LT-270

Service Manual

INTEGRATED MINING SYSTEMS FOR THE WORLD

DRILLING, LOADING, HAULING, PROCESS ENGINEERING

AND COMPONENT SUPPORT SYSTEMS.

Innovative Technologies. Unparalleled Support.

 LT-270 Service Manual

Introduction 1

Service Prerequisites....................................................................................................................................1

Safety Information 2

Safety Signs and Decals...............................................................................................................................3

Protective Equipment .................................................................................................................................3
Pressurized Items.........................................................................................................................................3
Accessing The Unit .....................................................................................................................................4
Hot Parts and Fluids ...................................................................................................................................4
Lifting ............................................................................................................................................................4
Repair Guidelines.........................................................................................................................................4
Fire Prevention.............................................................................................................................................5
Safe Operating Guidelines..........................................................................................................................6

Systems 7

Hydraulic System .........................................................................................................................................7

Hydraulic System Settings ...................................................................................................................7
Hydraulic Reservoir ..............................................................................................................................8
Reservoir Breather ................................................................................................................................8
Return Circuit ........................................................................................................................................9
Hydraulic Accumulators ......................................................................................................................9
Determining Brake Accumulator Pre-charge Pressure .................................................................10
Hydraulic Cylinders ............................................................................................................................10
Main Hydraulic Pump ........................................................................................................................11
Pump Compensator............................................................................................................................12
Dump/Hoist/Steer Valve .................................................................................................................13
Load Sense Signal Circuit ..................................................................................................................15
Hydraulic Pilot Circuit........................................................................................................................17
Steering Circuit ....................................................................................................................................18
Hoist/Dump Circuits.........................................................................................................................19
Brake System Circuits.........................................................................................................................21
Brake Test Procedures .......................................................................................................................27
Electrical System ........................................................................................................................................28
Welding Procedure for Electronically Controlled Engines ..........................................................28
Repair Safety Review ..........................................................................................................................29
Power Circuit.......................................................................................................................................30
Charging System..................................................................................................................................31
Lighting Circuit ...................................................................................................................................31
Starting System ....................................................................................................................................32
Brake Circuit ........................................................................................................................................33
Warning/Monitoring Circuits ...........................................................................................................36
Fire Suppression Switch.....................................................................................................................37
Transmission Shift Circuits ...............................................................................................................38
Electrical Maintenance Procedures ..................................................................................................39

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 LT-270 Service Manual

Powertrain...................................................................................................................................................40
Transmission/Torque Converter Circuit ........................................................................................41
Fuel System ..........................................................................................................................................43

Maintenance Procedures 45

Safe Working Practices .............................................................................................................................45

Fluid Specifications....................................................................................................................................47
Diesel Fuel ...........................................................................................................................................48
Hydraulic Fluid....................................................................................................................................49
Transmission Fluid .............................................................................................................................50
Engine Oil............................................................................................................................................51
Engine Coolant ...................................................................................................................................52
Axle Fluid.............................................................................................................................................53
Pivot Point Lubrication......................................................................................................................55
Periodic Maintenance Charts ...................................................................................................................56
Period: Every 8 Service Hours (Daily).............................................................................................56
Period: Every 250 Service Hours .....................................................................................................57
Period: Every 500 Service Hours (3 Months).................................................................................60
Period: Every 1000 Service Hours (6 Months) ..............................................................................61
Period: Every 2000 Service Hours (Annually)................................................................................62
Period: Every 4000 Service Hours (2 Years) ..................................................................................63
Bolt Torque Charts....................................................................................................................................64
Bolt & Capscrew Torque Values For the Axles.............................................................................65
Lifting Attachments (Shackles / Clevises) ......................................................................................67
Expander Pin Installation and Removal.................................................................................................68
Installation............................................................................................................................................68
Dismounting Instructions..................................................................................................................69
Torque Schedule (hours of operation) ............................................................................................69
Torque Values for Bolts and Specialty Fasteners ..........................................................................69
Changing the Dump Cylinder..................................................................................................................70
Removing the Dump Cylinder..........................................................................................................70
Installing the Dump Cylinder............................................................................................................70
Testing the Dump Cylinder...............................................................................................................70
Changing the Boom...................................................................................................................................71
Removing the Boom ..........................................................................................................................71
Installing the Boom ............................................................................................................................72
Testing the Boom ...............................................................................................................................72
Changing the Hoist Cylinders..................................................................................................................73
Removing the Hoist Cylinder(s) .......................................................................................................73
Installing the Hoist Cylinders............................................................................................................73
Testing the Hoist Cylinders...............................................................................................................74
Changing the Front Frame.......................................................................................................................74
Removing the Front Frame...............................................................................................................74
Installing the Front Frame.................................................................................................................75
Check the Machine’s Operation .......................................................................................................76

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Changing the Articulation Joint Pins ......................................................................................................76

Removing the articulation pins .........................................................................................................76
Upper Articulation Pin Assembly.....................................................................................................77
Lower Articulation Pin Assembly ....................................................................................................78
Check the mid-ship Hinge Operation .............................................................................................79
Changing The Hydraulic Pump ...............................................................................................................80
Removing The Hydraulic Pump.......................................................................................................80
Installing The Hydraulic Pump.........................................................................................................81
Check Pump Operation .....................................................................................................................81
Changing An Accumulator.......................................................................................................................82
Removing An Accumulator...............................................................................................................82
Installing An Accumulator ................................................................................................................82
Recharging An Accumulator.............................................................................................................82
Check The Accumulator Pre-charge................................................................................................83
Engine Installation.....................................................................................................................................84
Removing the Engine.........................................................................................................................84
Installing the Engine...........................................................................................................................85
Engine Servicing ........................................................................................................................................85
Air Intake System.......................................................................................................................................86
Exhaust System ..........................................................................................................................................88
Flex Plates ...................................................................................................................................................90
Changing The Torque Converter ............................................................................................................90
Removing the Torque Converter .....................................................................................................90
Installing the Torque Converter .......................................................................................................91
C270 Torque Converter Servicing ..........................................................................................................91
Changing the Transmission......................................................................................................................92
Removing the Transmission..............................................................................................................93
Installing the Transmission ...............................................................................................................93
Transmission Cooling ........................................................................................................................93
T20000 Transmission Servicing...............................................................................................................94
Changing Drivelines ..................................................................................................................................94
Changing the Front Axle ..........................................................................................................................95
Changing The Rear Axle...........................................................................................................................96
Axle Service Instructions..........................................................................................................................97

Optional Equipment 98

Ansul Fire Suppression System ...............................................................................................................98

Operation .............................................................................................................................................98
Main Components ..............................................................................................................................99
Main Suppressant Tank......................................................................................................................99
Actuators ..............................................................................................................................................99
Nozzles .................................................................................................................................................99
Hoses and Lines ................................................................................................................................100
Inspecting the Fire Suppression System........................................................................................100
Responding to a Fire Emergency ...................................................................................................100

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Cleaning the Machine.......................................................................................................................101

Fire Suppression System Maintenance ..........................................................................................101
Maintaining the Suppressant Canister ...........................................................................................102
Maintaining the Propellant and Actuator Cartridges...................................................................102
Maintaining the Nozzles ..................................................................................................................102
Maintaining the Hoses, Lines and Fittings....................................................................................103
Recharging the Fire Suppression System ......................................................................................103
Hydraulic Filler Pump Option...............................................................................................................104

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 LT-270 Service Manual

INTRODUCTION

This manual has been prepared in such a way that service technicians will
gain an understanding of the maintenance and adjustment procedures
required to properly maintain the LT-270 LHD.

Note: Repairs are to be performed by trained and qualified personnel only!

Upon completion of this manual you will be able to safely troubleshoot, dis-
mantle and repair the MTI LT-270 LHD. The modules in this manual have
been written in a manner that will allow you to quickly navigate to the section
that is applicable to the information you require. This manual is intended to
supply information necessary for a mechanic in the day-to-day maintenance
of the LHDs under their control. Service information for major components
(axles, transmissions, etc.) can be found in the appropriate component service
manual.

SERVICE Each owner of an MTI LT-270 may have prerequisite training for his or her
PREREQUISITES maintenance staff. A certain level of competence and understanding of heavy
equipment repair practices are required to safely carry out maintenance and
repairs to this unit. The following is a list of prerequisites that should be the
minimum requirements for service technicians:

» General safety knowledge

» Knowledge of standards and practices of your particular company

» Knowledge of government codes and regulations

» Basic mechanical systems knowledge

» Basic hydraulic systems knowledge

» Basic electrical systems knowledge

Anyone attempting to maintain or repair this equipment requires the above

skills. It is the responsibility of the site management to provide the necessary
skills development.

MTI can provide training for the necessary skills development required. Con-
tact the MTI Service department for more information on the training courses
that are available.

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 LT-270 Service Manual

SAFETY INFORMATION

Improper operation, maintenance, lubrication or repair of this product can be

dangerous and could possibly have results leading to injury or death. Safety
decals on the unit and warning labels in this publication help identify poten-
tial situations that may cause safety risks for both machine and personnel.

MTI cannot anticipate every possible circumstance that might involve a

potential hazard. The warnings in this publication and on the machine are
therefore not all inclusive. If a tool, procedure, work method, or operating
technique not specifically recommended by MTI is used, you must satisfy
yourself that it is safe for you, and others. You should also ensure that the
product would not be damaged or made unsafe by the operation, lubrication,
maintenance, or repair procedures you choose.

Note: The information, specifications, and illustrations in this publication are

based on information available at the time it was written. The specifi-
cations, torques, pressures, measurements, adjustments, illustrations
and other items are subject to change and these changes can affect the
service given to this product. Components on your unit may not be
exactly as shown in the illustrations and photographs in this manual.

Do not operate or perform any maintenance, lubrication, or repair on this

product until you have read and understood the required information. Safety
precautions and warnings are provided in this manual and on the machine. If
these warnings are not heeded, bodily injury or death could occur to you or
others.

The symbol to the left will help identify safety precautions when used in con-
junction with the words “Warning!” or “Danger!” in the text. These warn-
ings can be assumed to indicate the following:

» Attention!

» Be alert!

» Your safety is involved!

The personnel maintaining this unit may be unfamiliar with the procedures or
systems involved; this makes it important to use caution when repairing these
machines. Becoming familiar with the controls, systems and functions on the
unit and carrying out proper procedures helps to ensure a safe and productive
work experience.

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 LT-270 Service Manual

SAFETY SIGNS Thoroughly read all warning signs and decals on the product and in this man-
AND DECALS ual before operating this machine. Immediately replace any damaged, illegi-
ble or missing warning plates, signals or decals as soon as they are noticed as
being missing. Your safety or that of your co-workers could depend on it!

PROTECTIVE Always wear the protective equip-

EQUIPMENT ment required for the job’s condi-
tions or worksite regulations.

1 - Hard Hat
2 - Hearing Protection
3 - Safety Glasses
4 - Reflective Stripes
5 - Gloves
6 - Safety Boots

Warning: Never wear loose cloth-

ing or jewelry that could
potentially catch on
moving parts of the
machine!

PRESSURIZED Carefully relieve all pressure in air, water or hydraulic lines and circuits
ITEMS before disconnecting any hosing, fitting or related items. Always ensure that
all raised components (booms, gates, etc.) are correctly blocked or secured
against falling in the event of pressure loss during circuit repair.

Be alert of possible high pressure fluids/gases when disconnecting compo-

nents from a circuit that utilizes pressure. If possible, lower the boom to the
ground before performing any work on the machine. If this cannot be done,
make sure that the boom is blocked securely and correctly. This will prevent
it from dropping unexpectedly. Loose or damaged hosing can cause fires.
Always check tubes, lines and hosing carefully.

Warning: NEVER use your bare hands to inspect hosing for hydraulic leaks.
Pinholes in the hosing can create fluid leaks at high velocity and
pressure that can be easily missed by the naked eye. If high pres-
sure fluids penetrate the skin, personal injury can occur!

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 LT-270 Service Manual

ACCESSING THE Use available steps and handles when entering or leaving the operating area
UNIT of the unit. Keep operating area clean from debris such as mud or rocks on
any steps or access points. Always use available handles/rails when climbing
up or down steps. For repair purposes use the designed access provided.
When this is not possible, provide a safe manner to complete the task, such as
ladders, work platform or scaffolds.

HOT PARTS AND To help prevent the possibility of burns, be aware that after running for
FLUIDS extended periods there is a potential for extremely hot machine parts and
component lines or hoses on the unit. Take care to avoid contact with these
components until they have cooled down to acceptable temperatures.

LIFTING Check with the local job site regulations for requirements when lifting heavy
components. MTI recommends using a hoist or appropriate lifting device
when lifting heavy components in order to avoid potential back injury.

Always make sure to check that all chains, hooks, slings and lifting devices
are in good working condition and are the correct capacity for the required
job. Always ensure any hooks are correctly positioned and securely attached
to the component before lifting them away from the machine.

REPAIR Here are some general safety guidelines that anyone servicing the unit should
GUIDELINES follow:

» Always disconnect the batteries before starting to work on the unit.

» Attach the proper warning tags when working on the machine.
» If possible, make all repairs with the unit on a level and stable surface.
» Chock the wheels, to prevent the unit from moving.
» Be careful when removing inspection covers.
» Always use tools that are in good condition and proper for the job.
» Always replace hydraulic fittings with an equivalent or better quality;
never use a lower quality replacement.
» Be careful not to damage any electrical wiring when removing compo-
nents; never connect wiring to a hose or line that contains fluid.
» Ensure that all guards or safety devices are properly installed and func-
tioning correctly. If a guard or safety device has to be removed to per-
form a repair, use extra caution.
» Always tighten connections and bolts to the correct torque.
» Never operate a machine if any part or component is damaged. Always
make sure that all shields or guards are properly installed and function-
ing correctly.

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FIRE Fire can lead to severe emergencies where both human life and property may
PREVENTION be lost. Even when confined, a fire may cause very expensive damage to your
equipment. A fire may start at any time, not only when the equipment is
being used, but also when left unattended between work shifts.

To help reduce the risk of fire, follow the preventative instructions listed
below:

» Inspect the machine daily for potential fire hazards.

» Always ensure that excess grease and oil accumulation, including spill-
age from filling, is cleaned up immediately.

» Use only non-flammable cleaning agents for cleaning the machine or

machine components.

» Store any combustible materials in a fireproof location.

» Make sure the local fire extinguisher(s) is charged at all times and know
how to use it properly.

» Before performing any repair work such as welding, the area around the
repair location should be cleaned, and a fire extinguisher positioned
close at hand.

» Hydraulic oil is flammable. Do not weld on hydraulic tanks!

» Be cautious when smoking around the machine.

» Learn and obey all local worksite fire regulations and procedures.

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 LT-270 Service Manual

SAFE OPERATING Repairing an LHD sometimes requires operating the unit to ensure repairs
GUIDELINES were completed successfully. When operating the LT-270 safety must always
be the prime consideration. It is important that the reader learn how to operate
the machine in a safe and competent manner.

Most companies have rules regulating the use of underground machinery.

These rules will reflect any unusual local conditions and regulations and must
be obeyed. However, the following is a list of safety recommendations, which
can supplement these regulations:

» Thoroughly study the operating controls and procedures in the Opera-

tor’s manual (and decals on the unit) prior to operating the machine.

» Become totally familiar with your company’s rules governing under-

ground machinery operation at your work site.

» Always wear required protective clothing/devices; avoid wearing loose

clothing.

» Always be aware of other workers in your area of operation.

» Check gauges and indicator lights frequently to verify proper function

of all machine systems.

There are also many undesirable practices that should be totally avoided!
Examples include, but are not limited to, the following:

» Do not operate the machine under the influence of drugs or alcohol.

» Never operate the machine after a warning system has been activated or
if a warning system is inoperable or has been disabled.

These practices and others can cause severe damage to the unit. The unit can
be rebuilt, but the unwanted practices can cause severe bodily harm to you,
the operator, or to a fellow co-worker.

Always be conscientious of your actions when operating any heavy equip-

ment underground!

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 LT-270 Service Manual

SYSTEMS

This section of the manual will break down the various major power systems
of the LT-270 (hydraulic, electric and powertrain) into their individual cir-
cuits in order to explain their function. An understanding of their function
helps the service technician to troubleshoot any problems that may not be
specifically explained in this manual. For systems or circuits relating to third
party equipment, please consult the appropriate service manual.

HYDRAULIC The hydraulic system of the LT-270 is primarily concerned with boom and
SYSTEM bucket movements (dump and hoist circuits) and tramming (steering and
braking). In addition to these major circuits, the hydraulic system also
includes the pilot and load sensing systems which support the main circuits.
A single variable displacement piston pump provides power to the hydraulic
system.

Hydraulic System Settings

Pump Pressure Settings: Stand-by Pressure @ 400 psi

System Pressure @ 2700 psi
Pump Flow: 25.5 gpm @ 2400 engine rpm
LS Relief Settings: Boom Up @ 2400 psi
Boom Down @ 1450 psi
Bucket Dump @ 1450 psi
Bucket Roll Back @ 2400 psi
Steer Left & Right @ 2000 psi
Pilot Pressure: 400psi + 50 psi
Pilot Accumulator Gas Pre-charge: 90 psi ±10 psi
Brake Accumulator Gas Pre-charge: 1000 ±50 psi
Accumulator Charge Valve: Low Limit: 1800-1900 psi
High Limit: 2250-2350 psi
Charging Rate: 1.5gpm@ 1000 psi
Pressure Switches: P1 - 1600 psi Accumulator
(Brake Pending)
P2 - 1300 psi Accumulator (ABA)
P3 - 400 psi (Brake On Indicator)

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 LT-270 Service Manual

The dump/hoist and steering circuits are closed-center systems that are fed
filtered high pressure oil by the main pump. Some units may also have an
optional pilot accumulator for emergency steer situations in the pilot circuit.
In the brake circuit, the main pump charges an accumulator which feeds oil to
the brakes even in emergency braking situations.

The load sensing system controls the volume of flow produced by the main
pump in response to load demands of the brake charging valve and the steer/
hoist/dump valve. In addition, the main control valve has internal circuits
which give oil priority to steer functions first over hoist/dump demands.

Some of the major components of the hydraulic system are discussed in more
detail in the following sections.

Hydraulic Reservoir
The hydraulic reservoir of the LT-270 is used
to store oil for all of the hydraulic circuits on
the machine. The volume of oil stored in the
reservoir changes based on the function
being used. For instance when the boom is
lifted, the cylinders extend, thus requiring
more oil. The reservoir is also engineered to
act as a heat exchanger between the oil and
the surrounding air which helps keep the
hydraulic system at the correct temperature.
The hydraulic return filter is mounted
directly onto the tank.

Reservoir Breather
The reservoir breather serves sev-
eral purposes. The first purpose is
to prevent low pressure from
developing in the reservoir as this
could cause the hydraulic pump to
cavitate when drawing oil. The
breather also filters any air intro-
duced to the tank and prevents air-
borne solid contaminants from
entering. The breather’s third
function is to hold a positive pres-
sure in the reservoir when possi-
ble. The positive pressure will help force oil into the pump inlet and again
help to avoid cavitation. The pressure in the reservoir is not allowed to build
too high as the breather has a check valve that reacts to pressure much like a
relief valve.

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 LT-270 Service Manual

Return Circuit
The return circuit uses both manifolds and direct lines to bring all of the
hydraulic oil back to the reservoir. Most functions return oil via return mani-
folds to the return filter. This is where most of the hydraulic flow is used and
is therefore very important that it is filtered upon return.

