SAFETY

LETOURNEAU
MACHINE ASSEMBLY MANUAL
SECTION 3

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
SCOPE OF THIS PUBLICATION .......................................................................................................................... 3
SAFETY STANDARDS .......................................................................................................................................... 3
PERSONNEL ......................................................................................................................................................... 3
SAFETY IN EXTREME CONDITIONS................................................................................................................... 3
TAILGATE SESSIONS........................................................................................................................................... 3
HAND/AUDIBLE SIGNALS .................................................................................................................................... 4
HOISTING .............................................................................................................................................................. 4
MAJOR ASSEMBLIES: ................................................................................................................................... 4
SUB-ASSEMBLY COMPONENTS: ................................................................................................................ 4
OVERHEAD HOISTS: .................................................................................................................................... 4
TAG LINES: .................................................................................................................................................... 4
PROTECTIVE EQUIPMENT:.......................................................................................................................... 4
MATERIAL SAFETY DATA SHEETS (MSDS) ...................................................................................................... 5
SAFETY EQUIPMENT ........................................................................................................................................... 5
SITE SPECIFIC SAFETY TRAINING .................................................................................................................... 5
FALL PROTECTION .............................................................................................................................................. 5
WARNINGS AND CAUTIONS ............................................................................................................................... 5
GENERAL SAFETY GUIDELINES ...................................................................................................................... 10
BE PREPARED BEFORE STARTING ............................................................................................................. 10
MOUNTING AND DISMOUNTING THE MACHINE ......................................................................................... 10
LADDER MOUNTED ON HYDRAULIC RESERVOIR ..................................................................................... 11
SAFETY IN MATERIAL HANDLING OPERATIONS........................................................................................ 12
END THE OPERATING PERIOD SAFELY. ..................................................................................................... 13
SAFETY IN SERVICE AND REPAIR OPERATIONS .......................................................................................... 14
PRE-SERVICE OR REPAIR PREPARATIONS AND CAUTIONS ................................................................... 14
ELECTRICAL HAZARDS ................................................................................................................................. 14
PRE-SERVICE OR REPAIR PREPARATIONS AND CAUTIONS ................................................................... 16
FRAME LOCK .................................................................................................................................................. 17
GENERAL SERVICE OR REPAIR PRECAUTIONS ........................................................................................... 19
LOCATION OF ISOLATION SWITCHES AND INDICATORS............................................................................. 22
BATTERY ISOLATION SWITCH (ITEM #1) ISOLATION AND CONTROL SWITCHES ASSEMBLY ........ 22
BATTERY ISOLATON INDICATION LIGHT (ITEM #2) ISOLATION AND CONTROL SWITCHES
ASSEMBLY ................................................................................................................................................... 22
STARTER ISOLATION SWITCH (ITEM #3) ISOLATION AND CONTROL SWITCHES ASSEMBLY ........ 22
STARTER ISOLATOR INDICATION LIGHT (ITEM #4) ISOLATION AND CONTROL SWITCHES
ASSEMBLY ................................................................................................................................................... 22
MANUAL BLEED VALVE ASSEMBLY ................................................................................................................ 23
KLENZ ENABLE SWITCH (FILTER PURGE)...................................................................................................... 24
LIFTING (JACKING) THE MACHINE ................................................................................................................... 25
JACK STANDS AND PLACEMENT ..................................................................................................................... 30

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LIST OF ILLUSTRATIONS
FIGURE 1. HIGH VOLTAGE INDICATOR LIGHTS .......................................................................................... 6
FIGURE 2. HIGH VOLTAGE CABINET - ILLUMINATED LED INDICATES - DC BUS 24 VOLTS IS
APPLIED ....................................................................................................................................... 14
FIGURE 3. TYPICAL BRAKING GRID (SHOCK HAZARDS) ......................................................................... 15
FIGURE 4. ELECTRICAL CABINET (SHOCK HAZARD) ............................................................................... 15
FIGURE 5. FRONT AXLE ACCESS PANEL (SHOCK HAZARDS) ................................................................ 16
FIGURE 6. CRUSH HAZARD AREAS ............................................................................................................ 17
FIGURE 7. ISOLATION AND CONTROL BOX SWITCH ASSEMBLY ........................................................... 20
FIGURE 8. RADIATOR CAP AND VENT VALVE ........................................................................................... 20
FIGURE 9. LOCATION OF ISOLATION SWITCHES AND INDICATOR LIGHTS .......................................... 22
FIGURE 10. MANUAL BLEED VALVE ASSEMBLY (HOIST/BUCKET CYLINDER BLEED DOWN) .............. 23
FIGURE 11. LOCATION OF KLENZ ENABLE SWITCH (FILTER PURGE) ..................................................... 24
FIGURE 12. BLOCKING AXLE TO PREVENT SWIVELING ............................................................................ 25
FIGURE 13. ANTI-PIVOT AXLE WIDGET ........................................................................................................ 27
FIGURE 14. TYPICAL FRAME LOCKED/UNLOCKED (L-1150) ...................................................................... 29
FIGURE 15. TYPICAL FRAME LOCKED/UNLOCKED (L-1350/L-1850/L-2350) ............................................. 29
FIGURE 16. JACKING POINTS FOR PLACING JACK STANDS UNDER FRONT AXLE - TYPICAL ALL
MODELS ....................................................................................................................................... 30
FIGURE 17. FRONT AXLE JACKING AND JACK STAND PLACEMENT LOCATION (TYPICAL) ................. 31
FIGURE 18. FRONT AXLE JACK STANDS ...................................................................................................... 32
FIGURE 19. REAR FRAME JACK STANDS - FRONT END ............................................................................ 33
FIGURE 20. RECOMMENDED JACK STAND PLACEMENT LOCATIONS .................................................... 34
FIGURE 21. STANDARD OPERATIONAL HAND SIGNALS FOR CONTROLLING PORTAL, ....................... 35

TABLES
TABLE 1. LOADER AXLE WEIGHTS - IN OPERATING MODE (NOT LOADED) ....................................... 30

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SCOPE OF THIS PUBLICATION

This publication contains general and specific safety precautions. The operator and maintenance personnel
should read these safety precautions carefully and understand them before operating or performing
maintenance operations to the machine.

