SUGGESTED MANPOWER,

FIXTURES,
TOOLS AND SUPPLIES
LETOURNEAU
MACHINE ASSEMBLY MANUAL
SECTION 4

Every effort has been made to make this manual as accurate as possible based on the information available
at the time of publication and printing. Continuous improvement and advancement of product design may
cause changes to machines which may not have been included in this publication. The company reserves the
right to make changes and improvements at any time. To ensure the most current information, please contact
your dealer representative.

TABLE OF CONTENTS
SUGGESTED MANPOWER, FIXTURES, TOOLS AND SUPPLIES .................................................................... 5
SUGGESTED MANPOWER REQUIREMENTS .................................................................................................... 5
MANPOWER AND HEAVY EQUIPMENT EXPENSE ESTIMATE CHART ....................................................... 5
EQUIPMENT AND PERSONNEL NEEDS – REAR FRAME ASSEMBLED .................................................. 5
EQUIPMENT AND PERSONNEL NEEDS – ENGINE AND REAR AXLE REMOVED .................................. 6
FIXTURES, TOOLS AND SUPPLIES .................................................................................................................... 7
COMPONENT POSITIONING EQUIPMENT ..................................................................................................... 7
HOISTING LIFTING TOOL/FIXTURE ................................................................................................................ 8
POWER & AIR REQUIREMENTS.................................................................................................................... 10
RECOMMENDED HAND TOOLS .................................................................................................................... 10
SPECIAL TOOLS/FIXTURES .......................................................................................................................... 12
POWER UNIT LIFTING FIXTURE ................................................................................................................... 12
JACK STANDS ............................................................................................................................................. 13
REAR AXLE LIFTING FIXTURE................................................................................................................... 13
PIN DEPTH MEASUREMENT TOOL ........................................................................................................... 13
MIDDLE PINION REMOVAL HUB - 57" PLANETARY DRIVE..................................................................... 13
MIDDLE PINION REMOVAL ARM - 57" PLANETARY DRIVE .................................................................... 13
HYDRAULIC CYLINDER .............................................................................................................................. 13
PRESSURE STRUCTURE BRAKE ACTUATOR ......................................................................................... 13
WRENCH STRUCTURE............................................................................................................................... 13
2-1/2" I.D. HEAVY PIPE APPROXIMATELY 5-FT. LONG ........................................................................... 13
HYDRAULIC TANK WITH TRANSFER PUMP/HOSING AND FILTRATION .............................................. 13
L-950 BUCKET CYLINDER LIFTING FIXTURE........................................................................................... 13
ADJUSTMENT BAR ..................................................................................................................................... 13
1-1/4" -7 ALL THREAD ................................................................................................................................. 13
BALL CAP INSTALLATION FIXTURES ........................................................................................................... 14
1/2" x 2" UNC FASTENER ............................................................................................................................ 14
1-1/4" - 7 x 24" GRADE 8 ALL-THREAD ...................................................................................................... 14
STUD FOR INSTALLATION OF MIDDLE PIVOT BALL CAPS - OPTIONAL .............................................. 14
REACTION STUD ......................................................................................................................................... 14
1-1/4" x 7 UNC TAP ...................................................................................................................................... 14
DIAL INDICATOR WITH MAGNETIC BASE ................................................................................................ 14
DIAL INDICATOR WITH REMOTE READOUT ............................................................................................ 14
LIFTING FIXTURES FOR LOWER MIDDLE PIVOT BALL CAP. ................................................................. 14
SAFETY EQUIPMENT ..................................................................................................................................... 14
FACE SHIELD WITH ATTACHING HEADGEAR ......................................................................................... 14
SAFETY GLASSES ...................................................................................................................................... 14
HARD HAT .................................................................................................................................................... 14
STEEL TOE BOOTS ..................................................................................................................................... 14
EAR PLUGS.................................................................................................................................................. 14
MASKS/RESPIRATORS............................................................................................................................... 15
LOADER ASSEMBLY MANUAL r00
COPYRIGHT 2012 4-1
GENERATION2
11/8/2012
DRAFT
LeTourneau
 LEATHER WORK GLOVES ......................................................................................................................... 15
WELDING GLOVES ..................................................................................................................................... 15
DIELECTRIC GLOVES WITH LINER ........................................................................................................... 15
KEVLAR TERRY CLOTH GLOVES ............................................................................................................. 15
NITRILE GLOVES ........................................................................................................................................ 15
FALL PROTECTION - SAFETY HARNESS AND LANYARD ...................................................................... 15
FLASHLIGHT ................................................................................................................................................ 15
AUXILIARY LIGHTING ................................................................................................................................. 15
AIR TOOL GROUP ........................................................................................................................................... 16
7" AIR DISC GRINDER WITH GRINDING WHEEL AND STEEL BRUSH WHEEL..................................... 16
4" AIR DISC GRINDER WITH GRINDING WHEEL, STEEL WIRE BRUSH AND ABRASIVE CLEANING
DISC .............................................................................................................................................................. 16
1/2", 3/4" AND 1" DRIVE IMPACT WRENCHES WITH A FULL RANGE OF SOCKETS ............................ 16
1-1/4" 12-POINT SOCKET 1" DRIVE IMPACT ............................................................................................ 16
1" 12-POINT SOCKET MODIFIED 1" DRIVE IMPACT ................................................................................ 16
1" DRIVE LONG EXTENSION - IMPACT ..................................................................................................... 16
3/8" AIR RATCHET ....................................................................................................................................... 16
AIR BLOW NOZZLES ................................................................................................................................... 16
AIR DIE GRINDER ....................................................................................................................................... 16
HAND-HELD AIR-POWERED GREASE GUN ............................................................................................. 16
TIRE INFLATION ADAPTER - FOR STANDARD SCHRADER VALVE ...................................................... 16
HALTEC MEGA-BORE INFLATION TOOL .................................................................................................. 17
SOCKET STRUCTURE ................................................................................................................................ 17
PAINT SPRAY GUN ..................................................................................................................................... 17
AIR CONDITIONING TOOLS ........................................................................................................................... 17
MANIFOLD AND GAUGE ASSEMBLY FOR R134A REFRIGERANT WITH ADAPTER ............................ 17
VACUUM PUMP WITH PROPER CONNECTIONS FOR R134A SYSTEM ................................................ 17
HYDRAULIC SYSTEM TEST INSTRUMENTS ................................................................................................ 17
HYDRAULIC GAUGE ASSEMBLY 0-4000 PSI............................................................................................ 17
204T HOSE WITH ATTACHMENT COUPLINGS ........................................................................................ 17
BUSHING ...................................................................................................................................................... 17
QUICK COUPLING, FEMALE X 1/4" FP ...................................................................................................... 17
QUICK COUPLING PLUG ............................................................................................................................ 17
GAUGE ......................................................................................................................................................... 17
RELIEF VALVE TEST FITTING.................................................................................................................... 17
TEE ............................................................................................................................................................... 17
REDUCER .................................................................................................................................................... 17
RDFA RELIEF VALVE TEST BLOCK ASSEMBLY ...................................................................................... 18
QUICK COUPLING CAP .............................................................................................................................. 18
QUICK COUPLING, MALE X 1/4" FP ........................................................................................................... 18
PIPE NIPPLE - 1/4" HEX .............................................................................................................................. 18
TEE, 1/4" FP ................................................................................................................................................. 18
ADAPTER, 1/4" MP X #8 MJ ........................................................................................................................ 18
RELIEF MANIFOLD, T3A ............................................................................................................................. 18
PRESSURE GAUGE - 0-4000 PSI ............................................................................................................... 18
ADAPTER, #8 MO X #8 MJ .......................................................................................................................... 18
O-RING, 3/8" ................................................................................................................................................. 18
GAUGE ASSEMBLY, 0-4000 PSI ................................................................................................................ 18
PIPE COUPLING - 1/4"................................................................................................................................. 18
ADAPTER, 1/4" MP X #4 MJ ........................................................................................................................ 18
QUICK COUPLING, FEMALE X 1/4" FP ...................................................................................................... 18
QUICK COUPLING PLUG ............................................................................................................................ 18
PRESSURE GAUGE - 0-4000 PSI ............................................................................................................... 18
HOSE ASSEMBLY, #4 X 224" ...................................................................................................................... 18
HUSCO RELIEF TEST BLOCK .................................................................................................................... 18
ELECTRONIC TEST INSTRUMENTS ............................................................................................................. 19
FLUKE TYPE 97 SCOPEMETER OR EQUIVALENT .................................................................................. 19
SIMPSON 260 MULTIMETER (OR EQUIVALENT) ..................................................................................... 19
LOADER ASSEMBLY MANUAL r00
4-2 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 FLUKE MODEL 189 MULTIMETER OR EQUIVALENT ............................................................................... 19
500V MEGGER - BIDDLE ............................................................................................................................ 19
REMOTE INTERFACE TESTER .................................................................................................................. 19
CUTTING AND WELDING EQUIPMENT ......................................................................................................... 19
ACETYLENE TORCH WITH CUTTING AND ROSEBUD TIPS ................................................................... 19
ARC WELDER .............................................................................................................................................. 19
WELDING HOOD ......................................................................................................................................... 19
MISCELLANEOUS ITEMS ............................................................................................................................... 19
ROPE ............................................................................................................................................................ 19
ALIGNMENT BARS - TAPERED .................................................................................................................. 19
PRY BARS .................................................................................................................................................... 19
TIRE SLING .................................................................................................................................................. 19
3- AND 6-FOOT LADDERS AND/OR MOBILE WORK PLATFORMS ......................................................... 19
10-FOOT MOBILE WORK PLATFORMS ..................................................................................................... 19
JUMP START ADAPTERS - TWO MODELS ............................................................................................... 20
GREASE GUN .............................................................................................................................................. 20
HEAT GUN.................................................................................................................................................... 20
LEVEL ........................................................................................................................................................... 20
SUPPLIES ........................................................................................................................................................ 20
LOCTITE RC569 THREAD LOCKING COMPOUND ................................................................................... 20
LOCTITE RC271 THREAD LOCKING COMPOUND ................................................................................... 20
LOCTITE BLUE SILICONE GASKET COMPOUND .................................................................................... 20
LOCTITE ANTI-SEIZE COMPOUND ........................................................................................................... 20
PLASTIC WIRE TIE WRAPS ........................................................................................................................ 20
BLACK TIE WRAP, 20" LONG ..................................................................................................................... 20
BLACK TIE WRAP, 14-1/2" LONG ............................................................................................................... 20
ABRASIVE DISCS ........................................................................................................................................ 21
EMERY CLOTH ............................................................................................................................................ 21
MEDIUM - 240 GRIT ..................................................................................................................................... 21
COARSE - 18O GRIT ................................................................................................................................... 21
EXTRA COARSE - 36 GRIT ......................................................................................................................... 21
PENETROX-A ELECTRIC JOINT COMPOUND .......................................................................................... 21
OIL ABSORBENT ......................................................................................................................................... 21
ISOPROPYL ALCOHOL ............................................................................................................................... 21
PADLOCK ..................................................................................................................................................... 21
LUBRICANTS and Fluids ................................................................................................................................. 21
30W MOTOR OIL ......................................................................................................................................... 21
NLGI #2 LITHIUM-BASED GREASE ............................................................................................................ 21
MOBY LUBE, SPRAY ................................................................................................................................... 21
GEAR OIL ..................................................................................................................................................... 21
ANTI-FREEZE............................................................................................................................................... 21
LUBRIPLATE WHITE GREASE ................................................................................................................... 21
HYDRAULIC OIL .......................................................................................................................................... 22
TIRE INSTALLATION........................................................................................................................................... 30
LINCS II INPUT SIMULATOR BOX (VCU VIA THE DIGITAL BOARD) .............................................................. 33
3-PIN CONNECTOR ........................................................................................................................................ 34
LEDS ................................................................................................................................................................ 34
FOUR POSITION SWITCH .............................................................................................................................. 35
+24V SWITCH POSITION ............................................................................................................................ 35
4-20mA SWITCH POSITION ........................................................................................................................ 36
FREQUENCY SWITCH POSITION .............................................................................................................. 36
GROUND SWITCH POSITION..................................................................................................................... 37
INSTRUCTIONS FOR USE OF THE INPUT SIMULATOR BOX ..................................................................... 37
4-20mA Device: ............................................................................................................................................ 37
SPEED SENSORS: ...................................................................................................................................... 37
FlOW SWITCH & LEVEL SWITCH TEST: ................................................................................................... 40
BUCKET CYLINDER LIFTING FIXTURE ............................................................................................................ 41