All other circuits that return to the reservoir are considered drain lines. These
lines require a very low-pressure return to avoid damage to the component
they are draining. The main hydraulic pump has a case drain directly to tank.
Also note there are bypass valves built into the return filters. They allow oil
to bypass the filter in the event it becomes clogged or when the oil is cold.
The return filters must be replaced every 250 operating hours.

Hydraulic Accumulators
The standard LT-270 is equipped with two gas-charged
hydraulic accumulators. One accumulator is installed
on the brake circuit and the other is installed on the
pilot pressure control circuit.

An accumulator acts just like a battery does in an elec-

trical system. It can be filled under pressure, and it pro-
duces flow for the circuit when needed. An accumulator must only be filled
with nitrogen gas; any other type of gas may cause it to explode if oil and the
gas mixed under pressure.

Warning: NEVER fill an accumulator with compressed air or pure oxygen!

An accumulator requires a pre-charge specific to the circuit that it supplies.

Too low a charge will result in the circuit cycling too often, too high a charge
can result in other, more excessive damage to the other components in the cir-
cuit. Refer to the hydraulic schematic in the parts manual, or to “Hydraulic
System Settings” on page 7 for the proper pre-charge pressures for the brake
and pilot circuit accumulators.

If the unit were to have an engine or hydraulic system failure, the unit would
lose all hydraulic power. In this situation, an Automatic Brake Actuation
(ABA) fail-safe built into the system design would apply the brakes. If the
park brake fails to set up, the operator will still have repeated service brake
applications due to the accumulator in the brake circuit.

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 LT-270 Service Manual

Determining Brake Accumulator Pre-charge Pressure

If your unit is equipped with a brake sys-
tem pressure gauge, run the unit until the
gauge shows full brake system pressure
(A). Shut the machine off and open the
brake accumulator drain valve to achieve a
slow, steady drop in pressure, or cycle the
circuit to discharge it using the service
brake pedal. Watch the pressure gauge
drop. It will drop slowly until the accumu-
lator reaches the pre-charge pressure (B).
Once this pressure is reached, the gauge
will drop to zero psi almost instantly (C).
The last reading on the gauge just before the pressure went to zero psi is the
accumulator pre-charge pressure.

Hydraulic Cylinders
The standard LT-270 uses four hydraulic cylinders for its standard operations.
Additional cylinders may be used in optional equipment. See “Optional
Equipment” on page 98 for more details.

Each cylinder is designed to resist the effects of the underground mine envi-
ronment. All cylinders are double-acting, unbalanced types and utilize a
heavy-duty bolt-in gland. The cylinders are also protected from shock load
when their control is in neutral by individual port relief valves.

» Hoist - Two (2) cylinders

» Dump - One (1) cylinder
» Steering - One (1) cylinder

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 LT-270 Service Manual

Main Hydraulic Pump

The LT-270 uses a single hydraulic pump to power all of its hydraulic func-
tions. The pump is a variable displacement, axial piston type. This type of
pump is well suited for use in the load sensing design of this hydraulic sys-
tem. The pump supplies oil to the main control valve, braking system and the
pilot control circuit. Variable displacement piston pumps are used because of:

» High operating rpm with low noise emissions

» Good oil inlet characteristics
» Excellent choice of control options

Pump flow is measured in either gallons per minute (gpm) or liters per min-
ute (L/min.) and is proportional to pump rpm and pump displacement. The
rpm is dependant on the engine speed and the displacement is dependant on
swash plate angle.

This type of system is efficient and compact. By only pumping the required
amount of oil, less heat is generated and less fuel is burned. When the system
is on standby, the pump only produces enough oil flow for cooling and lubri-
cating. This mode produces a low standby pressure, however the pump is
ready to produce full flow at full pressure at any time.

This type of pump is also suitable for creating oil flow at pressures up to 3600
psi with little loss of pumping volume. Below is a cutaway view of the pump.

1 Pump Housing 8 Control Piston

2 Cylinder Barrel 10 Shaft Seal
3 Piston and Slipper Shoes 11 Compensator Control
4 Ported End Plate 12 Spring
5 Input Shaft 13 Stroking Plunger
6 Swash Plate 14 Valve Plate

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 LT-270 Service Manual

Operation
When the pump is not turning and there is no control pressure, the swash
plate will be forced to its maximum angle by the spring-operated stroking
plunger (item 13). As the pump begins to turn, the piston slipper shoes
(item 3) follow the angle of the swash plate (item 6), causing the pistons to
move in and out of the cylinder barrel (item 2). As any given piston begins to
move out of the cylinder barrel, it creates a void or space between it and the
valve plate (item 14).

At the same time the opening opposite of the piston on the barrel begins to
pass a kidney shaped inlet port of the valve plate, allowing oil from the reser-
voir to fill the void. The pump continues to rotate and the valve plate blocks
off the opening for that particular piston. The piston is now forced into the
barrel by the swash plate angle. At the same time the opening of the barrel for
that piston is beginning to line up with a kidney shaped outlet port of the
valve plate. The piston now forces oil out of the barrel into the outlet line of
the pump.

The stroke length of each piston determines the displacement of the pump.
The stroke length for each piston is determined by the angle of the swash
plate at any given time. Therefore the pump displacement is determined by
the swash plate angle. The swash plate angle is determined by several factors.
At maximum displacement, the swash plate is held at maximum angle by a
spring-loaded plunger and by the pressure of the oil being pumped acting on
the end of the pistons. At any other angle, the control piston (item 8) is push-
ing on the swash plate forcing it back to a smaller angle.

The hydraulic system is load-sensing. This means the pumps are able to
respond to the demands of the hydraulic system and will only supply what the
system needs. The compensator control (item 11) is responsible for this.
When a pressure signal is received from the system it causes the compensator
to adjust oil pressure to the back of the swash plate control piston. This
causes the swash plate to change angle according to the signal the compensa-
tor has received from the hydraulic system.

Pump Compensator
The pump compensator assembly
is remotely mounted on the
LT-270. It is located in the rear
frame area close to the air intake
filter (shown right). Refer to
“Hydraulic System Settings” on
page 7 for compensator values.

Compensator

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 LT-270 Service Manual

Dump/Hoist/Steer Valve
The Dump/Hoist/Steer control valve (item 10) is a stacked valve bank; each
control section is a separate module and can be replaced as such. The valve
has sections with directional control spools that control the dump, hoist, and
steer functions, an inlet section that controls oil distribution and provides
steer priority, and an end section that is used to supply oil to the pilot pressure
control system.

Incoming oil at port ‘P’ encounters the steering section compensator before
any other spool, and also satisfies the demand of the pilot pressure-reducing
valve.

The purpose of the steer compensator is critical in the sense that it will con-
trol in what order oil will be distributed to the valve sections. The steer prior-
ity valve will restrict the amount of oil going to the other sections when
steering is actuated. This ensures that the operator can steer the unit before
any other task is accomplished. On a side note, as the brakes are fed from the
pump on a separate (accumulator) circuit, the operator can also stop the unit
at all times. This tandem priority (steering and brakes) ensures that the opera-
tor is ensured safety in an emergency or system failure by being able to stop
and steer the unit.

The compensator valves in the hoist and dump sections will regulate how
much oil is delivered to each of those functions. A pilot signal from the load
sense line of each section will adjust pump flow to maintain function speed
during changing conditions. For example, the operator begins to lift the boom
while still using rollback. Normally a drop in rollback speed and slow
response on the boom lift would be seen. Instead, the two compensators,
working together, modulate oil flow to attempt to maintain the rollback speed
while accommodating the boom lift demand.

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 LT-270 Service Manual

A couple of items will govern the effectiveness of these compensator valves.

First is whether the steering is being used or the brake accumulators are
charging at this point. Either of these events will limit oil flow delivery to the
hoist/dump sections, slowing their speed. The other item is output flow of the
pump. If engine rpm is lowered (e.g. tractive effort is lugging down the
engine) or pump efficiency is inadequate, then speed will also be lowered by
these events.

The valve sections also contain port relief valves for each actuator port. Each
port relief valve can be set individually. These port relief valves will protect
the circuit from pressure spikes caused either by an internal system event, or
from pressure induced by the implement (normally a cylinder). Each section
is connected to a common load sense port through a series of shuttle valves,
to signal the pump to provide the necessary flow and pressure. All of the con-
trol sections are shifted by pilot controls and can only be shifted mechani-
cally if the end user has specified the optional design feature.

The dump/hoist/steer valve (shown below) is located in the front frame, oppo-
site of the operator. It is mounted horizontally with the pilot actuation ports
facing the outside of the machine and access able by removing the top cover
or the side cover.

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 LT-270 Service Manual

Load Sense Signal Circuit

All of the load sense components are linked to the pump via the load sense
signal circuit. Load sensing is simply a hydraulic line (or group of lines) that
sends a pressure signal from a hydraulic load to the compensator valve on the
pump. The signal is taken from a load port at a control spool, or flow control
valve. In this case it is taken from the directional control valve sections in the
main valve stack, or the brake accumulator charge valve. The pump will
receive a single load sense demand from the function that is requesting the
highest value, through a series of shuttle valves.

Load sensing, simply stated, is a function and pump working as a team. Both
the function and the pump must be considered when troubleshooting or
repairing a load sensing system.

Pump Compensator Function

The first (smaller) compensator in this design of pump control sets the
standby pressure, and regulates all requirements up to maximum compen-
sated pressure. When the hydraulic system sends a signal to the pump to pro-
vide more flow, it does this by shifting the control spool in the compensator

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 LT-270 Service Manual

valve to drain the oil in the control piston (initially using standby pressure).
This allows the spring, plunger and output flow resistance to increase the
swash angle of the pump, increasing flow. As output pressure increases, the
load sense signal will increase proportionally in an attempt to maintain con-
trol of the pump. Once desired flow is met, the spring, plunger and output
flow resistance, opposed by the load sense signal via the standby compensa-
tor spool, will increase or decrease output of the pump to maintain the desired
reaction. Changing requirements of the circuit(s) in use will cause the load
sense signal to modulate the flow and pressure as it continually signals the
pump.

The second control spool in the compensator valve controls the maximum
pressure limit of the pump. Once the pump reaches a predetermined pressure
level (set at this compensator), the spool will now seize control of the pump
output, limiting it to the preset value, regardless of demand via the standby
compensator. This prevents the pump from over pressurizing the circuit. In
essence this spool works as a safety relief, without generating the excessive
heat that a safety relief installed downstream from the pump outlet would.

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 LT-270 Service Manual

Hydraulic Pilot Circuit

To simplify control valve placement and eliminate cumbersome linkages or
cables, a hydraulic pilot control circuit is used to shift the control valve
spools. An added advantage to hydraulic pilot controls is low operator effort
on the control levers. This circuit uses hydraulic pressure supplied by a pres-
sure-reducing valve integrated into the main control valve. An accumulator
(item 22) with a 90 psi pre-charge is used to maintain flow for the system and
is only charged by the main hydraulics via the pressure-reducing valve when
necessary.
Example circuit only

The hydraulic pilot control circuit feeds two joystick controls. A two-position
joystick (item 16) is used for steering, and a four-position joystick (item 15) is
used to operate the hoist and dump functions. Both joysticks are spring-return
to center, meaning that when released, the joystick returns to the neutral posi-
tion. Note that this does not mean that the function will return to a certain
position, only that actuation will stop (e.g. the unit will not return to a straight
ahead position when released, but will remain articulated at an angle).

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 LT-270 Service Manual

Assuming the pilot system is fully charged by the main hydraulic system,
when the operator moves a control lever to actuate a function, oil is directed
through the pilot control joystick to a piston or cavity at the end of the
selected main control valve spool. This causes the spool to shift and connect
incoming high pressure from the pump to the hydraulic function. In the con-
trol spool, return oil from the function is connected to tank. When the opera-
tor releases the joystick control, pilot pressure is blocked at the joystick and
the piston or cavity of the main control valve is connected to return, allowing
the control spool springs to return the spool to center and block high oil pres-
sure from reaching the hydraulic implement.

Steering Circuit
If the operator is not steering the unit in Example circuit only
either direction then the steer joystick (item
23) is in the neutral position. In this posi-
tion, the joystick blocks pilot pressure oil
from reaching the steer section control spool
and connects any remaining pressure in the
steer circuit back to the hydraulic tank.
Inside the main valve, the steer control
spool’s middle position blocks oil from
entering or leaving the cylinder, thus main-
taining the cylinder’s position. At the same
time, the load sense pressure lines are con-
nected to tank, causing the pump to de-
stroke and return to low-pressure standby.

Steering Actuated
When the operator actuates the steer joy-
stick left or right, pilot oil is connected to
the appropriate input port (input A or B) of
the steer control section. Shifting the control
spool connects oil from the pressure port ‘P’
to the appropriate outlet port (output A or B)
and then to the steering cylinder port. This Steer Priority
causes the cylinder to extend/retract as dic- Valve

tated by the selection. At the same time oil

leaving the opposite end of the cylinder is directed back to the return circuit
through the valve spool.

The load sense signal sent from the steer control spool in reaction to the work
required by the cylinder, not only adjusts pump flow via the pump’s compen-
sator, it also acts on the steer priority valve in the pressure inlet section of the
valve. Load sense pressure felt by the priority valve, coupled with the force
of its bias spring, will shift the priority valve spool and limit the amount of oil
that can be delivered to the rest of the working sections from pressure port

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 LT-270 Service Manual

‘P’. This ensures that the steer section will have enough flow to maintain
steering capability even if other functions (e.g. hoist and dump) are used at
the same time.

The port relief remains passive unless pressure increases to their preset level,
at which time they will open, venting oil to the return circuit and thus pre-
venting damage to the circuit/components (such as in the case of outside
forces acting on the steer cylinder).

By actuating the joystick in the opposite direction, the control spool shifts in
the opposite direction and the cylinder articulates the unit the opposite way.
Everything occurs as explained above except that the ‘A’ and ‘B’ ports are
now connected to ‘P’ and ‘T’ opposite to the previous explanation. Also the
opposite port relief is now considered for protection.

Hoist/Dump Circuits
Note: As these two functions operate in an identical manner we will consider
them in one explanation.

If the operator is not extending or retracting a function cylinder, the pilot con-
trol lever is in the neutral position, blocking flow of pilot oil to the section
control spool. It also connects the pilot pistons at both control valves to the
return circuit. The control valve spool is in the centered (neutral) position and
oil from pressure port ‘P’ is blocked. The outlet lines connected to the cylin-
ders are also blocked, trapping oil in the cylinders so the cylinders should not
move. No load sense signal is being sent at this time and the pump de-strokes
to standby pressure if no other demand is present.

Note: The shock valves regulate pressure from the cylinder to the valve sec-
tion.

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 LT-270 Service Manual

Boom Hoist or Bucket Dump Actuated

When the operator actuates a function, the joystick connects pilot oil pressure
to the function’s control spool causing it to shift. This connects oil from the
inlet pressure port ‘P’ to the appropriate outlet port (A or B) of the valve sec-
tion. At the same time a load sense pressure signal is sent back to the main
pump to call for more flow in response to the load being applied.

Example circuit only

From the outlet port the oil is sent to the ports of the actuated cylinders. Oil
from the opposite side of the cylinder is connected to tank via port ‘T’ of the
main valve.

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 LT-270 Service Manual

Brake System Circuits

The LT-270 brake system performs two functions:

» It controls the speed of the machine during normal use when the opera-
tor uses the service brakes.
» It can bring the machine to a complete stop and hold it in place with the
emergency/park brakes (EPB). This can occur when the operator pushes
the EPB button or it can happen automatically with the built-in Auto-
matic Brake Actuation (ABA) systems built into the LT-270.

All brake systems use friction to slow down or stop the machine. The brake
uses friction devices at the wheel-ends of the machine, and actuating devices
in the operator compartment to control the brakes. The brake system uses a
closed centered hydraulic system, with an accumulator to operate the wheel-
ends.

The LT-270 uses hydraulically-applied, spring-released, totally enclosed, wet

disc service brakes. This type of brake is used for service brake applications.
A driveline spring applied disk brake combined with the wheel end brakes is
used for emergency and park brake application. The oil under pressure stored
in the brake accumulator applies the wheel-end brakes.

The main hydraulic pump, which features a variable displacement piston

pump, feeds the brake system in three steps:

» The main hydraulic pump feeds the brake accumulator charging valve.
» The charging valve charges the brake circuit accumulator.
» The accumulator supplies pressure to release/apply the brakes.

The brake accumulator charge valve has two settings:

» The lower charging limit (Cut-in Pressure) is set between 1800 to 1900
psi.
» The maximum charging (Cut-out pressure) limit is set between 2250 to
2350 psi.
» The charging rate is 1.5 gpm at 1000 psi.

When the accumulator pressure drops below 1800 psi, the charging valve
sends a signal to the hydraulic pump which in turn starts to produce flow. The
charging valve charges the accumulator until the pressure reach 2250 psi then
the charging valve signals the pump to stop producing flow.

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 LT-270 Service Manual

Brake Circuit Manifold

The accumulator charge valve sends oil under pressure to the accumulator
manifold. The manifold (item 18) sends oil to the brake accumulator (item 8),
the brake pedal (not shown), accumulator gauge (item 7), the bleed valve
(item 17), and the dual pressure relief manifold (not shown) which returns oil
to the tank.

The bleed valve is used to bleed off accumulator pressure when the system
requires service. It can also be used to troubleshoot the system by quickly
checking the accumulator pre-charge pressure.

Return to tank.

To Brake Pedal From Charge

Valve

Accumulator Pressure Switch Manifold

The charging valve sends the oil under pressure
to the accumulator pressure switch manifold
(item 18). Two hydraulic pressure switches are
connected to this manifold:

» P1 - The low accumulator pressure warn-

ing (Brake Pending) switch.
» P2 - The brake application (ABA) pres-
sure switch.

The low accumulator pressure switch warns the operator before the accumu-
lator pressure drops below a predetermined limit. This warning should give
the operator enough time to park the machine safely before the emergency
brakes applies.

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 LT-270 Service Manual

The brake actuation switch applies the brake when the accumulator pressure
drops below a precise pressure. The low accumulator switch is set at 1600
psi. The brake actuation switch is set at 1300 psi.

Park Brake Valve

The park brake valve (shown
right) controls the application of To brake pedal ‘PP’ port
the service and park brakes.

Note: Shown with both solenoid

valves de-energized.

The HV2A brake test solenoid

valve is energized and shifted as From
brake
soon as power is applied to the accumulator
unit via the master switch. This
solenoid can only be temporarily de-energized using the ‘Brake Test’ button;
this test allows the holding power of the driveline parking brake to be tested
by itself. Under normal operating conditions, the valve is shifted, connecting
the brake pedal’s ‘PP’ port to the brake accumulator pressure or back to tank.

When the park brake is released, the HV2B solenoid valve is energized. The
valve then directs pressure from the brake accumulator to the driveline brake.
This pressure collapses the brake springs and releases the brake. The valve
also connects any pressure at the ‘PP’ port of the brake pedal back to tank via
the ‘Mod Ped’ port, ensuring the brake pedal is not actuated.

When the operator applies the park brake, the HV2B Park Brake solenoid is
de-energized to the state shown above, and directs pressure in the driveline
brake line to tank, allowing the springs to apply the caliper and engage the
brake. It also connects the oil from the brake accumulator to the ‘PP’ port of
the brake pedal, fully shifting the spools (making the pedal inoperative to the
operator) and fully applying the service brakes.