LeTourneau cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings and cautions contained herein are therefore not all inclusive. You must satisfy yourself that any
procedure undertaken is safe for you and others. Each job site and assembly of a machine presents hazards
that are unique to that situation. If a dangerous situation develops, only the alertness of the personnel
conducting the assembly or test procedures are available to respond to the situation.
Before any procedures for the assembly of the machine are undertaken, it is CRITICALLY IMPORTANT to
read, understand and follow all warnings, cautions and safety advisories contained herein.

SAFETY STANDARDS
LeTourneau endeavors to comply with the purposes and the applicable occupational safety and health
standards as set forth by the Mine Safety and Health Administration (MSHA), Society of Automotive
Engineers (SAE), Institute of Electrical and Electronics Engineers (IEEE), and International Standards
Organization (ISO).
The customer should acknowledge that compliance with the above applicable organizations under the law is
the responsibility of each employer, and the employer should take all actions necessary to maintain and
operate LeTourneau equipment or accessories according to applicable standards. Carefully review the
procedures given in this manual with all operators ANNUALLY. It is essential that all operators be familiar
with, AND FOLLOW, safety precautions. Operating instructions must be given to everyone using the machine
before operation and at least once a year thereafter.

PERSONNEL
Assembly of the machine must be conducted only by trained and experienced personnel. Qualifications
include, but are not limited to:
● Proven, in-depth knowledge of the assembly and operation of LeTourneau equipment.
● Reviewing and demonstrating a thorough understanding of all procedures presented in this manual.
● Experience with hoisting and assembly of extremely heavy and large equipment.
● Familiarity with the hazards posed by working with high voltage electrical equipment.
● Use of hand tools and use of automatic hand tools such as impact wrenches.

SAFETY IN EXTREME CONDITIONS

The instructions for the unloading, assembly and testing have been written following documentation under
ideal conditions, with the ground in a dry and hard condition with reasonably congenial weather temperatures.
The erection area must be accessible by heavy-lift cranes and large forklift trucks. Obviously, there will be
many situations under which the erection will be made that are less than desirable, such as freezing or wet
conditions. The erection crew must make appropriate and necessary adjustments under less than ideal
conditions, for safe and proper assembly and testing procedures.

TAILGATE SESSIONS
It is recommended that the supervisor of machine assembly and testing procedures conduct daily ―tailgate‖
sessions with all members of the assembly, contract crane crews and on-site mine personnel. These
sessions should cover all aspects of the warnings, cautions and safety advisories within this manual. Any
assembly or testing procedure to be conducted that day which might pose a potential hazard (such as lifting
components, hoisting major assemblies, electrical testing, inclement weather etc.) or require the use of
particular safety gear or equipment should also be covered.
The tailgate sessions should also cover all assembly or testing procedures to be conducted that day so that
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any questions as to procedural matters, order of assembly, job assignments and use of tools and equipment
can be discussed and answered. Be sure to consult with mine safety personnel and include any topics they
would like to include which might affect their personnel. These measures will result in a safer and more
productive working environment.

HAND/AUDIBLE SIGNALS
Hand Signals: It is essential that the crew be familiar with standard hand signals for controlling crane
operation for the type of crane used for unloading and assembly procedures (ASME/ANSI B30.3-1990). A
chart, "STANDARD OPERATIONAL HAND SIGNALS FOR CONTROLLING PORTAL, TOWER AND PILLAR
CRANES", is provided within this manual. It is critically important that all crew members and contract crane
crews be in unison as to the hand signals used to conduct the assembly. It is recommended that the hand
signals be printed from the machine's manual DVD and posted at the job site. The hand signals can be
printed on 81/2‖ x 11‖ or A4 paper.

Crane operators should accept operational hand signals from only one person at a time, but accept
an emergency stop signal from anyone who gives it.
Audible Signals: Audible signals used for safety alerts and controlling operations may vary from one mine site
to another. It is essential to inform all personnel on-site of the meaning of various audible signals that might
be used and what they are expected to do when/if they are sounded.
HOISTING
MAJOR ASSEMBLIES:
While these instructions have been developed to assist the erection crew, LeTourneau does not accept any
liability for the failure of the erection crew to properly check the condition of their lifting equipment including
cranes, wire rope, slings, chains and fixtures in clement or inclement conditions. It is mandatory that the
erection crew supervisor inspect contract crane crew credentials, crane certification, crane load ratings and
the overall condition of the crane and any lifting fixtures, slings, chains etc. provided by the contract crane
company.
SUB-ASSEMBLY COMPONENTS:
To avoid back injuries and the possibility of injury from dropping components, it is recommended that a hoist
be used to lift any item which weighs 50 lbs. (22.68 kgs.) or more.
OVERHEAD HOISTS:
Alert any personnel in the area of items being hoisted overhead and require them to stand clear.
TAG LINES:

A tag line must be attached to any loads hoisted overhead or to elevated areas of the machine.
● UNDER NO CIRCUMSTANCES, is it permitted for personnel to stand on a pallet and be hoisted to
upper areas of the machine to work or gain access.
● UNDER NO CIRCUMSTANCES, is it permitted for personnel to be hoisted by a crane to upper
areas of the machine to work or gain access.
● UNDER NO CIRCUMSTANCES, is it permitted for personnel to remain or stand under
components while they are hoisted or positioned for assembly.
● UNDER NO CIRCUMSTANCES, are loads to be allowed to remain suspended from a crane or
forklift.
PROTECTIVE EQUIPMENT:
It is mandatory that hard hat, safety glasses and steel-toed shoes/boots be worn at all times during the
assembly. Other protective gear such as respirators, face shields, hearing protection, gloves, etc. must be
worn as required by job conditions and local requirements.
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MATERIAL SAFETY DATA SHEETS (MSDS)