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-3
GENERATION2
11/8/2012
DRAFT
LeTourneau
 LIST OF ILLUSTRATIONS
Figure 1. LIFTING FIXTURE (P/N 103-3411) FOR MODEL 35A PLANETARY DRIVE & MOTOR ............. 23
Figure 2. LIFTING FIXTURE (P/N 426-5522) FOR MODEL 45 PLANETARY DRIVE & MOYOR ............... 23
Figure 3. LIFTING FIXTURE (P/N 421-7211) FOR MODEL 51A2 PLANETARY DRIVE & MOTOR ........... 24
Figure 4. LIFTING FIXTURE (P/N 421-7198) FOR MODEL 57 PLANETARY DRIVE & MOTOR ............... 24
Figure 5. FRONT AXLE JACKS .................................................................................................................... 25
Figure 6. REAR FRAME JACK STANDS - FRONT END ............................................................................. 27
Figure 7. RECOMMENDED JACK STAND PLACEMENT LOCATIONS ..................................................... 28
Figure 8. BALL CAP ALIGNMENT STUD ..................................................................................................... 29
Figure 9. REACTION STUD USED FOR BALL CAP INSTALLATION - (P/N 425-4570) ............................. 29
Figure 10. BALL CAP LIFTING FIXTURE ....................................................................................................... 29
Figure 11. MEGA BORE TIRE INFLATION VALVE - (P/N 423-1174)............................................................ 29
Figure 12. MECHANICAL HANDLER (PREFERRED METHOD) (SHEET 1 OF 2) ....................................... 30
Figure 13. TIRE HANDLING METHODS ........................................................................................................ 31
Figure 14. LINCS II INPUT SIMULATOR BOX ............................................................................................... 33
Figure 15. L-950/L-1150/L-1350/L-1850/L-2350 BUCKET CYLINDER LIFTING FIXTURE .......................... 41

LOADER ASSEMBLY MANUAL r00

4-4 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 SUGGESTED MANPOWER, FIXTURES, TOOLS AND SUPPLIES
This suggested manpower, fixtures, tools and supplies list has been prepared in advance for the
machine design current at time of preparation. There is no guarantee that the listing is complete. It is
offered as a reasonably close guide to actual needs. This list includes items shipped with the
machine per the approved tool group.

