Microsoft Word - Tire Handler Owners Manual PDF

LIFT CO., INC.
MODEL W300YXL-TH
Owners Manual
Serial #: HWIGGINSWLC130005
Feb, 2013
2571 Cortez Street - Oxnard, CA 93036-1642

(805) 485-7821 - (805) 485-5230
Email: wigginslift@wigginslift.com
Website: www.wigginslift.com
Table of Contents
Table of Contents
Introduction
Read Before Ordering
Date of Shipment
New Forklift Truck Delivery Inspection Report
Daily Safety Check
Safety and Operation
Safety Alert Symbol
Signal Words
General Safety and Warnings
Start Safely
Hazards and Cautions
Operation
Operation Check
Controls
Drive
Lift a Load
Park and Shutdown
Transport and Setup
Loading and Unloading
Safety While Servicing
Cooling System
Electrical System
Hydraulic System
Fuel System
Wheels and Tires
Replacement Parts
Warning Decal
Safety While Operating
Safety Instructions Decal
Load Handling Safety
Warning
Modification
Record Retention
Ownership Records
Instructions for Pressure Washing
Table of Contents
Decal Locations
Control Descriptions and Locations
Instrument Panel
Various Controls
Control Valve
Fans, Pressure Gauges, Parking Brake, Wipers, and Fire Extinguisher
Seat Controls and Indicators
Air Conditioner Controls
Maintenance Check Lists
Fork Inspection
Checklist
Instructions
Inspection Poster (Link)
Fork Arm Wear Caliper Guide (Link)
8 Hour Daily, Weekly and Monthly Service Sheet
Schedule Normal Use
Schedule Severe Duty
Schedule High Filtration
Lubrication and Maintenance
Grease Recommendations
Grease Point Locations
Lubrication Positions
IMT Attachment Manual Link
Engine and Transmission
Maintenance Item Locations
Air Filter Parts Identification
Maintenance
Engine
Important Reference Numbers
General Information
Engine Operation Report
Unusual Engine Noise
Crankcase Breather Tube
Fuel-Water Separator
Cooling Fan
Lubricating Oil Level
Drive Belts
Table of Contents
Engine (Continued)
Coolant Level
Maintenance Specifications
Fuel Recommendations and Specifications
Lubricating Oil Recommendations and Specifications
Coolant Recommendations and Specifications
Transmission
Specifications, Service Data–Powershift Transmission, and Torque Converter
Recommended Lubricants for Clark-Hurth
Trouble Shooting Guide
Drive Axle
General /Serial Number Identification
General/Axle Oil
General/Bolt Torque Charts
General/Hydraulic Connections
Parking Brake Inspection and Adjustment
Parking Brake Pressure Test
Mast and Carriage
Warning
Daily Inspection
Mast Lubrication
100 Hour Inspection
500 Hour Inspection
Carriage Inspection
Chain Inspection and Tension
Hydraulic System
Filter, Filler, and Gauge Locations
Hydraulic Diagrams
Electrical System
Relay Identification and Locations
Battery Location
Electrical Diagrams
Troubleshooting Wiggins Yard Bull® / All Terrain
New Lift Truck Warranty Policy
Introduction
It is the operator’s responsibility to read and understand this manual before

operating the Wiggins Yard Bull®. It is important that the owner and operator know and understand
all applicable laws, rules and requirements for operator training and certification. As an operator of
this powered industrial truck, the operator is responsible for the safety of him/herself and co-
workers or bystanders. Good safety practices not only protect the operator and the equipment, but
also protect anyone who might be in the vicinity. Only authorized persons are allowed to operate
the Wiggins Yard Bull®. The Operation and Safety Manual must always be kept in the cabin or in
the vicinity of the authorized operator for reference.
Perform operator daily check before operating this equipment.

Report damage or faulty operation immediately. Do not operate this equipment if it is damaged or
does not operate correctly. If in doubt always contact the producer
importer or official expert of the Wiggins Yard Bull
Introduction
READ BEFORE ORDERING

1. SPECIFY SERIAL NUMBER OF UNIT.
2. SPECIFY MODEL NUMBER OF UNIT.
3. PROVIDE PART NUMBER AND PART DESCRIPTION.
Introduction
Date of Shipment:
To: Company Representative
In conjunction with Wiggins Warranty Policy, enclosed are four (4) check sheets that must be performed at
their respective intervals in order for Wiggins to honor the warranty policy. It is mandatory that a copy of
completed check sheets and a signed copy of this agreement be mailed or faxed, within thirty (30) days of
ship date, for Wiggins records.
Failure to comply with the above requirements may invalidate warranty claims.
Wiggins warranty for this vehicle is for starting on and ending

on . It will remain in effect by performing the required maintenance check lists in the
following documents.
Accepted By:
Serial Number:
Date:
Introduction
New Forklift Truck Delivery Inspection Report

Owner name: Dealer name:
Street address: Street address:
City, State, Zip: City, State, Zip:
Date of Inspection: Machine model:
Hour meter: Serial Number:
Engine make and S/N: Rated lift capacity:
Average number of lifts per month: Per year:
Note: Do not use check marks. Indicate by Yes, No, or O.K. If fluid level is checked, indicate whether high, low, or
O.K.
A. General checks:
CHECK FOR ANY SHIPPING DAMAGE BEFORE UNLOADING

Battery terminal and connections Fan Belts Tire Inflation PSI
Battery Cables Alternator charging Brake master cylinder
Battery electrolyte level All gauges working Lube complete machine
Engine oil All controls working freely Hydraulic oil level
Air cleaner & hose connections Pump drive coupling Tighten wheel nuts (must be
Coolant in radiator Check hydraulic hoses & fittings checked daily for 10 days, then
Check steer axle hoses Check surge brake fluid weekly).
(tow only).
B. Main unit structures:
Check for deformed, cracked welds or misaligned members in the frame and body
Check all bolts
Check mast hanger caps
Check paint
C. Drive axle and wheels:
Oil level in drive axle Oil level in transmission

Check drive line bolts Check for damaged tires
Operate steering system Lube steer axle bearings, king pins, axle pivot
D. Mast system:
Check for pins, bearings, shafts, Alignment of chains and rollers

rollers and locking devices Alignment of hoses and rollers
Chain adjustment Check forks for level
Introduction
E. Operational test:
Travel forward and reverse

Check service and parking brake performance
Check steering performance
Drive unit and operate all hydraulic systems
Hoist up and down. Check chain and hose reeving and sheave rotation
Check front and rear lift cylinder synchronization
Always test with load close to rated capacity of machine.
LOAD TESTED: Describe:
Total weight of load: Length of load:
Have you briefed the operator on proper use and operation of this machine:
Have you briefed maintenance personnel in required scheduled maintenance of this machine:
Customer comments:
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS AND TO RETURN THIS FORM TO WIGGINS LIFT
COMPANY WITHIN 30 DAYS OF DELIVERY MAY INVALIDATE WARRANTY CLAIMS.
Customer: Title:
Date:
Inspector: Date:
Introduction
Daily Safety Check

1. Check for broken, missing or damaged parts. Check for loose or missing fasteners.
2. Check that no safety switches have been bypassed and that no warning tags have been placed on
the vehicle.
3. Check that warning decals, special instructions and operator’s manuals are legible and stored in the
proper location.
4. Check forks for rust, cracks or misalignment. Replace the forks IN SETS when the condition of the
fork(s) is questionable. Replace with factory approved forks ONLY.
IMPORTANT: DO NOT use forks which have been repaired by welding.
5. Check that the means to retain forks, if so equipped, are in place to prevent forks from
changing position or coming off the carriage.
6. Check tires for cuts, bulges, tread depth and air pressure if pneumatic.
7. Check service and parking brakes for proper operation.
8. Keep engine and radiator clean and free of dirt or flammable debris.
9. Check engine oil and cooling system for proper levels. Add oil or coolant as required.
10. Check the level of the hydraulic system. If necessary, fill to the required level with the proper type
fluid.
11. Inspect hydraulic hoses and connections for wear or leaks. Repair or replace any damaged or worn
hose with officially original accepted hydraulic hoses.
12. Check condition and operation of seat belt and its mounts.
13. Keep steps, pedals and non-skid surfaces clean and free of grease, oil, dirt, snow or ice.
14. Make sure all doors, guards or covers are in place and secured properly.
15. Perform the Pre-Operation Check List in Section 3.0.
16. Perform all maintenance procedures as required in Section 5.0.
17. Make sure work lights, mirror, gauges and operator console are kept clean. Check that lights, horn,
and wipers operate properly. Make sure electrical connections are clean and free of damage.
18. Remove or secure any loose objects.
19. Survey the work area and notice any potential obstacles.
COMPLETED BY: SERIAL #:

O.K.: DATE: HOURS:
Do not operate the Wiggins Yard Bull® if any of the Daily Safety Check procedures are faulty. If in doubt
always contact the producer importer or official expert of Wiggins Yard Bull®.
RECOGNIZE SAFETY INFORMATION:

This is the safety-alert symbol. When you see this symbol on your
machine or in this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS:

A signal-word — DANGER, WARNING, or CAUTION — is used
with the safety-alert symbol. DANGER identifies the most serious
hazards.
Safety signs with signal word DANGER or WARNING are typically

near specific hazards.
General precautions are listed on CAUTION safety signs.

CAUTION also calls attention to safety messages in this manual.
FOLLOW SAFETY INSTRUCTIONS:

Carefully read all safety messages in this manual and on your
machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs.
Learn how to operate the machine and how to use controls properly.
Do not let anyone operate without proper training and instruction.
WARNING: Drugs and Alcohol will affect an operator’s alertness and coordination. An operator should
NEVER use drugs or alcohol while operating a forklift. An operator taking prescription or over-the-
counter medication must consult a medical professional regarding any side affects of the medication
that would hinder their ability to safely operate this equipment. NEVER allow anyone to operate this
forklift when their alertness or coordination is impaired.
WEAR PROTECTIVE CLOTHING - Wear all protective gear and clothing issued to you or called for by job conditions.
• Wear close fitting clothing and safety equipment appropriate to the job.
• Wear a suitable hearing protective device such as earmuffs or earplugs to protect objectionable or
uncomfortable loud noises.
• When you drive connecting pins in or out, guard against injury from flying pieces of metal or debris; wear
goggles or safety glasses.
You may also need: Hard Hat, Safety Shoes, Heavy Gloves, Reflective clothing, Wet Weather gear,
Respirator or filter mask.
DO NOT USE starting fluid.
BEWARE OF EXHAUST FUMES:

• Prevent asphyxiation. Engine fumes can cause sickness or death.
• If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe
extension to remove exhaust fumes or open doors and windows to bring enough outside air into the area.
KNOW THE EQUIPMENT:

Study all safety and information decals on your forklift and in your operators’ manual. Make sure all
manufacturers’ protective structures, guards, shields, screens, panels, and seat belts are in good repair, in place and
fastened. NEVER modify or remove any safety components on your forklift. Know the pinch points and rotating parts
on the forklift – awareness on YOUR part can prevent accidents.
Know the following about your forklift:

• How to operate all controls.
• The functions of all gauges, lights, and dials.
• The rated load capacity at different positions.
• Speed/gear ranges.
• Braking and steering characteristics.
• Turning radius and clearances.
AVOID POWER LINES:

• Serious injury or death can result from contact with electric lines.
• Never move any part of the machine or load closer to electric lines than 3 m (10 ft) plus twice the line
insulator length. Use a signal person to guide operator. Use shrouds or insulators as necessary.
KNOW THE WORK AREA:

Before you operate, learn as much as possible about the work area. Observe the worksite and inspect the
surface(s) over which you will travel. Avoid: Holes, Drop-offs, Obstacles, Rough Spots, Electrical Lines and apparatus,
Soft Soil, Deep Mud, Standing Water, Oil Spills, Wet Spots, and Slippery Surfaces. If any of these conditions exist in
the work area, correct the condition before operating.
When operating on docks, ramps, or floors, check for weak spots. Clear the worksite of any trash or anything
that could puncture a tire. When required, check the forklifts fully loaded ground pressure weight when operating on a
hollow floor system.
Watch for conditions that could cause: Loss of Control, Collision, or a Tip-over. Know exactly how much
clearance you have under power lines, telephone lines, doorways and canopies.
PLAN YOUR WORK:

Before you operate, know how and where you will travel, turn and pickup, lift and place loads. Choose a
smooth level route to prevent possible tip-over or loss of load. If possible, avoid crossing: Ruts, Ditches, Curbs, and
Exposed Railroad Tracks. When these conditions cannot be avoided, keep the load as low as possible and travel
VERY SLOWLY and with EXTREME CAUTION.
USE a signal person Near the
Check for blind spots on the worksite. Stop and sound your
Point the Load is to be Landed
horn before proceeding slowly around a blind corner.

Know the weights of all the loads you will transport before
lifting. Avoid loads of loose material if possible and check that loads
are properly secured.
Obtain written instructions and approval from the equipment
manufacture before suspending “free-rig” loads. Suspended loads
are very dangerous.
Use a signal person if you will be placing loads in landing
areas with poor visibility.
Know and Understand:

• The rules covering traffic at the worksite;
• The meaning of all signs, flags, and markings.
• Hand, flag, whistle, siren, or bell signals.
Know the rules for movement of people and forklifts on the worksite. Slow down and sound your horn, making
sure that your approach has been acknowledged by those in your path. Stop your forklift until your presence has
been recognized or until the path is clear.
Operating in an area with public access requires that you create a “safety zone” for the operation of your
machine. Mark your working “safety zone” using cones, barricades and warning tape. Make sure a trained signal
person is available to warn people away from the working area. Be sure that all available warning devices are
activated and working properly.
PROVIDE
Ensure that adequate clearance is provided between both rear tail swing
Adequate Clearance for
and front fork swing if the forklift to avoid injury to personnel or damage to Fork and Tail Swing
objects nearby.
Know where you will be expected to park your forklift at the end of the
work day, preferably in a level area out of traffic. If the area is on a slope or
incline, position the forklift straight up the slope, set the parking brake, lower
the forks to the ground, and block the wheels.
ENGAGE
Remember: Parking Brake
• Be Alert – Knowing that conditions can change. BEFORE Dismounting
• Use Common Sense – Showing that you are a responsible operator.
• Be a Defensive Operator – Preventing accidents before they happen.
START SAFELY:
Before entering the operator’s compartment, walk completely around the forklift checking that no one is under
or on the forklift.
USE HANDHOLDS AND STEPS:
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always maintain a three point contact with the steps and
handrails and face the machine. Do not use the steering wheel or any controls as hand holds.
• Never jump on or off the machine. Never mount or dismount a moving machine.
• Be careful of slippery conditions on steps and handrails when leaving the machine.
Always use “three point contact” with the machine, face the machine when you enter or leave the machine.
(“Three point contact” means that three out of the four arms and legs are in contact with the machine at all times
during mount and dismount.)
Warning: Never grab onto control levers or the steering wheel when mounting. Avoid stepping on foot pedals
while entering, to prevent you from accidently engaging or disengaging a control, which could cause unexpected
forklift movement.
Descriptions of Safety Features and Components: The Wiggins Yard Bull® has safety features to protect the
operator, nearby pedestrians, the loads being moved and the equipment itself. The operator must learn these
features in order to safely operate this sophisticated and highly capable machine. Always wear your seatbelt!
Horn and Motion Alarm: The center of the steering wheel is a button for activating a horn to warn
pedestrians and other equipment operators. In addition, whenever the forklift truck is moving in reverse, a beeping
motion alarm will sound. This motion alarm will not sound when the transmission is in neutral. It has a switch that can
be set at two levels. It is Wiggins factory pre-set at the recommended higher level.
Wiggins StabiLift®(pat pend): Both the weight of the load and the location of its center of gravity combine
to produce a load moment that must be less than the counterweight’s righting moment in order for the truck to remain
stable. The fulcrum, or balancing line, is where the drive tires contact the ground. For a more detailed description of
stability, please see Appendix A. This system warns the operator when a load being lifted is near or at the rated
capacity on the data plate of the Wiggins Yard Bull®. It also can disable the lift function when the load moment is
larger than the design capacity of the truck.
Green Light: The green light will be lit when the load is well within the rated capacity. Ordinary
caution should be used while driving with this load, with the mast tilted back and the forward speed
kept moderate. If the load is large, the yellow light may flash while driving over uneven ground.
Yellow Light: The yellow light comes on when the load moment is close to the rated capacity of the
machine. When the yellow light is on, the operator must remain in the lowest transmission gear and
the speed should be no greater than 5 kph, about a medium walking pace. The mast should be tilted
back, which may result in the yellow light going off in favor of the green. Every effort should be made
to keep the load as low as possible until in a position to place it. Sudden braking or activation of the
E-stop (see Section 2.5) may cause a wet load to slip forward on the forks, possibly resulting in
damage to the load. Again, the red light may flash while driving over uneven ground. Keep it low and
slow!
Red Light: When the rated capacity of the machine is exceeded, the red light comes on. A factory
set switch disables the lift function whenever the red light is on. Use of the machine while the red
light is on can result in equipment or load damage. Bearings and wear pads will wear prematurely.
Tires may become damaged by overheating. The risk of tipping forward under sudden braking is
high!
Wiggins StabiLock®: The Wiggins Yard Bull® can be designed to be used for placing loads in very high
racks. When lifting even a small load to the maximum height, operators can become uncomfortable with lateral
stability. Since a fork lift normally has a triangle of stability (see Appendix A) as the load is lifted and the center of
gravity rises while the mast is tilted back, the truck becomes less stable, particularly in a turn. For high lifts such as
this, the operator can activate the StabiLock® switch and lock the stabilizing cylinders on the rear axle, thus extending
that stability triangle into a stability rectangle. The truck feels more stable and the operator can perform the high lifts
with confidence. While the switch is on, an alarm will also sound so that the operator remembers to turn off the
StabiLock® when the mast is lowered again.
Brakes and E-Stop: There are two brakes: Service and Parking. The Service Brake is connected to the
foot brake pedal and the amount of braking is controlled by the amount of foot pressure on the pedal. The Parking
Brake is also the emergency brake. When this brake is activated, the truck comes to stop in a short distance. The
optional red E-Stop (#1) button on the dash panel will stop the engine, which stops the hydraulic pump, and the
Parking Brake will come on. If there is damage to the hydraulic system and the system loses pressure, the Parking
Brake will come on. The Parking Brake switch (#2) on the dash panel will also turn on this brake. If the Parking
Brake has been activated while the truck was in motion, the brake pads must be inspected by qualified personnel.
1 2
PREHEAT PARK BRAKE ON SHUTDOWN ENGAGED
OFF
ACC IGN PUSH TO
START OVERRIDE LIGHTS
2
START 4
0
E-STOP STOP WAIT TO
ENGAGED ENGINE START
HAZARDS and CAUTIONS: Before you operate this powered industrial truck, you must be trained and authorized.
You must read and understand the operator’s manual and all safety labels on the unit. Control the load and the forklift
at all times. Be aware of overhead and side clearances. Turn to face the direction of travel when backing.
• WARNING! LIFTING PERSONNEL CAN RESULT IN INJURY OR DEATH. This unit is not designed for lifting
personnel. Do NOT lift when a person is on or near the forks. Never lift a load with a passenger.
• NO RIDERS! Do NOT allow riders. The only person on the truck when it is in motion shall be the
operator.
• Do NOT stand or walk under an elevated fork or load. Never climb on the mast or boom or other areas for the
forklift. You may get pinned or wedged from a fall, resulting in injury.
• WARNING! LIFTING A LOAD THAT EXCEEDS THE RATED LOAD CAPACITY AND LOAD CENTER CAN
LEAD TO TIPPING DANGER. This unit is designed for lifting a maximum specified load, as stamped on the data
plate. A chart is provided in this manual that provides the maximum loads at various load centers. Know and
understand the chart. If this equipment includes the Wiggins StabiLift® system, see Section 2.2. Do not
overload.
• WARNING! COLLISION CAN RESULT IN EQUIPMENT OR LOAD DAMAGE, INJURY OR DEATH. Watch for
pedestrians, obstructions, doors, and overhead wires. When traveling and turning, slow down and watch for side
clearances for both the load and tail swing. When traveling in reverse, face the direction of travel.
• Wear the seat belt any time the truck is in motion.
• Drive carefully, keeping the forks as low as possible and tilted back as necessary.
• WARNING! LOSS OF CONTROL CAN RESULT IN TIPPING DANGER. Do not turn on a slope.
Slow down to turn and keep the load low. Center the load before lifting or lowering a load. If the
carriage is elevated, keep the speed of tilting slow and avoid sudden movements.
• Bring truck to a complete stop before changing direction between forward and reverse.
• PARKING: Select a flat and level area to stop the forklift. Lower the forks to the ground. Put transmission into
neutral and set the parking brake. Turn off the key to stop the engine.
• Before lifting a load, make sure the forks are adjusted to the best width for the load and that the load is stable and
centered.
• Carry the load as low as possible while maintaining good visibility.

• Follow traffic rules when traveling.
• Keep all other personnel away from the forklift before starting the engine.
• WARNING! Never leave the operator’s seat without first safely shutting down the forklift. A running, unattended
forklift could unexpectedly move or be operated by inexperience personnel.
• WARNING! Do not jump from a moving or tipping machine. Remain seated with the seat belt securely and
properly fastened whenever the machine is in motion. If the machine tips:
o Do not jump.
o Brace you feet firmly on the floor.
o Grip the steering wheel tightly.
o Lean away from the direction of the fall.
• WARNING! When ascending or descending grades, loaded trucks shall be driven with the load upgrade.
Unloaded trucks should be operated on all grades with the load engaging means downgrade. On all grades the
load and load engaging means shall be tilted back if applicable, and as low as possible while clearing roadway.
OPERATION:
Perform the Daily Safety Check before proceeding. We suggest that there should be an official document
that the operator signs to the effect that he has read all the procedures; understands them and carried them out
before using the Wiggins Yard Bull®. This is normal procedure for products such as this and can prevent any
confusion if any damage occurs during operation.
Safe Operating Procedures:
• Start: After performing and completing the Daily Safety Check List.
• Fasten your seatbelt.
• Check that the parking brake is on and the gear selector is in neutral.
• Check that the hydraulic controls are in their centered, neutral position and that no objects are nearby
that might fall against the levers or joysticks.
• Warn all others in the area that you are going to start the forklift.
• Turn the ignition key to the “ON” position.
• Wait until all engine indicators are off, about 10 seconds.
• Turn the ignition key to “START” position to start engine. If the engine fails to start in less than 10
seconds, repeat the previous three steps.
WARNING – Never allow passengers to ride on the forklift. This forklift is designed for ONE PERSON
only.
Operation Check - After the engine is started and running smoothly, perform the following operational checks.
1. Check all instruments, gauges, and indicator lights.
2. Verify operation of the work lights and horn.
3. Check the steering, right and left.
4. All control levers for proper operation.
5. Brakes and inching pedal, if provided, for proper operation.
6. Briefly lift the fork carriage and check for smooth motion and normal sounds. Check also during
lowering. Lubricate components as necessary.
7. Briefly lift the negative mast section and check for smooth operation and normal sounds. Check
also during lowering. Lubricate components as necessary.
8. Lift the forks clear of the ground and operate the fork controls, again checking for smooth
operation. Lubricate components as necessary.
9. At idle, tilt the mast forward and back. If this equipment has the Wiggins StabiLift® system, tilt
back until the mast stops and verify operation of the red light. Tilting forward slightly should allow
the red light to go off and the green light to come on.
10. Without releasing the parking brake, and with a foot ready on the service brake pedal, place the
truck in gear. It should not move. Place the gear selector in neutral.
11. Release the parking brake, place the truck in gear and verify operation of the service brakes and
steering. The motion alarm should be on while in gear.
If there is any indication that an abnormal condition exists or the controls do not respond correctly, shutdown
safely and correct the condition before operating.
Be sure that you can control both the speed and direction before moving.
If in doubt always contact the producer importer or official expert for the Wiggins Yard Bull®.
Controls - The controls of the Wiggins Yard Bull® are conveniently located within easy reach of the operator.
Gauge Panel: The parking brake switch is guarded from accidental activation. When down, the
parking brake is off and the truck is free to move. When up, the parking brake is on. The key switch has
three positions: Off, Ing, Start. If the equipment includes the Wiggins StabiLock® System, there will be an
additional switch for activating the axle locking hydraulics.
Hydraulic Controls: The hydraulic controls can be levers, joysticks or a combination of the two
types. The response speed of a hydraulic function is directly related to the amount movement of the control.
The operator should always begin activation of a control by moving the control a small amount until the
function responds so the operator can be satisfied that the correct control and direction is happening as
expected. The first control moves the fork carriage up and down. Pulling the control back toward the
operator raises the carriage. Pushing it forward lowers the carriage. The second control tilts the mast. There
may be three controls for the forks: Left Fork, Right Fork and Side Shift. The Side Shift control moves the
forks in the same direction at the same time and can be used with the rated load in place.
Foot Pedals: The brake and throttle pedal are on the right side of the steering column and perform
the same as in an automobile. On the left side of the steering column is a declutch or inching pedal. This
pedal allows the operator to increase throttle speed without having to shift the gear selector into neutral.
Steering: The steering is hydraulic. On some short wheel base trucks, the hydraulic pressure may
not be sufficient to move the steer tires past a certain point unless the truck is moving forward or reverse.
This is normal. Even rolling just a few inches allows the tires to turn to their fullest extent.
Drive: Care and patience while driving will allow the operator to maintain control of the load and the forklift
and allow enough time so the operator can watch the tail swing and load clearances. Start moving in low gear.
Wiggins suggests staying in low gear when carrying a load. With exceptionally long loads or high lifts, Wiggins
recommends use of one or two spotters.
Lift a Load: Wiggins Yard Bulls® are designed for many different load handling configurations. For
attempting to lift loads of uncertain weight and load center, Wiggins provides an indicator that can protect the
equipment and the operator from an overload condition. For lift heights above 13.5 m, Wiggins provides a steer axle
lock that gives maximum stability.
Wiggins StabiLift®: By sensing how strongly the tilt cylinders must work to hold
OK CAUTION OVERLOAD
the mast in position, the Wiggins StabiLift® system tells the operator whether a load
is below, at or above the rated capacity of the forklift. As the load is lifted clear of WIGGINS STABILIFT SYSTEM
TM
MARINA BULL
Patent Pending
105522
the ground, the lights may change from green to yellow. If the weight of the load
combined with its center of gravity exceeds the capacity of the forklift, the red light will come on, an alarm will
sound, and the carriage will stop lifting.
Wiggins StabiLock®: When lifting to 20 feet or higher, Wiggins recommends use of the active steer
axle locking system. Prepare to raise the mast by facing the rack where the load is to be placed or retrieved
and shift gear selector into neutral. Uncover the red Steer Axle Lock switch to toggle the switch into the up
position for a high lift. Raise the mast to the desired height. When the forks are at the proper height to clear
the load supports on the desired level, shift gear selector into forward low gear and inch forward using the
brakes gently. Reverse the process to lower. Please note that increasing throttle speed will not lower the
mast more quickly. Turn off the Steer Axle Lock switch before leaving the area.
Park and Shutdown: Select a flat and level area to stop the forklift. Lower the forks to the ground. Put
transmission into neutral and set the parking brake. Turn off the key to stop the engine. At the end of each work day,
rinse all debris residue and dirt off the mast, forks and fork carriage using fresh water. The official authorized person
must always remove the starter key if the Wiggins Yard Bull® is left unattended. The key must be stored in a safe
place.
Transport and Setup: Some Wiggins Yard Bulls® are designed with long tilt cylinders to enable shipment on
single trailers. The larger capacity models or models with lift heights above about 25 feet typically require the removal
of the mast and shipment in two or three parts. Both cases are described below.
If Mast is Attached: Care must be taken to prevent damage to the mast, lift cylinders, lift chain and hydraulic
hoses. When the tractor is to be driven on or off the trailer, the mast must be upright to provide ground clearance at
the bottom of the ramp.
Loading: With the mast in its tilt back position, drive the Yard Bull® in reverse up the trailer ramp to
provide maximum traction to the drive tires. Once the truck is in position, the mast may be lowered. Set the
parking brake and secure the engine key prior to leaving the truck. Use the chain down diagram as shown in
Fig. 2.1. Do not place chain over an axle, any mast parts, cylinder base or frame piece except as shown in
the diagram. Ensure that the tires are at least 60% on the trailer deck support. Install cylinder rod protection
materials to the lift cylinders to prevent damage from the slackened chain.
Unloading: Ensure that all chains are disconnected and removed from the trailer bed. Check fuel
level and tire condition. Check for hydraulic fittings that may have loosened during transport. Start engine
and check for hydraulic leaks. Raise mast to the upright position. Install or position forks as required.
If Mast is Shipped Separately: Care must be taken to prevent damage to the mast, lift cylinders, lift chain
and hydraulic hoses. The mast assembly can weigh 10 tonnes and the crane must be selected accordingly.
Loading: Secure the lifting bridle to the top of the mast. When the crane has control of the mast,
remove the tilt cylinder pins at the counterweight and retract the tilt cylinders. Disconnect all hydraulic hoses
and electrical wiring between the truck and the mast. Remove the retaining bolts from the mast pins on the
frame and remove the pins. The mast is now free to be moved to its shipping location. Drive the Yard Bull in
reverse up the trailer ramp to provide maximum traction to the drive tires. Set the parking brake and secure
the engine key prior to leaving the truck. Use the chain down diagram as shown in Fig. 2.1. Do not place
chain over an axle, any mast parts, cylinder base or frame piece except as shown in the diagram. Ensure
that the tires are at least 60% on the trailer deck support.
Unloading: Ensure that all chains are disconnected and removed from the trailer bed. Check fuel
level and tire condition. Check for hydraulic fittings that may have loosened during transport. Start engine
and check for hydraulic leaks. Drive the truck carefully down the ramp – CAUTION – due to light weight on
the front axle, excessive use of the brakes while on the ramp may cause the front tires to skid. Drive the truck
to the mast and line up the pin holes to insert the mast pins. After the pins are inserted, install the retaining
bolts and tighten. Use the tilt cylinder controls to line up the tilt clevis pins so they can be installed. Connect
the remainder of the hoses and electrical wires to the mast. Remove the crane lifting bridle. Verify proper
operation of all functions. Install carriage and forks as needed.
SAFETY WHILE SERVICING:

Stop the machine. DO NOT service the machine while the engine is running or hot, or if the machine is
in motion.
Note: When making major repairs or complex adjustments, it is recommended that you consult your
Wiggins Dealer and have the work carried out by trained personnel.
HANDLE FUEL SAFELY - AVOID FIRES

• Handle fuel with care: it is highly flammable. Do not refuel the machine
while smoking or when near open flame or sparks.
• Always stop engine before refueling machine. Fill fuel tanks outdoors.
• Prevent fires by keeping machine clean of accumulated trash, grease,
and debris. Always clean up spilled fuel.
PREPARE FOR EMERGENCIES

• Be prepared before a fire starts.
• Keep a first aid kit and fire extinguisher handy.
• Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your
telephone.
AVOID HIGH-PRESSURE FLUIDS

• Escaping fluid under pressure can penetrate the skin causing serious injury.
• Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
• Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
• If an accident occurs, see a doctor immediately.
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with
Wiggins Lift equipment enclose such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow procedures and recommended equipments.
(See your Wiggins Lift Co., INC dealer for MSDS’s on chemical products used with Wiggins Lift equipment.)
WORK IN CLEAN AREA

Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt shortcuts.
SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing.
or necklace when you work near machine tools or moving parts. If these
items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
ILLUMINATE WORK AREA SAFELY

Tie long hair behind your head. Do not wear a necktie, scarf, loose
clothing. or necklace when you work near machine tools or moving
parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and

entanglement in moving parts.
REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. Refer to the Decal Locations Page
located in your Wiggins Manual.
USE PROPER LIFTING EQUIPMENT

Lifting heavy components incorrectly can cause severe injury or
machine damage.
Follow recommended procedure for removal and installation of

components in the manual.
AVOID HARMFUL ASBESTOS DUST

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed
in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
AVOID HEATING NEAR PRESSURIZED FLUID LINES

Flammable spray can be generated by heating near pressurized
fluid lines, resulting in severe burns to yourself and bystanders.
Do not heat by welding, soldering, or using a torch near pressurized
fluid lines or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate flame area.
REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating:

• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove
solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at
least 15 minutes before welding or heating.
USE PROOPER TOOLS

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
CONSTRUCT DEALER-MADE TOOLS SAFELY

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and
good workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or
from your John Deere dealer.
LIVE WITH SAFETY

Before returning machine to customer, make sure machine is functioning properly, especially the safety
systems. Install all guards and shields.
COOLING SYSTEM
• DO NOT remove the radiator cap while the engine is running or hot.
• DO NOT add coolant to the radiator while the engine is running.
• Before removing the radiator cap, turn cap slowly to relive the pressure.
• When adding coolant, make sure coolant being added is compatible and will mix with existing coolant.
ELECTRICAL SYSTEM
To prevent serious injury or death from exploding gases:
Do not work on batteries without proper instruction and training.
Batteries contain sulfuric acid electrolyte. Always wear protective clothing and eye protection when
servicing. In case of electrolyte contact, rinse area with plenty of water and seek medical attention.
Prevent Battery Explosions:
CAUTION: Battery gas can explode.
• Before making adjustments or servicing the electrical system, disconnect the battery negative (-) cable
first to prevent short circuits.
• Do not produce sparks with cable clamps when charging the battery or starting the machine engine with a
slave (jumper) battery.
• Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.
• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
• Always remove grounded (-) battery clamp first and replace it last.
• Batteries produce explosive hydrogen gas when charged. Charge in an area with adequate ventilation.
Halt charging if battery temperature exceeds 52° C.
• Wash hands after handling battery.
HYDRAULIC SYSTEM
High pressure fluid hazard. To prevent serious injury or death:
Relive pressure on system before repairing, adjusting or disconnecting.
Wear proper hand and eye protection when searching for leaks.
Keep all components in good care.
• Ensure all hydraulic connections are tight.
• Relive all pressures before disconnecting hoses or lines. Escaping oil under pressure can cause serious
injury.
• NEVER check for leaks with your hand. Leaks can be located by holding a piece of cardboard or wood (at
least two feet long) with your hand at one end and passing the other end over the suspected area (wear
eye protection). Look for discoloration of the cardboard or wood.
• Hydraulic fluid escaping through a pin hole sized opening can burn or puncture skin, resulting in wounds
that could cause blood poisoning, infection, disability, gangrene, amputation, or death.
• NEVER adjust the pressure of the pump or valve.
• If injured by escaping fluid, no matter how small the wound is, see a doctor at once. A
typical injection injury may be a small wound that does not look serious. However,
severe infection or reaction can result if proper medical treatment is not administered
immediately by a doctor who is familiar with injection injuries.
FUEL SYSTEM
Diesel Fuel is flammable and must be handled with care.
• Never refuel or service the fuel system on the machine while smoking
or near open flames or sparks.
• Never refuel machine while the engine is running.
• DO NOT use a fuel can unless necessary.
• Always clean up any spilled fuel.
• Fuel injection system servicing must be referred to your Wiggins
Dealer. Unauthorized servicing may void all warranties.
Clean Fuel:
Many diesel engine operating troubles result directly or indirectly from dirt in the fuel system. That is
why proper fuel storage and handling are so important. One of the most important aspects of diesel fuel is
cleanliness. The fuel should not contain more than a trace of foreign substance; otherwise, fuel pump and
injector troubles will occur. Diesel fuel, because it is more viscous than gasoline, will hold dirt in
suspension for longer periods. Therefore, every precaution should be made to keep the fuel clean.
It requires only a little WATER in a fuel system to cause an engine to miss, and if present in large
enough quantities, the engine will stop entirely. Many fuel filters are designed to clog completely when
exposed to water, thereby stopping all fuel flow. Water that enters a tank with the fuel or that is formed by
condensation in a partially empty tank or line usually settles to the lowest part of the fuel system. This
water should be drained off daily.
WHEELS and TIRES

Do not attempt to service a tire unless you have the proper equipment and experience to
perform the job. Have the work carried out by your Wiggins Dealer or a qualified repair
service.
• This machine must be supported on suitable blocks or stands, NOT a hydraulic jack.
• NEVER exceed 10 bar (145 psi) or the maximum pressure inflation pressure specified on the tire.
Overinflating may break the bead, or the rim, with dangerous, explosive force.
• Wear suitable protective clothing, gloves, and eye/face protection.
REPLACEMENT PARTS
Where replacement parts are necessary for periodic maintenance and servicing, replacement parts
from Wiggins must be used to restore your equipment to original specifications. Wiggins will not claim
responsibility for installation of unapproved parts and/or accessories and damages as a result of their usage.
WARNING DECAL
Before Operation:
• Be trained and authorized.
• Read and understand your operator's manual.
• Inspect and check your truck daily.
• Do not operate a faulty truck.
• Know and understand the capacity of your truck.
Do not overload.
During Operation:
• Watch for pedestrians, obstructions and overhead
wires.
• Observe all safe driving rules.
• Do not carry passengers or lift people.
• Wear seat belt.
• Drive slowly and do not turn on a slope.
• Travel with load secure and stable.
• Keep forks as low as possible and tilted back as necessary.
Parking:
• Lower attachments.
• Shift into Neutral.
• Set parking brake.
• Turn off key.
• Do not park on a slope.
SAFETY WHILE OPERATING
Review ENTIRE manual before operating this machine.
Safety Instructions:
1. Before you operate this truck you must be trained and
authorized.
2. Read and understand the operator's manual and all
safety labels before operating this truck.
3. Perform operator daily check before operating this
truck.
4. Before lifting load, adjust forks for a stable load.
5. When traveling and turning, slow down and watch for
side clearances for both the load and the tail swing.
6. Watch for overhead obstructions including high voltage
wires and doors.
7. Drive carefully, keeping forks as low as possible and
tilted back as necessary.
8. Do not stand or walk under an elevated load.
Load Handling Safety:

Heed these safety rules:
• When lifting or loading, tilt mast back.
• Use caution when tilting mast forward to ensure load does not shift off forks.
• Never carry maximum rated load with center of load 24 inches above forks.
• Avoid sudden starts and stops to prevent load from shifting.
• Lift loads on level ground to prevent rollover.
• Always watch for overhead obstructions when operating and lifting loads.
• Do not exceed the lifting capacity of the forklift.
• Always ensure forks of the proper capacity are used. Never interchange forks with forks of a
different rating.
• Do not add or subtract weight from the counterweight.
• Avoid raising the load when the wind velocity is excessive.
WARNING – Avoid traveling with mast or boom elevated. Start, stop, travel, steer and brake smoothly.
Slow down for turns. Slow down for rough, slippery, or soft terrain.
Modification, Record Retention, Ownership
Records, Instructions for Pressure Washing
MODIFICATION
Modification or alteration of the forklift shall be made only with prior consent from Wiggins Lift Co., INC.
RECORD RETENTION
The owner shall retain the following records for at least 3 years:
A. Purchase Information
B. Records of persons trained upon delivery of the equipment.
C. Written records of frequent inspections, maintenance performed and parts replaced.
OWNERSHIP RECORDS
When a change of ownership occurs, it is the responsibility of the seller to notify Wiggins Lift Co., INC. with th
following within 60 days of the sale:
A. Serial number of machine.
B. Name and address of new owner.
INSTRUCTIONS FOR PRESSURE WASHING

When pressure washing, protect and DO NOT direct jet on the following components:
Alternator, Axle Pivot pins, Radiator, Starter motor, Hydraulic oil cooler, Transmission oil
cooler, Instrument panel, Electrical Harness, and connections, and Safety Decals.
Decal Locations
1. 101439 BOTH SIDES 10X
2. 102981 BOTH SIDES 4X
3. 104325
4. 105029 BOTH SIDES
5. 128005 BOTH SIDES 6. 106280

WHITE LETTERS
9. 106284 10. 107646
7. 106282 8. 106283
11. 108297
14. 146463
12. 113078 13. 117464 15. 166983 BOTH SIDES
Decal Locations
16. 166999 BOTH SIDES 18. 240034
19. 244594 BOTH SIDES 4X 17. 182152 20. 182152 BOTH SIDES
21. 244598 23. 244599
22. 125045
24.580749
25. 622212
26. 834591
27. 128004 BOTH SIDES

CONTROLS
Instrument Panel
1 2 4 6 8 9
3 5
7
10 17
11 13 14 15 16
12
1. – Engine Oil Pressure Gauge 16. – Light Switch

2. – Not used 17. – Not used
3. – Parking Brake Light
4. – Engine Water Temperature Gauge
5. – Push to Start Button
6. – Voltmeter Gauge
7. – Engine Shut Down Light
8. – Hour Meter Gauge
9. – Transmission Temperature Gauge
10. – Wait to Start Light
11. – Not used
12. – Not used
13. – Engine Warning Light
14. – Ignition Switch
15. – Not used
Instrument Panel Info
1. Engine Oil Pressure Gauge 9. Transmission Temperature Gauge

Display engine oil pressure. Ensure transmission is operating in normal
temperature range. Stop engine if needle is above
2. Not used 240 F.
3. Parking Brake Light 10. Wait to Start Light

When illuminated, parking brake is When illuminated, preheat is on.
engaged. When extinguished, parking Maximum preheat time is 30 seconds.
brake is disengaged.
11. Not used
4. Engine Water Temperature Gauge
Ensure engine is operating in normal 12. Not used
temperature zone. Stop engine if
needle moves above 250 F. 13. Engine Warning Light
When illuminated, something is wrong with engine.
5. Push to Start Button Ask mechanic to check the engine.
When start the engine, push down the
button and the same time turn Ignition 14. Ignition Switch
Switch to start position. ACC--- Auxillary power is on.
OFF --- Stop
6. Voltmeter Gauge IGN --- Ignition powers all electrical
Indicates battery charge. Equipment
Normal readings are between 12-15 volts. SART--- Start
7. Engine Shut Down Light 15. Not used

When illuminated, shut down the engine.
Ask mechanic to check the engine. 16. Light Switch
Up position--- turn on all lights
8. Hour Meter Gauge Down position---turn off all lights
Records hours of the engine operation.
Observe this gauge for periodic
maintenance schedules.
Various Controls
7 6
5
1. Steering Wheel
• Turn wheel left for left turn.
• Turn wheel right for right turn. 8
2. Horn Button
• Push to activate.
3. Shifter
• Center position is Neutral. 5. Accelerator Pedal
• Push forward for forward drive • Push to increase engine speed.
o Twist shifter to shift
through 3 speeds. 6. Brake Pedal
• Pull back for reverse drive • Push to engage service brake.
o Twist shifter to shift
through 3 speeds. 7. Inching / Declutch Pedal
• Push to disengage transmission and to
4. Signal Control Lever apply service brake.
• Push forward for Left Turn.
• Pull back for Right Turn, 8. Steering Column Adjustment
• Pull tab out for Hazard Lights. • Push lever inside of boot to tilt column.
Control Valve
1 2 3 4 5 6
1. Lift
2. Tilt Forward / Back
3. Side Shift
• Forward = Left
• Reward = Right
4. Arm Rotation
• Forward = Clockwise
• Reward = Counter Clockwise
5. Pad Rotation
• Forward = Forward Rotation
• Reward = Backward Rotation
6. Arm Position
• Forward = In
• Reward = Out
Fans, Pressure Gauges, Parking Brake, Wipers, and Fire Extinguisher
1. Pressure gauge – Pump A

2. Pressure gauge – Pump B
3. Lower Fan
4. Parking Brake
• Push to Engage
• Pull to Release
5. Upper Fan
6. Rear Wiper
• Toggle ON / OFF
7. Front Wiper
• Toggle ON / OFF – 2 Speed
8. Fire Extinguisher
1 2 3
5
6
7
Seat Controls and Indicators

(Controls and indicators may vary depending on
particular model of seat used)
1. Knob for lumbar support

2. Armrest
3. Knob for armrest angle adjustment
4. Belt Roller
5. Handle for backrest adjustment
6. Handle for level adjustment
7. Seat level indicator
8. Handle for fore/aft adjustment
9. Seat belt buckle
Air Conditioning controls 1 2
1. Fan Speed
2. Thermostat
3. Heater and Air Conditioning Toggle
4. Air Conditioning ON/OFF
3 4
Maintenance Check Lists: The maintenance check lists provided are based on normally expected operating
conditions. Unusual conditions, such as high or low temperatures, dusty winds or severe rain storms may require
more frequent lubrication or filter replacement.
Forks in use shall be inspected at intervals of not more than 12 months (for single shift operations) or whenever any
defect or permanent deformation is detected. Certain applications will require more frequent inspections, and possibly
non-destructive testing methods to check for cracks.
1. Inspect for surface cracks.

Pay special attention to the heel and
welds attaching all mounting components to
the fork blank. Forks with surface cracks shall
not be returned to service.
2. Check for straightness of blade and shank.

The fork should be withdrawn from service if the
deviation from straightness exceeds allowable
“A” and “B” values.
Allowable “A” = (.005) x (S)
Allowable “B” = (.005) x (L)
Example: 48" or 1,219 mm long blade Allowable
B = (.005) x (48") = .24"
or B = (.005) x (1,219) mm = 6.10 mm
3. Check for excessive fork angle.

When Y value exceeds 2 3/8" (60 mm) or 2 3/4"
(70 mm) on fully tapered, the fork is rejected.
4. Check tip alignment.

When “A” is less than or equal to 42" (1,067 mm),
then the maximum recommended difference in fork
tip elevation is B = .25" (6.35 mm). If “A” greater
than 42" (1,067 mm), then the maximum
recommended difference in fork tip elevation is
B = .375" (9.53 mm).
5. Check for positioning lock damage.

Check the positioning lock and other fork
retention devices to make sure they are
in place and working.
6. Check for wear.

Set the top jaws of caliper by measuring
the thickness of the shank. Position the
bottom jaws over the flanks of the fork
arm blade. If inside jaws of caliper hit
fork, it is OK. If inside jaws of caliper pass
over the fork arm, it must be taken out of
service. Refer to clipboard.
7. Check fork marking.

If the fork identification marking is not
clearly legible, it shall be renewed.
Reprinted from ASME/ANSI B56. 1-2000 carrier shall be checked. If the difference in tip heights
6.2.8 Inspection and Repair of Forks in Service on Fork Lift exceeds 3% of the length of the blade, the set of forks shall
Trucks not be returned to service until repaired in accordance
(a) Forks in use shall be inspected at intervals of not with para 6.2.8.2.
more than 12 months (for single shift operations) or whenever any (e) Positioning Lock (Where Originally Provided).
defect or permanent deformation is detected. Several applications It shall be confirmed that the positioning lock is in good repair
will require more frequent inspection. and correct working order. If any fault is found, the fork shall
(b) Individual and Load Rating of Forks. When forks are be withdrawn from service until satisfactory repair has been
used in pairs (the normal arrangement), the rated capacity of each effected.
fork shall be at least half of the manufacturer’s rated capacity of (f ) Wear
the truck, and at the rated load center distance shown on the lift (1) Fork Blade and Shank. The fork blade
truck nameplate. and shank shall be thoroughly checked for wear,
6.2.8.1 Inspection. Fork inspections shall be carried out carefully special attention being paid to the vicinity of the
by trained personnel with the aim of detecting any damage, heel. If the thickness is reduced to 90% of the
failure, deformation, etc., which might impair safe use. Any fork original thickness, the fork shall not be returned to
which shows such a defect shall be withdrawn from service, and service.
shall not be returned to service unless it has been satisfactorily (2) Fork Hooks (Where Originally
repaired in accordance with para 6.2.8.2. Provided). The support face of the top hook and the
(a) Surface Cracks. The fork shall be thoroughly retaining faces of both hooks shall be checked for
examined visually for cracks and if considered necessary, wear, crushing, and other local deformations.
subjected to a non-destructive crack detection process, special If these are apparent to such an extent that the
attention being paid to the heel and welds attaching all mounting clearance between the fork and the fork carrier
components to the fork blank. This inspection for cracks must also becomes excessive, the fork shall not be returned to
include any special mounting mechanisms of the fork blank to the service until repaired in accordance with para
fork carrier including bolt type mountings and forged upper 6.2.8.2.
mounting arrangements for hook or shaft type carriages. The forks (g) Legibility of Marking (When Originally Provided). If
shall not be returned to service if surface cracks are detected. the fork marking in accordance with para 7.25.2 is not
(b) Straightness of Blade and Shank. The straightness clearly legible, it shall be renewed. Marking shall be
of the upper face of the blade and the front face of the shank shall renewed per instructions from original supplier.
be checked. If the deviation from straightness exceeds 0.5% of
the length of the blade and/or the height of the shank, 6.2.8.2. Repair and Testing
respectively, the fork shall not be returned to service until it has (a) Repair. Only the manufacturer of the fork or an
been repaired in accordance with para 6.2.8.2. expert of equal competence shall decide if a fork may
(c) Fork Angle (Upper Face of Blade to Load of the be repaired for continual use, and the repairs shall only
Shank). Any fork that has a deviation of greater than 3 deg. from be carried out by such parties. It is not recommended
the original specification shall not be returned to service. The that surface cracks or wear be repaired by welding.
rejected fork shall be reset and tested in accordance with para When repairs necessitating resetting are required, the
6.2.8.2. fork shall subsequently be subjected to an appropriate
(d) Difference in Height of Fork Tips. The difference in heat treatment, as necessary.
height of one set of forks when mounted on the fork
FORK INSPECTION POSTER

(Open Link Below “CNTRL + Click Link”)
FORK ARM WEAR CALIPER GUIDE

(Open Link Below “CNTRL + Click Link”)
8 HOUR DAILY, WEEKLY AND MONTHLY SERVICE SHEET
1. LUBRICATE COMPLETE LIFT-WEEKLY (LUBRICATE MAST RAIL DAILY WITH TEF-GEL

PRODUCTS ON MARINA TRUCKS ONLY).
2. MARINA FORKLIFTS MUST BE SPRAYED/WASHED DAILY WITH FRESH WATER.
3. CHECK ENGINE OIL-DAILY
4. CHECK OIL FILTERS FOR LEAKS-DAILY
5. CLEAN AIR CLEANER-MONTHLY
6. CHECK HYDRAULIC OIL FILTERS FOR LEAKS-DAILY
7. CHECK COOLANT IN RADIATOR-DAILY
8. CHECK TRANSMISSION OIL LEVEL-BI-WEEKLY
9. CHECK DIFFERENTIAL OIL LEVEL (IF APPLICABLE)-BI-WEEKLY
10. CHECK EMERGENCY BRAKE OPERATION-DAILY
11. CHECK SURGE BRAKE FLUID (IF APPLICABLE) -DAILY
12. CHECK BRAKES UNDER POWER-DAILY
13. CHECK HYDRAULIC OIL (DIP STICK LEVEL)-DAILY
14. CHECK AXLE MOUNTING NUTS AND BOLTS-DAILY FOR THE FIRST 40 HRS. THEN EVERY PM
THEREAFTER. CALL WIGGINS LIFT CO., INC. FOR TORQUE SPECS.
15. CHECK ALL LUBE POINTS-WEEKLY
16. CHECK ALL HYDRAULIC HOSES & FITTINGS FOR LEAKS-DAILY
17. CHECK GENERAL CONDITION OF UNIT-DAILY
18. DRIVE UNIT & OPERATE ALL HYDRAULIC SYSTEMS-DAILY
19. CHECK ADJUSTMENT OF TILT BACK LOCK NUTS FOR TIGHTNESS-DAILY
20. CHECK WHEEL NUTS-DAILY FOR THE FIRST 40 HRS. THEN EVERY PM THERE- AFTER. CALL
WIGGINS LIFT CO., INC. FOR TORQUE SPECS.
21. CHECK TIRE AIR PRESSURE (IF APPLICABLE) -DAILY. CALL WIGGINS LIFT CO., INC. OR
TIRE MANUFACTURER FOR PROPER TIRE PRESSURES.
NEEDS ATTENTION:
COMPLETED BY: SERIAL #:
O.K.: DATE: HOURS:
WIGGINS LIFT CO - MAINTENANCE SCHEDULE

WIGGINS YARD BULL / ALL TERRAIN - NORMAL USE - TIER III ENGINE
SEE MANUAL FOR DETAILS
EVERY EVERY 1000 HOURS

250 500 OR
DAILY WEEKLY HOURS HOURS ANNUALLY
SAFETY CHECK X
INSPECT FOR LEAKS X
CHECK FUEL AND HYDRAULIC FLUID LEVELS X
OPERATIONAL CHECK X
INSPECT (CLEAN AS REQD) AIR PRE-CLEANER X
LUBRICATE MAST AND AXLE GREASE FITTINGS X
LUBRICATE CHAIN X
LUBRICATE LINKAGES, PEDALS, HINGES, JOYSTICK X
INSPECT HOSE AND CHAIN ROLLERS X
INSPECT (ADJUST) WEAR PAD CLEARANCES X
INSPECT HYDRAULIC HOSES FOR RUBBING X
INSPECT HYDRAULIC HOSES FOR WEEPING X
CHECK TRANSMISSION FLUID LEVEL X
CHECK ENGINE OIL LEVEL X
CHECK COOLANT LEVEL X
CHECK TILT BACK ADJUSTMENT X
CHECK PNUEMATIC TIRE AIR PRESSURE X
CHECK MACHINE FOR RUST X
CHECK MACHINE FOR LOOSE NUTS AND BOLTS X
INSPECT PARKING BRAKE PADS FOR WEAR X

CLEAN HYDRAULIC OIL FILTER MAGNETS X
CLEAN RADIATOR AND CHECK HOSES X
CHECK DIFFERENTIAL FLUID LEVEL X
CHECK AIR FILTER CHANGE IF REQUIRED X
CHECK BATTERY CABLES FOR CORROSION X
CHECK FAN BELT(S) X
CHECK TIRE WEAR X
CHECK WHEEL NUT TORQUE X
SAMPLE HYDRAULIC OIL, CHANGE WHEN REQUIRED X
SAMPLE TRANSMISSION OIL CHANGE IF REQ'D X
CHANGE TRANSMISSION OIL FILTER(S) X

CHANGE ENGINE OIL AND FILTER X
CHANGE FUEL FILTERS X
CHANGE HYDRAULIC OIL FILTER(S) X
CHANGE DIFFERENTIAL OIL X
REPACK STEER AXLE WHEEL BEARINGS X
CHANGE TRANSMISSION OIL AND FILTER(S) X

FLUSH RADIATOR CHANGE COOLANT X
CIRCLE SERVICE INTERVAL, ABOVE.