Most mines will require MSDS data be on hand at the assembly site for any chemicals, lubricants, paint or
other substances used during the assembly of the machine. This issue must be addressed prior to the
machine arriving on site. Not having this information on hand could delay the assembly of the machine.
SAFETY EQUIPMENT
All safety devices and gear must meet OSHA, ANSI and MSHA standards. Mine safety personnel will likely
verify the certification of all items used. The mine may also require persons other than mine personnel to
wear safety helmets of a specific color. This issue must be addressed prior to the machine arriving on site.
SITE SPECIFIC SAFETY TRAINING
Mines in the United States will require site specific training per MSHA regulations for all persons on mine
property. The method and amount of training will vary from mine to mine. This training must be completed
prior to entering mine property for site preparation. Be sure to involve crane operators and any vendors who
might be involved in the assembly process (dealer, engine manufacturer, fire control personnel, etc.) prior to
beginning the assembly process so the schedule, as established on the "ORDER OF ASSEMBLY
DIAGRAM", can be maintained. Proof of completion of the training must be carried by any persons on
mine property at all times.
FALL PROTECTION
It is MANDATORY that fall protection, in the form of an OSHA, ANSI and MSHA approved safety harness and
lanyard be worn by any personnel working on elevated structures of the machine outside the protection of
handrails. The lanyard must be tethered at all times to a heavy structural member, capable of breaking the fall
supporting the weight of a person.
WARNINGS AND CAUTIONS
Before any assembly of structural components, it is CRITICALLY IMPORTANT to read and comply with the
following warnings and cautions:

Visual and dial indicator inspections of the ball joint assemblies require operational tests of the
machine. These tests should be performed by only qualified and experienced personnel. It is
CRITICALLY IMPORTANT that no personnel be in close proximity to the machine during these tests
as serious injury or loss of life is possible. A signal person should advise the operator during these
inspections.
It is recommended that a dial indicator with a remote indicating unit or gauge amplifier be used for
inspections. The remote indicating unit should be placed outside the pivot area where it can be seen
from a safe distance.
When performing dial indicator tests on the ball joints, 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 not involved in performing the dial indicator test are safe positions prior
to doing any testing.

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Do not perform visual or dial indicator inspections of the rear axle ball caps on an operating machine.
Use jacks or cranes of appropriate capacity.

Following completion of assembly operations, it is CRITICALLY IMPORTANT that the frame lock be
removed from the locked position and properly stowed or machine damage will result.

Do not weld on the spherical part of the ball or the neck area. The ball base assemblies are special
heat-treated steel. Any welding to the ball or neck will cause damage to the steel and detrimentally
affect the strength of the ball. Welding can cause structural failure to the ball, resulting in damage or
injury.

Converter bus voltage is present when red LED lights are ON. The red LED is located, on the right
interface card, on the converters (applicable to SR machines).

Figure 1. HIGH VOLTAGE INDICATOR LIGHTS

LeTourneau machines are designed as off-highway equipment for use in open pit applications that
are in remote locations. Due to their very large size they must work in an area with few other
machines, and their only proximity to buildings would be for routine maintenance or repair. They are
not to be operated near office buildings or residential areas.

Do not allow anyone to stand on any area of the machine, particularly near steps in the area between
the tires when the engine is running. There is no clearance for persons in this area when the machine
is turned.
Attach the frame lock before performing service work or lifting the machine or transporting on
another vehicle. Before operating, be sure frame lock is removed and secured.

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Before performing any assembly operations, lock out the machine’s starting capability with the
Battery Isolation and Starter Isolation Switches. Serious injury or death is possible if the machine is
started or moved while assembly operations are being conducted.

NEVER remove the axle access covers unless the electrical system is turned off and locked out.
Contact with high voltage terminals inside the axle will result in serious injury or loss of life.

BEFORE attempting to assemble any of the major components of the machine, BE SURE to provide
hoists or cranes and lifting devices of adequate capacity and height. Refer to "MACHINE JACKING
INSTRUCTIONS". Refer to GENERAL INFORMATION for approximate weights of the L/D-950, L-1150,
L-1350, L-1850 or L-2350 structural components.

NEVER stand under or place any body part under components while hoisted. Serious injury or loss of
life could result in the event of an accident.

BEFORE working in the pivot or “pinch” area of the articulated machine, place the frame lock in the
locked position to prevent the machine from turning. There is no room for a person in this area when
the machine turns and serious injury or loss of life could result. Enter this area only when necessary.

NEVER use the lift arms and bucket to lift personnel! Serious injury or loss of life is possible.

There are no provisions on any LeTourneau built machine to accommodate the transportation of any
persons other than the operator alone, unless the cab is factory equipped with a training seat.
Ladders and catwalks attached to the machine are designed for servicing of the machine while the
machine is stopped only. They are NOT designed for transporting riders at any time. Serious injury or
loss of life could result while riding in any location other than the operator’s cab.

To prevent injury, wear hardhat, protective glasses, steel-toed shoes or boots and other protective
equipment as required by job conditions at all times during the assembly procedure.

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BEFORE welding on any structural members of the machine, refer to FIELD WELDING PROCEDURES,
located in the section of this Assembly Manual entitled "GENERAL INFORMATION". Serious damage
to electrical, electronic, and engine controls is possible unless precautions described in this
publication are adhered to.