SUGGESTED MANPOWER REQUIREMENTS

MANPOWER AND HEAVY EQUIPMENT EXPENSE ESTIMATE CHART

EQUIPMENT AND PERSONNEL NEEDS – REAR FRAME ASSEMBLED

Based on 12-hour workdays with good conditions and experienced personnel who have tools on site. This will vary
depending on site conditions, available equipment, personnel experience and available tooling.

COMMENTS
Days 8 and 9 for commissioning activities which typically require minimal support personnel.
Requirement for portable generator and air compressor depend on availability of equipment at erection site.
Use of commercial tire handler recommended - use of slings to install wheels/tires acceptable.
The SUGGESTED MANPOWER REQUIREMENTS show what is required in minimum staffing and is in addition to
the factory product support or distributor representative assigned to supervise the erection of the machine. Local
ordinances, weather conditions and the labor market may have some effect on manpower and erection time.
* The electrician will need all the tools and instruments necessary to reconnect and check cabling and wiring.

EQUIPMENT DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 DAY 6 DAY 7 DAY 8 DAY 9
75-Ton Crane 1 1 1 1 1
150-Ton Crane 1 1
Forklift 1 1 1 1 1
Stands 3 3 3 3 3
Air Compressor 1 1 1 1 1 1 1
Portable
1 1 1 1 1 1 1
Generator
Welder 1 1 1 1 1 1 1
Oxy/Acetylene 1 1 1 1 1 1
Commercial Tire
1
Handler

WORKERS DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 DAY 6 DAY 7 DAY 8 DAY 9
75-Ton Crane
1 1 1 1 1
Operator
150-Ton Crane
1 1
Operator
75-Ton Crane
1 1 1 1 1
Rigger
150-Ton Crane
1 1
Rigger
Welder 1 1 1 1 1
Mechanic 2 2 2 2 2 2 2 1 1
Electrician * 1 1 1 1 1 1
General Labor 2 2 2 2 2 2 2

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-5
GENERATION2
11/8/2012
DRAFT
LeTourneau
 EQUIPMENT AND PERSONNEL NEEDS – ENGINE AND REAR AXLE REMOVED

Based on 12-hour workdays with good conditions and experienced personnel who have tools on site. This will vary
depending on site conditions, available equipment, personnel experience and available tooling.

COMMENTS
Days 8 - 10 for commissioning activities which typically require minimal support personnel.

Requirement for portable generator and air compressor depend on availability of equipment at erection site.

Use of commercial tire handler recommended - use of slings to install wheels/tires acceptable.

The SUGGESTED MANPOWER REQUIREMENTS show what is required in minimum staffing and is in addition to
the factory product support or distributor representative assigned to supervise the erection of the machine. Local
ordinances, weather conditions and the labor market may have some effect on manpower and erection time.

* The electrician will need all the tools and instruments necessary to reconnect and check cabling and wiring.

EQUIPMENT DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 DAY 6 DAY 7 DAY 8 DAY 9 DAY 10
75-Ton Crane 1 1 1 1 1 1
150-Ton Crane 1 1 1
Forklift 1 1 1 1 1 1
Stands 3 3 3 3 3 3
Air Compressor 1 1 1 1 1 1 1 1
Portable Generator 1 1 1 1 1 1 1 1
Welder 1 1 1 1 1 1 1 1
Oxy/Acetylene 1 1 1 1 1 1 1 1
Commercial Tire
1
Handler

WORKERS DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 DAY 6 DAY 7 DAY 8 DAY 9 DAY 10
75-Ton Crane
1 1 1 1 1 1
Operator
150-Ton Crane
1 1 1
Operator
75-Ton Crane Rigger 1 1 1 1 1 1
150-Ton Crane Rigger 1 1 1
Welder 1 1 1 1 1
Mechanic 2 3 3 3 3 2 2 1 1 1
Electrician * 1 1 1 1 1 1 1 1 1
General Labor 2 2 2 2 2 2 2

LOADER ASSEMBLY MANUAL r00

4-6 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 FIXTURES, TOOLS AND SUPPLIES
“HOW OBTAINED” KEY

1. Purchase/Contract locally
2. Purchase from Technologies
3. Fabricate
4. Shipped with Machine

Items listed as "SHIPPED WITH MACHINE" (4) are to be left with customer following
delivery.

HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED

COMPONENT POSITIONING EQUIPMENT

2 Lifting the major structural
L-950 components such as the
L-1150 front and rear frames, lift
75-TON MOBILE CRANE N/A 1 L-1350 arms, bucket, ROPS, cab,
1- hydraulic cylinders, etc.
L-1850 Refer to (L/D-950, L-1150
L-2350 L-1350, L-1850 and L-
2350) COMPONENT
1- WEIGHTS in GENERAL
150-TON MOBILE CRANE N/A 1 L-1850 INFORMATION) for
L-2350 individual component
weights.
10-TON CAPACITY Positioning small
N/A 1 1
OUTDOOR FORKLIFT components
Mounting wheels/tires on
TIRE MANIPULATOR N/A 1 1
machine

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-7
GENERATION2
11/8/2012
DRAFT
LeTourneau
 The lifting capacity of the equipment listed should be adequately rated and certified for the weight
of the components listed in GENERAL INFORMATION. Refer to the component weights listed in
(L/D-950, L-1150 L-1350, L-1850 and L-2350 COMPONENT WEIGHTS) for approximate weights of
components which might be shipped separate from the front or rear frame assembly. Always
allow a safety margin above listed weights.

To avoid the possibility of injury, it is recommended that any component weighing 50 lbs. (22.7
kgs.) or more be lifted with the forklift or cranes.

HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
HOISTING LIFTING TOOL/FIXTURE
WIRE ROPE SLINGS:
3/8" X 10 FT. 2
1/2" X 10 FT. 2
3/4" X 12 FT. 4 Hoisting miscellaneous
NPN 1
3/4" X 20 FT. 4 components
1" X 15 FT. 2
1-1/2" X 25 FT. 2
SHACKLES:
3/8" 4
3/4" 8 Hoisting miscellaneous
NPN 1
1-1/2" (LONG components
4
SHANK)
LIFTING EYES:
1-1/2" WITH 3/4"-16
407-5803 2 4 A/R
UNF SHANK
1-1/2" WITH 1"-14
407-5801 2 1 A/R
UNS SHANK
LIFTING
EYE/PLATE FOR
411-6384 2 1 Mounting ROPS
ROPS
STRUCTURE
LIFTING EYE, 1" -
14 NS X 2-3/16 X 4- 415-1459 2 2 A/R
7/16" EYE
LIFTING EYE, 3/4" -
16 X 1-1/2" X 1-1/2", 407-5803 2 4 A/R
EYE

