-[1,B]
AC OUT 8
YEL 062-6 1.5mm² Sheet_03-[1,G]
FRONT WIPER 7
DIODE 5 (ANODE)
DIODE 2 (ANODE)
6
DIODE 5 (CATHODE)
DIODE 2 (CATHODE)
BLU 071-12 Sheet_02-[7,A]

LEFT LO BEAM 5
(SH8 H1)
BLU 071-11 Sheet_02-[6,A]

LEFT HIGH BEAM 4
YEL 073-7 1.5mm²
TRAILER SERVICES
RADIO 3
YEL 061-7 Sheet_03-[7,H]
FC03-XM LIGHTS BAT 2 2
1
2
3
4
YEL 061-6 1.5mm² Sheet_03-[7,H]

1 LIGHTS BAT 1 1
3
3
X78
YEL 074-9 1.5mm²

2 REAR/ROOF WIPER 15
BLU 071-20 1.5mm² BLU 071-20-1 Sheet_03-[4,H]
3 FC03-XD
S10 BLU 071-20-2 Sheet_03-[2,A]
4
GRN 081-1
GRN 082-1
5
YEL 063-22
BLK 000-34
BLU 071-20 1.5mm²

6 HIGH BEAM IN 15
YEL 063-26 1.5mm² YEL 063-26 1.5mm² YEL 063-26-1 Sheet_03-[3,H]
BEACON 14
YEL 051-3-3 1.5mm² Sheet_03-[6,H] S09 YEL 063-26-2 Sheet_03-[2,H]
BOOM WORKLIGHTS 13
YEL 051-3-2 1.5mm² Sheet_03-[7,H]
REAR WORKLIGHTS 12
YEL 051-3-1 1.5mm² Sheet_03-[7,H]
FC03-XC FRONT WORKLIGHTS 11
YEL 062-11 1.5mm² YEL 062-15 1.5mm² Sheet_02-[1,A]
7 KEY 2 BRAKE LIGHTS 10
YEL 063-38 BLU 047-9 Sheet_03-[2,A]
1 KEY 1 FLASHER C2 9
YEL 062-7 YEL 071-29 1.5mm² YEL 071-291.5mm² YEL 079-29-2 1.5mm² Sheet_03-[1,H]
2 KEY 1 FLASHER 49A 8
Sheet_02-[4,A] BLK 000-19-4 YEL 062-9 BLU 071-28 1.5mm² Sheet_03-[1,H] S08 YEL 071-29-1 1.5mm² Sheet_03-[4,H]
3 KEY 1 FLASHER 49 7
Sheet_02-[4,A] YEL 080-1 YEL 080-1 YEL 061-8 1.5mm²
4 FLASHER 6
YEL 062-12
8 KEY 2 5
YEL 063-25 BLU 071-2 1.5mm² Sheet_02-[8,C]
9 KEY 2 LEFT SIDE LIGHT 4
YEL 063-22 BLU 071-1 1.5mm² Sheet_02-[8,B] YEL 061-8 1.5mm² YEL 061-8-2 1.5mm² Sheet_03-[1,H]
5 KEY 1 RIGHT SIDE LIGHT 3
BLU 072-2 BLU 071-26 1.5mm² Sheet_03-[7,H] S07 YEL 061-8-1 1.5mm² Sheet_03-[4,H]
6 KEY 2 SIDE LIGHT IN 2
BLU 071-25 1.5mm² Sheet_03-[4,H]
10 LO BEAM IN 1
Twisted Pair (TX)
11 TX FC03-XF
Twisted Pair (RX)
12 RX
15
BLK 000-50 1.5mm²
FRONT WASHER GND 14
GRY 048-16 Sheet_02-[1,D]
FUEL PUMP 13
START RELAY OUTPUT 12
GRY 048-9 Sheet_02-[5,D]
FUEL RELAY/ECM IGN 11
BLU 008-3 Sheet_02-[5,D]
REVERSE ALARM RELAY 10
BLU 008-3-1 Sheet_02-[8,C]
4
4
REVERSE ALARM 9
YEL 062-16 Sheet_03-[5,B]
JOYSTICK PWR 8
YEL 075-3 Sheet_03-[8,B]
LMI DISPLAY PWR 7
YEL 062-19 Sheet_02-[8,E]
KEYPAD PWR 6
YEL 75-4 Sheet_03-[2,B]
DISPLAY PWR 5
4
3
YEL 061-11-1 2.5mm² Sheet_02-[5,H]
CONTROLLER PWR 2
YEL 061-11-2 2.5mm² Sheet_02-[5,H]
CONTROLLER PWR 1
FC03-XG
BLK 000-44 1.5mm² Sheet_02-[8,H]
GND 15
BLK 000-51 1.5mm²
REAR/ROOF WASHER GND 14
YEL 061-10 1.5mm²
X123A POWER SOCKET 13
Sheet_02-[5,A] GRN 070-4 GRN 070-4 YEL 063-31 1.5mm²
1 AIR SEAT PWR 12
POWER DISTRIBUTION BOARD
Sheet_02-[8,H] GRN 050-2 GRN 050-2

2 11
Sheet_02-[6,H] LGR 070-8-2 LGR 070-8-2
3 START RELAY GND 10
YEL 062-3-2
4 START CMD 9
YEL 063-39 Sheet_02-[2,A]
5 START PWR 8
6 START PWR 7
GRY 048-18 Sheet_02-[1,D]
(REFER TO SHEET 6 FOR INTERNAL SCHEMATIC)
FUEL VALVE 6
YEL 062-17
X123B KEY SIGNAL IN 5
(SH11 A1)
Sheet_02-[3,F] GRN 070-1 GRN 070-1 YEL 061-9 Sheet_03-[3,C]

1 KEY BAT (EMS) 4
Sheet_02-[3,F] GRN 050-1 GRN 050-1 YEL 063-11 2mm²
2 AUX FUNCTION PWR 3 [8,B]
PLATFORM RELAY BOX
3 DPF SOOT SN PWR 2

4 1
5 FC03-XH
BLK 000-11 BLK 000-19-3 2mm²
6 [7,B]
BLK 000-21 1.5mm² Sheet_02-[6,A]
5
5
GND 15
BLK 000-20 1.5mm² Sheet_02-[6,A] BLK 000-19-4
GND 14
BLK 000-19 2.5mm² BLK 000-19-2 Sheet_02-[6,A]
GND 13
BLK 000-43 1.5mm² Sheet_02-[1,D] S111
GND 12
BLK 000-42 1.5mm² Sheet_02-[1,D]
GND 11
BLK 000-41 Sheet_02-[1,D] BLK 000-19-1 Sheet_02-[3,A]
GND 10
BLK 000-40 Sheet_02-[1,D]
GND 9
BLK 000-11
GND 8
BLK 000-38 1.5mm²
GND 7
BLK 000-37 1.5mm² Sheet_03-[8,D]
GND 6
BLK 000-36 1.5mm²
GND 5
BLK 000-35 1.5mm²
GND 4
BLK 000-34
GND 3
BLK 000-33 2.5mm² Sheet_02-[5,H]
GND 2
BLK 000-32 2.5mm² Sheet_02-[5,H]
GND 1
FC03-XK
BLK 000-31 Sheet_03-[2,C]
GND 15
BLK 000-23 Sheet_02-[6,A]
GND 14
BLK 000-30 1.5mm² Sheet_03-[5,C]
YEL 063-31 1.5mm²
BLK 000-35 1.5mm²
GND 13
BLK 000-13 Sheet_02-[8,C]
GND 12
BLK 000-17 1.5mm² Sheet_02-[8,B]
WH71
2
1
GND 6
BLK 000-16 1.5mm² Sheet_02-[8,B]
GND 5
BLK 000-24 1.5mm² Sheet_02-[8,B]
GND 4
BLK 000-15 1.5mm² Sheet_02-[8,B]
GND 3
BLK 000-22 Sheet_02-[6,A]
1
M
GND
BLK 000-14 1.5mm²
GND 2
BLK 000-6
GND 7 AIR RIDE SEAT
6
6
BLK 000-5 1.5mm²