WIGGINS YARD BULL SERIAL NUMBER: MODEL NUMBER:
RECORD ENGINE HOURS:
PERFORMED BY:
DATE:
PLEASE SEND COPY OF THIS REPORT TO
WIGGINS LIFT CO. FOR OUR RECORDS

WIGGINS YARD BULL / ALL TERRAIN - SEVERE DUTY - TIER III ENGINE
1000
EVERY EVERY HOURS
250 500 OR
SAFETY CHECK X
INSPECT FOR LEAKS X
OPERATIONAL CHECK X
LUBRICATE CHAIN X

CHECK FAN BELT(S) X
CHECK TIRE WEAR X
SAMPLE HYDRAULIC OIL, CHANGE WHEN REQUIRED X
SAMPLE TRANSMISSION OIL CHANGE IF REQ'D X
CHANGE TRANSMISSION OIL FILTER(S) X

CHANGE HYDRAULIC OIL FILTER(S) X
CHANGE DIFFERENTIAL OIL X
CHANGE TRANSMISSION OIL AND FILTER(S) X X


WIGGINS YARD BULL SERIAL NUMBER: MODEL NUMBER:
PERFORMED BY:
DATE:
PLEASE SEND COPY OF THIS REPORT TO WIGGINS
LIFT CO. FOR OUR RECORDS

WIGGINS YARD BULL - NORMAL USE, TIER III ENGINE, HIGH FILTRATION
1000
EVERY EVERY HOURS
250 500 OR
SAFETY CHECK X
INSPECT FOR LEAKS X
OPERATIONAL CHECK X
LUBRICATE CHAIN X

CHECK ELECTRICAL CONNECTORS X
CHECK FAN BELT(S) X
CHECK TIRE WEAR X
SAMPLE HYDRAULIC OIL, CHANGE WHEN NECESSARY X
SAMPLE TRANSMISSION OIL, CHANGE WHEN
NECESSARY X

CHANGE DIFFERENTIAL HIGH PRESSURE FILTER X

CHANGE HYDRAULIC HIGH PRESSURE FILTER X
CHANGE TRANSMISSION HIGH PRESSURE FILTER X

WIGGINS MARINA BULL SERIAL NUMBER: MODEL NUMBER:
PERFORMED BY:
DATE:
PLEASE SEND COPY OF THIS REPORT TO WIGGINS
LIFT CO. FOR OUR RECORDS
Torque values:
¾-16 450-500 Dry
320-384 Lubed
M22x1.5 480-575 Dry

450-500 Lubed
1 1/8-16 750-900 Dry
PRC 7534 ¾-16

PRC 3805/3806 ¾-16 – Typical but may vary
PRC 1756 Most common M22x1.5, but Taylor has a ¾-16 option.
PRC 785 M22x1.5
JD1400 ¾-16
JD1600 ¾-16
Most Wiggins Steer Axle use 1 1/8-16 Nuts
Lubed refers to a pressure bearing grease or anti-seize lubricants, not a light coat of oil. Threads should
be lubricated, but it is important to keep the faces of the rim, washer or nut free from lubricant
For nuts used on hub-piloted wheels, apply two drops of oil to a point between the nuts and flanges and
two drops to the last 2 or 3 threads at the end of each stud. Also, lightly lubricate the pilots on the hub
to ease wheel installation and removal. Do not get lubricant on the mounting face of the drum or wheel.
LUBRICATION and MAINTENANCE
Grease Recommendations:
Use grease based on the expected air temperature range during the service interval.
The following greases are preferred:
• SAE Multipurpose EP grease with a maximum of 5% molybdenum disulfide.
• For the ambient temperature range 14 F° to 122 F° (-10 C° to 50 C°) use SAE NLGI # 2.
• For the ambient temperature range -4 F° to 86 F° (-20 C° to 30 C°) use SAE NLGI # 1.
• For the ambient temperature range -22 F° to 50 F° (-30 C° to 10 C°) use SAE NLGI # 0.
Contact Wiggins Lift Co., Inc. for more information (805) 485-7821.
All Hood and Door Hinge Points
Steer Axle Points
Drive Line Points

Mast Cylinder Tilt Pin Chassis Cylinder Tilt Pin
Carriage Roller Bearing Lube Points Mast Chain use Tefgel Mast roller bearings lube points
(Inside Carriage Rail) (Wpn – 671864)
Fork Bushing Lube Points Chain Roller Pins
For Tire Handler Attachments

(Open the following link “CNTRL + Click Link” or Refer to the IMT Manual Included)
Differential Valve Bleeder Mast Pin Location
Oil Level Plug Oil Level Plug

Hydraulic Brake Bleeder
Accelerator, Braking, and Inching Pedals Control Lever Lube Points

(Wpn – 671864) (Wpn – 671864)
(WPN = Wiggins Part Number)

Engine & Transmission Maintenance Item Locations
TYPICAL LOCATIONS SHOW,

MAY VARY PER TRUCK
Engine Fuel Filter
Engine Oil Dipstick
Engine Oil Fill
Oil Drain Plug
Fuel Water Separator

Engine Oil Filter
Radiator Fill Tank

Transmission Oil Dipstick Transmission Oil Fill Cap
Axle Oil
Cooler Filter
Transmission
Oil Filter
Transmission Oil Fill
AIR FILTER PARTS DENTIFICATION
Dust Ejector
Secondary
Element
Wing Nut
Wing Nut Element

Maintenance
Engine – Cummins QSB 4.5 and QSB6.7

Important Reference Numbers
Fill in the part name and number in the blank spaces provided below. This will give you a reference
whenever service or maintenance is required.
Name Number Number

Engine Model
Engine Serial Number (ESN)
Control Parts List (CPL)
Fuel Pump Part Number
Electronic Control Module (ECM)
Electronic Control Module Serial Numbers (ECM)
Filter Part Numbers:
• Air Cleaner Element
• Lubricating Oil
• Fuel
• Fuel-Water Separator
• Coolant
• Crankcase Ventilation
• Cummins Particulate Filter
Governor Control Module (GCM) (if applicable)
Belt Part Numbers:
•
•
•
Clutch or Marine Gear (if applicable):
• Model
• Serial Number
• Part Number
• Oil Type
• Sea Water Pump
• Model
• Part Number
Maintenance
Daily Maintenance Procedures – Overview
General information
Preventative maintenance begins with day-to-day awareness of the engine and its system. Before
starting the engine, check the oil and coolant levels. Look for:
• Leaks
• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance.
• Odor of fuel
Engine Operation Report

The engine must be maintained in top mechanical condition if the operator is to get optimum
satisfaction from its use. The maintenance department needs daily running reports from the operator
to make necessary adjustments in the time allocated. The daily running report also helps to make
provisions for more extensive maintenance work as the reports indicate the necessity.
Comparison and intelligent interpretation of the daily report, along with a practical follow-up action,
will eliminate most failures and emergency repairs.
Report to the maintenance department any of the following conditions:

• Low lubricating oil pressure
• Low power
• Power increases or engine surge
• Erratic or no accelerator control or response
• Any warning lights flashing or staying on
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel, or lubricating oil ,
• Any fuel, coolant, or lubricating oil leaks
• Loose or damaged parts
• Worn or damaged belts
Unusual Engine Noise

During daily maintenance checks, engine noise that can indicate that service is required.
Maintenance
Crankcase Breather Tube

Maintenance Check
Inspect the breather tube for sludge, debris, or ice in the tube.
Inspect the tube more frequently in icy conditions.
Fuel-Water Separator
Drain
WARNING
Drain the water-fuel separator into a container and dispose of in

accordance with local environmental regulations.
Cummins Inc. requires a fuel-water separator or fuel filter be installed in the
fuel supply system.
Drain the water and sediment from the separator daily.
Canister Type
Shut off the engine.
Pull up on the drain valve lever until fluid drains out of the drain tube.
Drain the filter sump until clear fuel is visible.
Push up on the drain valve until fluid drains out of the drain.
Spin-On Type
Shut off the engine.
Use your hand to open the drain valve. Turn the valve
counterclockwise approximately 3 ½ turns until the valve drops
down 25.4mm [1 in] and draining occurs.
Drain the filter sump until clear fuel is visible.
CAUTION When closing the drain valve, do not overtighten the valve.
Overtightening can damage the threads.
To close the valve, turn clockwise until it is hand tight.
Cooling Fan
Inspection WARNING
Warning: Personal injury can result from a fan blade
failure. Never pull or pry on the fan. This can damage the fan
blade(s) and cause fan failure.
NOTE: Rotate the crankshaft by using the engine barring gear.
A visual inspection of the cooling fan is required daily. Check for

Cracks, loose rivets, and bent or loose blades. Check the fan to
make sure it is securely mounted. Tighten the capscrews if
Necessary. Replace any fan that is damaged.
Maintenance
Lubricating Oil Level

Maintenance Check CAUTION
Never operate the engine with oil level below the L (low) mark or above the H
(high) mark. Poor engine performance or engine damage can occur.
The engine must be level when checking the oil level to make sure the measurement
is correct.
Shut off the engine for an accurate reading.
Wait at least 15 minutes after shutting off the engine to
check the oil level. This allows time for the oil to drain into
the oil pan.
For additional lubricating oil recommendations and oil pan
capacity information, refer to Lubricating Oil Recommendations and
Specifications.
Drive Belts
Maintenance Check
Poly-Vee Belt
Inspect the belts daily. Check the belt for intersecting cracks. Traverse
(across the belt width) cracks are acceptable. Longitudinal (direction of belt
OK
length) cracks that intersect with transverse cracks are not acceptable.
Replace the belt if it is frayed or has pieces of material missing. Refer to
(Engine Manual/Section A) for belt adjustment and replacement procedures.
Belt damage can be caused by:
OK
Incorrect tension.
• Incorrect size or length.
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the side of belts.
Cogged Belt
Inspect the belts daily. Replace the belts if they are cracked, frayed, or have
chunks of material missing. Small cracks are acceptable. Adjust the belts that
have a glazed or shiny surface, which indicates belt slippage. Correctly
installed and tensioned belts will show even pulley and belt wear. Refer to
(Engine Manual /Section A) for belt adjustment and replacement procedures.
Maintenance
Belt damage can be caused by:

• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts
Measure the belt tension in the center span of the pulleys.
Refer to the Belt Tension Chart for the correct gauge and tension value for
the belt width used.
An alternate method (deflection method) can be used to check belt tension
by applying 110 N [25 lbf] force between the pulleys on v-belts. If the
deflection is more than one belt thickness per foot of pulley center distance,
the belt tension must be adjusted.
Refer to (Engine Manual/Section A) for adjustment procedures.
For cogged belts, make sure that the belt tension gauge is positioned so that
the center tensioning leg is placed directly over the high point (hump) of a
cog. Other positioning will result in incorrect measurement.
Coolant level
Check
WARNING
Warning: Do remove the radiator cap from a hot engine. Wait

until the temperature is below 50° [120°F] before removing the
pressure cap. Failure to so can result in personal injury from
heated coolant spray or steam. Remove the filler cap slowly
to relive coolant system pressure.
NOTE: Never use a sealing additive to stop leaks in the coolant
system. This can result in coolant system plugging and inadequate
coolant flow causing the engine to overheat.
The coolant level must be checked daily.
CAUTION
Caution: Do not add cold coolant to a hot engine. Engine
castings can be damaged. Allow the engine to cool to below
50° [120°F] before adding coolant.
NOTE: On applications that use coolant recovery system, check to

make sure the coolant is at the appropriate level on the coolant
recovery tank depending on the engine temperature.
Maintenance
Maintenance Specifications
Lubricating Oil System
Specifications
Oil Pressure
Low idle (minimum allowed) ..............................................................................69 kPa [10 psi]
At rated (minimum allowed) .............................................................................207 kPa [30 psi]
Oil-regulating valve-opening pressure range ................... 448 kPa [65 psi] to 517 kPa [75 psi]
Oil filter differential pressure to open bypass ...................................................345 kPa [50 psi]
Lubricating Oil Filter Capacity ...........................................................................0.95 liters [1 qt]
Oil Capacity of Standard Engine (four-cylinder)
4.5 liters [275 C.l.D.] Engines (Suspended Oil Pan)
Pan only .....................................................................……...11 liters [11.6 qt]
Total system ..........................................................................13 liters [13.7 qt]
High to low (on dipstick) .........................................................1.9 liters [2.0 qt]
4.5 liters [275 C.l.D.] Engines (Aluminum Oil Pan)
Pan only ............................................................................... 13 liters [13.7 qt]
Total system ..........................................................................1.5 liters [15.9 qt]
High to low (on dipstick) ..........................................................3.0 liters [3.2 qt]
4.5 liters [275 C.l.D.] Engines (High Capacity Oil Pan)
Pan only ................................................................................16 liters [16.9 qt]
Total system ...........................................................................18 liters [19.0 qt]
High to low (on dipstick) ..........................................................6.0 liters [6.3 qt]
Oil Capacity of Standard Engine (six-cylinder)
6.7 liters [409 C.I.D] Engines (Standard Oil Pan)
Pan only .............................................................................14.2 liters [15.0 qt]
Total System .......................................................................16.7 liters [17.6 qt]
High to Low (on dipstick) .........................................................1.9 liters [2.0 qt]
6.7 liters [409 C.l.D] Engines (Suspended Oil Pan)
Pan only..............................................................................17.2 liters [18.5 qt]
Total System .......................................................................19.7 liters [20.8 qt]
High to Low (on dipstick) ....................................................... 2.8 liters [3.0 qt]
6.7 liters [409 C.l.D] Engines (High Capacity Oil Pan)
Pan only ........................................................................... 23.9 liters [25.3 qt]
Total System...................................................................... 26.4 liters [27.9 qt]
High to Low (on dipstick) ........................................................7.4 liters [7.8 qt]
Maximum Oil Temperature
For 4.5 liters [275 C.I.D.] and 6.7 liters [409 C.I.D.] Engines .............................138°C [280°F]
NOTE: lf the type/oil capacity of the oil pan is not known:
Contact a Cummins® Distributor/Dealer.
Determine the capacity of the oil pan option for the engine being serviced by using
OuickServe™ Online and the engine serial number.
• Fill the lubricating oil pan to the smallest oil pan capacity listed tor the engine being
serviced. Then add 0.95 liters [1 qt] of oil at a time until it reaches the high mark on the
dipstick. Record the number of quarts added so that capacity is known the next time the oil is
drained.
Maintenance
Fuel Recommendations and Specifications
Fuel Recommendations
WARNING
Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that the
fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe
damage to both the fuel pump and the fuel injectors.
CAUTION
Lighter fuels can reduce fuel economy or possibly damage fuel system components.
Cummins Inc. recommends the use of ASTM number 2D fuel. The use of number 2D diesel fuel will
result in optimum engine performance.
At operating temperatures below 0°C [32°F], acceptable performance can be obtained by using
blends of number 2D and number 1D.
The following chart lists acceptable substitute fuels for this engine.
An "A" means OK only if fuel lubricity is adequate. This means the BOCLE number is 3100 or greater
as measured by ASTM specification D6078, Scuffing Load Ball On Cylinder Evaluator (SLBOCLE).
Lubricity can also be measured by ASTM, specification D6079, ISO 12156, High Frequency
Reciprocating Rig (HFRR) in which the fuel must have a wear scar diameter of 0.45 mm [0.02 in] or
less.
Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not
warrantable.
Winter blend fuels, such as found at commercial fuel-dispensing outlets, are combinations of number
1D and 2D diesel fuels and are acceptable.
NOTE: Cummins Inc. recommends that the cetane number of diesel fuel be a minimum of 45 for
engines that are expected to operate at temperatures below O°C [32°F] and a minimum of 40 for
engines that are operated at temperatures above 0°C [32°F].
NOTE: Using diesel fuel with lower than recommended cetane number can cause hard starting,
instability, and I excessive white smoke. To maintain satisfactory operation at low ambient
temperatures, it is important to specify diesel fuel of the correct cetane number.
Additional information for fuel recommendations and specifications can be found in Fuel for
Cummins® Engines, Bulletin 3379001. See ordering information in the back of Engine manual.
Maintenance
Lubricating Oil Recommendations and Specifications
General Information
CAUTION
The fuel sulphur content should not exceed 0.5 mass percent sulphur. lf the fuel sulphur
content is greater than 0.5 mass percent sulphur, seek advice from your local Cummins®
Distributor. For recommendations of fuel for Cummins® engines, refer to Fuel for Cummins®
Engines, Bulletin 3379001.
CAUTION
Extending the oil and filter change interval beyond the recommendations will decrease engine
life due to factors such as corrosion, deposits and wear.
CAUTION
Cummins Inc. does not recommend the use of A.C.E.A. E4/MB 228.5 formulation oils, which do
not attain one or more of the following lubricant qualifications: A.P.I. CH-4. Cl-4, A.C.E.A. E5,
E7, C.E.S. 20071, C.E.S. 20072, C.E.S. 20076, C.E.S. 20077, C.E.S. 20078. If A.C.E.A. E4/MB
228.5 formulation oils, which do not comply with the oil specifications listed above, are used
in Cummins® automotive engines, problems such as wear to overhead, sliding tappets,
camshaft and crankshaft bearings may be experienced.
The use of quality engine lubricating oils, combined with appropriate oil drain and filter change
intervals, is a critical factor in maintaining engine performance and durability. Extending the oil and
filter change interval beyond the recommendations will decrease engine life due to factors such as
corrosion, deposits and wear.
NOTE: The responsibility is with the owner. lf recommendations are ignored, warranty could be
affected.
NOTE: A.C.E.A. = Association des Constructeurs Européen d'AutomobiIes, A.P.l. = American
Petroleum Institute and C.E.S. = Cummins® Engineering Standard.
Cummins Inc. recommends the use of a high-quality SAE 15W~40 heavy-duty engine oil, such as
Valvoline Premium Blue™, which meets or exceeds the American Petroleum Institute (API)
performance classification CH-4/SJ or Cl—4/ SK and the Association des Constructeurs Européen
d'AutomobiIes (A.C.E.A.) performance classification E5 or E7.
Maintenance
1. CG-4/SH and E-3 oils can be used in areas where none of the recommended oils are available, but
the oil drain interval must be reduced by one half ofthe interval given in the maintenance schedule.
See the oil drain interval information in Section 2 of engine manual.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit, and oil
consumption control. The sulfated ash must not exceed 1.85 mass percent.
Special “break-in" oils are not recommended for use in new or rebuilt Cummins® engines. Use the
same lubricating oil that will be used in normal engine operations.
Use of "synthetic engine oils" (those made with API group 3 or group 4 base stocks) is permitted
subject to the same performance and viscosity limitations of petroleum (mineral) based engine oils.
The same oil change intervals must be applied to synthetic oils that are applied to petroleum (mineral)
based engine oils.
For further details and discussion of engine lubricating oils for Cummins® engines, refer to
Cummins® Engine Oil Recommendations, Bulletin 3810340.
CAUTION
An SAE 10W-30 designation on a product is a viscosity

designation only. This designation alone does not imply
that the product meets Cummins Inc. requirements. Only
10W30 oils with diesel performance credentials listed in
table above can be used in Cummins® engines if the
reduced ambient temperature indicated in chart above is
observed.
The primary Cummins Inc. recommendation is for the use of 15W—40 multigrade for normal
operation at ambient temperatures above -15°C [5°F]. The use of multigrade oil reduces deposit
formation, improves engine cranking in low temperature conditions and increases engine durability by
maintaining lubrication during high temperature operating conditions. Since multigrade oils have been
shown to provide approximately 30 percent lower oil consumption, compared with monograde oils, it‘s
important to use multigrade oils to be certain your engine will meet applicable emissions
requirements. While the preferred viscosity grade is 15W-40, lower viscosity multlgrades can be used
in colder climates. See the accompanying chart.
Oils meeting a 10W30 viscosity grade, must meet a minimum High Temperature/High Shear viscosity
of 3.5cSt., and ring wear/liner wear requirements of Cummins® and Mack™ tests. Thus, they can by
Maintenance
used over a wider temperature range than 10W30 oils meeting older API performance classifications.
As these oils will have directionally thinner oil films than 15W-40 oils, top quality Fleetguard® filters
must be used above 20°C [70°F]. Some oil suppliers might claim better fuel economy for these oils.
Cummins Inc. can neither approve nor disapprove any product not manufactured by Cummins
Inc. These claims are between the customer and oil supplier. Obtain the oil supp|ier‘s commitment
that the oil will give satisfactory performance in Cummins® engines or do not use the oil.
An example of the API service symbols are shown in the

accompanying illustration. The upper half of the symbol
displays the appropriate oil categories.
The center section identifies the SAE oil viscosity grade.

.
As the engine oil becomes contaminated, essential oil

additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.
Progressive contamination of the oil between oil and filter
change intervals is normal. The amount of contamination
will vary depending on the operation of the engine,
kilometers or miles on the oil, fuel consumed, and new oil
Extending oil and filter change intervals beyond the

recommendations will decrease engine life due to factors
such as corrosion, deposits, and wear.
See the oil drain chart in Engine Manual, Section 2 to

determine which oil drain interval to use for your application.
New Engine Break-in Oils

CAUTION
A sulfated ash limit of 1.85 ercent has been laced on all en ine lubricating oils recommended
for use in Cummins® engines. Higher ash oils can cause valve and/or piston damage and lead
to excessive oil consumption.
CAUTION
The use of a synthetic-base oil does not justify extended oil change intervals. Extended oil
change intervals can decrease engine life due to factors such as corrosion, deposits, and
wear.
Maintenance
Special break-in engine lubricating oils are not recommended tor new or rebuilt Cummins® engines.
Use the same type of oil during the break-in as is used in normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the EMA
Lubricating Oils Data Book for Heavy-Duty Automotive and Industrial Engines. The data book can be
ordered from: Engine Manufacturers Association, Two North LaSalle Street, Chicago, IL 60602; (312)
827-8733,(www.englnemanufacturers.0rg).
Coolant Recommendations and Specifications
Fully Formulated Coolant/Antifreeze
Cummins Inc. recommends the use of fully formulated

antifreeze/coolant meeting Cummins Engineering
Standards (C.E.S.) 14603. For further details and
discussion of coolant for Cummins® engines, refer to
Coolant Requirements and Maintenance, Bulletin 3666132.
Typically, antifreeze/coolants meeting ASTM4985
(GM6038M specification) or ASTM D6210 criteria are
acceptable antifreeze/coolants for engines covered by
the engine manual.
Low-silicate antifreeze/coolants meeting ASTM D4985
(GM6038M specification) are not adequate for extended
service intervals.
Cummins inc. recommends using either a 50/50 mixture
of good-quality water and fully formulated antifreeze, or
fully formulated coolant when filling the cooling system.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Cummins inc. recommends using Fleetguard® Compleat.

It is available in both glycol forms (ethylene and 3 so
propylene).
Maintenance
Fully formulated antifreeze must be mixed with good-

quality water at a 50/50 ratio (40- to 60—percent working
range). A 50/50 mixture of antifreeze and water gives a
-36°C [-33°F] freezing point and a108°C [226°F] boiling
point, which is adequate for locations in North America.
The actual lowest freezing point of ethylene glycol antifreeze
is at 68 percent. Using higher concentrations of antifreeze
will raise the freezing point of the solution and increase the
possibility of a silica gel problem.
A refractometer must be used to measure the freezing

point of the coolant accurately. Use Fleetguard®
refractometer, Part Number C2800.
Do not use a floating ball hydrometer. The use of floating

ball hydrometers can give an incorrect reading.
Cooling System Sealing Additives

Do not use sealing additives in the cooling system. The
use of sealing additives will:
• Buildup in coolant low-flow areas
• Plug the radiator and oil cooler
• Possibly damage the water pump seal.
Maintenance
Cooling System Soluble Oils

Do not use soluble oils in the cooling system. The use of
soluble oils will:
• Corrode brass and copper

• Damage heat transfer surfaces
• Damage seals and hoses.
Drive Belt Tension

Tension Chart
NOTE: This chart does not apply to automatic belt tensioners.

* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Sealants
General Information
Use the sealants listed below or sealants containing equivalent properties.
Maintenance
Transmission – Clark 32000

Specifications and Service Data-Power Shift Transmission and Torque Converter
Converter Out Pressure Oil Filtration
Converter outlet oil temp 180° - 200° F Full flow oil filter safety by-pass, also strainer screen
(82.3° – 93.3° C). in sump at bottom of transmission case.
Transmission in NEUTRAL.
Operating specifications: Clutch Pressure
25 P.S.I. (172.4 kPa) minimum pressure at 240-300 P.S.I (1654.8 – 2068.4 kPa) – With parking
2000 R.P.M. engine speed AND a maximum brake set (see note), oil temperature 180° - 200° F
of 70 P.S.I. (482.6 kPa) outlet pressure with (82.3° – 93.3° C), engine at idle (400-600 RPM),
engine operating at no-load governed speed. Shift thru direction and speed clutches. All clutch
pressure must be equal within 5 P.S.I. (34.5 kPa). If
Controls clutch pressure varies in any one clutch more than
Forward and Reverse – Manual 5 P.S.I. (34.5 kPa) repair clutch.
Speed Selection – Manual NOTE: Never use service brakes while making
clutches oil cooled and lubricated. clutch pressure checks. Units having brake
actuated declutching in forward and/or reverse
Clutch Inner Disc will not give a true reading.
Friction. ALWAYS USE PARKING BRAKE WHEN MAKING
CLUTCH PRESSURE CHECKS.
Clutch Outer Disc
Steel.
Lubrication
Type of Oil Normal * Drain Period

See Lube Chart
Every 500 hours, change oil filter element.
Capacity Every 1000 hours, drain and refill system as follows:
Consult Owners Manual on applicable Drain with oil at 150° - 200° F (82.3° – 93.3° C).
machine model for system capacity. Torque NOTE: It is recommended that filter elements be
Converter, Transmission and allied hydraulic changed after 50 and 100 hours of operation on
system must be considered as a whole to new and rebuilt or repaired units.
whole to determine capacity.
(a) Drain transmission and remove sump
screen. Clean screen thoroughly and
Check Period
replace, using new gaskets.
Check oil level DAILY with engine running
(b) Drain oil filters, remove and discard
running at 500-600 R.P.M. and oil at
filter elements. Clean filter shells and
150° - 200° F (82.3° – 93.3° C). Maintain
install new elements.
oil level to FULL mark.
(c) Refill transmission to LOW mark.
(d) Run engine at 500-600 RPM to prime

converter and lines.
(e) Recheck level with engine running at

500-600 RPM and add oil to bring level
to LOW mark. When oil temperature is
hot (180° - 200° F) (82.3° – 93.3° C),
make final oil level check. BRING OIL
LEVEL TO FULL MARK.
* Normal drain periods and filter change intervals are for average environmental and duty-cycle
conditions. Severe or sustained high operating temperatures or very dusty atmospheric condition
will cause accelerated deterioration and contamination. For extreme conditions, judgment must be
used to determine the required change intervals.
Maintenance
Recommended Lubricants for Clark-Hurth Components Power Shifted

Transmission and Torque Converters
Maintenance
Trouble Shooting Guide

For the
R and HR Model, 32000 Transmission
The following data is presented as an aid to locating the others. By studying the principles of operation
the source of difficulty in a malfunctioning unit. It is necessary together with the data in this section, it may be
to consider the torque converter charging pump, transmission possible to correct any malfunction which may occur in
lines as a complete system when running down the source of the system.
trouble since the proper operation of any unit therein TROUBLE SHOOTING PROCEDURE
depends greatly on the condition and operations of BASICALLY CONSITS OF TWO CLASSIFICATIONS:
MECHANICAL AND HYDRAULIC.
Mechanical Checks
Prior to checking any part of the system from a 2. Check shift levers and rods for binding or
hydraulic standpoint, the following mechanical checks should restrictions in travel that would prevent full
be made: engagement. Shift levers by hand at control valve, if
1. A check should be made to be sure all control full engagement cannot be obtained, difficulty may be
lever linkage is properly connected and adjusted at all in control cover and valve assembly.
connecting points.
Hydraulic Checks
Before checking on the torque converter, is impractical, the latter means should be employed as
transmission, and allied hydraulic system for pressures and follows:
rate of oil flow, it is essential that the following preliminary Engage shift levers in forward and high speed
checks be made: and apply brakes. Accelerate engine half to three-
Check oil level in transmission. This should be done quarter throttle.
with oil temperatures (180° - 200° F) (82.3° – 93.3° C). DO NOT Hold stall unit desired converter outlet
ATTEMPT THESE CHECK WITH COLD OIL. To bring the oil temperature is reached. CAUTION: FULL THROTTLE
temperature to this specification it is necessary to either work the STALL SPEEDS FOR AN EXCESSIVE LENGTH WILL
machine or “stall” out the converter. Where the former means OVERHEAT THE CONVERTER.
Low Clutch Pressure
Cause Remedy
1. Low oil level. 1. Fill to proper level.
2. Clutch pressure regulating valve spool stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.
5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
Low Converter Charging Pump Output

2. Suction screen plugged. 2. Clean suction screen.
3. Air leaks at pump intake hose and connections or 3. Tighten all connections or replace hose if
collapsed hose. (R-32000 only) necessary.
4. Defective oil pump. 4. Replace pump.
Maintenance
Overheating
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter

assembly.
2. Worn oil pump. 2. Replace.
4. Pump suction line taking air. (R-32000 only) 4. Check oil line connections and tighten securely.
Noisy Converter
1. Worn coupling gears. 1. Replace.

