Section 8 - Assembly Manual
Section 8 - Assembly Manual
Section 8 - Assembly Manual
START-UP
LETOURNEAU
MACHINE ASSEMBLY MANUAL
SECTION 8
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
LIST OF ILLUSTRATIONS
Figure 1. CLEANING OF HOIST CYLINDER PINS .............................................................................. 7
Figure 2. WASHER/SEAL ASSEMBLY ................................................................................................. 8
Figure 3. PLACEMENT OF CHAIN AROUND HOIST CYLINDER ....................................................... 8
Figure 4. ALIGNMENT OF THE HOIST CYLINDER BORE WITH THE LIFT ARM BORE .................. 9
Figure 5. HOIST CYLINDER PIN BEING DRIVEN INTO THE BORE .................................................. 9
Figure 6. INSTALLATION OF THE INSIDE SAWCUT BUSHING ...................................................... 10
Figure 7. INSTALLATION OF THE OUTER SAWCUT BUSHING...................................................... 10
Figure 8. SAWCUT BUSHING BEING DRIVEN INTO THE BORE .................................................... 10
Figure 9. INSTALLATION OF THE RETAINING BOLT AND INSIDE WASHER................................ 11
Figure 10. INSTALLATION OF THE NUT AND OUTSIDE WASHER .................................................. 11
Figure 11. TIGHTENING OF HOIST CYLINDER PIN RETAINING BOLT AND NUT - (1 OF 2) .......... 12
Figure 12. TIGHTENING OF HOIST CYLINDER PIN RETAINING BOLT AND NUT - (2 OF 2) .......... 12
Figure 13. OUTSIDE WASHER BEING DRIVEN IN - TO CENTER - THE OPEN IN THE BORE ....... 13
Figure 14. TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - (1 OF 2) ............ 13
Figure 15. TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - (2 OF 2) ............ 14
Figure 16. POSITIONING OF BUCKET FOR REMOVAL OF PINS ..................................................... 15
Figure 17. REMOVAL OF BUCKET PINS - (1 OF 3) ............................................................................ 15
Figure 18. REMOVAL OF BUCKET PINS - (2 OF 3) ............................................................................ 16
Figure 19. REMOVAL OF BUCKET PINS - (3 OF 3) ............................................................................ 16
LIST OF TABLES
Table 1. TIRE SIZE AND INFLATION DATA - RECOMMENDED COLD TIRE INFLATION
PRESSURE.......................................................................................................................... 93
Table 2. CAPSCREW IDENTIFICATION AND TORQUE CHART .................................................. 103
Table 3. BALL BASE-SOCKET-CAP SPECIFICATIONS ................................................................ 110
Table 4. BALL CAP WEIGHT CHART ............................................................................................. 111
Record the hoist cylinder part number and serial numbers on the Commissioning Form.
a. Remove the bolts, nuts and washers from each side of the hoist cylinder pins in the lift arms.
b. Use a slide hammer to remove the inside saw cut bushings.
c. Insert retaining bolt through pin and install nut, rotate retaining bolt a few turns by hand.
d. Use bolt and nut as a slide hammer to unseat and remove pin.
e. Remove the outer saw cut bushings by driving them out from inside the bore.
f. Clean the pins of: paint, rust, nicks, and burrs. Refer to illustration "CLEANING OF HOIST
CYLINDER PINS".
This photograph shows the hoist cylinder pins being cleaned and positioned on front frame grating
prior to installation.
g. Install the retaining bolts and nuts through each pin. Turn the nuts, several turns, by hand. The bolts
will serve as a handle on the pins to make them easier to maneuver during the installation process.
h. Position the pins onto the grating near their mounting locations. Block them so that they cannot
inadvertently fall.
i. Lubricate the hoist cylinder bore with NLGI #2 lithium-based grease. The cylinder bore is lubricated,
but the saw cut bushing bores are not lubricated.
j. Ensure that both hoist cylinder rams are positioned, so they will slide inside the lift arms.
The hoist cylinder rod, level link to bell crank and level link to bucket bores must have
washer/seal assembly P/N 423-6577 installed to each side of the bore.
1. Apply grease around the outer perimeter of the bore to help hold the washer/seal in
place during installation of the hoist cylinder or level link.
2. Place the washer/seal into position in the bore with the seal flange to the pin side, as
shown in illustration "WASHER/SEAL ASSEMBLY".
3. Apply grease to the outside of the washer/seal to help it slide past the lift arms or bell
crank or bucket (as applicable).
l. Wrap a chain around the upper end of one of the hoist cylinders and hoist it slightly to bring it in line
with the lift arm bore. Refer to illustration "PLACEMENT OF CHAIN AROUND HOIST CYLINDER"
This photograph shows a chain wrapped around the hoist cylinder to hoist the cylinder into alignment with
lift arm bore.
Figure 4. ALIGNMENT OF THE HOIST CYLINDER BORE WITH THE LIFT ARM BORE
Note that the cylinder rod has been extended.
u. Use a hammer to tap the bushings into the bore as required. Refer to illustration "SAWCUT
BUSHING BEING DRIVEN INTO THE BORE".
w. Install the outside washer and nut. Refer to illustration "INSTALLATION OF THE NUT AND OUTSIDE
WASHER".
This photograph shows the use of a 1-inch impact wrench to tighten the bolt and nut.
Figure 11. TIGHTENING OF HOIST CYLINDER PIN RETAINING BOLT AND NUT - (1 OF 2)
This photograph shows the backup wrench for nut and bolt tightening.
Figure 12. TIGHTENING OF HOIST CYLINDER PIN RETAINING BOLT AND NUT - (2 OF 2)
Figure 13. OUTSIDE WASHER BEING DRIVEN IN - TO CENTER - THE OPEN IN THE BORE
aa. Use a click-type torque wrench with a torque multiplier to torque the nut to the torque value listed in
the CAPSCREW TORQUE CHART. Refer to the following illustrations.
● "TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - 1 OF 2"
● "TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - 2 OF 2"
This photograph shows the use of a click-type torque wrench and torque multiplier to torque the nut and
bolt. Note 2-1/2" I.D. pipe approximately five feet long serving as a backstop extension for the torque
multiplier.
Figure 14. TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - (1 OF 2)
This photograph shows the backup socket and extension used for torquing the hoist cylinder retaining bolt
and nut.
Figure 15. TORQUING OF HOIST CYLINDER PIN RETAINING NUT AND BOLT - (2 OF 2)
bb. Recheck the hydraulic reservoir fluid level and fill to the full mark on the sight gauge.
b. Remove pin retainer plates from the bucket and level link pins on the bucket.
c. Screw a slide hammer into the pin puller plate and pull the pins and sleeves from the bucket ear
bores. Refer to the following illustrations.
● "REMOVAL OF BUCKET PINS - 1 OF 3"
● "REMOVAL OF BUCKET PINS - 2 OF 3"
This photograph shows a slide hammer being used to pull the pins and sleeves from the bucket ear
bores.
d. Remove spiral retaining rings and remove pin puller plates. Refer to illustration "REMOVAL OF
BUCKET PINS - 3 OF 3"
This photograph shows the bucket pins, sleeve, pin puller plate and retainer plate following removal .
Figure 20. LIFT ARM PIVOT BORE BEING CLEANED OF PAINT AND RUST
g. Lubricate lift arm bucket pin bores with NLGI #2 lithium-based grease.
h. Hoist bucket into position for pin installation. Refer to illustration "MOUNTING OF BUCKET TO LIFT
ARMS - 1 OF 2". Use the forklift to tilt the bucket to align the lift arm bores with the bucket bores, if
necessary. Refer to illustration "MOUNTING OF BUCKET TO LIFT ARMS - 2 OF 2". Gaps on each
side of the lift arm bosses should be about the same on each side (placement of shims will improve
gaps later).
This photograph shows the bucket being hoisted to align the lift arm bucket pivot bores with the bucket
ear bores.
Refer to "LIFT ARM AND LINKAGE GROUP - L-1350 - PIN AND BUSHING INSTALLATION, VIEW E"
for an illustration of the bucket to lift arms pin assembly installation.
i. Drive the bucket pins into the bores as suggested below. Refer to illustration "INSTALLATION OF
BUCKET PIVOT PIN - 1 OF 2"
DO NOT use a hard-steel sledge hammer to contact the tapered ends of the pins. Contacting the
edge of the tapered section of the pin with a sledge hammer can render the pin unusable as the
deformation of the taper will prevent the tapered bushing from seating correctly. Use either a soft-
faced dead blow hammer, a mild steel drift or insert a bolt (below Grade 5) into the end of the pin
and strike the bolt head.
This photograph shows bucket pivot pin being driven into its bore. Note the bolt inserted into the end of
the pin to protect the pin from damage from the sledge hammer.
This photograph shows the bucket pivot pin installed into its bore an equal distance from each side.