GND 8
BLK 000-3 2.5mm²
GND 9
BATTERY NEGATIVE
BATTERY NEGATIVE
BATTERY NEGATIVE
BATTERY NEGATIVE
BATTERY NEGATIVE
BATTERY NEGATIVE
BATTERY POSITIVE
BATTERY POSITIVE
BATTERY POSITIVE
BATTERY POSITIVE
BATTERY POSITIVE
BLK 000-2 2.5mm²
GND 10
BLK 000-1
GND 11
YEL 074-9-4 1.5mm² Sheet_03-[8,H]
FC03-XL
2
3
4
5
1
2
3
4
5
6
1
BRN 074-6-2 Sheet_03-[4,H]
YEL 074-9 1.5mm²
FC03-XB
FC03-XA
BRN 074-6 1.5mm² BRN 074-6-1 Sheet_02-[1,D]
S90 GRY 048-15 Sheet_02-[5,D]
GRY 048-13 Sheet_02-[5,D]
YEL 061-10-3 Sheet_02-[2,A]
RED 001-4 4mm²

RED 001-3 4mm²
RED 001-2 4mm²
RED 001-1 4mm²
BLK 000-56 4mm²
BLK 000-55 4mm²
BLK 000-54 4mm²
BLK 000-53 4mm²
MS48
1
YEL 061-10-1 1.5mm²
2
BLK 000-36 1.5mm²
YEL 074-9-4 1.5mm²
3
POWER SOCKET
YEL 061-10 1.5mm²
S91
S93
YEL 074-9-3
YEL 074-9-1
BRN 074-5 1.5mm² Sheet_03-[8,H]

YEL 062-4 2.5mm² Sheet_02-[8,G]
YEL 061-10-2
[2,H]
[5,H]
[5,F]
YEL 061-4 1.5mm² Sheet_03-[3,C]
YEL 074-9-2 1.5mm²
7
7
YEL 074-9-3 Sheet_03-[8,H]

BRN 074-11 1.5mm² Sheet_03-[8,H]
BRN 074-10 1.5mm² Sheet_03-[8,H]
BLU 051-3 1.5mm² Sheet_03-[7,H]
BLU 072-1 Sheet_03-[3,H]
BLU 051-2 1.5mm² Sheet_03-[7,H]
S37
S30
Sheet_03-[8,H]
Sheet_03-[8,H]
BRN 074-11 1.5mm²
YEL 062-3-4 1.5mm²

YEL 062-3-5 1.5mm²
YEL 062-4-1 1.5mm²

YEL 062-4-2 1.5mm²
YEL 061-4-2 1.5mm²
YEL 061-4-1 1.5mm²
YEL 074-9-2 1.5mm²
BRN 074-10 1.5mm²
BRN 074-13 1.5mm²
BLK 000-14 1.5mm²

BRN 074-1 1.5mm²
BLU 051-3 1.5mm²

BLU 051-2 1.5mm²
BLK 000-2 2.5mm²

BLK 000-3 2.5mm²
BLK 000-5 mm²1.5
YEL 061-10-2
GRY 048-15
GRY 048-13
YEL 074-9-1
BRN 049-4
BRN 049-3
BRN 049-1
BRN 049-2
BRN 049-2
BRN 049-1
BRN 049-3
BRN 049-4
BLU 072-2
BLK 000-1
BLK 000-6
BLU 063-2
BLU 072-1
BLK 000-19-3 2mm²

YEL 063-11 2mm²
BLK 000-51 1.5mm²
BLK 000-50 1.5mm²
BRN 074-5 1.5mm²

BRN 074-6 1.5mm²
BLK 000-56 4mm²

BLK 000-55 4mm²
BLK 000-54 4mm²
BLK 000-53 4mm²
RED 001-4 4mm²

RED 001-3 4mm²
RED 001-2 4mm²
RED 001-1 4mm²
BLU 075-9-16
X64
X52
SW82
1
1
1
1
6
1
8
7
5
4
3
2
9
7
6
8
9
5
4
3
2
1
SW82-1
MS92SX-
MS92DX-
11
MS92SX+
MS92DX+
15
14
12
10
13
50B
50A
17B
17A
19B
19A
58B
58A
15B
15A
30B
30A
X112
X110
X106
4
3
2
1
4
3
2
1
2
1
2
1
B
A
WH65-2
WH65-1
C
TO
TO
CAB
CAB
ROOF
ROOF
(SH5 F2)
(SH5 E4)
HARNESS
HARNESS
TO
TO
M
M
(SH5 A2)
ENGINE
ENGINE
HARNESS
HARNESS
REAR FRONT
(SH10 G1/G4)
(SH10 G1/G4)
AUX FUNC PWR

2
2
2
2
1
1
1
1
3
3
3
3
0
0
0
0
P
P
P
P
TANK, DUAL WASHER, PUMPS
8
8
5-POSITION IGNITION
CAB 3 OF 3
F
B
C
A
G
H
D
Cab Harness Electrical Schematic (Continued) 9.8.1
Electrical System
MAM3790G
F
B
C
A
G
H
REAR WIPER MOTOR

CAB SIDE HARNESS
1
1
LIGHT, DOME
RADIO
M
1
YEL 063-11-2
2
G
H
P
L
LGR 049-1
3
4
TO MAIN
(SH4 H8)
CAB HARN
X112 5
2
1
1
4
3
2
1
1
2
3
4
5
6
7
8
9
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
YEL 063-11 1.5mm² S374

A 6
BLK 000-19-3 1.5mm² BLK 000-19-6
X64
LB05
MS21
WH07
B 7
(SH8 C8)
MS21-1
BLU 075-9-16 BLU 075-9-16

LB05-GND
SWITCH, BOOM RIDE
C 8
AUX FUNC PWR
SW47
YEL 063-2
BLU 072-2
BRN 049-1
BRN 049-2
BRN 049-3
BRN 049-4
BRN 049-4
BRN 049-3
BRN 049-2
BRN 049-1
YEL 074-9-2
YEL 074-9-1
BLK 000-6-2
BLK 000-6-1
YEL 061-10-2
S375
X115
YEL 063-11-3
BLK 000-5 1.5mm²
BRN 074-1 1.5mm²
1
BLK 000-14 1.5mm²
BRN 074-11 1.5mm²

BRN 074-10 1.5mm²
BRN 074-13 1.5mm²
BLK TWISTED PAIR 1

2 LB1
WHT TWISTED PAIR 1 LGR 047-1
3 1
BLK 000-19-5
ANALYZER
4
BLK 000-19-7
2
LB1-GND
LAMP, RIDE CONTROL
WHT TWISTED PAIR 1

BLK TWISTED PAIR 1
BLK 000-19-4 1.5mm²

YEL 063-11-1
LGR 049-1
LGR 047-1
X56
8
7
6
5
4
3
2
1
2
2
8
7
6
5
4
3
2
1
X56
BLK 000-6-2
BLK 000-6-1
LGR 049-1 0.5mm²

LGR 047-1 0.5mm²
BRN 074-1 1.5mm² G

4
YEL 063-11-1 0.5mm²
BRN 074-13 1.5mm² P

BLK 000-19-4 1.5mm²
3
S355
BLK 000-14 1.5mm²

2 M
YEL 074-9-1 L
BLK TWISTED PAIR 1 0.5mm²
WHT TWISTED PAIR 1 0.5mm²
1
H
WH08
ROOF WIPER MOTOR
BLK 000-6
S377
CO03-J1
YEL 063-11-1 0.5mm²
1 POWER
BLK 000-19-4 0.5mm²
2 GROUND
LGR 049-1 0.5mm²
3 BOOM RIDE SGN
4
5
6
GRN 076-1 0.5mm² BLU 051-2-2
7 RIDE VALVE 1
3
3
GRN 076-2 0.5mm² BLK 000-3-2

