Document Outline

• Effectivity Page
• Table of Contents
• Section 1 Safety Practices
  • 1.1 Introduction
  • 1.2 Disclaimer
  • 1.3 Operation & Safety Manual
  • 1.4 Do Not Operate Tags
  • 1.5 Safety Information
  • 1.6 Safety Alert System and Signal Words
  • 1.7 Safety Instructions
    • 1.7.1 Personal Hazards
    • 1.7.2 Equipment Hazards
    • 1.7.3 General Hazards
    • 1.7.4 Operational Hazards
  • 1.8 Safety Decals
• Section 2 General Information and Specifications
  • 2.1 Replacement Parts and Warranty Information
  • 2.2 Thread Locking Compound
  • 2.3 Torque Charts
    • 2.3.1 SAE Fastener Torque Chart
    • 2.3.2 Metric Fastener Torque Chart
    • 2.3.3 Hydraulic Hose Torque Chart
  • 2.4 Specifications
    • 2.4.1 Travel Speeds
    • 2.4.2 Hydraulic Cylinder Performance
    • 2.4.3 Platform Hydraulic Performance Specifications
    • 2.4.4 Electrical System
    • 2.4.5 Engine Fan Speed
    • 2.4.6 Engine Performance Specifications
    • 2.4.7 Transmission Performance Specifications
    • 2.4.8 Tires
  • 2.5 Fluids, Lubricants and Capacities
    • 2.5.1 3706PS, 3707PS, 4014PS & 4017PS
    • 2.5.2 33.7, 37.6 & 37.7
  • 2.6 Service and Maintenance Schedules
    • 2.6.1 10 & 1st 50 Hour
    • 2.6.2 50 & 1st 250 Hour
    • 2.6.3 250 & 500 Hour
    • 2.6.4 1000, 1500 & 3000 Hour
  • 2.7 Lubrication Schedule
    • 2.7.1 50 Hour Lubrication Schedule
    • 2.7.2 500 Hour Lubrication Schedule
• Section 3 Boom
  • 3.1 Boom System Component Terminology - 3706PS, 3707PS, 33.7, 36.6 & 37.7
  • 3.2 Boom System - Two Section
    • 3.2.1 Boom System Operation
  • 3.3 Boom Assembly Maintenance
    • 3.3.1 Complete Boom Removal
    • 3.3.2 Complete Boom Installation
    • 3.3.3 Second Section Boom Removal
    • 3.3.4 First Boom Section Removal
    • 3.3.5 Extend/Retract Cylinder Removal
    • 3.3.6 Extend/Retract Cylinder Installation
    • 3.3.7 First Boom Section Installation
    • 3.3.8 Second Boom Section Installation
  • 3.4 Boom System Component Terminology - 4014PS
  • 3.5 Boom System - Three Section
    • 3.5.1 Boom System Operation
  • 3.6 Boom Assembly Maintenance
    • 3.6.1 Boom Removal
    • 3.6.2 Second and Third Boom Section Removal
    • 3.6.3 Third Boom Section and Extend/ Retract Cylinder Removal
    • 3.6.4 Third Boom Section and Extend/ Retract Cylinder Installation
    • 3.6.5 Second and Third Boom Section Installation
    • 3.6.6 Complete Boom Installation
  • 3.7 Boom Chain Removal/ Installation
    • 3.7.1 Retract Chain Removal
    • 3.7.2 Retract Chain Installation
    • 3.7.3 Extend Chain Removal
    • 3.7.4 Extend Chain Installation
  • 3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation
    • 3.8.1 Extend/Retract Hose Removal
    • 3.8.2 Extend/Retract Hose Installation
    • 3.8.3 Tilt/Auxiliary Hose Removal
    • 3.8.4 Tilt/Auxiliary Hose Installation
  • 3.9 Extend/Retract Cylinder Removal/Installation