This photograph shows the retainer plate being used to drive a sleeve down until it bottoms out against
the thrust washers in the lift arm bores.
This photograph shows a pin puller plate about to be installed in its bore.
This photograph shows the spiral retaining ring being maneuvered into mounting position in its bore.
o. Determine which side has the smaller gap between lift arm boss and bucket ears and shim from that
side.
p. Install shims in shim space to completely fill space. Last shim should extend past face of bolt ring.
q. Place the shim pack against the pin retainer plates and insert a stiff wire through the plate and shims.
The wire will center the shims on the retainer plate and hold them in place during installation. Refer to
the following illustrations.
● "INSTALLATION AND SHIMMING OF BUCKET PIVOT PINS - 5 OF 8"
● "INSTALLATION AND SHIMMING OF BUCKET PIVOT PINS - 6 OF 8"
This photograph shows a piece of stiff wire inserted through a retainer plate and shim pack prior to
mounting.
r. On the other end of pin, install shims just short of filling shim space. Using various thicknesses of
shims as a feeler gauge between lift arm bosses and bucket ears will determine the set up needed to
just fall short of filling shim space. Refer to illustration "INSTALLATION AND SHIMMING OF
BUCKET PIVOT PINS - 7 OF 8".
This photograph shows one of the shims being used to determine the final shim pack thickness.
t. Torque bolts per the CAPSCREW TORQUE CHART. Refer to illustration "TORQUING OF BUCKET
PIVOT PIN RETAINER PLATE CAPSCREWS".
This photograph shows the torquing of the retainer plate retaining bolts.
b. Remove the level link pins from the bucket and bell cranks and clean of paint and rust and remove
any nicks and burrs.
c. Lubricate the level link pin bores with NLGI #2 lithium-based grease. The level link pin bores are
lubricated. The sawcut bushing bores on the bell cranks and the bucket are not lubricated.
Refer to illustration "LIFT ARM AND LINKAGE GROUP - L-1350 - PIN AND BUSHING
INSTALLATION" located in the section of this manual entitled ASSEMBLY PRIOR TO ENGINE
START-UP, PART 1 for standard level link-to-bucket pin installation.
d. Install a suitable fiber lifting sling around the level link and hoist into position for mounting on the
bucket. Refer to illustration "LEVEL LINKS BEING HOISTED INTO MOUNTING POSITION".
e. Install washer/seal P/N 423-6577 to level link bore. Refer to NOTE above for washer/seal installation
instructions.
1. Install a retainer ring into a groove in the bore of new level link structure.
2. Align the spherical bearing with bore of level link structure from side opposite the retainer ring.
Ensure that the split line of spherical bearing‟s outer ring is positioned 90º to the centerline of
level link assembly. Apply a light coat of 30W oil to the OD of the spherical bearing.
3. Using a sleeve with O.D. slightly smaller than the level link structure bore I.D., placed against the
outer race of the spherical bearing. Press the spherical bearing into bore of level link assembly.
B. JOINT ASSEMBLY
1. Apply grease to both sides of the spherical bearing outer face and position the O-rings in position
on both sides of spherical bearing. The grease will aid to holding the O-rings in place while
installing the level link structure. The O-rings may catch on the bucket hinge bosses. If this
occurs, use a suitable tool to force the O-ring back into position.
2. Center the self aligning bushing in reference to the bucket hinge boss bore.
3. Apply grease to the hardened surface of the straight pin. Install the pin.(Pin is installed from the
center of the bucket pointed outward. Position the pin lug cap plate between the square bolt
blocks on the bucket.)
4. Install the retaining bar over the pin lug cap. Torque the retaining bolts.
C. PIN REMOVAL
1. Unload the pin joint by placing bucket on the ground and neutralizing the hydraulic pressure.
2. Remove the retaining bare over the pin lug cap.
3. Remove the pin
B. JOINT ASSEMBLY
Once, fastener torque is achieved, remove the torquing device and strike the area around the
bucket bosses to help seat the tapers. Re-torque the bolt and repeat the striking procedure until
no further advancement is recorded.
9. The fastener torque needs to be checked immediately after the first 15 minutes of operation, then
rechecked at 2, 4, 8, and 16 hour intervals or until no further nut advancement is recorded.
C. PIN REMOVAL
1. Unload the pin joint by placing bucket on the ground and neutralizing the hydraulic pressure by
using the manual hydraulic bleed valve assembly.
2. Remove the fastener, nut, and the two capture washers.
3. Loosen the sawcut bushing by using a drift or heavy bar (made from soft metal such as brass) to
strike the end of the pin.
4. If the bushings have seized in the bore, install the bushing removal tool by fastening to the
sawcut bushing. Tighten the four fasteners evenly. If the bushing does not come out when
fasteners are tight, strike the center of bushing removal tool with hammer.
5. With the bushings removed, push the pin from the bore of the spherical bearing.
h. Install pin into the bore. Refer to illustration "INSTALLATION OF LEVEL LINK PIN AT BUCKET".
i. Install the sawcut bushings to each end of the pin. Refer to illustration "INSTALLATION OF
SAWCUT BUSHINGS ".
Figure 41. INSTALLATION OF THE INSIDE WASHER TO THE BUCKET LEVEL LINK BORE
Figure 42. INSTALLATION OF THE OUTSIDE WASHER, FASTENER AND NUT TO THE BUCKET
LEVEL LINK BORE
This photograph shows the use of a 1-inch impact wrench to tighten the retaining fastener and nut.
Figure 43. TIGHTENING OF LEVEL LINK TO BUCKET PIN RETAINING FASTENER AND BOLT
l. Blow the horn to alert all persons around the machine that the engine is about to start. Wait 30
seconds for them to exit the area.
m. Start the engine.
n. Install the washer/seal P/N 423-6577 to the level link bore. Refer to NOTE above for installation
instructions.
o. Move the joystick control to position the bell crank, in conjunction with the crane, to align the level link
and bell crank bores for pin installation. Refer to illustration "ALIGNING LEVEL LINK WITH
BELLCRANK".
These photograph shows the level link being moved into position for pin installation on the bellcrank. The
engine is started and the bellcrank is positioned horizontally with the joystick control while the crane
moves the level link vertically to align the level link pin bore with the bellcrank pin bore.
This photograph shows the level link pin in the bellcrank bore.
r. Install the sawcut bushings to each end of the pin bore with the sawcut 90° to the center of the pin (at
the top of the bore). Refer to illustration "INSTALLATION OF THE SAWCUT BUSHINGS TO THE
BELLCRANK LEVEL LINK PIN BORES".
Figure 49. INSTALLATION OF THE SAWCUT BUSHINGS TO THE BELLCRANK LEVEL LINK PIN
BORES
Figure 50. INSTALLATION OF THE WASHERS, FASTENER AND NUT TO THE BELLCRANK
LEVEL LINK PIN BORE
t. Tighten the fastener and nut with a 1-inch impact wrench. Measure the distance the washers are
pulled into the bore and use a sledge hammer to drive them to a position that is equal on each side.
This will center the pin and sawcut bushings in the bore.
Figure 51. TIGHTENING FASTENER AND NUT WITH 1 INCH IMPACT WRENCH
u. Use a click-type torque wrench and a torque multiplier to torque the fasteners and nuts on the bell
crank level link pins and bucket level link pins. Refer to the following illustrations.
● "TORQUING OF LEVEL LINK PIN RETAINING FASTENERS AND NUTS - 1 OF 2"
● "TORQUING OF LEVEL LINK PIN RETAINING FASTENERS AND NUTS - 2 OF 2"
To torque the bell crank level link pins, install a 2-1/2” I.D. steel pipe, approximately five feet long,
over the torque multiplier handle. Rest the pipe against the ground as a backstop for the torque
multiplier, as shown in illustration "TORQUING OF LEVEL LINK PIN RETAINING FASTENERS AND
NUTS - 1 OF 2".
This photograph shows a 2-1/2" I.D. pipe, approximately five feet long serving as a backstop extension for
the torque multiplier handle.
This photograph shows the level link bucket pin being torqued.
Figure 53. TORQUING OF LEVEL LINK PIN RETAINING FASTENERS AND NUTS - (2 OF 3)
Figure 54. TORQUING OF LEVEL LINK PIN RETAINING FASTENERS AND NUTS - (3 OF 3)
Record the steering cylinder part number and serial numbers on the Commissioning Form .
The steering pin fasteners are drilled for grease injection. DO NOT torque to the amount shown on
the CAPSCREW TORQUE CHART for that size bolt.
• Torque L-1350/L-1850/L-2350 steering pin fasteners to 850 ft. lbs. lubed with 30W
motor oil.