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 LT-270 Service Manual

Modulated Brake Pedal

When the brakes are released, the oil pressure from
the accumulator manifold is blocked at the modu-
lated brake valve ‘P’ port. The wheel end wet disk
brake lines are open to the tank through the modulate
brake valve ‘A’ port to ‘T’ port, as shown below.

When the modulated brake pedal is depressed, spring

tension moves the spool downward, opening the ‘P’
port to the ‘A’ port allowing the oil pressure to reach
the wheel end brakes. The oil pressure will also apply
pressure against the bottom of the valve spools and
as spring tension at the top of the spools and the out-
let oil pressures equalize, the spools will shift back
towards their initial position, proportionally regulat-
ing the oil pressure being applied to the brake hubs.

The more the pedal is depressed, the more oil flow, under pressure, is allowed
to reach the wheel end until the pressure reaches a maximum of 1500 psi.
This will allow the brakes to be fully applied, limiting maximum output pres-
sure of the pedal.

Hydraulic Applied Wet Brakes

The wheel ends of the LT-270 LHD are a hydraulic applied spring released,
brake assembly. They are composed of rotating friction discs splined to the
wheel hub and steel plates splined to the brake housing. The brakes are oil
cooled for better performance and longer life.

Hydraulic pressure forces the discs and plates together to provide braking
force. When the oil pressure is released, the springs separate the disks from
the plates, releasing the brakes.

Charging the Brake Accumulator

When the accumulator pressure drops below the cut-in pressure, the accumu-
lator charge valve will send pressure to the load sensing port of the hydraulic
pump. The hydraulic pump will increase oil flow in response. The charge
valve will then send the oil to the accumulator via the accumulator manifold.

When the accumulator pressure reaches the charge valve cutout pressure, the
accumulator charge valve will drop the pressure in the load sensing line of the
hydraulic pump. The hydraulic pump will stop delivering flow to the accu-
mulator charge valve (de-stroke). The accumulator is now ready to deliver oil
pressure to apply and release the brakes if certain criteria are met.

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 LT-270 Service Manual

Emergency/Park Brakes Applied

Note: Any time that the Power On (key) switch is closed, power will be
applied to the Brake Test section of the brake solenoid block, keeping
it shifted. This includes when the operator applies/releases the emer-
gency brake button. The only time the brake test section will de-ener-
gize is if the operator pushes and holds the Brake Test button in.

When the engine is running, the operator can apply the emergency/park brake
system by pushing the EPB button in. This will de-energize the park brake
solenoid valve (HV2B) and its bias spring will shift the valve. At this point,
the ‘EBR’ port is connected to the tank and pressure is drained from the
driveline brake caliper, allowing the brake to apply. In addition, the ‘PR’ port
applies pressure from the brake accumulator to the ‘PP’ port of the brake
pedal, causing it apply and send pressure to the brake discs in the wheel ends,
applying the service brakes. There are now a total of five physical brake com-
ponents holding the unit in place.

Emergency Brake On, Service Brakes Released by Brake Test Section

With the emergency/park brake applied as described above, it is not possible
to test the emergency brake caliper independent of the service brakes. There-
fore it is necessary to provide a means to release the service brakes while
keeping the emergency brake applied.

To accomplish this, the operator ensures that the EPB button is in the applied
position; his foot is off of the service brake pedal, and then pushes the Brake
Test button. This will de-energize the brake test valve HV2A, allowing the
bias spring to return the spool to the normal position. This connects the ‘Mod
Ped’ port to the tank port, relieving pressure from the brake pedal ‘PP’ port,
releasing the service brakes. The emergency brake remains applied (pressure
connected to the ‘EBR’ port), and the operator can now place the transmis-
sion in SECOND gear, FORWARD or REVERSE, and bring the unit to full
throttle for five seconds to ensure that the emergency brake is functional.

Note that the Brake Test button is spring returned, so if the operator releases
the button at any time, the brake test section will re-energize and apply the
service brakes once again.

Also note that failure of the emergency brake independent of the service
brakes constitutes a failed safety system and the unit must not be operated
under this condition.

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 LT-270 Service Manual

Emergency/park Brakes Reset and Released

Note: Any time that the Power On (key) switch is closed, power will be
applied to the brake test section of the brake solenoid block, keeping it
shifted. This includes when the operator applies/releases the EPB but-
ton. The only time the brake test section will de-energize is if the oper-
ator pushes and holds the Brake Test button in.

When the engine is running, the operator can release the emergency/park
brakes by pulling the EPB button out to the “Reset” position. This will ener-
gize the HV2B park brake solenoid and shift its control spool. This connects
the ‘Mod Ped’ port to the ‘T’ port (via the shifted brake test solenoid), drain-
ing hydraulic oil from the brake pedal ‘PP’ pilot port to the reservoir, allow-
ing the brake pedal spools to return to their normal position. With no physical
or pilot pressure on the brake pedal valve, the wheel ends are connected to the
reservoir, allowing the wheel end brake springs to release the brake discs.

For the driveline brake, the ‘PR’ pressure port is connected to the ‘EBR’ port,
sending oil pressure to the driveline disk brake and P3 pressure switch. The
oil under pressure will compress the brake actuating springs and release the
driveline disk brake.

All five brakes are now released, and the operator has service brake control of
the unit.

Service Brake Applied

When the engine is running with the emergency/park brake released, the
operator can apply the service brakes by depressing the modulated brake
pedal valve. When the operator depresses the pedal, the brake valve spools
will shift to connect the ‘P’ ports to the ‘A/A1’ ports. The oil under pressure
is sent to the wheel ends of the front and rear axles to apply the service
brakes. The pressure in the A/A1 lines modulates the pedal position via inter-
nal pilot lines. The maximum pressure the brake pedal will allow in the brake
system is 1500 psi.

Service Brake Released

When the engine is running with the emergency/park brake released and the
service brake applied, the operator can release the service brakes by releasing
the modulated brake pedal valve. When the operator releases the pedal, the
modulated valve spools will shift, dead ending the ‘P’ ports and connecting
the ‘A/A1’ ports to the ‘T’ ports. The oil under pressure will be released to
the reservoir via the return manifold and the brake springs will release the
wheel end brakes. By using a modulated valve, the operator can control the
machine speed and can also stop the machine by controlling the amount of
pressure applied against the wheel end brakes.

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 LT-270 Service Manual

Brake Test Procedures

These tests of the brake systems must be performed before operating this
machine. It is also highly recommended that these tests also be performed
before entering a ramp. before starting tests, the park brake button MUST be
pushed in (applied).

Service Brake Test

With the service brake pedal depressed, release the emergency/park brakes by
pulling out the large red button labeled Park-Emergency. Place the transmis-
sion in forward or reverse 2nd gear (3rd gear for 2604). Rev the engine to full
throttle. The machine should not move. If it does, the service brakes system is
considered unsafe and the defect should be reported to your supervisor. DO
NOT OPERATE THE MACHINE!

Parking Brake Test

The large red button labeled Park-Emergency will need to be in the pushed in
position. Place the transmission in forward or reverse 2nd gear (3rd gear on
2604). Release the service brake foot pedal. Push the button labeled ‘Brake
Test’ and hold. Rev the engine to full throttle. The machine should not move.
If it does, the parking brake is considered unsafe and the defect should be
reported to your supervisor. DO NOT OPERATE THE MACHINE!

Emergency Brake Test

The large red button labeled Park-Emergency will need to be in the pushed in
position. Place the transmission in forward or reverse 2nd gear (3rd gear on
2604). Release the service brake foot pedal. Rev the engine to full throttle.
The machine should not move. If it does, the emergency brake is considered
unsafe and the defect should be reported to your supervisor. DO NOT OPER-
ATE THE MACHINE!

Note: When the Park-Emergency button is pushed in, both the parking brake
and the service brakes are applied. When the power switch to the
machine is turned off, the service brakes release leaving only the park-
ing brake holding the machine.

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 LT-270 Service Manual

ELECTRICAL The electrical system of the unit is a 24-volt self-contained system recharged
SYSTEM by the diesel-powered alternator. The major electrical circuits are the:

» “Power Circuit” on page 30

» “Charging System” on page 31
» “Starting System” on page 32
» “Lighting Circuit” on page 31
» “Brake Circuit” on page 33
» “Warning/Monitoring Circuits” on page 36
» “Transmission Shift Circuits” on page 38

Welding Procedure for Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to the
engine control modules, sensors, and associated components. When possible,
remove the control module from the unit before welding. If removal of the
module is not possible, the following procedure must be followed. This pro-
cedure is considered to be the safest procedure to weld a component and
should provide a minimum of risk of damage to electronic components.

Note: Do not ground the welder to electrical components such as the control
module or sensors. Improper grounding can cause damage to the drive
train bearings, hydraulic components, electrical components, etc.
Clamp the ground cable from the welder to the component to be
welded. Place the clamp as close as possible to the weld. This will help
reduce the possibility of damage.

To weld on an electronically controlled engine:

» Stop the engine and turn switched power to the OFF position.
» Open the master switch so that it disconnects power from the batteries.
» Disconnect the cables from the control module. Move the cables to a
position that will not allow them to accidently make contact with any of
the control module pins.
» Connect the welding ground cable directly to the part to be welded.
Place the ground cable as close as possible to the weld in order to
reduce the possibility of welding current damage.
» Protect the wiring harness and control module from welding debris and
splatter.
» Use standard welding practices to weld the materials.

Caution: If electrical/electronic components are used as a ground for the

welder, or electrical/electronic components are located between the welder
ground and the weld, current flow from the welder could severely damage the
component.

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 LT-270 Service Manual

Repair Safety Review

The following is a review of some important safety recommendations for
working on or around electrical systems or components. These are not all-
inclusive and do not replace site-specific safety regulations that pertain to the
troubleshooting, repair and maintenance of electrical systems.

» Always open master disconnect switch and/or disconnect batteries prior

to performing any electrical repair.
» Always follow correct lock out/tag out procedures for your site.
» Verify that the system is at a “zero energy state” prior to working on any
system.
» If a system must be live to facilitate troubleshooting, take the appropri-
ate steps to safeguard yourself and others.
» Never speak to, or disturb the concentration of, a person working on
electrical equipment/systems.
» Only fully trained and qualified persons should work on electrical sys-
tems.
» Care must be taken when handling the batteries; the acid contained
inside can cause severe injury or death.
» Always replace components with manufacturer-approved items.
» Use the proper tools and test equipment for the task at hand.
» Never use magnetic tools or instruments on or around electronic com-
ponents especially PLCs or control modules.
» Care must be taken if the unit requires a “boost” from another unit. Fol-
low proper boosting procedures to remove the risk of explosion or sys-
tem damage.
» Ensure that the master disconnect switch is open prior to welding any-
where on the unit. See “Welding Procedure for Electronically Con-
trolled Engines” on page 28 for more information.
» Only trained and qualified technicians should perform troubleshooting
and repairs.
» Always disconnect power prior to attempting repairs.
» A thorough understanding of the electrical system (ie. studying the sys-
tem schematic prior to attempting diagnostics) and a good quality
multi-meter are essential tools to troubleshoot and repair the electrical
system.
» Always repair the circuits to OEM standards.
» For troubleshooting/repair of PLC/ECMs refer to the service manual
pertaining to the PLC/ECM in question for technical information, and in
most cases you will require a diagnostics tool that can be connected to
and communicate with the PLC or ECM.

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 LT-270 Service Manual

Power Circuit
The power on circuit consists of:

» Master switch
» Circuit Breakers
» Terminal block

The LT-270 uses two 12-volt batteries that are maintenance-free by design.
The alternator recharges the batteries to maintain the source of the electrical
system in proper working condition.

The electrical system is equipped with a master disconnect switch which will
disconnect the battery from the system when the machine is not in use or in
case of an emergency. The master switch should always be turned off when
the unit is not in operation as this prevents the batteries from discharging. For
this reason the operator must turn the master switch off when he parks the
unit at the end of the shift. The master switch is also needed for safety. The
operator can disconnect the battery from the machine completely by simply
turning the master switch off in case of an emergency. The switch may be
equipped with an optional locking device to ease the lock out/tag out proce-
dure. They come in various styles and are simple in design and use.

The master switch will feed the electrical system when closed. A set of con-
tacts supply the main power for the electrical system via a 60-amp circuit
breaker. The circuit breaker is designed to protect the system from high cur-
rent conditions. It trips at its predetermined amperage and is reset manually.
The terminal block consists of insulated terminal connections that connect
multiple circuits to the same source. The purpose of the terminal block is to
allow different circuits to be connected to the same power source.

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 LT-270 Service Manual

Charging System
The charging system consists of an integral AC generator, cables to the bat-
tery, and a voltage regulator. The alternator features an integral solid-state
regulator that is mounted inside the alternator end frame. The regulator volt-
age is preset and cannot be adjusted. The AC generator uses one wire with an
adequate ground return to complete the electrical circuit and charge the bat-
teries. The AC generator output should be checked at the “Rated Voltage”.
The rated voltage of a 24-volt AC generator is 28 volts.

Optional Pre-Heat Starting Aid

This unit’s engine may be equipped with a pre-heat starting aid, used to warm
up the combustion chamber to start the engine easily in cold weather condi-
tions and to help prevent white smoke on cold startup. It will be actuated
automatically by a temperature sensor and the engine control module. When
the operator closes the main key switch, this sensor will actuate the pre-heat
aid for a predetermined amount of time if the ambient temperature is below a
certain point. If the ambient temperature is high enough, the pre-heat aid will
not activate.

Lighting Circuit
The lighting circuit consists of four or more working lights and is typically
divided into two separate circuits: the front light circuit and the rear light cir-
cuit. Each lighting circuit consists of:

» One 20 Amp circuit breaker

» A light switch
» Two lights

Two lights are located on the front of the unit and two lights are located at the
rear of the unit. This is the standard layout of the lights, but optional lights
may have been ordered. Power is sent to the light circuit via the Master
switch and 20 amp circuit breakers. When the operator pulls up on a light
switch on the main dash, power is sent to the appropriate set of lights.

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 LT-270 Service Manual

Starting System
The starting system consists of a 24-volt starter motor, start switch, (ST) relay
and contacts, and may incorporate an engine pre-heat system. To be able to
start the engine, the following conditions must be met:

» The master switch must be closed

» The power (key) switch must be closed
» The engine must be stopped (engine oil pressure below 12 psi)
» The brake button must be in the APPLIED position
» The transmission must be in NEUTRAL

Assuming all of the above conditions to be true, when the operator closes the
start switch, power is sent to the auxiliary start relay (ST) and to the hydraulic
unload solenoid valve HV1. The normally-open ‘ST’ contacts in the starter
circuit close and power the starter motor on the engine. Once engine oil pres-
sure rises above 12 psi, power will be removed from the start circuit and sent
to the brake circuit instead. This prevents the starter from being engaged
when the engine is already running.

At the same time, power sent to the unload valve will shift the unload sole-
noid controlled valve and dump the hydraulic pressure in the load sense cir-
cuit causing the main pump to de-stroke, which allows the starter to turn the
engine with a minimum of effort.

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 LT-270 Service Manual

Brake Circuit
The LT-270 brake circuit consists of the following components:

» The engine oil pressure switch

» The n/o transmission contacts ‘TW’
» The accumulator pressure switch
» The emergency/park brake (EPB) switch
» The start circuit’s n/o park brake relay/contacts ‘BR’
» The park brake solenoid (HV2B)
» The red ‘Park Brake On’ light
» The ‘Park Brake On’ light pressure switch
» The amber ‘Brake Impending’ light

To be able to release the brakes the following conditions must be met:

» The engine must be running and engine oil pressure must be equal to or
higher than 12 psi;
» The transmission oil pressure and temperature must reach operating val-
ues to close the n/o ‘TW’ contacts;
» The brake accumulator pressure must be equal to or higher than 1300
psi
» The park brake button must have been pulled up to the third RESET
position and then allowed to spring return to the RELEASED position.

Note: Schematic shown with switches in open/default states.

With the engine running and all components at operating values, power will
be sent to the EPB button and the n/o ‘BR’ contacts. When the EPB button is
pulled up to the RESET position, the contacts in the start and brake circuits
open and the two contacts in the brake circuit close. This powers the (BR)
brake relay and closes the normally-open ‘BR’ contacts after the brake but-
ton. After the EPB button spring returns to the RELEASED position, the

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 LT-270 Service Manual

closed ‘BR’ contacts continue to supply power to the (BR) relay and HV2B
solenoid; this keeps the circuit energized until the EPB button is pushed down
again.

The energized brake solenoid valve directs pressure in the hydraulic circuit to
release the brakes and allow the unit to move freely.

If the operator pushes down on the EPB button (brakes APPLIED position),
power is cut to the ‘BR’ contacts which in turn denies power to the (BR)
relay and to the brake solenoid as well. See “Brake System Circuits” on
page 21 for more information.

If there is a fault in any of the associated components of the brake system,

then a ‘Brake Impending’ or ‘Automatic Brake Actuation’ event may occur.

‘Brake Impending’ Circuit

The ‘Brake Impending’ warning system consists of:

» An amber ‘Brake Impending’ light on the main dash

» Transmission temperature and pressure monitoring via the (TW) relay/
contacts
» Brake accumulator pressure switch (P1)

This is a simple circuit that monitors the brake accumulator pressure and
transmission oil pressure/temperature to warn the operator that one of these
systems is reaching an unacceptable level. The amber ‘Brake Impending’
light will illuminate if the accumulator switch or transmission contacts closes
giving the operator a chance to bring the unit to a controlled stop before an
‘Automatic Brake Application’ (ABA) can occur.

The switches are set as descending pressure, meaning that when setting the
switches (if not preset), it is necessary to have the pressure(s) above the val-
ues stated on the electrical schematic, and then cause the pressure to drop at a
controlled rate. Once it reaches the value stated on your schematic, the light
should illuminate.

If the monitored pressures continue to fall below the value of the switches
found in the brake circuit, then the unit will engage the brakes automatically
(ABA) as a safety precaution.

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 LT-270 Service Manual

Automatic Brake Application (ABA)

The brake system has been designed with a feature known as ‘Automatic
Brake Application’ or ABA. This feature can, under certain conditions, apply
the emergency/park brakes without any operator input. This protects both the
operator and the machine from harm in the event of a failure in one of the
unit’s vital systems.

The ABA system consists of:

» The engine oil pressure switch in the start/brake circuit

» The transmission oil pressure/temperature monitor system in the brake
circuit
» The brake accumulator pressure switch in the brake circuit

If any of these pressure switches were to open due to a failure in their moni-
tored system then power to the brake circuit would be interrupted. In the
same way as if the operator had pushed down on the EPB button, the (BR)
brake relay loses power which opens the brake relay contact and removes
power from the brake solenoid. In the hydraulic circuit, the solenoid valve
shifts to its normal position and causes the brakes to apply.

This event can occur at any time that a monitored parameter drops to an unac-
ceptable level.

Warning: The ‘Brake Impending’ light on the dash is designed to warn the
operator that an ABA is imminent. However in the case of a cata-
strophic failure, the operator may not have time to heed the warn-
ing and the brakes will self-apply suddenly.
For this reason it is important that the operator always remain com-
fortably in the operator’s seat/area and utilize the seat belt, if so
equipped.

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 LT-270 Service Manual

Warning/Monitoring Circuits
The LT-270 is equipped with several warning and monitoring circuits. These
circuits will be examined individually in this section.

