JLG 520AJ Service & Maintenance Manual (3121665) – PDF DOWNLOAD (ENG)

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JLG 520AJ Service & Maintenance Manual (3121665) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 520AJ Service & Maintenance Manual (3121665) – PDF DOWNLOAD

Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS.........................................................................................................................................................................................................................  3
	A General....................................................................................................................................................................................................................................................................  3
	B Hydraulic System Safety....................................................................................................................................................................................................................................................  3
	C Maintenance................................................................................................................................................................................................................................................................  3
Section 1. Specifications........................................................................................................................................................................................................................................................ 21
	1.1 Operating Specifications................................................................................................................................................................................................................................................. 21
	1.2 Dimensional Data......................................................................................................................................................................................................................................................... 21
	1.3 Capacities............................................................................................................................................................................................................................................................... 21
	1.4 Tires.................................................................................................................................................................................................................................................................... 21
	1.5 Engine Data.............................................................................................................................................................................................................................................................. 21
	1.6 Hydraulic Oil............................................................................................................................................................................................................................................................ 22
	1.7 Maintenance and Lubrication.............................................................................................................................................................................................................................................. 23
		1. Swing Bearing......................................................................................................................................................................................................................................................... 23
		2. Swing Bearing/Worm Gear Teeth......................................................................................................................................................................................................................................... 25
		3. Hydraulic Tank........................................................................................................................................................................................................................................................ 25
		4. Hydraulic Return Filter............................................................................................................................................................................................................................................... 25
		5. Hydraulic Tank Breather............................................................................................................................................................................................................................................... 26
		6. Wheel Drive Hub....................................................................................................................................................................................................................................................... 26
		7. Drive Brake........................................................................................................................................................................................................................................................... 26
		8. Oil Change with Filter - Deutz 2.3 L3................................................................................................................................................................................................................................. 26
		9. Fuel Filter/Water Separator - Deutz 2.3 L3............................................................................................................................................................................................................................ 27
		10. Charge Filter........................................................................................................................................................................................................................................................ 27
		11. Air Filter........................................................................................................................................................................................................................................................... 27
Section 2. General............................................................................................................................................................................................................................................................... 33
	2.1 Machine Preparation, Inspection, and Maintenance......................................................................................................................................................................................................................... 33
		General.................................................................................................................................................................................................................................................................. 33
		Preparation, Inspection, and Maintenance................................................................................................................................................................................................................................. 33
		Pre-Start Inspection..................................................................................................................................................................................................................................................... 33
		Pre-Delivery Inspection and Frequent Inspection.......................................................................................................................................................................................................................... 33
		Annual Machine Inspection................................................................................................................................................................................................................................................ 33
		Preventive Maintenance................................................................................................................................................................................................................................................... 33
	2.2 Service and Guidelines................................................................................................................................................................................................................................................... 34
		General.................................................................................................................................................................................................................................................................. 34
		Safety and Workmanship................................................................................................................................................................................................................................................... 34
		Cleanliness.............................................................................................................................................................................................................................................................. 34
			1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provi........... 34
			2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter..................... 34
			3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their co........... 34
		Components Removal and Installation...................................................................................................................................................................................................................................... 34
			1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted..................................... 34
			2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees................................... 34
			3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering..................................................................................................... 34
		Component Disassembly and Reassembly..................................................................................................................................................................................................................................... 35
		Pressure-Fit Parts....................................................................................................................................................................................................................................................... 35
		Bearings................................................................................................................................................................................................................................................................. 35
			1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing................................................................. 35
			2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned................................................................................................................................................................................ 35
			3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install....................................................................................... 35
			4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race................................. 35
		Gaskets.................................................................................................................................................................................................................................................................. 35
		Bolt Usage and Torque Application........................................................................................................................................................................................................................................ 35
			1. Always use new replacement hardware when installing locking fasteners. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area........... 35
			2. Unless specific torque requirements are given within the text, standard torque values should be used on heat- treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart in Section 1.)............................... 35
		Hydraulic Lines and Electrical Wiring.................................................................................................................................................................................................................................... 35
		Hydraulic System......................................................................................................................................................................................................................................................... 35
			1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.............................................................................................................................. 35
			2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly............................................................................................. 35
		Lubrication.............................................................................................................................................................................................................................................................. 35
		Battery.................................................................................................................................................................................................................................................................. 35
		Lubrication and Servicing................................................................................................................................................................................................................................................ 35
	2.3 Lubrication and Information.............................................................................................................................................................................................................................................. 36
		Hydraulic System......................................................................................................................................................................................................................................................... 36
			1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means: e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenanc........... 36
			2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera........... 36
			3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil........................................................ 36
			4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is........... 36
		Hydraulic Oil............................................................................................................................................................................................................................................................ 36
			1. Refer to Section 1 for recommendations for viscosity ranges....................................................................................................................................................................................................... 36
			2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.................................................................................................................................................... 36
		Changing Hydraulic Oil................................................................................................................................................................................................................................................... 36
			1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this ........... 36
			2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replac........... 36
			3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.................. 36
		Lubrication Specifications............................................................................................................................................................................................................................................... 36
	2.4 Cylinder Drift........................................................................................................................................................................................................................................................... 37
		Theory................................................................................................................................................................................................................................................................... 37
		Cylinder Leakage Test.................................................................................................................................................................................................................................................... 37
		Cylinder Thermal Drift................................................................................................................................................................................................................................................... 37
	2.5 Pins and Composite Bearing Repair Guidelines............................................................................................................................................................................................................................. 38
		1. Pinned joints should be disassembled and inspected if the following occurs:........................................................................................................................................................................................... 38
			a. Excessive sloppiness in joints.................................................................................................................................................................................................................................... 38
			b. Noise originating from the joint during operation................................................................................................................................................................................................................. 38
		2. Filament wound bearings should be replaced if any of the following is observed:....................................................................................................................................................................................... 38
			a. Frayed or separated fibers on the liner surface................................................................................................................................................................................................................... 38
			b. Cracked or damaged liner backing.................................................................................................................................................................................................................................. 38
			c. Bearings that have moved or spun in their housing................................................................................................................................................................................................................. 38
			d. Debris embedded in liner surface.................................................................................................................................................................................................................................. 38
		3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):..................................................................................................................................................... 38
			a. Detectable wear in the bearing area............................................................................................................................................................................................................................... 38
			b. Flaking, pealing, scoring, or scratches on the pin surface........................................................................................................................................................................................................ 38
			c. Rusting of the pin in the bearing area............................................................................................................................................................................................................................ 38
		4. Re-assembly of pinned joints using filament wound bearings............................................................................................................................................................................................................ 38
			a. Housing should be blown out to remove all dirt and debris. Bearings and bearing housings must be free of all contamination........................................................................................................................................ 38
			b. Bearing/pins should be cleaned with a solvent to remove all grease and oil. Filament wound bearings are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins)................................................................... 38
			c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation and operation..................................................................................................................... 38
	2.6 Welding on JLG Equipment................................................................................................................................................................................................................................................. 38
		Do the Following When Welding on JLG Equipment........................................................................................................................................................................................................................... 38
		Do NOT Do the Following When Welding on JLG Equipment.................................................................................................................................................................................................................... 38
Section 3. Chassis & Turntable................................................................................................................................................................................................................................................... 45
	3.1 Tires and Wheels......................................................................................................................................................................................................................................................... 45
		Tire Damage.............................................................................................................................................................................................................................................................. 45
		Wheel and Tire Replacement............................................................................................................................................................................................................................................... 45
		Wheel Installation....................................................................................................................................................................................................................................................... 45
			1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts...................................................................................................................................................................... 45
			2. Tighten nuts in the following sequence:........................................................................................................................................................................................................................... 45
			3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart...................................................................................................................................... 45
			4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check and torque every 3 months or 150 hours of operation............................................................................................................ 45
	3.2 Oscillating Axle System.................................................................................................................................................................................................................................................. 46
	3.3 Lockout Cylinder Bleeding................................................................................................................................................................................................................................................ 46
		1. Position turntable to normal stowed position so axle is free to oscillate. Drive charge pressure will pass through lockout valve built into swivel and down to pilot section of holding valves on cylinders. This will automatically purge air from pil............... 46
		2. Attach end of clear tubing to bleeder valve nipple and place other end in container to catch oil. Using a wrench, slowly turn bleeder valve counterclockwise to bleed air from cylinder. Have operator in platform just crack drive controller in rever............... 46
		3. Repeat procedure for other lockout cylinder........................................................................................................................................................................................................................... 46
	3.4 Oscillating Axle Lockout Test............................................................................................................................................................................................................................................ 46
		1. Place a 6 in. (15 cm) high block with ascension ramp in front of left front wheel..................................................................................................................................................................................... 46
		2. From platform control station, activate machine hydraulic system...................................................................................................................................................................................................... 46
		3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/ TORQUE SELECT control switches to LOW positions......................................................................................................................................................................... 46
		4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block................................................................................................................................. 46
		5. Carefully activate SWING control lever and position boom over right side of machine................................................................................................................................................................................... 46
		6. With boom over right side of machine, place DRIVE control lever to REVERSE. Drive machine off block and ramp.......................................................................................................................................................... 46
		7. Have an assistant check to see left front wheel remains locked in position off of ground.............................................................................................................................................................................. 46
		8. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground. It may be necessary activate ............... 47
		9. Place 6 in. (15 cm) high block with ascension ramp in front of right front wheel...................................................................................................................................................................................... 47
		10. Place DRIVE control lever to FORWARD. Carefully drive machine up ramp until right front wheel is on top of block..................................................................................................................................................... 47
		11. Carefully activate SWING control lever and position boom over left side of machine................................................................................................................................................................................... 47
		12. With boom over left side of machine, place DRIVE control lever to REVERSE. Drive machine off block and ramp.......................................................................................................................................................... 47
		13. Have an assistant check to see that right front wheel remains locked in position off ground.......................................................................................................................................................................... 47
		14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground. It may be necessary activate............... 47
		15. If lockout cylinders do not function properly, have qualified personnel correct malfunction before further operation................................................................................................................................................. 47
	3.5 Drive Orientation System................................................................................................................................................................................................................................................. 47
	3.6 Chassis Tilt Indicator System............................................................................................................................................................................................................................................ 47
	3.7 Drive System............................................................................................................................................................................................................................................................. 48
		1. Bolt.................................................................................................................................................................................................................................................................. 49
		2. Bolt.................................................................................................................................................................................................................................................................. 49
		3. Bearing............................................................................................................................................................................................................................................................... 49
		4. Keeper Pin............................................................................................................................................................................................................................................................ 49
		5. Washer................................................................................................................................................................................................................................................................ 49
		6. Washer................................................................................................................................................................................................................................................................ 49
		7. Bolt.................................................................................................................................................................................................................................................................. 49
		8. Wear Pad.............................................................................................................................................................................................................................................................. 49
		9. Shim.................................................................................................................................................................................................................................................................. 49
		10. Shim................................................................................................................................................................................................................................................................. 49
		11. Axle................................................................................................................................................................................................................................................................. 49
		12. Axle Lockout Cylinder................................................................................................................................................................................................................................................ 49
		13. Pin.................................................................................................................................................................................................................................................................. 49
		14. Shim................................................................................................................................................................................................................................................................. 49
		15. Washer............................................................................................................................................................................................................................................................... 49