• Torque D/L-950/L1150 steering pin fasteners to 425 ft. lbs. lubed with 30W motor oil.
f. Remove fasteners, lock washers, flat washers, fastener block and capture plate from bottom of
steering pin mounting location.
g. Drive lower saw cut bushing from the bore.
h. Clean the steering cylinder bore of any paint or rust. Refer to illustration "CLEANING OF THE
STEERING CYLINDER ROD EYE BORE".
i. Lubricate the steering cylinder bore with NLGI #2 lithium-based grease. Refer to illustration
"LUBRICATION OF THE STEERING CYLINDER ROD EYE".
j. Place a small amount of grease on the O-rings and place them into their slots on the cylinder rod eye.
Refer to illustration "INSTALLATION OF THE UPPER AND LOWER O-RING SEALS".
Note the lower sawcut bushing is driven down flush with the frame to prevent damage to the O-ring as the
rod eye is moved into position.
k. Install the lower sawcut bushing into the bore. Drive the sawcut bushing down flush with the
frame to avoid tearing the O-ring when the cylinder rod eye is pushed into place.
l. Station an operator at the controls and a person on the catwalk outside the cab in position to see
hand signals and relay them to the operator.
m. Place a 2” x 4” board, approximately eight feet long, under the cylinder rod, as shown in the following
illustrations. This board will serve as a lever to raise the cylinder rod eye and guide it into position.
● "MANEUVERING OF STEERING CYLINDER ROD FOR INSTALLATION OF PIN - 1 OF 2"
● "MANEUVERING OF STEERING CYLINDER ROD FOR INSTALLATION OF PIN - 2 OF 2"
This photograph provides another view of the cylinder rod eye being guided into position.
n. Blow the horn to alert all persons around the machine that the engine is about to start. Wait 30
seconds for them to exit the area. Follow all local rules for starting engine.
o. Start the engine.
p. Move the steering joystick control SLOWLY to move the cylinder out.
q. As the cylinder rod moves out, exert downward force on the end of the board to raise the cylinder rod
eye.
r. Check frequently to ensure the O-rings are in proper position and are not torn.
Check hole alignment in steering pin. Lubrication hole must be 90º to the action of the
cylinder.
t. Install the upper sawcut bushing. Refer to illustration "INSTALLATION OF THE UPPER
SAWCUT BUSHING".
Figure 65. INSTALLATION OF THE FASTENER AND WASHER TO THE STEERING CYLINDER
PIN
v. Install the fasteners, lockwashers, flatwashers, bolt block and capture plate. Refer to illustration
"INSTALLATION OF THE FASTENERS, LOCKWASHERS, FLATWASHERS, BOLT BLOCK AND
CAPTURE PLATE".
w. Tighten the steering pin fastener and nut. Refer to the following illustrations.
● "TIGHTENING OF THE NUT"
● "BACK-UP WRENCH IN POSITION FOR TIGHTENING THE NUT"
Steering cylinder pin retaining fastener torques to 425 ft. lbs for models D/L-950 and L-1150. 850
ft. lbs. for models L-1350/L-1850/L-2350. DO NOT exceed torque values.
x. Refer to illustration "TORQUING OF THE FASTENER AND NUT AT STEERING CYLINDER ROD".
Figure 69. TORQUING OF THE FASTENER AND NUT AT STEERING CYLINDER ROD
Figure 70. TORQUING OF THE STEERING CYLINDER DEAD END FASTENER AND NUT
z. Reinstall the auto lube system line and pin lug cap. Refer to illustration "COMPLETED STEERING
CYLINDER PIN ASSEMBLY INSTALLATION".
This photograph shows the use of optional torque multiplier fixture, shown in the section of the Assembly
Manual entitled "SUGGESTED MANPOWER, FIXTURES, TOOLS AND SUPPLIES".
Figure 72. TORQUING TOF THE HOIST CYLINDER BALL CAP CAPSCREWS
1. CAPSCREW LUBRICATED WITH 30W MOTOR OIL ON THE THREADS AND UNDER THE
HEADS.
2. FOLLOW THE NUMBERED SEQUENCE IN INCREMENTAL TIGHTENING UNTIL ALL
FASTENERS ACHIEVE DESIRED TORQUE. DO NOT TIGHTEN ANY ONE FASTENER BEFORE
OTHERS ARE DRAWN DOWN INCREMENTALLY.
3. REFER TO ILLUSTRATION “CAPSCREW IDENTIFICATION AND TORQUE CHART” FOR
PROPER TORQUE AMOUNT.
Figure 75. L-950/L-1150 HOIST CYLINDER BALL CAP INSTALLATION TORQUE
SPECIFICATIONS
OPERATIONAL HAZARD
Before performing inspections or repair to the machine, lockout the machine’s starting
capability with the Battery Isolation Switch. Serious injury or loss of life is possible if the
machine is started while maintenance or repair operations are being conducted.
Operational inspections of the “KLENZ™” system are required as part of the preventive
maintenance program. Exercise caution during all procedures to avoid hot or rotating
components. Alert all personnel in the area of operational testing being conducted and
instruct them to stay clear of the area.
The “KLENZ™” Enable Switch must be turned to the OFF position and compressed air
pressure relieved prior to performing any inspection or service work to the “KLENZ™”
filtration system. Personal injury and serious component damage is possible.
FIRE HAZARD
Under no circumstances should lit cigarettes or any burning object be put into the hood or
ducting of the “KLENZ™” filtration system. No welding repairs should be performed inside the
filtration unit, without fire protection. Serious injury or loss of life could occur.
Never spray ether cold starting aid into the air intake of the “KLENZ™” filtration system.
Personal injury and serious component damage is possible. The use of ether is NOT
recommended by LeTourneau as an engine starting aid.
CRUSH HAZARD
Use the Battery Disconnect switch or Battery Isolation switch to help prevent starting the
machine. Failure to prevent starting the machine could result in severe injury or death.
Use caution when opening the inlet KLENZ door. If the loader is on a slight incline or in high
wind, the door could quickly swing wide open. This could result in personal injury or damage
to the door and hinges
1. MIST ELIMINATORS
2. GASKET
Figure 81. KLENZ CLEAN AIR SYSTEM DOOR
c. Verify that the panels are positioned so that the baffles will direct water down and to the outside of the
KLENZ unit. Refer to illustration MIST ELIMINATOR-BAFFLES AND AIRFLOW DIAGRAM ".
Reinstalling Baffles
Figure 83. MIST ELIMINATOR BAFFLES AND AIR FLOW DIAGRAM
d. Replace the panels and close the access panel door.
1. BELLCRANK SENSOR
POSITION GUARD
STRUCTURE
2. LOCKWASHER
3. FASTENER
4. FLEX COUPLING
5. POSITION INDICATOR
ASSEMBLY
6. BAR ADAPTER
7. BELLCRANK LIMIT MOUNT
STRUCTURE
8. SHIM
9. FASTENER
10. CAPSCREW
11. LOCKWASHER
12. FASTENER
13. FLATWASHER
14. CABLE CONNECTOR
15. 11 GAUGE SHIM
This photograph shows the bellcrank transducer wiring harness being secured to auto lube system lines
with wire ties
c. Secure the wiring harness to the brackets on the inside of the lift arms, as shown in illustration
"SECURING BELLCRANK POSITION INDICATOR WIRING HARNESS - 2 OF 2".
This photograph shows the bellcrank transducer wiring harness secured into brackets on the inside of
the lift arms.
For bellcrank transducer calibration instructions refer to "CALIBRATION PROCEDURES IN THE LINCSII
SECTION OF THIS CHAPTER.
For bellcrank transducer calibration instructions refer to "CALIBRATION PROCEDURES IN THE LINCSII
SECTION OF THIS CHAPTER.
Figure 97 FRESH GREASE EXITING ONE OF THE LIFT ARM BALL CAPS
Figure 98. FRESH GREASE EXITING ONE OF THE HOIST CYLINDER BALL
LINCS II
Figure 100. SET THE AUTOMATIC LUBE CYCLE TIME
Maintenance Level (or higher) Security Access is required to set the Auto Lube Cycle Time.
Current Production Models: To check the oil level – the dipstick can be removed and inspected for
proper oil level.
Oil level should be at the dot on the dipstick (middle of crankshaft).
If the level is not full, check for leaks and repair as necessary.
Oil can be added through the Dipstick hole.
The pump gearbox does not have a drain port. The oil can be removed by:
Removing the pump and turning it over
Use a suction tool such as the Lincoln 615 suction gun shown below
Solenoid Coil
The coil has to be oriented as shown in the figure to properly engage the solenoid when energized.
There are three flat spade type terminals on the coil. The terminal in the middle should be oriented toward
the block.
The end of the coil with the solid metal washer goes against the retainer nut – NOT against the block
A pump that does not have the pressure and flow properly adjusted may fail quickly.
1. Oil Pressure Control: Pressure reducing relief setting is used for setting the maximum hydraulic
pressure on the motor at stall.