1. Worn oil pump. 2. Replace.
2. Worn or damaged bearings. 3. A complete disassembly will be necessary to
determine what bearing is faulty.
Lack of Power
1. Low engine RPM at converter stall. 1. Turn engine check governor.

2. See “Overheating” and make same checks. 2. Make corrections as explained in “Overheating”.
Maintenance
DRIVE AXLE –
General/Serial Number Identification
Axle Identification
Each Teaml/late ll Axle has a serial number Each John Deere lnboard Planetary Axle has
plate located on the input side of the differential a 13-digit alphanumeric serial number plate.
case. Major design changes may be noted The top line of the plate identities the
within this Component Technical Manual producing factory, component type
(CTM) and will refer to the information on the identification, and six position sequential
serial number plate. serial number.
This CTM is used for TeamMate ll Axles with The alphanumeric code on the second line
the following information on the SECOND line, identities the axle configuration.
first positions (reading left to right) of the serial

number plate: IMPORTANT: Serial number plates must
be masked when painting axles to prevent
1200 Series 1400 Series 1600 Series the information from becoming illegible.
2523R 2513R 2503R This information is used for service and
warranty purposes.
IMPORTANT: Use CTM18 for TeamMate
Axles with 2500R, 2501R, 2510R, 2511R, or
NOTE: Some serial number plates include
2521R in the same first five positions of the
the addition of bar-coding.
SECOND line of the serial number plate.
Serial Number Plates – John Deer Applications
1—Manufacturing Unit 4—Six Position Serial 6—Design Version 7—19—Top Assembly

RO = Waterloo Works Number 0 = Transitional Number
2—Component 5—Axle Series 1 = TEAMMATE ™ I
Identification 250 = 1200 Series 2 = Not used
AG = Inboard Planetary 251 = 1400 Series 3 = TEAMMATE ™ II
3—Configuration Identity 252 = 1600 Series
250 = 1200 Series
251 = 1400 Series
252 = 1600 Series
Maintenance
Serial Number Plate – OEM Applications – 1600 Series
1—Manufacturing Unit D—Flange-to-Flange Width; E—Input Housing and H—Differential Type

RO = John Deere Wheel Attachment; Auxilliary Brake 1 = Standard
Waterloo Works Outer Bearing Lube 1 = Standard - No Brake 3 = Air Boost,DIFF-LOK
2—Component 1 = None 2 = Park Brake C = Oil Circulation,
Identification 2 = 1994mm (78.5 in.); Spring Apply – DIFF-LOK
AG = Inboard Axles M24-3; Permlub Hydraulic Release I—Differential Case
3—Configuration Identity 3 = 2198 mm (86.5 in.); 3 = Park Brake Cover - 1 = Standard
251 = Series Code .75 in. – 10; No Brake J—Final Drive Reduction
(1400 Series) Greased F—Mounting Type 1 = None
4—Serial Number 1 = Fixed Mounting 2 = 3.714:1
5—Master Machine Code 2 = Oscillation - 3 = 5.143:1
251 = 1400 Series Dual Center Pivot K—Trim
6—Family Code G—Brake Type 1 = Nothing
2 = Transmission Axle 1 = No Brakes (Interfactory)
3= TEAMMATE™ II Axle 2 = Independent Brakes 3 = Primer (tan)
7—Manufacturing Unit 3 = Dual Brakes 4 = Paint (yellow)
R = John Deere A = Dual Brakes L—Miscellaneous Parts
Waterloo Works No Axles 1 = Miscellaneous parts
A—Input Rotation No breather
Travel Direction 2 = Miscellaneous Parts
1 = Clockwise Breather
(Toward input)
2=Clockwise
(Away from input)
3 = Counterclockwise
(Toward input)
4=Counterclockwise
(Away from input)
B—Spiral Bevel Reduction
1 = 4.364:1
2 = 4.909:1
3 = 5.273:1
4 = 5.818:1
C—Input Yoke –
Size and Style
1 = 8C
2 = 1710
4 = 7C with Brake Flange
Maintenance
General/Axle Oil
Transmission, Hydraulic, and Gear Case Oil
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oils are preferred:

John Deere HY·GARD®
John Deere Low Viscosity HY-GARD®
Other oils may be used if they meet one of the following:

John Deere Standard JDM J20C
John Deere Standard JDM J20D
John Deere Standard JDM J27A
Use the following oil when a biodegradable fluid is

required:
• John Deere BIO-HY-GARD™ ¹
¹ BIO-HY-GARD meets or exceeds the minimum biodegradability of 80% within 21 days according to
CEC-L-33-T-82 test method. BIO-HY-GARD should not be mixed with mineral oils because this
reduces the biodegradability and makes proper oil recycling impossible.
Service and Maintenance Schedule
Service and maintenance is highly dependent upon operating conditions and vehicle application.
Refer to the vehicle operators manual for recommended service and maintenance intervals and
procedures.
Maintenance
Drain and Refill Axle Oil
1. Remove plug (B) to drain oil A

2. Remove fill plug (A) and out level plug (C).
IMPORTANT: Wait several minutes for oil

to transfer to final drives.
There is only a small hole
connecting drive
compartment to center
compartment. This may
have to be repeated several
times.
3. Fill axle until oil is to bottom of oil level

plug (C) hole.
Oil Capacity C
(Approximate)
Greased Outer Bearing Axles

1200 Series .........................18.9 L (20 qt)
1400 Series……………….…28.4 L (30 qt)
1600 Series ........................ 45.5 L (48 qt)
Oiled Outer Bearing Axles

1200 Series .........................21.8 L (23 qt)
1400 Series……………….…31.2 L (33 qt)
1600 Series ........................ 48.3 L (51 qt)
B
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require lubricant recommendations different from those
in this manual.
Synthetic lubricants may be used if meeting the performance requirements in this manual.
The temperature limits and service intervals apply to both conventional and synthetic oils.
Refined base stock products may be used if the finished lubricant meets the performance
requirements.
Maintenance
Lubricant Storage
Equipment can operate at top efficiency only if clean lubricants are used.
Use clean containers to handle all lubricants.
Store lubricants and containers in an area protected from dust, moisture, and other contamination.
Store containers positioned to avoid water and dirt accumulation.
Make certain all containers are correctly marked to identify contents.
Properly dispose of all old containers and any residual lubricant.
Mixing of Lubricants
ln general, avoid mixing different brands or types of oil. Oil manufacturers blend additives to their oils
to meet certain specifications and performance requirements.
Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant
performance.
Refer to lubricant specifications to obtain specific information and recommendations.
Grease
Use grease based on NLGI consistency numbers and

the expected air temperature range during the service
interval.
The following greases are preferred:

• John Deere HIGH TEMPERATURE EP GREASE
• John Deere MOLY HIGH TEMPERATURE EP
GREASE
• John Deere GREASE-GARD™
Other greases may be used if meeting the following

• NLGI Performance Classification GC-LB
Maintenance
General/Bolt Torque Charts
Metric Bolt and Cap Screw Torque Values
DO NOT use these values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical
property class.
Fasteners should be replaced with the same or higher property class. If higher property class
fasteners are used, these should only be tightened to the strength of the original.
Make sure fasteners threads are clean and that you I properly start thread engagement. This will
prevent them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque
shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts
to the full torque value.
ª “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
“Dry" means plain or zinc plated without any lubrication.
Maintenance
Unified Inch Bolt and Cap Screw Torque Values
DO NOT use these values if a different torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical
property class.
Fasteners should be replaced with the same or higher property class. If higher property class
fasteners are used, these should only be tightened to the strength of the original.
Make sure fasteners threads are clean and that you I properly start thread engagement. This will
prevent them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque
shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts
to the full torque value.
b
Grade 2 applies for hex cap screws (nut hex bolts) up to 152 mm (6-in,) long. Grade 1 applies for hex cap
screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.
Maintenance
Unified Inch Bolt and Cap Screw Torque Values – Grade 180
DO NOT use these values if a different

torque value or tightening procedure is given
for a specific application. Torque values
listed are for general use only. Check
tightness of fasteners periodically.
Fasteners should be replaced with the same

or higher property class. If higher property
class fasteners are used, these should only
be tightened to the strength of the original.
Make sure fasteners threads are clean and

that you I properly start thread engagement.
This will prevent them from failing when
tightening.
General/Hydraulic Connections
Hydraulic Connections
There are several different combinations for hydraulic lines and fittings, for brakes, differential
housings, and lubrication lines.
Refer to the vehicle repair manual and/or parts information for the actual application of a particular
axle configuration,
Brake Inspection
External Brake Inspection
Brake disks can be inspected for wear through

the external inspection ports (A).
Remove axle housing and replace brakes if oil

grooves on facing material are no longer visible.
(See Drive Axle Manual; Remove Axles, Group 35)
A
Maintenance
Parking Brake Inspection and Adjustment
A - Dust Seal E - Lock Nut H - Spring Washers K - Parking Brake Disk

B - Seals F - Cover l – Shaft L - Cap Screw [3 used}
C - Piston G - Snap Ring J - Brake Pad Assembly
D - Parking Brake Adjusting Thickness
Screw
PAD-TO-DISK RUNNING CLEARANCE
Maximum .............................4.76 mm (0.187 in)

Minimum.............................. 0.5 mm (0.020 in)
1. Park machine on level surface. 7. Tighten mounting bracket to support bracket cap
screws to 70 N-m (50 lb-ft).
2. Stop engine. This will engage park brake.
8. Loosen adjusting screw 180° (1/2 turn). This
3. Put blocks in front and behind tires. provides approximately 0.5 mm (0.02 in.) pad-to-disk
clearance.
4. Loosen mounting bracket to support bracket cap
screws 9. Tighten adjusting lock nut (E) to 100 N-rn (74 lb-ft)
while holding the adjusting screw in position.
5. Remove park brake adjustment cover cap screws
(L) and cover (F). Loosen the lock nut [E). 10. Install cover (F) and tighten cap screws (L).
6. Tighten park brake adjustment screw (D) to 100 N-

m (75 lb-ft).
Maintenance
Parking Brake Pressure Test
Specifications
Oil Temperature ················· 40° ±6°C (100° ±10°F)

Engine Speed ......................Slow Idle
Park Brake Pressure ……….16 200 kPa ±45 kpa
(162 ±3.5 bar)
(2350 ± 50 psi)
Tools Required
• Gauge 20 500 kPa (205 bar} (3000 psi)

• 38H1029 Tee-(-4 M ORFS X -4 ORFS X -4 M ORFS)
-(Parker 4R6LO-S)
• Test Hose
1. Install tee onto park brake inlet and connect inlet pressure line.
2. Install hose and gauge.
3. Connect a temperature reader and heat the hydraulic oil to specification.
4. Put the park brake switch in the "OFF" position.
5. Read the park brake pressure.
6. Check brake pump pressure according to vehicle instructions if pressure is too high or low.
7. Check the park brake solenoid valve according to vehicle instructions if pressure does not drop to
zero when park brake is "ON".
Maintenance
MAST
For proper operation and extended lift, your Wiggins Lift Mast should be inspected and serviced
regularly as part of your normal lift truck maintenance schedule according to the following outlines
and ANSI B56.1 procedures. The recommended intervals are for masts operating under normal
conditions. If the mast us operating in severe conditions or corrosive atmospheres, the inspections
should be performed more frequently.
WARNING: Never work on the mast with a load on the forks or attachment, in the raised position
without supports or while anyone is near the lift truck control handles per ANSI B56.1.
Daily Inspection:
1. Extend the carriage a few inches off the ground and make sure the mast chains are under equal
tension. Refer to Chain Inspection Section.
2. Extend the mast to its fullest height to make sure the mast rails and carriage extend freely without
binding.
3. While the mast is extended, inspect the upright rails for proper lubrication. Refer to Rail
Lubrication Section (see Next Page).
4. Make sure the internal reeving hoses (if equipped) travel evenly in the hose guides. Adjust the
hose ends if required. Tighten the fittings making sure they do not twist.
Mast Lubrication:
• Lubricate all grease fittings on the mast per Wiggins
Maintenance Schedule. (Refer to “Lube and Grease
Points” pages for locations and recommend grease).
• To lubricate Inner Mast Rail, fully extend mast. Apply
Tefgel, (Wpn – 671864), to both outside webs of
Inner Mast Sections.
• To Lubricate inside webs of inner
rails, lower mast sections and apply to exposed
inner mast rail.
Maintenance
100 Hour Inspection

After each 100 hours of lift truck operation, and in addition to the daily inspection:
1. Inspect and lubricate the full length of the chains with Tefgel. (Wiggins Part Number 671864 -
TEFGEL PEN GEL LUBE)
CAUTION: The chains must be coated with a film of lubricant at all times.
500 Hour Inspection

After each 500 hours of lift truck operation, and in addition to the daily and 100 hour inspection:
1. Check for equal distances between the insides of the uprights (See Fig 1). If the distances
are not equal, follow the applicable instructions described below:
Canted Mast Bearings – Typical for Extruded Rail (Shown in Fig 1)
a. Shim the load rollers on the uprights and carriage so that the total side clearance is
no greater than .06 inches (1.5 mm) occurs at the tightest point throughout the travel
of the member. Pry between the upright and load roller so that the opposite load
roller is tight against the upright. (See Fig 1)
Straight Mast Bearing – Typical for Fabricated Rail (Shown in Fig 2 and 3)
b. Adjust set screws so the uprights and carriage distances are equal. Tighten locking
nut to secure set screw. (See Fig 2 and 3)
2. Check the Chains for wear and stretch. Refer to Chain Inspection section
.06 in.
(1.5 mm)
MAX.
Pry Here
Load Roller
Fig 1.
Fig 1.
Mast Bearing Clearances
Canted Bearings Shown
Carriage Rail
Inner Rail
Outer Rail
Inside of Upright
Distances
Maintenance
Fig 2.
Fig 3.
LOCK NUT
SET SCREW
Maintenance
Carriage Inspection
1. Inspect the rollers for excessive wear or damage. Rollers with visible flat spots or cracks should
be replaced.
2. Lower Fork or Attachment to level ground and tilt the mast forward or back to release load on
rollers. Inspect the roller bearings by turning the rollers on their shafts. Rollers with roughness or
noticeable restrictions to turning should be replaced.
3. Inspect all welds between the carriage side plates and the carriage fork bars. If any welds are
cracked, replace the carriage.
4. Inspect the roller stub shafts. If they are damaged or if there are cracks at the base of the stub
shafts, the carriage must be replaced or repaired. Contact Wiggins Lift Co., Inc. for repair
procedures.
Set Screw
Lock Nut Thrust Pad Thrust Pad Retainer
Side Thrust
Pad
Stubshaft
Chain Anchor
Cotter Pin Pin
Chain Anchor Load Roller
Snap Ring
Front Upright
Chain Pin
Carriage shown above is for a Tire Handler

Additional Service, Safety and Maintenance information on NON-
Wiggins attachments will be provided as a separate manual.
Maintenance
Chains
Inspection and Tension
Each pair of chains has been factory-lubricated using heat and pressure to force the lubricant
thoroughly into the chain links. Avoid removal or contamination of this factory lubricant. Do
not wash, sand blast, etch, steam clean, or paint the chains on initial mast installation.
The chains must be adjusted with equal tension to ensure proper load distribution and mast
operation. To determine equal tension, extend the unloaded mast to put the chains under
tension. Press the center of a strand of chain with your thumb, then press at the same place
on the other chain of the pair. Each chain in a pair should have equal “give”. If tension is not
equal, adjust the chains as described in Chain Adjustment.
Inspect the chains. If inspection reveals that one strand of a pair of chains requires
replacement, both strands of the pair should be replaced.
• Check for rust and corrosion.

• Check for cracked side plates. If you find cracked side
plates, replace both strands of chain.
• Check for tight joints. If tight joints are caused by rust or
corrosion, loosen them with SAE 40 wt. oil or penetrating
oil. If they cannot be loosened, or if the tight joints are
caused by bent pins or plates or worn contour, replace both
strands of chain.
• Check for abnormal protrusion or turned pins. Replace both
strands of chain.
• Check for chain side wear. If pins and outside plates show
signs of wear, check for misalignment. If wear is excessive,
replace both strands of chain.
• Check for work, broken or misaligned chain anchors.
Replace or adjust as required.
• Lubricate the full length of the chains with Tefgel
(WPN -671864)
Maintenance
Measuring Chain Stretch

Regular inspection and lubrication of
the chains will increase their service lift
and reduce down time.
Chain
If the chains stretch beyond the Wear
Scale
recommended about, they should be
replaced in pairs. Chain stretch can be
measured with the chain wear scale.
Measure the chains according to the
instructions printed on the chain wear
scale. Measure the chains according to the
instructions printed on the chain wear
scale, without a load on the carriage.
• To check the free lift chains,
raise the carriage 1ft. (30 cm) New Chain Stretched Chain
off the ground to put tension on the chains.

• To check the main lift chains, raise the mast until the inner upright starts to
extend putting tension on the chains.
Main Lift Chain Adjustment

The main lift chains should be adjusted so that when the unloaded mast is fully lowered, the
uprights are positioned as shown. Approximately 10 in (25.4 cm)
Ground Clearance
1. Adjust on chain to achieve the correct upright position
when fully lowered.
2. Adjust the other chain to achieve equal chain tension
Tighten the nuts together.
3. Raise and lower the mast several times to confirm the
adjustments.
Uprights Flush
Carriage 2.5-3 in (6.3-7.6 cm)

Below Uprights
Maintenance
HYDRAULIC SYSTEM
Hydraulic Oil Filler

• Refer to the Wiggins Maintenance
Schedule for Oil Filter replacement
recommendation.
Hydraulic Oil Filler Hydraulic Oil Gauge

• Refer to the Wiggins
• Check Hydraulic oil level Daily
Maintenance Schedule for Oil
Change recommendation.
Hydraulic Oil Recommendations
Wiggins Lift Co. Inc. recommends the use of mineral-based hydraulic oil containing anti-wear additives. Use
oil viscosity based on the expected air temperature range during the period of oil change.
The following oils are preferred:
For the ambient temperature range is -25 F° to 104 F° (-32 C° to 40 C°) use Chevron synthetic All-Weather
THF CPS226607 (SAE 10W)
For the ambient temperature range is 23 F° to 115 F° (-5 C° to 46 C°) use Chevron 1000
THF (SAE 30)
Maintenance
ELECTRICAL SYSTEM
Engine Relay Enclosure
Battery (read Safety While

Servicing “Electrical” before
servicing)
Relay Identification
Horn
Main Relay Enclosure
Mast Lights
Overhead Lights
Neutral
Back Up
Forward
Parking Brake
Ignition Power
Auxiliary
Air Conditioner
Maintenance
Troubleshooting
Wiggins Yard Bull® / All Terrain
This section provides general guidelines on the types of problems operators may encounter in the field, the
causes of the problems, and suggestions for proper corrective actions.
WARNING
When troubleshooting, ensure that the forklift is parked on a firm, level surface, there is no load on the forks,
parking brake is on and use wheel chocks.
When replacing or testing the continuity of any electrical component, disconnect the battery ground cable.
When changing hydraulic components, make sure the engine is stopped and keep the component clean.
General Procedure
Troubleshooting should be carried out in two steps. First, to determine the possible causes, both the hydraulic
and electric schematics should be thoroughly studied. Loose terminal connections and short circuits are
always a potential cause when troubleshooting. Second, check suspect components electrically, hydraulically
and mechanically to determine if there is a fault.
Careful inspection and accurate analysis of the symptoms listed in the Troubleshooting Guide will help the
mechanic find the problem more quickly. This manual cannot cover all possible problems that may occur. For
engine problems, first read the Engine Manual. If a specific problem is not covered in this manual, call
805-485-7821 for service assistance.
Maintenance
SYMPTOM POSSIBLE CAUSE SOLUTION
Engine 1. Battery terminal Check, clean and tighten terminal.

does not corroded or loose
crank
2. Discharged battery Check the condition of battery. If
serviceable, recharge battery. If
defective, replace battery.
3. Start solenoid Replace the starter solenoid if
defective.
IF serviceable,
4. Key switch Replace switch if inoperative.
5. Starter motor Repair or replace starter
6. Main circuit fuse or Check the fuse and replace if required
breaker
Engine 1. Engine cold Warm up engine with block heater or

cranks but glow plug.
will not start
2. Out of fuel Fill tank and bleed lines.
3. Blocked fuel line Remove obstruction.
4. Fuel filter clogged Clean or replace filter.
5. Air in the fuel system Bleed system
6. Water in the fuel system Drain tank if necessary to remove all

water.
7. Fuel pump defective or
damaged Check fuel delivery, replace pump if
necessary
8. Oil Pressure Sender or
Coolant Temperature Check senders. Replace if
sender inoperative inoperative.
9. Emergency stop switch

open Check Emergency Stop Switch
Maintenance
Engine 1. Fuel or air filter clogged Clean or replace the filter element
starts, then
stops 2. Low fuel level
Fill fuel tank.
3. Air leaks in the fuel
system Tighten all fuel line connections and
clamps.
4. Fuel pump defective or
damaged Check fuel delivery, replace pump if
necessary.
5. Water in fuel
Drain the tank if necessary to remove
all water.
6. Key switch
Damaged key switch. Replace it.
Engine 1. Hydraulic oil low Check hydraulic oil level. Add oil as
starts, required.
but no
functions 2. Hydraulic pump Check pressure and delivery of the
work damaged hydraulic pump. Replace if required
3. Damaged Relief Valve Adjust or replace relief valve
4. Damaged Charge Valve Check the valve. Replace if necessary.
Loss of 1. Clogged Air Filter Clean or replace the filter.

power
2. Clogged Fuel Filter Replace the filter.
3. Incorrect fuel Refill tank with proper fuel.
4. Fuel pump damaged Repair or replace pump.
Engine 1. Fuel tank empty Refill tank and bleed lines.

stops
2. Water in fuel
Drain the tank and remove all water
Maintenance
Engine stop 3. Oil Pressure Sender or

Replace the sender
Coolant Temperature
Sender damaged
Forks will 1. Faulty Hydraulic Pump. Check pressure and delivery of pump
not lift or
lower 2. Faulty Relief Valve. Check the valve. Readjust or replace if
required.
3. Damaged Adjust or replace the valve

Counterbalance
Valve on lift cylinder
4. Clogged pilot line or port Check and clean the hoses and fittings
to the Counterbalance
Valve
If not overloaded, check the overload
5. Faulty Stabilift System Pressure Switch, connector.
Replace the seals or cylinder.

6. Damaged lift cylinder.
Mast will not 1. Faulty Hydraulic Pump. Check pressure and delivery of pump
tilt
2. Faulty Relief Valve. Check the valve. Readjust or replace if
required.
3. Damaged
Counterbalance Valve Adjust or replace the valve
on tilt cylinder
4. Clogged pilot line or Check and clean the hoses and fittings
port to the
Counterbalance Valve
Forks 1. Faulty Hydraulic Check pressure and delivery of the

cannot be Pump. pump
positioned or
swung 2. Faulty Relief Valve. Check the valve. Readjust or replace if
required.
Maintenance
3. Damaged Counterbalance Check the valve. Adjust or replace

Forks
Valve on fork cylinder. the valve.
cannot be
positioned or
4. Damaged fork Change the seals or cylinder
swung
cylinder
Truck will 1. Faulty Relief Valve Readjust or change relief valve.

not steer
2. Faulty Hydraulic Pump Repair or replace pump.
3. Faulty Steer Motor

Repair or replace Steer Motor.
4. Damaged steer cylinder
Replace the seals or cylinder.
Brake does 1. Damaged accumulator

Recharge or replace accumulator.
not work
2. Faulty Brake Pedal
Valve Repair or replace Pedal Valve.
3. Faulty Charge Valve

Repair or replace Charge Valve.
4. Damaged Brake
Readjust or repair Brake.
Parking 1. Faulty Brake Solenoid Repair or replace the valve.

Brake does Valve
not work
2. Damaged accumulator Recharge or replace accumulator.
3. Faulty Charge Valve Repair or replace Charge Valve.
4. Damaged Parking Brake Readjust or repair Parking Brake.