		1. Thrust Bearing........................................................................................................................................................................................................................................................ 50
		2. Bolt.................................................................................................................................................................................................................................................................. 50
		3. Bolt.................................................................................................................................................................................................................................................................. 50
		4. Bolt.................................................................................................................................................................................................................................................................. 50
		5. Keeper Pin............................................................................................................................................................................................................................................................ 50
		6. Washer................................................................................................................................................................................................................................................................ 50
		7. Washer................................................................................................................................................................................................................................................................ 50
		8. Steer Cylinder........................................................................................................................................................................................................................................................ 50
		9. Link.................................................................................................................................................................................................................................................................. 50
		10. Nut.................................................................................................................................................................................................................................................................. 50
		11. Kingpin.............................................................................................................................................................................................................................................................. 50
		12. Spindle.............................................................................................................................................................................................................................................................. 50
		13. Pin.................................................................................................................................................................................................................................................................. 50
		1. Thrust Bearing........................................................................................................................................................................................................................................................ 51
		2. Bolt.................................................................................................................................................................................................................................................................. 51
		3. Bolt.................................................................................................................................................................................................................................................................. 51
		4. Bolt.................................................................................................................................................................................................................................................................. 51
		5. Bolt.................................................................................................................................................................................................................................................................. 51
		6. Bearing............................................................................................................................................................................................................................................................... 51
		7. Pin................................................................................................................................................................................................................................................................... 51
		8. Keeper Pin............................................................................................................................................................................................................................................................ 51
		9. Bolt.................................................................................................................................................................................................................................................................. 51
		10. Washer............................................................................................................................................................................................................................................................... 51
		11. Washer............................................................................................................................................................................................................................................................... 51
		12. Washer............................................................................................................................................................................................................................................................... 51
		13. Washer............................................................................................................................................................................................................................................................... 51
		14. Pin.................................................................................................................................................................................................................................................................. 51
		15. Steer Cylinder....................................................................................................................................................................................................................................................... 51
		16. Link................................................................................................................................................................................................................................................................. 51
		17. Nut.................................................................................................................................................................................................................................................................. 51
		18. Kingpin.............................................................................................................................................................................................................................................................. 51
		19. Spindle.............................................................................................................................................................................................................................................................. 51
		20. Bracket.............................................................................................................................................................................................................................................................. 51
		21. Pivot Plate.......................................................................................................................................................................................................................................................... 51
		22. Link................................................................................................................................................................................................................................................................. 51
		23. Link................................................................................................................................................................................................................................................................. 51
		24. Pin.................................................................................................................................................................................................................................................................. 51
		25. Bolt................................................................................................................................................................................................................................................................. 51
		26. Washer............................................................................................................................................................................................................................................................... 51
	3.8 Wheel Drive Assembly..................................................................................................................................................................................................................................................... 52
		Removal.................................................................................................................................................................................................................................................................. 52
			1. Use a jack to lift the frame enough so the tire and wheel assembly is off the ground. Place blocking strong enough to support the weight of the machine under the frame and remove the jack....................................................................... 52
			2. Remove hardware securing wheel and remove tire and wheel assembly. Using suitable lifting device lift the tire and wheel assembly and place in a suitable area.................................................................................................... 52
			3. Tag and disconnect the hydraulic lines running to the drive motor. Cap or plug all openings to ensure no dirt enters the hydraulic system......................................................................................................................... 52
			4. Use a supporting device capable of handling the weight of the drive hub and drive motor, and unbolt the drive hub from the frame. Remove the entire assembly from the machine..................................................................................... 52
			5. Remove the capscrews and washers that secure the drive motor to the drive hub and remove the drive motor. Remove and discard the brake gasket between the drive motor and drive hub............................................................................... 52
		Installation............................................................................................................................................................................................................................................................. 52
			1. Install a new brake gasket between the drive motor and drive hub. Apply a coat of JLG Threadlocker P/N 0100011 on capscrews. Install the washers and capscrews to secure the drive hub and drive motor, and torque to 70 ft. lbs. (95 Nm)......................... 52
			2. Place the drive hub flange against the mounting flange on the axle and fasten it in place with the bolts and washers. Torque the bolts to 190 ft. lbs. (260 Nm)................................................................................................... 52
			3. Using adequate support, install wheel into wheel assembly and secure with hardware. See “Wheel Installation” for torque details................................................................................................................................... 52
	3.9 Torque Hub............................................................................................................................................................................................................................................................... 53
		Roll and Leak Testing.................................................................................................................................................................................................................................................... 53
		Tightening and Torquing Bolts............................................................................................................................................................................................................................................ 53
			1. Tighten (but do not torque) bolt ”A” until snug................................................................................................................................................................................................................... 53
			2. Go to opposite side of bolt circle and tighten bolt ”B” until equally snug........................................................................................................................................................................................ 53
			3. Continue around bolt circle and tighten remaining bolts........................................................................................................................................................................................................... 53
			4. Apply specified torque to bolt ”A”................................................................................................................................................................................................................................ 53
			5. Continue around bolt circle and apply equal torque to remaining bolts............................................................................................................................................................................................. 53
		Main Disassembly for “B” Drives.......................................................................................................................................................................................................................................... 54
			1. Turn hub (1G) on side, Remove coupling (14) from wide end of spindle (1A)......................................................................................................................................................................................... 54
			2. Mark location of shoulder bolt holes on outside of ring gear and hub for easy realignment when rebuilding. Remove four shoulder bolts (13) and 12 bolts (12) from cover (6)....................................................................................... 54
			3. Remove 16 flat washers (16) from cover (6)........................................................................................................................................................................................................................ 54
			4. Lift cover sub-assembly (6) off ring gear (4). Set cover on table with interior side facing up.................................................................................................................................................................... 54
			5. Remove O-ring (5) from counterbore around edge of cover (6A). Discard O-ring...................................................................................................................................................................................... 54
			6. Remove thrust washer (11) from counter- bore in top of carrier (3A)............................................................................................................................................................................................... 54
			7. Remove input gear (8) from middle of carrier sub-assembly (3)..................................................................................................................................................................................................... 54
			8. Lift ring gear (4) off hub (1G)................................................................................................................................................................................................................................... 54
			9. Lift carrier sub-assembly (3) out of hub (1G)..................................................................................................................................................................................................................... 54
			10. Remove thrust spacer (9) from input shaft (7) in middle of spindle (1A).......................................................................................................................................................................................... 54
			11. Lift input shaft sub-assembly (7) out of middle of spindle (1A). Stand input shaft (7A) on splined end........................................................................................................................................................... 54
			12. Using retaining ring pliers, remove retaining ring (7B) from groove on input shaft (7A).......................................................................................................................................................................... 54
			13. Remove one spacer (7D), one spring (7C), and other spacer (7D) from input shaft (7A)............................................................................................................................................................................. 54
			14. Remove thrust washer (11) from around spindle (1A)............................................................................................................................................................................................................... 54
			15. Lift internal gear (2) out of hub (1G)........................................................................................................................................................................................................................... 54
			16. Remove O-ring (5) from counterbore in hub (1G). Discard O-ring................................................................................................................................................................................................... 54
			17. Main disassembly for ”B” drives is complete...................................................................................................................................................................................................................... 54
		Hub-Spindle Disassembly.................................................................................................................................................................................................................................................. 54
			1. Remove retaining ring (1I) from around spindle (1A) ia hub (1G)................................................................................................................................................................................................... 54
			2. Remove spacer (1H) from around spindle (1A) in hub (1G)........................................................................................................................................................................................................... 54
			3. Set hub (1G), with small end/spindle facing down, on something that will support the hub’s flange while it lifts hub up so spindle is not resting on anything. Carefully press or hammer spindle (1A) down and out of hub (1G).................................... 54
			4. If seal and bearing cone did not come out of small end of hub (1G) when you pressed spindle out of hub, remove seal (1B) and bearing cone (1D) from small end of hub (1G). Discard seal........................................................................... 54
			5. Bearing cone (1F) should be lying loose in wide end of hub (1G). Remove bearing cone (1F) from inside hub (1G).................................................................................................................................................... 54
			6. Remove bearing cup (1C) from counterbore in small end of hub (1G)................................................................................................................................................................................................. 54
			7. Turn hub (1G) over and lift it out of flange-support. Remove bearing cup (1E) from counterbore in wide end of hub (1G)............................................................................................................................................ 54
			8. Turn hub (1G) over onto its small end. Remove two pipe plugs (1J) from side of hub (1G)........................................................................................................................................................................... 54
			9. Press nine studs (1N) out of stud holes in hub (1G)............................................................................................................................................................................................................... 54
			10. Hub-spindle disassembly is complete.............................................................................................................................................................................................................................. 54
			1. Hub-Spindle Sub-Assembly.......................................................................................................................................................................................................................................... 59
				A. Spindle....................................................................................................................................................................................................................................................... 59
				B. Seal.......................................................................................................................................................................................................................................................... 59
				C. Bearing Cup................................................................................................................................................................................................................................................... 59
				D. Bearing Cone.................................................................................................................................................................................................................................................. 59
				E. Bearing Cup................................................................................................................................................................................................................................................... 59
				F. Bearing Cone.................................................................................................................................................................................................................................................. 59
				G. Hub........................................................................................................................................................................................................................................................... 59
				H. Spacer........................................................................................................................................................................................................................................................ 59
				I. Retaining Ring................................................................................................................................................................................................................................................ 59
				J. Pipe Plug..................................................................................................................................................................................................................................................... 59
				K. Stud.......................................................................................................................................................................................................................................................... 59
			2. Internal Gear..................................................................................................................................................................................................................................................... 59
			3. Carier Sub-Assembly............................................................................................................................................................................................................................................... 59
				A. Carrier Housing............................................................................................................................................................................................................................................... 59
				B. Thrust Washer................................................................................................................................................................................................................................................. 59
				C. Needle Roller................................................................................................................................................................................................................................................. 59
				D. Spacer........................................................................................................................................................................................................................................................ 59
				E. Planet Shaft.................................................................................................................................................................................................................................................. 59
				F. Cluster Gear.................................................................................................................................................................................................................................................. 59
				G. Roll Pin...................................................................................................................................................................................................................................................... 59
			4. Ring Gear......................................................................................................................................................................................................................................................... 59
			5. O Ring............................................................................................................................................................................................................................................................ 59
			6. Cover Sub-Assembly................................................................................................................................................................................................................................................ 59
				A. Cover......................................................................................................................................................................................................................................................... 59
				B. Cover Cap..................................................................................................................................................................................................................................................... 59
				C. Bolt.......................................................................................................................................................................................................................................................... 59
				D. Disconnect Cap................................................................................................................................................................................................................................................ 59
				E. Disconnect Rod................................................................................................................................................................................................................................................ 59
				F. O Ring........................................................................................................................................................................................................................................................ 59
				G. O Ring........................................................................................................................................................................................................................................................ 59
				H. Pipe Plug..................................................................................................................................................................................................................................................... 59
				I. ID Plate...................................................................................................................................................................................................................................................... 59
			7. Input Shaft Sub Assembly.......................................................................................................................................................................................................................................... 59
				A. Seal.......................................................................................................................................................................................................................................................... 59
				B. Retaining Ring................................................................................................................................................................................................................................................ 59
				C. Spring........................................................................................................................................................................................................................................................ 59
				D. Spacer........................................................................................................................................................................................................................................................ 59
			8. Input Gear........................................................................................................................................................................................................................................................ 59
			9. Thrust Spacer..................................................................................................................................................................................................................................................... 59
			11. Thrust Spacer.................................................................................................................................................................................................................................................... 59
			12. Bolt............................................................................................................................................................................................................................................................. 59
			13. Shoulder Bolt.................................................................................................................................................................................................................................................... 59
			14. Coupling......................................................................................................................................................................................................................................................... 59
			16. Flat Washer...................................................................................................................................................................................................................................................... 59
		Cover Disassembly........................................................................................................................................................................................................................................................ 60
			1. Remove two bolts (6C) holding disconnect cap (6D) to cover (6A)................................................................................................................................................................................................... 60