2. Oil Flow Control: Flow control for setting the pump speed.
Required Tools:
1. Hex Key Wrench
2. Combination Wrench
3. Gauge 0 – 5000 psi and high pressure tee.
Prior to working on the Auto Lube Pump, all safety precautions (such as risk assessments and
isolation of energy sources) should be taken per mine site regulation. Adjustments of the Auto
Lube Pump will require the machine to be operational. Among the safety precautions are items
such as:
Install safety link
Clear area
Set park brake
Chock tires
Be sure that grease pressure has been bled from the system before removing a pressure switch
or transducer to insert the tee.
Part of the adjustment is to cause the Auto Lube Pump to stall out. If the adjustment takes more
than 90 seconds it will be possible to get a Long Cycle Alarm message in the cab.
2. Install tee and pressure gauge (0 – 5000 psi) in the grease supply line next to pressure transducer.
3. Loosen the jam nut on the pressure reducing relief valve and turn the adjustment screw three
turns counterclockwise (CCW). This should assure minimal pressure when the Auto Lube Pump
starts.
The automatic lubrication system is hydraulically powered. The engine must be running to make
adjustments. LINCS software will turn on the solenoid and Auto Lube Pump for 90 seconds.
TIRE INFLATION
Do not inflate tire until the wheel and tire have been mounted on the machine.
Over-inflation and under-inflation tire pressures can cause serious tire and machine problems.
Of particular significance is over-inflation of the rear tires. This condition can have a very detrimental
effect on frame fatigue and traction motor overspeed. Over-inflated rear tires can also cause the rear of
the machine to “bounce”. This action, in turn, multiplies any stresses through the rear frame and the
articulation ball/sockets. Under severe instances, the rear tires can lose traction and cause an
instantaneous motor overspeed.
If anything less than these requirements is used, the system will not work to its full potential.
INFLATION PROCEDURES – STEP 1
For clarity reasons, valve is not shown installed in rim. Assume for these instructions elbow is
installed into rim.
1) KNURLED NUT 2) SHUT-OFF VLAVE (BALL TYPE) A). HANDLE SHOWN IN CLOSED POSITION B)
PLAN VIEW
Figure 107. TIRE INFLATION INSTRUCTIONS - STEP 4
Refer to Tire size and inflation date in the Tire Size Inflation Data Recommended Cold Tire Inflation
Pressures Table, within this section, for the proper tire pressure. The tire inflation data is also
located on a metal plated mounted on the right-hand side of the front frame at the pivot area (refer
to TIRE DATA PLATE LOCATED ON THE RIGHT SIDE OF THE FRONT FRAME). The front and rear
tires have different pressures.
Couple air hose to male quick connector. Make sure air available to inflator is at 100 psi (6.9 bar).
Slowly open ball valve connected to the inflator and air compressor to inflate the tire.
1) SCHRADER VALVE 2) HANDLE SHOWN IN OPEN POSITION FOR TIRE INFLATION 3) SHUT-OFF
VALVE 4) TO TIRE
Figure 110. TIRE INFLATION INSTRUCTIONS - STEP 7
1) KNURLED NUT 2) STEM NUT 3) HANDLE CLOSED 4) MALE PIECE 5) HANDLE SHOWN IN CLOSED
POSITION
Figure 111. TIRE INFLATION INSTRUCTIONS - STEP 8
1) CAP
Figure 113. TIRE INFLATION INSTRUCTIONS - STEP 10
The inflation pressures in the previous table are based on latest information from the tire
manufacturers and should be applicable for the majority of locations. However, it is possible that
local conditions could require a variation in the recommended pressures. It is possible that a tire
manufacturer issue might issue an official Technical Bulletin regarding a tire pressure deviation
from the table., the user should provide the tire manufacturer recommendation to Wheel Loader
Product Support before changing the recommended tire pressure. Failure to consult with the tire
manufacturer and LeTourneau regarding specific tire pressure and application can result in
severe tire damage or tire failure and may possibly affect machine warranty.
Recommended inflation pressures are “cold” pressures. If pressure is checked before the tire
cools down (in some cases this can be up to 24 hours) allow a margin of 15 psi (1 bar) over
recommended “cold” pressure for pressure build up due to heat.
To maintain these pressures, weekly inspections should be instituted to verify cold inflation
pressures. When possible, daily checks by the operators will help to maintain optimum pressure
levels, lengthen tire life and increase machine performance.
The Tire Data Plate located on the right side of the front frame shows the proper tire pressures.
Table 1. TIRE SIZE AND INFLATION DATA - RECOMMENDED COLD TIRE INFLATION
PRESSURE
If the bucket is not at the proper angle, the bellcrank stop shim packs can be increased or decreased to
obtain the desired position.
1. Increasing the number of shims under the bellcrank stops will result in a tooth up position.
2. Decreasing the number of shims under the bellcrank will result in a tooth down position.
1. SHIM
2. SHIM
3. STOP BLOCK
4. LOCKWASHER
5. CAPSCREW
Figure 115. BUCKET ROLLBACK AND BELLCRANK STOP BLOCK INSPECTION (TYPICAL)
The rollback stop blocks are positioned so that they contact the lift arms at the SAE standard carry
position. The SAE standard carry position is defined where the bottom of the bucket pivot is at an angle
that is 15° tangent to the tire. The rollback stop blocks should contact the lift arm prior to the bucket
cylinder achieving full extension from this height down. This protects the bell cranks and bucket cylinders
from loads when the bucket is rolled back while filling the bucket in the bank.
This procedure provides the correct height at which the lift arms are positioned for bucket rollback stop
block placement. The additional tables take into account setting stops when the loader has different tire
sizes.
The size of the bucket rollback stop mounting blocks on back of the bucket will vary depending
on the machine type and whether the lift arm is high lift or standard lift. The orientation and
standoff measurement of these blocks must be considered when swapping buckets between
machine or lift arm types. The rollback stop position should be checked anytime a bucket is
changed.
This is a one time procedure that matches the stops on a bucket to the lift arms on a loader. As
long as the same bucket is being used on the loader - the only maintenance required is to replace
the rubber stop pads when they are worn or damaged.
The angle of contact between the rollback stop and the lift arm is critical. The rubber stop must
contact the arm squarely. The rollback stop mount pad must be properly positioned and
angularity between the stop block and lift arm verified before trying to make adjustments. The
mounting structure angles and heights will be different depending on what type of bucket is used
and whether the machine has high lift arms or standard lift arms.
If the angle of contact is not correct, the mount structure will have to be cut off and re-welded to
the correct position. All cutting and welding on the bucket structure has to follow the LeTourneau
Field Welding Procedures (formerly known as Let-1). The most up to date revision of this
document is located in LeTrak knowledgebase article KB #436.
a. Locate the loader on a flat open area without overhead obstructions. Bucket should be placed flat
and on the ground level.
b. Block the tires and prevent the machine from starting following all local safety rules and procedures.
c. Remove the bucket rollback stop blocks and shims from both left and right sides of the bucket.
d. Start the loader following all local safety rules and procedures.
During the following steps performed while replacing the bucket stop blocks, several
measurements will have to be obtained. Follow all local safety rules and procedures while
obtaining these measurements. Crush hazards that could result in serious injury or death exist
during this process.
e. Position the bucket at the height listed in the appropriate table. The correct table is determined
based on some specific criteria.
o Generation2 machines: Use Generation2 machine table (Hoist Cylinder Extension Method)
ALL Generation 2 machines will be set using hoist cylinder extension only.
f. Bypass limits
1. 50 Series Loader with LINCS II:
Access the LINCS™ System Settings/Machine Settings screens and check the box to
bypass the bucket and hoist limits. This requires maintenance level access.
Access the LINCS™ Operator User Preference Inhibit Park Brake Release Mode: Enable
(this allows the park brakes to remain set while the hydraulics are operable). Place the
park brake switch in the released position. Park brake light will flash red because brakes
are still set.
g. SLOWLY roll the bucket back until it stops. The bucket cylinders are fully extended at this time. DO
NOT force the bucket back after contact is made. See the CAUTION above if machine is equipped
with the linear position transducer under the bellcrank.
h. Use a permanent marker to place a mark, on one of the cylinder rods, that is 1” (25.4 mm) from the
rod wiper.
i. SLOWLY roll the bucket forward toward the dump position to retract the cylinder until the mark is
flush with the rod wiper [1” (25.4 mm) retracted].
j. Install the stop blocks on both sides, with necessary shims, to achieve full contact of both stop block
pads with the lift arms on both sides. The bucket rollback stop blocks must make simultaneous,
even, and full contact with the lift arms.
Special instructions for machines with linear position transducer under right hand bell
crank:
Install the linear position transducer under the bell crank.
The machine should be positioned straight and not turned to either side. Install the frame lock
prior to any testing. Failure to do so could result in injury. Be sure all personnel are secure and in
safe positions prior to doing any testing. Place signs to alert other personnel to keep a safe
distance from the machine.