Wiggins Lift Truck Warranty
WARRANTY PERIOD • Expenses to investigate complaints, unless the problem

is caused by a defect in WLC material or workmanship.
Wiggins Lift Co., Inc. (WLC) warrants new fork lift truck products and • Giving WLC notice within 30 days of defect covered by
other products manufactured by WLC associated with new fork lift the Warranty and promptly making the
trucks to be free, under normal use and with proper maintenance, Wiggins Fork Lift Truck available for repair. All claims
from defects in workmanship or material and in compliance with the for coverage under the warranty must be filed with WLC
design and construction specifications of: no later than thirty (30) days after the expiration of the
Warranty Period.
1) Part II ANSI 856.6 as required by OSHA standard • Giving timely prior written notice of the transfer of
1910.176(b)(2);2) Part III ANSI 856.1 revision in effect at the time of ownership of the Wiggins Fork Lift Truck covered to this
manufacture and (3) the fire protection designation (G,LPG,D,E,etc) Warranty. Any transfer of ownership of the Wiggins Fork
specified on the product for 24 months or 4,000 hours of operation, Lift Truck covered by this Warranty will be covered only
whichever occurs first from the date the truck is placed into service or for the remainder of the Warranty Period, if any.
from the date of delivery to the original customer from an authorized
Wiggins dealer. NOTE: All international Warranty parts shipments are F.O.B. point of
debarkation, duties and tariffs included, (local taxes excluded).
WLC RESPONSIBILITIES
This warranty requires timely maintenance and periodic inspection of
If a defect in material or workmanship is identified during the the Wiggins Fork Lift Truck as indicated in the operator’s manual
Warranty Period, Wiggins will, during furnished with each Wiggins Fork Lift Truck. The cost of routine
normal working hours and through a place of business of a Wiggins maintenance and service is the responsibility of the customer. The
Fork Lift Truck dealer or other customer is required to keep documented evidence of when and by
WLC authorized source: whom maintenance and service are performed.
• Provide (at WLC’s choice) new, remanufactured or WARRANTY LIMITATIONS / DISCLAIMERS

WLC –approved repaired parts or assembled
components needed to correct the defect. THE FOREGOING SHALL CONSTITUTE THE SOLE AND
• NOTE: Items under the Warranty become the EXCLUSIVE REMEDY OF ANY OWNER OF A WIGGINS FORK LIFT
property of WLC. AND THE SOLE AND EXCLUSIVE RESPONSIBILITY OF WLC, AND
• Replace lubricating oil, filters, antifreeze and other IN LIEU OF ALL OTHER WARRANTIES EXPRESSED, IMPLIED OF
service items made unusable by the defect. STATUTORY INCLUDING BUT NOT LIMITED TO ANY WARRANTY
• Provide labor to correct the defect. OF MERCHANTABLILTY, OR FITNESS FOR A PARTICULAR
PURPOSE. WLC NEITHER ASSUMES NOR AUTHORIZES ANY
Wiggins is NOT responsible for the following: PERSONS TO ASSUME FOR IT ANY OTHER OBLIGATION OR
• Any use or installation which WLC determines RESPONSIBILITY IN CONNECTION WITH THIS WIGGINS FORK
improper. LIFT TRUCK WARRANTY. IN NO EVENT SHALL WLC BE
• Repairs by other than a WLC authorized repair facility. RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR
• Abuse, accident, neglect and/or improper repair or CONSEQUENTIAL DAMAGES, OR ANY DELAY OR ECONOMIC OR
storage. COMMERCIAL LOSS RESULTING FROM WLC’S PERFORMANCE
OR NON-PERFORMANCE UNDER THIS WARRANTY. THIS
• Any parts or accessories installed on a Wiggins Lift
WARRANTY IS EXPRESSLY IN LIEU OF ALL WARRANTIES,
Truck which were not manufactured, recommended or
OBLIGAGIONS OF RESPONSIBILITIES OF WIGGINS’S DEALERS,
installed by WLC including, without limitation, forks,
EXPRESSED, IMPLIED OR STATUTORY.
attachments, masts, tires, and batteries. Claims with
respect to such items, if any, shall be made solely to
WARRANTY COVERAGE IS NOT EXTENDED TO REPAIRS OR
the respective manufacturer.
PARTS AND SERVICE REQUIRED AS A RESULY OF NORMAL OR
• Loss of time, loss of equipment use, other
ACCELERATED WEAR AND TEAR (I.E. BRAKE SHOES, BELTS,
consequential damage or other matters not
HOSES, SEALS, AND PACKING, TIRES, LIGHT BULBS, BATTERY
specifically included.
CONNECTORS) AND PERIODIC MAINTENANCE WHICH IS
PERFORMED IN ACCORDANCE WITH PUBLISHED SCHEDULED
Parts replaced under this Warranty are warranted for the remainder of
(I.E. TUNE-UP, PARTS, FILTERS, SPARKPLUGS AND ELECTRICAL
the Warranty Period for the Wiggins Fork Lift Truck. WLC reserves
COMPONENTS).
the right to make any changes in design and improvement without
incurring any obligation to incorporate such improvements in any
product already shipped from its factory premises or which is in the MODEL: ________________________________________________
hands of a customer.
SERIAL NO.: ____________________________________________
MAINTENANCE WIGGINS DEALER: _________________________
TRUCKS WITH KNOWN FAILED OR DEFECTIVE ________________________________________________________
PARTS MUST BE IMMEDIATELY REMOVED FROM CUSTOMER: ____________________________________________
SERVICE.
DATE: __________________________________________________
CUSTOMER RESPONSIBILITIES:
The customer is responsible for:
• All transportation expenses, if any, related to a claim
under this Warranty
• Labor expenses, except as stated under “WLC
Responsibilities”
• Federal, State and local taxes, if applicable.
• Parts shipping charges in excess of those which are
usual and customary.
# 99900699
TH3565 Manual de Servicio

Rev. 20071019
Printed on 23 October, 2007

3
CHAPTER 1
In This Chapter
Generalidades ............................................................................3
Lubricación .................................................................................4
Sistema Hidraulico .....................................................................5
Mantenimiento Preventivo..........................................................8
Lista de Inspeccion del Tirehand................................................10
Problemas ..................................................................................12
Lista de Piezas de Repuesto Recomendada .............................13
TH3565 Etiquetas Advertencia...................................................15
Generalidades
Es esencial el mantenimiento regularmente programado para mantener el Tirehand
(manipulador de neumáticos) en operación eficiente. Esta sección contiene información
importante para el adecuado procedimiento de mantenimiento y los intervalos de servicio
necesarios. El personal responsable del mantenimiento de esta unidad deberá familiarizarse
con la frecuencia y tipo de mantenimiento necesario, y realizar las tareas en los intervalos
recomendados.
4 TH3565 Manual de Servicio Manual # 99900699
Lubricación
Mantener el programa adecuado de lubricación variará con las condiciones climáticas y la
frecuencia del uso. El cuadro de lubricación tiene el propósito de servir como un programa para
carga de trabajo normal, y condiciones de clima moderado. Los periodos de carga de trabajo
pesado acortaran los intervalos de servicio.
Punto de Aplicación Lubricación Aplicación Intervalo

Pivote del portador, puntos en los brazos
Bocinas lineales Shell Alvania 2EP Pistola de grasa, Semanalmente
Pines en bisagras o manual
Cojinetes engranajes de las garras Shell Retinax "A"
sujetadoras o o
Engranajes de accionamiento, en las garras Equivalente
sujetadoras neumática
Cilindros abrazaderas
Cojinetes engranajes, cuerpo
Engranaje de accionamiento, cuerpo
Pistola a presión
Piñón de engranaje, cuerpo
5
Sistema Hidraulico
Selecciòn del Fluido Hidraulico

Las especificaciones de viscosidad mínimas para el aceite hidráulico que se debe usar en el
Tirehand están indicadas en la tabla debajo. Cualquier empresa mayorista de aceites puede
suministrar productos que reúnan estos requerimientos.
Los aceites seleccionados para este equipo, además de reunir los requerimientos de
viscosidad, deben tener las siguientes propiedades de aditivos:
1 Inhibidores anti-espuma
2 Inhibidores anti-oxidante
3 Aditivos resistentes al moho
4 Aditivos anti-desgaste
Especificaciones de Fluido Hidraulic

La tabla debajo contiene especificaciones de aceite para un alto rango de temperaturas de
operación. Condiciones del Ártico presentan requerimientos especiales que no están
contempladas en este cuadro, y deben ser analizadas individualmente.
Consulte su proveedor de aceites para el adecuado aceite hidráulico para usar bajo estas
condiciones severas. Los reservorios de calentadores eléctricos están disponibles para mejorar
la operación en temperaturas extremadamente bajas.
ESPECIFICACIONES DE FLUIDO HIDRAULICO

Rango de Temperatura Ambiente, grados -18 - 32°C bajo 0°C 0 -32°C (32- sobre 32°C
C (F) (0-90°F) (bajo 32°F) 90°F) (sobre 90°F)
Punto de llenado mínimo, grados C (F) -34ºC (- -32ºC (-25ºF) -12ºC -12ºC (+10ºF)
30ºF) (+10ºF)
Viscosidad mínima, SSU @ -18 grados C 4.000 4.000 --- ---
(0ºF)
Viscosidad mínima, SSU @ 38 grados C 140-190 100-130 150-200 200-315
(100ºF)
Viscosidad mínima, SSU @ 100 grados C 48 41 43 47
(210ºF)
Índice de Viscosidad Mínima 139 90 90 90
Deterioro de Fluido Hidraulico

Contaminación de los aceites hidráulicos por solventes, agua, polvo u otros abrasivos causarán
deterioro del aceite. Presencia sustancial de estas impurezas resultará en una prematura baja
de las propiedades de los aditivos y reducirán el índice de viscosidad. Presencia de agua en el
sistema, u operaciones a altas temperaturas (sobre 180o F), resultará en un incremento del
rango de oxidación del aceite. La oxidación produce formación de materiales barnizados y lodo
en el aceite. Operar el sistema por periodos prolongados, contaminarán o malograrán el
aceiteoo o, incrementará el desgaste del componente, causando una reducción significativa de
la duración del servicio.
Periódicamente, retire una muestra de aceite, y revise la calidad del aceite.

1 Ponga la muestra en un contenedor limpio de vidrio.
2 Huela el aceite para detectar olores rancios o quemados.
3 Examine visualmente si el color del aceite está oscuros, o nubloso.
4 Deje la muestra en reposo por unos minutos.
Inspeccione la muestra por si hay presencia de agua, la cual se asentará en el fondo del vaso.
El agua puede ser resultado de una fuga en el sistema, o condensación por temperatura
extremas.
Cuando se observen cualquiera de estas condiciones, el sistema debe ser purgado y llenado
con aceite nuevo. Se debe cambiar el aceite en el sistema completo, incluyendo el reservorio.
1 Luego de cada 800 horas de operación, o cada (6) meses, lo que ocurra primero.
2 Luego de falla de la bomba u otro componente mayor.
Purgado del Sistema Hidraulico

Purgar el sistema hidráulico requiere suficiente aceite nuevo para rellenar el reservorio,
mangueras, cilindros, y permitir algo de pérdida durante el proceso. Para reducir perdida de
aceite durante este proceso, operar el motor del vehiculo a velocidad baja. Durante la purga, se
suministra aceite nuevo en la bomba, y el aceite usado se descarga de la línea de succión. Se
necesitan dos operadores durante el proceso, uno para operar los controles, y el otro para
regular la velocidad del motor.
PRECAUCION
NO PERMITA QUE EL RESERVORIO ESTE POR DEBAJO DE 1/3 DE SU CAPACIDAD

DURANTE LA OPERACION.
Se logra la purga de la siguiente manera:

1 Ubicar la unidad en un área con suelo a nivel sólido, y espacio para acomodar el rango total
de operación de la unidad. Cambie el vehículo a neutro.
7
2 Levante el brazo a aproximadamente 5 pies sobre el nivel del piso. Operar la función de
cambio de lado totalmente en una dirección.
3 Con el manipulador de llantas derecho del lado de arriba, rotarlo de manera que quede a 30
grados horizontal. Extender los brazos sujetadores a toda su carrera.
4 Apague el motor, escurra el reservorio hidráulico y retire las mangueras de succión y de
presión. Escurra y vuelva a armarlo.
NOTA
EL METODO PARA DESECHAR EL ACEITE USADO ES A CRITERIO DEL PERSONAL DE

SERVICIO.
5 Desconectar la línea de retorno y direccionarla dentro de un contenedor de desperdicios.

Conecte el puerto de la línea de retorno en el reservorio, y llene con aceite limpio.
NOTA
FAMILIARIZARSE CUIDADOSAMENTE CON LOS SIGIENTES PASOS, Y ESTE

PREPARADO PARA REALIZARLOS EN UNA SECUENCIA, SIN INTERRUPCION, O PARE
EL MOTOR AL FINALIZAR CADA PASO. SI NO LO HACE PUEDE OCURRIR EXCESIVO
DESPERDICIO DE ACEITE.
6 Arranque el motor y enganche la bomba si es necesario. Con el retorno direccionado en el

contenedor de desperdicios, retracte los brazos sujetadores, rote las garras, y opere el
movimiento lateral a toda su carrera. Rotar el Tirehand de regreso a su posición horizontal.
Pare el motor.
7 Reconecte la línea de retorno en el reservorio, y cambie el filtro de retorno. Todos los
componentes del Tirehand están ahora purgados.
8 Revise el nivel de aceite en el reservorio, y agregue aceite si fuera necesario.
NOTA
ESTA SECCION HA CUBIERTO LA PURGA DEL MANIPULADOR. EL SISTEMA

HIDRAULICO DEL VEHICULO PORTADOR DEBE DE HACERSE SEGUN EL MANUAL DE
SERVICIO DEL FABRICANTE.
Purgando Aire Atrapado

Puede que se introduzca aire en el sistema, tanto a través de una fuga en el sistema, o debido a
la desconexión de un componente hidráulico durante el servicio. El aire en el sistema causará
una operación errática, y debe ser corregido.
Para purgar aire del sistema, extender y retraer varias veces el cilindro afectado. Al final de la
carrera, sostener la válvula abierta por unos cuantos segundos. Repetir este procedimiento
varias veces, hasta que la operación esté suave y continua.
Reemplazo del Elemento del Filtro

NOTA
ALGUNOS VEHICULOS PORTADORES PUEDEN NO ESTAR EQUIPADOS CON FILTROS

DE LINEA DE SUCCION Y DE RETORNO. ESTAS INSTRUCCIONES APLICAN PARA
AQUELLOS VEHICULOS QUE REQUIEREN INSTALACION DE FILTROS IMT. SI EL
VEHICULO TIENE FILTROS DE LINEA DE SUCCION Y DE RETORNO, REFIERASE A LAS
INSTRUCCIONES DEL FABRICANTE.
Los filtros hidráulicos deben regularmente pasar por servicio, para evitar acumulación de
contaminantes en el reservorio o a través de todo el sistema. Estos deben ser cambiados luego
de las primeras 50 horas de operación, y luego cada 200 horas. Para cambiar los elementos de
filtros:
1 Cierre la puerta de la válvula y retire el elemento de filtro.
2 Instale un nuevo elemento, asegurándose que el sello de jebe esté en su lugar.
3 Abir la puerta de la válvula y revise por fugas.
PRECAUCION
SI LA PUERTA DE LA VALVULA NO ES REABIERTA ANTES DE LA OPERACION LA

BOMBA PUEDE FALLAR.
Mantenimiento Preventivo
La lista de inspección del manipulador de neumáticos (página sub-siguiente) ha sido diseñada
para asesorarlo en mantener el Tirehand en condición óptima de operación. La información en
esta sección se refiere solamente al Tirehand. Los rubros que aplican al Tirehand deben ser
revisados antes de que éste sea puesto en operación. Inspeccionar en la frecuencia indicada
en la sección oscurecida. Consulte la guía de servicio del fabricante para información del
vehículo portador.
INSPECCION REGULAR
Cada (3) meses, o mas seguido cuando el equipo está sujeto a trabajo pesado, las
inspecciones a continuación deben ser realizadas además del mantenimiento preventivo en la
lista de inspección.
MONTAJES DEL BRAZO DEL TIREHAND

1 Revisar por defectos estructurales tales como soldaduras rajadas, abolladuras, o
torceduras.
9
2 Revisar las válvulas de sostenimiento de los cilindros.

3 Revisar los cilindros por fugas.
4 Revisar en ambos brazos sujetadores, desgaste y lubricación de los cojinetes internos y
externos.
5 Revisar los tiempos de operación. Ambos brazos sujetadores deben funcionar juntos en el
mismo rango de movimiento.
ROTACION AXIAL DE LOS AGARRADORES
1 Revisar por defectos estructurales.
2 Revisar por fugas en los motores.
3 Revisar los cojinetes de disco ubicados en los ejes de soporte.
4 Revisar todos los pines, y sus retenedores.
SISTEMA HIDRAUILCO
CILINDROS
1 Revisar los vástagos por daños, tales como escamosidades, melladuras, y revisar por moho
en las unidades fuera de servicio.
2 Revisar las uniones de soldadura, y fugas en los sellos.
3 Revisar por movimientos sin propósito, indicando posible fuga alrededor del pistón.
4 Revisar el contenedor de cilindro por rajaduras y melladuras.
BOMBA HIDRAULICA
1 Revisar por fugas en los sellos del eje y juntas de sección.
2 Revisar por caída en la velocidad de operación
3 Revisar la presión de operación del sistema.
VALVULA DE CONTROL HIDRAULICO
1 Revisar por fugas en las juntas de sección y carretes.
2 Revisar por la facilidad de movimiento del carrete.
3 Revisar los ajustes de la válvula de alivio.
RESERVORIO DE ACEITE Y MANGUERAS
1 Revisar los filtros por elementos atascados.
2 Revisar el nivel de aceite en el reservorio.
3 Revisar todas las mangueras por daños.
BRAZO PORTADOR Y CILINDROS

1 Revisar por defectos estructurales, tales como melladuras, dobladuras, y soldaduras
rajadas.
2 Revisar todos los pines y sus retenedores.
3 Revisar por daños en los vástagos de cilindro, y revisar por fugas.
MONTAJE DEL CILINDRO DE MOVIMIENTO LATERAL
1 Revisar el cilindro por fugas y daños.
2 Revisar los bujes lineales por daños y lubricación.
3 Revisar por defectos estructurales.
4 Revisar los pines retenedores del cilindro.
MONTAJE DE ROTACION
1 Revisar el torque de perno de la tórnamesa.
2 Revisar por contragolpes en el piñón y cojinete de engranaje.
11
Lista de Inspeccion del Tirehand

RUBRO DESCRIPCION FRECUENCIA
*Indica rubro crítico DIARIA SEMANAL MENSUAL
Inspección Visual Inspeccionar por fugas hidráulicas, partes sueltas
y daño estructural obvio en los miembros.
*Pernos de Montaje Revisar el torque (ajustar con llave inglesa
mecánica)
Sistema de Revisar por excesivo contragolpe (juego) entre el
Rotación engranaje de piñón y el cojinete de engranaje de
la tornamesa.
Garra=0.15 - 0.25 mm (.006"-.010") /
Cuerpo=0.20 - 0.33 mm (.008"-.013")
*Daño Estructural Revisar por fracturas en las soldaduras, rajaduras
por fatiga, defectos estructurales, dobladuras y
abolladuras.
Controles Revisar por excesivo desgaste y limpieza.
Fugas Revisar por fugas de fluido hidráulico.
*Pernos de Montaje Revisar el torque en la parte superior e inferior de
Sistema de los pernos del cojinete de engranajes. (Ver Tabla
Rotación Datos de Torque)
Eléctricos Revisar el adecuado funcionamiento de los
controles remotos, luces auxiliares, etc.
Revisar por deterioro, suciedad y humedad.
Aceite Hidráulico Revisar la calidad del aceite.
Manguera Revisar por fugas en la superficie y en los
Hidráulica terminales.
Revisar por ampollas, deformación y abrasión.
Bomba y Motor Revisar por pernos sueltos, fugas, ruidos
inusuales, vibración, velocidad de operación
reducida, y excesivo calentamiento del aceite.
Filtro Hidráulico Revisar lecturas al vacío con la maquina
encendida y el PTO (toma fuerza) engrochada.
Un vacío de 8" de mercurio o mas alto indica que
el está filtro obstruido.
Válvulas de Control Revisar por fugas, rajaduras y regreso lento a
neutro.
*Cilindros Revisar por fugas, vástagos con muescas, cortes,
o abollados, caja contenedora abollada, pines de
mando deformados, moho en el vástago.
*Válvulas de Realizar prueba de sostenimiento con el Tirehand
Sostenimiento cargado.
Problemas
La Tabla es usada como una referencia rápida en el diagnóstico de mal funcionamiento in situ.
Tener cuidado en anotar las posibles causas en orden de ocurrencia probable.
SISTOMA CAUSA PROBABLE
Controles no responden 1) Bomba no embragada – si viene embrague eléctrico.
2) Poca cantidad de aceite.
3) Está rota la línea de presión hidráulica.
4) Está obstruida la válvula de cierre en línea de succión
5) Bomba hidráulica defectuosa
6) Válvula de alivio mal colocada
Operación lenta 1) Poca cantidad de aceite
2) Bomba hidráulica operando a velocidad reducida
3) Válvula de alivio está colocada muy abajo
4) Bomba o cilindro gastados
5) Debido a la excesiva temperatura del aceite, la bomba está
deslizándose (pasa rápido) Esto incrementará el desgaste de
los componentes.
6) El filtro está sucio
7) Los carretes de la válvula están inoperativos
8) Obstruida la válvula del cilindro de retención.
Control de rotación lento o 1) Están obstruidos los orificios del puerto interno.
errático 2) Los engranajes de rotación están dañados o cerrados
Los brazos y cojines derivan 1) El aceite hidráulico está desviándose en los anillos de los
cuando cargan y los controles se pistones.
neutralizan 2) Las válvulas de los cilindros de retención están defectuosas
o contaminadas.
Ruido inusual durante la 1) Debido al poco aceite hidráulico ocurre burbujeo (cavitación)
operación 2) Carga excesiva
3) Restricción o colapso de la línea de succión
4)Los controles de desvío en la válvula de alivio están muy
bajos
5) La válvula de alivio está dañada
6) Debido a la acumulación de partículas, está obstruida la
válvula de cierre.
Esquivada lateral lenta o rechina 1) Rodajes necesitan lubricación
2) Daño mecánico al soporte
3) Cilindro inferior dañado
Brazo (soporte) rechina o suena 1) Los brazos necesitan lubricación interna y externa
2) Rodajes dañados
13
Lista de Piezas de Repuesto Recomendada

Esta lista no necesariamente indica que los ítems pueden fallar en el transcurso del año. Su
intención es proveer al usuario con un stock de partes suficiente para mantener operativa la
unidad con un mínimo tiempo de parada esperando los repuestos. Puede haber fallo de partes
no consideradas en esta lista. Las partes no listadas están consideradas como no críticas o
ítems de desgaste normal durante el primer año de operación. Y debe contactarse al distribuidor
o fabricante para su disponibilidad.
Designación Item No. No. Parte Descripción Cant
del conjunto
40711512 CONJUNTO SUB-BASE

5 60030244 Cojín de desgaste 1
11 72601682 Tornillo tapón 40
12 72063116 Arandela 40
40711513 CONJUNTO CARROCERIA
7 60250283 Buje 2
9 60250285 Buje 2
10 71056373 Cojinete d engranaje plataforma 1
giratoria
12 72063116 Arandela 62
16 71056264 Engranaje intermedio 2
17 71056486 Engranaje de piñón 2
21 73051004 Motor hidráulico 2
24 73054538 Válvula contra balance 4
32 7Q072112 Anillo 4
33 70034295 Buje 2
34 60020120 Buje 2
35 60020121 Buje 2
36 71056074 Engranaje de mando 2
3B083930 CILINDRO MOVER DE LADO
5 9b015930 Juego de Sellos 1
3C041930 ABRAZADERA DE CILINDRO
4 60020190 Buje 8
Designación Item No. No. Parte Descripción Cant

del conjunto
8 9C222432 Juego de sellos 2
51713669 CONJUNTO MANGO CABINA CONTROL

3 77040373 Interruptor de palanca SPST 1
4 77040372 Idem ant. SPDT 4
51713432 CONJUNTO MANGO CONTROL REMOTO

17 77040372 Idem ant. 3
18 77040373 Idem ant. SPST 1
51713668 CONTROL DUAL CONJUNTO CAJA JIC

3 77040374 Idem ant. SPDT 1
51713676 CONJUNTO MANGO CABINA CONTROL
3 77040373 Idem ant. 1

4 77040372 Idem ant. 4
40712858 CONJUNTO ABRAZADERA
5 60020230 Buje 16
20 73051004 Motor hidráulico 2
24 7Q72112 Anillo 4
25 71056265 Engranaje de piñón 2
26 71056072 Engranaje intermedio 2
27 71056361 Cojinete engranaje plataforma 2

giratoria
32 72063116 Arandela 36
36 72063119 Arandela 40
41 71056011 Engranaje de mando 2
42 60020115 Buje 2
43 60020116 Buje 2
44 60020187 Buje 2
45 60020188 Buje 2
15
TH3565 Etiquetas Advertencia
70397274
PELIGRO
17
Revisiones
DATE LOCATION DESCRIPTION
00TH3565:99900699: 20110209 i
Tirehand 3565
SERVICE MANUAL
Section 1 SPECIFICATIONS
Section 2 INSTALLATION
Section 3 OPERATION
Section 4 MAINTENANCE
Section 5 PARTS
Section 6 INSTALLATION PROCEDURES
Section 7 REPAIR
IOWA MOLD TOOLING CO., INC.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711
TECHNICAL SUPPORT FAX: 641-923-2424
MANUAL PART NUMBER 99900699
Iowa Mold Tooling Co., Inc. is an Oshkosh Corporation company.

00TH3565:99900699: 19980204 ii
INTRODUCTION - READ CAREFULLY!

This manual is provided to assist you in the Three means are used throughout this manual to
identification and ordering of parts, for your IMT gain the attention of personnel. They are NOTE’s,
equipment. It contains information such as CAUTION’s, and WARNING’s and are defined as
specifications, parts lists, capacities, and parts follows:
identification.
NOTE
It is the user’s responsibility to maintain and operate A NOTE is used to either convey additional
this equipment in a manner that will result in the information or to provide further emphasis for a
safest working conditions possible. previous point.
Warranty of this equipment will be void on any part CAUTION

of the unit subjected to overloading, abuse, lack of A CAUTION is used when there is the very strong
maintenance and unauthorized modifications. No possibility of damage to the equipment or premature
warranty - verbal, written, or implied - other than the equipment failure.
official, published IMT new machinery and
equipment warranty will be valid on this unit. WARNING
A WARNING is used when there is the potential for
In addition, it is also the user’s responsibility to be personal injury or death.
aware of existing Federal, State, and Local codes
and regulations governing the safe use and Treat this equipment with respect and service it
maintenance of this equipment. regularly. These two things can add up to a safer
work environment.
REVISIONS LIST
DATE LOCATION DESCRIPTION OF CHANGE
20020206 5-6 ADDED MOBILTAC NOTE
7-1,20 WARRANTY
20060720 5-11 ECN 10189 - ADDED NOTE REGARDING NOT PAINTING GORTITE ROD COVER
20070323 COVER, 3-3 UPDATED OWNERSHIP STATEMENT, NEW SERIAL NUMBER TAG
20070820 5-17 ECN 10434 - UPDATE 91712814 HYD KIT
20080212 1-6 ECN 10661 - REVISED CAPACITY CHART
20080808 5-5,6,8 ECN 10767, 10788, 10821- PARTS LIST UPDATED, DRAWINGS UPDATED.
20081231 1-3 UPDATED TIREHAND SPECIFICATIONS
20090427 5-7 ECN 11001 - ADDED FALLBACK ARMS TO 40712858 TH3565 CLAMP ASM.
20090819 5-7,8 ECN 11059, 11074, 11076
20101220 5-8 ECN 11354-UPDATE HYD SCHEMATIC
20110209 5-8 ECN 11375, 11383 - HYD HOSE AND FITTING CHANGES TO 91711516
00TH3565:99900699: 19970808 1-1
SECTION 1. TIREHAND 3565 SPECIFICATIONS

GENERAL SPECIFICATIONS ................................................................................... 3
VEHICLE COMPATABILITY ....................................................................................... 3
GEOMETRIC CONFIGURATION ............................................................................... 4
CENTER OF GRAVITY LOCATIONS ......................................................................... 5
CAPACITY CHART .................................................................................................... 6
00TH3565:99900699: 19970808 1-2
NOTES
00TH3565:99900699: 20081231 1-3
TIREHAND 3565 SPECIFICATIONS

GENERAL SPECIFICATIONS
TIREHAND MAXIMUM CAPACITY 25,000 lb (11,340 kg)
BODY ROTATION 390° (6.81 Rad)
CLAMPING SPAN 41" to 164" (1.04 - 4.17m)
METHOD OF CLAMPING Parallelogram
CLAMPING PAD ROTATION 360° (6.28 Rad.) continuous
SIDE SHIFT (standard) 16" (40.6cm) lateral movement
CLAMPING LOAD HOLDING VALVES Counterbalance valve
HYDRAULIC CONTROL VALVE Located on body assembly
HYDRAULIC CONTROLS Cab-mounted 4-function remote control
ROTATION SYSTEMS Dual spur gear drives
TIREHAND WEIGHT 16,600 lbs (7530 kg)
TIREHAND HORIZONTAL CENTER OF GRAVITY

FROM VEHICLE ATTACHMENT POINT 47" (1.19m)
HORIZONTAL CENTER OF GRAVITY FROM

VEHICLE ATTACHMENT POINT FOR TIREHAND
PLUS AN 18,000 LB TIRE & RIM ASSEMBLY 90" (2.29m)
HORIZONTAL CENTER OF GRAVITY FROM

VEHICLE ATTACHMENT POINT FOR TIREHAND
PLUS A 25,000 LB TIRE & RIM ASSEMBLY 97" (2.46m)
OPTIMUM PUMP CAPACITY 15 U.S. GPM @ 2500 PSI