			2. Remove disconnect cap (6D) from on top of cover cap (6B) and cover (6A)........................................................................................................................................................................................... 60
			3. Remove two bolts (6C) holding cover cap (6B) to cover (6A)........................................................................................................................................................................................................ 60
			4. Remove cover cap (6B) from cover (6A)............................................................................................................................................................................................................................. 60
			5. Remove disconnect rod (6E) from cover cap (6B).................................................................................................................................................................................................................... 60
			6. Pry O-ring (6F) out of groove inside cover cap (6B). Discard O-ring............................................................................................................................................................................................... 60
			7. Remove O-ring (6G) from flange of cover cap (6B). Discard O-ring.................................................................................................................................................................................................. 60
			8. Remove pipe plug (6H) from cover (6A)............................................................................................................................................................................................................................. 60
			9. Cover disassembly is complete..................................................................................................................................................................................................................................... 60
		Carrier Disassembly...................................................................................................................................................................................................................................................... 60
			1. Using a punch and hammer, drive roll pin (3G) into planet shaft (3E).............................................................................................................................................................................................. 60
			2. Using a punch and hammer, drive planet shaft (3E) out of planet shaft hole in carrier housing (3A)................................................................................................................................................................ 60
			3. When you remove planet shaft (3E) from carrier housing, one thrust washer (3B), one cluster gear (3F), and one more thrust washer (3B) will come off planet shaft and come to rest inside carrier. Remove these parts from inside carrier......................... 60
			4. Remove 16 needle rollers (3C) from inside one end of cluster gear (3F). Discard needle rollers.................................................................................................................................................................... 60
			5. Remove one spacer (3D) from inside cluster gear (3F).............................................................................................................................................................................................................. 60
			6. Remove remaining 16 needle rollers (3C) from other side of cluster gear (3F). Discard needle rollers.............................................................................................................................................................. 60
			7. Repeat steps 1-6 to remove and disassemble two remaining cluster gears............................................................................................................................................................................................ 60
			8. At this point carrier disassembly is complete..................................................................................................................................................................................................................... 60
		Assemble Carrier......................................................................................................................................................................................................................................................... 60
			1. Apply grease to inside of one cluster gear (3F) and line one half of cluster gear with 16 needle rollers (3C)..................................................................................................................................................... 60
			2. Place spacer (3D) inside cluster gear (3F) so it rests on top of needle rollers................................................................................................................................................................................... 60
			3. Line remaining half of cluster gear (3F) with 16 needle rollers................................................................................................................................................................................................... 60
			4. Set carrier housing (3A) on table, sideways. Insert a planet shaft (3E), roll pin hole last, into one of the planet shaft holes from roll-pin-holed side of carrier housing (3A).................................................................................. 61
			5. Place thrust washer (3B) on end of planet shaft (3E) inside carrier. Fit tang of thrust washer into slot on inside edge of planet shaft hole...................................................................................................................... 61
			6. Following thrust washer, place cluster gear (3F), large end toward roll pin hole in carrier housing, on planet shaft (3E)......................................................................................................................................... 61
			7. Following cluster gear, place one more thrust washer (3B) onto planet shaft (3E) through opposite planet shaft hole in carrier housing (3A)....................................................................................................................... 61
			8. Use an alignment punch or similar tool to align roll pin holes in carrier housing (3A) and planet shaft (3E)...................................................................................................................................................... 61
			9. Drive roll pin (3G) into aligned roll pin holes in carrier housing (3A) and planet shaft (3E)..................................................................................................................................................................... 61
			10. Repeat steps 1 through 9 to assemble and install two remaining cluster gears..................................................................................................................................................................................... 61
			11. At this point carrier sub-assembly is complete................................................................................................................................................................................................................... 61
		Cover Sub-Assembly....................................................................................................................................................................................................................................................... 62
			1. Using disconnect rod, push O-ring (6F) into groove inside cover cap (6B).......................................................................................................................................................................................... 62
			2. Place O-ring (6G) onto cover cap (6B) so it rests against flange of cover cap..................................................................................................................................................................................... 62
			3. Insert disconnect rod (6E) into cover cap (6B).................................................................................................................................................................................................................... 62
			4. Set cover (6A) on table, exterior side up. Place cover cap (6B) on cover (6A). Align pipe plug hole in cover cap over pipe plug hole in cover..................................................................................................................... 62
			5. Place two cover cap bolts (6C) in any two bolt holes 180° apart on cover cap (6B) and tighten bolts............................................................................................................................................................... 62
			6. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of torque to both bolts (6C)........................................................................................................................................................................... 62
			7. With large end down, place disconnect cap (6D) on cover cap (6B), aligning pipe plug hole in disconnect cap over pipe plug hole in cover cap...................................................................................................................... 63
			8. Place two remaining bolts (6C) in bolt holes in disconnect cap (6D) and tighten bolts............................................................................................................................................................................. 63
			9. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5 Nm) of torque to both bolts (6C)........................................................................................................................................................................... 63
			10. Apply a light coat of “Never-Seize” to pipe plug (6H) and tighten it in pipe plug hole in cover (6A)............................................................................................................................................................. 63
			11. At this point cover sub-assembly is complete..................................................................................................................................................................................................................... 63
		Hub-Spindle Sub-Assembly................................................................................................................................................................................................................................................. 63
			1. Set hub (1G) on large end. Press bearing cup (1C) into counterbore in small end of hub (1G)....................................................................................................................................................................... 63
			2. Press nine studs (1N) in stud holes in hub (1G)................................................................................................................................................................................................................... 63
			3. Apply a light coat of “Never-Seize” to two pipe plugs (1J) and tighten them in two pipe plug holes in side of hub (1G)............................................................................................................................................ 64
			4. Turn hub (1G) over to small end. Press bearing cup (1E) into counterbore in deep end of hub (1G).................................................................................................................................................................. 64
			5. Set hub (1G) on large end. Place bearing cone (1D) into bearing cup (1C).......................................................................................................................................................................................... 64
			6. Press seal (1B) in small end of hub (1G).......................................................................................................................................................................................................................... 64
			7. Oil spindle, then lower hub (1G) small end down, onto spindle (1A)................................................................................................................................................................................................ 64
			8. Press bearing cone (1F) on spindle (1A) in hub (1G)............................................................................................................................................................................................................... 64
			9. Place spacer (1H) on spindle (1A) in hub (1G)..................................................................................................................................................................................................................... 65
			10. Place retaining ring (1I) over spacer onto spindle (1A) in hub (1G).............................................................................................................................................................................................. 65
			11. At this point hub-spindle sub-assembly is complete............................................................................................................................................................................................................... 65
		Main Assembly............................................................................................................................................................................................................................................................ 65
			1. Grease O-ring (5) and place it into counterbore in hub (1G)....................................................................................................................................................................................................... 65
			2. Oil exposed surfaces inside hub (1G).............................................................................................................................................................................................................................. 65
			3. Place internal gear (2) in hub (1G) so its internal splines mesh with external splines of spindle (1A). Oil internal gear (2)..................................................................................................................................... 65
			4. Place thrust washer (11) around spindle (1A) so it rests on bottom of internal gear (2)........................................................................................................................................................................... 66
			5. Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A).................................................................................................................................................................... 66
			6. Place spring (7C) on smooth end of input shaft (7A)............................................................................................................................................................................................................... 66
			7. Place other spacer (7D) on smooth end of input shaft (7A)......................................................................................................................................................................................................... 66
			8. Using retaining ring pliers, insert retaining ring (7B) in groove on input shaft (7A) by compressing spring and spacers together.................................................................................................................................. 66
			9. With large splined end down, place input shaft sub- assembly (7) into spindle (1A)................................................................................................................................................................................ 66
			10. Place thrust spacer (9) onto input shaft (7)..................................................................................................................................................................................................................... 67
			11. Set carrier sub-assembly (3) on a flat work surface so large ends of cluster gears (3F) face up. Locate punch marks on face of each cluster gear (3F) and position them at 12 o’clock............................................................................ 67
			12. With “X” marked side facing up, place ring gear (4) around cluster gears (3F).................................................................................................................................................................................... 67
			13. Place carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning “X” marked shoulder bolt hole in ring gear (4) over one of the shoulder bolt holes in hub. Mark location of shoulder bolt holes on outside of............... 67
			14. With internal splines facing up (counterbore end facing down), place input gear (8) into mesh with carrier sub- assembly (3)..................................................................................................................................... 67
			15. Oil all exposed surfaces inside hub (1G). Place thrust washer (11) into counterbore in top of carrier............................................................................................................................................................ 67
			16. Set cover (6A) on table, interior side up. Grease O-ring (5) and place in counterbore around edge of cover (6A).................................................................................................................................................. 68
			17. Place cover sub-assembly (6) on ring gear (4). Align pipe plug holes before disassembly.......................................................................................................................................................................... 68
			18. Place four flat washers (16) on top of bolt holes in cover sub-assembly.......................................................................................................................................................................................... 68
			19. Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten.............................................................................................................................................................................. 68
			20. Place remaining 12 flat washers (16) on remaining bolt holes in cover (6)........................................................................................................................................................................................ 68
			21. Place 12 bolts in remaining bolt holes in cover (6) and tighten.................................................................................................................................................................................................. 68
			22. Torque shoulder bolts (13) 18 to 25 ft. lbs. (25 to 34 Nm). Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 Nm).................................................................................................................................................... 69
			23. Turn hub (1G) on its side. Insert coupling (14) into end of spindle (1A)......................................................................................................................................................................................... 69
			24. Roll test unit in clockwise and counterclockwise directions. Perform same number of turns in each direction as the ratio of the unit. The ratio is the last two digits of the model number on the unit’s ID tag.................................................. 69
			25. Leak test unit at a pressure of 5 psi (34.47 kPa) for 2 to 3 minutes............................................................................................................................................................................................. 69
			26. At this point main assembly is complete.......................................................................................................................................................................................................................... 69
		Tool List................................................................................................................................................................................................................................................................ 70
			1. T-118126 SEAL PRESSING TOOL FOR SEAL (1B)......................................................................................................................................................................................................................... 70
			2. T-138903 ASSEMBLY PRESSING TOOL FOR CUP (1C)...................................................................................................................................................................................................................... 70
			3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E)...................................................................................................................................................................................................................... 70
			4. T-109691 ASSEMBLY PRESSING TOOL FOR CONE (1F)..................................................................................................................................................................................................................... 70
	3.10 Re-Align Torque Hub Input Coupling...................................................................................................................................................................................................................................... 71
		Equipment Required....................................................................................................................................................................................................................................................... 71
			1. Hydraulic power supply (hand pump) capable of producing 200 psi (13.8 bar)........................................................................................................................................................................................ 71
			2. Hydraulic fittings to adapt hydraulic supply to brake release port on hub......................................................................................................................................................................................... 71
		Procedure................................................................................................................................................................................................................................................................ 71
			1. Using appropriate fittings, connect a line from hydraulic power supply to brake port.............................................................................................................................................................................. 71
			2. Pressurize brake release port to 155 - 200 psi (10.6 - 13.8 bar) to release brake................................................................................................................................................................................. 71
			3. Verify brake is released by rotating input coupling or hub spindle. Once brake is released, input coupling is free to re-align with drive motor................................................................................................................... 71
			4. Install drive motor on hub. Release hydraulic pressure at brake release port. Coupling remains in position........................................................................................................................................................ 71
			5. Disconnect hydraulic power supply and reconnect line to brake release port........................................................................................................................................................................................ 71
	3.11 Drive Motor............................................................................................................................................................................................................................................................. 71
		Description.............................................................................................................................................................................................................................................................. 71
		Shaft Seal Replacement................................................................................................................................................................................................................................................... 72
			Removal.............................................................................................................................................................................................................................................................. 72
				1. Remove snap ring (1) and support washer (2)................................................................................................................................................................................................................... 72
				1. Snap Ring..................................................................................................................................................................................................................................................... 72
				2. Support Washer................................................................................................................................................................................................................................................ 72
				3. Shaft Seal.................................................................................................................................................................................................................................................... 72
					2. Carefully pry out and discard shaft seal (3).............................................................................................................................................................................................................. 72
			Inspect components................................................................................................................................................................................................................................................... 72
			installation......................................................................................................................................................................................................................................................... 72
				1. Cover shaft splines with an installation sleeve to protect shaft seal during installation..................................................................................................................................................................... 72
				2. Install a new shaft seal (3) with cupped side facing motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging seal..................................................................................................... 72
				3. Install seal support washer (2)............................................................................................................................................................................................................................... 72
				4. Install snap ring (1)......................................................................................................................................................................................................................................... 72
				5. Remove installation sleeve.................................................................................................................................................................................................................................... 72
		Loop Flushing Valve...................................................................................................................................................................................................................................................... 72
			Removal.............................................................................................................................................................................................................................................................. 72
				1. Remove plug (1) and (2) with 11/16" internal hex wrench....................................................................................................................................................................................................... 72
				1. Plug.......................................................................................................................................................................................................................................................... 72
				2. Plug.......................................................................................................................................................................................................................................................... 72
				3. Plug.......................................................................................................................................................................................................................................................... 72
				4. O-ring........................................................................................................................................................................................................................................................ 72
				5. O-ring........................................................................................................................................................................................................................................................ 72
				6. O-ring........................................................................................................................................................................................................................................................ 72
				7. Spring........................................................................................................................................................................................................................................................ 72
				8. Spring........................................................................................................................................................................................................................................................ 72
				9. Spring........................................................................................................................................................................................................................................................ 72
				10. Washer....................................................................................................................................................................................................................................................... 72
				11. Washer....................................................................................................................................................................................................................................................... 72
				12. Shift Spool.................................................................................................................................................................................................................................................. 72
				13. Orifice Poppet............................................................................................................................................................................................................................................... 72
					2. Use 1/4 in. in hex wrench to remove plug (3).............................................................................................................................................................................................................. 72
					3. Remove O-rings (4, 5, and 6).............................................................................................................................................................................................................................. 72
					4. Use pliers to remove centering springs (7, 8, and 9)...................................................................................................................................................................................................... 72
					5. Remove spring retaining washers (10 and 11)............................................................................................................................................................................................................... 72
					6. Remove shift spool (12)................................................................................................................................................................................................................................... 72
					7. Remove orifice poppet (13)................................................................................................................................................................................................................................ 72
					8. Inspect new O-rings and sealing area for rust, wear, or contamination. Check springs and poppet for wear.................................................................................................................................................. 72