8 TANK VALVE 2
CAB ROOF HARNESS
GRN 076-3 0.5mm² LB12

9 FLOAT VALVE
10
LIGHT, WORKLIGHT
LGR 047-1 0.5mm²

11 INDICATOR
12
CO03-J2
BLU 051-2-1
1 1
RIDE AND FLOAT OPTION

BLK 000-3-1
2 X52 2
BLK 000-6
3 1 LB11
YEL 061-10-2
CONTROLLER, TH RIDE & FLOAT
4 2
S356
LIGHT, WORKLIGHT
YEL 063-2
5 3
S358
BRN 074-10 1.5mm²

6 4
BRN 074-11 1.5mm²
7 5
BLK 000-5 1.5mm²
8 6
RED CAN-CABLE 2 YEL 074-9-2
CONTROLLER HARNESS 9 CAN HIGH 7
BLK CAN-CABLE 2 BLU 072-2
10 CAN LOW 8
TO MAIN
(SH4 G8)
WHT TWISTED PAIR 1 0.5mm² BLU 51-2 1.5mm² BLU 51-2 1.5mm²
CAB HARN
11 TX 9
BLK TWISTED PAIR 1 0.5mm² BLK 000-3 1.5mm² BLK 000-3 1.5mm²
12 RX 10
BLU 51-3 1.5mm² BLU 51-3 1.5mm²
11
S1100
BLK 000-19-8 1.5mm²

BLK 000-2 1.5mm² BLK 000-2 1.5mm²
GRN 076-3 0.5mm²
GRN 076-2 0.5mm²
GRN 076-1 0.5mm²
12
BLU 072-1
13
X55 BLK 000-1
4
3
2
1
14
15
4
3
2
1
X55_1
X32 X32
4
4
WHT 099-5 WHT 099-5

1 1
S357
BRN 074-6-1 BRN 074-6-1

2 2
BLK CAN-CABLE 2-1
BLK CAN-CABLE 2-2
S1099 RED CAN-CABLE 2-1

RED CAN-CABLE 2-2
S359
GRN 076-3
GRN 076-2
GRN 076-1
3 3
BLK 058-8 BLK 058-8 BLU 051-3-1
4 4 1
YEL 062-9-5 1.5mm² YEL 062-9-5 1.5mm² BLK 000-2-1
5 5 2
YEL 057-1 YEL 057-1
6 6 LB10
BLK 000-19-8 1.5mm²

GRY 048-21 GRY 048-21
7 7
BLU 072-1
BLK 000-1
LIGHT, WORKLIGHT
GRY 048-18 GRY 048-18

8 8
LB45
BRN 073-9 BRN 073-9

2
1
9 9
WHT 048-23 WHT 048-23
LB45-GND
10 10
GRY 048-22 GRY 048-22
11 11
GRN 076-2 GRY 048-25 GRY 048-25 BLU 051-3-2
1 12 12 1
BLK 000-19-9 YEL 063-39 YEL 063-39 BLK 000-2-2
2 13 13 2
GRY 048-3 GRY 048-3
HV118 14 14 LB09
MCV VENT
1
2
VALVE, TANK
GRY 048-24 GRY 048-24
AUX POWER SOCKET
15 15
LIGHT, WORKLIGHT
WHT 099-1 WHT 099-1

X1023
16 16
ORG 078-3 ORG 078-3
17 17
GRY 048-11 GRY 048-11
18 18
S362
GRY 048-12-1 GRY 048-12-1
19 19
GRY 048-1 GRY 048-1
20 20
LIGHT, BECON
21 21
TO CAB HARNESS
TO ENGINE HARNESS
WHT 099-4 WHT 099-4

22 22
BLK
BLU
WHT 099-2 WHT 099-2

23 23
WHT 099-3 WHT 099-3
FLOAT VALVE 24 24
HV117 25 25
GRN 076-3 BLK 000-40 BLK 000-40
1 26 26
BLK 000-19-10 BLK 000-41 BLK 000-41
2 27 27
5
5
BLK 000-42 1.5mm² BLK 000-42 1.5mm²

HV119 28 28
GRN 076-1 BLK 000-43 1.5mm² BLK 000-43 1.5mm²
1 29 29
WITH FLOAT
BLK 000-19-11 WHT TWISTED CABLE 2 WHT TWISTED CABLE 2
2 30 30 SWITCH, PARK BRAKE
BLK TWISTED CABLE 2 BLK TWISTED CABLE 2
VALVE, RIDE CONTROL

31 31
RED CAN-CABLE 2-1 RED CAN-CABLE 2-2
RIDE VALVE 32 32
BLK CAN-CABLE 2-1 BLK CAN-CABLE 2-2
N/C
33 33
N/O
SHLD 1-6 CAN CABLE S SHLD 1-6 CAN CABLE S LAMP, TRAILER BRAKE
SW77
34 34
GRN 047-1 GRN 047-1
PARK BRAKE
35 35
UGM GROUND
GRY 048-16 GRY 048-16

TO CAB HARNESS
36 36
Applied
GRY 048-10 2mm² GRY 048-10 2mm²

Released
37 37
J2-28
C
C
B
A
B
A
2
1
HARNESS, LIGHT EXTENSION
CHASSIS HARNESS
X119
SW77A
SW77B
LB50_2
LB50_1
BLK 000-58
BLU 047-21
LGR 071-14
LGR 071-14
YEL 062-9-2
YEL 062-9-8
LGR 071-1-4
BLK 000-58-1
BLU
BLK
CAB HARNESS
S405
CHASSIS HARNESS
6
6
LB1024
1
2
X307
S406
YEL 063-25-3
1
BLK 000-44-5
2
WHT 049-11
3
BOOM HARNESS
+
SN400
BLK 000-44-5
BLK 000-58-2
YEL 062-9-9
LGR 071-1-4
BLU 047-21
2
YEL 063-25-3
1
WHT 049-11
X120A
4
3
2
1
SWITCH, PROX
BOOM EXTEND 1
-
4
3
2
1
X308 X308
YEL 063-25-3 YEL 063-25-3
X120B
1 1
BLK 000-44-5 BLK 000-44-5
2 2
WHT 049-11 WHT 049-11
3 3 CO04-J1
YEL 062-12-7 YEL 062-12-7 YEL 062-12-6
4 4 1 POWER
BLU 047-21
YEL 062-9-9
LGR 071-1-4
BLK 058-6-5 BLK 058-6-5 BLK 058-6-4

BLK 000-58-2
ITALIAN TRAILER BRAKE
5 5 2 GROUND
WHT 049-14 WHT 049-14
6 6 3
WHT 049-14
4 EXT PROX SW
5
6
7
8
+
SN392 9
BLK 058-6-5 FLEXAIR FAN
S408
2 10
S407
7
7
YEL 062-12-7
1 11
WHT 049-14
3 12
SWITCH, PROX
-
BOOM EXTEND 2
CO04-J2
2
1
1
2
HV1161
3
YEL 062-12-7
YEL 062-12-6
BLK 058-6-5
BLK 058-6-4
4
CONTROLLER, BOOM EXTENSION LIMIT

FLEXAIR FAN HARNESS
5
WHT 094-1
6
BLK 000-77
7
S401
S402
8
RED CAN CABLE 4-2 H
9 CAN HIGH
BLK CAN CABLE 4-2 L
10 CAN LOW
11 TX
CHASSIS HARNESS
12 RX
S404
S403
BLK 058-6-3
BLK 058-6-2
YEL 062-12-5
YEL 062-12-4
YEL 062-9-11
BLK 000-58-4
LGR 071-1-4
LGR 076-4
FLEXAIR FAN OPTION