Horn Circuit
Pressing in the horn button will send power to the horn via the closed ‘Horn
Override’ button, sounding the horn until such a time as the operator releases
the horn button. The button is spring-return so releasing will allow it to return
to its normally-open state.

Monitor Circuits
The exact configuration of system monitors depends on customer and work-
site requirements. The monitoring gauges can include:

» An hourmeter
» A voltmeter
» An engine temperature gauge/sender
» A transmission temperature gauge/sender
» An engine pressure gauge
» A transmission pressure gauge
» Other parameters based on engine manufacturer

The hourmeter tracks the number of hours that the engine has been running.
As soon as the engine is running the hourmeter is powered and will continue
to track engine hours. The panel fan and heater located in the main dash are
powered at the same time as well; these items function to keep moisture from
the main dash.

Senders connected to the engine and transmission activate the temperature

gauges. The senders are calibrated with the gauge to provide an accurate
reading of the component operating status.

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 LT-270 Service Manual

Fire Suppression Switch

The fire suppression pressure switch is installed in the fire suppression actua-
tor circuit and it will open when nitrogen pressure from the propellant bottle
is sent to the suppressant tank. Opening this switch will disconnect the power
feeding the engine control module, causing the engine to shut down. It is a
safety feature and should never be disconnected or rendered inoperable for
any reason!

There are two designs of switches that may be used on your unit; one auto-
matic resets in the case of its having been actuated, while the other has to be
reset manually. Determine which type has been installed on your unit so that
in the event that the fire suppression has been activated, you will know if it is
necessary to reset this switch manually or not to restart the diesel engine.
Also note that the first type that automatically resets cannot return to its n/c
state until such a time as all pressure is removed from the actuation circuit. It
will be necessary to pull the manual ring on the safety relief located on the
actuation side of the fire suppression propellant canister to ensure all pressure
has been vented from the actuation lines. It is recommended that you perform
this function, regardless of which type of switch is used on your circuit.

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 LT-270 Service Manual

Transmission Shift Circuits

The unit uses solenoid valves to shift the transmission. When shifted, these
solenoids direct transmission oil pressure to the appropriate clutch pack(s) to
engage the various directional/gear ranges.

Power is fed to the shifter tower from the Power (key) switch. The design of
the shifter is such that there is always a speed range selected. There is no neu-
tral position for the speed range selector lever. The speed range that the oper-
ator selected last will have the switch closed, sending power to the
appropriate solenoid. By selecting a different gear range, the selected switch
will close and the previously selected range switch will open.

The direction lever has three positions. The centre position is NEUTRAL. In
this position both the forward and reverse switches are open and the transmis-
sion is in NEUTRAL, and whichever speed range is selected.

Moving the lever to either the FORWARD or REVERSE position will close
the appropriate switch, energizing the correct solenoid to accomplish direc-
tional engagement.

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 LT-270 Service Manual

Electrical Maintenance Procedures

Visual Inspection: (engine not running)
A visual inspection of the machine should be performed at the beginning of
each service interval. Make sure the master switch is in the OPEN position
and then walk around the unit paying attention to the wiring harnesses where
they are exposed, and check lights for damage. Check the wiring harnesses
for damage, looseness or fraying. Pay particular attention to the starter and
alternator; they must be properly secured and in good condition and the elec-
trical connections should be tight.

Check Engine Belts

Included in the visual inspection at the beginning of the shift should be the
engine belts. Before inspecting the belts be sure to open the master switch
and put the proper protection tag on the unit to prevent accidental engine
starting that could result in serious personal injury. Visually check all belts
for proper tension and check the condition of the belts looking for cracks or
for frayed and broken cords. If any worn or damaged belts are found they
should be replaced to avoid a battery discharge problem or possible damage
to pulleys.

Warning: When making these checks, always ensure the master switch is in
the OPEN position, to prevent the engine from cranking.

Note: Newly installed belts require re-tensioning after 15-30 minutes of

operation.

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 LT-270 Service Manual

POWERTRAIN The powertrain of the MTI series LT-270 is designed to multiply the torque
output of the engine and transmit it through an arrangement of drivelines and
gears to the drive wheels. The power from the engine is sent directly from the
engine’s flywheel to the torque converter. From the torque converter it is
transferred to the transmission through a driveline. From the transmission a
series of drivelines drive the axle differentials and eventually the wheel ends.
The transmission provides the forward and reverse gears that are manually
selected by the operator.

Air Cleaner Radiator

Engine

Exhaust

Front Axle Transmission Rear Axle Torque Convertor

Dana is the manufacturer of the transmission and torque converter that is used
in the LT-270 LHD. The torque converter is a C270 model and the transmis-
sion is a series T20000. These two components transmit the engine power to
the differentials via the drivelines, where it is then transmitted to the wheel
ends.

The same hydraulic system is used to operate both the torque converter and
transmission, so it is necessary to consider both of these components in the
diagnosis of any power transmission problems.

The following explanation pertains to the MTI installed portion of the Trans-
mission/Torque Converter hydraulic circuit. For information on the systems
integral to the Dana components, see the appropriate Dana service literature.

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 LT-270 Service Manual

Transmission/Torque Converter Circuit

Oil is drawn from the transmission sump by the charge pump and delivered to
the pressure-regulating valve via the high-pressure transmission filter (item
10). The transmission filter removes contaminates from the oil that could
possibly harm the system. It must be changed as outlined in the preventative
maintenance sheets.

The pressure-regulating valve controls the oil pressure being delivered to the
torque converter (item 9), and also feeds the distribution manifold (item 5)
that feeds the transmission (item 7), shifter block (item 8) and pressure switch
manifold (item 2).

(1) Oil cooler (7) Transmission

(2) Pressure switch manifold (8) Shifter manifold block
(3) Transmission fill (9) Torque converter
(4) Trans./Torque breather (10) High pressure filter
(5) Distribution manifold (11) Scavage/charge pump
(6) Torque convertor vent

Oil passing through the torque converter will be sent through the oil cooler
(item 1) and returned to the transmission sump. There is also a gravity drain
hose that returns case leakage oil from the torque converter to the transmis-
sion sump. The configuration and routing of this hose must not be altered at

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 LT-270 Service Manual

any time as it has been taken into account during the design process to ensure
adequate drainage of the torque converter.

To control the transmission shifting, a five-section solenoid block has been

added. There are the necessary connections to supply this block with pressur-
ized oil, return to transmission sump, and the necessary directional and gear
range signal lines. They all connect directly to the appropriate port on the
transmission control valve.

A remotely mounted filler neck allows replenishment of the transmission

sump level. A single breather vent (item 4) is used to vent both the transmis-
sion and torque converter.

Checking Circuit Fluid Level

To check the sump level, start the unit, bring the oil to operating temperature,
place the transmission selector in NEUTRAL and open the petcock located on
the opposite side of the unit from the operator. The oil should be at this pet-
cock level.

Transmission Pressure Switches

The monitor manifold has two switches attached to it that read the transmis-
sion control/clutch pack pressure. One is a 60-psi (descending) switch and the
other is a 100-psi (descending) switch. They monitor the transmission pres-
sure and perform various functions depending on the electrical circuit config-
uration of your unit. For exact functioning of these switches, see the electrical
section of this manual.

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 LT-270 Service Manual

Fuel System
A manual shut-off valve (item 8) installed in the suction line allows the fuel
to be shut-off near the tank (item 9) in case service is required in the fuel sys-
tem. Ensure the shut-off valve is opened once the unit is ready to return to
service. If necessary, the manual primer pump (item 6) may need to be used to
prime the fuel lines after servicing.

(1) Overflow valve & restrictor

(2) Mechanical injection pumps (4)
(3) Fuel return
(4) Primary filter (supplied with
engine)
(5) Rotary fuel pump (v-belt driven)
(6) Manual priming pump
(7) Fuel/water separator
(8) Shut-off valve
(9) Fuel tank

The fuel is drawn from near the bottom of the fuel reservoir via a suction tube
and then through the primary fuel/water separator (item 7) by the fuel pump
(item 5). The fuel then goes through the fuel filter (item 4) at the engine.
When the fuel enters the inlet, it will now supply the injectors (item 2) with
pressurized fuel. An overflow valve regulates the fuel pressure being felt by
the injectors and sends excess fuel to the reservoir via the return circuit (item
3). The fuel outlet from the engine connects directly to the reservoir. The res-
ervoir incorporates a second tube to ensure that the return fuel is directed as

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 LT-270 Service Manual

close to the bottom of the reservoir as possible, preventing aeration of the

fuel.

The reservoir provides storage area for the fuel necessary to run the unit and
provides cooling of the fuel that has passed through the circuit and has
absorbed heat from the engine and pressurization, etc. The walls of the reser-
voir allow this heat to be transferred directly to atmosphere. For this reason
the reservoir should be kept as clean as possible to allow transfer of heat. The
reservoir also provides connection points for the suction and return circuits. It
is a non-pressurized reservoir with a filler neck that has a snap-closed cap
attached to it to allow replenishment. A breather vent allows air to be drawn
and expelled from the reservoir as necessary to ensure a pressure or vacuum
is not created within the reservoir. A suction tube located in the reservoir
allows fuel to be drawn from the bottom of the tank below fluid level. This
tube must be maintained in good condition to ensure that no air can be drawn
into the suction circuit. If a suction leak is suspected and no fault external to
the reservoir can be found, then it will be necessary to pressure check from
the suction connection point to the end of this tube.

The fuel/water separator will remove larger contaminates from the fuel, and
provide a means of separating water from the diesel fuel. The bottom of the
filter is the separator section and incorporates a manual valve that can be
opened to drain off the water that has been trapped by this section. It should
be visually checked for the presence of water during the operators walk
around inspection, and any water present drained off. A hose may have been
attached to the bottom of the water separation section to ensure that drained
water/fuel will be directed below the rear frame and to the ground. This will
ensure that any fuel that drains with the water will not be present in the rear
frame area where it could possibly create a fire hazard. Always ensure that
the drain hose is present and does indeed direct the drained fluid outside the
rear frame to ground. The filter element itself is to be changed at the regular
service intervals (see scheduled maintenance tables) or sooner as necessary.

The secondary filter removes very fine contaminates from the fuel as it is
directed to the fuel inlet of the engine. This filter must be replaced at regular
service intervals (see scheduled maintenance tables).

The return circuit is a low-pressure system that connects the fuel outlet point
of the engine flow to the reservoir. The return circuit must be kept as restric-
tion free as possible to allow the fuel circuit to do its job properly. Of prime
importance is that the fuel return tube inside the reservoir remains in good
condition as this component prevents aeration of the fuel as it enters the res-
ervoir. If aeration of the fuel is suspected, and no fault external to the reser-
voir can be found, the reservoir must be drained and this tube pressure
checked between the connection point and the tube end to ensure integrity of
the tube.

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 LT-270 Service Manual

MAINTENANCE PROCEDURES

This section of the manual provides a general overview on the assembly/dis-

assembly and maintenance of major components and assemblies for the unit.
For specific technical information that may be required in addition to that
provided here (for example additional torque values for specialty assemblies
or fasteners), contact your MTI representative who can provide the necessary
technical assembly schematics.

The outlines provided in this section will provide assembly/disassembly and

maintenance procedures. See “Safety Information” on page 2 and “Safe
Working Practices” on page 45 for MTI safety recommendations and apply
them as necessary to any component repairs or maintenance.

Some third-party components may have their own maintenance manuals and
hence may only be referenced in this manual. These manuals can be found in
their own section after the main body of the MTI Service manual.

SAFE WORKING Safety must be the prime consideration when performing all of the proce-
PRACTICES dures in this section. The general safety guidelines for performing the tasks
are listed here. They are, however, not all-inclusive and must be reviewed and
approved by your site’s maintenance/safety departments.

» Follow the five-step safety system at all times.

» Practice site-specific fire prevention practices.
» There are many potentially hot components and systems on the unit, be
aware of their presence and guard against them at all times. Be aware
that many of them (e.g. hydraulic circuits) remain hot for some time
after the unit is shut down and this fact must be taken into account prior
to working on certain circuits/components.
» Practice site-specific lifting practices. Do not lift any items over 40 lbs
(18 kg) manually. Instead use an approved lifting device with the proper
rigging required to perform the lift.
» Many of the procedures listed will require a movable lifting device to
perform them safely. Ensure that you use this type of lifting device
whenever it is required by the task at hand.
» Properly inspect all lifting devices and rigging prior to their use. Never
use damaged or worn rigging; render them unusable and dispose of
them as necessary.
» Always be aware of pinch points and guard against them. This includes
those created when lifting/maneuvering parts during disassembly/
assembly.

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 LT-270 Service Manual

» Use only proper tools designed to perform the task at hand. Never use
power or hand tools that were not specifically designed to perform a
function, including “home made” tools, or tools that have been altered
from their original design.
» Always wear the necessary personal protective equipment as dictated
by the task, including but not limited to; safety footwear, hardhat, hear-
ing protection, full length sleeves/legs on your outerwear, and gloves to
protect your hands. Additional items may be required as necessary.
» Never wear loose clothing or jewelry that may be caught in moving/
rotating parts of the unit.
» Use extreme caution when working around moving/rotating parts.
» Perform repairs of the unit on solid, level ground.
» If a machine part has to be raised off the ground, properly block under-
neath it in your site’s prescribed method.
» Never work or pass directly under a suspended load.
» Never weld on fluid reservoirs; liquids contained within are flammable.
» Lock out, tag out, or otherwise prove all potential sources of energy
prior to beginning a task.
» Deplete or secure all potential energy sources prior to beginning a task
including, but not limited to: accumulated hydraulic pressure or air
pressure, supporting of cylinders that may move, etc.
» Ensure that other personnel cannot be placed in harms way by any of
your actions or work methods.
» Do not allow other personnel into the work area unless necessary.
» Do not smoke when working around flammable liquids.
» Never operate or repair the unit unless you are fully trained and quali-
fied to do so.
» When necessary to perform the task safely, get assistance from others.
» Tighten all fasteners to the proper torque specification. Specialty item
torque specifications can be obtained from your MTI representative by
requesting the appropriate assembly schematic.

Always take the time to ensure that the task can be done safely! Never
sacrifice the safety of yourself or others for the sake of getting a job done
faster!

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 LT-270 Service Manual

FLUID There are a variety of vital fluids used on the LT-270. To avoid the potential
SPECIFICATIONS damage caused by incorrect use of fluids, this section will detail the specifi-
cations for the various oils and fluids used on this unit. The following sec-
tions will provide the following information:

» Type of fluid used for each system (as specified by the manufacturer of
each component).
» The location of the fluid’s filler device.
» The location of the fluid’s monitor (sight gauge, dipstick, etc.)
» The location of the fluid’s reservoir.
» Any precautions required when adding fluids to the unit.

COMPONENT RECOMMENDED FLUID QUANTITY

Engine Fuel Ultra-low sulphur diesel 129 liters [34 USG]
(BF4M2012C) fuel meeting the follow- (tank capacity)
ing specifications:
DIN EN590; BS2869:A1
and A2; ASTM D975-
88:1-D and 2-D; NATO
F-54 And F-75.
Engine Coolant Minimum: 12.5 liters [3.3 USG]
(BF4M2012C) 35% Deutz protectant to
65% water
Maximum:
45% Deutz protectant to
55% water
Engine Oil Essolube 15W-40 10 liters [2.6 USG]
(BF4M2012C)
Torque / Transmission Oil Essotrans-30 Transmission: 18.9 liters
(components only)* [5 USG]
Axle Oil SAE 85W-90 14.6 liters [3.9 USG]
Hydraulic Oil Essolube 15W-40 ~97.3 liters [~25.7 USG]
(tank capacity)
Pivot Joint Lubrication Good quality EP grease As required

*Maintain oil level to upper level petcock on transmission.

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 LT-270 Service Manual

Diesel Fuel
Care must be taken to
ensure that the system is 2
kept clean at all times. As a
good general practice:

» Check the fuel level

via the three sight
glasses (item 1) before
filling. Do not overfill.
1
» Ensure that the filling
nozzle on the fuel con-
tainer is wiped clean
and is free of material
that could enter the
fuel tank.

» Ensure that the area

around the filler cap (item 2) on the fuel tank is clear of contaminants,
and that the screen in the filler neck is in good condition.

» Clean up any spills once the task has been completed and dispose of
rags or absorbents used in the cleanup in your company's prescribed
manner.

See “Fluid Specifications” on page 47 for fuel capacity and specifications.

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 LT-270 Service Manual

Hydraulic Fluid
Hydraulic fluid is added to
the system by a filler pump.
Any time hydraulic fluid is
added to the system, make
sure to clean up any spills
that might occur and dispose
of cleanup materials in your
company’s prescribed proce- 1
dure.

As a general rule use the fol-

lowing procedures:

» Before filling, check

the level of oil on the
sight glasses (item 1) on
the side of the tank.

» Make sure that the end

of the suction hose is
wiped clean.

» Make sure the suction and transfer hoses are in good condition and do
not leak.

» If filling when oil is cold, take care not to overfill as the fluid will
expand once warmed up to operating temperature.

See “Fluid Specifications” on page 47 for hydraulic oil capacity and specifi-
cation.

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 LT-270 Service Manual

Transmission Fluid
The transmission sump is the reservoir for the trans-
mission and torque converter fluid because the two
systems are interconnected. The transmission and
torque converter hydraulic system is designed with
very close tolerances and therefore must be kept very
clean. The filters should always be changed as per
maintenance schedules for longer transmission and
torque converter life.

Maintenance checks include:

» Check the fluid level daily via the transmission

petcocks. Fluid level should be measured only
after the unit has been warmed up (oil tempera-
ture between 180 to 200°F) and engine running
at idle (500 to 600 rpm).

» Transfer fluid from a clean container into the filler neck (shown above).
Add until fluid reaches the upper petcock with oil at operating tempera-
ture.

Note: It is recommended that filter elements on the transmission circuit be

changed after 50 and 100 hours of operation on new and rebuilt or
repaired units.

Every 500 hours change oil filter element. Every 1000 hours drain and refill
system as follows:

» Drain transmission with oil at 150 to 200°F. Remove sump screen and
clean thoroughly. Replace screen into transmission with new gaskets.
» Drain oil filter. Remove and discard filter element. Clean filter shell and
install new element. Replace filter.
» Refill transmission to lower petcock level. Run engine on idle to prime
converter and hoses. Recheck level and add to lower petcock. When oil
is at operating temperatures make final level check and bring oil to
upper petcock level.

See “Fluid Specifications” on page 47 for transmission system fluid specifi-

cations and capacity.

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 LT-270 Service Manual

Engine Oil
The engine oil is stored in the engine sump, and from there it is circulated to
all the various parts that require lubrication by the pump. As a general rule
use the following procedure for ensuring proper engine oil levels:

» Ensure the unit is parked on level ground.

» If machine is running, shut down engine and allow oil to drain to the oil
pan before checking oil level.

» Remove the engine oil dipstick and wipe with a clean, non-fibrous
cloth.

» Insert it back into the engine, all the way to the stop and remove.

» Check oil level on dipstick. If necessary, top up to the “FULL” indicator

via the oil filler cap on top of the engine.

Note: Operating the engine when the oil level is above the “FULL” mark
could cause the crankshaft to dip into the oil. The air bubbles created
by this action reduces the oil’s lubricating characteristics and could
result in loss of engine power. If engine is accidently over-filled, drain
off some of the oil so that the dipstick indicates the oil level is in the
proper operating range.