LOADER ASSEMBLY MANUAL r00

4-8 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
HOISTING LIFTING TOOL/FIXTURE (continued)
CANVAS SLINGS:
124-3301
1" X 4 FT. Sling
Endless
124-3302
1" X 6 FT. Sling
Endless
124-3303
1" X 6 FT. Sling Eye-
Eye
124-3304
1" X 6 FT. Sling
Endless
124-3305
1" X 10 FT. Sling
Endless
124-3306
1" X 8 FT. Sling
Endless
124-3307
Hoisting miscellaneous
2" X 6 FT. Sling 1,2 A/R
components
Endless
124-3308
1" X 12 FT. Sling
Endless
124-3309
2" X 14 FT. Sling Eye-
Eye
124-3310
4" X 12 FT. Sling Eye-
Eye
124-3311
2" X 12 FT. Sling
Endless
124-3312
2" X 8 FT. Sling
Endless
124-3331
4" X 6 FT. Sling Eye-
Eye
3-TON CHAIN COME- Positioning heavy
NPN 1 2
ALONGS components

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-9
GENERATION2
11/8/2012
DRAFT
LeTourneau
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
POWER & AIR REQUIREMENTS
PORTABLE GENERATOR
Supply current for
(REQUIRED IF COMMERCIAL
NPN 1 1 lights, tools and air
SERVICE UNAVAILABLE AT
compressor.
ASSEMBLY SITE)
AIR COMPRESSOR NPN 1 1 Power tools, The air compressor must
inflate tires, be a minimum of 120 psi
general cleaning. 100CFM with 20 cubic ft.
storage tank and hoses
and couplers with a
minimum inside diameter
of 11/16" (18.84mm).
RECOMMENDED HAND TOOLS
FULL SET OF MECHANIC'S HAND
TOOLS INCLUDING BUT NOT
LIMITED TO THE FOLLOWING:
END WRENCHES
OPEN END AND BOX END
●
WRENCHES 3/8" TO 1-1/2"
RATCHES AND SOCKET
WRENCHES
● 12-POINT SAE SOCKETS 1/4"
UP TO 1-1/4" SIZES WITH 3/8",
1/2" AND 3/4" DRIVES AS
REQUIRED WITH VARIOUS An 8-lb. sledge
LENGTH EXTENSIONS with the handle
HAMMERS cut to
1 A/R A/R approximately 24"
● 2 AND 3-LB. BALL PEEN
● 8 TO 16-LB. SLEDGE is handy for
driving in pins in
● SOFT FACE HARD RUBBER
tight places on the
● BRASS
lift arms.
TORQUE WRENCHES
● 25 TO 250 FT.-LB. 1/2" DRIVE
WITH AUDIBLE OR VISUAL
INDICATOR
● 100 TO 700 FT.-LB. 3/4" DRIVE
WITH AUDIBLE OR VISUAL
INDICATOR
PIPE WRENCHES
● VARIOUS SIZES UP TO 48- NPN 1 A/R A/R
INCHES
TORQUE Installation of Proto model 6232 1"
MULTIPLIER/HYDRAULIC various driver, 18.5:1 ± 5% or
TORQUE WRENCH components equivalent.
NPN 1,2 1
TORQUE MULTIPLIER OF requiring extreme
● 3000 FT.-LB. (4,000 N.M) torque - rims, ball
CAPACITY caps, etc.
Installation of Enerpac #KAS10TS or
sawcut bushing equivalent
HYDRAULIC TORQUE
● NPN 1 1 fasteners - lift
WRENCH
arms - wheel
fasteners.
Comparable to
403- WILLIAMS TOOL
SPANNER WRENCH 1,2 A/R Brake adjustment.
4209 COMPANY SPANNER
WRENCH #472.

LOADER ASSEMBLY MANUAL r00

4-10 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
RECOMMENDED HAND TOOLS (continued)
TAP AND DIE SET
● SAE UP TO AND NPN 1 1 set Chase threads
INCLUDING 1-1/4" SIZE each
BOTH COARSE AND FINE
THREADS It is recommended
that multiple taps
(1" X 8 UNC)be used
to clean out threads
for planetary drive to
axle and wheel to
planetary drive
retaining fasteners be
on hand to speed the
process.
HAND FILES
● RANGE OF SIZES AND
TYPES - SLIM TAPER, NPN 1 A/R A/R
ROUND TO DOUBLE CUT
12" FLAT
SCREWDRIVER SET
● PHILLIPS AND FLAT, NPN 1 A/R A/R
SHORT AND LONG
HANDLES
MISCELLANEOUS HAND
NPN 1 A/R A/R
TOOLS
● HEX-HEAD WRENCHES
SAE AND METRIC IN
FULL RANGE OF SIZES
● PUNCH AND CHISEL SET
● HACKSAW AND BLADES
● MAGNETIC RETRIEVAL
TOOL
● INSPECTION MIRROR
● SETSCREW EXTRACTOR
SET
● Cutting metal
METAL SNIPS
banding
● OIL FILTER WRENCH(S) A/R
● Leveling frames
LEVEL - 3-FT.
on jack stands
● 2" PAINT BRUSHES Spreading grease
● TAPE MEASURE A/R
● Marking fasteners
WHITE PAINT PEN Diagraph GP-X or equivalent
to verify torquing
● PUTTY KNIVES Cleaning
● SCRAPERS/RAZOR Various cleaning
BLADE duties

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-11
GENERATION2
11/8/2012
DRAFT
LeTourneau
 HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
RECOMMENDED HAND TOOLS (continued)
MISCELLANOUS HAND
TOOLS (CONTINUED)
●RAGS A/R
● Installation of steering
8-FT. 2X4 BOARD cylinder pins
● Pull electrical wires
MECHANICS WIRE and hose through
fittings
● Hydraulic o-rings
SEAL PICKS install/removal
●5-LB. DEAD BLOW Install handrails on Install handrails on
HAMMER catwalks catwalks
● Removal of sawcut Removal of sawcut
SLIDE HAMMER - SET bushings bushings
SPECIAL TOOLS/FIXTURES
PLANETARY DRIVE Refer to illustration
LIFTING FIXTURES 57 "LIFTING
Planetary FIXTURE FOR
Drive MODEL 57
421-7198 PLANETARY
DRIVE”
Refer to illustration
51A2 "LIFTING
Planetary FIXTURE FOR
Drive MODEL 51A2
421-7211 PLANETARY
Install planetary DRIVE”
4 1 A/R driver/traction Refer to illustration
45 motor assembly "LIFTING
Planetary
FIXTURE FOR
Drive
MODEL 45
426-5522
PLANETARY
DRIVE”

Refer to illustration
35A
"LIFTING FIXTURE
Planetary
FOR MODEL 35A
Drive
PLANETARY
103-3411
DRIVE”

POWER UNIT LIFTING

FIXTURE
DETROIT DIESEL
12V4000 ENGINE
423-7811
WITH G100 Refer to illustration
GENERATOR Installation power "POWER UNIT
2 1 A/R
DETROIT DIESEL unit, if required. LIFTING
16V4000 ENGINE FIXTURES"
423-3190
WITH G200
GENERATOR

LOADER ASSEMBLY MANUAL r00

4-12 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
SPECIAL TOOLS/FIXTURES (continued)
Construct as shown on
JACK STANDS
prints provided - 2 each
required for front and rear
frames. Refer to
illustrations "MACHINE
Support front and
FRONT AXLE JACK
NPN 3 2 each rear frames during
STANDS", "MACHINE
assembly.
REAR FRAME JACK
STANDS - FRONT END"
and "MACHINE REAR
BUMPER JACK
STANDS".
REAR AXLE LIFTING 102- Install rear axle, if
2 2
FIXTURE 3317 required