(57 liters/min @ 172.4 bar)
COUNTERWEIGHT NEEDED As required for stabilization
ALLOWABLE BEAD BREAKING METHOD Push Bar, ONLY
VEHICLE COMPATABILITY
The Tirehand 3565 will permanently adapt to either a forklift truck or a front-end loader. When mounting to a forklift
truck, it is recommended that the truck be equipped with a sideshifter. If adapted to a front-end loader, quick
couplers are available which enable the disconnection of the Tirehand so that the original bucket can be quickly
coupled to the machine for normal operations.
IMT reserves the right to change specifications and design without notice. Where applicable, specifications are in
accordance with SAE standards.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711 FAX: 641-923-2424
00TH3565:99900699: 19930401 1-4
GEOMETRIC CONFIGURATION
00TH3565:99900699: 19930401 1-5
CENTER OF GRAVITY LOCATIONS
00TH3565:99900699:20070212 1-6
Tirehand 3565
CAPACITY CHART
MAXIMUM CAPACITY
25,000 LB
(11,340 KG)
CLAMPING SPAN
MIN: 41" (104.1 cm)
MAX: 164" (416.5 cm)
70397310
00TH3565:99900699:19960830 2-1
SECTION 2. TIREHAND 3565 INSTALLATION
GENERAL ....................................................................................................................... 3
CONTROL BOX INSTALLATION ................................................................................... 3
TIREHAND INSTALLATION .......................................................................................... 3
TESTING ......................................................................................................................... 3
TYPICAL HYDRAULIC INSTALLATION ....................................................................... 4
00TH3565:99900699: 19960830 2-2
NOTES
00TH3565:99900699:19960830 2-3
GENERAL TESTING
Each installation of the IMT Tirehand will differ. Raise the Tirehand to provide adequate clearance for
Therefore, this section contains only general operating all Tirehand functions. Operate all Tirehand
information, and should be used as a reference for functions and check for leaks.
your particular installation. Carefully read and
understand this section before attempting to install WARNING
the Tirehand. STAY CLEAR OF ALL PINCH POINTS WHILE
OPERATING THIS UNIT. FAILURE TO COMPLY MAY
CONTROL BOX INSTALLATION CAUSE SERIOUS INJURY OR DEATH.
Carefully examine the interior of the cab of the carrier
vehicle to determine the best possible location for the NOTE
valvebank remote control box. Consider the IF THE OPERATION OF THE TIREHAND
following: FUNCTIONS APPEARS ERRATIC, IT MAY BE
NECESSARY TO ELIMINATE AIR FROM THE
1. EASE OF OPERATION. SYSTEM.
2. EASE OF INSTALLATION.
3. POSSIBLE INTERFERENCE WITH OTHER Test the unit at rated capacity, and note any points of
CONTROLS IN THE VICINITY. instability. Add counterweights if needed.
After selecting the best location for the control box, If the carrier vehicle is articulating, make certain that
fabricate a mounting bracket, if necessary. Whether steering of the vehicle is not hindered by the routing
the control box, is mounted directly to the existing of the hydraulic hoses. Check for any possible point
panel, or mounted using a fabricated bracket, it must where hoses may be subjected to excessive wear.
be held rigidly and be accessible to the electrical
cables. Complete the installation.
TIREHAND INSTALLATION
The Tirehand may be installed on any loader, or
forklift, having sufficient lifting capacity and stability.
The Tirehand is usually equipped with a base, unless
specified by the customer. The function of the base
is to interface the Tirehand with a particular carrier
vehicle. The base is mounted, by use of pins, to the
carrier vehicle thereby providing the means for
installing the Tirehand sub-base. The sub-base is
mounted to the base through side shift shafts, riding
on linear bushings. Remember that each installation
will vary and it may be necessary to cut a hole in the
cab for control cable routing.
1. Install the Tirehand to the carrier vehicle, as

described above.
2. Check all lubrication points for adequate
lubrication.
3. Operate the carrier vehicle to check for
unobstructed vertical movement. Determine whether
stop blocks may be required in order to prevent the
Tirehand from coming in contact with the carrier
vehicle. Install stop blocks if necessary, to prevent
damage to the Tirehand and/or carrier vehicle.
00TH3565:99900699:19960830 2-4
TYPICAL HYDRAULIC INSTALLATION
00TH3565:99900699:19981014 3-1
SECTION 3. TIREHAND 3565 OPERATION

GENERAL ....................................................................................................................... 3
SAFETY FACTORS ........................................................................................................ 3
SERIAL NUMBER PLACARD ....................................................................................... 3
WORK STATION POSITIONING..................................................................................... 3
OPERATOR TRAINING .................................................................................................. 4
CONTROLS .................................................................................................................... 4
CONTROL DECAL ......................................................................................................... 4
TASK PERFORMANCE ................................................................................................. 4
“TOP” DECAL ................................................................................................................4
POWER LINE PROXIMITY.............................................................................................. 5
OPERATING REQUIREMENTS DECAL ....................................................................... 5
OPERATING RESTRICTIONS DECAL ..........................................................................6
TIREHAND OPERATING RESTRICTIONS ................................................................... 7
00TH3565:99900699:19930401 3-2
NOTES
00TH3565:99900699:20070323 3-3
GENERAL Warranty of this unit will be void on any part
Every Tirehand has an identification placard (drawing determined to have been misused due to overloading,
below) fastened to the unit between the clamping improper operation, or lack of maintenance. No
arms. When ordering parts, communicating warranty warranty, written, verbal, or implied, other than the
information, or referring to the unit in any way, always published IMT new machinery and equipment
include the assigned model and serial numbers. All warranty will be valid with this unit.
inquiries should be directed to Iowa Mold Tooling Co.,
Inc., 500 Hwy 18 West, Garner, Iowa 50438. EQUIPMENT INSPECTION
Before operating this unit, always perform the safety
SAFETY FACTORS checks listed below. They are vital to the detection of
There are three important factors involved in the safe equipment malfunction and damage, which may be
operation of this unit. They are: potential safety hazards.
1. The operator must have the competence to know Structural Soundness - Inspect the unit for damaged,
the machine and how to safely control it. or loose fasteners.
2. The Tirehand must be in good mechanical Hydraulic Oil Supply - Check the oil level in the
condition. reservoir, and fill if needed.
3. The unit must never be loaded to exceed the Controls - Make a short test for proper control
maximum rated capacity. operation.
The safety precautions presented in this section Repairs - Correct all defects or malfunctions before
should be read and observed at all times during putting the unit into service.
operation.
This equipment inspection should be performed
before each work task and as a periodic preventative
LOAD LIMITS
maintainance check.
The Tirehand is designed to be operated within
specific maximum allowable load limits, as noted in
Section 1. of this manual. Overloading will result in WORK STATION POSITIONING
potentially serious safety hazards and shortened A firm, level, and dry surface is the best location from
service life of the unit. Exceeding the rated capacity which to operate this equipment. Overhead
of the Tirehand will cause instability and possible obstructions should be avoided.
structural failure.
Care should be used to make certain that all
personnel are clear of the work area, before the
operation begins.
At job sites where the terrain is graded or unfirm, the

operation of the Tirehand should be restricted to
compensate for instability.
WARNING
IOWA MOLD TOOLING CO., INC. THE OPERATOR SHOULD BE ALERT, AT ALL
BOX 189, GARNER, IA 50438-0189 TIMES, FOR THE PRESENCE OF PERSONNEL IN
THE WORK AREA. OPERATIONS MUST BE
MODEL SUSPENDED UNTIL THE WORK AREA IS
NUMBER CLEARED.
70029119
SERIAL
NUMBER
MFG
DATE
SERIAL NUMBER PLACARD

00TH3565:99900699: 19930401 3-4
OPERATOR TRAINING NOTE
The Tirehand is designed for operator simplicity. Prior DIRECTION OF PAD ROTATION IS AS SEEN FROM
to operating this unit, the operator must become THE OPERATOR’S STATION WITH THE “TOP”
thoroughly familiar with control functions, operating DECAL POINTING UP. ROTATING THE TIREHAND
procedures, and safety precautions. In addition, the 180 DEGREES (3.14 RAD.) WILL CAUSE THE PADS
operator must be prepared to take any remedial TO ROTATE IN A DIRECTION THAT IS OPPOSITE
action needed in an emergency situation. TO THAT SHOWN ON THE CONTROL DECAL.
CONTROLS TASK PERFORMANCE

The controls for the Tirehand, as well as the carrier Prior to operating this unit, become thoroughly
vehicle, are located in the cab. They should be familiar with the operating requirements and
positioned within easy reach, near the operator restrictions. To begin operation:
station.
1. Manuever the vehicle into a position which
VEHICLE CONTROLS provides proper orientation of the Tirehand to the tire,
The vehicle is equipped with controls which allow the with the boom at the proper elevation.
operator to raise, lower, and tilt the Tirehand.
2. Position the opened hand to properly grasp the
TIREHAND CONTROLS tire.
The controls for the Tirehand are located in the cab of
the carrier vehicle. Their function and operation is as WARNING
follows: MAKE CERTAIN THAT PERSONNEL ARE CLEAR
BEFORE CONTINUING THE OPERATION.
Clamp-Push the lever to clamp the tire and pull to
release. 3. Advance the carrier vehicle, manipulate the
controls to perform the desired function, and grasp
WARNING the tire.
ATTEMPTING TO USE THE CLAMPING ACTION OF
THE TIREHAND TO SEAT THE BEAD OF THE TIRE
IS A HAZARDOUS PRACTICE, AND SHOULD NOT
BE ATTEMPTED.
Side shift-Push the lever for right movement, and pull

for left movement.
Rotation-Push the lever for clockwise rotation, and

pull for counterclockwise rotation.
Axial- Push the lever to rotate the pads forward,

and pull the lever to rotate the pads backward.
CONTROL DECAL “TOP” DECAL

00TH3565:99900699:19930401 3-5
POWER LINE PROXIMITY 3. In transit with no load and boom lowered, the
Except where the electrical distribution and clearance shall be a minimum of four (4) feet (1.22m)
transmission lines have been de-energized and
visibly grounded at point of work, or where insulating 4. It is recommended that a person be designated
barriers not a part of or an attachment to the unit to observe the clearance and give timely warning for
have been erected to prevent physical contact with all operations where it is difficult for the operator to
the lines, unit shall be operated proximate to, under, maintain the desired clearance by visual means.
over, by or near power lines only in accordance with
the following: In addition to the above mentioned safety measures,
the operator must take into account sag, sway and
1. For lines rated 50 kV or below, minimum deflection factors, in allowing for proper clearances.
clearance between the lines and any part or the unit
or load shall be ten (10) feet (3.05m).
2. For lines rated over 50 kV, minimum clearance

between the lines and any part of the unit or load
shall be ten (10) feet plus 0.4 inch (3.05m plus 1 cm)
for each 1 kV over 50 kV, or use twice the length of
the insulator but never less than ten (10) feet
(3.05m).
OPERATING REQUIREMENTS DECAL

00TH3565:99900699:19981014 3-6
FAILURE TO OBEY THE FOLLOWING

WILL RESULT IN
! DANGER DEATH, SERIOUS INJURY,
INSTABILITY OR EQUIPMENT DAMAGE
NEVER attempt to handle tires filled with NEVER drag the tire - the unit is designed
ballast. Stability or structural failure may to lift and carry.
result if load limit is exceeded.
NEVER transport a tire rotated more than NEVER use the unit for any jacking, pulling
30° off the horizontal plane. or dragging operation involving an object
FOR EXAMPLE: Do not transport in a or another vehicle.
vertical plane.
30°
30°
NEVER impact-load or hammer-push with NEVER operate hand below ground level.
the unit.
NEVER operate the unit while persons not NEVER clamp an uninflated tire and then
required for operation are in the work area. inflate. Damage or injury WILL result.
NEVER sling a load using one arm of NEVER use one arm of the Tirehand to
the Tirehand. break beads.
70393671
OPERATING RESTRICTIONS DECAL

00TH3565:99900699:19981014 3-7
TIREHAND OPERATING RESTRICTIONS

The Tirehand is intended to be a tire lifting and The rotation system on the Tirehand is designed to
positioning device. There are possible allow the user to manipulate large tires. It is a
misapplications of this machine that can cause precision function that was not designed to apply high
serious damage to the Tirehand rotation gears. It is loads. However, the load holding valves that are built
possible to break the teeth on the Tirehand rotation into this system to help control the tire during
bearing by applying forces while attempting to break handling will also prevent the body of the Tirehand
tire beads with one arm of the Tirehand, or by from rotating freely when loads are applied to a single
slinging a load under one arm of the Tirehand Tirehand arm. When one arm is used for bead
breaking, these forces can translate into torques that
Use of a single Tirehand arm for lifting or carrying attempt to rotate the body of the Tirehand. The load
a load will void the tire hand warranty. holding valves will not allow this to occur. In this
situation, the forces that are created in the Tirehand
rotation turntable are well in excess of what the gear
NEVER sling a load using one arm of teeth can tolerate. Using one arm of the Tirehand
the Tirehand. for bead breaking will void the warranty of the
Tirehand.
NEVER use one arm of the Tirehand to

break beads.
A separate bead breaker or a push bar that carries

the load to both arms of the Tirehand must be used to
separate the tire from the rim. It is acceptable to use
the Tirehand for holding the sidewall and flange away
from the bead while O-rings and locking rings are
being installed.
00TH3565:99900699:19981014 3-8
00TH3565:99900699:19930401 4-1
SECTION 4. TIREHAND 3565 MAINTENANCE

GENERAL ....................................................................................................................... 3
LUBRICATION POINTS ................................................................................................. 3
LUBRICATION ................................................................................................................ 3
LUBRICATION CHART ..................................................................................................4
HYDRAULIC SYSTEM ................................................................................................... 4
HYDRAULIC FLUID SPECIFICATIONS ........................................................................ 4
PREVENTATIVE MAINTENANCE ................................................................................. 6
REGULAR INSPECTION ............................................................................................... 6
TIREHAND INSPECTION CHECKLIST ........................................................................ 7
00TH3565:99900699:19930401 4-2
NOTES
00TH3565:99900699:19930401 4-3
GENERAL LUBRICATION
Regularly scheduled maintenance is essential to Maintaining the proper lubrication schedule will vary
keeping the Tirehand operating efficiently. This with climatic conditions and frequency of use. The
section contains information important to the proper lubrication chart is intended to serve as a schedule
maintenance procedures and necessary service for a normal work load, and moderate weather
intervals. Personnel responsible for the maintenance conditions. Periods of heavy use will shorten service
of this unit should become familiar with the frequency intervals.
and the type of maintainance needed, and perform
these tasks at the recommended intervals.
LUBRICATION POINTS
00TH3565:99900699: 19930401 4-4
LUBRICATION CHART
HYDRAULIC SYSTEM HYDRAULIC FLUID DETERIORATION

Contamination of the hydraulic oil by solvents, water,
HYDRAULIC FLUID SELECTION dust or other abrasives will cause deterioration of the
Minimum viscosity specifications for hydraulic oil to oil. Sustained presence of these impurities will result
be used in the Tirehand are indicated in the table in the premature breakdown of the additive properties,
below. Any major oil company can supply products and reduce the viscosity index. Introduction of water
which meet these requirements. to the system, or operating at high temperatures
(above 180 degrees F), will result in an increase in
Oils selected for this equipment, in addition to the oil oxidation rate. Oxidation produces varnish-
meeting the viscosity requirements, should have the forming materials and sludge in the oil. Operating the
following additive properties. system for any prolonged period, with contaminated
or broken down oil, will increase component wear,
1. Antifoam inhibitors causing significantly reduced service life.
2. Antioxident inhibitors Periodically, draw an oil sample, and check for oil
3. Rust resistant additives quality.
4. Antiwear additives
1. Place the sample in a clean glass container.
HYDRAULIC FLUID SPECIFICATIONS 2. Smell the oil to detect rancid or burnt odor.
Table below contains oil specifications for a full range 3. Visually examine the oil for a dark, or cloudy,
of operating temperatures. Arctic conditions present color.
special requirements which are not in the scope of 4. Allow the sample to stand for several minutes.
this chart, and must be analyzed individually. Inspect the sample for water, which will settle to the
Consult your oil supplier for the proper hydraulic oil to bottom of the glass, if present. Water can result from
be used under these severe conditions. Electric a leak in the system, or condensation from
reservoir heaters are available to improve operation at temperature extremes.
extremely low temperatures.
HYDRAULIC FLUID SPECIFICATIONS

00TH3565:99900699:19930401 4-5
When any of these conditions are observed, the NOTE
system should be purged and filled with new oil. The BE THOROUGHLY FAMILIAR WITH THE
oil in the complete system, including the reservoir, FOLLOWING STEPS, AND BE PREPARED TO
should be changed: PERFORM THEM IN AN UNINTERRUPTED
SEQUENCE, OR STOP THE ENGINE AT THE END
1. After every 800 hours of operation, or every six OF EACH STEP. IF THIS IS NOT DONE,
months, whichever occurs first. EXCESSIVE OIL WASTE WILL OCCUR.
2. After pump, or other major component failure. 6. Start the engine and engage the pump if
necessary. With the return directed into the waste
HYDRAULIC SYSTEM PURGING container, retract the clamp arms, rotate the pads,
Purging the hydraulic system requires a new oil and operate the side shift full stroke. Rotate the
sufficient to completely refill the reservoir, hoses, Tirehand back to the horizontal position. Stop the
cylinders, and to allow for some loss during this engine.
operation. To reduce oil loss during this process,
operate the vehicle engine at reduced speed. In 7. Reconnect the return line to the reservoir, and
purging, new oil is supplied to the pump, and used oil change the return filter. All components of the
is discharged from the return line. Two operators will Tirehand are now purged.
be required during this procedure, one to operate the
controls, and one to regulate the engine speed. 8. Check the reservoir oil level, and add oil if
necessary.
CAUTION
DO NOT ALLOW THE RESERVOIR TO DROP NOTE
BELOW 1/3 CAPACITY DURING THIS OPERATION. THIS SECTION COVERED THE PURGING OF THE
TIREHAND. THE CARRIER VEHICLE’S HYDRAULIC
Purging is accomplished as follows: SYSTEM SHOULD BE COVERED IN THE
MANUFACTURER’S SERVICE MANUAL.
1. Locate the unit in an area that provides solid,
level footing, and space to accomodate the full PURGING TRAPPED AIR
operating range of the unit. Shift the vehicle into Air may be introduced into the system, either through
neutral. a leak in the system, or due to disconnecting a
hydraulic component for servicing. Air in the system
2. Raise the boom approximately 5 feet above will cause erratic operation, and must be corrected.
ground level. Operate the side shift function fully in
one direction. To purge air from the system, extend and retract the
affected cylinder several times. At the end of the
3. With the Tirehand right side up, rotate it so that it stroke, hold the valve open for a few seconds.
is 30 degrees off horizontal. Extend the clamping Repeat this procedure several times, until operation is
arms to full stroke. smooth and continuous.
4. Kill the engine, drain the hydraulic reservoir and FILTER ELEMENT REPLACEMENT
remove the suction and pressure hoses. Drain and
reassemble. NOTE
SOME CARRIER VEHICLES MAY NOT BE
NOTE EQUIPPED WITH A SUCTION AND RETURN LINE
THE METHOD OF WASTE OIL DISPOSAL IS LEFT FILTER. THESE INSTRUCTIONS APPLY TO THOSE
TO THE DISCRETION OF THE SERVICE VEHICLES WHICH REQUIRE IMT INSTALLED
PERSONNEL. FILTERS. IF THE VEHICLE HAS SUCTION AND
RETURN LINE FILTERS, REFER TO THE
5. Disconnect the return line and direct it into a MANUFACTURER’S INSTRUCTIONS.
waste container. Plug the return line port on the
reservoir, and fill with clean oil.
00TH3565:99900699:19960830 4-6
The hydraulic filters must be serviced regularly, to HYDRAULIC SYSTEM
avoid accumulation of contaminants in the reservoir,
or throughout the system. They must be changed CYLINDERS
after the initial 50 hours of operation, and every 200 1. Check rods for damage, such as scarring, and
hours thereafter. To change filter elements: check for rust on out of service units.
2. Check for weld joint and seal leaks.
1. Close the gate valve and remove the filter 3. Check for drift, indicating possible leakage
element. around the piston.
2. Install the new element, making certain that the 4. Check cylinder case for cracks and dents.
rubber seal is in place.
3. Open the gate valve and check for leaks. HYDRAULIC PUMP
1. Check for leaks at shaft seal and section joints.
CAUTION 2. Check for drop in operating speed.
PUMP FAILURE WILL OCCUR IF THE GATE VALVE 3. Check system operating pressure.
IS NOT REOPENED BEFORE OPERATION.
HYDRAULIC CONTROL VALVES
PREVENTATIVE MAINTENANCE 1. Check for leaks at section joints and spools.
The Tirehand Inspection Checklist (next page) is 2. Check for ease of spool movement.
designed to assist in keeping the Tirehand in peak 3. Check all relief valve settings.
operating condition. The information in this section
refers to the Tirehand only. Items which apply to your OIL RESERVOIR AND HOSES
Tirehand should be checked before it is put into 1. Check filters for clogged elements.
operation. Inspect to the frequency indicated by the 2. Check oil level in the reservoir.
darkened block. Consult the manufacturers service 3. Check all hoses for damage.
guide for information on the carrier vehicle.
CARRIER BOOM AND CYLINDERS
1. Check for structural defects, such as dents,
REGULAR INSPECTION bends, and weld cracks.
Every three months, or more often when the 2. Check all pins and their retainers.
equipment is subjected to heavy use, the following 3. Check cylinder rods for damage, and check for
inspections should be performed in addition to the leaks.
preventative maintenance checklist.
SIDE SHIFT ASSEMBLY
TIREHAND ARM ASSEMBLIES 1. Check cylinder for leaks and damage.
1. Check for structural defects such as weld 2. Check linear bushings for damage and
cracks, dents, or bends. lubrication.
2. Check cylinder holding valves. 3. Check for structural defects.
3. Check cylinders for leaks. 4. Check cylinder retaining pins.
4. Check both internal and external clamping arm
bearings for wear and lubrication. ROTATION ASSEMBLY
5. Check operating timing. Both clamping arms 1. Check turntable bolt torque.
should function together at the same rate of 2. Check for pinion gear/gear bearing backlash.
motion.
AXIAL PAD ROTATION

1. Check for structural defects.
2. Check motors for leaks.
3. Check disc bearings located on support shafts.
4. Check all pins, and their retainers.
00TH3565:99900699:19960830 4-7
TIREHAND INSPECTION CHECKLIST
00TH3565:99900699:19930401 4-8
NOTES
00TH3565: 99900699:19920221 5-1
SECTION 5. TIREHAND 3565 PARTS

GENERAL ..................................................................................................................... 3
CYLINDER IDENTIFICATION ...................................................................................... 3
WELDMENT IDENTIFICATION .................................................................................... 3
CYLINDER PART NUMBER LOCATION ..................................................................... 3
ORDERING REPAIR PARTS ........................................................................................ 3
WELDMENT PART NUMBER LOCATIONS ................................................................ 4
SUB-BASE ASM (40711512) ....................................................................................... 5
BODY ASM (40711513) ................................................................................................ 6
CLAMP ASM (40712858) ............................................................................................. 7
HYDRAULIC SCHEMATIC (91711516) ....................................................................... 8
DECAL KIT (95711613) ................................................................................................ 9
SIDE SHIFT CYLINDER (3B083930) ......................................................................... 10
CLAMP CYLINDER (3C041930) ................................................................................ 11
FLANGE GRABBER ATTACHMENT (30712621) ..................................................... 12
CONTROL KIT-CAB & GROUND CONTROL (90713667) ........................................ 13
HANDLE ASM-CAB CONTROL (51713669) ............................................................. 14
HANDLE ASM-RC (51713432) .................................................................................. 15
JIC BOX ASM-DUAL CONTROL (51713668) ............................................................ 16
HYDRAULIC SCHEMATIC-BULKHEAD (91712814) ............................................... 17
CLAMP ASM (40711514) ........................................................................................... 18
CONTROL KIT-CAB CONTROL (90713678) ............................................................. 19
HANDLE ASM-CAB CONTROL (51713676) ............................................................. 20
CABLE ASM 18GA/16WIRE X 56 (51713677) ........................................................... 21
FIELD CONVERSION-CAB/GROUND CTRL-51712657 (99900911) ....................... 22
00TH3565: 99900699:19920221 5-2
NOTES
00TH3565: 999006997:19920221 5-3
GENERAL ORDERING REPAIR PARTS
This section contains the exploded parts drawings, When ordering replacement parts:
with accompanying parts lists, for the assemblies
used in the manufacture of the Tirehand. These 1. Give the serial number of the unit.
drawing are intended to assist in ordering parts and
repairing the unit. 2. Give the model number of the unit.
CYLINDER IDENTIFICATION 3. Specify the complete part number. When

To be certain that proper replacement are received, it ordering cylinder parts, or one of the main weldments,
is necessary to specify the correct letter/number always use the stamped part number.
sequence for any parts request. The number
stamped on the cylinder case must be used when 4. Give a complete description of the part.
ordering cylinder parts.
5. Specify the quantity required.
WELDMENT IDENTIFICATION
Each of the major weldments bears a stamped part
number. Anytime that a major weldment is replaced,
it is necessary to specify the complete part number
stamped on that weldment. The locations of the part
numbers are as shown on the next page.
CYLINDER PART NUMBER LOCATION

00TH3565: 99900699:19930401 5-4
WELDMENT PART NUMBER LOCATIONS
00TH3565: 40711512.01:REV D 20080808 5-5
SUB-BASE ASM (40711512)
1. 52715926 SUB-BASE (WAS 52714630) 1
2. BASE WELDMENT REF
3. 60117123 PIN 2
4. 72053509 GREASE ZERK 1/4-28 4
5. 60030244 WEAR PAD 1
6. 72060795 CAP SCR 1/2-13X1-1/2 SH 11
7. 60010830 PIN 2
8. 72063037 MACH BUSHING 1-1/2X10GA NR 4
9. 72066132 RETAINING RING 4
10. 60117131 PIN RETAINER PLATE 4
11. 72601749 CAP SCR 3/4-10X8 HHGR8 40
12. 72063116 WASHER 3/4 FLAT HARD 40
13. 72060185 CAP SCR 3/4-10X2 24
14. 72063056 WASHER 3/4 LOCK 24
15. 3B083930 SIDE SHIFT CYLINDER 1
00TH3565: 40711513.01:REV. J 20080808 5-6
BODY ASM (40711513) 19. 72066095 RETAINING RING 1
1. 60133321 MOTOR ACCESS COVER 2 20. 72060206 CAP SCR 3/4-10X2 HHGR8 8
(WAS 60117039) 21. 73540004 HYD MOTOR (FROM 5-15-98) 2
2. 60117741 COVER PLATE 1 73051004 HYD MOTOR (TO 5-15-98) 2
3. 60121379 PINION SUPPORT PLATE 2 5V151830 C’BALANCE BLOCK(TO 5-15-98) 2
4. 60122408 BODY COVER 1 72060738 CAP SCR (TO 5-15-98) 8
5. 52715930 BODY 1 73054538 C’BALANCE VALVE(TO 5-15-98) 4
6. 52711520 ROTATION STOP SLIDE 1 7Q072112 O-RING (TO 5-15-98) 4
7. 60250283 BUSHING-BOTTOM PINION REF 22. 70029119 PLACARD-SERIAL NUMBER 1
8. 60250284 THRUST WASHER 2 23. 72661636 TACK-METAL 2
9. 60250285 BUSHING-TOP PINION REF 25. 60010844 GREASE PLATE 2
10. 71056373 TURNTABLE BEARING 1 26. 72060117 CAP SCR 1/2-13X1-1/2 4
11. 72601468 CAP SCR 3/4-10X4-1/2 HHGR8 34 27. 53000713 GREASE EXTENSION 38" 1
12. 72063116 WASHER 3/4 FLAT HARD 62 28. 60106032 STUD 1/2-13X2 4
13. 72060092 CAP SCR 1/2-13X1-1/4 28 29. 72053301 COUPLING 1/8NPT 1
14. 72601989 CAP SCR 3/4-10X1-1/4 HHGR8 20 30. 72053508 ZERK 1/8NPT 7
15. 72063053 WASHER 1/2 LOCK 32 31. 72062080 NUT 1/2-13 LOCK 4
16. 71056264 INTERMEDIATE GEAR 2 33. 70034295 BUSHING-PINION SUPPORT REF
17. 71056486 PINION GEAR 2 34. 60020120 BUSHING-BOTTOM DR GEAR REF
18. 72063039 MACH BUSHING 2X10GA 1 35. 60020121 BUSHING-TOP DRIVE GEAR REF
36. 71056074 DRIVE GEAR REF
37. 72060091 CAP SCR 1/2-13X1 4
NOTE
TURNTABLE BACKLASH = .010" TO .017" (.254 TO
.432mm).
NOTE: APPLY MOBILTAC 375 NC LUBRICANT (OR