» Replace dipstick in engine before starting.

See “Fluid Specifications” on page 47 for engine oil capacity and specifica-
tions.

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 LT-270 Service Manual

Engine Coolant
The cooling system on this unit is
external to the engine and features a
fan-cooled radiator and surge tank. The
surge tank provides a protected cham-
ber for engine coolant to expand or
contract based on operating conditions
and has a filler cap to allow introduc-
tion of coolant into the system. There is
a sight gauge located on the surge tank
which shows the current levels of cool-
ant. The surge tank is located in the
rear frame of the unit, in front of the
engine. (1) Rad cap 15 psi (closed)
(2) Engine vent line
Filling the Cooling System (3) Cold fill level (3.3 US gallons)
(4) Liquid level sight gauge
To add coolant to the cooling system: (5) Rad fill line
(6) Level switch
» Remove the filler cap located on (7) Radiator vent line
the top of the surge tank.

» Pour the correct coolant into the tank; the coolant will flow from the
tank into the radiator, through the crankcase into the cylinder head and
back to the tank.

» Install filler cap.

» Run motor until it warms up to operating temperature.

» Recheck fluid level and top up as necessary.

See “Fluid Specifications” on page 47 for engine coolant capacity and speci-
fications.

Warning: DO NOT remove the cap immediately after running the engine as
the surge tank may contain extremely hot liquid. Wait until the
coolant system has dissipated heat before opening the filler cap!

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 LT-270 Service Manual

Axle Fluid
The oil level in the axle differential must be checked independently of the oil
levels in the planetary reduction assemblies. The filling, draining, and check-
ing points are shown in the diagram below. Note that for the wheel end plane-
tary assemblies, the same point is used for filling, draining, and checking the
oil level. The wheel must be rotated in order to have the check point at correct
position for the different service [Link] draining axle components,
allow enough time for housings to drain completely.

Oil filling plug

Oil draining plug

Check level plug

Checking and Filling Differential Oil Level
To check oil level in axles with differential drive and planetary wheel ends,
the axle should be run first, then allowed to stand for a minimum of five min-
utes on level ground. This procedure will allow oil to drain back to its normal
level.

After the five minute interval proceed as follows: remove oil check plug in
differential housing for oil level inspection. If oil level is not to the bottom of
the check hole, add necessary lubricant via the filling hole.*

Checking and Filling Planetary Wheel Ends

Check wheel end lubricant level with wheel hub oil level plug in the position
shown above (item 2). Remove oil level plug. If lubricant is below oil level
hole, rotate tire and fill to proper level.* Reinstall plug.

* When filling the axle housing, planetary wheel ends and brakes, allow
enough time for lubricant to flow through the various components in the dif-
ferential, planetary housing and brake assembly. After filling, allow a few
minutes for oil to attain its level and re-check. Add oil if necessary.

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 LT-270 Service Manual

Draining the Axle Center and Wheel Ends

Draining is best accomplished immediately after the unit has operated a short
time or completed a trip. The lubricant is then warm and will flow freely,
allowing full drainage in minimum time. This is particularly desirable in cold
weather.

Remove plug at bottom of axle housing and allow sufficient time for lubri-
cant to drain. With planetary wheel ends, rotate wheel until filler hole is
down. Remove plug and allow sufficient time for draining. Be sure planet
cover oil level hole is in proper position when refilling wheel ends.

See “Fluid Specifications” on page 47 for axle oil capacity and specs.

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 LT-270 Service Manual

Pivot Point Lubrication

The LT-270 has many moving parts and pivot points, which results in the
wear of metal on metal. Without proper lubrication these pivot points would
wear out prematurely resulting in early replacement of parts such as pins and
bushings.

This unit has a central grease manifold that lubricates all grease points except
for the dump cylinder rod end pin. On a daily basis the operator should apply
grease at the dump cylinder rod end pin. The mechanic should grease this
same pivot point at every service or whenever they are working on the unit,
as well as checking and greasing the U-joints at every service.

Components requiring daily lubrication can be found listed below. The fol-
lowing points need to be greased at the beginning of each shift. Each grease
point receives two (2) shots of grease.

Note: There may be other pivot points with greasing requirements not cov-
ered by the remote grease circuit. Ensure these pivot points are greased
as well!

Grease points on the Front Frame Assembly

» Upper L/H Boom Pin
» Lower R/H Hoist Pin
» Front Steer Cylinder Pin
» Upper R/H Boom Pin
» Lower L/H Hoist Pin
» Upper Dump Cylinder Pin
» Pillow Block Bearing
» Lower Articulation Pin

Grease points on the Rear Frame Assembly

» Front Trunnion
» Rear Trunnion

Be careful of over greasing; not only does it waste grease, it also collects dirt
unnecessarily and requires extra cleaning to remove. If you are responsible
for greasing the universal joints be certain to use only a hand operated low-
pressure grease gun and operate the handle very slowly so as not to damage
the bearing cap seals.

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 LT-270 Service Manual

PERIODIC This section will outline MTI’s recommended actions for periodic preventa-
MAINTENANCE tive maintenance. Each service period will have its goals outlined in chart
CHARTS form for ease of checking and reading. It is the responsibility of the customer
to review and revise these recommended checks as required based on work-
site rules and regulations.

Note: Recommended service intervals are based on typical working condi-

tions. The customer’s worksite conditions may influence the frequency
of these intervals (i.e. how often filter elements need to be changed).

Period: Every 8 Service Hours (Daily)

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 8 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Perform ‘Pre-start Check’ from Operator’s Manual
OK Serviced Item Service By
System fluids - Check level / replenish as necessary
Indicators & gauges - Inspect for proper operation
Greasing - Grease all check points
Walk around inspection - Leaks / damage / loose components
- Proper operation of lights
- Tire wear / pressure - 80 psi
- Wheel fastener torque - 330 ft-lbs)
- Drain fuel/water separator
- Check pins and pin guards for damage
/ wear / torque / lubrication
Safety equipment - Fire suppression and related
(if installed) - Back-up alarm
- Seat belt
- ROPS and fasteners
- Check horn operation
Emergency and Service - Test function before machine
Brakes operation
Expander Pin Installations
If an expander-type pin has been replaced the torque needs to be re-checked
after 1 hour, 3 hours, 10 hours (or 1 day) and 40 hours (4 days) of operation
regardless of the existing service schedule. After this initial re-checking
period, the torque can be re-checked at regular servicing periods.

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 LT-270 Service Manual

Period: Every 250 Service Hours

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 250 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Prior to performing this service, complete all previous timed services.
FILTER LIST
PART NUMBER DESCRIPTION QUANTITY STOCK #
See Parts Manual Engine oil filter
See Parts Manual Engine air filter primary
See Parts Manual Engine air filter secondary
See Parts Manual HP Hydraulic filter element
See Parts Manual Hyd. Return filter element
See Parts Manual Engine fuel pre-filter
See Parts Manual Fuel / Water sep. element
See Parts Manual Transmission filter
See Parts Manual Engine belt(s)
Note: The following information may be from operation / maintenance /service manuals. Refer
to those publications for safety messages, additional information and procedures to per-
form these functions.
Utilize lock out procedure: install steering lock bar & wheel chocks.
250 Hour Checks Done OK or X
by: (See note)
Record location of leaks
Steam clean complete unit - remove all covers
Check seat cushions, suspension and seat belt operation
Check operation of throttle, transmission controls, dump / hoist con-
trols and steering controls
Horn operation
All gauges
Warning system(s)
Perform brake test and record results (2nd gear, full throttle)
Service brake operation
Park brake operation
Check steering cylinders and pins for condition

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 LT-270 Service Manual

Check steering and hoist/dump stop blocks

Fire extinguisher & brackets
Fenders, hoods, and grill
Check oil level in front axle
Check oil level in rear axle
Check wheel fastener torques - all tires: 330 ft-lbs
Check rim condition
Tire pressures: Front: 80 psi
Tire height and groove depth: L/F R/F L/R R/R
Tire brand #5: L/F R/F L/R R/R
Engine oil psi: Idle: High idle:
Transmission clutch pressure (250 psi ±)
Brake system: Kick in (1800 to 1900) / Kick out (2250 to 2350)
Steering load sense relief pressure - 2000 psi
Boom Down/Bucket Dump load sense relief setting - 1450 psi
Boom Up/Bucket Rollback load sense relief setting - 2400 psi
System Pressure - 2700 psi
Pilot system / standby pressure - 400 + 50 psi
FRAME Done OK or X
by: (See note)
Inspect all grease lines and manifolds
Inspect all hoods and grab handles for damage
Check for damage, cracks (record locations)
Check condition and mounting of side cutters
Inspect boom for cracks (record location)
Inspect boom and quick attach pins & bushings
Inspect articulation pins for wear
DRIVE TRAIN Done OK or X
by: (See note)
Check axle oil levels (2)
Remove & clean differential breathers (2)
Check axle assembly for leaks
Check axle mounts for cracks, wear, and mounting torque (740 ft-lbs)
Inspect all U-joints for play and bolt tightness
Check hanger bearings for play and bolt tightness
Grease all drive lines and hanger bearings

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 LT-270 Service Manual

Check transmission oil level

Check tightness of transmission mount bolts
Remove & clean transmission & torque converter breather
ENGINE Done OK or X
by: (See note)
Change engine oil and filters and take sample
Change air filters and check housing
Check all air intake pipes for leaks
Inspect engine area for any fuel or oil leaks
Check all belts for tightness and condition
Check bell housing / engine frame support for cracks (110 ft-lbs)
Check torque & hydraulic pump for leaks and mount bolt tightness
Check engine mounts, rubbers and bolts (110 ft-lbs)
Check exhaust system, mounts & for leaks
ELECTRICAL Done OK or X
by: (See note)
Check inside of dash for loose or missing parts
Check for frayed, bare or loose wires
Clean battery terminals and connections
Test battery specific gravity (if applicable)
Inspect all switches and connections
Inspect starter and alternator mountings and wiring
HYDRAULIC Done OK or X
by: (See note)
Check all valves for leaks and mountings
Inspect all cylinder for leaks and mountings
Inspect dump cylinder hoses for burst protection (nylon/plastic
sleeve)
Check dump/steer/hoist cylinder swivel fittings for leaks
Boom lower speed
GENERAL Done OK or X
by: (See note)
Check overall appearance of machine
Test drive

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 LT-270 Service Manual

Period: Every 500 Service Hours (3 Months)

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 500 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Prior to performing this service, complete all previous timed services.
OK Serviced Item Service By
Engine - Pre-heat - Check operation repair/replace as
required
Engine - Motor mounts - Check condition, re-torque as required
and bolts
Engine - Valve clearance - Check & adjust per manufacturer’s
specifications
Engine & Transmission - Check for proper operation of senders,
Monitoring system lights, etc.
Transmission & Axle - Check condition, re-torque bolts as
mounts required
Portable fire - Have charge inspected by qualified
extinguisher personnel
Axle assemblies - Grease axle shaft bearings
Articulation joint - Re-torque as required
expander pin bolts
Hydraulic system - Replace filter elements

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 LT-270 Service Manual

Period: Every 1000 Service Hours (6 Months)

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 1000 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Prior to performing this service, complete all previous timed services.
OK Serviced Item Service By
Transmission oil - Change oil
- Clean suction strainer
Hydraulic fluid - Change fluid
- Change filter element
Hydraulic system hoses - Check all hoses for leaks, rubbing or
damage to cover
Axle assemblies - Change lubricant
Service and Park Brakes - Check for proper operation and
condition
- Check for wear and damage
Axle oscillation - Check for proper lubrication, possible
bushings wear
& bearings
Wheel rims - Check for damage or cracks
- Check torque on all wheel fasteners
Fire suppression system - Conduct semi-annual inspection as per
manufacturer’s procedures

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 LT-270 Service Manual

Period: Every 2000 Service Hours (Annually)

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 2000 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Prior to performing this service, complete all previous timed services.
OK Serviced Item Service By
Axles & planetaries - Change lubricant
Engine cooling system - Drain and change coolant
Engine - fuel injectors - Remove & test cracking pressure, spray
pattern
Engine - compression - Test & record compression
Engine - starter motor - Remove starter, check condition and
operation
Engine - alternator - Check condition and operation
Battery - Check condition and operation
- Remove & load test, clean terminals
- Fill if needed, using distilled water only
Hydraulic system - Check all relief valve settings, reset as
required
Catalytic exhaust - Check operation condition per
conditioner manufacturer’s specifications
Hoist, dump, steering, - Check for proper contact, repair or
stop blocks replace as required

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 LT-270 Service Manual

Period: Every 4000 Service Hours (2 Years)

Preventative Maintenance Inspection Order
DATE: UNIT#:
EQUIPMENT: LT-270 PM TYPE: 4000 Hours
DATE ISSUED: DATE COMPLETED:
LOCATION: HOUR METER READING:
Prior to performing this service, complete all previous timed services.
OK Serviced Item Service By
Engine - compression - Test & record compression
- Conduct leak-down test
Engine - inspection - Remove & bench test injection pump
pump
Engine cooling system - Drain, flush & service cooling system
- Check engine thermostat operation
Transmission - Check all clutch pressures, per
manufacturer’s specifications
Transmission oil cooler - Drain & reverse flush
Center pins & bushings - Inspect/overhaul as required
Torque converter - Check charge pressure
- Leakage flow rate
Hydraulic reservoir - Drain, remove, clean out covers. Suction
strainer, remove contaminants, clean and
refill
Planetaries - Disassemble, inspect & repair as
required
Axle oscillation - Inspect/overhaul as required
Bushings & bearings - Inspect/overhaul as required
All machine frame - Inspect all welds & members for cracks/
members damage

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 LT-270 Service Manual

BOLT TORQUE The following torque charts are for fasteners that are lightly lubricated on the
CHARTS threads. If the fasteners are heavily coated in oil subtract 10% from the torque
values in the chart. If the fasteners are to be installed dry add 10% to the
torque value. If the fastener size is not known, measure the fasteners as
shown in the illustration.

Amount of threads in 1”

X Dimension = (Example 1/2”)

Pitch

X Dimension = (Example M8 or 8mm)

Y Dimension = Distance of 10 threads

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 LT-270 Service Manual

Bolt & Capscrew Torque Values For the Axles

FASTENER THREAD SIZE TORQUE VALUE LB-FT (N M)

3 Breather .58-18 20 Minimum (27 Minimum)
4 Plug, Oil Fill (Housing) .75-14 35 minimum (47.5 minimum)
5 Plug, Heat Indicator .50-14 25 minimum (34 minimum)
6 Plug, Oil Drain .50-14 25 minimum (34 minimum)
7 Capscrew, Differential Case .38-16 35-50 (48-68)
.44-14 60-75 (81-102)
.50-13 85-115 (115-156)
.56-12 130-165 (176-224)
.62-11 180-230 (224-312)
Grade 10.9 Flange Head M12 X 1.75 85-103 (115-140)
Grade 10.9 Standard Hex Head M12 X 1.75 74-96 (100-130)
Grade 12.9 Standard Hex Head M12 X 1.75 105-125 (143-169)
Grade 12.9 Flange Head M16 X 2 203-251 (275-340)
Grade 12.9 Standard Head M16 X2 220-310 (300-420)
8 Nut, Differential Case Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 X 1.75 74-96 (100-130)
M16 X 2 220-310 (300-420)
9 Nut, Ring Gear Bolt .50-13 75-100 (102-136)
.50-20 85-115 (115-156)
.62-11 150-190 (203-258)
.62-18 180-230 (244-312)
M12 X 1.25 66-81 (90-110)
M12 X 1.75 77-85 (104-115)
M16 X 1.5 192-214 (260-190)
M16 X 1.5 196-262 (265-355)
10 Capscrew, Bearing Cup .56-12 110-145 (149-197)
.62-11 150-190 (203-258)
.75-10 270-350 (366-475)
.88-14 360-470 (488-637)
.88-9 425-550 (576-746)
M16 X 2 181-221 (245-300)
M20 X 2.5 347-431 (470-585)
M22 X 2.5 479-597 (650-810)
FASTENER THREAD SIZE TORQUE VALUE LB-FT (N M)

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 LT-270 Service Manual

FASTENER THREAD SIZE TORQUE VALUE LB-FT (N M)

11 Nut, Housing to Carrier Stud .44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
12 Capscrew, Carrier to Housing .44-14 50-75 68-102
.50-13 75-115 102-156
.56-12 110-165 149-224
.62-11 150-230 203-312
.75-10 270-400 366-542
M12 X 1.75 74-89 100-120
M16 X 2 181-221 245-300
13 *Jam Nut, Thrust Screw .75-16 150-190 (203-258)
.88-14 150-300 (203-407)
1.12-16 150-190 (203-258)
M22 X 1.5 148-210 (200-285)
M30 X 1.5 236-295 (320-400)
14 Nut, Drive Pinion .88-20 200-275 (271-373)
1.0-20 300-400 (407-542)
1.25-12 700-900 (949-1220)
1.25-18 700-900 (949-1220)
1.50-12 800-1100 (1085-1491)
1.50-18 800-1100 (1085-1491)
1.75-12 900-1200 (1220-1627)
M32 X 1.5 738-918 (1000-1245)
M39 X 1.5 922-1132 (1250-1535)
M45 X 1.5 996-1232 (1350-1670)
15 Capscrew, Bearing Cage .38-16 30-50 (41-68)
.44-14 50-75 (68-102)
.50-13 75-115 (102-156)
.56-12 110-165 (149-224)
.62-11 150-230 (203-312)
M12 X 1.75 70-110 (90-150)
16 *Plug, Oil Fill (Carrier) .75-14 25 minimum (34 minimum)
1.5-11.5 120 minimum (163 minimum)
M24 X 1.5 35 minimum (47 minimum)
17 *Capscrew, Lock Plate .31-18 20-30 (27-41)
M8 X 1.25 21-26 (28-35)
FASTENER THREAD SIZE TORQUE VALUE LB-FT (N M)

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 LT-270 Service Manual

Lifting Attachments (Shackles / Clevises)

STOCK INSIDE WIDTH MAX. SAFE WORKING LOAD

DIAMETER AT PIN [SINGLE VERTICAL PULL]
(INCHES) (INCHES) (POUNDS)
.1875 .3750 665
.2500 .4688 1,000
.3125 .5313 1,500
.3750 .6563 2,000
.4375 .7188 3,000
.5000 .8125 4,000
.6250 1.0625 6,500
.7500 1.2500 9,500
.8750 1.4375 13,000
1.0000 1.6875 17,000
1.1250 1.8125 19,000
1.2500 2.0313 24,000
1.3750 2.2500 27,000
1.5000 2.3125 34,000
1.7500 2.8750 50,000
2.0000 3.2500 70,000
2.5000 4.1250 100,000
3.0000 5.0000 150,000
3.5000 5.7500 200,000
4.0000 6.5000 260,000

STOCK INSIDE WIDTH MAX. SAFE WORKING LOAD

DIAMETER AT PIN [SINGLE VERTICAL PULL]
(MM) (MM) (KG)
48 95 300
63 119 450
79 135 680
95 167 905
111 183 1360
127 206 1815
159 267 2950
190 318 4310
223 365 5900
254 430 7725
286 460 8635
318 515 10910
349 570 12275
381 585 15450
445 730 22725
508 825 31750
635 1045 45360
762 1270 68040
889 1460 90720
1016 1650 117935

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 LT-270 Service Manual

EXPANDER PIN Double check the minimum and maximum wear points of the lug holes to
INSTALLATION ensure that you have purchased the correct size expansion sleeve for each
AND REMOVAL side of the pin. Each expansion sleeve expands to a maximum of 2.0 mm
(0.08 inch). If the maximum wear diameter of the lug hole is more than 2.0
mm (0.08 inch) larger than the diameter of the sleeve, contact MTI to order
the appropriate oversize expansion sleeve.