PIN DEPTH 423-

1 1
MEASUREMENT TOOL 4221

MIDDLE PINION 423- L-1850/L-2350

REMOVAL HUB - 57" 4 1
4752 Only
PLANETARY DRIVE
MIDDLE PINION 423- L-1850/L-2350
REMOVAL ARM - 57" 4 1
4753 Only
PLANETARY DRIVE
HYDRAULIC 424- L-1350/L-1850/L-
4 1
CYLINDER 1656 2350

PRESSURE 424- L-1350/L-1850/L-

STRUCTURE BRAKE 4 1
1662 2350
ACTUATOR
408-
WRENCH STRUCTURE 4 1
0984
2-1/2" I.D. HEAVY PIPE Used to torque ball caps,
APPROXIMATELY 5- NPN 1 1
etc.
FT. LONG
HYDRAULIC TANK
WITH TRANSFER NPN 1 1 Fill hydraulic reservoir
PUMP/HOSING AND
FILTRATION
Hoist bucket Refer to illustration
L-950 BUCKET
103- cylinders for "L-950 BUCKET
CYLINDER LIFTING 4 1
4320 installation of lift CYLINDER LIFTING
FIXTURE
arms FIXTURE".
425- D-950 -Push plate
ADJUSTMENT BAR 1 1,2
6398 installation
Hold shims in
place while
1-1/4" -7 ALL THREAD NPN 2 1
installing the
capture plates.

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-13
GENERATION2
11/8/2012
DRAFT
LeTourneau
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
BALL CAP INSTALLATION FIXTURES
1/2" X 2" UNC Hold shims in
2
FASTENER place
Space ball caps out for positioning
1-1/4" - 7 X 24" of lift arms, frames, rear axle, etc.
Ball cap
GRADE 8 ALL- NPN 1 3 Refer to STUD FOR
installation
THREAD INSTALLATION OF MIDDLE
PIVOT BALL CAP - OPTIONAL..
STUD FOR
INSTALLATION Construction of these studs optional -
OF MIDDLE Hold shims in these studs shown in this Assembly
3 3
PIVOT BALL place Manual. Refer to illustration "BALL
CAPS - CAP ALIGNMENT STUD".
OPTIONAL
Refer to illustration "REACTION
425-
REACTION STUD 4 Ball cap installation STUD USED FOR BALL CAP
4570
INSTALLATION - P/N 425-4570"
1-1/4" X 7 UNC Chase threads,
TAP if required

DIAL INDICATOR
WITH MAGNETIC 1 Dial indicator
BASE
inspection of ball
DIAL INDICATOR joints
WITH REMOTE
READOUT
LIFTING Remove/Install
FIXTURES FOR Refer to illustration "BALL CAP
3 2 lower middle pivot
LOWER MIDDLE LIFTING FIXTURE"
ball cap
PIVOT BALL CAP.
SAFETY EQUIPMENT
Required when
153-
FACE SHIELD performing
9728
WITH ATTACHING 153- 1,2 compressed
HEADGEAR surface grinding,
9104
use of air, etc.
General eye
SAFETY 153- protection - to be
1,2
GLASSES 9784 worn at ALL
TIMES Required for all crew members to
A/R
General head perform duties listed.
153- protection - to be
HARD HAT 1,2
9720 worn at ALL
TIMES
Foot protection -
STEEL TOE NPN 1 to be worn at
BOOTS ALL TIMES
153- Hearing
EAR PLUGS 1,2
9282 protection - A/R

LOADER ASSEMBLY MANUAL r00

4-14 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
SAFETY EQUIPMENT (continued)
MASKS/RESPIRATORS
153-
● Dust Mask Breathing protection
9202
- required for dusty
Toxic Fume 153-
● 1,2 A/R conditions, toxic
Respirator 9205
fumes and painting
153-
● Paint Respirator operations
9265
LEATHER WORK GLOVES
● Standard 150-
3855 Recommended for
1,2 A/R
● Thermal 153- each crew member
9347
Required for anyone
153-
WELDING GLOVES 1,2 A/R performing welding
9793
operations
153-
Required for anyone
DIELECTRIC GLOVES 9311
1,2 A/R working with high 14" Lineman's gloves.
WITH LINER 153-
voltage
9312
Required for anyone
KEVLAR TERRY CLOTH 153- performing cutting torch
1,2 A/R A/R
GLOVES 9346 operations or handling
heated parts.
NITRILE GLOVES
153-
● Medium
9796
Required for anyone
153-
● Large 1,2 A/R working with toxic
9797
chemicals.
153-
● X-Large
9798
Required for any
FALL PROTECTION -
crew member Must be
SAFETY HARNESS AND
NPN 1,2 A/R working on elevated OSHA/ANSI/MSHA
LANYARD
structure outside approved.
handrails.
FLASHLIGHT NPN 1 A/R
AUXILIARY LIGHTING NPN 1 A/R A/R

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-15
GENERATION2
11/8/2012
DRAFT
LeTourneau
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
AIR TOOL GROUP
7" AIR DISC GRINDER
WITH GRINDING NPN 1 1 A/R
WHEEL AND STEEL
BRUSH WHEEL
4" AIR DISC GRINDER
WITH GRINDING
WHEEL, STEEL WIRE NPN 1 2 A/R
BRUSH AND ABRASIVE
CLEANING DISC
1/2", 3/4" AND 1" DRIVE
IMPACT WRENCHES 1
NPN 1 A/R
WITH A FULL RANGE each
OF SOCKETS
1-1/4" 12-POINT Installation of
408-
SOCKET 1" DRIVE 4 1 planetary drives
6118
IMPACT and miscellaneous

1" 12-POINT SOCKET 416-

MODIFIED 1" DRIVE 4 1 Installation of wheel
2114
IMPACT
1" DRIVE LONG NPN 1 1 A/R
EXTENSION - IMPACT
3/8" AIR RATCHET NPN 1 2

AIR BLOW NOZZLES NPN 1 A/R

AIR DIE GRINDER NPN 1 1

HAND-HELD AIR-
POWERED GREASE NPN 1 1
GUN
Should have facility to
allow technician to stand
clear of tire during inflation.