EQUIV) TO THE EXTERNAL TEETH OF THE TURNTABLE
BEARING AND PINION GEAR.
00TH3565: 40712858.01:REV. N 20090819 5-7
CLAMP ASM (40712858) 25. 60132496 BAR-STOP 3565TH W-FALLBACK 2
1. 3C041930 CYLINDER 2 26. 71056011 GEAR-DRIVE 2
2. 40711513 BODY ASM-TH3565 1 27. 71056072 GEAR-INTERMEDIATE 2
3. 52711539 PIN-TYPE MM 3.00X10.00 ( 8.88) 8 28. 71056265 GEAR-PINION 2
4. 52711540 PIN-TYPE MM 3.00X36.25 (35.12) 4 29. 71056627 GEAR-TURNTABLE BRNG HRD 2
5. 52712974 COVER-INTERMEDIATE GEAR 4 30. 72053301 COUPLING-GLV .12 SCH 40 2
6. 52715927 ARM WLDMT-BLKHD RG-TH3565 2 31. 72053371 REDUCER BUSH-BLK .25- .12 2
7. 52715928 ARM WLDMT-TH3565 2 32. 72053508 ZERK-NPT .12 4
8. 52721752 WLDMT- TH3565 CLAW 45 DIA 2 33. 72060092 CAP SCR .50-13X 1.25 HH GR5 Z 32
(WAS 52714673) 34. 72060148 CAP SCR .62-11X 1.25 HH GR5 Z 4
9. 52721802 PIN-WLDMT 2 35. 72060177 CAP SCR .62-11X 3.00 HH GR8 Z 40
10. 52722482 FLAG-WLDMT 3565 W-FALLBACK 1 36. 72060184 CAP SCR .75-10X 1.75 HH GR5 Z 12
11. 52722483 FLAG-WLDMT 3565 RH FALLBACK1 37. 72060833 SCR-THRD.CUT .31-18X.75 4
12. 52722484 HAND WLDMT-3565TH FB LH 1 38. 72062080 NUT .50-13 HEX NYLOCK 4
13. 52722485 HAND WLDMT-3565TH FB RH 1 39. 72063002 WASHER .31 FLAT 4
14. 53000715 GREASE EXTENSION 18 OAL 2 40. 72063003 WASHER .38 FLAT 4
15. 60010235 COVER-PINION GEAR 2 41. 72063008 WASHER .75 FLAT 12
16. 60010351 SPRING-COMPRESSION 2 42. 72063028 MACHY BUSHING .75X14 GA NR 2
17. 60020115 BUSHING-ROTATION 2 43. 72063039 MACHY BUSHING 2.00X10 GA NR 2
18. 60020116 BUSHING-ROTATION SM CRANE 2 44. 72063053 WASHER .50 LOCK 32
19. 60020172 THRUST WASHER-SPUR GEAR 2 45. 72063055 WASHER .62 LOCK 4
20. 60020226 THRUST WASH-BRZ 2 46. 72063116 WASHER .75 N FLAT H ASTMF 36
21. 60106032 STUD- .50-13X1.75 4 47. 72063119 WASHER .62 FLAT ASTM F436 40
22. 60119984 COVER-ACCESS HOLE CLAW 2 48. 72066095 RETAINING RING-EXT 2.00 STD 2
23. 60120423 GREASE PLATE-DRIVE GEAR 2 49. 72066185 COTTER PIN .16X1.00 PLAIN 2
24. 60122391 COVER-HAND TH3565 2 50. 72601295 CAP SCR .75-10X 3.50 HH GR8 Z 36
51. 73540004 MOTOR ASM W/ CB 2
THIS CLAMP ASSEMBLY REPLACES 40711514,
36 36
EFFECTIVE 5-5-95 WITH SERIAL NUMBER 41 41
3565TH951008. 3
4
41 36 36 41
3 4 41 36 36
2 41
3
6
4
7
44 33
33 5
44 27
20 19
36 3
41 41
48 37 36
39 32 1
25 41
43 28 15 45
34 36 6
3 3
13 22 4
44 41
21 33
29 7 36
31 49
51 8 16 42
38 35 9
8
47 1
3
36 41 40
30 40
17 32
19 26
18 12
27 46
50
DETAIL 20 24
44
17 26 18 GEAR TRAIN 28 48 43 12 33 23
00TH3565: 91711516.01:REV. M 20110209 5-8
HYDRAULIC SCHEMATIC (91711516) 15. 51395721 HOSE ASM 3/8X28 (WAS 51711949) 4
ITEM PART NO. DESCRIPTION QTY 16. 72533373 UNION-BULKHEAD 3/4 37°JIC 4
1. 51711413 VALVEBANK (SEE PARTS BELOW) 1 17. 72532973 PRESSURE SWIVEL #12 1
2. 73054915 FLOW DIVIDER 1 18. 72053760 ELBOW #6MJIC #6MSTR 90° 4
3. 72532358 ADAPTER #8MSTR #8MJIC 4 19. 72532992 ADAPTER #4MSTR #6FSTR 8
4. 72531205 TEE #8MJIC 5 20. 72053776 ELBOW #6MSTR #6MJIC 45° 4
5. 72532987 NIPPLE-DIAGNOSTIC 1 21. 72532963 ADAPTER #16MSTR #8FSTR 1
6. 72532696 ELBOW #12MJIC #12FJIC 90° 1 22. 51396451 HOSE-FF 1/2x17 1
7. 72053763 ELBOW #8MJIC #8MSTR 90° 9 23. 60114669 ELBOW-PRESSURE GAUGE 1
8. 72532980 PRESSURE SWIVEL 2 24. 72532369 ADAPTER #12MSTR #16MJIC 1
9. 72532951 ADAPTER #12MSTR/#8FSTR 2 25. 51395043 HOSE ASM 3/4X75 (WAS 51704808) 1
10. 51395042 HOSE ASM 1/2X15 (WAS 51703866) 5 26. 51397345 HOSE ASM 1X81 (WAS 51711821) 1
11. 51394460 HOSE ASM 3/8X93 (WAS 51703601) 4 27. 72532666 ELBOW #8MJIC#8MSTR 90°XLG 4
12. 51705232 HOSE ASM 3/8X90 (WAS 51713152) 4 28. 72532971 ELBOW #16MJIC/90/#16FJIC SW 1
13. 51394114 HOSE ASM 3/8X45 (WAS 51704997) 2 29. 73540435 VALVE-CHECK INLINE 3500 PSI 1
14. 51395054 HOSE ASM 1/2X63 (WAS 51712756) 4 30. 72534780 ADAPTER-#16MJIC/#16MJIC 1
31. 51399098 HOSE ASM 1X67 1
BODY ROTATION BODY ROTATION

MOTOR MOTOR
A 15 15 B
4 20
19 20 19
B A
4
15 15
19 20 20
19
10
16 16
12 11 11 12 10
4
A 19 19 B
18 18
18 PAD ROTATION MOTORS 18 A
B 19 19
4
12 11 11 12
16 16
10
TO UPPER
TO LOWER BULKHEAD 10
BULKHEAD
ON ARMS
ON ARMS
7 SHIFT 7
27 PAD 27
ROT
27 BODY 27
ROT
7 CLAMP 7
1 VALVEBANK
28 29 30
26 22
24
17 31
25 23
6 4
5
14
A
10
14
9 14
7 3 3
2
7
VALVEBANK 51711413 SPARE PARTS:
21 7 CLAMP CYL
FLOW 9
77041284 - COIL FOR 12V VALVE PILOT
DIVIDER 14 77041770 - COIL FOR 24V VALVE PILOT
3 3 77040469 - COIL FOR 12V VALVE SPOOLS
73540030 - COIL FOR 12V VALVE SPOOLS
CLAMP CYL WITH CARTRIDGE
8 7 7 8 77040523 - COIL FOR 24V VALVE SPOOLS
13 13 WITH CARTRIDGE
SIDE SHIFT
CYLINDER
00TH3565: 95711613.01:19980511 5-9
DECAL KIT (95711613)
ITEM PART NO. DESCRIPTION QTY
1. 70391612 DECAL-GREASE WKLY LH 16
2. 70391613 DECAL-GREASE WKLY RH 15
3. 70392524 DECAL-ROTATE/GREASE 7
4. 70029251 DECAL-IMT DIAMOND 2
5. 70393666 DECAL-TH3565 IDENT 2
6. 70393704 DECAL-TOP 4
7. 70393671 DECAL-TH OPERATION 2
8. 70393672 DECAL-DANGER OPERATION 2
9. 71393695 CAPACITY CHART 2
00TH3565: 3B083930.01:19930401 5-10
SIDE SHIFT CYLINDER (3B083930)
1. 4B083930 CASE ASM 1
2. 4G083930 ROD ASM 1
3. 6I402144 PISTON 1
4. 6H040020 HEAD 1
5. 9B015930 SEAL KIT (INCL:6-15) 1
6. 7T66P400 PISTON SEAL (PART OF 5) 1REF
7. 7T2N4040 WEAR RING (PART OF 5) 2REF
8. 7T61N143 LOCK RING (PART OF 5) 1REF
9. 7Q072127 O-RING (PART OF 5) 1REF
10. 7Q10P342 BACK-UP RING (PART OF 5) 1REF
13. 7R546020 U-CUP SEAL (PART OF 5) 1REF
14. 7R14P020 ROD WIPER (PART OF 5) 1REF
15. 6A025020 WAFER LOCK (PART OF 5) 1REF
16. 6C150020 STOP TUBE 1.50 1
17. 6C300020 STOP TUBE 3.00 2
NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS
OF THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL
REDUCE FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM

HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON AND HEAD GLANDS,
LOCK RING AND ROD THREADS BEFORE
ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEEN

THE HEAD AND THE CASE WHEN ASSEMBLING
THE CYLINDER.
00TH3565: 3C041930.01:REV. C 20060720 5-11
CLAMP CYLINDER (3C041930)
1. 4C041930 CASE ASM (INCL:3,4) 1
2. 4G041930 ROD ASM (INCL:4) 1
3. 7PNPXT02 PIPE PLUG 1/8NPT (PART OF 1) 3REF
4. 70034441 BEARING-GARMAX (PART OF 1&2)
(FROM 5-1-98) 4REF
60020190 BUSHING (TO 5-1-98) 4REF
72053508 ZERK 1/8NPT (TO 5-1-98) 2REF
5. 73054242 C’BAL VALVE 25GPM 1
6. 6HX05530 HEAD 1
7. 6IX05520 PISTON 1
8. 9C222432 SEAL KI (INCL:9-17) 1
10. 7Q10P354 BACKUP RING (PART OF 8) 1REF
12. 7R546030 U-CUP SEAL (PART OF 8) 1REF
13. 7R14P030 ROD WIPER (PART OF 8) 1REF
14. 7T66P550 PISTON SEAL (PART OF 8) 1REF
16. 7T61N200 LOCK RING (PART OF 8) 1REF
17. 6A025030 WAFER LOCK (PART OF 8) 1REF
18. 6C300030 STOP TUBE 3R X 3L 2
19. 70393660 ROD COVER 1
20. 72661293 HOSE CLAMP 6-1/4 1
21. 72661286 HOSE CLAMP 3" 1
NOTE
IT IS RECOMMENDED THAT ALL COMPONENTS
OF THE SEAL KIT BE REPLACED WHENEVER THE
CYLINDER IS DISASSEMBLED. THIS WILL
REDUCE FUTURE DOWNTIME.
APPLY “LUBRIPLATE #630-2” MEDIUM

HEAVY,MULTI-PURPOSE LUBRICANT OR
EQUIVALENT TO ALL PISTON AND HEAD GLANDS,
LOCK RING AND ROD THREADS BEFORE
ASSEMBLY.
USE “NEVER-SEEZ” OR EQUIVALENT BETWEEN

THE HEAD AND THE CASE WHEN ASSEMBLING
THE CYLINDER.
DO NOT PAINT GORTITE ROD COVER, #19.

00TH3565: 30712621.01:19940909 5-12
FLANGE GRABBER ATTACHMENT
(30712621)
1. 52702082 PIN 2
2. 72066145 HAIRPIN .19 2
3. 76393209 RUBBER DOCK BUMPER 2
4. 72060095 CAP SCR 1/2-13X2 HHGR5 4
5. 52712622 RIM FLANGE GRABBER 2
00TH3565: 90713667.01:19960725 5-13
CONTROL KIT-CAB & GROUND
CONTROL (90713667)
1. 51713669 HANDLE ASM-CAB CONTROL 1
2. 51713432 HANDLE ASM-RC 1
3. 51713668 JUNCTION BOX-DUAL CNTRLS 1
4. VALVEBANK REF
5. 77044309 TERMINAL BLOCK-14 TERM 1
6. 60105825 MOUNTING BAR 1
7. 60118646 BRACKET 1
8. 89044188 CABLE 14GA DUPLEX X 18 1
00TH3565: 51713669.01:19960725 5-14
HANDLE ASM-CAB CONTROL
(51713669)
1. 89044116 CABLE 18GA/16WIRE X 408 1
2. 70392812 DECAL-CONTROL 1
3. 77040373 TOGGLE SWITCH SPDT 1
4. 77040372 TOGGLE SWITCH SPDT 4
5. 60111300 JIC BOX 1
6. 77044579 CONNECTOR 1
7. 77044621 PIN 16
8. 77044668 PLUG-SEALING 7
9. 89044053 CABLE 14AWG 3WIRE 20"
12. 77040186 TERM 1/4 FSLPON 16-14GA 3
13. 77044341 TERMINAL BLOCK-4 1
14. 60045031 WIRE GRN X 4 7
15. 77040051 TERM #8 SPRSPD 16-14GA 22
16. 77044556 DIODE 2.2A 274V 2
17. 83034392 SHRINK FIT 2
18. 77044018 STRAIN RELIEF 3/8-1/2 2
20. 77044201 NUT 1/2 ELEC 2
00TH3565: 51713432.01:19980204 5-15
HANDLE ASM-RC (51713432) 12. 72066340 POP RIVET 1/8X3/8 2
ITEM PART NO. DESCRIPTION QTY 14. 72061009 SHT MTL SCR #6X3/4 PH 8
1. 60045031 WIRE 18GA X 4 GRN 5 15. 77040051 TERMINAL #8SPRSPD 16-14GA 12
2. 60119335 CONTROL HANDLE 1 17. 77040372 TOGGLE SWITCH SPDT 3
3. 77044668 PLUG-SEALING 11 18. 77040373 TOGGLE SWITCH SPST 1
4. 60119277 COVER-RC HANDLE FRONT 1 20. 77044579 CONNECTOR 1
5. 70034306 BACK COVER-RC HANDLE 1 21. 89044136 CABLE 18GA/12WIRE X 25' 1
6. 70029119 PLACARD-SERIAL NO. 1 22. 77044556 DIODE 2.2A 274V 2
8. 77044621 PIN 12 23. 83034392 PIPE-PVC 1/8 EXP HEAT SHRINK 2
9. 70392862 DECAL-DGR RC ELECTRO SM 1 24. 70392785 PLUG 1/2 3
10. 71394285 DECAL-RC HANDLE 1 25. 77044196 CONNECTOR 3/4 STRAIN REL 1
00TH3565: 51713668.01:20000714 5-16
JIC BOX ASM-DUAL CONTROL (51713668) 8. 89044116 CABLE 18GA 16WIRE 1FT
1. 60119433 JIC BOX 1 9. 77044201 NUT 1/2 ELEC LOCK 1
2. 70393722 DECAL-GROUND/CAB CTRL 2 10. 77044018 STRAIN RELIEF 1/2 1
3. 77040374 TOGGLE SWITCH SPDT 1 11. 77044667 PLUG CAP 2
4. 77040051 TERMINAL #8 SPRSPD 16-14GA 34 12. 77044620 CONNECTOR 2
5. 77044309 TERMINAL STRIP-14 1 13. 60119809 MTG PLATE 2
6. 89044136 CABLE 18GA 12WIRE 1FT 14. 72601725 MACHSCR #6-32X1/2RDHDPHIL 8
7. 89044136 CABLE 18GA 12WIRE 6FT 15. 72601726 NUT #6-32 HEX LOCK 8
00TH3565: 91712814.01:REV E 20070820 5-17
HYDRAULIC SCHEMATIC-BULKHEAD 11. 51394460 HOSE ASM 3/8X93 4
(WAS 51703601)
(91712814) 12. 51396967 HOSE ASM 3/8X81.5 4
1. 60118044 BULKHEAD PLATE 1 (WAS 51713152)
2. 73054915 FLOW DIVIDER 1 14. 51394428 HOSE ASM 1/2X75 4
3. 72532358 ADAPTER #8MSTR #8MJIC 4 (WAS 51703703)
4. 72531205 TEE #8MJIC 5 15. 51395721 HOSE ASM 3/8X28 4
5. 72060091 CAP SCR 1/2-13X1 HHGR5 2 (WAS 51711949)
7. 72053763 ELBOW #8MJIC #8MSTR 90° 5 16. 72533373 UNION-BULKHEAD 3/4JIC 37° 10
8. 72532980 PRESSURE SWIVEL 8 18. 72053760 ELBOW #6MJIC #6MSTR 90° 4
9. 72532963 ADAPTER #16MSTR #8FSTR 1 19. 72532992 ADAPTER #4MSTR #6FSTR 8
10. 51395042 HOSE ASM 1/2X15 5 20. 72053776 ELBOW #6MSTR #6MJIC 45° 4
(WAS 51703866) 21. 72532951 ADAPTER #12MSTR #8FSTR 2
22. 51709389 HOSE ASM 1/2X14 1
23. 91720641 HYDRAULIC KIT (INCL 3,5,7-21) 1
00TH3565:40711514.01:19980504 5-18
CLAMP ASM (40711514) 25. 71056265 PINION GEAR 2
ITEM PART NO. DESCRIPTION QTY 26. 71056072 INTERMEDIATE GEAR 2
1. 52711511 CLAW 2 27. 71056361 TURNTABLE BEARING 2
2. 52711509 COVER PLATE 2 28. 60020226 THRUST WASHER 2
3. 60117029 END CAP PLATE 2 29. 72063039 MACH BUSHING 2X10GA NR 2
4. 52711504 ARM 2 30. 72066095 RETAINING RING 2" 2
131482-8 ARM (TH SN: 3565F2493002 ONLY) 31. 72601295 CAP SCR 3/4-10X3-1/2 HHGR8 36
5. 60020230 BUSHING (PART OF 4) REF 32. 72063116 WASHER 3/4 FLAT HARD 36
6. 52711539 PIN 8 33. 72060833 CAP SCR 5/16-18X3/4 SLFTPG 4
7. 52711540 PIN 4 34. 72063002 WASHER 5/16 4
8. 72060184 CAP SCR 3/4-10X1-3/4 12 35. 60010235 PINION GEAR COVER 2
9. 72063008 WASHER 3/4 12 36. 72063119 WASHER 5/8 FLAT HARD 40
10. 72053509 ZERK 1/4-28 32 37. 72060177 CAP SCR 5/8-11X3 HHGR8 40
11. 72060092 CAP SCR 1/2-13X1-1/4 8 38. 72063003 WASHER 3/8 4
12. 72063053 WASHER 1/2 LOCK 8 39. 72531826 REDUCER BUSHING 1/4 1/8NPT 2
13. 3C041930 CLAMP CYLINDER 2 40. 72062080 NUT 1/2-13 LOCK 4
14. 72053508 ZERK 1/8NPT 10 41. 71056011 DRIVE GEAR REF
15. 52711538 HAND 2 42. 60020115 BUSHING REF
16. 53000715 GREASE EXTENSION 18" 2 43. 60020116 BUSHING REF
17. 72053301 COUPLING 1/8NPT 2 44. 60020187 BUSHING REF
18. 60020172 THRUST WASHER 2 45. 60020188 BUSHING REF
19. 60106032 STUD 1/2-13X2 4 46. 52711547 ARM W/BULKHD & RING 2
20. 73540004 HYD MOTOR (FROM 5-15-98) 2 131482-9 ARM (TH SN: 3565F2493002 ONLY)
73051004 HYD MOTOR (TO 5-15-98) 2
5V151830 C’BALANCE BLOCK (TO 5-15-98) 2 THIS CLAMP ASSEMBLY IS REPLACED BY 40712858,
73054538 C’BALANCE VALVE (TO 5-15-98) 4 EFFECTIVE 5-5-95.
72060738 CAP SCR (TO 5-15-98) 8
7Q072112 O-RING (TO 5-15-98) 4
00TH3565: 90713678.01:19970128 5-19
CONTROL KIT-CAB CONTROL 6. 60105825 MOUNTING BAR-TERM BLOCK 1
7. 60118646 TERM MTG BRACKET 1
(90713678) 8. 89044188 CABLE 14AWG DUPLEX X 18 1
1. 51713676 HANDLA ASM-CAB 1 9. 60119806 MTG BRACKET-CONNECTOR 1
3. 51713677 CABLE ASM 18GA 16WIRE X 56 1 10. 72060004 CAP SCR 1/4-20X1 HHGR5 2
4. VALVEBANK REF 11. 72062104 NUT 1/4-20 LOCK 2
5. 77044309 TERMINAL BLOCK-14 1 12. 77040051 TERMINAL #8SPRSPD 16-14GA 28
00TH3565: 51713676.01:19990715 5-20
HANDLE ASM-CAB CONTROL 7. 77044621 PIN 16
(51713676) 9. 89044053 CABLE 14AWG 3WIRE 20"
1. 89044116 CABLE 18GA/16WIRE X 408 1 10. 70145495 HEAT SHRINK 3/4 W/ADHESIVE 4”
2. 70392812 DECAL-CONTROL 1 12. 77040186 TERM 1/4 FSLPON 16-14GA 3
3. 77040373 TOGGLE SWITCH SPDT 1 13. 77044341 TERMINAL BLOCK-4 1
4. 77040372 TOGGLE SWITCH SPDT 4 14. 60045031 WIRE GRN X 4 5
5. 60111300 JIC BOX 1 15. 77040051 TERML #8 SPRSPD 16-14GA 21
6. 77044579 CONNECTOR 1 18. 77044018 STRAIN RELIEF 3/8-1/2 2
20. 77044201 NUT 1/2 ELEC 2
00TH3565: 51713677.01:19960725 5-21
CABLE ASM 18GA/16WIRE X 56
(51713677)
1. 89044116 CABLE 18GA/16WIRE X 56" 1
3. 77040051 TERM #8 SPRSPD 16-14GA 10
4. 77044620 CONNECTOR 1
5. 77044580 SOCKET 16
00TH3565:99900911.01:19960830 5-22
FIELD CONVERSION-CAB/GROUND
CTRL-51712657 (99900911)
1. 51713669 HANDLE ASM-CAB CTRL 1
2. 51713432 HANDLE ASM-RC 1
3. 51713668 JIC BOX ASM 1
00TH3565:99900699: 19960830 6-1
SECTION 6. INSTALLATION PROCEDURES

GENERAL ....................................................................................................................... 3
LOADER INSTALLATION .............................................................................................. 3
LIFT TRUCK INSTALLATION ........................................................................................4
00TH3565:99900699: 19960830 6-2
NOTES
00TH3565:99900699: 19960830 6-3
GENERAL Fill the reservoir. Start the loader’s engine and
This section contains information related to the operate all controls to purge air from the system.With
installation of the Tirehand to loaders and lift trucks. the loader running, check for leaks and repair if
It is intended to be used only as a supplement to the necessary.
other sections in this manual. Remember,
installations will vary from one particular case to Recheck all hoses and cables for clearance.
another.
Check the reservoir oil level and fill if necessary.
LOADER INSTALLATION Test operate the Tirehand.
Mount the Tirehand to loader arms using the original
loader pins. NOTE
STOP BLOCKS SHOULD BE WELDED TO THE
Install the flow control divider in the pressure line LOADER ARMS TO LIMIT ARTICULATION, IF
continuing the original line on. The controlled flow line NECESSARY. LOCATIONS AND SIZES OF STOPS
will go to the valvebank. TO BE DETERMINED AT TIME OF INSTALLATION.
Route the hoses as shown in figure below.
Locate the control handle inside the cab where

convenient to operate.
Connect the 3-wire power cable to 12-volt power. The

green wire to 12V positive, the black wire to the coil
on the flow divider, and the white wire to ground.
Route the control cable to the Tirehand and connect.
Check all hoses and cables for clearances. Make

sure that steering or moving the arms will not pinch or
overstress the hoses or cables.
GENERAL LOADER INSTALLATION

00TH3565:99900699: 19960830 6-4
LIFT TRUCK INSTALLATION Check all hoses and cables for clearances. Make
Mount the Tirehand to lift truck using the original sure that steering or other movements of the lift truck
carriage pin. will not pinch or overstress the hoses or cables.
Install the flow control divider in the pressure line Fill the reservoir. Start the lift truck’s engine and
continuing the original line on. The controlled flow line operate all controls to purge air from the system.
will go to the valvebank.
With the lift truck running, check for leaks and repair
Route the hoses as shown in figure below. if necessary.
Locate the control handle inside the cab where Recheck all hoses and cables for clearance.
convenient to operate.
Check the reservoir oil level and fill if necessary.
Connect the 3-wire power cable to 12-volt power. The
green wire to 12V positive, the black wire to the coil Test operate the Tirehand.
on the flow divider, and the white wire to ground.
Route the control cable to the Tirehand and connect.
GENERAL LIFT TRUCK INSTALLATION