This test needs to be performed on flat level ground so the lift arms cannot move up and down during the
test.
a. Set the bottom plane of the bucket flat on the ground.
b. Mount the magnetic base of a dial indicator on the frame structure next to the lift arm ball cap so the
indicator contacts the ball cap as near to center as possible. The centerline of the dial indicator
should be aligned with the centerline of the ball cap. It may be necessary to scrape off some paint on
the frame in order to have the magnetic base securely mounted.
Refer to illustration "DIAL INDICATOR SETUP FOR CHECKING LIFTARM BALL JOINTS" for an
example of dial indicator setup. Ball joint shown in the illustration is a lift arm ball cap; however,
dial indicator installation is the same for other ball joints.
Figure 119. DIAL INDICATOR SET-UP FOR CHECKING LIFTARM BALL JOINTS
c. Move the machine backwards three to four feet and apply the brakes. Zero the dial indicator.
d. Release the brakes and slowly move the machine forward three to four feet (with the bucket still on
the ground).
e. As the machine begins to move forward, the dial indicator needle should “snap” from the zero setting
to some value.
Use only capscrews available under LeTourneau P/N shown for these applications. Inspect the
thread count, size of bolt and type of bolt removed from the original application before installing
new bolts. Always make sure the bolt thread count, size and type matches the old or new
application before installing bolts.
Table 2. CAPSCREW IDENTIFICATION AND TORQUE CHART
1. All capscrews to be lubricated on the threads and under the heads with 30W motor oil.
2. Use properly calibrated hydraulic torque wrench or torque multiplier.
3. Inspect the bolt thoroughly to determine the exact type of bolt (especially size and thread
count). Check the "CAPSCREW TORQUE CHART", of this manual, to determine the proper
amount of torque to be applied to the bolt. Read all NOTES or KEY ITEM callouts on the
"TORQUE CHART" before determining the torque amount.
4. Use Parts Catalog to determine what bolt PN is used.
The “snap” value is the endplay reading for the lift arm ball cap. Take care to read only the “snap”
reading. Failure to do this can lead to very tight ball socket assemblies, heat, and rapid wear.
The machine should be positioned straight and not turned to either side. Install the frame lock
prior to any testing. Failure to do so could result in injury. Be sure all personnel are secure and in
safe positions prior to performing any testing. Place signs to alert other personnel to keep a safe
distance from the machine.
a. Set the bottom plane of the bucket flat on the ground.
b. Mount the magnetic base of a dial indicator on the frame structure next to the hoist cylinder
ball cap so the indicator contacts the ball cap as near to center as possible. The centerline of
the dial indicator should be aligned with the centerline of the ball cap. In this case, the dial
indicator will typically be nearly horizontal. It may be necessary to scrape off some paint on
the frame in order to have the magnetic base securely mounted.
c. Slowly power down the machine with the hoist until the weight comes off of the tires. (It is not
necessary to lift the front end of the machine). Zero the dial indicator.
d. Slowly hoist the lift arms.
e. As the arms begin to move up, the dial indicator needle should “snap” from the zero setting to
some value.
The “snap” value is the endplay reading for the lift arm ball cap. Take care to read only the “snap”
reading. Failure to do this can lead to very tight ball socket assemblies, heat, and rapid wear.
f. Repeat the test while holding the joystick in the “Power Down” position.
g. Repeat the test several times as you hoist up and down until you are able to obtain consistent
numbers.
h. Repeat the test on both left and right hoist cylinder ball caps.
i. Compare this reading to those in table “ BALL BASE-SOCKET-CAP SPECIFICATIONS",. If
above the maximum reading for (or minimum new setup reading) the shim pack will have to be
adjusted. Adjust the shim pack to bring the endplay into the “New Setup Range”. Refer to
figure "SNAP VALUE (DEFLECTON AND CLEARANCE)".
The machine should be straight and not steered to either side. Install the frame lock prior to doing
any testing. Failure to do so could result in injury. Be sure all personnel are secure and in safe
positions prior to doing any testing. Place signs to alert other personnel to keep a safe distance
from the machine.
Remote readout electronic dial indicators are available from many manufacturers such as Starrett,
Brown and Sharp, Federal, Mitutoyo and others.
Figure 121. DIAL INDICATOR SETUP FOR CHECKING HOIST CYLINDER BALL JOINTS
c. Slowly power down with the hoist until the weight comes off of the tires (it is not necessary to lift the
front end of the machine). Zero the dial indicator.
d. Slowly hoist the lift arms.
e. As the arms begin to move up, the dial indicator needle should “snap” from the zero setting to some
value. After that, the needle will typically continue to move slowly in the same direction.
The “snap” value is the endplay reading for the middle pivot ball cap. Take care to read the “snap”
reading. All other needle movement is due to deflection and cap movement. Failure to do this can lead to
very tight ball socket assemblies, heat, and rapid wear.
f. Repeat the test powering down.
g. Repeat the test several times as you hoist the unit up and down until you are able to obtain consistent
numbers.
h. Repeat the test for top and bottom pivot ball caps.
i. Compare the reading obtained to those in table “ BALL BASE-SOCKET-CAP SPECIFICATIONS",
below. If above the maximum reading (or below the minimum new setup reading), the shim pack will
have to be adjusted. Adjust the shim pack to bring the endplay into the “New setup range”. Refer to
table "SNAP VALUE (DEFLECTION AND CLEARANCE,” above).
It is not recommended that endplay readings be taken on the rear axle of an operating machine.
These readings should be taken using either jacks or a crane of appropriate capacity (LOADER
JACKING INSTRUCTIONS, located in Section 3 in this manual).
The machine should be straight and not steered to either side. Install the safety link prior to doing
any testing. Failure to do so could result in injury.
a. Set the bottom plane of the bucket flat on the ground.
b. Mount the magnetic base of a dial indicator on the axle structure next to the pivot ball cap so the
indicator contacts the ball cap as near to center as possible. The centerline of the dial indicator needs
to be aligned with the centerline of the ball cap. In this case, it should be vertical. It may be necessary
to scrape off some paint in order to have the magnetic base securely mounted (refer to figure "
TYPICAL INDICATOR SETUP FOR MEASURING ENDPLAY IN BALL AND CAP ASSEMBLY,"
above).
c. Slowly raise the frame with the jack until the ball caps hold the weight of the axle.
Do not lift the machine high enough to allow the axle to oscillate or false readings will be
obtained.
d. Lower the frame slowly and smoothly until the frame rests on the axle. As the frame begins to lower,
the dial indicator needle should “snap” from the zero setting to some value.
The “snap” value is the endplay reading for the rear oscillating axle ball cap. Take care to only
read the “snap” reading. Failure to do this can lead to very tight ball socket assemblies, heat and
rapid wear.
Do not do this test while powering up with a jack. Typically a jack will hoist in a jerky manner and
cause the needle of the dial indicator to simulate a “snap” reading. Even though it is actually
showing deflection.
e. Repeat the test several times as you hoist the unit up and down until you are able to obtain consistent
numbers.
f. Compare this reading to those in table " BALL BASE-SOCKET-CAP SPECIFICATIONS," below.
If above the maximum reading (or below, the minimum new setup reading), the shim pack will have to
be adjusted. Adjust the shim pack to bring the endplay into the “New setup range”. Refer to figure
"SNAP VALUE (DEFLECTION AND CLEARANCE)," above.
The machine should be straight and not steered to either side. Install the frame lock prior to doing
any testing. Failure to do so could result in injury. Be sure all personnel are secure and in safe
positions prior to doing any testing. Place signs to alert other personnel to keep a safe distance
from the machine.
a. Set the bucket on the ground and place the hoist lever in the FLOAT position.
b. Mount the magnetic base of a dial indicator on the front frame structure next to the middle pivot
ball cap so the indicator transducer or remote gauge head contacts the ball cap as near to center
as possible. The centerline of the indicator transducer or remote gauge head needs to be aligned
with the centerline of the ball cap. In this case, it will be horizontal. It may be necessary to scrape
off some paint in order to have the magnetic base securely mounted. Refer to illustration "DIAL
INDICATOR SETUP FOR CHECKING LOWER MIDDLE PIVOT BALL JOINT".
c. Slowly power down with the hoist until the weight comes off of the tires (it is not necessary to lift the
front end of the machine). Zero the dial indicator.
d. Slowly hoist the lift arms.
e. As the arms begin to move up, the dial indicator needle should “snap” from the zero setting to some
value. After that, the needle will typically continue to move slowly in the same direction.
Figure 123. DIAL INDICATOR SETUP FOR CHECKING LOWER MIDDLE PIVOT BALL JOINT
The “snap” value is the endplay reading for the middle pivot ball cap. Take care to read the
“snap” reading. All other needle movement is due to deflection and cap movement. Failure to do
this can lead to very tight ball socket assemblies, heat and rapid wear.
It is not recommended that endplay readings be taken on the rear axle of an operating machine.