			installation......................................................................................................................................................................................................................................................... 72
				1. Install orifice poppet (13)................................................................................................................................................................................................................................... 72
				2. Install shift spool (12)...................................................................................................................................................................................................................................... 72
				3. Install spring retaining washers on springs (10 and 11)....................................................................................................................................................................................................... 72
				4. Carefully install centering springs (7, 8, and 9)............................................................................................................................................................................................................. 72
				5. Install new O-rings (6, 4, and 5)............................................................................................................................................................................................................................. 72
				6. Use 1/4 in. hex wrench to torque plug (3) to 20 ft. lbs. (27 Nm).............................................................................................................................................................................................. 72
				7. Use 11/16 in. internal hex and torque plugs (2 and 1) to 27 ft. lbs. (37 Nm).................................................................................................................................................................................. 72
		Troubleshooting.......................................................................................................................................................................................................................................................... 73
		Disassembly.............................................................................................................................................................................................................................................................. 74
			1. Plug.............................................................................................................................................................................................................................................................. 74
			2. Plug.............................................................................................................................................................................................................................................................. 74
			3. Plug.............................................................................................................................................................................................................................................................. 74
			4. O-ring............................................................................................................................................................................................................................................................ 74
			5. O-ring............................................................................................................................................................................................................................................................ 74
			6. O-ring............................................................................................................................................................................................................................................................ 74
			7. Spring............................................................................................................................................................................................................................................................ 74
			8. Spring............................................................................................................................................................................................................................................................ 74
			9. Spring............................................................................................................................................................................................................................................................ 74
			10. Washer........................................................................................................................................................................................................................................................... 74
			11. Washer........................................................................................................................................................................................................................................................... 74
			12. Shift Spool...................................................................................................................................................................................................................................................... 74
			13. Orifice Poppet................................................................................................................................................................................................................................................... 74
				1. Using a 11/16 in. wrench, remove plug (1) and (2)............................................................................................................................................................................................................. 74
				2. Using a 5/8 in. hex wrench, remove plug (3)................................................................................................................................................................................................................... 74
				3. Remove O-rings (4, 5, and 6).................................................................................................................................................................................................................................. 74
				4. Using pliers, remove centering springs (7, 8, and 9).......................................................................................................................................................................................................... 74
				5. Remove spring retaining washers (10 and 11)................................................................................................................................................................................................................... 74
				6. Remove shift spool (12)....................................................................................................................................................................................................................................... 74
				7. Remove orifice poppet (13).................................................................................................................................................................................................................................... 74
			14. Lock Nut......................................................................................................................................................................................................................................................... 74
			15. O-ring Plug...................................................................................................................................................................................................................................................... 74
			16. Control Line Plug................................................................................................................................................................................................................................................ 74
			17. Control Line Plug................................................................................................................................................................................................................................................ 74
			18. Cavity Plug...................................................................................................................................................................................................................................................... 74
			19. Drain Plug....................................................................................................................................................................................................................................................... 74
			20. Drain Plug....................................................................................................................................................................................................................................................... 74
			21. Work Port Plug................................................................................................................................................................................................................................................... 74
				8. Remove all fittings from unit. Discard O-rings................................................................................................................................................................................................................ 74
				9. Using an 11/16 in. hex wrench, loosen speed sensor lock nut (14) if equipped and remove speed sensor. Units without speed sensor have an O-ring plug (15) installed in that location; remove it with a 1/4 inch internal hex wrench........................... 74
				10. Using a 1/4 in. internal hex wrench, remove control line plugs (16, 17). Discard O-rings. Using a 3 mm hex wrench, remove cavity plug (18) (if equipped with two- line control), from X2 cavity.............................................................. 74
				11. Using a 5/16 in. internal hex wrench, remove drain plugs (19, 20). Discard O-rings........................................................................................................................................................................... 74
				12. If equipped with axial ports, use a 9/16 in. an internal hex wrench and remove work port plugs (21). Discard O-rings......................................................................................................................................... 74
			22. Screw............................................................................................................................................................................................................................................................ 75
			23. End Cap.......................................................................................................................................................................................................................................................... 75
			24. O-ring........................................................................................................................................................................................................................................................... 75
				13. Using an 8 mm internal hex wrench, remove endcap screws (22)................................................................................................................................................................................................. 75
				14. Remove endcap (23). Remove O-ring (24) from housing or endcap................................................................................................................................................................................................ 75
			25. Valve Plate...................................................................................................................................................................................................................................................... 75
			26. End Cap.......................................................................................................................................................................................................................................................... 75
			27. O-ring........................................................................................................................................................................................................................................................... 75
			28. O-ring........................................................................................................................................................................................................................................................... 75
			29. Angle Stop....................................................................................................................................................................................................................................................... 75
			30. Servo Spring..................................................................................................................................................................................................................................................... 75
				15. Remove valve plate (25) and timing pin (26) from endcap...................................................................................................................................................................................................... 75
				16. Remove and discard O-rings (27, 28).......................................................................................................................................................................................................................... 75
				17. Remove rear shaft bearing (29) from endcap with a bearing puller............................................................................................................................................................................................. 75
				18. Remove minimum angle stop (29) and servo spring (30) from housing............................................................................................................................................................................................ 75
			31. Cylinder Kit Assembly............................................................................................................................................................................................................................................ 76
				19. Turn housing on its side and remove cylinder kit assembly (31). Set assembly aside. Do not to scratch running surface........................................................................................................................................ 76
			32. Snap Ring........................................................................................................................................................................................................................................................ 76
			33. Support Washer................................................................................................................................................................................................................................................... 76
			34. Shaft Seal....................................................................................................................................................................................................................................................... 76
				20. Turn housing over and remove snap ring (32), retaining shaft seal, and support washer. Remove support washer (33). Carefully pry out shaft seal (34). Discard seal........................................................................................... 76
			35. Inner Snap Ring.................................................................................................................................................................................................................................................. 76
			36. Snap Ring........................................................................................................................................................................................................................................................ 76
			37. Bearing.......................................................................................................................................................................................................................................................... 76
			38. Shaft............................................................................................................................................................................................................................................................ 76
				21. Remove inner snap ring (35) and shaft/bearing assembly....................................................................................................................................................................................................... 76
				22. Remove snap ring (36) retaining shaft front bearing. Pull bearing (37) off shaft (38)........................................................................................................................................................................ 76
			39. Swashplate....................................................................................................................................................................................................................................................... 77
			40. Servo Piston..................................................................................................................................................................................................................................................... 77
			41. Piston Seal...................................................................................................................................................................................................................................................... 77
			42. O-ring........................................................................................................................................................................................................................................................... 77
			43. Journal Bearings................................................................................................................................................................................................................................................. 77
				23. Turn housing over and remove swashplate (39) by lifting on end opposite servo lever.......................................................................................................................................................................... 77
				24. Remove servo piston (40). Remove piston seal (41) and O-ring (42) from servo piston. Discard seal and O-ring................................................................................................................................................. 77
				25. Remove journal bearings (43) from housing. If bearings will be reused, note location and orientation of each bearing for reassembly.......................................................................................................................... 77
				26. Remove pistons (44) and slipper retainer (45) from cylinder block (46)....................................................................................................................................................................................... 77
				27. Remove ball guide (47), hold-down pins (48), and retaining ring (49) from cylinder block..................................................................................................................................................................... 77
			44. Piston........................................................................................................................................................................................................................................................... 77
			45. Slipper Retainer................................................................................................................................................................................................................................................. 77
			46. Cylinder Block................................................................................................................................................................................................................................................... 77
			47. Ball Guide....................................................................................................................................................................................................................................................... 77
			48. Holddown Pins.................................................................................................................................................................................................................................................... 77
			49. Retaining Ring................................................................................................................................................................................................................................................... 77
			50. Block Spring Washer.............................................................................................................................................................................................................................................. 77
			51. Spiral Retaining Ring............................................................................................................................................................................................................................................ 77
			52. Block Spring..................................................................................................................................................................................................................................................... 77
			53. Inner Block Spring Washer........................................................................................................................................................................................................................................ 77
				28. Turn block over. Using a press, apply pressure on block spring washer (50) to compress block spring enough to safely remove spiral retaining ring (51). Maintain pressure and unwind spiral retaining ring (51). Carefully release pressure and remove....... 77
		Inspection............................................................................................................................................................................................................................................................... 78
			Piston............................................................................................................................................................................................................................................................... 78
			Slippers............................................................................................................................................................................................................................................................. 78
			Ball Guide and Slipper Retainer...................................................................................................................................................................................................................................... 78
			Cylinder Block....................................................................................................................................................................................................................................................... 78
			Valve Plate.......................................................................................................................................................................................................................................................... 79
			Swashplate and Journal Bearings...................................................................................................................................................................................................................................... 79
			Shaft Bearings....................................................................................................................................................................................................................................................... 79
			Shaft................................................................................................................................................................................................................................................................ 79
			Servo Piston and Minimum Angle Stop.................................................................................................................................................................................................................................. 79
			Loop Flushing Spool.................................................................................................................................................................................................................................................. 79
		Assembly................................................................................................................................................................................................................................................................. 80
			1. Install new O-ring (1) and piston seal (2) to servo piston (3). Install piston seal over O-ring................................................................................................................................................................... 80
			1. O-ring............................................................................................................................................................................................................................................................ 80
			2. Piston Seal....................................................................................................................................................................................................................................................... 80
			3. Servo Piston...................................................................................................................................................................................................................................................... 80
				2. After piston seal has relaxed, lubricate and install servo piston into housing bore. Align piston with ball socket facing inside of housing................................................................................................................... 80
				3. Install inner block spring washer (4), block spring (5), and outer washer (6) in cylinder block. Using a press, compress block spring enough to expose retaining ring groove. Wind spiral retaining ring (7) into cylinder block.............................. 80
			4. Block Spring Washer............................................................................................................................................................................................................................................... 80
			5. Block Spring...................................................................................................................................................................................................................................................... 80
			6. Outer Washer...................................................................................................................................................................................................................................................... 80
			7. Spiral Retaining Ring............................................................................................................................................................................................................................................. 80
			8. Retaining Ring.................................................................................................................................................................................................................................................... 80
			9. Holddown Pins..................................................................................................................................................................................................................................................... 80
			10. Ball Guide....................................................................................................................................................................................................................................................... 80
			11. Piston........................................................................................................................................................................................................................................................... 80
			12. Slipper Retainer................................................................................................................................................................................................................................................. 80
				4. Turn block over and install retaining ring (8), hold-down pins (9), and ball guide (10) to cylinder block..................................................................................................................................................... 80
				5. Install pistons (11) to slipper retainer (12). Install piston/ retainer assembly in cylinder block. Ensure concave surface of retainer seats on the ball guide. Lubricate pistons, slippers, retainer, and ball guide before assembly. Set cylinder kit....... 81
				6. Install journal bearings (13) into housing seats. Use assembly grease to keep bearings seated during assembly. Ensure locating nubs drop into cavities in seats. If reusing bearings, install them in original location and orientation. Lubricate jour....... 81
			13. Journal Bearings................................................................................................................................................................................................................................................. 81
			14. Swash Plate...................................................................................................................................................................................................................................................... 81
				7. Install swashplate (14) in housing. Tilt swashplate and guide servo lever ball into its socket in servo piston rod. Ensure swashplate seats into journal bearings and moves freely. Lubricate swashplate running surface...................................... 81
				8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) on shaft................................................................................................ 81
			15. Front Shaft Bearing.............................................................................................................................................................................................................................................. 81
			16. Shaft............................................................................................................................................................................................................................................................ 81
			17. Snap Ring........................................................................................................................................................................................................................................................ 81
			18. Snap Ring........................................................................................................................................................................................................................................................ 81
				9. While holding swashplate in place, turn housing on its side. Install shaft/bearing assembly into housing from flange end. Install snap ring (18).............................................................................................................. 81
				10. Verify swashplate and bearings are properly seated. Install cylinder kit (19) onto shaft. Install with slippers facing swashplate. Rock shaft to align block splines and slide cylinder kit into place. Orient motor with shaft pointing downward and ....... 82
			19. Cylinder Kit..................................................................................................................................................................................................................................................... 82
				11. Lubricate and install servo spring (20), and minimum angle stop (21) into housing bore....................................................................................................................................................................... 82
			20. Servo Spring..................................................................................................................................................................................................................................................... 82
			21. Minimum Angle Stop............................................................................................................................................................................................................................................... 82