NEVER work on the engine while it is running unless specifically instructed by the engine
manufacturer. Serious injury or loss of life from entanglement in rotating components is possible.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin and cause serious personal injury,
blindness or death. If any fluid is injected into the skin, it must be removed within a few hours by a
doctor familiar with treating this type of injury.
Fluid leaks under pressure may not be visible. When searching for leaks, NEVER use your hand; use
a piece of metal. Wear work gloves and keep your hand well away from the possible source of
leakage. DO NOT tighten or loosen fuel or hydraulic lines without first relieving the pressure. Wear
safety goggles for eye protection and any locally required PPE.

WRONG RIGHT

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known
to cause cancer and birth defects or other reproductive harm.

Refer to safety instructions located in TIRE AND RIM MOUNTING AND DEMOUNTING in the
section of the machine's service manual entitled TIRE AND RIM MAINTENANCE, before
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inflating, deflating or removing or installing wheels and tires. Serious injury or loss of life is
possible unless safety precautions are followed.

Under no circumstances should any cutting or welding be performed on a rim with inflated tire. Doing
so could cause an explosion, which could result in serious injury or loss of life. Never mount or
dismount an inflated tire.

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GENERAL SAFETY GUIDELINES

BE PREPARED BEFORE STARTING
These guidelines should be followed before attempting to operate the machine.
a. KNOW THE EQUIPMENT: Read all sections of this manual thoroughly. BE SURE to understand all
control functions, capacities, clearances, limitations, and routine maintenance required for safe operation.
Support personnel should also be familiar with this information. Learn the location and function of ALL
controls, indicators, warning devices and caution instructions. Improper operation or improper
maintenance of this machine can result in hazardous conditions.
b. This machine must be operated in accordance with the information and instructions contained in this
manual.

LeTourneau equipment is designed as off-highway equipment for use in open pit applications that are
in remote locations. Due to their very large size they must work in an area with few other machines,
and their only proximity to buildings would be for routine maintenance or repair. They are not to be
operated near office buildings or residential areas.
Be familiar with the machine’s safety devices (if so equipped) such as:
1. Seat belts
2. Rollover protective structure (ROPS) and falling object protective structure (FOPS)
3. Articulated steering frame lock
4. Shields and guards
5. Visual and audible warning devices
6. Manual fire supressor or fire suppression system
7. Isolation and Control Switch Box
8. Battery Isolation switch
9. Starter Isolation switch
10. Emergency Stop buttons
11. Rearview mirrors
12. Battery Isolation Station
13. All lighting
Know the work area; clear away trash and debris. Remove anything that could puncture a tire.
Check overhead clearances. Know the size of doorways and canopies. Know how much clearance there is
under power and telephone lines.
Complete the daily walk-around inspection and services. Perform the inspections and maintenance per
Section 02. Check it thoroughly for visual defects, such as leaks, cracks, frayed hoses, worn insulation, and
loose parts.

MOUNTING AND DISMOUNTING THE MACHINE

These guidelines should be followed when mounting and dismounting the machine:

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There are no provisions on any LeTourneau built machine to accommodate the transportation of any
persons other than the operator alone, unless a training seat in the cab is optionally provided.
Ladders and catwalks attached to the machine are designed for servicing of the machine while the
machine is stopped only. They are NOT designed for transporting riders at any time. Serious injury or
death could result while riding on any location of the machine other than the cab operator’s seat or
training seat (if so equipped).
Always use ―three-point support‖ with the machine, and face the ladder while entering of leaving it. ―Three
point support‖ means that three out of four arms and legs are in contact with the machine at all times during
mount and dismount.

Before dismounting, ensure the ground conditions are stable, to prevent slipping or falling when
stepping off the ladder. Always ensure firm ground before releasing the ladder/handrail.

a. Clean shoes and wipe hands before attempting to climb on the machine.
b. Look for icy conditions that could make use of a ladder or stairway treacherous. Follow all local work rules
used during icy conditions.
c. Use handholds, ladders, or steps (as provided) when mounting and dismounting.
d. NEVER attempt to mount or dismount a moving machine.
e. NEVER jump off the machine.
f. NEVER try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull
equipment up onto the platform.
g. Observe proper shutdown procedures before dismounting.

LADDER MOUNTED ON HYDRAULIC RESERVOIR

A ladder is mounted on the hydraulic reservoir. When using this ladder, refer to instructions in ―
MOUNTING AND DISMOUNTING THE MACHINE‖ as previously explained in this document.
START UP SAFELY
These guidelines should be followed in the normal operation of the machine:
a. Do not wear loose clothing or jewelry that can catch on controls or other parts of the machine.
b. Make certain all protective guards and covers are secured in place on the machine.
c. Keep the machine, especially walkways, platforms and steps, free of foreign material, such as debris, oil,
tools, and other items that are not part of the machine.
d. Secure all loose items such as lunch boxes, tools, and other items that are not part of the machine.

e. Start up safely. Use all local procedures such as blowing the horn before starting up.
1. Allow at least 30 seconds for anyone working on or around the machine to exit the area. The operator
should also inspect the machine before the shift and after work breaks to be sure no one is around it
before starting.
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2. Visually determine the area is clear before moving the machine.

Do not allow anyone to stand on any area of the machine, particularly near steps in the area between
the tires when the engine is running. There is no clearance for persons in this area when the machine
is steered.
Attach the frame lock before performing service work or lifting the machine or transporting on
another vehicle. Before operating, be sure frame lock is removed and securely stored.
f. Follow the engine manufacturer’s recommended starting procedure. After engine has been started, check
all gauges and instruments to be sure that everything is operating properly.