These readings should be taken using either jacks or a crane of appropriate capacity (MACHINE
JACKING INSTRUCTIONS).
The machine should be straight and not steered to either side. Install the safety link prior to doing
any testing. Failure to do so could result in injury.
a. Set the bucket on the ground and place the hoist lever in the FLOAT position.
b. Mount the magnetic base of a dial indicator on the axle structure next to the pivot ball cap so the
indicator contacts the ball cap as near to center as possible. The centerline of the dial indicator needs
to be aligned with the centerline of the ball cap. In this case, it should be vertical. It may be
necessary to scrape off some paint in order to have the magnetic base securely mounted.
c. Slowly raise the frame with the jack until the ball caps hold the weight of the axle.
Do not lift the machine high enough to allow the axle to oscillate or false readings will be
obtained.
d. Lower the frame slowly and smoothly until the frame rests on the axle. As the frame begins to lower,
the dial indicator needle should “snap” from the zero setting to some value.
The “snap” value is the endplay reading for the rear axle ball cap. Take care to only read the
“snap” reading. Failure to do this can lead to very tight ball socket assemblies, heat and rapid
wear.
Do not do this test while powering up with a jack. Typically a jack will hoist in a jerky manner and
cause the needle of the dial indicator to simulate a “snap” reading. Even though it is actually
showing deflection.
e. Repeat the test several times as you hoist the unit up and down until you are able to obtain consistent
numbers.
f. Compare this reading to those in illustration "BALL BASE/SOCKET/CAP SPECIFICATIONS". If
above the maximum reading (or below, the minimum new setup reading), the shim pack will have to
be adjusted. Adjust the shim pack to bring the endplay into the “New setup range”.
These weights are only approximate and provided as a guide for determining proper lifting
procedures and equipment. In all cases, adequate equipment should be used to provide a good
safety margin.
Figure 124. USE OF A CHAIN COME ALONG TO PULL THE STAIRS INTO PROPER ALIGNMENT
b. Inspect the mounting location of all handrails to ensure they are straight and properly seated in their
mounts. The handrails are properly seated when the handrail pipe is at the bottom of the mount.
Check this by examining the handrail through the slot at the bottom of the mounts. Refer to the
following illustrations.
● "SECURING HANDRAILS - 1 OF 2"
● "SECURING HANDRAILS - 2 OF 2"
This photograph shows a technician checking each handrail fastener to ensure they are tight.
This ladder/catwalk assembly was hoisted up to its mounting location by the forklift.
d. Install axle and front frame covers. Check each cover to ensure the gaskets are secure and properly
aligned to provide a good seal. Reseal any that are loose or misaligned with silicone gasket sealer.
Refer to illustration "INSTALLATION OF ONE OF THE ACCESS COVERS TO THE FRONT
FRAME".
GEN1
To install the adhesive signs:
a. Clean and dry the surface to be sure it is free of dust, oils, fingerprints or oxidation. Use isopropyl
alcohol to clean the surface.
b. Temperature of the mounting surface should be 50° F (10°C) or above.
c. Apply the label firmly and evenly on the surface and rub it down vigorously and apply mild heat of
100° to 130° F (38° to 54° C) to achieve good bonding.
GEN2
a. Attach stainless steel safety and identification labels inside cab and on the outside of loader with #6
right hand drive screws.
The following are the user preferences stored in the User Access Key:
1) Language
2) Unit System
3) Clock Format
4) Access Level
The different User Access Levels (i.e. Operator, Maintenance, etc.) allow access to different menus and
different LINCS II functions.
DO NOT set or change any settings during an actual loading operation or cycle. Before entering any
information, or making/changing any settings on any screen in the LINCS system, ensure the machine
is in an area clear of ALL hazards and personnel. Failure to do so could result in serious injury or
death to personnel.
YELLOW WARNINGS
A WARNING means that the equipment has experienced a fault that affects the standard operation but does
require an immediate shut down. The yellow light on the console turns on, the beeper sounds, and a
WARNING message is displayed. The machine should be safely moved to a safe location and then shut
down.
Some Warnings result in automatic changes in machine operation. For example, over-temperature conditions
in the Traction Drive System may result in reduced Motor Torque.
The operator can acknowledge the Warning by pressing the Acknowledge Switch on the left joystick.
BLUE NOTICES
A NOTICE provides information to the operator as an aid to normal operation. The Notice message will
automatically clear after a few seconds. The operator can clear the display early by pressing the
Acknowledge Switch on the left joystick.
In the following example, a Red Alarm was artificially generated and acknowledged.
Acknowledging the Red Alarm leaves a red “banner” at the top of the screen.
This particular Red Alarm has a 15 minute countdown as shown by the numbers in the middle of the
banner.
When the counters reaches 00, a sequence of actions occurs as designated by the software and the
engine shuts down.
In the following example illustration screen, a combination of 33 Warnings and Notices were artificially
created to demonstrate the displayed number (33).
As the acknowledge button is pressed, the number counts downward until all screens are acknowledged.
The touch screen is deactivated to touch when a Yellow Warning is being displayed on the screen.
ALL Red Alarms, Yellow Warnings or Blue Notices must be acknowledged, by using the Acknowledge
Button, before the screen becomes active to touch again.
Blue Notices will eventually remove themselves from the monitor screen. They have a timed delay
before automatic removal. They can also be manually removed by using the Acknowledge Button.
The left and right turn signal indicators blink when the turn signal is active. The turn signal buttons are located
at the top of the left joystick. The turn signal will cancel when the machine is steered straight.
The Bucket Angle measurement shows angle of the bucket as compared to the machine frame.
The Bucket Angle is usually near zero (0.0°) when the bucket is flat and level with the ground. But the
actual “zero” of the Bucket Angle can be changed by the operator. So Bucket Angle measurement may
show zero even when the bucket is not horizontal.
The Bucket Angle zero (0.0°) is set with the “ZERO TOOTH TO GROUND” setting located on the User
Preferences Screen.
A positive angle (+°) is shown when the bucket teeth are above the zero position and a negative angle (-°)
is shown when the bucket teeth are below the zero position.
Refer to “ZERO TOOTH TO GROUND” for more information.
The Weight measurement shows the current material weight in the bucket. The data can also be displayed
in metric units by navigating to the User Preferences Screen and selecting metric units.
The Weight measurement resets when the bucket is dumped after a completed dump cycle.
LOAD WEIGHT
A load weight will be registered during a load cycle if the following parameters are met:
o The lift arms are below horizontal.
o The lift arm height and bucket angle meet predetermined height and angle requirements.
o The bucket contains at least the minimum load needed to register a load weight.
o No commanded movement (by the right joystick) to the lift arms or bucket.
A load weight will also be registered if the lift arms are hoisted above horizontal and a previous load
weight has not been registered during this load cycle.
LOADING CYCLE TIMER
The Loading Cycle Timer indicates the length of a loading cycle. A loading cycle is the time recorded
between two bucket dumps. A bucket dump is defined as a loaded bucket being rolled forward past
10 degrees down of the machine frame angle.
LOAD CYCLE TIMES
The current and average cycle times are displayed on an analog and digital gauge, which resembles a
stop watch.
The Loading Cycle Timer provides, in analog format (1. gauge needle), data for the current load cycle.
The timer provides, in digital format (2. Avg:), the average time based on previous load cycles.
Shift – displays the weight of the material loaded during the shift (tons).
Productivity – displays the number of tons loaded per hour during the shift.
Trucks Filled – indicates the number of trucks loaded during the shift.
Truck – displays current weight of truck being loaded (tons). This value is reset by pressing the horn
button on the right joystick.
The size of the truck is set on the User Preferences Screen by selecting Truck Capacity.
The unit system (Imperial or Metric) for indicating weight is set on the User Preferences Screen by
selecting Unit System.
Selecting Reset Production Data on the User Preference screen will set the Shift Production Data to
zero. The size of the truck selected will not be changed.
Some of these icons only appear if the machine is operating in an abnormal mode.
Alarm Icon
The red Alarm Icon appears on the screen when an Alarm occurs and the Alarm
Message is displayed. The Red Lamp on the dash is illuminated at the same time.
Touching the Alarm Icon will select the Event Screen and display the list of the most
recent alarms. The Alarm Icon remains on the screen after the Alarm Message is
acknowledged until the condition that caused the alarm is corrected
Warning Icon
The yellow Warning Icon appears on the screen when a Warning occurs and the
Warning Message is displayed. The Yellow Lamp on the dash is illuminated at the same
time. Touching the Warning Icon will select the Event Screen and display the list of the
most recent warnings. The Warning Icon remains on the screen after the Warning
Message is acknowledged until the condition that caused the warning is corrected.
GAUGES
SYSTEM AIR PRESSURE GAUGE
The System Air Pressure Gauge provides an analog and digital display of the compressed air
system pressure. The System Air is used for operation of the Service Brakes, KLENZ, Air
Horn, etc.