TIRE INFLATION
ADAPTER - FOR NPN 1 1 Tire inflation
STANDARD SCHRADER
VALVE

LOADER ASSEMBLY MANUAL r00

4-16 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 LET HOW
QTY. PURPOSE COMMENTS
P/N OBTAINED
AIR TOOL GROUP (CONTINUED)
Required for rims
HALTEC MEGA-BORE 423-
2 1 Tire inflation equipped with Haltec
INFLATION TOOL 1174
mega-bore valve.
416-
SOCKET STRUCTURE 4 1
3884
Required if aerosol
PAINT SPRAY GUN NPN 1 1 A/R touch-up spray not
adequate.
AIR CONDITIONING TOOLS

MANIFOLD AND
422- Listed tools
GAUGE ASSEMBLY
2494 and supplies
FOR R134A 1 1 A/R
422- provided under
REFRIGERANT WITH
2495 air conditioning
ADAPTER
service group
422-2491.
VACUUM PUMP WITH
PROPER 415-
1 1 A/R
CONNECTIONS FOR 6194
R134A SYSTEM
HYDRAULIC SYSTEM TEST INSTRUMENTS
HYDRAULIC GAUGE 416- Setting hydraulic 1 unit shipped with
1,4 2
ASSEMBLY 0-4000 PSI 2120 pressures machine.
204T HOSE WITH
ATTACHMENT N/A 1 2
COUPLINGS
403-
BUSHING 4 1
2503
QUICK COUPLING, 404-
4 1
FEMALE X 1/4" FP 1347
QUICK COUPLING 404-
4 1
PLUG 1349
415-
GAUGE 4 1
4747
RELIEF VALVE TEST 416-
4 1
FITTING 2332
407-
TEE 4 1
8968
416-
REDUCER 4 1
2330

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-17
GENERATION2
11/8/2012
DRAFT
LeTourneau
 HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
HYDRAULIC SYSTEM TEST INSTRUMENTS (CONTINUED)
RDFA RELIEF
VALVE TEST
1
BLOCK
ASSEMBLY
QUICK
COUPLING 422-2437 4 1
CAP
QUICK
COUPLING,
422-2435 4 1
MALE X 1/4"
FP
PIPE NIPPLE -
403-0298 4 1
1/4" HEX
TEE, 1/4" FP 403-1446 4 1
ADAPTER, 1/4"
402-1571 4 1
MP X #8 MJ
RELIEF
421-9116 4 1
MANIFOLD, T3A
PRESSURE
GAUGE - 0-4000 411-6596 4 1
PSI
ADAPTER, #8
400-2455 4 1
MO X #8 MJ
O-RING, 3/8" 400-2280 4 1
GAUGE
ASSEMBLY, 0- 411-8705 4 2
4000 PSI
PIPE COUPLING
401-2921 4 1
- 1/4"
ADAPTER, 1/4"
401-6785 4 1
MP X #4 MJ
QUICK
COUPLING,
404-1347 4 1
FEMALE X 1/4"
FP
QUICK
COUPLING 404-1349 4 1
PLUG
PRESSURE
GAUGE - 0-4000 411-6596 4 1
PSI
HOSE
ASSEMBLY, #4 418-6438 4 1
X 224"
HUSCO RELIEF
421-0352 4 1
TEST BLOCK

LOADER ASSEMBLY MANUAL r00

4-18 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
ELECTRONIC TEST INSTRUMENTS
FLUKE TYPE 97
SCOPEMETER OR 421-0965 1.2 1
EQUIVALENT
SIMPSON 260
MULTIMETER (OR 415-3582 1,2 1
EQUIVALENT)
FLUKE MODEL 189
415-3585
MULTIMETER OR 1,2 1
(01)
EQUIVALENT
500V MEGGER -
415-3594 1,2 1
BIDDLE
REMOTE INTERFACE Troubleshooting
427-0252 2 1 GEN2
TESTER wiring
CUTTING AND WELDING EQUIPMENT
ACETYLENE TORCH
WITH CUTTING AND NPN 1 1 A/R
ROSEBUD TIPS
Rated output 180
ARC WELDER NPN 1 1 A/R
amps minimum.
WELDING HOOD 150-9232 1,2 1 Welding operations
MISCELLANEOUS ITEMS
ROPE NPN 1 A/R A/R
ALIGNMENT BARS -
NPN 1 A/R
TAPERED
Various sizes -
PRY BARS NPN 1 A/R A/R
lengths - 1' to 4'.
Mounting wheels
and tires if Construct as shown
TIRE SLING NPN 3 1 recommended tire on illustration "TIRE
manipulator is not HOISTING SLING"
available.
3- AND 6-FOOT
LADDERS AND/OR
NPN 1 2 A/R
MOBILE WORK
PLATFORMS
10-FOOT MOBILE
NPN 1,3 2 A/R
WORK PLATFORMS

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-19
GENERATION2
11/8/2012
DRAFT
LeTourneau
 HOW
LET P/N QTY. PURPOSE COMMENTS
OBTAINED
MISCELLANEOUS ITEMS (CONTINUED)
Socket P/N 414-6686
- same end for loader
and auxiliary vehicle -
lugs in by inverting
plug.
Socket P/N 416-3355
is a Caterpillar
adapter CAT P/N
852633. LeTourneau
JUMP START
414-6686 does not furnish
ADAPTERS - 1,2 1 A/R Jump starting
416-3355 auxiliary vehicle
TWO MODELS
adapter - purchase
through Caterpillar
dealer - installed as
customer specified
option - mine site
auxiliary vehicles
may already be
equipped with this
socket.
Miscellaneous
GREASE GUN 423-4048 4 1
lubrication
HEAT GUN NPN 1 1 Install safety labels
Leveling frames when
LEVEL NPN 1 1
placing onto jack stands.
SUPPLIES
LOCTITE RC569
THREAD Threaded connections of
410-3739 1,2 A/R
LOCKING Auto Lube System
COMPOUND
LOCTITE RC271
THREAD
045-9283 1,2 A/R A/R
LOCKING
COMPOUND
LOCTITE BLUE
SILICONE
415-0226 1,2 A/R A/R
GASKET
COMPOUND
LOCTITE ANTI-
SEIZE 045-9294 4 A/R A/R
COMPOUND
PLASTIC WIRE
NPN 1 A/R
TIE WRAPS
BLACK TIE
WRAP, 20" 406-9344 1,2 100
LONG A/R for electrical
BLACK TIE installation
WRAP, 14-1/2" 401-8728 1,2 100
LONG

LOADER ASSEMBLY MANUAL r00

4-20 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
SUPPLIES (CONTINUED)
ABRASIVE
124-2295 1,2 A/R 60 grit
DISCS
EMERY CLOTH
MEDIUM - 240
124-1833 1,2 A/R
GRIT
COARSE - 18O
124.1832 1,2 A/R
GRIT
EXTRA COARSE
124-1831 1,2 A/R
- 36 GRIT
PENETROX-A Required for all
410-5600
ELECTRIC JOINT 1,2 A/R electrical
(8 oz.)
COMPOUND connections
OIL
NPN 1 A/R
ABSORBENT
ISOPROPYL Clean areas to install
NPN 1 A/R
ALCOHOL safety labels
Use to disable
loader's starting
ability with
PADLOCK NPN 1 1 Security maintenance
lockout switch at
end of each
workday.
LUBRICANTS AND FLUIDS
30W MOTOR OIL NPN 1 A/R Thread lubricant
NLGI #2
14-oz. Cartridge
LITHIUM-BASED 421-6205 4 40 General lubrication
Exxon Unirex
GREASE
MOBY LUBE,
412-3626 4 2
SPRAY
Hydraulic pump 75W-140 synthetic
GEAR OIL 412-3740 4 1
gearbox - 5-gallon pail
ANTI-FREEZE Amounts shown
88 gal. are for machines
● L/D-950
(333 l.) requiring power unit
88 gal installations at
● L-1150
(333 l) 50/50 mix.
423-9357 1,2 101.5 gal. Engine For machines not
● L-1350
(382 l.) requiring power unit
110 gal. installation,
●L-1850
(416 l.) sufficient amount to
130 gal. top off radiator
●L-2350 required.
(492 l.)
151-0360
LUBRIPLATE WHITE (6-LB. 1,2 A/R
GREASE CAN)