Diesel exhaust fumes can cause sickness. If necessary to start an engine in an enclosed area, be sure
adequate ventilation is provided. Serious injury or loss of life is possible.

a. Operate bucket and hoist controls through a complete cycle when area conditions permit — check for
faulty operation. Report any sluggishness, binding, or over travel to the appropriate personnel.
b. To be sure direction of travel and speed can be controlled, move the direction control switch to forward
and reverse positions, and press the accelerator pedal slowly.
c. Test brakes before operating. Test park brakes to make sure the machine will be able to stop and stay
stopped. (when first moved, check dynamic braking).
d. Check lights, backup alarm or other warning and safety devices.
e. Sit properly, in an alert position. Check out controls in a safe area while moving slowly. STEER
MACHINE BOTH RIGHT AND LEFT to be sure steering is operating properly.
f. Never carry an unauthorized rider. The operator’s cab is designed for one person only (unless equipped
with a training seat). If training seat is used, make certain the training seat belt restraint is used at all
times.

NEVER use the bucket or lift arms to lift personnel. Serious injury or loss of life is possible.
g. Watch out for overhead dangers. Keep a safe distance from overhead power lines.

SAFETY IN MATERIAL HANDLING OPERATIONS

Remember these rules when working with the machine in mining operations:
a. Go slowly in congested areas, over rough ground and on slopes. Keep the machine’s speed slow enough
to be in COMPLETE CONTROL AT ALL TIMES. Follow all local rules and regulations concerning
operation of equipment near a high wall.
b. Give loaded vehicles the right of way. Follow local traffic rules for the job site. Watch out for other
vehicles.
c. Position the bucket three or four feet above the ground and rolled back so it does not block vision when
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traveling.
d. The bucket should not be used as a brake except in an emergency if all other means fail.
e. Load, carry and unload safely. Start and stop smoothly when carrying a load.
f. Stay back from edge of banks and pits. Edges can cave off or the machine can lose its footing and slide
over the edge.
g. Know the employer’s hand signals. It is important to know the exact meaning of all hand signals
applicable to and used during operation. Failure to correctly respond to a hand signal could result in
severe injury or death. Accept operational signals from one person only, but accept an emergency
shutdown signal from anyone who gives it.
h. Be alert. Be aware of what is going on around the machine. Maintain a safe operating distance between
the machine and other equipment and personnel.
i. When dumping into hauling vehicles, BE CAREFUL NOT TO CONTACT THE VEHICLE with the loader
lift arm or bucket.
j. Use caution on slopes. Operate straight up and down slopes whenever possible. Use extreme caution
during any side hill operations. NEVER DESCEND A GRADE FASTER THAN THE MACHINE COULD
CLIMB THAT SAME GRADE. Refer to Grade Plate located in the cab for grade operation requirements.
k. Keep the bucket close to the ground for stability. If an overload causes the machine to tip forward, DO
NOT PANIC - - LOWER THE LOAD TO THE GROUND and the machine will stabilize.
l. Be careful in a hazardous area. Whenever possible, two people should work together in hazardous areas
- one to operate the machine and the other to direct and watch for dangers.
1. NEVER enter a dust cloud or a dark area such as an underpass or building before checking it for
obstructions or hazards that cannot be seen.
2. Watch for overhead dangers, such as overhanging trees or falling rocks. Do not undercut banks.
Keep a safe distance from overhead power lines – and check for buried power and utility lines before
digging.
m. Report a malfunctioning machine. EVEN A MINOR PROBLEM CAN BECOME SERIOUS. Report any
mechanical problems to supervision.

GEN 2:
There are two entry/exit doors (left and right) in the cab. During an emergency, determine which door
is to be used as the emergency exit.
If the machine must be left unattended:
1. Lower bucket to ground.
2. Set the park brake switch.
3. Push the engine select switch to the LOW position. Let idle for four to five minutes.
4. Turn key switch to OFF position.
5. Place a "DO NOT OPERATE" sign on the controls if the machine must be left unattended and safety or
maintenance deficiencies exist. Follow all local rules for each situation.
END THE OPERATING PERIOD SAFELY.
a. Park in an unobstructed, flat area.
b. Lower the bucket to the ground. Bucket should be flat and level with the ground.

Shutdown properly
a. Set the park brake switch.
b. Push the engine select switch to the LOW position and let the engine idle for four or five minutes.
c. Place all controls in the OFF position and turn key switch to the OFF position.
d. To prevent unauthorized starting, remove the ignition key.
e. To prevent tampering, lock the cab door.

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SAFETY IN SERVICE AND REPAIR OPERATIONS

PRE-SERVICE OR REPAIR PREPARATIONS AND CAUTIONS

The machine’s large size and diesel-electric power unit make it necessary to take special precautions to
ensure a safe working environment.

The following precautions and procedures should be adhered to anytime the machine is brought in for service
or repair: All local rules should also be followed.

In addition to the following instructions, anyone performing service operations to the machine should
be familiar with the location and operation of all service switches and connections as described in
“SERVICE SWITCHES”, located in Section 01 of the Service Manual.

DO NOT ENTER THE HIGH VOLTAGE CABINET if the engine is running. Do not enter the High Voltage
Cabinet if the bus voltage indicator LED’s on the SR converter assemblies are illuminated. Do not
touch any electrical component or assembly inside the High Voltage Cabinet if the bus voltage
indicator LED’s on the SR converter assemblies are illuminated. Check ALL converter panel LED’s for
voltage before entering.

SR converter assemblies are inverted on the opposite wall of the high voltage cabinet.

ELECTRICAL HAZARDS

Figure 2. HIGH VOLTAGE CABINET - ILLUMINATED LED INDICATES - DC BUS 24 VOLTS IS

APPLIED

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High voltage is present on the dynamic braking

grids when the drive is enabled.
Do NOT touch the braking grids when the
generator is primed or until five minutes after the
engine has been shut down. Contact with the
braking grid could result in serious injury or loss
of life.
BRAKING GRIDS ON OTHER MODELS APPEAR DIFFERENT
LOCATED AT REAR OF MACHINE

Figure 3. TYPICAL BRAKING GRID (SHOCK HAZARDS)

NEVER open high voltage cabinet while engine is running. High voltage is present when the drive is
enabled (at any throttle speed) and may be present even if the machine is shut down.