    • 3.9.1 Extend/Retract Cylinder Removal
    • 3.9.2 Extend/Retract Cylinder Installation
  • 3.10 Boom Sections Adjustment
    • 3.10.1 Chain Adjustments
  • 3.11 Boom System Component Terminology - 4017PS
  • 3.12 Boom System - Four Section Boom
    • 3.12.1 Boom System Operation
  • 3.13 Boom Assembly Maintenance
    • 3.13.1 Boom Removal
    • 3.13.2 Second, Third and Fourth Boom Section Removal
    • 3.13.3 Third and Fourth Boom Section Removal
    • 3.13.4 Fourth Boom Section Removal
    • 3.13.5 Hose Carrier Removal
    • 3.13.6 Hose Carrier Installation
    • 3.13.7 Fourth Boom Section Installation
    • 3.13.8 Third and Fourth Boom Section Installation
    • 3.13.9 Second, Third and Fourth Boom Section Installation
    • 3.13.10 Complete Boom Installation
  • 3.14 Boom Chain Removal/ Installation
  • 3.15 Boom Sections Adjustment
    • 3.15.1 Chain Adjustments
  • 3.16 Boom Extend and Retract Chains - 4014PS & 4017PS
    • 3.16.1 Boom Chain Inspection
    • 3.16.2 Inspection Guidelines - 4014PS
    • 3.16.3 Inspection Guidelines - 4017
    • 3.16.4 Expose Chains for Inspection
    • 3.16.5 Chain Lubrication
  • 3.17 Boom Wear Pads
    • 3.17.1 Wear Pad Inspection
    • 3.17.2 Boom Wear Pad Installation/ Lubrication
  • 3.18 Quick Coupler
    • 3.18.1 Quick Coupler Removal (3706PS, 3707PS, 33.7, 37.6 & 37.7)
    • 3.18.2 Quick Coupler Installation (3706PS, 3707PS, 33.7, 37.6 & 37.7)
    • 3.18.3 Quick Coupler Removal (4014PS & 4017PS)
    • 3.18.4 Quick Coupler Installation (4014PS & 4017PS)
  • 3.19 Forks
  • 3.20 Boom Prop (If Equipped)
    • 3.20.1 Installation and Removal Procedures
  • 3.21 Emergency Boom Lowering Procedure
    • 3.21.1 Equipment and Supplies Required
    • 3.21.2 Lowering Procedure
  • 3.22 Troubleshooting
• Section 4 Cab and Covers
  • 4.1 Operator Cab and Covers Component Terminology
  • 4.2 Operator Cab
    • 4.2.1 Operator Cab Safety
    • 4.2.2 Serial Number Plate
  • 4.3 Cab Components
    • 4.3.1 Steering Wheel
    • 4.3.2 Steering Column/Orbitrol Valve
    • 4.3.3 Service Brake
    • 4.3.4 Electronic Throttle Pedal
    • 4.3.5 Joystick Assembly
    • 4.3.6 Window Wiper Assembly
    • 4.3.7 Heater/Air Conditioning System (if Equipped)
    • 4.3.8 Cab Heater/Air Conditioning Controls
    • 4.3.9 Air Conditioning (if Equipped)
  • 4.4 Cab Removal
  • 4.5 Cab Installation
• Section 5 Axles, Drive Shafts, Wheels and Tires
  • 5.1 Axle, Drive Shaft and Wheel Component Terminology
  • 5.2 Axle Serial Number
  • 5.3 Axle Specifications and Maintenance Information
  • 5.4 Axle Replacement
    • 5.4.1 Axle Removal
    • 5.4.2 Axle Installation
  • 5.5 Mechanical Park Brake
    • 5.5.1 Mechanical Park Brake Removal
    • 5.5.2 Mechanical Park Brake Installation
    • 5.5.3 Mechanical Park Brake Adjustment
  • 5.6 Hydraulic Park Brake
    • 5.6.1 Park Brake Test
  • 5.7 Brake Inspection
  • 5.8 Steering Angle Adjustment