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-21
GENERATION2
11/8/2012
DRAFT
LeTourneau
LUBRICANTS AND FLUIDS (continued)
300 gal.
(1136 l)
L/D-950
Amount shown
L-1150
required to fill
HYDRAULIC OIL system, bleed
400 gal
pumps, remotes,
(1514 l)
etc.
L-1350
L-1850,
L-2350
STANDARD
CLIMATE FLUID
412-3226
ARTIC CLIMATE
FLUID
412-1205
SPRAY 12-oz. can - Freeall
LUBRICANT
045-2200 1 A/R
brand or WD-40
PLANETARY
DRIVE
LUBRICANT
24 gallons required
425-0628 to complete fill four
6 gal.
● 35A MOBILGEAR 35A planetary
(22 l)
SHC XMP drives with auto
220 lube system.
422-4612 80 gallons required
MOBILGEAR to complete fill four
20 gal
● 45 SHC 460 45 planetary drives
synthetic (76 l)
with auto lube
lubricant system.
Planetary Drive 150 gallons
1,2
lubrication required to
36 gal. completely fill four
●51A2 422-4612 (136 l.) 51A2 planetary
MOBILGEAR drives with auto
SHC 460 lube system.
synthetic
lubricant 105 gallons
(or equivalent) required to
(55-gal. drum) 25 gal. completely fill four
● 57"
(95 l.) 57" planetary driver
with auto lube
system.
NLGI #2 Moly
BULK GREASE Grease - Amount
Machine lubrication via
- MOLY 404-1626 1,2 240 lbs. shown required to
auto lube system
LUBRICANT fill auto lube
system.

LOADER ASSEMBLY MANUAL r00

4-22 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 PLANETARY DRIVE 35A

1. LIFTING FIXTURE 2. CAPSCREW 1-8UNC x 2-3/4 NC GR8 3. LIFTING CLEVIS

Figure 1. LIFTING FIXTURE (P/N 103-3411) FOR MODEL 35A PLANETARY DRIVE & MOTOR

1. LIFTING FIXTURE 2. CAPSCREW 1-8UNC x 2-3/4 NC GR8 3. LIFTING CLEVIS

Figure 2. LIFTING FIXTURE (P/N 426-5522) FOR MODEL 45 PLANETARY DRIVE & MOYOR

LOADER ASSEMBLY MANUAL r00

COPYRIGHT 2012 4-23
GENERATION2
11/8/2012
DRAFT
LeTourneau
 51A2 Planetary Drive
1. LIFTING FIXTURE 2. CAPSCREW 1-8UNC x 2-3/4 NC GR8 3. LIFTING CLEVIS
Figure 3. LIFTING FIXTURE (P/N 421-7211) FOR MODEL 51A2 PLANETARY DRIVE & MOTOR

1. LIFTING FIXTURE 2. CAPSCREW 1-8UNC x 4” NC GR8 3. LIFTING CLEVIS

Figure 4. LIFTING FIXTURE (P/N 421-7198) FOR MODEL 57 PLANETARY DRIVE & MOTOR

LOADER ASSEMBLY MANUAL r00

4-24 COPYRIGHT 2012
GENERATION2
LeTourneau 11/8/2012
DRAFT
 Figure 5. FRONT AXLE JACKS

Overall height of front frame jack stand varies with loader model and height of tires. Typically, 48" (1219 mm) to 50" (1270 mm) is suitable for L/D-
950/L-1150/L-1350 and 55" (1397 mm) to 57" (1448 mm) is typically suitable for L-1850/L-2350. Top of cradle is 2" (51 mm) above top of jack stand
top plate. It is essential to measure the tires and calculate optimal height with wooden blocking in place to ensure tires clear the ground.
Placement of forklift plates is relative to the height of the jack stand. They are normally positioned 12" (305 mm) to 14" (356 mm) below the top of
the jack stand.

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-25

GENERATION2
11/8/2012 LeTourneau
DRAFT
 THIS PAGE INTENTIONALLY LEFT BLANK

4-26 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
 Figure 6. REAR FRAME JACK STANDS - FRONT END

Overall height of rear frame jack stand - front end varies with loader model and height of tires. Typically, 48" (1219 mm) to 50" (1270 mm) is suitable
for L/D-950/L-1150/L-1350 and 55" (1397 mm) to 57" (1448 mm) is typically suitable for L-1850/L-2350. It is essential to measure the tires and
calculate optimal height with wooden blocking in place to ensure tires clear the ground.
Placement of forklift plates is relative to the height of the jack stand. They are normally positioned 12" (305 mm) to 14" (356 mm) below the top of
the jack stand.

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-27

GENERATION2
11/8/2012 LeTourneau
DRAFT
Placement of forklift plates is relative to the height of the jack stand. They are normally positioned 12"
(305 mm) to 14" (356 mm) below the top of the jack stand.

1)-Bucket at carry height in rollback position 2)-Clear of ground 3)-Jack stands placed under front axle each
side as close as possible to frame structural support member 4)-Frame lock in locked position 5)-Radius of
tire +6” (150mm) 6)-Jack stands placed under rear bumper each side in line with frame.
FIGURE 7. RECOMMENDED JACK STAND PLACEMENT LOCATIONS
(LOADER USED FOR ILLUSTRATIVE PURPOSES)

4-28 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
 Figure 8. BALL CAP ALIGNMENT STUD

MATERIAL: GR8
Figure 9. REACTION STUD USED FOR BALL CAP INSTALLATION - (P/N 425-4570)

Figure 10. BALL CAP LIFTING FIXTURE

1) INFLATOR
2) KNURLED NUT
3) SHUT-OFF VALVE
4) QUICK COUPLE 11/16” MIN. INSIDE DIAMETER
(CUSTOMER FURNISHED)
5) MALE PIECE
6) BALL VALVE

Figure 11. MEGA BORE TIRE INFLATION VALVE - (P/N 423-1174)

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-29

GENERATION2
11/8/2012 LeTourneau
DRAFT
TIRE INSTALLATION
The following procedure is applicable to both front and rear wheel assemblies.

The preferred method of handling the tires is with commercial truck-mounted equipment designed for
this purpose. This equipment is available by contracting with a specialty tire handling equipment
company. The following recommendations are made to aid in field installation should commercial tire
handling equipment not be available.

Figure 12. MECHANICAL HANDLER (PREFERRED METHOD) (SHEET 1 OF 2)

The following hoists and rigging are required for installation of the wheel and tire assembly:

A crane of suitable height and capacity to hoist the wheel and tire to the loader is required. ALWAYS ALLOW
A SAFETY MARGIN ABOVE THE LISTED WEIGHT. The approximate weight of the wheel and tire
assemblies on LeTourneau loaders is:
L/D-950 – 8,600 lbs. (3901 kgs.)
L-1150 – 8,600 lbs. (3901 kgs.)
L-1350 – 16,000 lbs. (7303 kgs.)
L-1850 – 17,000 lbs. (7711 kgs.)
L-2350 – 22,000 lbs. (9979 kgs.)
Two (2) wire rope slings of equal length (36 ft. recommended), of sufficient capacity for lifting the applicable
wheel and tire assembly weight (refer to illustration "Figure 13", below). ALWAYS ALLOW A SAFETY
MARGIN ABOVE THIS WEIGHT. The slings should be covered with a protective rubber covering to prevent
the cable from cutting into the tire (automotive heater hose or equivalent is recommended). The sling ends
can also be fitted over a suitable lifting ring, if desired.