RL300
YEL 062-9-10
BLK 000-58-3
5
2
3
1
4
BLU 047-21
LGR 076-4
WHT 094-1
BLK 000-77
1
1
SN400-2
SN400-1
86
85
30
87
HV400
87a
2
1
9
8
7
6
5
4
3
2
1
11
12
10
CO678-J2.1
BLK CAN CABLE 4 L

BLK CAN CABLE 4-1 L
RED CAN CABLE 4-1 H

RED CAN CABLE 4-1 H
RELAY, SPST, 12V
SWITCH, PRESSURE
8
8
SN220_A SN220_B
BLK 058-6-3 BLK 058-6-2 VALVE, TRAILER BRAKE
1 1
YEL 062-12-5 YEL 062-12-4
2 2
3 3
CAB ROOF, RIDE AND FLOAT & BOOM EXT LIMIT
(TH417 PLATFORM ONLY)

TO GEARBOX TCM
4 4
BLK CAN CABLE 4-1 L BLK CAN CABLE 4 L
HARNESS
SENSOR
5 5
BOOM ANGLE
REAR CHASSIS
RED CAN CABLE 4-1 H RED CAN CABLE 4-1 H
TH417 BOOM EXTENSION LIMIT

6 6
CAB ROOF, RIDE & FLOAT & BOOM EXT LIMIT

F
B
C
A
G
H
D
Cab Roof, Ride, Float and Boom Extend LImit 9.8.2
Electrical System
MAM3800G
F
B
C
A
G
H
1
1
K5
K3
IGN
K7
K6
K4
K2
RELAY
PWR 2
K1
IGN
IGN
START
RELAY
RELAY
WORK
RELAY
RELAY
PWR 3
PWR 1
RELAY
LIGHTS
ALARM
K8
REVERSE
FUEL
RELAY
XQ
DIAGNOSTIC
CONNECTOR
FLASHER
4
3
2
1
49a
C2
31
49
87a
87a
87a
87a
87a
87a
87a
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
D1
D14
2
2
X178
KEY 1
1
KEY 1
1 2
KEY 1
2 3
KEY 1
XA
3 4
KEY 1
4 5
KEY 2
BAT POSITIVE
5 6
XC
KEY 2
7
KEY 2
8
KEY 2
9
KEY 2
10
TX
11
RX
12
X179
LIGHTS BAT 1
1
LIGHTS BAT 2
2
RADIO
3
LEFT HI BEAM
4
LEFT LO BEAM
5
EMPTY
1 6
FRONT WIPER
2 7
AC OUT
XD
3 8
3
3
AC IN
XB
4 9
RIGHT HI BEAM
5 10
RIGHT LO BEAM
BAT NEGATIVE
6 11
LEFT SIDE LIGHT
12
RIGHT SIDE LIGHT
13
FAN
14
REAR/ROOF WIPER
15
X190
LOW BEAMS IN
1
SIDE LIGHTS IN
2
RIGHT SIDE LIGHT
3
LEFT SIDE LIGHT
4
EMPTY
5
FLASHER
6
FLASHER 49
7
FLASHER 49a
XF
8
FLASHER C2
9
BRAKE LIGHTS
10
FRONT WORKLIGHTS
11
REAR WORKLIGHTS
12
BOOM WORKLIGHTS
13
BEACON
14
HIGH BEAM IN
15
4
4
X181
CONTROLLER
1
CONTROLLER
2
CONTROLLER
3
EMPTY
4
DISPLAY PWR
5
KEYPAD PWR
6
LSI DISPLAY PWR
7
XG
JOYSTICK PWR
8
REVERSE ALARM
9
REVERSE ALARM RELAY
10
FUEL RELAY
11
K2 87
12
FUEL PUMP
13
FRONT WASHER GND
14
K8 30
15
X189
EMPTY
1
SPARE BAT
2
AUX FUNCTION PWR
3
KEY BAY (EMS)
4
5
5
KEY SIGNAL IN
5
FUEL VALVE
6
K2 30
7
XH
F29, K8 87a
8
K2 86
9
K2 85
10
K2 87a
11
SEAT
12
POWER SOCKET
13
REAR WASHER GND
14
GND
15
X183
GND
1
GND
2
GND
3
GND
4
GND
5
GND
6
GND
7
GND
8
XK
GND
9
GND
10
GND
11
GND
6
6
12
GND
13
GND
14
GND
15
X188
GND
1
GND
2
GND
3
GND
4
GND
5
GND
6
GND
7
XL
GND
8
GND
9
GND
10
GND
11
GND
12
GND
13
GND
14
GND
15
X186
D8
7
7
1
D9
2
D10
3
D11
F11
XM
F24
F29
F13
F12
F08
F16
F27
F18
F02
F22
F23
F09
F30
F28
F20
F15
F21
F17
F19
F14
F10
F26
F25
F06
F07
F04
F05
F01
F03
4
D12
5
5A
D13
15A
30A
15A
15A
15A
15A
15A
15A
25A
10A
15A
15A
15A
15A
15A
15A
15A
15A
15A
10A
20A
20A
7.5A
7.5A
7.5A
7.5A
7.5A
7.5A
7.5A
6
AC
FAN
X187
SEAT
FUEL
KEY 2
KEY 1
RADIO
1
KEY BAT
BEACON
D2
FLASHER
2
REAR WIPE
LIGHTS BAT 2
LIGHTS BAT 1
3
LEFT HI BEAM
CONTROLLER
FRONT WIPER
LEFT LO BEAM
BRAKE LIGHTS
RIGHT HI BEAM
D3
AUX FUNC PWR

RIGHT LO BEAM
POWER SOCKET
4
REVERSE ALARM
FRT WORKLIGHTS
LEFT SIDE LIGHTS
DISPLAY/JOYSTICK
DPF SOOT SENSOR
RIGHT SIDE LIGHTS
REAR WORKLIGHTS
5
BOOM WORKLIGHTS
D4
6
XP
7
D5
8
9
D6
10
11
D7
12
8
8
POWER DISTRIBUTION BOARD

F
B
C
A
G
H
D
Power Distribution Board 9.8.3
Electrical System
9.8.4
1 2 3 4 5 6 7 8
ORG 078-3
1
SN690
GENERIC
GENERIC
H H
HV787
S689 BLK 000-71-1-1
2
WHT 092-1
1
GENERIC
PUMP DISP
G G
HV783
BLK 000-71-1-2
2
WHT 091-4
1
GENERIC
TRANS 1ST
HV782
BLK 000-71-1-3
2
WHT 091-5
1
GENERIC
TRANS 2ND
F F
HV781
BLK 000-71-3-1
2
S789 WHT 091-6
1
GENERIC
TRANS 3RD
Transmission and Reverse Fan
HV785
BLK 000-71-3-2
2
BLK 000-71-1 WHT 091-2
1
GENERIC
TRANS FH
CO678-J2
BLK 000-71 S687 BLK 000-71-3
1 12
WHT 093-1
1 2 11
BLK 000-70-1 BLK 000-70 BLK 000-71-2 S688

E 2 3 10 HV784
E
S748 BLK 000-71-2-1
HV747 4 9 2
GENERIC
WHT 091-6 WHT 091-3
FAN SPEED
5 8 1
GENERIC
WHT 091-5
TRANS REV
6 7
WHT 091-4
7 6
WHT 091-3
8 5 HV786
WHT 091-2 BLK 000-71-2-2
9 4 2
WHT 091-1 WHT 091-1
10 3 1
GENERIC
TRANS FL
WHT 093-1
11 2
WHT 093-2 WHT 093-2 WHT 092-1
1 12 1
BLK 000-70-2
2 CO678-J5
HV746
GENERIC
FAN REVERSE
D CO678-J4
D
1
2
RED 1-7 CAN CABLE H
3
BLK 1-7 CAN CABLE L
4
SHLD 1-7 CAN CABLE S
5
6
7
TCM
8
X262 CO678-J1 SN816