				12. Press rear shaft bearing (22) into endcap. Install bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface........................................................................................... 82
			22. Rear Shaft Bearing............................................................................................................................................................................................................................................... 82
			23. Timing Pin....................................................................................................................................................................................................................................................... 82
			24. Valve Plate...................................................................................................................................................................................................................................................... 82
				13. Install timing pin (23) into bore in endcap. Install pin with groove facing toward or away from shaft. Press pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above endcap surface......................................................................... 82
				14. Install valve plate (24) on endcap. Install valve plate with yellow surface toward cylinder block. Align slot in valve plate with timing pin. Apply a liberal coat of assembly grease to endcap side of valve plate to keep it in place during install....... 82
				15. Install endcap (25) on housing with endcap screws (26). Check endcap properly seats on housing without interference.......................................................................................................................................... 83
			25. End Cap.......................................................................................................................................................................................................................................................... 83
			26. Screw............................................................................................................................................................................................................................................................ 83
				16. Using an 8 mm internal hex wrench, tighten endcap screws. Tighten screws in opposite corners slowly and evenly to compress servo spring and properly seat endcap. Torque endcap screws 35 to 45 ft. lbs. (47-61 Nm).......................................... 83
				17. Before installing shaft seal, ensure shaft turns smoothly with less than 120 in. lbs. (13.5 Nm) of force. If shaft does not turn smoothly within specified force, disassemble and check unit................................................................. 83
				18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with cup side facing motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging seal. Install seal support washer (28) and snap ri....... 83
			27. Shaft Seal....................................................................................................................................................................................................................................................... 83
			28. Seal Support Washer.............................................................................................................................................................................................................................................. 83
			29. Snap Ring........................................................................................................................................................................................................................................................ 83
				19. Install remaining plugs and fittings to housing. Refer to drawing below for wrench sizes and torque settings................................................................................................................................................. 83
				20. Install orifice poppet (30).................................................................................................................................................................................................................................. 84
				21. Install shift spool (31)..................................................................................................................................................................................................................................... 84
				22. Install spring retaining washers on springs (32 and 33)...................................................................................................................................................................................................... 84
				23. Carefully install centering springs (34, 35, and 36)......................................................................................................................................................................................................... 84
				24. Install new O-rings (37, 38, and 39)......................................................................................................................................................................................................................... 84
				25. Using a 5/8" wrench, torque plug (40) to 20 ft-lb (27 Nm).................................................................................................................................................................................................... 84
				26. Using a 11/16" wrench, torque plugs (41 and 42) to 27 ft- lb (37 Nm)......................................................................................................................................................................................... 84
			30. Orifice Poppet................................................................................................................................................................................................................................................... 84
			31. Shift Spool...................................................................................................................................................................................................................................................... 84
			32. Spring........................................................................................................................................................................................................................................................... 84
			33. Spring........................................................................................................................................................................................................................................................... 84
			34. Spring........................................................................................................................................................................................................................................................... 84
			35. Spring........................................................................................................................................................................................................................................................... 84
			36. Spring........................................................................................................................................................................................................................................................... 84
			37. O-ring........................................................................................................................................................................................................................................................... 84
			38. O-ring........................................................................................................................................................................................................................................................... 84
			39. O-ring........................................................................................................................................................................................................................................................... 84
			40. Plug............................................................................................................................................................................................................................................................. 84
			41. Plug............................................................................................................................................................................................................................................................. 84
			42. Plug............................................................................................................................................................................................................................................................. 84
		Initial Start-Up Procedures.............................................................................................................................................................................................................................................. 84
			1. Fill reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into reservoir. Never reuse hydraulic fluid.......................................................................................................... 84
			2. Fill inlet line leading from pump to reservoir. Check inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks.......................................................................................................... 84
			3. Fill pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into upper most case drain port................................................................................................................................................ 84
			4. Install case drain lines into upper most case drain ports to ensure pump and motor stay filled with oil........................................................................................................................................................... 84
			5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pressure gauge port of pump to monitor system pressure during start up....................................................................................................................................... 84
			6. Watch pressure gauge and run engine at lowest possible speed until system pressure builds to normal levels (minimum 160 psi [11 bar]). Once system pressure is established, increase to full operating speed. If system pressure is not maintained; shu........... 84
			7. Operate hydraulic system at least fifteen minutes under light load conditions..................................................................................................................................................................................... 84
			8. Check and adjust control settings as necessary after installation................................................................................................................................................................................................. 84
			9. Shut down engine and remove pressure gauge. Replace plug at charge pressure gauge port............................................................................................................................................................................ 84
			10. Check fluid level in reservoir; add clean filtered fluid if necessary. Motor is now ready for operation.......................................................................................................................................................... 84
	3.12 Drive Brake............................................................................................................................................................................................................................................................. 85
		Disassembly.............................................................................................................................................................................................................................................................. 85
			1. Supporting the brake on Face A, remove the socket head capscrews and washers (13 & 14) in equal increments to ensure the spring pressure within the break is reduced gradually and evenly. If a press is available, the cylinder housing (8) can be sec........... 85
			2. Remove the cylinder housing (8) and piston (9) subassembly and disassemble if necessary, removing O-ring seals (15 & 17) and backing rings (16 & 18) as necessary................................................................................................. 85
			3. Remove the gasket (7) from the housing............................................................................................................................................................................................................................ 85
			4. Remove the friction plates (3&6) and pressure plate (4)........................................................................................................................................................................................................... 85
			5. Remove the dowel pins (19)........................................................................................................................................................................................................................................ 85
			6. Remove the springs (22 & 23). Note the color and arrangement of the springs so they can be assembled in the same order............................................................................................................................................ 85
			7. If it’s necessary to replace the ball bearing (10) or shaft seal (12), and reverse the brake position so it is supported on Face C of the housing (2)............................................................................................................. 85
			8. Remove the internal retaining ring (11)........................................................................................................................................................................................................................... 85
			9. Using a press or similar device, remove the brake shaft (1) from the housing (2) and lay it aside................................................................................................................................................................. 85
			10. Reverse the position of the housing (2) and press out the ball bearing (10). if necessary, the shaft seal (12) can be removed.................................................................................................................................... 85
		Inspection............................................................................................................................................................................................................................................................... 85
			1. Inspect the friction plates (3 & 6) and friction surface on the pressure plate (4) for wear or damage............................................................................................................................................................. 85
			2. Examine the friction plates (3) and brake shaft (1) for wear or damage to the splines............................................................................................................................................................................. 85
			3. Examine the input and output splines of the brake shaftfor wear or damage......................................................................................................................................................................................... 85
			4. Examine the compression springs (22 & 23) for damage or fatigue................................................................................................................................................................................................... 85
			5. Check the ball bearing (10) for axial float or wear............................................................................................................................................................................................................... 85
			6. Examine O-ring seals (15 & 17) and backing rings (16 & 18) for damage............................................................................................................................................................................................. 85
		Assembly................................................................................................................................................................................................................................................................. 85
			1. Lightly lubricate the rotary shaft seal (12) and assemble it to the housing (2) taking care not to damage the seal lip............................................................................................................................................ 85
			2. Apply a ring of Loctite 641 or equivalent adhesive to the outside diameter of bearing (10) and assemble fully in the housing (2). Secure the bearing in place with the retaining ring (11). Remove any excess adhesive with a clean cloth. Press the sh........... 85
			3. Assemble the springs into position as recorded during Disassembly................................................................................................................................................................................................. 85
			4. Lubricate the )-rings (15 & 17) with Molykote 55M or equivalent silicone grease and assemble them, with the backing rings (16 & 18) to the piston (9). To ensure correct brake operation, it is important that the backing rings are assembled opposite........... 85
			5. Correctly orient the piston aligning spaces with the two dowel pin holes and install into the cylinder housing (8) taking care not to damage the seals. Carefully lay these parts aside........................................................................... 85
			6. Install the dowel pins (19) in the housing (2) followed by the pressure plate (4) and friction plates. For example, in inner plate (3) followed by an outer plate (6) in the correct sequence..................................................................... 85
			7. Position the gasket (7) in the correct location................................................................................................................................................................................................................... 85
			8. Align the two holes in the cylinder with the dowel pins (19) and assemble the piston and cylinder subassembly to the remainder of the brake. Secure in place with the capscrews and washers (13 & 14). Torque to 55 ft.lbs. (75 Nm)............................... 85
	3.13 Swing Bearing........................................................................................................................................................................................................................................................... 87
		Description.............................................................................................................................................................................................................................................................. 87
		Removal.................................................................................................................................................................................................................................................................. 87
			1. Attach an adequate support sling to boom and draw all slack from sling. Prop or block boom if possible............................................................................................................................................................ 87
			2. Tag and disconnect hydraulic lines running through center of turntable and frame. Use a suitable container catch residual hydraulic fluid. Cap lines and ports.................................................................................................... 87
			3. Clean area around swing motor to prevent any dirt from entering system............................................................................................................................................................................................ 87
			4. Tag and disconnect hydraulic lines running to swing motor. Cap or plug all openings............................................................................................................................................................................... 87
			5. Remove the grease fittings (3) attached to the frame and outer race of the swing bearing.......................................................................................................................................................................... 87
			6. Attach suitable overhead lifting equipment to base of turntable weldment.......................................................................................................................................................................................... 87
			7. Scribe a line on inner race of swing bearing (4) and underside of turntable to help align bearing during installation. Remove bolts (2) and washers (5) from turntable and bearing inner race. Discard bolts...................................................... 87
			8. Use lifting equipment to lift complete turntable assembly from bearing. Ensure no damage occurs to turntable, bearing, or frame components. Carefully place turntable on a suitably supported trestle............................................................. 87
			9. Scribe a line on outer race of swing bearing and frame to help align bearing during installation.................................................................................................................................................................. 87
			10. Remove bolts (1) and washers (5) from outer race of bearing to frame. Discard bolts.............................................................................................................................................................................. 87
			11. Use suitable lifting equipment to remove bearing and rotation box assembly from frame. Move to a clean, suitably supported work area............................................................................................................................. 87
			1. Bolt.............................................................................................................................................................................................................................................................. 88
			2. Bolt.............................................................................................................................................................................................................................................................. 88
			3. Grease Fitting.................................................................................................................................................................................................................................................... 88
			4. Washer............................................................................................................................................................................................................................................................ 88
			5. Washer............................................................................................................................................................................................................................................................ 88
			6. Capscrew.......................................................................................................................................................................................................................................................... 88
			7. Swing Motor....................................................................................................................................................................................................................................................... 88
			8. Turntable Bearing................................................................................................................................................................................................................................................. 88
		Disassembly.............................................................................................................................................................................................................................................................. 89
			1. Remove bolts and washers securing swing motor to swing drive housing.............................................................................................................................................................................................. 89
			2. Carefully pull swing motor from housing........................................................................................................................................................................................................................... 89
			3. Remove two bolts (6) that hold turntable bearing (7) to housing (5)............................................................................................................................................................................................... 89
			4. Remove two front screws (14) on cover plate (9) immediately in front of pinion (10)............................................................................................................................................................................... 89
			5. Remove eight cap screws (11) from gear cap (12). Pry cap from housing. Cover plate (9) will come off with cap. Note where sealant is on cover and plate so it can be applied in same location during assembly. Note number and color of shims (13) betw........... 89
			6. Remove remaining small screws (14) from cover plate (9). Pry cover plate (9) from gear cap (12). Discard cover plate. Note number and color of shims (15) between cover plate and cap............................................................................. 89
			7. Lift directly up and remove pinion and gear assembly from housing (5)............................................................................................................................................................................................. 89
			8. Disassemble pinion and gear assembly using a press. Support worm gear (20) on press wIth pinion (10) facing down. Allow room for pinion to be pressed out of gear. Press pinon out of bearing (22), spacer (21), and worm gear (20)............................... 89
			9. Remove oil seal (18) and O-ring (19) from face of worm gear (20). Note how seal is assembled...................................................................................................................................................................... 89
			10. Remove bearing (17) and grease ring (16) from pinion (10) with an external bearing puller or press............................................................................................................................................................... 89
			11. Remove motor adapter (2) and shim (3)............................................................................................................................................................................................................................ 89
			12. Remove two bolts (26) from worm cap (25). Remove and discard shims (24) and oil seal (28)........................................................................................................................................................................ 89
			13. Remove worm gear (8) from housing (5) by pushing worm from motor end using a steel rod and hammer. Use a soft hammer to tap worm on hex end to remove bearing (4) from opposite end of housing................................................................... 89
			14. If necessary, remove bearing cup from motor adapter (2) using a small pry bar or by welding a small bead of weld on internal diameter of the cup................................................................................................................. 89
			15. Remove bearing (23) from worm (8) using an external bearing puller or press...................................................................................................................................................................................... 89
		Assembly................................................................................................................................................................................................................................................................. 91
			1. Press bearing (17) in gear cap (12)............................................................................................................................................................................................................................... 91
			2. Place bearing (4) in housing (5).................................................................................................................................................................................................................................. 91
			3. Place oil seal (18) and O-ring (19) on hub of worm gear (20)...................................................................................................................................................................................................... 91
			4. Place worm gear (20) on press with face seal up. Press pinion (10) into worm gear. Place grease ring (16) on pinion with cup shape up............................................................................................................................. 91
			5. Turn assembly over. Place spacer (21), with hub facing up, on pinion against gear hub............................................................................................................................................................................. 91
			6. Press bearing (22) on pinion and tight to spacer and gear......................................................................................................................................................................................................... 91
			7. Place pinion gear assembly in housing. Place gear cap (12) and shims (13) over gear/pinion assembly to achieve a slight preload on pinion bearings. Remove cap and shims and set shims aside...................................................................... 91
			8. Install new cover plate (9) on cap (12) with six screws (14) and shims (15) equal or close to total thickness of shims removed. Apply sealant (Permatex #2 or equivalent) to both sides of each shim and tighten screws, taking care not to twist screw........... 91
			9. Install bearing (4) with small end facing to outside of machine in motor end of housing (5)....................................................................................................................................................................... 91
			10. Install worm (8), hex end facing away from motor side, into housing (5).......................................................................................................................................................................................... 91
			11. Install motor adapter (2) and shim (3) to bore end of housing.................................................................................................................................................................................................... 91
			12. Install bearing (23) with small end facing to outside of machine on hex end of worm (8).......................................................................................................................................................................... 91
			13. Install worm cap (25) using shims (24) to achieve 0.000 to 0.001in. end play. Install bolts (26) and sealant. Torque to 80 ft. lbs. (108.5 Nm)................................................................................................................... 91
			14. Install pinion/gear assembly in housing so gear teeth mesh with worm gear teeth.................................................................................................................................................................................. 91
			15. Apply silicone sealant to cap assembly contact area on housing................................................................................................................................................................................................... 91
			16. Place gear cap assembly over pinion assembly and install shims set aside in Step 6............................................................................................................................................................................... 91
			17. Install eight 12 point bolts (11). Torque to 60 ft-lb (81 Nm).................................................................................................................................................................................................... 91
			18. Install two small screws......................................................................................................................................................................................................................................... 91
			19. Install oil seal (27) in worm cap (8)............................................................................................................................................................................................................................ 91
			20. Install motor to adapter (2) with two bolts (1), washers, and sealant. Torque to 80 ft. lbs. (108 Nm)............................................................................................................................................................ 91
			21. Install turntable bearing (7) to housing (5) with two bolts (6) and washers...................................................................................................................................................................................... 91