If inspection or service procedures involve contact with any component of the electrical system,
opening the high voltage cabinet, or removing axle access covers, the electrical system MUST be
locked out. Accidental contact with energized terminals could result in serious injury or loss of life.
Figure 4. ELECTRICAL CABINET (SHOCK HAZARD)

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PRE-SERVICE OR REPAIR PREPARATIONS AND CAUTIONS

The machine’s enormous size and diesel-electric power unit make it necessary to take special precautions to
ensure a safe working environment.
The following precautions and procedures should be adhered to anytime the machine is brought in for service
or repair:

NEVER remove axle access panel on either axle unless electrical system is locked out. Some Warning
labels/placards may not be shown in above photo. Similar access panel is found on rear axle.

Figure 5. FRONT AXLE ACCESS PANEL (SHOCK HAZARDS)

In addition to the following instructions, anyone performing service operations to the machine should
be familiar with the location and operation of all service switches and connections as described in
SERVICE SWITCHES AND CONNECTIONS.

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FRAME LOCK

The frame lock should be moved to the locked position

EACH TIME service or repair operations are being
conducted. This is especially important when energized
tests of components are performed, when work is
MACHINE STEERED STRAIGHT being done in the pivot area of the machine, or if the
(Arrows indicate crush hazard areas-
machine is jacked up. There is no room for a person in
present on BOTH sides of machine)
the pivot area or the area between the tires when the
machine turns. Service personnel should enter this
area only when absolutely necessary.

CRUSH HAZARDS EXIST ON BOTH SIDES OF

MACHINE

AREA BETWEEN FRONT AND REAR OFMACHINE

(CRUSH HAZARD AREAS)
MACHINE ARTICULATED TO LEFT
(Arrows indicate crush hazard areas-present (BOTH sides of machine)

Figure 6. CRUSH HAZARD AREAS

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The frame lock (#1) on some models folds back under Some models have a holding pin (#1), on the
the high voltage cabinet and is held in position by a pin frame lock pivot bracket that holds the frame
(#2) at the end of the frame lock. lock (#2) in position when the frame is not
locked.

Following completion of service or repair operations, it is critically important that the frame lock be
removed from the locked position and properly secured in the unlocked position or machine damage
will result.
(LEFT SIDE OF MACHINE AT PIVOT AREA)
MOVE FRAME LOCK INTO UNLOCKED POSITION AND SECURE WITH RETAINING PIN (CRUSH
HAZARD AREAS)

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GENERAL SERVICE OR REPAIR PRECAUTIONS

a. Wear a hard hat, protective glasses and other protective equipment as required by job conditions.

b. NEVER use an open flame to check the battery, fuel, coolant, or to look for leaks anywhere on the
machine. Use lights as provided or a flashlight.
c. DO NOT make unauthorized modifications to the machine. These modifications may impair the function
and safety and affect machine life.
d. NEVER put maintenance fluids such as oils, solvents, diesel, etc. into glass containers.
e. NEVER use gasoline for cleaning purposes.

f. Pressurized air can cause personal injury. When using pressurized air for cleaning, wear a face shield,
protective clothing, and a vented nozzle.

g. Use stands to reach service or repair points.

h. The operator should use assistance from other personnel, when moving the machine around the service
area, and into and out of buildings.
i. Ensure ramps, floors, doors, and aisles are adequate to support and clear the machine when moving in
and out of a building. Refer to ―GENERAL INFORMATION‖, located in Section 01, for dimensions and
weight of the machine.
j. Consider the size and weight of the machine and its components when jacking it up or removing
components and assemblies. BE SURE to have adequate hoisting devices, tools and support facilities to
accommodate the weight of the machine or its components.
k. If possible, conduct all service and repair operations with the machine parked on a level, hard surface

If the machine becomes disabled in the field, it is recommended that only sufficient repairs be made
at the machine failure location to allow the machine to be moved. Then, move the machine to a safe
work area for completion of repairs. Test the machine, as required by the nature of the repairs, before
returning it to work.
l. Block the machine to prevent it from rolling while working on or under it.
m. Lower the bucket to the ground and use the main bleed valve assembly to vent pressure in the hoist and
bucket circuit before beginning inspection, service, or repair operations. Refer to Section 04 in the
Service Manual for information to vent pressure in the hoist and bucket circuit.
n. Set the park brakes.
o. Turn the Klenz enable switch to the OFF position. The Klenz enable switch is located inside the Isolation
and Control Switch Box Assembly, mounted on the left side, near the rear of the machine.

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1. AUTOLUBE SWITCH INSIDE 2) KLENZ ENABLE 3) LADDER LIGHTS 4) MAINTENANCE LIGHTS

LOCATED ON LEFT REAR OF MACHINE
Figure 7. ISOLATION AND CONTROL BOX SWITCH ASSEMBLY
p. Consider the size and weight of the machine and its components when jacking it up or removing
components and assemblies. BE SURE to have adequate hoisting devices, tools, and support facilities to
accommodate the weight of the machine or its components.

Component weights are provided in General Information of this Manual.

q. BE CAREFUL when working with or around a hot cooling system. Liquid cooling systems build up
pressure as the engine gets hot. Before removing the radiator cap, stop the engine and let the system
cool. Remove the radiator cap (slowly) only after the coolant is cold and de-pressurized. Refer to
illustration ―Error! Reference source not found.‖ below. A drain hose will drain hot coolant down to
ground level near the radiator/engine area. Be aware of hot coolant that can be expelled automatically or
manually any time the system is pressurized.