4-30 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
1) LIFTING RING SUITABLE FOR HOISTING WEIGHT OF WHEEL/TIRE ASSEMBLY 2) 36 FT.
RECOMMENDED (TOTAL LENGTH EYE-TO-EYE 3) PROTECTIVE RUBBER COVERING (AUTOMOTIVE
HEATER HOSE OR EQUIVALENT) 4) WIRE ROPE SLINGS JOINTLY SUITABLE TO HOIST WEIGHT OF
WHEEL/TIRE ASSEMBLY 5) SWAGED OR CLAMPED END 6) SECURE CABLE IN LUGS OF TIRE
TIRE HOISTING SLING (ALTERNATIVE METHOD) (SHEET 2 OF 2)
Figure 13. TIRE HANDLING METHODS

Persons NOT TRAINED in tire installation on these heavy machines, MUST NOT PERFORM the work
described in this publication. Severe injury or death may result because of failure to follow proper
procedures.

Under NO circumstances should the rim be heated while tire is still mounted and inflated. This means
NO welding and cutting torch or any other procedure that would cause extreme heat. Failure to
comply with this warning is dangerous and it could result in the loss of life.

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-31

GENERATION2
11/8/2012 LeTourneau
DRAFT
Before attempting to perform any maintenance or repair to the tire and rim assemblies on the
machine; it is IMPORTANT to pay close attention to all safety information within this section and to
read and understand tire manufacturers’ manuals on the mounting and dismounting of tires.
A filter on the air inflation equipment to remove the moisture from the airline aids in the prevention of
corrosion. The filter should be checked periodically to see that it is working properly.

The figures on the following page show typical power unit/engine lifting fixture installation for four (4)
machine power units. Installation of all power unit/engine lifting fixtures is similar to those shown.
Refer to your engine manufacturer's owner's manual (available on manufacturer's website) or
authorized distributor for additional information and recommendations concerning hoisting of the
power unit.

4-32 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
LINCS II INPUT SIMULATOR BOX (VCU VIA THE DIGITAL BOARD)
The LINCS II Input Simulator Box, P/N 4270252, is used for troubleshooting cabling and components
upstream in a circuit from a remote sensor back to the VCU.
The LINCS II Input Simulator Box is connected in place of a remote sensor (pressure transducer) and is used
to induce a signal back to the VCU to verify proper circuit operation. Utilizing this tester can greatly enhance
troubleshooting potential component failures and reduce downtime by isolating whether a sensor failure or
cabling failure is the root cause.
The tester is able to function in several ways to facilitate troubleshooting as many different sensor circuits as
possible. It can be used to test all pressure transducers regardless of pressure rating, temperature sensors,
and speed sensors.

Figure 14. LINCS II INPUT SIMULATOR BOX

P/N 4270252

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-33

GENERATION2
11/8/2012 LeTourneau
DRAFT
3-PIN CONNECTOR
The input simulator has a connector on one end with 3-pins. On the index pin for the connector, a green wire
provides ground, the white wire provides 24V and the black wire is the signal wire.

A ) INDEX PIN LOCATION

LEDS
If ground and 24V are provided to the box with the correct polarity, the Green LED will illuminate. If the
polarity is incorrect, the red LED will illuminate.

4-34 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
FOUR POSITION SWITCH
The output from the box onto the „signal‟ wire, is determined by the position of the four position switch.
A. +24V Selected = 24V on „signal‟ wire.
B. 4-20mA Selected = 4-20mA on signal wire with amplitude increasing as rotary potentiometer travels
clockwise.
C. Frequency Selected = Frequency on signal wire is a fixed frequency output.
D. Ground Selected = „Signal‟ wire grounded

+24V SWITCH POSITION

When the switch is in the “+24V” position, a 24 volt signal will be sent back to the LVCC as the signal for the
device that is being simulated.

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-35

GENERATION2
11/8/2012 LeTourneau
DRAFT
4-20MA SWITCH POSITION

When the “4-20mA” position is selected with the switch, the signal can be manipulated by rotating the knob
labeled POT 1.

FREQUENCY SWITCH POSITION

When the “Frequency” position is selected, the output from the circuit board will be a fixed frequency output.

4-36 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
GROUND SWITCH POSITION

When the switch is in the “Ground” position, this will simulate a device being grounded.

INSTRUCTIONS FOR USE OF THE INPUT SIMULATOR BOX

4-20MA DEVICE:
®
1. Disconnect the Turck cable from the suspected bad 4-20mA device cable ( this includes encoders,
transducers, hydraulic tank temperature sensors, and gear box temperature sensors) and connect
the cable to Turck connector on the test box.
2. Move the switch, on the input simulator box, to the “4-20mA” to enable any 4-20mA device.
3. Boot up LINCS II and browse channels to find the suspected bad channel.
4. Observe the input reported in LINCS II while rotating the pot on the test box.
5. If LINCS II indicates the pressure is adjusting, the pressure transducer has failed. If there is no
adjustment noted in LINCS II then there is either a bad cable or failed Turck Box.

SPEED SENSORS:

The Remote Interface Tester cannot be used to test wheel motor sensors.
1. Disconnect the cable from the speed sensor to be tested.
2. Connect the cable to the Turck connector on the Input Simulator Box.
3. Move the selector switch to “Frequency” on the Input Simulator Box.
4. Boot up LINCS II and browse channels to find the correct channel to monitor the speed sensor signal.
5. Verify on the LINCS II screen that the speed sensor channel is registering an RPM.
6. If an RPM is seen on LINCS II screen, the speed sensor is defective. If the speed sensor is not
defective, either cabling or the remote module is defective.

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-37

GENERATION2
11/8/2012 LeTourneau
DRAFT
 SENSOR TEST CONFIGURATION

There are several different types of sensor cables that are used on the loader, depending on the type of sensor.

For example, a solenoid may have a square connector. The sensor cable, being used, would have a square solenoid connector on one end and a large 3-pin
connector at the other end.

A transducer may have a small 4 or 5 pin round Turck connector. The transducer sensor cable, being used, would have a small 4 or 5 pin connector on one
end and a large 3-pin connector at the other end.

4-38 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
 THIS PAGE INTENTIONALLY LEFT BLANK

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-39

GENERATION2
11/8/2012 LeTourneau
DRAFT
FLOW SWITCH & LEVEL SWITCH TEST:
The test box can also be used to test the function of flow (driver filtration) switches and level (hydraulic and
coolant) switches.
1. Disconnect the appropriate switch cable from the Turck® box and connect the Input Simulator Box to
the Turck® box.
2. Boot up LINCS II and browse channels to find the appropriate switch channel. Note whether the
channel is looking for a 24 VDC signal.
3. View LINCS II screen to verify if the voltage is reported correctly, if correct the cabling and remote
module are good then the switch is bad.

4-40 COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00

GENERATION2
LeTourneau 11/8/2012
DRAFT
BUCKET CYLINDER LIFTING FIXTURE

Use with lifting clevises and fiber or wire rope slings.

Figure 15. L-950/L-1150/L-1350/L-1850/L-2350 BUCKET CYLINDER LIFTING FIXTURE

LOADER ASSEMBLY MANUAL r00 COPYRIGHT 2012 4-41

GENERATION2
11/8/2012 LeTourneau
DRAFT