			22. Fill worm gear with Mobil SHC 460 grease......................................................................................................................................................................................................................... 91
			23. Grease pinion gear with Lubriplate No. 930-AAA................................................................................................................................................................................................................... 91
		Installation............................................................................................................................................................................................................................................................. 93
			1. Install bearing to rotation box with two capscrews, with fill plug of bearing close to gear as bolt pattern allows. Do not tighten capscrews...................................................................................................................... 93
			2. Line up high spot (blue) of bearing with center tooth of worm gear. Set backlash to 0.008 - 0.010 inch (0.20 - 0.25 mm). Tighten capscrews as shown in Figure 3-39., Swing Bearing Torque Sequence................................................................ 93
			3. Apply Mobiltac 375 Open Gear Compound or equivalent to bearing and worm gear teeth................................................................................................................................................................................ 93
			4. Remove plugs at two locations on top of gear and fill bearing with Mobil SHC 460 grease. Reinstall plugs.......................................................................................................................................................... 93
			5. Use suitable lift equipment and install bearing/rotation box assembly to frame with soft spot (red) 90 degree relative to load axis. If reusing old bearing, align scribed line of outer bearing race with scribed mark on frame.................................. 93
			6. Apply a light coating of thread locking compound JLG PN 0100019 to new bearing bolts. Loosely install bolts and washers through frame and outer bearing race...................................................................................................... 93
			7. Following the torque sequence diagram in Figure 3-39., Swing Bearing Torque Sequence, tighten the bolts to torque of 206.5 ft. lbs. (280 Nm)...................................................................................................................... 93
			8. Remove lifting equipment from bearing............................................................................................................................................................................................................................. 93
			9. Use suitable lift equipment to carefully position turntable assembly above machine frame.......................................................................................................................................................................... 93
			10. Carefully lower turntable onto swing bearing. Align scribed line of inner race of bearing with scribed mark on turntable. If a new swing bearing is used, align 1/8" NPT holes with notches in frame............................................................. 93
			11. Apply light coating of JLG Thread Locking Compound PN 0100019 to new bearing bolts and install through turntable and inner race of bearing....................................................................................................................... 93
			12. Following the torque sequence diagram in Figure 3-39., Swing Bearing Torque Sequence, tighten the bolts to torque of 206.5 ft. lbs. (280 Nm)..................................................................................................................... 93
			13. Remove lift equipment............................................................................................................................................................................................................................................ 93
			14. Route hydraulic lines through center of turntable and frame. Connect as tagged prior to removal.................................................................................................................................................................. 93
			15. Activate hydraulic system following all safety precautions. Check swing system for proper and safe operation..................................................................................................................................................... 93
		Turntable Bearing Mounting Bolt Checks................................................................................................................................................................................................................................... 94
		Check Frame To Bearing Bolts............................................................................................................................................................................................................................................. 94
			1. Fully retract boom and elevate to 70° (full elevation). (See Figure 3-43.)........................................................................................................................................................................................ 94
			2. Try and insert a 0.0015 in. feeler gauge between bolt head and hardened washer at positions shown in Figure 3-41., Swing Bearing Feeler Gauge Check............................................................................................................... 94
			3. Ensure 0.0015 in. feeler gauge will not fit under bolt head to bolt shank......................................................................................................................................................................................... 94
			4. Swing turntable 90° and check selected bolts at that position..................................................................................................................................................................................................... 94
			5. Continue rotating turntable at 90° intervals until sampling of bolts are checked in all quadrants................................................................................................................................................................. 94
		Check Turntable To Bearing Bolts......................................................................................................................................................................................................................................... 94
			6. Fully retract boom and elevate to 70 degrees (full elevation). Try and insert a 0.0015 in. feeler gauge between bolt head and hardened washer at positions shown in Figure 3-41., Swing Bearing Feeler Gauge Check................................................ 94
			7. Lower boom to horizontal and fully extend boom. (See Figure 3-44.)................................................................................................................................................................................................ 94
			8. Try and insert a 0.0015 in. feeler gauge between bolt head and hardened washer at position indicated by arrow in Figure 3-41., Swing Bearing Feeler Gauge Check................................................................................................... 94
		Wear Tolerance........................................................................................................................................................................................................................................................... 94
			1. Position boom over side of machine with upper boom horizontal, telescope fully extended, and mid/lower boom stowed. Measure and record distance between swing bearing and turntable using a magnetic base dial indicator.......................................... 94
			2. At same point, position boom over side of machine with Upper Boom and Mid/Lower Boom fully elevated. Measure and record distance between swing bearing and turntable using a magnetic base dial indicator......................................................... 94
			3. If there is a difference greater than 0.057 in. (1.40 mm), replace swing bearing.................................................................................................................................................................................. 94
			4. If there is a difference less than 0.057 in. (1.40 mm) and any of the following conditions exist, remove and inspect bearing...................................................................................................................................... 94
				a. Metal particles in grease..................................................................................................................................................................................................................................... 94
				b. Increased drive power......................................................................................................................................................................................................................................... 94
				c. Noise......................................................................................................................................................................................................................................................... 94
				d. Rough rotation................................................................................................................................................................................................................................................ 94
			5. If bearing inspection shows no defects, reassemble bearing and return to service.................................................................................................................................................................................. 94
	3.14 Swing Motor............................................................................................................................................................................................................................................................. 98
		1. Hose fittings loose, worn or damaged.................................................................................................................................................................................................................................. 99
		2. Oil seal rings (4) deteriorated by excess heat........................................................................................................................................................................................................................ 99
		3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion................................................................................................................................................................................... 99
		4. Internal shaft seal (16) worn or damaged.............................................................................................................................................................................................................................. 99
		5. Worn coupling shaft (12) and internal seal (16)....................................................................................................................................................................................................................... 99
		1. Lack of sufficient oil supply......................................................................................................................................................................................................................................... 99
		2. High internal motor leakage........................................................................................................................................................................................................................................... 99
		3. Severely worn or damaged internal splines............................................................................................................................................................................................................................. 99
		4. Excessive heat........................................................................................................................................................................................................................................................ 99
		1. Line blockage......................................................................................................................................................................................................................................................... 99
		2. Internal interference................................................................................................................................................................................................................................................. 99
		3. Lack of pumping pressure.............................................................................................................................................................................................................................................. 99
		4. Excessive binding or loading in system external to motor unit......................................................................................................................................................................................................... 99
		Removal..................................................................................................................................................................................................................................................................100
			1. Thoroughly clean area around swing motor to prevent dirt from entering system.....................................................................................................................................................................................100
			2. Tag and disconnect hydraulic lines to swing motor. Cap or plug all openings.......................................................................................................................................................................................100
			3. Secure worm gear shaft so it does not pull out any when removing swing motor. Failure to do so could damage worm gear seals.......................................................................................................................................100
			4. Remove bolts securing swing motor to swing drive assembly.........................................................................................................................................................................................................100
			5. Carefully pull the swing motor from the swing drive...............................................................................................................................................................................................................100
			1. Bolt..............................................................................................................................................................................................................................................................101
			2. End Cover.........................................................................................................................................................................................................................................................101
			3. Commutator Seal...................................................................................................................................................................................................................................................101
			4. Seal Ring.........................................................................................................................................................................................................................................................101
			5. Commutator and Ring Assembly......................................................................................................................................................................................................................................101
			6. Ring..............................................................................................................................................................................................................................................................101
			7. Manifold..........................................................................................................................................................................................................................................................101
			8. Rotor Set.........................................................................................................................................................................................................................................................101
			9. Wear Plate........................................................................................................................................................................................................................................................101
			10. Drive Link.......................................................................................................................................................................................................................................................101
			11. Coupling Shaft...................................................................................................................................................................................................................................................101
			12. Woodruff Key.....................................................................................................................................................................................................................................................101
			13. Bronze Bushing...................................................................................................................................................................................................................................................101
			14. Thrust Washer....................................................................................................................................................................................................................................................101
			15. Thrust Bearing...................................................................................................................................................................................................................................................101
			16. Inner Seal.......................................................................................................................................................................................................................................................101
			17. Backup Washer....................................................................................................................................................................................................................................................101
			18. Housing..........................................................................................................................................................................................................................................................101
			19. Bearing..........................................................................................................................................................................................................................................................101
			20. Seal.............................................................................................................................................................................................................................................................101
			21. Backup Washer....................................................................................................................................................................................................................................................101
		Preparation Before Disassembly...........................................................................................................................................................................................................................................102
		Disassembly and Inspection...............................................................................................................................................................................................................................................102
			1. Place motor in a soft jawed vice, with coupling shaft (12) pointed down and vise jaws clamping firmly on sides of housing (18) mounting flange, or port bosses. Remove manifold port O-rings if applicable........................................................102
			2. Scribe an alignment mark down and across motor components from end cover (2) to housing (18) for proper reassembly orientation....................................................................................................................................102
			3. Remove special ring head bolts (1) with 1/2" or 9/16" socket. Inspect bolts for damaged threads or sealing rings. Replace damaged bolts...........................................................................................................................103
			4. Remove end cover assembly (2) and O-ring (4). Discard O- ring.....................................................................................................................................................................................................103
			5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure end cover valve apertures are free of contamination. Inspect end cover for cracks and bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary................103
			6. Remove commutator (6) and inspect for cracks or burrs.............................................................................................................................................................................................................103
			7. Remove commutator (5) and commutator seal (3). Remove seal from commutator. Use an air hose to blow air into ring groove until ring lifts out. Discard ring. Inspect commutator for cracks or burrs, wear, scoring, spalling, or brinelling. Replace co...........104
			8. Remove manifold (7). Inspect for cracks, surface scoring, brinelling, or spalling and replace if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard O-rings (4) on...........104
			9. Remove rotor set (8) and wearplate (9), together to hold rotor set in its assembled form, keeping same rotor vane to stator contact surfaces. Drive link (10) may come away from coupling shaft (12) with rotor set and wearplate. Shift rotor set on w...........104
			10. Discard O-ring (4) between rotor set and wearplate...............................................................................................................................................................................................................105
			11. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No visible lash (play) should be seen between mating spline parts. Remove O-ring (4) f...........105
			12. Remove thrust bearing (15) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion, and missing rollers.........................................................................................................................................106
			13. Check exposed portion of coupling shaft (12) for signs of rust and corrosion which might prevent its withdrawal through seal and bearing. Use crocus cloth or fine emery paper as needed.........................................................................106
			14. Remove coupling shaft (12), by pushing on output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or...........106
			15. Remove and discard O-ring (4) from housing (18)..................................................................................................................................................................................................................107
			16. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers.............................................................................................................................107
			17. Remove inner shaft seal (16) and back up ring (17) from housing (18). Discard both...............................................................................................................................................................................107
			18. Remove housing (18) from vise. Invert housing and remove outer shaft seal (20) with a blind hole bearing or seal puller. Discard seal............................................................................................................................107
			19. Inspect housing (18) assembly for cracks, machined surfaces for nicks, burrs, brinelling, or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If housing is defective...........107
			20. If housing (18) assembly has passed inspection to this point, inspect housing bearings/bushings (19) and (13) if they are captured in housing cavity. Two thrust washers (14) and thrust bearing (15) rollers must be firmly retained in bearing cages...........108
			21. Measure and note depth or location of bearing/bushing (13) in relation to housing wear plate surface, and depth or location of bearing/bushing (19) in relation to beginning of bearing/bushing counter bore before removing bearings/bushings. This e...........108
			22. Use a suitable size bearing puller to remove bearing/ bushings (19) and (13) from housing (18). If Bearings, bushing or thrust washers must be replaced without damaging housing. Remove thrust washers (14) and thrust bearing (15) if previously ret...........108
		Assembly.................................................................................................................................................................................................................................................................109
			1. If housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease. Press new bearing/bushing into counterbore at mounting flange end of housing, using a...........109
			2. Inner housing bearing/bushing (13) can now be pressed into its counter-bore in housing (18) flush to 0.03 inch (0.76 mm) below housing wear plate contact face. Use opposite end of bearing mandrel used to press in outer bearing/bushing (19)...................109
			3. Press new outer shaft seal (20) into housing (18) outer bearing counterbore. Press in outer shaft seal (20) until flange is flush against housing.................................................................................................................110
			4. Place housing (18) assembly into a soft jawed vise with coupling shaft bore down, clamping against mounting flange................................................................................................................................................110
			5. Assemble a new backup ring (17), new backup washer (14), and new inner shaft seal (16) with seal lip facing toward inside of motor, into their counterbores in housing (18).......................................................................................110
			6. Install thrust washer (14) and thrust bearing (15)................................................................................................................................................................................................................110
			7. Apply masking tape around splines or keyway on coupling shaft (12) to prevent damage to seal......................................................................................................................................................................110
			8. Apply a generous amount of clean, corrosion resistant grease to lower (outer) housing bearing/bushing (19). Install coupling shaft (12) into housing (18), seating it against thrust bearing (15).................................................................111
			9. Apply a small amount of clean grease to a new O-ring (4) and insert it in housing (18) seal ring groove...........................................................................................................................................................111
			10. Install drive link (10), long splined end down, in coupling shaft (12) and engage drive link splines in mesh with coupling shaft splines.........................................................................................................................111
			11. Assemble wear plate (9) over drive link (10) and alignment studs onto housing (18)...............................................................................................................................................................................112
			12. Apply a small amount of clean grease to a new O-ring (4) and assemble it into ring groove on wear plate side of rotor set stator.................................................................................................................................112
			13. Place assembled rotor set (8) on wear plate (9) with rotor counterbore and seal ring side down and splines into mesh with drive link splines.....................................................................................................................112
			14. Apply clean grease to new O-ring (4). Install in ring groove in rotor set contact side of manifold (7)...........................................................................................................................................................112
			15. Place manifold (7) over alignment studs and drive link (10) and onto rotor set. Be sure correct manifold surface is against rotor set............................................................................................................................113
			16. Apply grease to new O-ring (4) and insert it in manifold ring groove.............................................................................................................................................................................................113
			17. Install commutator ring (6) over alignment studs on manifold.....................................................................................................................................................................................................113
			18. Install new commutator seal (3) flat side up, into commutator (5). Assemble commutator over end of drive link (10) on manifold (7) with seal ring side up........................................................................................................113
			19. Install new O-ring (4) in end cover (2) and install end cover over alignment studs and on commutator set. If end cover has only 5 bolt holes be sure cover holes are aligned with 5 threaded holes in housing (18). Correct 5 bolt end cover bolt hole...........113
			20. Assemble bolts (1) and screw in finger tight. Remove and replace two alignment studs with bolts after other bolts are in place. Alternately and progressively tighten bolts to pull end cover and other components into place with a final torque of 2...........114
		One Piece Stator Assembly................................................................................................................................................................................................................................................115
			1. Place stator on wear plate (9) with O-ring (4) side down, after following assembly procedures 1 through 13. Be sure seal ring is in place.........................................................................................................................115
			2. If assembly alignment studs are not used, align stator bolt holes with wear plate and housing bolt holes. Turn two bolts (1) finger tight in bolt holes approximately 180 degrees apart to retain stator and wear plate stationary................................115
			3. Assemble rotor, counterbore down if applicable, into stator, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines....................................................................................................................115
			4. Assemble six vanes, or as many vanes that readily assemble in stator vane pockets.................................................................................................................................................................................115
			5. Grasp output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link, and rotor to seat rotor and assembled vanes into stator, creating the necessary clearance to assemble the sevent...........115
			6. Remove two bolts (1) if used to retain stator and wear plate. Go to Step 14 on page 3-68 to continue assembly.....................................................................................................................................................115
		Two Piece Stator Assembly................................................................................................................................................................................................................................................116
			1. Place stator half on wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure seal ring is in place...........................................................................................................116
			2. Align stator bolt holes with wear plate and housing bolts. Turn two alignment studs finger tight in bolt holes approximately 180° apart to keep stator half and wear plate stationary.............................................................................116
			3. Assemble rotor, counterbore down if applicable, into stator half, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines...............................................................................................................116
			4. Assemble six vanes, or as many vanes that readily assemble into stator vane pockets...............................................................................................................................................................................116
			5. Grasp output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat rotor and assembled vanes into stator half, creating necessary clearance to assemble seventh or...........116