1. RADIATOR CAP
2. VENT VALVE

(LOCATED ON TOP OF REAR FRAME)

Figure 8. RADIATOR CAP AND VENT VALVE

r. Keep clear of all rotating components. Wrapping, entanglement, or contact by clothing or extremities may
result in serious injury or death.

NEVER work on the engine while it is running unless specifically instructed by the engine
manufacturer. Serious injury or loss of life from entanglement in rotating components is possible.

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KEEP CLEAR OF THE ROTATING SHAFT. The shaft between the Hydraulic Pump Drive (HPD) and the
generator rotates any time the engine is rotating. Wrapping, entanglement, or contact by clothing or
extremities may result in serious injury or death.
s. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.

t. Avoid prolonged and repeated skin contact with used oil. With prolonged and repeated contact, serious
skin or bodily injury may develop. Wash thoroughly after contact.
u. BE CAREFUL with fluids under pressure. The hydraulic system is under pressure whenever the engine is
running and will hold pressure after shutdown.

Diesel fuel, hydraulic fluid, or grease under pressure can penetrate the skin and cause serious
personal injury, blindness, or death. If any fluid is injected into the skin, it must be removed as soon
as possible by a doctor familiar with treating this type of injury.
Fluid leaks under pressure may not be visible. When searching for leaks, NEVER use your hand; use
a piece of metal. Wear work gloves and keep your hand well away from the possible source of
leakage. DO NOT tighten or loosen fuel, hydraulic, or grease lines without first relieving the pressure.
Wear safety goggles for eye protection.

Battery post, terminals and related accessories contain lead and lead compounds, chemicals known
to cause cancer and birth defects or other reproductive harm.
Refer to safety instructions in Section 03 in the Service Manual before inflating, deflating, removing, or
installing tires and rims.

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LOCATION OF ISOLATION SWITCHES AND INDICATORS

1. BATTERY ISOLATION SWITCH

2. BATTERY ISOLATION 24 V INDICATION LIGHT
3. STARTER ISOLATION SWITCH
4.STARTER ISOLATION 24 V INDICATION LIGHT

Figure 9. LOCATION OF ISOLATION SWITCHES AND INDICATOR LIGHTS

BATTERY ISOLATION SWITCH (ITEM #1) ISOLATION AND CONTROL SWITCHES ASSEMBLY
If necessary to leave the machine unattended or if necessary to eliminate all electrical energy sources turn
the RED Battery Isolation Switch to the OFF position. This switch can be locked in the OFF position if desired.
BATTERY ISOLATON INDICATION LIGHT (ITEM #2) ISOLATION AND CONTROL SWITCHES
ASSEMBLY
When the switch is moved to the ON position 24V battery power is enabled and the RED light will illuminate.
STARTER ISOLATION SWITCH (ITEM #3) ISOLATION AND CONTROL SWITCHES ASSEMBLY
For maintenance where the 24 volts is required (for 24 volt circuit testing or for repairs at night in the pit) the
YELLOW Starter Isolation Switch can be turned to the OFF position. When the YELLOW Starter Isolation
Switch is turned OFF, there will be 24 volt power available for all machine functions, except engine cranking.
The switch can be locked in the OFF position if desired. When the Starter Isolation Switch is turned to the ON
position the engine cranking function is enabled.
STARTER ISOLATOR INDICATION LIGHT (ITEM #4) ISOLATION AND CONTROL SWITCHES
ASSEMBLY
The amber light is illuminated when the engine cranking function is enabled

If the machine becomes disabled in the field, it is recommended that only sufficient repairs be made
at the machine failure location to allow the machine to be moved. Then, move the machine to a safe
work area for completion of repairs. Test the machine before returning it to work, as required by the
nature of the repairs.

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MANUAL BLEED VALVE ASSEMBLY

The Manual Bleed Valve Assembly relieves the hydraulic pressure from the hoist and bucket circuit. When
the hydraulic system is being worked on, the pressure should be relieved by opening all the valves on the
assembly. When these valves are opened, the lift arms will lower (if elevated), and the bucket may move. Use
caution and make sure the area is clear of personnel before operating the valve assembly.

L950/L1150: LOCATED INSIDE FRONT FRAME L1350/L1850/L2350: LOCATED IN FRONT FRAME,

ARTICULATION ENTRY POINT, ON RIGHT SIDE UNDER HYDRAULIC VALVES

Figure 10. MANUAL BLEED VALVE ASSEMBLY (HOIST/BUCKET CYLINDER BLEED DOWN)

Using the Manual Bleed Valve Assembly is the only way to lower the lift arms and bucket, or relieve
residual system pressure from the hoist and bucket circuits.

 The Manual Bleed Valve Assembly shall not be operated when the engine is running. Operating
the manual bleed valve may cause the lift arms and bucket to descend rapidly.
 All personnel shall stand clear of the lift arms and bucket areas before the Manual Bleed Valve
Assembly is used to relieve system pressure. Operating the manual bleed valve may cause the lift
arms and bucket to descend rapidly. Failure to clear these areas of personnel prior to operating
the valve assembly can result in serious injury or death.

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KLENZ ENABLE SWITCH (FILTER PURGE)

The KLENZ Enable Switch (Filter Purge) is mounted in the ―Isolation and Control Switches‖ assembly,
mounted on the left side of the machine (rear area of rear frame). If this switch is left in the OFF position, a
yellow Warning will be displayed on the LINCS II screen when the engine is running. Refer to illustration
―LOCATION OF KLENZ ENABLE SWITCH (FILTER PURGE)‖.

KLENZ ENABLE
Figure 11. LOCATION OF KLENZ ENABLE SWITCH (FILTER PURGE)

BE SURE to turn the KLENZ Enable Switch to the ON position before returning the machine to service.