C BLK 000-84 BLK 000-84 C
1 1 12 2
BLK 000-42 1.5mm² WHT 098-1-1 WHT 098-1 INTERCOOLER AIR TEMP
2 2 11 1
YEL 062-9-5-1 WHT 098-1-2 S820
3 3 10
ORG 078-3 BLK 000-42 1.5mm²
4 4 9 SN813
RED 1-7 CAN CABLE H YEL 062-9-5-1 WHT 097-1-1 WHT 097-1
5 5 8 1 TRANSMISSION FLUID TEMP
BLK 1-7 CAN CABLE L RED 1-6 CAN CABLE H WHT 097-1-2 S815
6 6 7
BLK 1-6 CAN CABLE L BLK 000-83
7 7 6 SN817
SHLD 1-6 CAN CABLE S WHT 096-1-1 WHT 096-1
8 8 5 1
SHLD 1-7 CAN CABLE S WHT 096-1-2 S822 BLK 000-83 HYDRAULIC FLUID TEMP
9 9 4 2
RED 1-6 CAN CABLE H
TO ENGINE HARNESS
10 10 3
BLK 1-6 CAN CABLE L
11 11 2
SHLD 1-6 CAN CABLE S
12 12 1
CO678-J3
B B
WHT 096-1-2
WHT 098-1-2
WHT 098-1-2
WHT 097-1-2
WHT 097-1-2
WHT 096-1-2
1
2
1
2
1
2
X1075
X1078
1
2
1
2
1
2
X1079 X1079
X1075
X1078
A A
499ohm
499ohm
499ohm
TRANSMISION & REVERSE FAN
1 2 3 4 5 6 7 8
MAM3810G
Electrical System
9-21
9-22
9.8.5
1 2 3 4 5 6 7 8
BOOM HEAD HARNESS FRONT FRAME, BOOM & OPTIONS

TH414, TH514, & TH417
FRAME TO BOOM HARNESS REAR OF BOOM INSIDE BOOM HEAD WITHOUT PLATFORM ONLY
H X200 X201
H
TH414, TH514, & TH417 AUX 1/2 VALVE, FRAME LEVEL/STAB
A A
WITHOUT PLATFORM ONLY VALVE, DIVERTER, AUX
B B
GRN 070-3-1 1.5mm²
X78 C C 1
GRN 081-1 BLK 000-17-3 2.5mm² BLK 000-17-3 2.5mm² BLK 000-17-1 1.5mm²
1 HV255-UP D D 2
TO CAB GRN 082-1 GRN 081-2 S294
2 1 E E HV203
HARNESS YEL 063-22 BLK 000-34-1
(SH4 C2) 3 2 F F
1
2
1
2
1
2
1
2
1
2
1
2
1
2
BLK 000-34
4 HV255-DN G G
S283 GRN 082-2
1 H H
BLK 000-34-2
2 J J
HV237-SPD
HV237-FL-LT
HV237-FL-RT
HV237-LS-UP
HV237-LS-DN
HV237-RS-UP
HV237-RS-DN
GRN 070-3-4 GRN 070-3-4
K K
VALVE, TOW HITCH

GRN 070-3-5 TO TO GRN 070-3-5 S295
X404 L L
GRN 031-1
GRN 032-1
GRN 033-1
GRN 034-1
GRN 069-1
GRN 068-1
GRN 070-4
WHT 058-5
GRN 070-3-1 1.5mm² S274 BOOM BOOM VALVE, QUICK COUPLER
1
BLK 000-23-1
BLK 000-23-2
BLK 000-22-1
BLK 000-22-2
BLK 000-22-3
BLK 000-22-4
MHARNESS HARNESSM
GRN 055-1-1 1.5mm² GRN 055-1-4 GRN 055-1-4 GRN 055-1-1 1.5mm²
3 N N 1
BLK 000-17-1 1.5mm² S273 GRN 055-1-5 GRN 055-1-5 S296 BLK 000-16-1 1.5mm²
2 P P 2
S278 BLK 000-16-1 1.5mm²
4 R R HV202 X54
S272 WHT 065-6
S S 1
ORG 065-1
T T 2
ORG 065-2
U U 3
GRN 068-1
V V 4
GRN 069-1
W W 5
S240
G GRN 033-1
G
X X 6
GRN 034-1
Electrical System
7
GRN 031-1
8
GRN 032-1
9
10
GRN 070-4
11
WHT 058-5
12
GRN 082-2
YEL 063-22-2
BLK 000-34-3
GRN 082-1
GRN 081-2
YEL 063-22-1
BLK 000-34-4
GRN 081-1
BLU 071-11
13
AUX 1/2 BLU 071-12
5
3
4
2
1
5
3
4
2
1
14
RL263
RL277
VALVE, DIVERTER, AUX BLU 071-13
HV203 15
1 BLK 1.5mm² BLU 071-14
1 16
87
30
85
86
87
30
85
86
2 BLK 1.5mm² BLU 075-9-4
87a
87a
2 BOOM HARNESS 17 TO
BLU 071-16
18 CAB
BLU 071-3-3 HARNESS
19
BLU 071-4-6 (SH2 A6)
20
YEL 062-9-4
RELAY, SPDT, 12V, 20/40 AMP RELAY, SPDT, 12V, 20/40 AMP X204 21
1 BLK 1.5mm²
1 22
2 BLK 1.5mm² VALVE, QUICK COUPLER
2 HV202 23
3 BLK 1.5mm² 3 BLK 1.5mm²
TOW HITCH HARNESS 3 1 24
GRN/YEL 1.5mm² GRN/YEL 1.5mm²
4 2 25
F OPTION 2 SECTION M/C 26
F
27
28
29
LIGHT, WORKLIGHT
30
BOOM, LEFT
X206 S284 31
BLU 071-8 1.5mm² BLU 071-8-1
1 1 32
BLK 000-16-2 1.5mm² BLK 000-16-3 S239 BLK 000-19-2
2 2 33
S285 BLK 000-20 1.5mm²
LB275 34
BLK 000-21 1.5mm²
35
BLK 000-22
BOOM LIGHTS HARNESS 36
BLK 000-23
ALL MACHINES 37
RIGHT STABILIZER LEFT STABILIZER
Front Frame and Boom Options
SWITCH, PROX SWITCH, PROX

RIGHT STABILIZER LEFT STABILIZER
LIGHT, WORKLIGHT
SWITCH, PRES SWITCH, PRES
BOOM, RIGHT
+ - + - BLU 071-8-2
1
BLK 000-16-3
2
BLK 000-20 1.5mm²

BLU 071-14
BLU 071-13
BLU 071-16
BLU 071-4-6
BLK 000-21 1.5mm²
BLU 071-12
BLU 071-11
BLU 075-9-4
BLU 071-3-3
ORG 065-1
BLK 000-23-3
ORG 065-2
BLK 000-23-4
BLK 000-19-2
WHT 065-6
YEL 062-9-4
LB276
1
2
3
4
5
6
1
2
3
4
5
6
1
2
1
2
A
B
LB236
LB235
A
B
C
2
1
3
2
1
3
A
B
C
SN234
V238-CB
V238-AW
E E
SN365
SN372
SN371
EC366
LGR 032-2
LGR 034-2
LGR 032-2
LGR 034-2
-
WHT 032-1
+
WHT 034-2
YEL 063-25-2
BLK 000-44-4
BLK 000-44-3
YEL 063-25-1
VALVE, STEER SELECT
SWITCH, PROX, AXLE
FRONT AXLE
LOW
LOW
SIDE
SIDE
HIGH
HIGH
TURN
TURN
LIGHT, RIGHT HEADLIGHT LIGHT, LEFT HEADLIGHT
LARGE FRAME FRONT HARNESS