  • 5.9 Axle Assembly and Drive Shaft Troubleshooting
  • 5.10 Drive Shafts
    • 5.10.1 Drive Shaft Inspection
    • 5.10.2 Drive Shaft Maintenance
    • 5.10.3 Drive Shaft Removal
    • 5.10.4 Drive Shaft Cleaning and Drying
    • 5.10.5 Drive Shaft Installation
  • 5.11 Wheels and Tires
    • 5.11.1 Removing Wheel and Tire Assembly from Machine
    • 5.11.2 Installing Wheel and Tire Assembly onto Machine
  • 5.12 Towing a Disabled Machine
• Section 6 Transmission
  • 6.1 Transmission Assembly Component Terminology
  • 6.2 Transmission Serial Number
  • 6.3 Specifications and Maintenance Information
  • 6.4 Transmission Replacement
    • 6.4.1 Transmission Removal
    • 6.4.2 Transmission Installation
    • 6.4.3 After Transmission Service or Replacement
    • 6.4.4 Transmission Torque Converter Stall Test
  • 6.5 Torque Convertor Diaphragm
    • 6.5.1 Torque Convertor Diaphragm Removal/Installation
  • 6.6 Troubleshooting
• Section 7 Engine
  • 7.1 Introduction
    • 7.1.1 Disclaimer and Scope
  • 7.2 Engine Serial Number
  • 7.3 Specifications and Maintenance Information
    • 7.3.1 Component Terminology
  • 7.4 Engine Cooling System
    • 7.4.1 Surge Tank Cap
    • 7.4.2 Thermostat Replacement
    • 7.4.3 Radiator Assembly Replacement
  • 7.5 Engine Electrical System
  • 7.6 Fuel System
    • 7.6.1 Diesel Fuel
    • 7.6.2 Fuel Tank
    • 7.6.3 After Fuel System Service
  • 7.7 Engine Exhaust System
    • 7.7.1 Exhaust System Removal—ULS
    • 7.7.2 Exhaust System Installation—ULS
    • 7.7.3 Exhaust System Removal—LS
    • 7.7.4 Exhaust System Installation—LS
  • 7.8 Air Cleaner Assembly
    • 7.8.1 Air Cleaner Assembly Removal
    • 7.8.2 Air Cleaner Assembly Installation
  • 7.9 Engine Replacement
    • 7.9.1 Engine/Transmission Removal
    • 7.9.2 Transmission Removal/Installation
    • 7.9.3 Engine Disassembly, Inspection and Service
    • 7.9.4 Engine/Transmission Installation
  • 7.10 Troubleshooting
• Section 8 Hydraulic System
  • 8.1 Hydraulic Component Terminology
  • 8.2 Safety Information
  • 8.3 Specifications
  • 8.4 Hydraulic Pressure Diagnosis
    • 8.4.1 Pressure Checks and Adjustments
  • 8.5 Hydraulic Circuits
    • 8.5.1 Hydraulic Pressures
  • 8.6 Hydraulic Schematics
    • 8.6.1 3706PS, 3707PS, 33.7, 37.6 & 37.7
    • 8.6.2 4014PS & 4017PS
  • 8.7 Hydraulic Reservoir
    • 8.7.1 Hydraulic Oil Reservoir Draining
    • 8.7.2 Hydraulic Oil Reservoir Filling
    • 8.7.3 Hydraulic Oil Reservoir Removal/ Installation
  • 8.8 Engine Implement Pump
    • 8.8.1 Pump Replacement
  • 8.9 Auxiliary Pump (Platform Equipped Models Only)
    • 8.9.1 Auxiliary Pump Description
    • 8.9.2 Auxiliary Pump Replacement
  • 8.10 Control Valves
    • 8.10.1 Main Control Valve
    • 8.10.2 Reversing Fan Valve
    • 8.10.3 Service Brake Valve
    • 8.10.4 Service Brake Bleeding
    • 8.10.5 Service Brake Test
    • 8.10.6 Steering Orbitrol Valve