Caution: Prior to installation, ensure there are no existing structural damages

(i.e. cracks, severely bent lug ears etc.) that would affect the alignment of the
pivot lugs. If damage exists, it may result in the pin not functioning properly.
Repair structural damages BEFORE proceeding with installation.

Note: If you attempt to install the expander system with improperly sized
expansion sleeves, the installation will not be successful.

Visually inspect the bore surface of the mounting lugs. Remove any ridges or
other irregularities. If the lug hole has more than 1.5 mm (0.06 inch) differ-
ence between the minimum and maximum wear, the hole must be bored or
ground out to a difference that is less than 1.5 mm (0.06 inch).

Note: Re-torque is an intricate part of the installation and crucial to the suc-
cess of the repair. Make sure to follow the torque schedule and check
the torque at regular service intervals. Apply appropriate torque.
Tighten until the torque wrench “clicks out” on setting.

Proper greasing of your machine pivots are crucial for the functioning and
durability of the expander pin. We strongly recommend using grease with 3-
5% molybdenum disulfide, which allows much less wear and gives increased
load carrying capability.

Installation
» Lubricate the expander pin and the expansion sleeves with bearing
grease for easy insertion. First, insert only the expander pin into the
bore, then install the sleeves, tension washers and fastening elements.
Be sure not to damage the thread or the tapered ends of the expander
pin.

» Hand tighten the assembly centered, (or position as required), in its

final position in the pivot.

» Before tightening the pin assembly, find the appropriate torque value by
looking up the corresponding fastening element in the Table below.
Refer to the parts manual for the size of the fastening elements. Torque
the fastening elements alternately in order to maintain an equal clear-
ance between the tension washers and the mounting lugs on both sides

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 LT-270 Service Manual

of the expander pin. Tighten until the torque wrench “clicks out” on set-
ting.

Note: The tension washer located between the fastening element and the end
of the expander pin should NEVER come in contact with the pivot lug.
If this occurs on only one side of the pin, dismantle and re-assemble
pin assembly.

» Lubricate the pivot using grease with 3-5% molybdenum disulfide

before operating the machine. Proper lubrication maintenance will
greatly extend the life of the expander pin.

» Once the initial torque regiment and pivot lubrication have been com-
pleted, start the machine and move the unit back and forth. Tighten
again until torque wrench “clicks out” on settings. This procedure
ensures that the expansion sleeves have properly seated.

Dismounting Instructions
» Unscrew the fastening elements on both sides of the assembly and
remove the washers.

» Tap the expander pin body alternately on both sides until the expansion
sleeves come loose. Use a piece of plumbing pipe between the pin and
the mallet/hammer to prevent damage to the threads. Make sure that the
pipe does not come in contact with the expansion sleeve.

» Remove the expansion sleeves with channel lock pliers or a similar tool.
Remove the expander pin.

Torque Schedule (hours of operation)

» After 1 hour
» After 3 hours
» After 10 hours or 1 day *
» After 40 hours or 4 days *
*If the expansion sleeves have not seated within one week of operation, call
MTI service for instructions.

Torque Values for Bolts and Specialty Fasteners

Unit M12 M14 M16 M20 M24 M30 M36 M42

(Nm) 70 115 175 350 500 600 700 900
(Lbft) 52 85 129 258 369 443 516 664

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 LT-270 Service Manual

CHANGING THE Caution should be exercised whenever you work around and under a
DUMP CYLINDER machine. Never perform any work on a vehicle that is supported by hydraulic
jacks only, use the proper support stands to hold the machine up while you
work on it.

Safe Working Procedures:

» Remove quick attach frame and park the unit with the boom lowered.
» Release the hydraulic pressure in the cylinders.
» Shut the engine off and turn the Master switch off.
» Tag and chock the machine according to the shop procedures.
» Disconnect the rod side hydraulic hose.
» Cap the hose and the cylinder ports.

Removing the Dump Cylinder

» If equipped, remove dump cylinder guard. Disconnect the rod side
hydraulic hose. Cap the hose and the cylinder ports.
» Disconnect the piston side hose. Cap the hose and the cylinder ports.
» Disconnect the grease hose off the cylinder.
» Attach the dump cylinder to a lifting device using an appropriate sling.
» Remove the rod side expander pin as per “Expander Pin Installation and
Removal” on page 68.
» Remove the piston side expander pin as per “Expander Pin Installation
and Removal” on page 68.
» Lift the cylinder off the machine and lower it down to the ground.

Installing the Dump Cylinder

» Attach the new dump cylinder to the lifting device using a proper sling.
Ensure that all hinge points are pre-greased prior to assembly.
» Lift the dump cylinder and align the cylinder’s piston-side lug into the
frame bore.
» Reinstall the piston side expander pin as per “Expander Pin Installation
and Removal” on page 68.
» Reinstall the piston and rod side hoses, as well as the grease hoses.
» Ask your partner to start the engine. Extend the dump cylinder rod eye
and align it to the quick attach frame bore. Shut down engine.
» Reinstall rod side expander pin as per “Expander Pin Installation and
Removal” on page 68.

Testing the Dump Cylinder

» Remove any slings or lifting apparatus attached to the cylinder or boom.
Slowly hoist the boom up and remove any stands.
» Dump the quick attach frame forwards and backwards a few times to
remove any air in the cylinder. Carefully check for any hydraulic leaks
in dump cylinder. Check for full range of quick attach frame movement.
» Remove your tag from the machine. Log your repairs in the vehicle log.

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 LT-270 Service Manual

CHANGING THE It is important to work safely and follow the basic safety rules when replacing
BOOM the boom as the boom is very heavy and bulky.

Be sure the machine you are working on is properly blocked, tagged and
secured according to your company's safety procedures and policies. Always
use approved slings and lifting devices whenever lifting components and
never go under a suspended load. The proper gloves should always be worn
when working with slings.

Remember, the boom is heavy and bulky. Handle it with care and use the
proper lifting devices.

Safe Working Procedures:

» Remove quick attach frame and park the unit with the boom at ground
level.
» Properly and safely support the boom based on the procedure to be per-
formed.
» Shut the engine off and turn the Master switch off.
» Tag and chock the machine according to worksite procedures.

Removing the Boom

Observe pinch point safety rules throughout entire procedure! To safely
remove the boom assembly from the LT-270:

» Ensure the boom is properly supported by appropriate stands/cradles

and is safely attached to any slinging devices. Avoid working directly
under a slung boom if possible.
» Remove the dump cylinder as per “Removing the Dump Cylinder” on
page 70.
» Remove the hoist cylinders as show in “Removing the Hoist Cylin-
der(s)” on page 73.
» Remove both of the Boom to Frame expander pins as per “Expander
Pin Installation and Removal” on page 68. This frees the boom from the
front frame.
» Carefully lift the boom slowly off the machine.
» Remove the wheel chocks.
» Ask your partner to start the engine and back the unit away from the
boom.
» Lower the boom to the shop floor.
» Remove all components on the boom, inspect/replace them and install
them on the new boom.

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 LT-270 Service Manual

Installing the Boom

To properly install the boom:

» Attach the boom to an adequate and appropriate lifting device using the
proper sling.
» Lift the boom up enough to fit it onto the front frame.
» Remove the wheel chocks.
» Ask your partner to start the engine and carefully drive slowly under the
boom.
» Align the boom boss with the front frame boss.
» Guide your partner and be careful to not push the boom off the sling.

Caution: Keep your hands off the boom boss and frame boss while the unit is
in motion!

» Shut the engine off.

» Chock the machine according to the worksite procedures.
» Install the Boom to Frame expander pins as per “Expander Pin Installa-
tion and Removal” on page 68.
» To install the hoist cylinders, see“Installing the Hoist Cylinders” on
page 73.
» Reinstall the dump cylinder as outlined in the section “Installing the
Dump Cylinder” on page 70.
» Reconnect any grease hoses running to the cylinders.
» Reinstall the quick attach frame to boom and dump cylinder.

Testing the Boom

To properly test a newly installed boom:

» Ask your partner to start the engine.

» Raise the boom halfway up a few times.
» Ask your partner to tilt and dump the quick attach frame a few times.
» Carefully check for any hydraulic leaks of hoist and dump cylinders.
» Check for the proper operation and range of movement for both the
boom and quick attach frame.
» Remove your tag from the machine.
» Record the repairs in the log book.

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 LT-270 Service Manual

CHANGING THE To change the hoist cylinders, please observe the following procedures.
HOIST
CYLINDERS Safe Working Procedures:
» Lift the boom up and install the proper stands or use the optional boom
support pins (if installed on your unit).
» If stands are not available, build a crib approximately 4 to 5 feet in
height to support the boom during removal of the hoist cylinders.
» Avoid going under the boom if possible, whichever method is used.

Removing the Hoist Cylinder(s)

» Shut off the engine and turn the Master switch off.
» Relieve the hydraulic pressure from the hoist cylinders.
» Tag the machine according to site procedures.
» Disconnect the rod side hydraulic hose. Cap the hose and the cylinder
port.
» Disconnect the piston side hose. Cap the hose and the cylinder port.
» Attach the hoist cylinder properly to a lifting device using the proper
sling.
» Remove the rod side expander pin as per “Expander Pin Installation and
Removal” on page 68.
» Remove the piston side expander pin as per “Expander Pin Installation
and Removal” on page 68.
» Lift the cylinder from the machine and lower it down to the ground.
» Repeat this procedure for the other hoist cylinder.

Installing the Hoist Cylinders

» Attach the hoist cylinder to a lifting device using the proper sling. Lift
the hoist cylinder and align the piston side lug of the cylinder to the
machine frame bore.
» Install the Hoist to Frame expander pin as per “Expander Pin Installa-
tion and Removal” on page 68.
» Remove the caps off the cylinder ports and off the hoses.
» Reinstall the piston and rod side hydraulic hoses.
» Ask your partner to start the engine. Using the machines hydraulic cyl-
inders, align the cylinder rod side to the boom bores.

Caution: Be careful to not lift the boom off the stands and do not position
yourself under the boom during this operation.

» Shut the engine off.

» Reinstall the rod side expander pin as per “Expander Pin Installation
and Removal” on page 68.

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 LT-270 Service Manual

Testing the Hoist Cylinders

To properly test the newly installed hoist cylinder(s):

» Ask your partner to start the machine.

» Carefully lift the boom up enough to remove the stands or disengage the
boom support pins.
» Hoist the boom up and down a few times to remove the air in the cylin-
ders.
» Carefully check for any hydraulic leaks.
» Check for the proper operation and full movement range of the boom.
» Remove your tag from the machine.
» Log your repairs in the vehicle log.

CHANGING THE To safely change the front frame, it is very important to observe the basic
FRONT FRAME safety rules. Remember, the front frame is heavy and bulky. Handle it with
care and use the proper lifting devices.

Safe Working Practices:

» Remove quick attach frame and park the unit with the boom at ground
level.
» Shut the engine off and turn the Master switch off.
» Tag and chock the machine according to the shop procedures.
» Install the mid-ship steering locking bar.

Removing the Front Frame

Review the safety information at the beginning of this section.

» Ensure the mid-ship lock bar is installed properly.

» Remove the quick attach frame from the boom and dump cylinder and
set aside.
» Remove dump cylinder as outlined in the section “Removing the Dump
Cylinder” on page 70.
» Remove the boom as outlined in the section “Removing the Boom” on
page 71.
» Remove the hoist cylinders as outlined in the section “Removing the
Hoist Cylinder(s)” on page 73.
» Remove the mid-ship driveline and hanger bearing.
» Disconnect the steering cylinder at the rod end.
» Disconnect all hydraulic hoses at mid-ship and install marked caps and
plugs for easy installation when assembling.
» Disconnect all grease hoses at mid-ship and install marked caps and
plugs for easy assembly.
» Disconnect fire suppression hoses and install marked caps and plugs for
easy assembly.

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 LT-270 Service Manual

» Label wires at the mid-ship junction box and disconnect them. Don't cut
the wires; make sure you disconnect them at the terminal box.
» Remove front axle as outlined in the section “Changing the Front Axle”
on page 95.
» Make sure front and rear frames are safely blocked and attach the
approved slings to front frame and to lifting device.
» Remove mid-ship lock bar.
» Remove the top and bottom articulation joint pins using the proper
tools.
» Separate the front and rear frames using approved lifting devices.

Caution: Be careful; do not move the rear frame. It could fall off the blocks.

Installing the Front Frame

Guide the lifting device operator for lining up the front frame with the rear
frame. Be careful; do not move the rear frame. It could fall off the blocks.
Handle the front frame with care. Reverse the removal procedures above to
install the front frame and pay attention to the following:

» Tighten all fasteners to manufacturers recommended torque specs.

» Make sure when connecting wires that they are on the proper terminal.
» When installing hoses make sure marked caps and plugs are the same.
» When installing hoses make sure no dirt gets into system.
» Bleed brakes following manufacturers recommended procedures.
» Check all fluid levels.
» Remove the mid-ship lock bar.
» Reconnect all wires in the mid-ship to their proper terminal block and
remove the identification tags.
» Remove the fire suppression port and hose caps.
» Install the fire suppression hoses and remove the I.D. tags.
» Remove the grease hose and port caps.
» Install all grease hoses to their proper location and remove the I.D. tags.
» Remove all hydraulic hose and port caps.
» Install all hydraulic hoses to their proper location and remove the I.D.
tags.
» Install the steering cylinder expander pins as per “Expander Pin Instal-
lation and Removal” on page 68.
» Install the mid-ship driveline.
» Install the U-joint screws and tight them to proper specification.
» Install the hoist cylinders as per “Installing the Hoist Cylinders” on
page 73.
» Install the boom as detailed in “Installing the Boom” on page 72.
» Install the dump cylinder as per “Installing the Dump Cylinder” on
page 70.
» Install the quick attach frame to the boom and dump cylinder.

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 LT-270 Service Manual

Check the Machine’s Operation

After properly reinstalling all the components and hosing, complete the fol-
lowing procedure to ensure the unit is operating properly:

» Remove the mid-ship steering locking bar.

» Raise and lower the boom a few times to bleed air from system and
check operation of the boom. Tilt and dump the quick attach frame a
few times to bleed air from system and check operation of cylinder.
» Operate steering from left to right to check for proper steering function.
Perform brake tests as per recommended procedures.
» Check for any fluid leaks. Check operation of front lights and any other
electrical functions. Remove your tag(s) from the machine. Log your
repairs in the vehicle log.

CHANGING THE It is very important to observe safety rules and work safely when changing
ARTICULATION the articulation joint pins because the front and rear frames are very heavy
JOINT PINS and bulky. Be sure the machine you are working on is properly blocked,
tagged and secured according to your company's standard safety procedures
and policies.

Always use approved slings and lifting devices whenever lifting components
and never go under a suspended load. The proper gloves should always be
worn when working with slings.

» Park the unit with the boom and quick attach frame at ground level.
Shut the engine off and turn the Master switch off. Tag and chock the
machine according to the shop procedures.
» Install the mid-ship steering locking bar.
» Unscrew the expander pin on the rod side of the steering cylinder as per
“Expander Pin Installation and Removal” on page 68.
» Remove the U-joint bolts and remove the mid-ship driveline. Remove
and cap the articulation joint grease hoses.
» Secure the front and the rear frame on blocks according to your shop
blocking procedures.

Removing the articulation pins

See “Dismounting Instructions” on page 69.

Caution: Be careful, to not move the rear frame as it can fall off the support-
ing blocks. Handle the front frame with care.

» Clean the mid-ship hinge thoroughly. Inspect the hinges for cracks or
any damage.
» Do any necessary repairs before installing new articulation pins.

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 LT-270 Service Manual

Upper Articulation Pin Assembly

» Install double bearing cup (item 4) in center lug of front frame using a
brass punch and hammer, bringing bearing cup flush to bottom of front
frame center lug. Measure the gap from the top of the bearing cup to the
face of center lug. Select a shim that is the same size as you measured.
» Install bearing cone (item 5) into top half of bearing cup. Install grease
seals (item 2) into the retainer caps (item 3). Install shim (item 11) if
required, on top of center lug. Install bottom bearing cone, retainer caps
(item 3) with seal & apply loctite 243 to bolts (item 6) and torque 24 ft-
lbs.
» Install compression sleeve (item A) in bottom retainer cap of front frame
upper lug.
» Marry frames together lining up top & bottom bores. Install bottom pin
and collet. Install bolt and washer using never seize, hand tighten the
bolt to hold pin in place to prevent falling out.
» Install top pin and slowly lower front frame to put weight on the com-
pression sleeve of the upper articulation. Install jig and torque bolt to
280 ft-lbs. Install bottom collet, washer & bolt using never seize.
Torque bolt of the pin to 295 ft-lbs.

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 LT-270 Service Manual

» Remove jig, install top collet, bolt & washer using never seize & torque
to 370 ft-lbs. Install a dial indicator and lift front frame and check to see
how play is in the bearing. Bearing play should be within 0.001 & 0.005
thousand. If this is not achieved disassemble and reassemble again.

Lower Articulation Pin Assembly

» Install double bearing cup (item 4) in center lug of rear frame using a
brass punch and hammer. Bringing bearing cup flush to bottom of rear
frame center lug. Measure the gap from the top of the bearing cup to the
face of center lug. Select a shim (item 13) that is the same size as you
measured.

» Install bearing cone (item 5) into top half of bearing cup. Install grease
seals (item 2) into the retainer caps (item 3). Install shim (if required) on
top of center lug.

» Install bottom bearing cone (item 5), retainer caps (item 3) with seal &
apply loctite 243 to bolts (item 6) and torque 24 ft-lbs.

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 LT-270 Service Manual

» Install compression sleeve (item A) in top retainer cap of front frame

upper lug.

» Marry frames together lining up top & bottom bores. Install bottom pin
and collet. Install bolt and washer using never seize, hand tighten the
bolt to hold pin in place to prevent falling out.

» Using a rubber hammer, hit bottom pin bolt to ensure full contact is
made between pin and bearing. Torque bolt item 1 to 370 ft-lbs. Install
top bushing (item 11) and torque bolts (item 10) to 25 ft-lbs. This must
be done 2 or 3 times to reach the full 25 ft-lbs. Install set screws (item 9)
c/w loctite and torque to 30 ft-lbs.

» Install upper collet, bolt & washer. Torque bolt to 295 ft-lbs, install dial
indicator and lift front frame. Check to see how much play is in the
bearings, it should be 0.001 to 0.011 thousand play. If this is not
achieved, disassemble and reassemble

Check the mid-ship Hinge Operation

» Remove the mid-ship steering locking bar.
» Ask your partner to start the LT-270 engine.
» Ask your partner to steer from left to right and vice versa.
» Check for any hydraulic leaks.
» Check for the proper operation of the steering.
» Remove your tag from the machine. Record the repair in the log book.

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CHANGING THE Safe Working Practices:

HYDRAULIC This section will outline the procedure for the removal and installation of the
PUMP main hydraulic pump. The procedures are only intended to be a guideline,
and your own company's policies may dictate a different approach to this job
procedure.