TH414, TH514, & TH417
X35
WHT 034-2
1
WHT 032-1
D 2 X54 D
WHT 065-6
3 1
ORG 065-1
4 TO CAB 2
HARNESS ORG 065-2
S370 5 3
YEL 063-25 (SH2 H8)
6 4
BLK 000-44
7 5
S369 8 6
9 7
TH514 & TH417 FRAME STABILIZER HARNESS
8
9
10
11
BOOM HEAD HARNESS
TH414, TH514, & TH417 12
PLATFORM HARNESS BLU 071-11
CAB TO BOOM HARNESS WITH PLATFORM ONLY TH414, TH514, & TH417 13
1
2
3
4
5
6
A
B
C
WITH PLATFORM ONLY BLU 071-12

TH414, TH514, & TH417 BOOM HEAD BOOM HEAD 14
WITH PLATFORM ONLY REAR OF BOOM BOOM HARNESS BLU 071-13
X219
15
PLATFORM CONSOLE
LB23X-1
BLU 071-14
X200 X200 X201 X201 X289 X289 X290 16
HARNESS
TO FRONT
BLU 075-9-4
A A A A A A A 17
RED 12AWG RED 12AWG RED 12AWG YEL 061-5 2.5mm² YEL 061-5-1 2.5mm² RED 12AWG RED 12AWG BLU 071-16
B B B B B B B 18
S291 BLU 071-3-3
BLK 000-X-1
BLK 000-X-2
BLU 071-X-1
BLU 071-X-2
C C C C C C C 19 TO
BLU 071-X-3-1
BLU 071-X-4-1
BLU 071-X-4-2
BLU 071-X-3-2
BLK 12AWG BLK 12AWG BLK 12AWG BLK 000-48 2.5mm² BLK 000-48-1 2.5mm² BLK 12AWG BLK 12AWG BLU 071-4-6 CAB
D D D D D D D 20
C BLK/WHT 12AWG BLK/WHT 12AWG BLK/WHT 12AWG BLK 063-7-5 2.5mm² S386 BLK 063-7-5 2.5mm² BLK/WHT 12AWG BLK/WHT 12AWG YEL 062-9-4 HARNESS C
X36 E E E E E E E 21 (SH2 A6)
RED 12AWG YEL 18AWG YEL 18AWG YEL 18AWG WHT 049-5 WHT 049-5 YEL 18AWG YEL 18AWG
1 F F F F F F F 22
YEL 18AWG ORN 12AWG ORN 12AWG ORN 12AWG YEL 062-4 2.5mm² YEL 062-4 2.5mm² ORN 12AWG ORN 12AWG
2 G G G G G G G 23
BRN 18AWG BRN 18AWG BRN 18AWG BRN 18AWG WHT 049-12 WHT 049-12 BRN 18AWG BRN 18AWG
3 H H H H H H H 24
RED/BLK 18AWG RED/BLK 18AWG RED/BLK 18AWG RED/BLK 18AWG YEL 062-5 YEL 062-5 RED/BLK 18AWG RED/BLK 18AWG
4 J J J J J J J 25
S312
BLU 18AWG BLU 18AWG BLU 18AWG BLU 18AWG GRN 070-3-4 BLU 18AWG BLU 18AWG
5 K K K K K K K 26
BLU/BLK 18AWG BLU/BLK 18AWG BLU/BLK 18AWG BLU/BLK 18AWG GRN 070-3-5 S292 BLU/BLK 18AWG BLU/BLK 18AWG TO
6 L L L L L L L 27
S346
BLK 12AWG PLATFORM

7 M M M M M M M BOX 28
ORN 18AWG ORN 18AWG ORN 18AWG ORN 18AWG GRN 055-1-4 ORN 18AWG ORN 18AWG
8 N N N N N N N (SH11 G8) 29
ORN/BLK 18AWG ORN/BLK 18AWG ORN/BLK 18AWG ORN/BLK 18AWG GRN 055-1-5 S293 120 %%185 ORN/BLK 18AWG ORN/BLK 18AWG
9 P P P P P P P 30
BLK/WHT 12AWG CAN 2
10 R R R R R R R 31
S311
11 S S S S S S S 32
CAN CABLE H 8 0.75mm² CAN CABLE H 8 0.75mm² CAN CABLE H 8 0.75mm² CAN CABLE H 8 0.75mm² S244 BLK 000-19-2
12 T T T T T T T 33
CAN CABLE L 8 0.75mm² CAN CABLE L 8 0.75mm² CAN CABLE L 8 0.75mm² CAN CABLE L 8 0.75mm² BLK 000-20 1.5mm²
13 U U U U U U U 34
CAN CABLE SHLD 8 0.75mm² CAN CABLE SHLD 8 0.75mm² CAN CABLE SHLD 8 0.75mm² CAN CABLE SHLD 8 0.75mm² BLK 000-21 1.5mm²
14 V V V V V V V 35
ORN 12AWG
15 W W W W W W W 36
YEL/BLK 18AWG YEL/BLK 18AWG YEL/BLK 18AWG YEL/BLK 18AWG WHT 049-6 YEL/BLK 18AWG YEL/BLK 18AWG BLK 000-23
16 X X X X X X X 37
B B
HV203
BLK 000-X 1.5mm²
BLU 071-X-1
BLU 071-X-2
BLU 071-X-3
BLU 071-X-4
BLK 000-20 1.5mm²
BLU 071-14
BLU 071-13
BLU 071-16
BLU 071-4-6
BLK 000-21 1.5mm²
BLU 071-12
BLU 071-11
BLU 075-9-4
BLU 071-3-3
ORG 065-1
BLK 000-23-3
ORG 065-2
BLK 000-23-4
BLK 000-19-2
WHT 065-6
YEL 062-9-4
GRN 070-3-1 1.5mm²

1
BLK 000-48-2 1.5mm² VALVE, DIVERTER, AUX
2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
1
2
A
B
LB236
LB235
LB23X
SN234
AUX 1/2
V292-UP
V292-DN
HV202
GRN 055-1-1 1.5mm²
1 - +
BLK 000-48-3 1.5mm² VALVE, QUICK COUPLER
2 VALVE, STEER SELECT
SWITCH, PROX, AXLE
GENERIC
LOW
LOW
LOW
SIDE
SIDE
SIDE
HIGH
HIGH
HIGH
TURN
TURN
TURN
LIGHT, RIGHT HEADLIGHT LIGHT, RIGHT HEADLIGHT LIGHT, LEFT HEADLIGHT SMALL FRAME FRONT HARNESS
+
TH406 & TH407

X227 X227 SN226
BLK 000-48-4 BLK 000-48-4
2 2 B
YEL 061-5-2 YEL 061-5-2
1 1 A
WHT 049-6 WHT 049-6 HEADLIGHT EXTENSION
3 3 C
406/407 AG MACHINES
-
A HARNESS, PLAT REC

WITH FORWARD POSITION
A
SWITCH, PROX, PLAT REC
HEADLIGHTS
PLATFORM RECOGNITION
TH414, TH514, & TH417
AUSTRALIA ONLY FRONT FRAME, BOOM & OPTIONS
1 2 3 4 5 6 7 8
MAM3820G

9.8.6
1 2 3 4 5 6 7 8
H H
SENSOR, FUEL LEVEL SENDER SENSOR, ANGLE, BOOM REAR AXLE
SENSOR, LSI
SWITCH, PROX, AXLE
VALVE, MAIN CONTROL
LIFT LIFT TELE TELE TILT TILT AUX AUX

UP DN IN OUT UP DN 1 2 + -
-V
+V
LIN BUS
SENSOR,
YY%%185
Full: XX%%185
Empty:
ANGLE BOOM
(PLATFORM ONLY)
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
3
4
5
6
1
2
3
A
B
C
B
A
C
1
2
SN220
SN219
SN213
SN233
SN218
Rear Frame
HV214-TI
HV214-A1
HV214-A2
HV214-LU
HV214-LD
HV214-TU
HV214-TD
HV214-TO
GRY 047-2
GRN 003-1
GRN 004-1
GRN 013-1
GRN 014-1
GRN 025-1
GRN 026-1
GRN 070-7
GRN 070-2
GRN 078-1
WHT 065-7
BLK 058-6-2
BLK 058-6-1
WHT 058-2-1
WHT 058-2-2
WHT 058-3-1
WHT 058-3-2
WHT 058-1-1
WHT 058-1-2
WHT 058-4-1
WHT 058-4-2
YEL 062-12-4
BLK 000-13-2
YEL 062-12-1
YEL 062-12-2
BLK 000-13-1
BLK CAN CABLE L 2-3