Machine and component weights are provided in GENERAL INFORMATION (L/D-950, L-1150, L-1350,
L-1850, and L-2350), and machine jacking instructions are provided in MACHINE JACKING
INSTRUCTIONS.

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LIFTING (JACKING) THE MACHINE

The following precautions and instructions should be followed for safe jacking of the loader:
 Be sure the loader is on an adequate surface to support its weight when jacked up.
 NEVER jack up the machine by using the bucket and lift arms.
 The bucket should be lowered to three to four feet off the ground and placed in full rollback position.
 Be sure to provide adequate jacks or hoists when lifting the machine or any of its components. Refer
to table below ―LOADER AXLE WEIGHTS – IN OPERATING MODE (NOT LOADED)‖ for the proper
jacking points and weights. If placing jack stands under the front axle, the machine is jacked from the
side as shown in illustration below ―JACKING POINTS FOR PLACING JACK STANDS UNDER
FRONT AXLE – TYPICAL ALL MODELS‖.
 After hoisting the loader, it is recommended jack stands be used for support. Refer to illustrations
―FRONT AXLE JACK STANDS‖, ―REAR FRAME JACK STANDS – FRONT END‖: and ―REAR
BUMPER JACKS TANDS – REAR END‖‖, and to ―FRONT AXLE JACKING AND JACK STAND
PLACEMENT LOCATIONS‖ and ―RECOMMENDED JACK STAND PLACEMENT LOCATIONS‖.
Referenced illustrations located below.

 “LOADER AXLE WEIGHTS – IN OPERATING MODE (NOT LOADED)” and JACKING POINTS
FOR PLACING JACK STANDS UNDER FRONT AXLE – TYPICAL ALL MODELS” show front
jacking points when using and not using jack stands. When jacking under the front axle or
placing jack stands under the front axle, it is essential to get as close as possible to the
structural support member. Placing the jack or jack stand in any other area could cause
damage to the axle.

Anti-pivot axle widget placed between rear axle and frame to prevent swiveling - both sides.
Figure 12. BLOCKING AXLE TO PREVENT SWIVELING

If both wheels of the oscillating axle are off the ground at the same time, the axle may swivel
vertically. This is a potentially hazardous situation. Both sides of the axle should be blocked to
prevent swiveling (refer to illustration “BLOCKING AXLE TO PREVENT SWIVELING”, above).

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Figure 13. ANTI-PIVOT AXLE WIDGET

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FRAME LOCKED FRAME UNLOCKED

(LEFT SIDE OF MACHINE AT PIVOT AREA) (LEFT SIDE OF MACHINE AT PIVOT AREA)
1. SAFETY LINK
SAFETY LINK
2. HOLDING PIN
Figure 14. TYPICAL FRAME LOCKED/UNLOCKED (L-1150)

FRAME LOCKED FRAME UNLOCKED

(LEFT SIDE OF MACHINE AT PIVOT AREA)
(LEFT SIDE OF MACHINE AT PIVOT AREA)
1) Retaining pin for unlocked position
1) Safety Link
2) Safety Link

Figure 15. TYPICAL FRAME LOCKED/UNLOCKED (L-1350/L-1850/L-2350)

Before jacking the machine, place the frame lock in the locked position to help avoid unexpected and
uncontrolled movement of the machine. Failure to do so could result in serious injury or death.

Following completion of service or repair, BE SURE to place the frame lock in the unlocked position
or machine damage will result (refer to illustrations above).

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JACK STANDS AND PLACEMENT

Front Frame Each Rear Frame Each

Point Point
L/D-950 111,000 lb (50,348 kg) 84,000 lb (38,102 kg)
L-1150 111,000 lb (50,348 kg) 84,000 lb (38,102 kg)
L-1350 111,000 lb (50,348 kg) 84,000 lb (38,102 kg)
L-1850 154,000 lb (69,853 kg) 104,000 lb (47,173 kg)
L-2350 172,000 lb (78,017 kg) 126,000 lb (57,152 kg)
1) Jacking point if not using jack stands 2) Jacking point if placing jack stands under front axle 3)
Jacking point 4) Alternate jacking point
NOTES: • Weights at points of lifting on axle • Bucket empty and in ―carry‖ position • Frame in locked position
• All wheels chocked • All weights approximate – allow for adequate safety margin.
Table 1. LOADER AXLE WEIGHTS - IN OPERATING MODE (NOT LOADED)

PLACE JACK UNDER FRAME EACH SIDE AT LOCATION INDICATED. PLACE JACK STANDS UNDER
AXLE AS CLOSE AS POSSIBLE TO FRAME STRUCTURE SUPPORT MEMBER AS SHOWN IN
ILLUSTRATION FRONT AXLE JACKING AND JACK STAND PLACEMENT LOCATIONS, below.
Figure 16. JACKING POINTS FOR PLACING JACK STANDS UNDER FRONT AXLE - TYPICAL ALL
MODELS

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L-950/L-1150

Figure 17. FRONT AXLE JACKING AND JACK STAND PLACEMENT LOCATION (TYPICAL)

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Figure 18. FRONT AXLE JACK STANDS

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.

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Figure 19. REAR FRAME JACK STANDS - FRONT END

Overall height of rear bumper jack stand varies with loader model and height of tires. Typically, 38" (965 mm) to 40" (1016 mm) is suitable for L/D-
950/L-1150/L-1350 and 47" (1194 mm) to 48" (1219 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.

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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 20. RECOMMENDED JACK STAND PLACEMENT LOCATIONS
(LOADER USED FOR ILLUSTRATIVE PURPOSES)

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Figure 21. STANDARD OPERATIONAL HAND SIGNALS FOR CONTROLLING PORTAL,

TOWER, AND PILLAR CRANES

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