To be able to change the main hydraulic pump, it is very important to observe

the following basic safety rules:

» Park the unit with the boom and the bucket at ground level.
» Shut the engine off and turn the Master switch off.
» Tag the machine according to the shop procedures.
» Always use the appropriate lifting devices when you perform this task.
» Be sure that you have properly blocked the machine and applied the
appropriate tags to warn others that the unit is being serviced.
» Follow your company's procedures for blocking and tagging of equip-
ment.

Removing The Hydraulic Pump

Note: You may have to drain the hydraulic tank to prevent oil from escaping
through the inlet or return line.

» Remove any component(s) needed to be taken out around the hydraulic

pump.
» Label all hydraulic hoses that will be taken out from around the hydrau-
lic pump and cap them.
» Cap all hose ports to prevent dirt from entering the system.
» Label all the fire suppression hoses needed to be remove around the
hydraulic pump.
» Remove the fire suppression hoses around the hydraulic pump and cap
them.
» Cap the fire suppression system port to prevent the dirt from entering
the system.
» Remove the hydraulic pump inlet, outlet and drain line.
» Cap the hoses and the pump ports.
» Attach hydraulic pump to the proper lifting device using the proper
sling.
» Remove the hydraulic pump mounting bolts.
» Lift the pump off of the torque converter.
» Clean around the torque converter.
» Inspect the torque converter housing for cracks or for any sign of dam-
age.

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Note: Be careful not to damage the shaft when removing the pump from the
torque converter. Watch for pinch points. The pump is heavy enough
to cause severe hand injuries.

Installing The Hydraulic Pump

To install the hydraulic pump:

» Install the hydraulic pump in the proper position on the torque using a
new seal

Note: Be careful not to damage the shaft when installing the pump onto the
torque converter. Watch for pinch points. The pump is heavy enough
to cause severe hand injuries.

» Install the mounting bolts and torque the bolts to proper specification.
» Remove hydraulic pump off the lifting device.
» Remove the cap off the hoses and the pump ports.
» Fill the pump with oil.
» Install the hydraulic pump inlet, outlet and drain line.
» Remove the caps off the fire suppression system port and hoses.
» Install the fire suppression hoses to their proper location and remove the
tags.
» Remove the caps off the hydraulic hoses and ports.
» Install the hydraulic hoses to their proper location and remove the tags.
» Install the components remove during the pump removal phase.

Check Pump Operation

To check for the proper operation of the main hydraulic pump:

» Prior to running the pump, the pump housing must be full of oil. Verify
if the pump casing is full via the case drain connection.
» Open the accumulator drain valve to prevent the pump from being
loaded during the check up procedure.
» If you have drained the main hydraulic reservoir, clean the area before
refilling with the appropriate grade and type of oil.

» Ask your partner or an operator to start the engine. Immediately verify

if the pump runs quietly. Run the pump without load and allow it to
deliver without pressure for a few seconds.
» If the pump is not delivering oil without air bubbles after 60 seconds
stop the engine and recheck the system.
» If the pump runs properly, close the accumulator drain valve and check
for any hydraulic leaks.
» Check the oil temperature.
» Remove your personal protection tag or lock from the machine.

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CHANGING AN Safe Working Practices

ACCUMULATOR To be able to change an accumulator, it is very important to observe the fol-
lowing basic safety rules:

» Park the unit with the boom and the quick attach frame at ground level
» Shut the engine off and turn the Master Switch off
» Tag the machine according to the shop procedures.
» Always use the appropriate lifting devices when you perform this task.
» Be sure that you have properly blocked the machine and applied the
appropriate tags to warn others that the unit is being worked on. Follow
your company's procedures for blocking and tagging of equipment

Removing An Accumulator
To remove an accumulator from the LT-270:

» Release hydraulic pressure in the cylinders.

» Shut the engine off and turn the master switch off.
» Tag and chock the machine according to the shop procedures.
» Drain the accumulator’s hydraulic pressure by opening the accumulator
drain valve.
» Remove the accumulator service valve protector cap.
» Discharge the accumulator gas completely by depressing the service
valve with a blunt tool.
» Reinstall the accumulator service valve protector cap.
» Disconnect the hydraulic hose from the accumulator.

Note: Be careful when removing the hose. It may still have residual hydrau-
lic pressure. To remove the hose safely, unscrew the fitting about 2
turns and wiggle the hose to let the pressure escape if any pressure is
still in the accumulator.

» Cap the hose and the accumulator port.

» Remove the accumulator mounting bolts
» Remove the accumulator off of the mounting bracket.

Installing An Accumulator
To install an accumulator on the LT-270:

» Install the accumulator in its mounting bracket.

» Install the mounting bolts and torque it according to specification.
» Remove the accumulator port protective cap.
» Remove the hose protective cap and install the hose.
» Recharge the accumulator with dry nitrogen gas (see below).

Recharging An Accumulator

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To properly recharge an accumulator you will need a charging station. A

basic charging station consists of a bottle of dry nitrogen and a gauge set.

Note: Be very careful handling the dry nitrogen bottle. The bottle stores gas
under high pressure.

To recharge the accumulator:

» Bring the charging station beside the unit.

» Turn the gauge set adjusting handle counterclockwise until the spring
tension is completely released.
» Remove the service valve protective cap.
» Install the charging station adapter on the accumulator service valve.
» Turn the adapter handle clockwise completely. This will open the accu-
mulator service valve.
» Open the dry nitrogen bottle valve clockwise. Verify on the gauge set if
it has enough gas in the bottle before proceeding.
» Slowly turn the gauge set adjusting handle clockwise until the line pres-
sure gauge show the desired pressure.
» Turn the adapter handle counterclockwise completely. This will close
the accumulator service valve.
» Shut off the dry nitrogen bottle valve by turning the bottle valve coun-
terclockwise until tight.
» Turn the gauge set adjusting handle counterclockwise until the spring
tension is completely released.
» The line pressure gauge should show 0 psi.
» Remove the charging station adapter slowly from the accumulator ser-
vice valve.

Note: After removing the adapter off the accumulator service valve, turn the
gauge set adjusting screw handle clockwise about 1/2 turn to release
the gas pressure in the gauge set.

» Reinstall the service protective cap on the service valve.

» Retest the accumulator gas pre-charge.
» Remove your tag off the machine.

Check The Accumulator Pre-charge

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To retest the accumulator gas pre-charge

follow this simple procedure:

» Start the engine.

» Charge the accumulator to its maxi-
mum hydraulic pressure (A).
» Shut the engine off.
» To check the pre-charge, observe the
accumulator pressure gauge as the
accumulator drain valve is opened
one full turn.
» The gauge needle will drop slowly
until the pre-charge pressure is obtained (B) and then it will rapidly
drop to 0 psi (C).
» The last reading before the charge quickly dropped to zero (B) is the
nitrogen pre-charge.

ENGINE This section will outline the procedure for engine removal and replacement.
INSTALLATION The procedures are only intended to be a guideline, and your own company's
policies may dictate a different approach to this job procedure.

Safe Working Practices:

» Always use the appropriate lifting devices when you perform this task.
» Be sure that you have properly blocked the machine and applied the
appropriate tags to warn others that the unit is being worked on.
» Follow your company's procedures for blocking and tagging of equip-
ment.

Removing the Engine

To remove the engine:

» Disconnect the battery.

» Remove the torque converter from the engine as outlined in the section
“Removing the Torque Converter” on page 90, and safely secure it in a
suspended position.
» Drain the radiator and the engine oil and put in suitable containers.
» Shut off fuel tank valve if applicable.
» Remove all hoses and lines connected to the engine and install marked
caps and plugs for easy re-installation.
» Remove any linkages and electrical connections to the engine as neces-
sary.
» Remove the exhaust and intake plumbing from the engine.
» Attach a secure sling to the engine and connect to lifting device.
Remove engine mount bolts.
» Carefully lift the engine from machine.

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Installing the Engine

The proper procedure for installing the engine is to:

» Secure appropriate slings and lifting devices to the engine and lift it into
the engine compartment.
» Align the motor mounts with the bolt holes on the frame of the engine
compartment.
» Install the engine using new mounting bolts. Ensure the engine is
securely mounted to the frame of the engine compartment.
» Reconnect the exhaust and intake system plumbing for the engine.
» Install and connect any linkage if used for the throttle control system.
» Reinstall all electrical wiring for the starter and alternator systems.
» Reconnect the radiator hoses if applicable.
» Connect all fuel hoses to the engine.
» Follow the procedure outlined in “Installing the Torque Converter” on
page 91, and re-install the torque converter.
» Install new fuel, air and oil filters.
» Fill the engine with the appropriate oil to the full mark.
» Refill the radiator to its rated capacity.
» After all the necessary electrical and other connections are made, start
the engine up and check for any fluid leaks.
» Do not idle the engine any longer than necessary, as this could lead to
possible cylinder liner glazing.

ENGINE For engine operation and daily maintenance items, see the Deutz 2012 Oper-
SERVICING ation Manual #0297 9912 en.

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AIR INTAKE The main component of an air intake system is the air cleaner; usually a dry-
SYSTEM type air cleaner with a replaceable cartridge. Depending on the particular
work application, some air cleaners have a pre-cleaner and a secondary air
cleaner cartridge. The intake system also involves tubing and elbows/joints of
various materials to move the air from the cleaner to the engine. Some intake
systems have service indicators to help with servicing and to monitor the
cleanliness of the air cleaner.

Servicing the Air Cleaner

With proper air cleaner servicing, the engine will experience longer trouble-
free runtime because of less contamination entering the system. Proper ser-
vice intervals can also save you time and money by increasing the life of the
filters. Two of the most common problems encountered with air cleaner ser-
vicing are dust entering the intake system when the filters are changed, and
filters that are changed to often. A filter that may look dirty could in fact still
be good. Use filtration measuring tools to determine the life of the filter.

Low pre-cleaner efficiency will shorten the life of a filter element consider-
ably. Low pre-cleaner efficiency can be caused by a leaking dust cap, a dam-
aged or missing evacuator valve, plugged or built-up vanes of the pre-cleaner,
or damage to the pre-cleaner. Always examine the clean air transfer tubing
for cracks, loose clamps, or loose flange joints. Always check the air cleaner
housing for damage or holes and check the engine intake for damage or loose
bolts.

Radiator

Air Cleaner

Note: Engine removed for clarity.

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 LT-270 Service Manual

When servicing the air filter, follow

these general steps: Cover

» Remove the cover and baffle.

Baffle

» Unscrew the wing nuts to free

the elements from the body.
Remove the old elements from Primary
the outlet tube as gently as pos- Element
sible. If an element doesn’t slide
off, gently move it side-to-side
or twist it to help dislodge the
element.

» Once free, gently pull the ele- Secondary

ment from the body of the air Element
cleaner. Avoid knocking the fil-
ter element against the housing
while removing.

» Always clean the inside of the Clamp

filter housing carefully.

» Always clean the gasket sealing

area of the filter housing.
Housing
» Check for uneven dirt patterns Inlet
on your old elements. These
could indicate foreign materials Outlet
on the sealing edges causing
leakage around the elements.

» Press your fresh gasket to make sure it springs back. Inspect it to ensure
it is free from damage which could hinder its ability to seal correctly
around the outlet tube.

» When installing new elements, make sure the gasket is seated evenly.
Apply pressure to the outer rim of the element. Do not apply pressure to
the flexible center area.

» Install the safety element so it seals the interior diameter of the outlet
tube. Install the primary element so it seals the outside diameter of the
outlet tube.

» Check all the connections and ducts for air tightness.

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 LT-270 Service Manual

EXHAUST In a perfect engine you would have complete combustion and this would
SYSTEM leave no toxic emissions. Since there is no perfect engine at the present time,
we have exhaust which contains emissions. Exhaust emissions can include:

» Carbon Monoxide - A toxic gas that can cause headaches, nausea,

unconsciousness and even death in sufficient quantities.
» Aldehydes / Acroleins - In small amounts these gases irritate the eyes
and nose.
» Unburned fuel - Can create odours or cause potential fire hazards.

There are emission control systems available to help in reducing noxious and
toxic gases. These systems are usually added to the exhaust system and are
called catalytic purifiers.

Catalytic purifiers use a catalytic reaction to decrease carbon monoxide and

hydrocarbon exhaust emissions. These purifiers have a honeycomb-design
platinum catalyst that converts exhaust emissions to carbon dioxide and water
at most exhaust temperatures. Purifiers need only limited maintenance; regu-
lar cleaning is the main maintenance required. Suitable noise reduction is not
provided with purifiers, therefore the typical system also has an exhaust
silencer installed to help reduce noise to an acceptable level.

Servicing the Exhaust Purifier

The purifier is
mounted in the vehi- Example only
cle exhaust system.
The purifier works by
chemically reacting
the carbon monoxide
and hydrocarbons
with oxygen above a Back pressure
specific temperature,
thereby converting
them to harmless car-
bon dioxide and
water. The purifier
must be mounted as
close to the exhaust Lower output of gases
manifold as possible
in order to function properly. The purifier must be hot in order to operate effi-
ciently. It should be noted that most diesel engines, when idling, have exhaust
temperatures below operational temperatures of the purifier.

The purifier is no substitute for proper engine maintenance, but is rather a

system to improve engine exhaust quality. Loss of efficiency in the purifier

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 LT-270 Service Manual

can result when used on engines producing excessive amounts of black or

blue smoke. Other engine problems such as leaking injectors or loss of com-
pression will lead to lower exhaust temperatures and loss of purifier effi-
ciency. During regular preventive maintenance examinations, the back
pressure of the purifier should be checked and recorded. This reading should
be compared to the recorded back pressure when the purifier was first
installed.

If, during a regular back pressure check, a pressure of more than 3" of water
higher than the initial clean reading is found, it is an indication that the puri-
fier is becoming plugged with soot. This condition will prevent the gases
from contacting the catalytic coating on the purifier, resulting in very little
removal of harmful gas from the exhaust. The purifier should be removed and
cleaned and any problems with the engine or exhaust system should be
repaired before installing the cleaned purifier.

Excessive Smoke
If during regular operation the machine is observed emitting excessive
amounts of blue or black smoke it would indicate that the engine has a perfor-
mance problem which should be repaired as soon as possible, before it affects
the operation of the purifier. The smoke will result in soot forming on the
purifier element rendering it inoperative, thus increasing harmful exhaust
emissions considerably.

High Level Of Odour or Irritation

If there is a report of high levels of odour or irritating emissions coming from
the exhaust system, it could indicate that there is reduced purifier perfor-
mance. The odour and irritation is caused by emissions that the purifier
would normally remove if functioning properly. The purifier should be
cleaned or replaced if it is found to be damaged.

Cleaning the Purifier

To clean the exhaust purifier:

» Remove the purifier centre section from the engine exhaust.

» Use compressed air in a well ventilated area to remove the majority of
the accumulated soot. 50 psi of air blown from the outlet side toward
the inlet side should remove most accumulated soot.
» In some situations, soaking the purifier in a cleaning solvent may be
necessary. Do not use solvents which contain chlorine, sulphur, or met-
als. Under no circumstance is gasoline to be used.
» After an up to two hour soak, blow out the element with compressed air
to remove any residual cleaner and install once the catalyst is fully dried
out.

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 LT-270 Service Manual

FLEX PLATES Instead of using the old style fibre gear drive method to drive the torque con-
verter, the LT-270 has been designed to use flex plates. In the old style, if the
fibre gear became stripped, the drive connection between the flywheel of the
engine and the torque converter would be lost and therefore the machine
would be stranded. The fibre gears were designed to be the weakest link (like
a shear pin) in the drive train and would fail before major damage is done to
other portions of the drive train. With the development of new designs such
as load sensing, this took away the need for a weak link in the powertrain and
the fibre gear was replaced with flex plates made of spring steel to drive the
torque converter.

CHANGING THE This section will outline the

Example only
TORQUE procedures for removing Stud, washer and
CONVERTER and installing a torque con- self lock nut
verter. These procedures are
only intended to be a guide- Flywheel
line and your company may housing
have policies that dictate a
different approach to this
procedure. Flywheel

Safety
Be sure that the machine Impeller
you are working on is cover
blocked, tagged and secured
according to your com- Intermediate
drive plates
pany's standard safety pro-
cedures and policies.
Always use the proper slings
and lifting devices whenever
lifting any components and
never go under a suspended
load.

Removing the Torque Converter

To properly and safely remove the torque converter:

» Measure crankshaft tolerance and record measurement.

» Drain transmission oil into a suitable container.
» Disconnect the high-speed driveline from the torque converter and
remove.
» Remove all hoses connected to torque converter and install marked caps
and plugs for easy installation of hoses back on torque. Remove hydrau-
lic pumps from torque converter and let them hang on their hoses.

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 LT-270 Service Manual

» Remove pump drive adapters from torque converter.

» Remove bell housing inspection cover and remove nuts that hold flex
plate to flywheel.
» Install proper sling to torque housing and connect to lifting device.
» Remove nuts holding torque converter to engine and pry the torque
back slowly. Remove torque converter from compartment with lifting
device.

Installing the Torque Converter

Reverse the removal procedure above to install torque converter and pay
attention to the following:

» Remove burrs from mounting face of flywheel and pilot bore. Check
flywheel pilot bore run out and mounting face flatness.
» Tighten all fasteners to recommended torque specs.
» After torque installation check crankshaft tolerance and it should be
within 0.001" of previous reading.
» Install all new gaskets and O-rings as necessary.
» When installing hydraulic hoses make sure no dirt gets into the system
and tighten all fittings to specifications.
» Install new filters and fill transmission with oil, prime the suction line to
the torque, change pump before starting unit.
» Start and test-run unit and check for any leaks.

C270 TORQUE For torque converter repair, assembly, disassembly and maintenance, please
CONVERTER see the Dana C270 service manual #0032. The torque converter service man-
SERVICING ual can be found in a separate section at the end of this manual.

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 LT-270 Service Manual

CHANGING THE The transmission's output shafts are connected via drivelines to the front and
TRANSMISSION rear differentials. Universal joints are used to connect the drivelines to the
components to compensate for changes in alignment between components.

The differentials are supported by the axle housings and directs the torque
from the transmission to both adjacent wheels by means of two axles and a
planetary assembly. The planetary assembly is designed to increase the
torque at the wheel through gear reduction.

The torque converter and power shift transmission are mounted separately
from each other and are connected by a driveline. This allows for a more flex-
ible overall machine design. The speed and directional clutches are mounted
inside the transmission casing for a more compact design and are driven by
an external driveline from the torque converter. The power flow through the
gear train is directed by the speed and directional clutches to provide the
desired speed range and direction.

Operation
With the engine running, the converter pump draws oil through the suction
screen in the transmission sump and directs it through the oil filter and then to
the pressure-regulating valve. The pressure-regulating valve maintains pres-
sure in the control cover to actuate the speed and directional clutches. This is
a small portion of the volume of oil available in the system. The volume of oil
that is left is directed through the torque converter circuit and then to the oil
cooler in the radiator, where it returns to the transmission for positive lubrica-
tion. The regulator valve is made up of a valve spool operating in a closely
fitted bore. The valve is held in a closed position by a spring-loaded spool.
When the pre-determined pressure is reached the valve spool opens.

Transmission Replacement
The following section will outline a procedure for removing a transmission
and installing another unit. These procedures are only meant to be a guideline
and your company may have different policies that may require a different
approach to this procedure.