    • 8.10.7 Steer Select Valve
  • 8.11 Hydraulic Cylinders
    • 8.11.1 General Cylinder Removal Instructions
    • 8.11.2 Cylinder Pressure Checking
    • 8.11.3 Steering Cylinders
    • 8.11.4 Cylinder Torque Specifications
  • 8.12 Boom Ride Control (3706PS, 3707PS, 33.7, 37.6 & 37.7 - If Equipped)
    • 8.12.1 General Accumulator Information
    • 8.12.2 Accumulators
    • 8.12.3 Pre-Charging Accumulator
    • 8.12.4 Checking Pre-Charge
• Section 9 Electrical System
  • 9.1 Electrical Component Terminology
    • 9.1.1 General Overview
  • 9.2 Specifications
  • 9.3 Safety Information
  • 9.4 Keypad and Display Screen
    • 9.4.1 Keypad
    • 9.4.2 Display Screen
  • 9.5 Software Level 2 Accessibility
    • 9.5.1 Operator Tools
    • 9.5.2 Personalities
    • 9.5.3 Calibration
  • 9.6 Operator Tools
    • 9.6.1 Resetting the Anti theft Code
    • 9.6.2 Hardware Exchange
    • 9.6.3 Confirm Machine Service
    • 9.6.4 Review Service History
    • 9.6.5 Set Service Interval
    • 9.6.6 Cabin Joystick Telescope: X-Axis/ Roller
  • 9.7 Fuses and Relays
    • 9.7.1 Engine Compartment
    • 9.7.2 Power Distribution Board
  • 9.8 Electrical System Schematics
    • 9.8.1 Cab Harness Electrical Schematic 1 of 3
    • 9.8.2 Cab Roof, Ride, Float and Boom Extend LImit
    • 9.8.3 Power Distribution Board
    • 9.8.4 Transmission and Reverse Fan
    • 9.8.5 Front Frame and Boom Options
    • 9.8.6 Rear Frame
    • 9.8.7 Battery
    • 9.8.8 Platform
    • 9.8.9 LMIS
    • 9.8.10 Deutz Engine
  • 9.9 Circuit Breakdowns
    • 9.9.1 Constant Power Circuit from Battery
    • 9.9.2 Start Circuit
  • 9.10 Engine Start Circuit
    • 9.10.1 Starter
    • 9.10.2 Charging Circuit
    • 9.10.3 Alternator
  • 9.11 Window Wiper/Washer Windshield Wiper Motor
    • 9.11.1 Windshield Wiper Motor
    • 9.11.2 Rear and Roof Window Wiper Motor
    • 9.11.3 Windshield/Rear Window/Roof Window Washer Reservoir
  • 9.12 Solenoids, Sensors and Senders
    • 9.12.1 Transmission Solenoid Valves
    • 9.12.2 Transmission Oil Temperature Switch
    • 9.12.3 Transmission Mounted Speed Sensor
    • 9.12.4 Engine Coolant Temperature Sensor
    • 9.12.5 Fuel Level Sender
    • 9.12.6 Front and Rear Axle Steering Sensors
    • 9.12.7 Boom Angle Sensor
    • 9.12.8 Back-up Alarm
  • 9.13 Dash Switches
    • 9.13.1 Ignition Key Switch
    • 9.13.2 Dash Switches
  • 9.14 Platform Interlock Checks
  • 9.15 Platform Load System Check
  • 9.16 Load Stability Indicator (LSI) (CE & AUS)
    • 9.16.1 Load Stability Indicator
    • 9.16.2 LSI Sensor
    • 9.16.3 LSI System Calibration
    • 9.16.4 LSI-CAN Check PT
    • 9.16.5 500 Hour - LSI UGM Calibration Check
  • 9.17 Hand Held Analyzer
    • 9.17.1 Analyzer Usage
    • 9.17.2 Analyzer Software Version P4.5
  • 9.18 Fault Codes
    • 9.18.1 Indicator Cross Reference Table
    • 9.18.2 Machine Fault Codes
    • 9.18.3 Engine Fault Codes