			6. Place second stator half on a flat surface with seal ring groove up. Apply a small amount of grease to a new O- ring (4) and install it in stator half ring groove................................................................................................116
			7. Assemble second stator half over two alignment studs and rotor with seal ring side down onto the first stator half aligning any timing marks applied for this purpose.............................................................................................116
			8. Assemble six vanes, or as many vanes that readily assemble into stator vane pockets...............................................................................................................................................................................116
			9. Grasp output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link, and rotor to seat rotor and assembled vanes into stator, creating necessary clearance to assemble seventh or ful...........116
		Final Checks.............................................................................................................................................................................................................................................................116
			1. Pressurize motor with 100 psi dry air or nitrogen and submerge in solvent to check for external leaks.............................................................................................................................................................116
			2. Check motor for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. lbs. (68 Nm)....................................................................................................................................................116
			3. Pressure port with “A” cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with “B” cast under it is for counter clockwise coupling shaft rotation..............................116
			4. Use test stand and check motor operation..........................................................................................................................................................................................................................116
		Installation.............................................................................................................................................................................................................................................................116
			1. Carefully insert swing motor into swing drive, making sure swing motor shaft key is aligned correctly.............................................................................................................................................................116
			2. Secure swing motor to swing drive assembly with two bolts and flat washers. Apply threadlocker JLG P/N 0100019 to threads of retaining bolts and torque to 73.75 ft. lbs. (100 Nm)................................................................................116
			3. Connect hydraulic lines running to swing motor as tagged during removal...........................................................................................................................................................................................116
			4. Operate the swing function in both directions to ensure proper operation. Inspect the hose connections for any leakage............................................................................................................................................116
	3.15 Generator...............................................................................................................................................................................................................................................................117
		Every 250 hours..........................................................................................................................................................................................................................................................117
		Every 500 hours..........................................................................................................................................................................................................................................................117
		Overload Protection......................................................................................................................................................................................................................................................117
		Brushes and Slip Rings...................................................................................................................................................................................................................................................117
			inspecting brush position............................................................................................................................................................................................................................................117
			inspecting brushes...................................................................................................................................................................................................................................................117
			CLEANING SLIP RINGS..................................................................................................................................................................................................................................................117
		Generator Disassembly and Assembly.......................................................................................................................................................................................................................................119
			1. Rotor.............................................................................................................................................................................................................................................................119
			2. Stator Assembly...................................................................................................................................................................................................................................................119
			Disassembly..........................................................................................................................................................................................................................................................119
				1. Mark and disconnect all electrical leads, secure using cable ties.............................................................................................................................................................................................119
				2. Remove brush holder assembly..................................................................................................................................................................................................................................119
				3. Disassemble generator parts shown in Figure 3-50..............................................................................................................................................................................................................119
				4. Clean all parts with approved solvent and dry with compressed air, If applicable..............................................................................................................................................................................119
				5. Inspect all part for damage. Replace if necessary.............................................................................................................................................................................................................119
			assembly.............................................................................................................................................................................................................................................................119
				1. Assemble generator parts using torque values in table.........................................................................................................................................................................................................119
				2. Reconnect all leads. Use cable ties to secure leads away from moving or hot parts.............................................................................................................................................................................119
		Lead Connection List for Generator.......................................................................................................................................................................................................................................126
	3.16 Deutz Engine D2.3L3.....................................................................................................................................................................................................................................................127
		1. Gear Pump.............................................................................................................................................................................................................................................................127
		2. Piston Pump...........................................................................................................................................................................................................................................................127
		3. Pump Coupling Kit.....................................................................................................................................................................................................................................................127
		4. Engine................................................................................................................................................................................................................................................................127
		5. Engine Tray...........................................................................................................................................................................................................................................................127
		6. Muffler...............................................................................................................................................................................................................................................................127
		7. Oil Cooler............................................................................................................................................................................................................................................................127
		8. Radiator..............................................................................................................................................................................................................................................................127
		9. Forward Solenoid......................................................................................................................................................................................................................................................127
		10. Reverse Solenoid.....................................................................................................................................................................................................................................................127
		11. Hydraulic Filter.....................................................................................................................................................................................................................................................127
		12. Fan..................................................................................................................................................................................................................................................................128
		13. Relay................................................................................................................................................................................................................................................................128
		14. Relay................................................................................................................................................................................................................................................................128
		15. Relay................................................................................................................................................................................................................................................................128
		16. Air Cleaner..........................................................................................................................................................................................................................................................129
		17. Muffler..............................................................................................................................................................................................................................................................129
		18. Exhaust Pipe.........................................................................................................................................................................................................................................................129
		19. ECM..................................................................................................................................................................................................................................................................129
		20. Alternator...........................................................................................................................................................................................................................................................129
		21. Air Intake Restriction Indicator.....................................................................................................................................................................................................................................129
		Checking Oil Level.......................................................................................................................................................................................................................................................130
			1. Make sure machine and engine are level and switch engine OFF before checking oil level............................................................................................................................................................................130
			2. Remove oil dipstick and wipe with clean cloth.....................................................................................................................................................................................................................130
			3. Insert dipstick to the stop and remove again......................................................................................................................................................................................................................130
			4. Check oil level. Top oil level to MAX mark or as shown in figure below with an approved grade and type of oil outlined in engine manufacturer’s operator’s manual.................................................................................................130
			5. Replace dipstick until fully seated...............................................................................................................................................................................................................................130
		Changing Engine Oil......................................................................................................................................................................................................................................................130
			1. Allow engine to warm up. Engine oil should reach approximately 176° F (80° C).....................................................................................................................................................................................130
			2. Make sure machine and engine are level and switch off engine......................................................................................................................................................................................................130
			3. Place oil tray under engine.......................................................................................................................................................................................................................................130
			4. Open oil drain valve and drain oil................................................................................................................................................................................................................................130
			5. Close oil drain valve.............................................................................................................................................................................................................................................130
			6. Pour in new engine oil. Refer to Section 1 for capacity and refer to Figure 3-61., Engine Oil Viscosity...........................................................................................................................................................130
		Changing Oil Filter......................................................................................................................................................................................................................................................131
			1. Wipe area around filter to remove any dirt from area..............................................................................................................................................................................................................131
			2. Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off...........................................................................................................................................................................131
			3. Catch any escaping oil............................................................................................................................................................................................................................................131
			4. Clean any dirt from filter carrier sealing surface................................................................................................................................................................................................................131
			5. Lightly coat new oil filter rubber gasket with clean oil..........................................................................................................................................................................................................131
			6. Screw in new filter by hand until gasket is flush. Hand- tighten filter another half-turn.........................................................................................................................................................................131
			7. Check oil level...................................................................................................................................................................................................................................................131
			8. Check oil pressure................................................................................................................................................................................................................................................131
			9. Check oil filter cartridge for leaks..............................................................................................................................................................................................................................131
	3.17 Deutz EMR 2.............................................................................................................................................................................................................................................................132
	3.18 Bio Fuel in Deutz Engines...............................................................................................................................................................................................................................................144
		General..................................................................................................................................................................................................................................................................144
		Bio Fuel.................................................................................................................................................................................................................................................................144
			Permitted bio-diesel fuels...........................................................................................................................................................................................................................................144
			approved engines.....................................................................................................................................................................................................................................................144
			Basic conditions to be observed......................................................................................................................................................................................................................................144
			Plant oil............................................................................................................................................................................................................................................................144
		Biological Contamination In Fuels........................................................................................................................................................................................................................................144
			Symptoms.............................................................................................................................................................................................................................................................144
			Cause................................................................................................................................................................................................................................................................144
			Preventive measures..................................................................................................................................................................................................................................................145
			Fuel additives.......................................................................................................................................................................................................................................................145
	3.19 DGC Diagnostic Support and Trouble Code Definitions.....................................................................................................................................................................................................................146
		Section Layout...........................................................................................................................................................................................................................................................146
		Fault Code Broadcast.....................................................................................................................................................................................................................................................148
		Diagnostic Trouble Codes.................................................................................................................................................................................................................................................148
		CAN......................................................................................................................................................................................................................................................................148
		MIL Output...............................................................................................................................................................................................................................................................148
		Diagnostic Calibration Configuration and Corrective Actions..............................................................................................................................................................................................................148
		Fault/Diagnostic Trouble Code Interaction................................................................................................................................................................................................................................149
		DBW Diagnostic Test......................................................................................................................................................................................................................................................152
	3.20 Diagnostic Trouble Code Fault Descriptions..............................................................................................................................................................................................................................155
		DTC 116- ECT Higher Than Expected Stage 1................................................................................................................................................................................................................................155
		DTC 117- ECT/CHT Low Voltage.............................................................................................................................................................................................................................................156
		DTC 118- ECT/CHT High Voltage............................................................................................................................................................................................................................................158
		DTC 122- TPS1 Signal Voltage Low.........................................................................................................................................................................................................................................160
		DTC 123- TPS1 Signal Voltage High........................................................................................................................................................................................................................................162
		DTC 217- ECT Higher Than Expected 2......................................................................................................................................................................................................................................164
		DTC 219- RPM Higher Than Max Allowed Governed Speed......................................................................................................................................................................................................................165
		DTC 336- Crank Signal Input Noise........................................................................................................................................................................................................................................166
		DTC 337- Loss of Crank Input Signal......................................................................................................................................................................................................................................168
		DTC 521- Oil Pressure Sender/Switch High Pressure........................................................................................................................................................................................................................169
		DTC 524- Oil Pressure Low................................................................................................................................................................................................................................................172
		DTC 562- Battery Voltage (VBat) Low......................................................................................................................................................................................................................................176
		DTC 563- Battery Voltage (VBat) High.....................................................................................................................................................................................................................................178
		DTC 601- Microprocessor Failure - FLASH..................................................................................................................................................................................................................................180
		DTC 604- Microprocessor Failure - RAM....................................................................................................................................................................................................................................182
		DTC 606- Microprocessor Failure - COP....................................................................................................................................................................................................................................184
		DTC 642- 5 Volt External Low Voltage.....................................................................................................................................................................................................................................185
		DTC 643- 5 Volt External High Voltage....................................................................................................................................................................................................................................186
		DTC 1612- Microprocessor Failure - RTI 1.................................................................................................................................................................................................................................187
		DTC 1613- Microprocessor Failure - RTI 2.................................................................................................................................................................................................................................187
		DTC 1614- Microprocessor Failure - RTI 3.................................................................................................................................................................................................................................189
		DTC 1615- Microprocessor Failure - A/D...................................................................................................................................................................................................................................191
		DTC 1616- Microprocessor Failure - Interrupt.............................................................................................................................................................................................................................193
		DTC 1625- CAN J1939 Shutdown Request.....................................................................................................................................................................................................................................195
		DTC 1626- CAN J1939 Transmit (Tx) Fault..................................................................................................................................................................................................................................195
		DTC 1627- CAN J1939 Receive (Rx) Fault...................................................................................................................................................................................................................................196
		DTC 1628- CAN Address Conflict Failure...................................................................................................................................................................................................................................197
		DTC 1629- J1939 TSC1 Message Receipt Loss................................................................................................................................................................................................................................199
			Diagnostic Aids......................................................................................................................................................................................................................................................199
		DTC 1652- TPS1 Loss of Communications....................................................................................................................................................................................................................................  0
		DTC 2111- Unable to Reach Lower TPS......................................................................................................................................................................................................................................  0