Safety
Always be sure that the machine you are working on is properly tagged,
blocked and secured according to your company's standards safety proce-
dures and policies. Always use the proper slings and lifting devices whenever
lifting any components and never go under a suspended load. Ensure that all
guards or safety devices are properly installed and functioning.

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Removing the Transmission

To remove the transmission remove all hoods and components from around
the transmission, then:

» Drain the oil from the transmission sump.

» Remove the high speed drive line universal joint bolts from the trans-
mission.
» Remove the output shaft drive lines from the transmission.
» Disconnect the hydraulic control lines from the transmission.
» Remove the pump charge line and the suction line.
» Remove the torque drain line from the transmission.
» Secure the transmission with the appropriate lifting slings before
removing the transmission mounting bolts.
» Remove any hoses and hardware that will prevent you from removing
the transmission.
» Using the lifting device, remove the transmission from the frame of the
machine.

Installing the Transmission

Reverse the removal procedure above to install the transmission and pay
attention to the following:

» Remove fittings from the old transmission and install on new or rebuilt
unit.
» Tighten all fasteners to manufacturers recommended torque specs.
» Install new gaskets and O-rings as necessary.
» When installing hydraulic hoses and lines make sure no dirt gets into
system and tighten fittings to specs.
» Install new filters and fill unit with new, approved oil.
» Start and test drive unit and check for leaks.
» Recheck mount bolts after a few hours of operation.

Transmission Cooling
The LT-270 has an external cooler integrated into the radiator which is used
to keep the transmission oil from overheating. The oil is directed through the
torque converter circuit and then it goes to the oil cooler. From the oil cooler,
the oil goes to the transmission for positive lubrication. The transmission oil
cooler should be kept clean so it can function properly. Periodic inspection of
the radiator and hoses should be carried out, paying attention to leaks and
damage to hoses.

The torque converter and transmission hydraulic systems are important links
in the flow of power from the engine to the wheels. Since the two systems are
interconnected, the operation of either unit depends on the condition and
operation of the other. Therefore whenever a repair or overhaul is performed
on one unit, the condition of the whole system must be considered and the oil

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cooler in the radiator should be thoroughly cleaned. To clean, use oil, com-
pressed air and steam. The transmission oil cooler should be back flushed
until all foreign material has been removed. Flushing in the normal direction
of oil flow will not adequately clean the cooler. Do not use any type of flush-
ing compounds to clean the cooler.

T20000 For transmission repair, assembly, disassembly and maintenance, please see
TRANSMISSION the Dana T20000 service manual #0220. The transmission service manual
SERVICING can be found in a separate section at the end of this manual.

CHANGING This section will outline the procedure for driveline removal and replace-
DRIVELINES ment. The procedures are only intended to be a guideline, and your own com-
pany's policies may dictate a different approach to this job procedure.

Safe Working Practices

» Always use the appropriate lifting devices when you perform this task.
Be sure that you have properly blocked the machine and applied the
appropriate tags to warn others that the unit is being worked on.
» Follow your company's procedures for blocking and tagging of equip-
ment.

Removing a Driveline
To remove a driveline from the unit:

» Before attempting to remove any drivelines, make sure that the machine
is properly blocked, as removing a driveline could cause an unexpected
movement of the machine.
» Remove the bolts from the universal joints, one end at a time. Lower
each side of the driveline to the bottom of its travel.

If the driveline is a two-piece unit observe the phasing (See illustration

below) before removing from machine.
Installing the Driveline

To properly install a driveline, reverse the removal procedures above and pay
attention to the following:

» Check U-joints for wear or damage and replace, if necessary. Check

spline slip joints for wear or damage and replace, if necessary.
» When installing two-piece driveline make sure phasing is correct.
» Torque all bolts to manufacturers recommended torque specs.

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CHANGING THE Care should be taken whenever you work around and under a machine. Never
FRONT AXLE perform any work on a vehicle that is supported by hydraulic jacks only. Use
the proper support stands to hold the machine up while you work on it. Be
sure the machine you are working on is properly blocked, tagged and secured
according to your company's standard safety procedures and policies. Always
use the proper slings and lifting devices whenever lifting any components and
never go under a suspended load. The proper gloves should always be worn
when working with wire slings.

Removing the Front Axle

The procedure for removing the front axle is as follows:

» Park the unit with the boom and the quick attach frame at ground level.
» Shut the engine off and turn the Master Switch off.
» Tag the machine according to the shop procedures.
» Always use the appropriate lifting devices when you perform this task.
» Be sure that you have properly blocked the machine and applied the
appropriate tags to warn others that the unit is being worked on. Follow
your company's procedures for blocking and tagging of equipment.
» Raise the front of the machine with hydraulic jacks, until the wheels are
off the ground, and install the support stands under the frame of the
machine.
» Remove the wheel assemblies from the front axle, and place them in a
secure area.
» Drain the oil from the wheel ends and differential, before removing
from the unit.
» Remove the brake lines from the wheel ends and install caps and plugs
on the ends to prevent dirt from entering the brake lines.
» Remove the front driveline universal joint fasteners from the front dif-
ferential yoke, and remove the slip yoke from the driveline.
» Support the front axle with an overhead hoist and the proper slings
before you remove the axle mounting bolts from the frame.
» Lower the axle to the ground and pull it out from under the machine,
exercising caution not to disturb the frame supports.

Installing the Front Axle

Reverse the removal procedures above to install front axle assembly and pay
attention to the following:

Note: When installing mount bolts be sure to install hardened washers and
compression tubes.

» Tighten axle mount fasteners to 740 ft-lbs.

» When installing brake hoses make sure no dirt gets into system and
tighten fittings to proper specs.

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 LT-270 Service Manual

» Refill wheel ends and axle assembly with clean, approved lubricant.
» Test drive unit and perform a brake test according to your company pro-
cedures.
» Check for leaks.

CHANGING THE Be sure the machine you are working on is properly blocked, tagged, and
REAR AXLE secured, according to your company's standard safety procedures and poli-
cies. Caution should always be exercised whenever you work under or
around a machine. Never perform any work on a machine that is supported by
hydraulic jacks only; use approved support stands to hold the machine up
while you work on it. Always use the proper slings and lifting devices when-
ever lifting any components and never go under a suspended load. The proper
gloves should always be worn when working with slings.

Removing the Rear Axle

» Raise the rear end of the machine with hydraulic jacks, until the wheels
are off the ground, and install the support stands under the frame of the
machine.
» Remove the rear wheels from the machines rear axle, and place in a
secure position.
» Drain the oil from the rear wheel ends and differential, before removing
the axle assembly.
» Remove the brake lines from the wheel ends and install caps and plugs
on the ends to prevent dirt from entering the brake lines.
» Remove the driveline universal joint fasteners from the rear differential
yoke, and remove the slip yoke from the driveline.
» Support the rear axle assembly with an over-head hoist and the proper
slings before you remove the trunnion mounting bolts from the frame.
» Remove the trunnion mounting bolts, and lower the rear axle assembly
to the floor with the hoist.
» Once the rear axle assembly is removed from under the LHD, remove
the old cradle bushings and thrust washers.
» Inspect the bearing load area for any damage or wear.

Installing the Rear Axle

Note: Pre-lubricate all friction areas with suitable grease, before assembling
together.

» Install the front and rear trunnion bushings.

» Install the axle in place and align the trunnion bushings in place.
» Install the trunnion cradle supports, bolt and torque them in place.
» Refill the differential and wheel ends with new lubricant.
» Reinstall the drivelines, and tires. Remove the blocking from under the
machine.
» Test drive the unit.

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AXLE SERVICE For axle repair, assembly, disassembly and maintenance, please see the Dana
INSTRUCTIONS 163LD Maintenance and Repair Manual #MO163LF10. The axle service
manual can be found in a separate section at the end of this manual.

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 LT-270 Service Manual

OPTIONAL EQUIPMENT

In this chapter you can find detailed information on some of the major
options purchased with your particular LT-270 unit. Further breakdowns of
individual parts can be found in the accompanying Parts manual. More
detailed operating instructions can be found in the appropriate section of the
Operator’s manual.

ANSUL FIRE This unit is equipped with a fire sup-

SUPPRESSION pression system capable of extin-
SYSTEM guishing fires that might start on the
machine. The system distributes a dry,
fire suppressant chemical throughout
the unit when set off by the operator.
Distribution of the fire suppressant is
done through a series of hoses, mani-
folds and nozzles. The suppressant is
discharged when the operator, or
nearby personnel, depresses the
plunger of an actuator on the
machine. Nozzle placement has been
designed to cover as much of the
machine and its major components as
possible. Areas that are traditionally
considered a fire risk are protected. These areas include the engine compart-
ment, disc brake area and around the transmission.

Operation
The operator removes the safety pin from the remote/dash actuator (1) and
strikes the actuator button to puncture the actuator gas cartridge. This allows
nitrogen to pressurize the propellant cartridge actuator / receiver (2). The pro-
pellant cartridge actuator / receiver punctures the propellant cartridge (4)
seal. This releases high-pressure nitrogen gas into the chemical suppressant
canister (5).

This causes the high-pressure nitrogen to mix with the suppressant powder
and makes it fluid enough to flow though the hoses. The bursting disc at the
discharge union (6) holds the mixture in the tank until the pressure is high
enough to burst the disc. This allows the suppressant/propellant mixture into
the distribution hoses to the nozzles (7). At the nozzles, the pressure forces
the packing grease or plastic caps off the nozzles and spreads the fire suppres-
sant chemical throughout the machine.

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Main Components
Most fire suppression systems are very similar to one another; the system
used on LT-270 is no exception. This machine carries the standard compli-
ment of fire suppression equipment for a machine of its size. The LT-270 uses
a manual actuation or an automatic Checkfire actuation system. Components
that are installed are:

» Dry Chemical Tank

» Main propellant (nitrogen) cartridge
» Manual actuators (2)
» Nozzles
» Hoses, Lines and Tees
» Dry fire suppressant chemical (powder form)
» Optional Checkfire components

Main Suppressant Tank

The fire suppressant powder is stored in a large tank. This tank is normally at
or near atmospheric pressure. The tank is only pressurized when the system is
activated. Because the suppressant is a powder and is discharged from the
system under pressure, the tank is sealed from the atmosphere by a screw-on
cap with an O-ring seal. The tank ensures that the suppressant is free of mois-
ture until it is used. There are only two ports on the tank; an inlet for the pro-
pellant gas and a large discharge port at the bottom to allow the suppressant
out into the distribution hoses.

Actuators
This suppression system uses three actuators. The main actuator will auto-
matically pierce the seal of the main discharge cartridge when a manual actu-
ator is fired. The dashboard and remote actuators work in a similar manner
and are operated by hand. The operator strikes the button on top of the actua-
tor and pierces the seal on the actuator’s cartridge. The pressurized gas from
the cartridge operates the main actuator. Note that the dashboard and remote
actuators are protected from accidental actuation by a safety pin. The pin
must be removed before the button can be depressed.

Nozzles
The nozzles are responsible for directing the suppressant at high risk fire
areas. The nozzles produce a fan shaped discharge pattern that effectively
blankets the machine with chemical suppressant during a fire event. Keeping
the nozzles clean is very important and you will find that they are either
packed with special grease or capped with a plastic cap to prevent the
entrance of dirt. See “Fire Suppression System Maintenance” on page 101 for
more details.

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Hoses and Lines

To ensure proper performance of the fire suppression system, the correct type
and size of hose must be used. The LT-270 is equipped with special fire sup-
pression hose, which is similar to hydraulic hose. Hoses that are used in the
fire suppression system are colored red for easy identification. It also signi-
fies that it is a special type of hose. Care must be taken when replacing or
moving the hoses to ensure that they have the proper minimum bend radius,
are not too long and are not crushed or kinked in any way.

Inspecting the Fire Suppression System

The fire suppression system must be inspected daily as part of the pre-opera-
tive walk around inspection. This will ensure that the system is operable and
can give proper protection for the operator and the machine. The inspection is
similar to a bi-weekly or monthly inspection. DO NOT allow operation of the
LT-270 if the fire suppression is not in working order! When inspecting the
Fire Suppression System look for the following items:

» Check all components for physical damage.

» Check nozzles for damage and blockage.
» Check hose routing.
» Make sure safety pins are in place and easy to remove.

Responding to a Fire Emergency

In the event of a fire on the unit, the operator or service technician must react
as quickly as possible. The speed in reacting and performing the actuation
procedure will greatly affect the amount of damage to the machine and the
possible prevention of injury to worksite and personnel.

The following is a recommended procedure for response to a fire on the

machine. Follow any guidelines or procedures outlined by your company or
worksite. If a fire starts follow these steps:

» Bring the machine to a complete stop and shut down the machine func-
tions as quickly as possible. Set the park brake and turn off the engine.
This will prevent fuel or oil from being added to a hot area, which will
re-ignite the fire. If the situation does not allow for this procedure sim-
ply shut the unit down which will cause an ABA stopping the unit. Be
aware however that the unit will stop suddenly and violently if this
course of action is followed!
» Pull the safety pin from the actuator closest to you (dashboard or
remote) and discard it.
» Watch the machine from a safe distance until the risk of fire has dimin-
ished. This may take up to an hour for the unit to cool to a point where
the fire will not restart. At this time you may leave the machine to report
the fire.

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 LT-270 Service Manual

» As soon as possible activate your site's emergency response procedure

as dictated by site procedure.

Note that if the fire suppression does not activate from the actuator used, it is
permissible to try the other actuator only if it is safe to do so. Remember if
the machine is on fire, the actuators are not accessible, or the fire suppression
system fails, your life is not worth risking saving the machine. Fight the fire
in a safe manner with approved methods or retreat from the fire in your site's
prescribed manner. Be sure to initiate the emergency response team as
quickly as possible to ensure that the fire is fought, contained and guarded in
the proper manner.

When discharging the fire suppression system in the event of a fire you must
be aware of what is going to happen and how soon it is going to happen.
When you shut the machine down, be prepared for Automatic Brake Applica-
tion (ABA). If you aren't prepared you could possibly be injured. When you
actually discharge the fire suppression system, there will be a popping sound
followed by a loud hiss as the suppressant is forced through the hoses and
nozzles.

Be prepared to fight the fire with the portable extinguisher taken from the
machine. Although re-ignition or system failure is fairly unlikely, it is a possi-
bility. When the system discharges the suppressant it will be in the form of a
yellowish cloud that will surround the machine. Although the suppressant is
non-toxic, refrain from inhaling any more suppressant than necessary, as it is
in a powder form and may clog breathing passages. Note that you should
never attempt to operate a machine that has just been on fire as the risk of
equipment damage or personal injury will be very high.

Cleaning the Machine

After a fire the unit must be completely cleaned and serviced. Remember the
suppressant chemical powder is very fine and permeates almost everything
on the machine. The suppressant will easily wash off the LT-270 with a pres-
sure washer. Make sure after a fire to replace all damaged components and
change all affected fluid levels and their respective filters. Also be sure to
replace the air filter cartridge and thoroughly clean out the air filter canister.

Fire Suppression System Maintenance

Just like any other major component of the machine, the Fire Suppression
System must have regular maintenance performed on it. Because of the
nature of the mining environment and the nature of the Fire Suppression Sys-
tem, it must be properly maintained to ensure it will function as designed
should it ever be needed. Regular maintenance must be performed on the
nozzles, suppressant canister, main propellant cartridge, and actuator car-
tridges.

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Maintaining the Suppressant Canister

Because the chemical fire suppressant is a fine powder it is subject to settling,
packing and moisture. When tramming the LT-270, the suppressant is con-
stantly being shaken and settles into a hard packed cake at the bottom of the
canister. Maintenance of the canister is simple and should be done at least
once every two weeks. Visually inspect the canister for damage. Remove the
lid and check the seal for cracks, or other damage and replace if necessary.
Using a clean, dry tool, break the suppressant up into a powder. Be sure there
are no clumps. Replace the suppressant if it will not easily break down into a
powder. Reinstall the cap so it is sealed but not over tightened.

Maintaining the Propellant and Actuator Cartridges

There is little maintenance needed on the gas cartridges used for the actuators
and propellant. Whenever the fire suppression system is serviced, remove the
cartridges, clean and weigh them. If the measured weight is equal to that
stamped on the cartridge, it is OK to reuse. If the weight is lower than indi-
cated on the cartridge, it must be replaced. Note that properly calibrated
scales must be used to measure the cartridges to ensure accuracy. Also
inspect the seal in the actuator for damage and make sure there is a light coat-
ing of silicone grease on the seal.

Maintaining the Nozzles

The nozzles must be maintained with the rest of the system. To ensure that
the nozzles are kept clean and unblocked the outlets are filled with a special
grease or plastic cover. The grease is specially designed to come out of the
nozzle when the system is discharged. This grease should be inspected to
make sure it is present and has not hardened. Occasionally the grease should
be replaced with the correct special purpose grease. If plastic caps are used,
make sure they are in place and can come off the nozzle easily. Clean the noz-
zle and replace cap as necessary.

It is also good practice to disconnect the main discharge hose from the sup-
pressant canister at regular intervals, and using compressed air, blow air
through the entire discharge system (distribution tees, hosing and nozzles
with caps or grease in place). This ensures that the system will perform prop-
erly. Ensure all nozzles expel the caps or grease and that even flow is felt at
all of the nozzles.

Note: Ensure that when pressure testing the system, all compressed gas car-
tridges (nitrogen bottles) have first been removed to prevent injury or
accidental discharge of the suppression system.

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Maintaining the Hoses, Lines and Fittings

The fire suppression system uses many different hoses, lines, fittings and
check valves. These parts require very little maintenance. Perform a general
visual inspection of these parts for damage, kinks, twists, splits, cracks, etc.
Occasional pressure testing of the actual systems is recommended. Check for
leaks and flow-through of all of the components. If any of the components are
damaged repair or replace them as required.

Note: Ensure that when pressure testing the system, all compressed gas car-
tridges (nitrogen bottles) have first been removed to prevent injury or
accidental discharge of the suppression system.

Recharging the Fire Suppression System

These are the steps that must be taken to recharge the fire suppression system:

» Pull safety valve open to relieve residual pressure in the system.

» Remove the bursting disc union and replace bursting disc (flat side to
the dry chemical canister). Fill the suppressant canister with the correct
amount of dry chemical listed on the ID tag.
» Inspect the canister lid, gasket and threads. Put a light coating of heat
resistant grease on the gasket and reinstall the lid hand tight.
» Remove the propellant cartridge guard and propellant cartridge. Make
sure the pneumatic actuated piercing pin is fully retracted. Weigh and
install a new cartridge and the cartridge guard.
» Use compressed air to blow the discharge hosing clean, from the dis-
charge fitting at the suppressant canister onward to the nozzles. Blow
out the nozzle hosing individually if necessary to ensure all suppressant
has been removed. If in doubt that all suppressant has been removed,
replace the hosing with new. This should be done before washing the
unit for repair.
» Pack the nozzle openings with the special silicone grease or replace pro-
tective plastic caps as required.
» Retract the dash and remote actuator piercing pins as required and
install safety pin. Weigh and install new cartridges as needed. Weigh
unused cartridge to determine serviceability and reinstall or replace as
required.
» Recheck entire system to make sure that no steps were missed or over-
looked.

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HYDRAULIC The optional electric hydraulic filler pump is used to replenish the hydraulic
FILLER PUMP tank. Closing the momentary filler pump button will energize the (FPR) relay.
OPTION The n/o ‘FPR’ contacts will close and energize the filler pump.

104
NOTES
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