RED CAN CABLE H 2-3
BLK SENSOR CABLE 1
BLU SENSOR CABLE 1
RED SENSOR CABLE 1
G SENSOR, LSI
G
SENSOR, ANGLE, BOOM
REAR AXLE
S208
S212
S207
CAN 2
S216
SENSOR, FUEL LEVEL SENDER
120 OHM
VALVE, MAIN CONTROL SWITCH, PROX, AXLE
X34
GRN 025-1
1 AUX 2
-V
+V
LIN BUS
GRN 026-1 LIFT LIFT TELE TELE TILT TILT AUX AUX
2 UP DN IN OUT UP DN 1 2 + -
WHT 058-1
3
GRN 003-1
4
A
B
C
Empty: YY%%185
Full: XX%%185
GRN 004-1
5
WHT 058-2
TO 6
SN213
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
3
2
1
3
CAB GRN 014-1

7
HARNESS GRN 013-1
8
SN218
SN219
SN233
(SH2 C1)
WHT 058-3
HV214-TI
HV214-A1
HV214-A2
HV214-LU
HV214-LD
HV214-TU
HV214-TD
HV214-TO
9
GRN 070-7
10
GRN 070-2
11
SHLD CAN CABLE 2-3

GRY 047-2
GRN 003-1
GRN 004-1
GRN 013-1
GRN 014-1
GRN 025-1
GRN 026-1
GRN 070-7
GRN 070-2
GRN 078-1
WHT 065-7
WHT 058-4
BLK 058-6-1
12
WHT 058-2-1
WHT 058-2-2
WHT 058-3-1
WHT 058-3-2
WHT 058-1-1
WHT 058-1-2
WHT 058-4-1
WHT 058-4-2
BLK 000-13-2
YEL 062-12-1
YEL 062-12-2
BLK 000-13-1
BLK 058-6
13
BLK SENSOR CABLE 1
BLU SENSOR CABLE 1
RED CAN CABLE H 2-3

RED SENSOR CABLE 1
SHIELD SENSOR CABLE 1

14
BLK CAN CABLE L 2-3
15
SHLD CAN CABLE 2-3
F 16 F
S318
S319
S320
S317
X33
GRY 047-2 S311
1 X34
BLK 000-13 GRN 025-1
2 1
GRN 078-1 S231 GRN 026-1
3 2
WHT 065-7 WHT 058-1
4 X204 3
GRN 070-3-1 1.5mm² GRN 070-3-1 1.5mm² GRN 003-1
5 1 4
BLU 008-3 BLK 000-17-1 1.5mm² GRN 004-1
6 2 BOOM HEAD AUX 5
BLU 071-1 1.5mm² GRN 055-1-1 1.5mm² WHT 058-2
7 3 (SH8 F3) TO 6
BLU 071-2 BLK 000-16-1 1.5mm² CAB GRN 014-1
8 4 7
BLU 071-3-1 S230 HARNESS GRN 013-1
TO 9 (SH2 C1) 8
CAB BLU 071-4-1 WHT 058-3
10 9
HARNESS BLU 071-5 1.5mm² GRN 070-7
(SH2 B8) 11 10
RED SENSOR CABLE 1 GRN 070-2
12 11
BLK SENSOR CABLE 1 WHT 058-4
13 12
BLU SENSOR CABLE 1 BLK 058-6-1
SHIELD SENSOR CABLE 1
14 13
BLU 071-8 1.5mm²
15 14
+
GRN 055-1-1 1.5mm²
16 SN205 SN205 SN205 15
BLU 071-9 BLK 000-13-3 BLK 000-13-3

E 17 2 2 2 16
E
SHIELD SENSOR CABLE 1 YEL 062-12-3 YEL 062-12-3 YEL 063-4-1
18 1 1 1
GRN 049-13 GRN 049-13 GRN 070-5
19 3 3 3
YEL 062-12 BOOM RETRACT
20 X33
SWITCH, PROX
-
BOOM RETRACT
BLK 000-15 S232 YEL 062-12-1 EXTENSION GRY 047-2
21 1
BLK 000-24 YEL 062-12-2 TH417 ONLY BLK 000-13
22 BOOM RETRACTED 2
BLK 000-16 1.5mm² YEL 062-12-4 SENSOR GRN 078-1 S333
23 X206 3
BLK 000-17-1 1.5mm² BLU 071-8 1.5mm² (PLATFORM STANDARD) WHT 065-7
24 1 4 X204
BLK 000-16-2 1.5mm² GRN 070-3-1 1.5mm² GRN 070-3-1 1.5mm²
2 BOOM WORKLIGHTS 5 1
BOOM
S221
S222
(SH8 E3) BLU 008-3 BLK 000-17-1 1.5mm²
6 2 HEAD
BLU 071-1 1.5mm² GRN 055-1-1 1.5mm² AUX
7 3
S220
BLU 071-2 1.5mm² BLK 000-16-1 1.5mm² (SH8 F3)
8 4
BLU 071-3-1 1.5mm² S332
9
BLU 071-4-1 1.5mm²
TO 10
S224
S227
S228
CAB BLU 071-5 1.5mm²
11
HARNESS RED SENSOR CABLE 1
(SH2 B8) 12
BLK SENSOR CABLE 1 BOOM RETRACT
13
BLU SENSOR CABLE 1 SENSOR
14 (NOT CONFIGURED)
BLU 071-8 1.5mm²
15
GRN 055-1-1 1.5mm²
D 16 X205 D
BLU 071-9 BLK 000-13-3
17 2
SHIELD SENSOR CABLE 1 YEL 062-12-3 YEL 062-12-3
18 1
GRN 049-13 GRN 049-13
19 3
YEL 062-12 YEL 062-12-1
20
BLK 000-15 S334 YEL 062-12-2
21
BLK 000-24
22
BLK 000-16 1.5mm²
23
BLK 000-17 1.5mm²
24
S327
S229
S324
BLU 071-9-1
BLU 008-3-1
BLU 071-1-1
BLU 071-5-1
BLU 071-4-1
BLK 000-24-1
BLU 071-3-1
BLU 071-5-2
BLU 071-2
BLU 008-3-2
BLU 071-9-2
BLK 000-15-1
BLU 071-1-3
BLK 000-15-2
BLU 008-3-3
BLK 000-24-2
S323
X206
BLU 071-8 1.5mm²
1
7
6
5
4
3
2
1
7
6
5
4
3
2
1
1
2
1
2
LB209
LB210
LB211
AH215
BLK 000-16-2 1.5mm²
2
S325
BOOM WORKLIGHTS
(SH8 F3)
LIGHT, LICENSE ALARM, BACK-UP

S330
S328
S326
S322
LARGE FRAME REAR HARNESS

C TH414, TH514, & TH417 C
TAIL
TAIL
FOG
FOG
STOP
BACK
STOP
BACK
TURN
TURN
LIGHT, TAIL LIGHT, RIGHT LIGHT, TAIL LIGHT, LEFT
S329
BLU 071-3-7 1.5mm²