The digital display‟s unit system (Imperial or Metric) is set on the User Preferences Screen by
selecting Unit System.
When operating in cold climates, the oil pressure indicator will be higher after starting
during engine warm-up. In cold climates, it takes longer for the oil to warm-up and for the
oil pressure to reach normal operating range.
FUEL GAUGE
The Fuel Gauge provides analog and digital display of the amount of fuel in the fuel tank.
The digital display indicates the percent (%) full. For example, if the tank can hold 500 gallons
of fuel, 50% indicates that the tank contains 250 gallons of fuel.
The Speedometer provides analog and digital display of the machine speed.
The Speedometer indicates the speed in both forward and reverse directions.
The display‟s unit system (Imperial or Metric) is set on the User Preferences Screen by selecting Unit
System
The Main Menu Button is located in the lower left corner of the screen and is labeled LINCS II.
MENU SELECTIONS
Touching the Main Menu Button displays the Main Menu Selections. Touch a Main Menu item to
select the screen or function. The list of menu items varies depending on the security level of the
User Access Key. Menu items containing a red arrow have sub-selections. Touch the menu item to
display the submenu.
UNIT SYSTEM
Touch the arrows (14) to select the Unit System used for displaying values (Metric, Imperial, or Broadcast).
Broadcast units are a mixture of unit systems that is preferred by the factory.
TRUCK CAPACITY
Touch the arrows (14) to decrease or increase the Truck Capacity as displayed on the Main Operator
Screen.
LAMP TEST
Touching the Lamp Test button will turn on the dash Red Alarm light, Yellow Warning lights, and the Cab
Audible Alarm.
The screen button is momentary so the lights and alarm stay on as long as the button is touched.
ALTERNATE SPEED
Touch the arrows (14) to set the machine Alternate Speed.
The Alternate Speed is the speed limit used when the Alternate Speed function is engaged.
Use the overhead control console “Alternate Machine Speed” button to engage the Alternate Speed function
1) Logging/Monitoring
The Logging/Monitoring menu selection provides access to the Charting Screen and the Event
Logging Screen.
2) Production Reports
The Production Reports menu selection provides access to the production reports such as Loads,
Cycle Times, Loader Activity, etc.
The selected channel list can be rearranged by dragging the channel name to a new location.
Channel Types
4) Calculated (derived from other data) shown as a calculator.
5) Input (Analog, Digital, or CAN) shown by a green “in” arrow.
6) Touch the Channel Selection Screen Button to display this screen.
7) Touch the Channel Charting Screen Button to display the selected channels in a chart or plot format.
8) Touch the Event Logging Screen Button to display a list of event records.
9) Touch the Remove All Channels Button to clear the list of selected channels.
10) Touch the Filtering Button to select the amount of noise filtering to be applied to the channel values
on the Channel Selection Screen. Selecting “Rabbit” gives light filtering that removes a minimal
amount of noise. Selecting “Turtle” gives heavy filtering so the values are more stable.
CHARTING SCREEN
The Charting Screen provides a way to view channel data in a plot or strip chart form. Multiple channels can
be displayed showing data “live” (as it occurs) or “history” (from previous time).
LIVE DATA
HISTORY DATA
2. Channel Value
The Channel Value is displayed at the top right of a trace. For live data the number shows the most
recent data. For history data, the number shows the value of the channel measurement. The vertical
scale of the charts is automatically set to fit the selected data.
7. Channel Plot
The channel is displayed as a curve plot that varies in height proportionally to the data value. The
channels are shown in the same order as listed on the Channel Selection Screen.
8. Event Markers
Events are indicated at the bottom of a trace. The event type is indicated by the color of the marker
(i.e. Red – Alarm, Yellow – Warning). A circle indicates when the event was set (i.e. when the Alarm
occurred). A solid dot indicates that the event cleared.
The time selection can also be changed by dragging a trace to the left or the right.
a. Cursor 1 is the value of the data at the point where the orange cursor crosses the plot.
b. Cursor 2 is the value of the data at the point where the blue cursor crosses the plot.
c. Average is the average of the values between the two cursors.
d. Maximum is peak value of the data between the two cursors.
e. Minimum is the valley value of the data between the two cursors.
f. RMS is the root-mean-squared value of the data between the two cursors.
g. dy/dt is the slope of a line between the two data points that are marked by the two cursors.
The slope is a measure of the change in amplitude of the data divided by the time between
the two points.
h. Area Under Plot is the sum of all the data values between the two cursors times the time
(the integral). It could be used to determine the total fuel used in a load cycle by measuring
Engine: Fuel Rate.
Event logging provides a method for viewing events such as Alarms, Warnings, and Alerts.
7. Page Button
The Page Buttons allow the user to jump through sections of 100 events at a time. Touch the bottom
Page Button to display the next page of older events, going back in time. Touch the top Page Button
return to the next page of more recent events.
8. Scroll Buttons
Use the Scroll Buttons to navigate the event list.
The Summary View shows a summary that gives the total occurrences of each event type in the history log.
The numbers indicate only the amount of events that occurred within the selected Date Range. The Summary
View is sorted with the most frequent event listed at the top.
2. Profile
The Profile report provides a summary of loader activity. The left scroll bar selects the time width of the
display window. The bottom scroll bar selects the window position in time.
4. Cycle Times
The Cycle Times report provides a bar chart that shows the number of cycles by the cycle time value.
The data range is selected by touching the Setup Button.
CLEANING PROCEDURE
Clean the screen with a clean, dry, soft cloth. If this does not clean the screen adequately, use water or a mild
glass cleaner. Do not use a cleaner that contains ammonia. Apply the cleaner to a clean soft cloth and not to
the screen. Never use an abrasive cleaner or cloth.
CHANGE SOFTWARE
This feature is available to users with Maintenance Level Access or higher.
Change Software allows the user to load new system control software (LINCS-II). The software package
includes all files needed for the HMI, VCU, and Drive computers.
1) Put the USB device that contains the new software into the USB port in the cab.
2) Select Load New Software.
3) Select the desired software version on the Select Software Update dialog box.
4) Touch the Accept button to start the software update process.
5) The update can take several minutes and includes rebooting of all of the computers. Do not remove
the USB device until the process is complete.
Calibration Procedure
The calibration procedures are step by step processes and are displayed on consecutive screens. Each
calibration has requirements that must be met before the calibration can be performed.
1) Select desired calibration.
2) Comply with the requirements for this calibration.
3) Touch continue to proceed, or exit to cancel.
2. Hoist/bucket
The Hoist/Bucket Calibration sets the values for:
Bellcrank to Lift arm Position Sensor
Lift arm Position Sensor
Bucket and Lift arm hydraulic responses
Bucket and Lift arm limits
This is an automated calibration process that involves moving the lift arms up and down, rolling the
bucket back and forward, and dumping the bucket.
The machine MUST be in an open area that provides adequate clearance.
Do NOT allow any personnel near the machine during the calibration.
Requirements are:
1) Engine at high throttle
2) Pilot Supply Pressure at 450psi (3100kPa)
3) Bucket empty
4) Bucket level and on the ground
5) Park Brake set
6) Lift arm Position Sensor properly installed
7) Bellcrank Position Sensor properly installed
3. Steering
The Steering Calibration sets the values for:
Steering Position Sensor
Steering hydraulic responses
Steering limits
This is an automated calibration process that involves steering full right and full left.
The machine MUST be in an open area that provides adequate clearance.
COPYRIGHT 2012 LOADER ASSEMBLY MANUAL r00
GENERATION2
8-180 LeTourneau 11/8/2012
Do NOT allow any personnel near the machine during the calibration.
Requirements are:
1) Bucket OFF the ground
2) Engine running
3) Park Brake released
4) Steering Position Sensor properly installed
4. Load weight
The Load Weight Calibration gets the values of the Hoist Base Pressure needed to accurately weigh
the material in the bucket. This procedure does not use a calibrated load.
This is an automated calibration process that involves moving the lift arms up and down, rolling the
bucket back and forward, and dumping the bucket.
The machine MUST be in an open area that provides adequate clearance.
Do NOT allow any personnel near the machine during the calibration.
Requirements are:
1) Engine at high throttle
2) Pilot Supply Pressure at 450psi (3100kPa)
3) Hydraulic Oil Temperature greater than 120°F (49°C)
4) Bucket empty
5) Bucket level and on the ground
8) Park Brake set
9) Lift arm Position Sensor properly installed
10) Bellcrank Position Sensor properly installed
11) Lift arm and Bucket positions calibrated
The Configure Drives Screen allows the user to notify LINCS II of changes to the SR Drive Converters. The
screen is used when a converter or motor is disabled. It also used to change the RPT sensors. Changes to
this screen must be combined with wiring changes in the High-Voltage Cabinet.