00TH3565:99900699: 20020206 7-1
SECTION 7. TIREHAND 3565 REPAIR

7-1. GENERAL ........................................................................................................ 3
7-2. HYDRAULIC SYSTEM ..................................................................................... 3
7-2-1. CYLINDERS .................................................................................................. 3
7-2-1-1. CLAMP CYLINDER REMOVAL AND INSTALLATION ............................ 3
7-2-1-2. SIDE SHIFT CYLINDER REMOVAL AND INSTALLATION ...................... 4
7-2-1-3. CYLINDER DISASSEMBLY ...................................................................... 4
7-2-1-4. CYLINDER ASSEMBLY ............................................................................ 5
7-2-2. COUNTERBALANCE VALVES .................................................................... 6
7-2-3. HYDRAULIC PUMP ...................................................................................... 6
7-2-4. HYDRAULIC MOTORS ................................................................................. 6
7-2-4-1. HYDRAULIC MOTOR REMOVAL AND REPLACEMENT ......................... 6
7-2-5. RELIEF VALVE ADJUSTMENT .................................................................... 7
7-3. BEARINGS ....................................................................................................... 7
7-3-1. TURNTABLE GEAR-BEARING .................................................................... 7
7-3-1-2. AXIAL ROTATION GEAR-BEARING ......................................................... 7
7-3-2. BUSHING REMOVAL AND INSTALLATION ................................................ 8
Figure G-1. Securing Cylinder ............................................................................... 9
Figure G-2. Cylinder Components ........................................................................ 9
Figure G-3. O-ring Removal ................................................................................... 9
Figure G-4. Dynamic Rod Seal Removal .............................................................. 9
Figure G-5. Rod Seal Installation ........................................................................... 9
Figure G-6. Piston/Rod Assembly ......................................................................... 10
Figure G-7. Hydraulic Pump .................................................................................. 10
Figure G-8. Bushing Removal ............................................................................... 11
Figure G-9. Bushing Installation ............................................................................ 11
7-4. TROUBLESHOOTING ...................................................................................... 12
Table G-1. Troubleshooting .................................................................................... 12
TORQUE DATA CHART-DOMESTIC ...................................................................... 13
TORQUE DATA CHART-METRIC ............................................................................ 14
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE ......................... 15
TURNTABLE BEARING INSPECTION FOR REPLACEMENT.............................. 16
RECOMMENDED SPARE PARTS LIST .................................................................. 17
00TH3565:99900699: 19930401 7-2
NOTES
00TH3565:99900699: 19930401 7-3
7-1. GENERAL 7-2-1-1. CLAMP CYLINDER REMOVAL AND
This section describes disassembly, repair and INSTALLATION
assembly of many of the components used on the 1. Rotate the Tirehand until the clamp arm is in a
Tirehand. Some information presented here may not horizontal position.
apply to your model of Tirehand.
2. Shut off the carrier vehicle’s engine. Relieve
internal hydraulic pressure by cycling the controls.
7-2. HYDRAULIC SYSTEM
Certain procedures involving the hydraulic system 3. Support the hand assembly with a lifting device
require special consideration for proper functioning and straps capable of supporting the assembly. Take
and service life of the unit. These steps are to be up slack in the lifting device.
taken whenever a hydraulic component is
disconnected. 4. Remove the cylinder rod pin by removing the
3/4-10 cap screws and washer securing the pin.
1. ALWAYS relieve internal hydraulic pressure Drive out the pin.
before proceeding with the repair.
5. Make certain the hand assembly is well
2. NEVER allow foreign matter - dirt, water, metal supported, then remove the cylinder rod pins by
particles, etc. - to enter the hydraulic system through removing the 3/4-10 cap screws securing the pins.
the open connection. Seal the connection as tightly Drive out the pins.
as possible. If dirt does get in, a filter change is
required after about 50 hours of operation. 6. Swing the hand assmbly away, taking care to
keep dirt from the bushing surfaces.
3. ALWAYS cycle all of the controls after completing
a repair. This will eliminate air that is trapped in the 7. Support the clamp cylinder with a lifting device
cylinders, hoses, spool valves, etc. and avoid bumpy, and straps capable of supporting the cylinder.
erratic behavior during actual working conditions.
8. Remove the cylinder base pin securing screw and
4. ALWAYS check for hydraulic leaks after a repair. washer. Drive the pin only far enough to release the
A high pressure leak is hazardous and must be cylinder.
repaired before putting the unit to work.
9. Lift the cylinder away and repair as necessary.
7-2-1. CYLINDERS
All of the cylinders used on the Tirehand are of the
same basic type; therefore, the same disassembly
and repair instructions apply. Check the PARTS
section for specific information. The following list of
tools will be a definite asset in the disassembly and
repair of all IMT cylinders.
SPANNER WRENCH - IMT Part Number 3Y140510.
NEEDLE-NOSE PLIERS - For removal and

replacement of seals.
ICE PICK or SHARP AWL - For removal and

replacement of seals.
PLASTIC HAMMER - Used with the spanner wrench

for head and piston assembly.
00TH3565:99900699:19930401 7-4
To install the clamp cylinder: 4. Extend and retract the cylinder through five (5)
complete cycles to purge air that may be trapped in
1. Position the cylinder in the slings of the lifting the system. Check for leaks.
device and line up the base end pin boss and pin.
Seat the pin and secure using the 3/4-10 cap screw 5. Check the hydraulic reservoir fluid level with all
and washer. Torque to 265 ft-lb. cylinders retracted. Fill if necessary.
2. Lift the hand assembly with the slings and 6. Conduct a simulated job operation before
position the pin bosses in line with the pins. Drive in proceeding to the job site.
the pins and secure using the 3/4-10 hardware. Torque
to 265 ft-lbs. 7-2-1-3. CYLINDER DISASSEMBLY
3. Connect the hydraulic hoses to the clamp CAUTION

cylinder and axial rotation motor. IF SOLVENT IS USED TO CLEAN THE INTERNAL
CYLINDER COMPONENTS, ALL TRACES OF
4. Start the engine, cycle the CLAMP and AXIAL SOLVENT MUST BE REMOVED. ANY RESIDUE
controls through at least five cycles to purge any air WILL DAMAGE THE SEALS.
trapped in the system. Check for leaks.
WARNING
5. Check the hydraulic fluid level with all cylinders DO NOT USE COMPRESSED AIR TO ASSIST IN
retracted. Fill if necessary. WITHDRAWING THE PISTON/ROD ASSEMBLY.
THE USE OF COMPRESSED AIR MAY RESULT IN
6. Test the unit with a simulated job operation PROPELLING THE PISTON/ROD ASSEMBLY OUT
before proceeding to the job site. OF THE CYLINDER AND MAY CAUSE SERIOUS
INJURY OR DEATH.
7-2-1-2. SIDE SHIFT CYLINDER REMOVAL AND
INSTALLATION NOTE
Cylinder removal is accomplished as follows: IF THE CYLINDER IS BEING REPAIRED DUE TO A
WORN SEAL, WE RECOMMEND REPLACING ALL
1. Rotate the Tirehand so that the side shift cylinder COMPONENTS FOUND IN THE SEAL KIT. THE
is in a horizontal position. SMALL ADDITIONAL EXPENSE MAY SAVE
EXPENSIVE EQUIPMENT DOWN-TIME IN THE
2. Disconnect the hydraulic hoses from the cylinder NEAR FUTURE. REFER TO THE PARTS SECTION
port. Cap the hoses. FOR SEAL KIT NUMBERS.
3. Remove the retaining rings and bushings from the 1. Thoroughly wash the exterior of the cylinder
rod end and base end of the cylinder. Drive out the case.
pins.
NOTE
4. Disassemble and repair the cylinder. AFTER THE CASE HAS BEEN WASHED, PROCEED
WITH DISASSEMBLY IN A CLEAN ENVIRONMENT,
To install the cylinder: ONE THAT IS FREE OF DUST AND DIRT.
1. Line up the cylinder base-end pin boss with the 2. Remove counterbalance valve if disassembling
holes in the base. Drive in the pin and install the the clamp cylinder.
machinery bushing and retaining ring.
3. Place the cylinder on a flat surface near a
2. Connect the hydraulic hoses to the cylinder port. vise. Slip a pin through the pin boss and clamp the
pin in a vise (Figure G-1).
3. Extend and retract the cylinder until the rod-end
pin boss lines up with the holes in the sub-base. Drive CAUTION
in the pin and install the machinery bushing and DO NOT CLAMP THE CYLINDER IN A VISE. IT
retaining ring. MAY DAMAGE THE CYLINDER CASE.
00TH3565:99900699:19930401 7-5
4. Unscrew the head (Item 4, Figure G-2) in a
counterclockwise direction with the spanner wrench. 13. Spread the piston rings (item 9) and slide them
Withdraw the head from the cylinder case. over the land and off the end of the piston nearest to
the ring.
5. Secure the rod pin boss in the same manner as
the cylinder pin boss (Figure G-1). 14. Carefully lift the dynamic piston seal (item 10) out
of the groove with a thin blade such as a putty knife.
6. Unscrew the piston (Item 8, Figure G-2) from the Take care not to nick theedges of the groove. Twist
rod with the spanner wrench in the same manner as and break the seal.
the head (Step 4). CAUTION
DAMAGING THE EDGES OF THE GROOVE IS
CAUTION LIKELY TO CAUSE PREMATURE SEAL FAILURE.
DO NOT CLAMP THE MACHINED SURFACE OF
THE ROD IN A VISE. DAMAGE TO THE ROD WILL 15. Prick the companion o-ring with a pin or needle
RESULT. and lift it out of the groove. Roll it off the end of the
piston.
7. Remove the wafer lock (Item 13) and the stop
tubes (Item 7) from the rod (item 1). The wafer lock 16. Pry the lock ring (item 12) from its seat in the
was crushed to secure it and will have to be broken to bottom of the piston.
remove it.
17. Clean the piston, head, rod and cylinder. Dress
CAUTION any nicks and gouges in the head and piston that
MAKE CERTAIN THE ROD IS NOT DAMAGED may have occurred during disassembly.
DURING REMOVAL OF THE WAFER LOCK.
7-2-1-4. CYLINDER ASSEMBLY
8. Slide the head off the rod.
CAUTION
9. Inspect the cylinder interior and the rod for dents, USE ALL OF THE SEALS IN THE SEAL KIT. IT
nicks, scratches, etc. and replace if necessary. MAY SAVE EXPENSIVE DOWN-TIME IN THE
FUTURE.
CAUTION
FAILURE TO REPLACE A DAMAGED ROD OR 1. Install the wear ring (item 11). Make certain it is
CYLINDER MAY RESULT IN LEAKS AND POOR seated properly.
PERFORMANCE THAT WILL HAVE TO BE
REPAIRED. 2. Slide the piston seal (item 10) carefully into
position.
NOTE CAUTION
FURTHER WORK SHOULD BE DONE IN A WARM WORK THE PISTON SEAL CAREFULLY INTO
ENVIRONMENT (70°F OR WARMER). THIS MAKES POSITION FROM THE TOP OF THE PISTON USING
THE SEALS MORE PLIABLE AND EASIER TO THE ASSEMBLY GROOVE. DO NOT ATTEMPT TO
WORK WITH. INSTALL IT FROM THE BOTTOM OF THE PISTON.
YOU MAY STRETCH THE SEAL AND RENDER IT
10. Work a slack section into the head seal static o- USELESS.
ring (item 6) and pick it up out of the groove (Figure
G-3). Lift the static back-up out of its groove with the 3. Slide the piston rings (item 9) over the lands and
needle-nose pliers. allow them to snap into position.
11. Pinch the lip of the rod wiper (Item 2) with the 4. Carefully press the lock ring (item 12) into
needle-nose pliers and pull it out of the head. position.
12. Position the head with the top of the head up and
lift the wear ring (item 11) with the ice pick. Pry it out
of the groove and push it through the head. Remove
the rod seal as shown in Figure G-4.
00TH3565:99900699:19930401 7-6
5. Install the static back-up (item 5) and the o-ring 16. With a side-to-side or up-and-down motion, work
(item 6). Make certain that there are no twists. the piston into the cylinder and past the threads and
beveled area at the top of the cylinder case.
6. Position the head with the rod wiper pocket up.
Grasp the dynamic rod seal (item 3) with the needle- 17. Slide the piston into the cylinder. With a rotating
nose pliers (Figure G-5). motion, work the o-ring (item 6) and the back-up (item
5) past the threads and hand tighten the cylinder
CAUTION head.
DO NOT APPLY TOO MUCH PRESSURE TO THE
ROD SEAL OR YOU MAY CUT IT WITH THE 18. Secure the cylinder (Figure G-1) and torque the
NEEDLE-NOSE PLIERS. head in the same manner as the piston (step 14,
Figure G-6).
7. Insert the dynamic rod seal into the head and
allow it to snap into position. Use your fingers to help 19. Install the holding valves and their o-rings. Make
it if necessary. certain that the o-rings are in good position and
properly positioned.
8. Install the rod wiper (item 2).
7-2-2. COUNTERBALANCE VALVES
9. Generously lubricate the inside diameter of the Counterbalance valves are considered non-repairable
head with a non-fibrous bearing grease such as and must be replaced if inoperable.
Lubriplate.
7-2-3. HYDRAULIC PUMP
10. Carefully slide the head onto the rod. Make The installer or manufacturer of the carrier vehicle is
certain that the rod wiper (item 2) does not catch on to make provisions to supply 15 GPM of hydraulic
the rod when it is first started. Slide the head all of fluid at 2500 PSI.
the way onto the rod and up to the pin boss.
7-2-4. HYDRAULIC MOTORS
11. Slide the wafer lock (item 13) and stop tubes Four hydraulic motors are used on the Tirehand: two
(item 7 - if applicable) onto the rod. for Tirehand rotation and one each side for axial (pad)
rotation. These motors are not considered field-
12. Lubricate the entire threaded area of the rod and repairable and should be replaced if inoperable.
the inside diameter of the piston with non-fibrous
bearing grease. 7-2-4-1. HYDRAULIC MOTOR REMOVAL AND
REPLACEMENT
13. Secure the rod as shown in Figure G-1 and screw To remove rotation motor:
the piston onto the rod by hand. You should be able
to get the piston almost all the way onto the rod 1. Disconnect and cap the hydraulic hoses.
before using the spanner wrench. 2. Remove the two motor mounting bolts.
3. Remove the cushion block and hose fittings from
CAUTION the old motor.
CHECK TO MAKE CERTAIN THAT THE LOCK RING
(ITEM 12) STAYS IN POSITION. IT MUST REMAIN To install the new motor:
IN POSITION OR LEAKS MAY OCCUR RESULTING
IN POOR PERFORMANCE. 1. Install the cushion block and hose fittings from
the old motor. Do not use the old o-rings, they
14. Torque the piston onto the rod at 250 ft-lbs of should be replaced.
torque (Figure G-6). 2. Position the motor on the gear reducer, install the
four mounting bolts and torque them to the proper
15. Generously lubricate the outside diameter of both value (See Torque Table).
the head and piston with non-fibrous bearing grease. 3. Connect the hoses.
Also lubricate the threads and beveled area at the top
of the cylinder case.
00TH3565:99900699:19930401 7-7
4. Start the engine, rotate the Tirehand five (5) 3. Remove the cover then remove the 36 bolts that
times in both directions and check for leaks. secure the body to the gear-bearing. Slowly work the
hoses out of the rotation adapter while simultaneously
5. With all cylinders retracted, check the fluid level withdrawing the body. Set the body carefully to one
in the reservoir and fill if necessary. side.
7-2-5. RELIEF VALVE ADJUSTMENT 4. Disconnect the grease fitting extension from the
The hydraulic system is designed to operate at a turntable gear-bearing.
pressure requirement of 2500 PSI with an optimum oil
flow of 15 GPM. If the unit pressure is less than 5. Remove the 40 gear-bearing mounting bolts and
2500, the unit relief valve may require adjustment or remove the gear bearing.
replacement.
To install the gear-bearing:
The following procedure is recommended for relief
valve adjustment: 1. Position the gear-bearing and torque the 40
mounting bolts (see Torque Table).
1. Start the vehicle and engage the pump.
2. Install the grease fitting extension.
2. With the vehicle transmission in neutral, operate
any function full stroke and, with function lever still 3. Carefully position the body and clamp arms until
engaged at end of stroke, read the pressure on the the holes in the body line up with the holes in the
gauge at the control valve. It should read between gear-bearing. Install the mounting bolts and torque
2400-2600 PSI. to the proper value (see Torque Table).
3. If the pressure reading is low, shut off the engine 4. Connect the hydraulic hoses to the valvebank
and adjust the relief valve. Loosen nut on the and reconnect the electrical cable.
adjustment screw and turn screw to adjust. Test for
2500 PSI. 5. Start the engine and cycle all of the Tirehand
controls at least five (5) times in both directions to
7-3. BEARINGS purge the air in the system.
This paragraph covers the removal and installation of
turntable gear-bearings and bushings. 6. Check the system for leaks and repair any that
are found.
7-3-1. TURNTABLE GEAR-BEARING
To remove the Tirehand rotation gear-bearing: 7. With all cylinders retracted, check the fluid level
in the reservoir and fill if necessary.
1. Disconnect and cap the hydraulic hoses from the
valvebank. Disconnect the electrical cables 7-3-1-2. AXIAL ROTATION GEAR-BEARING
amphenol connector from the control box. To remove the axial rotation gear-bearing:
2. Support the clamp arms with an overhead lifting 1. Remove the 20 pad mounting bolts.
device capable of supporting the weight of the unit.
Take up the slack in the lifting device. 2. Disconnect the grease fitting extension.
WARNING 3. Remove the 20 gear-bearing mounting bolts and

THE LIFTING DEVICE MUST BE FASTENED TO remove the bearing.
THE TIREHAND IN SUCH A MANNER THAT WILL
PREVENT SHIFTING OF THE LOAD DUE TO
SLIPPAGE.
00TH3565:99900699:19930401 7-8
To install the bearing:
1. Position the bearing so that the holes align with

those in the arm. The grease fitting extension port
must be toward the pinion gear. Install and torque the
mounting bolts (see Torque Table).
2. Install the grease fitting extension.
3. Position the pad over the gear-bearing, install and

torque the mounting bolts (see Torque Table).
7-3-2. BUSHING REMOVAL AND INSTALLATION

To replace a bushing:
1. Remove the weldment containing the bushing.
2. Position the bushing removal tool as shown in

Figure G-9 and extract the bushing.
3. To install the bushing, assemble the tool as

shown in Figure G-10 and press the bushing in.
00TH3565:99900699:19930401 7-9
FIGURE G-1. SECURING CYLINDER FIGURE G-3. O-RING REMOVAL
1. ROD
2. WIPER
3. DYNAMIC ROD SEAL
4. HEAD
5. STATIC BACK-UP
6. STATIC O-RING
7. STOP TUBE
8. PISTON
9. PISTON RINGS
10. DYNAMIC PISTON SEAL
11. WEAR RING
12. LOCK RING
13. WAFER LOCK
FIGURE G-4. DYNAMIC ROD SEAL

REMOVAL
FIGURE G-2. CYLINDER COMPONENTS FIGURE G-5. ROD SEAL INSTALLATION

00TH3565:99900699:19930401 7-10
FIGURE G-6. PISTON/ROD ASSEMBLY FIGURE G-7. HYDRAULIC PUMP

00TH3565:99900699:19930401 7-11
FIGURE G-8. BUSHING REMOVAL FIGURE G-9. BUSHING INSTALLATION

00TH3565:99900699:19930401 7-12
7-4. TROUBLESHOOTING Care has been taken to list the most likely possible
Table G-1 is intended for use as a quick reference in causes in order of probable occurence.
diagnosing on-the-job malfunctions.
TABLE G-1. TROUBLESHOOTING

00TH3565:99900699: 19960322 7-13
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. Torque values specified are for bolts with residual oils or no special lubricants applied. If special
lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite,
collodial copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of
Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a
bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same
as when the bolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts
may result in bolt failure due to metal fatique causing serious injury or DEATH.
00TH3565:99900699: 19960322 7-14
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in kilogram-meters.
4. Torque values specified are for bolts with residual oils or no special lubricants applied. If special
lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite,
collodial copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of
Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
WARNING
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a
bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same
as when the bolt was new thus giving indeterminate clamp loads after torquing. Failure to replace gear-bearing bolts
may result in bolt failure due to metal fatique causing serious injury or DEATH.
00TH3565:99900699: 19930401 7-15
TURNTABLE BEARING FASTENER TIGHTENING SEQUENCE
Refer to the diagram below for proper tightening/torqueing sequence of the turntable bearing to the crane base and
crane mast. The total quantity of cap screws varies dependent on crane model.
TIGHTENING PROCEDURE:
1. Refer to the Torque Data Chart to determine the proper torque value to apply to the size of capscrew used.
2. Follow the tightening sequence shown in the diagram. Note that the quantity of capscrews may differ from
the diagram, but the sequence must follow the criss-cross pattern as shown in the diagram.
3. Torque all capscrews to approximately 40% of the specified torque value, by following the sequence.
(EXAMPLE: .40 x 265 FT-LBS = 106 FT-LBS)
(EXAMPLE-METRIC: .40 x 36 KG-M = 14.4 KG-M)
4. Repeat Step 3, but torqueing all capscrews to 75% of the specified torque value. Continue to follow the
tightening sequence.
(EXAMPLE: .75 x 265 FT-LBS = 199 FT-LBS)
(EXAMPLE-METRIC: .75 x 36 KG-M = 27 KG-M)
5. Using the proper sequence, torque all capscrews to the listed torque value as determined from the Torque
Data Chart.
00TH3565:99900699: 19930401 7-16
TURNTABLE BEARING INSPECTION FOR REPLACEMENT

Before a bearing is removed from a crane for If none of the above conditions exists, the bearing is
inspection, one of the following conditions should be functioning properly and need not be replaced. But, if
evident: one or more of the above conditions exists,
inspection may be required. Limits are measured in
1. Metal particles present in the bearinglubricant. “TILT” which is dependent on the internal clearances
2. Increased drive power required to rotate the of the bearing. TILT is the most practical
crane. determination of a bearings internal clearance once
3. Noise emitting from the bearing during mounted on a crane.
crane rotation.
4. Rough crane rotation. Periodic readings indicating a steady increase in TILT
5. Uneven or excessive wear between the pinion may be an indicator of bearing wear. Note that a
gear and turntable gear. bearing found to have no raceway cracks or other
structural irregularities should be reassembled and
returned to service.
TEST PROCEDURE
STEP 1.
With the crane horizontal and fully extended, measure
between the top and bottom mounting surfaces of the
turntable bearing (A1), using a dial indicator for
accuracy.
STEP 2.
Reverse the load by applying minimal downward
pressure on the boom while the boom is in the boom
support or on a solid surface. Again measure A2.
STEP 3.
Subtract A1 from A2 to determine tilt and compare
the result with the accompanying chart.
COMPARISON CHART - MODEL TO MEASURED TILT DIMENSION

NOTE 1007 5200 16035 9800
THE FIGURES LISTED IN IMT 1014 5200R 16042 12916
2015 5217 32018 13031
THIS CHART ARE CRANE, 2015GH 5800 32030 13034
SERVICE GUIDELINES LOADER 2109 7020 T30 14000
AND DO NOT, IN 2200 7025 T40 15000
OR 3000 7200 TH3565 BODY ROT’N 18000
THEMSELVES, REQUIRE 3016 7415 20017
THAT THE BEARING BE TIREHAND 321GH 9000 H1200
INSPECTED. MODEL
3816 TH10 BODY ROT’N H1200RR
425 TH14 BODY ROT’N T50
4300 TH3565 CLAMP TH2551B BODY ROT’N
IF THERE IS REASON 5016 TH2557B BODY ROT’N
TO SUSPECT AN 6016 TH2557A BODY ROT’N
EXCESS OF BEARING TH7 BODY ROT’N
TH1449 BODY ROT’N
WEAR AND THE
TH15B CLAMP
MEASURED TILT TH2551B CLAMP
DIMENSION EXCEEDS TH2557A CLAMP
THE DIMENSION
LISTED, REMOVE THE BALL DIA. .875” 1.00” 1.18”-1.25” 1.75”
BEARING FOR (REF) (22mm) (25mm) (30-32mm) (44mm)
INSPECTION.
TILT DIM. .060” .070” .075” .090”
(A1-A2) (1.524mm) (1.778mm) (1.905mm) (2.286mm)
00TH3565:99900699: 19960205 7-17
RECOMMENDED SPARE PARTS LIST

1 YEAR SUPPLY
TIREHAND 3565
FOR MANUAL: 99900699
This spare parts list does not necessarily indicate that the items can be expected to fail in the course of a year. It is intended to provide the
user with a stock of parts sufficient to keep the unit operating with the minimal down-time waiting for parts. There may be parts failures not
covered by this list. Parts not listed are considered as not being Critical or Normal Wear items during the first year of operations and you need
to contact the distributor or manufacturer for availability.
SHELF
ASSEMBLY LIFE ORDER
DESIGNATION ITEM NO. PART NO. DESCRIPTION QTY CODE (MO) QTY
40711512.01.19930401 SUB-BASE ASM

5 60030244 WEAR PAD 1
11 72601682 CAP SCR 40
12 72063116 WASHER 40
40711513.01.19960422 BODY ASM
7 60250283 BUSHING 2
9 60250285 BUSHING 2
10 71056373 TURNTABLE GEAR BEARING 1
11 72601468 CAP SCR 34
12 72063116 WASHER 62
14 72601485 CAP SCR 20
16 71056264 INTERMEDIATE GEAR 2
17 71056486 PINION GEAR 2
20 72060206 CAP SCR 8
21 73051004 HYD MOTOR 2
24 73054538 C’BALANCE VALVE 4
32 7Q072112 O-RING 4
33 70034295 BUSHING 2
34 60020120 BUSHING 2
35 60020121 BUSHING 2
36 71056074 DRIVE GEAR 2
3B083930.01.19930401 SIDESHIFT CYLINDER
5 9B015930 SEAL KIT 1
3C041930.01.19950420 CLAMP CYLINDER
4 60020190 BUSHING 8
8 9C222432 SEAL KIT 2
51713669.01.19960725 HANDLE ASM-CAB CONTROL
3 77040373 TOGGLE SWITCH SPST 1
4 77040372 TOGGLE SWITCH SPDT 4
51713432.01.19980204 HANDLE ASM-RC
18 77040373 TOGGLE SWITCH SPST 1
51713668.01.19960812 JIC BOX ASM-DUAL CONTROL
51713676.01.19960725 HANDLE ASM-CAB CONTROL
40712858.01.19960830 CLAMP ASM
5 60020230 BUSHING 16
20 73051004 HYD MOTOR 2
24 7Q072112 O-RING 4
25 71056265 PINION GEAR 2
26 71056072 INTERMEDIATE GEAR 2
27 71056361 TURNTABLE GEAR BEARING 2
31 72601295 CAP SCR 36
32 72063116 WASHER 36
36 72063119 WASHER 40
37 72060177 CAP SCR 40
41 71056011 DRIVE GEAR 2
42 60020115 BUSHING 2
43 60020116 BUSHING 2
44 60020187 BUSHING 2
45 60020188 BUSHING 2
00TH3565:99900699: 7-18
00TH3565:99900699: 19910816 7-19
00TH3565:99900699: 20020206 7-20
This parts manual is provided to the user to assist in servicing the equipment. It is the propertyof Iowa Mold Tooling Co., Inc and, as such,
may not be reproduced either whole or in part,whether by chemical, electrostatic, mechanical or photographic means without the
expressed written permission of an officer of Iowa Mold Tooling Co., Inc. One manual is provided with each piece of new equipment and
additional manuals may be obtained at a nominal price.

BOX 189, GARNER, IA 50438-0189
TEL: 641-923-3711
TECHNICAL SUPPORT FAX: 641-923-2424

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What are the main components and systems described in the manual?

What are the main components and systems described in the manual?

What maintenance and inspections are recommended for the equipment?

What maintenance and inspections are recommended for the equipment?

LIFT CO., INC.

2571 Cortez Street - Oxnard, CA 93036-1642

It is the operator’s responsibility to read and understand this manual before

Perform operator daily check before operating this equipment.

READ BEFORE ORDERING

To: Company Representative

Wiggins warranty for this vehicle is for starting on and ending

New Forklift Truck Delivery Inspection Report

Average number of lifts per month: Per year:

CHECK FOR ANY SHIPPING DAMAGE BEFORE UNLOADING

C. Drive axle and wheels:

Oil level in drive axle Oil level in transmission

Check for pins, bearings, shafts, Alignment of chains and rollers

Travel forward and reverse

Always test with load close to rated capacity of machine.

LOAD TESTED: Describe:

Total weight of load: Length of load:

Daily Safety Check

IMPORTANT: DO NOT use forks which have been repaired by welding.

7. Check service and parking brakes for proper operation.

15. Perform the Pre-Operation Check List in Section 3.0.

16. Perform all maintenance procedures as required in Section 5.0.

18. Remove or secure any loose objects.

COMPLETED BY: SERIAL #:

RECOGNIZE SAFETY INFORMATION:

UNDERSTAND SIGNAL WORDS:

Safety signs with signal word DANGER or WARNING are typically

General precautions are listed on CAUTION safety signs.

FOLLOW SAFETY INSTRUCTIONS:

DO NOT USE starting fluid.

BEWARE OF EXHAUST FUMES:

KNOW THE EQUIPMENT:

Know the following about your forklift:

AVOID POWER LINES:

KNOW THE WORK AREA:

PLAN YOUR WORK:

horn before proceeding slowly around a blind corner.

Know and Understand:

PREHEAT PARK BRAKE ON SHUTDOWN ENGAGED

• Wear the seat belt any time the truck is in motion.

• Carry the load as low as possible while maintaining good visibility.

Safe Operating Procedures:

1. Check all instruments, gauges, and indicator lights.

2. Verify operation of the work lights and horn.

3. Check the steering, right and left.

4. All control levers for proper operation.

5. Brakes and inching pedal, if provided, for proper operation.

SAFETY WHILE SERVICING:

HANDLE FUEL SAFELY - AVOID FIRES

PREPARE FOR EMERGENCIES

AVOID HIGH-PRESSURE FLUIDS

HANDLE CHEMICAL PRODUCTS SAFELY

WORK IN CLEAN AREA

SERVICE MACHINES SAFELY

Remove rings and other jewelry to prevent electrical