BLU 071-9-3 1.5mm²
BLK 000-17-2 1.5mm²
BLU 071-4-5 1.5mm²
BLU 071-1-2 1.5mm²
BLU 071-5-3 1.5mm²
BLU 071-2-2 1.5mm²
X321
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
X321
BLU 071-9-1
BLU 008-3-1
BLU 071-1-1
BLU 071-5-1
BLU 071-4-4
BLK 000-24-1
BLU 071-3-6
BLU 071-5-2
BLU 071-2-1
BLU 008-3-2
BLU 071-9-2
BLK 000-15-1
BLU 071-1-3
BLK 000-15-2
BLU 008-3-3
BLK 000-24-2
7
6
5
4
3
2
1
7
6
5
4
3
2
1
1
2
1
2
LB209
LB210
LB211
AH215
B B
LIGHT, LICENSE ALARM, BACK-UP

TAIL
TAIL
FOG
FOG
STOP
BACK
STOP
BACK
TURN
TURN
TRAILER SOCKET HARNESS LIGHT, TAIL LIGHT, RIGHT LIGHT, TAIL LIGHT, LEFT
BLU 071-3-7 1.5mm²
BLU 071-9-3 1.5mm²
BLK 000-17-2 1.5mm²
BLU 071-4-5 1.5mm²
BLU 071-1-2 1.5mm²
BLU 071-5-3 1.5mm²
BLU 071-2-2 1.5mm²
1
1
1
1
1
1
1
MS321-1
MS321-2
MS321-3
MS321-4
MS321-5
MS321-6
MS321-7
SMALL FRAME REAR HARNESS

TH406 & TH407
A A
TRAILER CONNECTOR
REAR FRAME
1 2 3 4 5 6 7 8
MAM3830G
Electrical System
9-23
9-24
9.8.7
1 2 3 4 5 6 7 8
GENERIC
GENERIC
OIL,PRES,SW
GENERIC COLD START ADV SOL GENERIC SW,TEMP,WATER SW,PRES,AIR FILTER
GENERIC FUEL PUMP FUEL,SOL GENERIC ENGINE CONTROLLER
ALTERNATOR GENERIC
M
ALTERNATOR ALTERNATOR
H H
B+
D+
W
B+
D+
W
GND
1
1
1
2
1
1
2
A
B
A
B
C
1 GND
1
1
2
1 GND
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
1 GND
1
1
1
1
1
1
T939
T568
T928
T543
EC549
X1157
EC545
EC546
EC547
SN550
CO577
SN551-1
SN551-2
EC567-W
EC567-GND
EC567-B+
EC567-D+
EC544-GND
EC544-W
EC544-B+
EC544-D+
BLK 058-8
YEL 057-1
BLK 000-41
RED 001-16
GRY 048-3
GRY 048-24
GRY 048-21
GRY 048-31
GRY 048-12-1
X772
GRY 048-11
GRY 048-16
YEL 085-4-1
YEL 062-9-5-1
WHT 085-2-1
BLK 000-43-1
BLK 000-43-2
BLK 000-43-3
BLK 000-52-1
BLK 000-52-2
BLK 000-52-3
BLK 000-52-4
BLK 000-52-5
BLK 000-62-1
GRY 048-12-1
GRY 048-18-1
RED 061-14-1
RED 061-14-2
RED 061-14-3
RED 061-14-4
1
BLK 000-41-1
BLK 000-69 2AWG
GRY 048-18
RED 001-5-1 2AWG
YEL 085-4-1
BLK 000-69 2AWG

BLK 000-69 2AWG
GRY 048-18-1
2
BLK 000-53 4mm²

BLK 000-54 4mm²
BLK 000-55 4mm²
BLK 000-56 4mm²
BLK 000-53 4mm²
BLK 000-54 4mm²
BLK 000-55 4mm²
BLK 000-56 4mm²
WHT 085-2-1 GRY 048-23 6mm²
BLK 000-69 2AWG

3 STARTER S TERM 1
BLK TWISTED PAIR 2
BLK CAN CABLE L 1-7
RED 001-5-1 2AWG

WHT TWISTED PAIR 2
RED CAN CABLE H 1-7

BLK 000-62-1
4 T933
X937
RED 001-5-2 2AWG 150A
STARTER B+ TERM 1 1 1
T572 IP938 X936
X106 X106
BLK 000-53 4mm² BLK 000-53 4mm²
1 1
BLK 000-54 4mm² BLK 000-54 4mm²
2 2
S597
BLK 000-55 4mm² BLK 000-55 4mm²
3 3
BLK 000-56 4mm² BLK 000-56 4mm²
4 4
G G
S576
S579
Electrical System
X110 X110
RED 001-1 4mm² RED 001-1 4mm²
BLK 058-8-1
BLK 058-8-2
1 1
RED 001-2 4mm² RED 001-2 4mm²
2 2
RED 001-3 4mm² RED 001-3 4mm²
3 3
RED 001-4 4mm² RED 001-4 4mm²
4 4
X32 X32
1 1 T759
BLK 000-52 4mm²
2 2 1 GND
3 3
BLK 058-8-1 BLK 000-59-1
4 4 T935
YEL 062-9-5 YEL 062-9-5 BLK 000-73
5 5 1 GND
YEL 057-1 BLK 000-59
6 6
GRY 048-21
7 X922 T929 7
GRY 048-18 RED 001-5-1 2AWG 150A RED 001-5-2 2AWG
8 1 1 1 STARTER B+ TERM 8
BRN 073-9 BRN 073-9-1 IP925 BRN 073-9 BRN 073-9 BRN 073-9-1
9 X923 9
S921 BRN 073-9-2 S934 BRN 073-9-2
10 X542 10
GRY 048-23 6mm²
F 11 1 STARTER S TERM 11 F
12 12 X262
YEL 062-9-5-1
13 X262 13 1
GRY 048-3 BLK 000-42 1.5mm²
14 1 14 2
GRY 048-24 BLK 000-42 1.5mm² YEL 062-9-5 YEL 062-9-5-2 YEL 062-9-5-2
15 2 15 3
YEL 062-9-5 S598 ORG 078-3
16 3 16 4
ORG 078-3 ORG 078-3 ORG 078-3 RED CAN CABLE H 1-7
17 4 17 5
GRY 048-11 GRY 048-11 BLK CAN CABLE L 1-7
18 5 18 6
GRY 048-12-1 GRY 048-12-1
19 6 19 7
GRY 048-1 GRY 048-1
20 7 20 8
21 8 21 9
RED CAN CABLE H 1-6
BLK 000-43-3
22 9 22 10
RED CAN CABLE H 1-6 BLK CAN CABLE L 1-6
23 10 23 11
BLK CAN CABLE L 1-6 SHLD CAN CABLE 1-6
24 11 24 12
SHLD CAN CABLE 1-6
25 12 25
BLK 000-40 BLK 000-40
26 26
BLK 000-41 BLK 000-41
27 27
BLK 000-42 1.5mm² BLK 000-42 1.5mm²
28 28
BLK 000-43-1

TELEHANDER TH336 337 406 407 414 514 417C - CAT - Service

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TELEHANDER TH336 337 406 407 414 514 417C - CAT - Service

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TELEHANDER TH336 337 406 407 414 514 417C - CAT - Service

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What are the main components discussed in the manual?

What are the main components discussed in the manual?

What safety practices are outlined in the manual?

What safety practices are outlined in the manual?

Service Manual

October 8, 2012 - A - Original Issue Of Manual

31200799 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C i

ii TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 31200799

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C i

3.25 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

ii TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C iii

iv TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

PARAGRAPH TITLE PAGE

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.2 DISCLAIMER WARNING

1-2 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

1.7 SAFETY INSTRUCTIONS 1.7.3 General Hazards

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 1-3

1-4 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

PARAGRAPH TITLE PAGE

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-1

2.1 REPLACEMENT PARTS AND 2.2 THREAD LOCKING COMPOUND

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

Before ordering parts or initiating service inquiries, make

2-2 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-3

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

2-4 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-5

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

2-6 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-7

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-8 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-9

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-10 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C 2-11

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

2-12 TH336C, TH337C, TH406C, TH407C, TH414C, TH514C, TH417C

2.3.3 Hydraulic Hose Torque Chart Flats Method:

Note: By definition the “Flats Method“ will contain some