The Machine Settings Screen allows the user to make changes to:
1) Klenz Timing (Low Throttle) 6) Maximum Propel Torque
2) Klenz Timing (High Throttle) 7) Bypass Hoist & Bucket Cylinder Limits
3) Autolube Timing 8) Bypass Bucket Cylinder Limits
4) Blower/Fan(s) Setup 9) Bypass Steering Angle Limits
5) Maximum Machine Speed
The selections on the Machine Settings Screen are not active until the “Apply Changes” button (10) is
touched. When a selection is changed but not applied, its name color becomes yellow and an asterisk (*)
appears. If the selections are not to be applied, touch the “Discard Changes” button (11). Machine Settings
are stored in the VCU and do not change when the LINCS-II system is restarted.
3. Autolube Timing
Autolube Timing is the number of minutes between the lubrication cycles. Touch the arrows (12) to
cycle through the choices.
Do NOT attempt to use the machine for normal production with limits bypassed. Bypassing the limits
removes protections. Machine damage or personal injury can occur.
8. Bypass Bucket Cylinder Limits
Touch the box to bypass the Bucket Cylinder Limits. A check mark will appear when the limits are
bypassed. The Bypassed Limits Icon will be displayed on the bottom of the screen. This bypass is
automatically selected when the Lift arm Position Sensor is malfunctioning.
Do NOT attempt to use the machine for normal production with limits bypassed. Bypassing the limits
removes protections. Machine damage or personal injury can occur.
Do NOT attempt to use the machine for normal production with limits bypassed. Bypassing the limits
removes protections. Machine damage or personal injury can occur.
The User Security Key must be in the “reader” (mounted on the console) before the software can
read, create, or change any settings.
Remote Server IP allows the user to set the Internet Address to be used on the secondary Ethernet port. This
is the port that is used for connecting to remote clients through the Ethernet hub.
1. Serial Number
Select the numeric Serial Number of the machine with the pop-up touch pad. The serial number can
contain digits 0 to 9 and a decimal („.‟). For example, use “2001” for L1150-2001. Touch the green
Accept Button when done,
2. Machine Type
Select the Machine Type from the list (i.e. L-1150). Touch the arrows to scroll through the selections.
4. Bucket
Select the type of Bucket from the list (“Clamshell” or “ Standard”). Touch the arrows to scroll through
the selections.
5. Engine Type
Select the Engine Type for list (i.e. “Cummins”). Touch the arrows to scroll through the selections.
6. Time Zone
Select the Time Zone for the machine‟s location. Touch the arrows to scroll through the selections.
7. Auxiliary Steering
Touch the box to set the Auxiliary Steering option. The box contains a checkmark when Auxiliary
Steering is enabled.
8. Power Ladder
Touch the box to indicate that a Power Ladder is installed on the vehicle.
9. Driver Filtration
Touch the box to set the Driver Filtration option. The box contains a checkmark when Driver Filtration
is enabled.
Touching the Input, Output, or Calculated buttons displays a value selection screen where the channel is
“forced”.
Numeric channel values are entered by using the onscreen keypad.
Discrete channel values are selected by touching the arrows.
Touch the green Accept Button to save the value.
Touch the red Cancel Button to discard the value. This will also return a previously forced channel to
normal operation.
Field Access provides a method for LeTourneau Mining Products Engineering to obtain diagnostic information
from LINCS II. Field Access puts the HMI in a temporary state.
The software that runs on the HMI computer of LINCS-II can be installed on a laptop. This installation allows
the user to view downloaded logs from a machine. A laptop can also be used to temporarily replace the
machine‟s HMI computer when needed for troubleshooting. The normal features of the HMI software are also
available such as Log On and Data Logging.
When the HMI software runs on a laptop, it appears as a Windows application and has a menu bar for
additional features.
1. File
1.1 Open Log File (Crtl+O)
The Offline HMI can be used to view logs that have been retrieved from a machine. These logs
contain event data and optionally channel data. Click Open Log File … to display a file select
dialog box. Navigate to the LINCS-II log file desired and click OK. Log files have an “l2l”
extension. The channel data can be viewed on the Logging/Monitoring Screen. A subset of the
channel data can be saved with the Download Log feature. This allows the user to focus on a
problem area and create a smaller log file that can be more easily distributed.
1.2 Screen Capture
Screen Capture makes a screenshot of the display as a PNG file. Click Screen Capture to display
a dialog box and enter the name of the file.
1.3 Exit (Ctrl+Q)
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.
When the “4-20mA” position is selected with the switch, the signal can be manipulated by rotating the knob
labeled POT 1.
When the switch is in the “Ground” position, this will simulate a device being grounded.
SPEED SENSORS:
The Remote Interface Tester cannot be used to test wheel motor sensors.
Disconnect the cable from the speed sensor to be tested.
6. Connect the cable to the Turck connector on the Input Simulator Box.
7. Move the selector switch to “Frequency” on the Input Simulator Box.
8. Boot up LINCS II and browse channels to find the correct channel to monitor the speed sensor signal.
9. Verify on the LINCS II screen that the speed sensor channel is registering an RPM.
10. 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.
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.
The torque specifications listed on the CAPSCREW TORQUE CHART provide recommendations
for both dry and lubricated threads. Lubricated fasteners should be lubricated with 30W motor oil
on the threads and under the heads.
LOSS OF PRELOAD
It is important that tightness and torques be checked routinely as shown in the section of the machine's
Service Manual entitled P.M. SCHEDULES (POST BREAK-IN PERIOD.
Fasteners may become loose even when they are torqued to specifications. This is possible because
after initial tightening, some of the preload is lost due to vibration from operational conditions and the
redistribution of loading in the fasteners members.
FASTENER, CAPSCREW, NUT AND WASHER GRADE SPECIFICATIONS
The use of the proper grade fasteners, capscrews, nuts and washers as the machine is originally
equipped cannot be stressed too highly. The grade markings for fasteners and capscrews are provided in
the CAPSCREW TORQUE CHART. All fasteners and capscrews used on LeTourneau equipment are
Grade 8 or better. Refer to the section of the machine's entitled Parts Catalog for the LeTourneau part
numbers of the fasteners, capscrews, nuts and washers as shown in the component illustrations in the
machine's Service Manual.
It is essential to use a calibrated torque wrench and, when required, a torque multiplier to
accurately torque the capscrews on the machine to the specifications listed on the CAPSCREW
TORQUE CHART, located in the section of this manual entitled FORMS. Use of an air impact
wrench alone, in lieu of a calibrated torque wrench, could result in improper tightening, ultimately
causing component damage.
It is mandatory to remove all paint, rust and debris from all mating surfaces and threads prior to
installation and torquing of all fasteners and capscrews ¾” or 16 mm and larger.
Figure 155. CLEANING PAINT AND RUST FROM THREADS USING TAP
All fasteners and capscrews are to be lubricated on the threads and under the head with 30W
motor oil unless thread locking compound or dry torque is specified. All fasteners and capscrews
are to be torqued to the specifications listed on the CAPSCREW TORQUE CHART.
Key Items:
“LUBED” is defined as having the threads and under the head lubricated with engine oil. Engine oil is defined as SAE 30
or 40 weight oil, including multi viscosity grades 5W-30 through 15W-40. No other lubricant (such as anti seize, MolyKote,
copper coat, grease, etc.) is permitted unless specifically called out in a LTI procedure.
**LUBED = LUBRICATED WITH ENGINE OIL ON THREADS AND UNDER HEAD
(SAE 30 or 40 weight oil, including multi viscosity grades 5W-30 through 15W-40)
NOTE: No other lubricant (such as anti seize, never seize, MolyKote, copper coat, grease, etc.)
is permitted unless specifically called out in a LTI procedure.
All capscrews and fasteners should be started by hand until a minimum of three (3) threads are engaged prior to any air
impact equipment being used.
If a procedure in a LeTourneau publication calls for the use of Loctite® threadlocker on the threads, the torque
specification for “lubed” should be used. The threads on both the fastener and mating part should be thoroughly cleaned
with a proper quick dry solvent that does not leave an oily film prior to use of Loctite®. The Loctite® thread threadlocker
should only be used on the threads - not the head.
Certain applications in components such as planetary drives or lift arm ball caps may specify a FERRY brand of
capscrew. Use only FERRY brand capscrews in these applications.
LeTourneau recommends that any old 12pt LeTourneau-fabricated (fabrication was stopped many years ago) capscrew
(refer to illustration under FASTENER AND CAPSCREW MARKINGS ON HEAD) be replaced at the time of repair with
alloy capscrews. If new capscrews are not available, then the LeTourneau-fabricated capscrews should only be torqued to
Grade 5 specifications (70% of Grade 8 value - lubed).
ERECTION LOCATION:
DESCRIPTION OF DAMAGE:
RECOMMENDED DISPOSITION:
3. OTHER
SIGNATURES:
Name or Title of
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Suggestions
(describe thoroughly - use additional sheets if necessary)
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Phone Date