		DTC 2112- Unable to Reach Higher TPS.....................................................................................................................................................................................................................................202
		DTC 9999- Throttle Actuator Failsafe Spring Failure......................................................................................................................................................................................................................203
		DTC to SPN/FMI Table.....................................................................................................................................................................................................................................................204
	3.21 Counterweight...........................................................................................................................................................................................................................................................205
Section 4. Boom & Platform.......................................................................................................................................................................................................................................................207
	4.1 Boom Systems.............................................................................................................................................................................................................................................................207
		Platform Control Enable System...........................................................................................................................................................................................................................................207
		Transport Position Sensing System........................................................................................................................................................................................................................................207
		Platform Load Sensing System (LSS) (if Equipped).........................................................................................................................................................................................................................207
		Beyond Transport Position - Drive Speed Cutback System...................................................................................................................................................................................................................207
		Drive/Steer –Boom Function Interlock System..............................................................................................................................................................................................................................207
		Jib Lift End of Stroke Dampening (if equipped)...........................................................................................................................................................................................................................207
		Main Boom Lift End of Stroke Dampening...................................................................................................................................................................................................................................207
		Emergency Decent System..................................................................................................................................................................................................................................................207
	4.2 Platform.................................................................................................................................................................................................................................................................208
		Platform/Support Removal.................................................................................................................................................................................................................................................208
			1. Disconnect electrical cable from control console..................................................................................................................................................................................................................208
			2. Remove the bolts securing the platform to the platform support, then remove the platform..........................................................................................................................................................................208
			3. Using a suitable device, support the platform support.............................................................................................................................................................................................................208
			4. Remove the bolts and locknuts securing the support to the rotator.................................................................................................................................................................................................208
			5. Using a suitable brass drift and hammer, remove the center bolt and locknut.......................................................................................................................................................................................208
			6. Remove the platform support from rotator..........................................................................................................................................................................................................................208
		Platform/Support Installation............................................................................................................................................................................................................................................209
			1. Using a suitable device, support the platform support and position it on the rotator..............................................................................................................................................................................209
			2. Install the rotator center bolt and locknut.......................................................................................................................................................................................................................209
			3. Apply JLG Threadlocker P/N 0100011 to the eight bolts securing the support to the rotator and install the bolts...................................................................................................................................................209
			4. Torque the nut on the rotator center bolt and the retaining bolts. See Figure 4-3.................................................................................................................................................................................209
			5. Using a suitable lifting device, position the platform on the platform support and install the bolts securing the platform to the platform support. See Figure 4-2................................................................................................209
			6. Connect the electrical cable to the platform control console......................................................................................................................................................................................................209
	4.3 Rotator..................................................................................................................................................................................................................................................................212
		Removal..................................................................................................................................................................................................................................................................212
			1. Remove the platform and platform support. Refer to Section 4.2, Platform..........................................................................................................................................................................................212
			2. Tag and disconnect hydraulic lines to rotator. Use suitable container to retain any residual hydraulic fluid. Cap or plug all openings of hydraulic lines and ports...............................................................................................212
			3. Supporting the rotator and jib lift cylinder, remove hardware from pin #1. Using a suitable brass drift and hammer remove pin #1..................................................................................................................................212
			4. Remove the hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2 and remove the rotator....................................................................................................................................................212
		Installation.............................................................................................................................................................................................................................................................212
			1. Supporting the rotator and jib lift cylinder, align rotator with jib lift cylinder and jib. Using a soft head mallet, install pin #1 to the jib assembly. Install hardware securing pin #1........................................................................212
			2. Using a soft head mallet install pin #2 to jib assembly and install the rotator. Install hardware securing pin #2.................................................................................................................................................212
			3. Install the platform and platform support. Refer Section 4.2, Platform............................................................................................................................................................................................212
			4. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines to the rotator as tagged during removal..........................................................................................................................................212
	4.4 Jib......................................................................................................................................................................................................................................................................213
		Removal..................................................................................................................................................................................................................................................................213
			1. Remove the platform and platform support. Refer to Section 4.2, Platform..........................................................................................................................................................................................213
			2. Using a suitable lifting device, adequately support jib assembly weight along entire length.......................................................................................................................................................................213
			3. Tag and disconnect hydraulic lines from level cylinder and jib lift cylinder. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports...............................................................213
			4. Attach an adequate supporting device to the Level cylinder to support its weight..................................................................................................................................................................................213
			5. Remove mounting hardware from level cylinder pin #1. Using a suitable brass drift and hammer, remove the pin #1...................................................................................................................................................213
			6. Remove mounting hardware from jib pivot pin #2. Using a suitable brass drift and hammer, remove the pivot pin from jib assembly...................................................................................................................................213
			7. Remove the jib assembly from the boom.............................................................................................................................................................................................................................213
		Disassembly..............................................................................................................................................................................................................................................................213
			1. Remove mounting hardware from jib pivot pin #1 and #2. Using a suitable brass drift and hammer, remove the pin #1 and #2 from jib pivot...........................................................................................................................213
			2. Remove the jib pivot from jib assembly............................................................................................................................................................................................................................213
			3. Attach an adequate supporting device to the lift cylinder assembly to support its weight..........................................................................................................................................................................213
			4. Remove mounting hardware from pin #3. Using a suitable brass drift and hammer, remove the pin #3..................................................................................................................................................................213
			5. Carefully remove the lift cylinder from jib assembly..............................................................................................................................................................................................................213
			6. Remove mounting hardware from pin #4. Using a suitable brass drift and hammer, remove the pin #4..................................................................................................................................................................213
			7. Remove rotator from jib assembly..................................................................................................................................................................................................................................213
		Inspection...............................................................................................................................................................................................................................................................213
			1. Inspect pivot pins for wear, scoring, tapering and ovality, or other damage. Replace pins as necessary............................................................................................................................................................213
			2. Inspect pivot attach points for scoring, tapering and ovality, or other damage. Replace pins as necessary.........................................................................................................................................................213
			3. Inspect inner diameter of pivot bearings for scoring, distortion, wear, or other damage. Replace bearings as necessary............................................................................................................................................213
			4. Inspect lift cylinder attach pin for wear, scoring, tapering and ovality, or other damage. Ensure pin surfaces are protected prior to installation. Replace pins as necessary.....................................................................................213
			5. Inspect inner diameter of rotator attach point bearings for scoring, distortion, wear, or other damage............................................................................................................................................................213
			6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary..............................................................................................................................................214
			7. Inspect structural units of jib assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary..........................................................................................................................214
		Assembly.................................................................................................................................................................................................................................................................214
			1. Supporting the rotator and jib lift cylinder, align the jib lift cylinder rod end and rotator with the jib assembly. Using a soft head mallet, install pin #3. Install hardware securing pin #3...................................................................214
			2. Using a soft head mallet install pin #4 to jib assembly and rotator. Install hardware securing pin #4.............................................................................................................................................................214
			3. Align the jib lift cylinder barrel end and jib pivot to the jib assembly. Using a soft head mallet, install pin #2 and secure with mounting hardware..............................................................................................................214
			4. Align jib pivot with jib assembly. Using a soft head mallet, install pin #1 into jib assembly and secure with mounting hardware...................................................................................................................................214
		Installation.............................................................................................................................................................................................................................................................214
			1. Attach an adequate lifting device to the jib assembly and position it in front of the fly boom....................................................................................................................................................................214
			2. Lift the jib assembly into position on the boom fly section and install the pin #2 using a soft head mallet. Secure the pin #2 in place with the bolt and keeper pin..............................................................................................214
			3. Align level cylinder with fly boom and jib pivot and install pin #1 using a soft head mallet. Secure the pin #1 in place with the bolt and keeper pin.............................................................................................................214
			4. Install the platform and platform support. Refer Section 4.2, Platform............................................................................................................................................................................................214
			5. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines to the level cylinder and jib lift cylinder as tagged during removal.............................................................................................................214
	4.5 Platform Level Cylinder..................................................................................................................................................................................................................................................215
		Removal..................................................................................................................................................................................................................................................................215
			1. Tag and disconnect hydraulic lines from platform level cylinder. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports............................................................................215
			2. Place blocking or a soft material under the platform level cylinder barrel to protect the rod from being scratched................................................................................................................................................215
			3. Using a suitable lifting device, adequately support jib assembly..................................................................................................................................................................................................215
			4. Remove mounting hardware from platform level cylinder pin #1. Using a suitable brass drift and hammer, remove the cylinder pin #1 from platform level cylinder....................................................................................................215
			5. Remove mounting hardware from platform level cylinder pin #2. Using a suitable brass drift and hammer, remove the cylinder pin #2 from jib pivot..................................................................................................................215
			6. Carefully remove the platform level cylinder assembly from fly boom...............................................................................................................................................................................................215
		Installation.............................................................................................................................................................................................................................................................215
			1. Using a suitable lifting device, adequately support jib assembly..................................................................................................................................................................................................215
			2. Support the platform level cylinder. Using a soft head mallet, install pin #1 to the platform level cylinder. Install hardware securing pin #1 and torque to 40.5 ft. lbs. (55 Nm)................................................................................215
			3. Using soft head mallet install pin #2 to jib pivot and install the platform level cylinder. Install hardware securing pin #2 and torque to 40.5 ft. lbs. (55 Nm)..................................................................................................215
			4. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines to the platform level cylinder as tagged during removal..........................................................................................................................215
	4.6 Main Boom Powertrack.....................................................................................................................................................................................................................................................216
		Removal..................................................................................................................................................................................................................................................................216
			1. Disconnect wiring harness connectors located in turntable.........................................................................................................................................................................................................216
			2. Tag and disconnect hydraulic lines from connectors at boom assembly. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports........................................................................216
			3. Remove hydraulic lines and electrical cables from Powertrack......................................................................................................................................................................................................216
			4. Using suitable lifting device, adequately support Powertrack weight along entire length...........................................................................................................................................................................216
			5. Remove bolt #1 securing the powertrack on the tube carrier........................................................................................................................................................................................................216
			6. Remove bolt #2 securing the powertrack on the base boom section. Remove the powertrack assembly...................................................................................................................................................................216
		Installation.............................................................................................................................................................................................................................................................216
			1. Using suitable lifting device, adequately support the powertrack weight along entire length.......................................................................................................................................................................216
			2. With powertrack supported and using all applicable safety precautions, install hardware #2 securing rail to the base boom.........................................................................................................................................216
			3. Install hardware #1 to tube carrier...............................................................................................................................................................................................................................216
			4. Remove tag and reconnect all hydraulic lines and electrical cable from powertrack.................................................................................................................................................................................216
			5. Reconnect dual capacity indicator limit switch from side of boom section..........................................................................................................................................................................................216
			6. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines from connectors at boom assembly as tagged during removal........................................................................................................................216
	4.7 Powertrack Maintenance...................................................................................................................................................................................................................................................217
		Remove Link..............................................................................................................................................................................................................................................................217
			1. Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a T- 20 torx bit, remove 8-32 x 0.500 screw from one side..................................................................................................217
			2. Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack...................................................................................................................................................................217
			3. To remove a link, rivets holding links together must be removed. Use a right-angle pneumatic die grinder with a ¼” ball double cut bur attachment.................................................................................................................218
			4. Insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed...............................................................................................................218
			5. After grinding it may be necessary to use a center punch with a hammer to remove rivet............................................................................................................................................................................218
			6. Insert flat head screwdriver between links. Twist and pull links apart............................................................................................................................................................................................219
			7. Remove link from other section of powertrack using screwdriver....................................................................................................................................................................................................219
		Install New Link.........................................................................................................................................................................................................................................................220
			1. Squeeze cut-out end of new link into half-shear (female) end of track section.....................................................................................................................................................................................220
			2. Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use a screwdriver if necessary........................................................................................................................................220
			3. After new link is installed round half-shears do not fit properly in cut-outs.....................................................................................................................................................................................220
			4. Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will rotate into cut-outs....................................................................................................................................221
			5. Parts shown below connect new link to powertrack..................................................................................................................................................................................................................221
			6. Push pin through center hole then slide washer on pin.............................................................................................................................................................................................................221
			7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed........................................................................................................................................................221
			1. Install new 8-32 x 0.500 self-threading torx head screw in end of new aluminum round bar. Torque to 18-20 in. lbs. (2-2.25 Nm)....................................................................................................................................222
			2. Pull up on other end of round bar and slide new poly roller on bar................................................................................................................................................................................................222
			3. Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in. lbs. (2-2.25 Nm).................................................................................................................................................................223
		Replace Fixed End Brackets...............................................................................................................................................................................................................................................223
			1. Remove rivets as shown in link removal instructions on page 4-12..................................................................................................................................................................................................223
			2. Parts used: Bracket Center Pin and Center Pin Snap Ring...........................................................................................................................................................................................................224
			3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it............................................................................................................................................................224
		Replace Moving End Brackets..............................................................................................................................................................................................................................................224
			1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-20. Repeat on other bracket if replacing it...................................................................................................................224
			2. Install center pin with snap ring in new bracket..................................................................................................................................................................................................................225
			3. Install radius pins and snap rings in original locations. Repeat with other moving end if replacing it............................................................................................................................................................225
			4. Make sure both brackets rotate correctly..........................................................................................................................................................................................................................225
	4.8 Boom Cleanliness Guidelines..............................................................................................................................................................................................................................................231
		1. JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom. This package reduces the amount of contamination which can enter...............231
		2. JLG recommends that you follow all guidelines for servicing your equipment in accordance with the instructions outlined in the JLG Service & Maintenance Manual for your machine. Periodic maintenance and inspection is vital to the proper operation ...............231
		3. Debris and foreign matter inside of the boom can cause premature failure of components and should be removed. Methods to remove debris should always be done using all applicable safety precautions outlined in the JLG Service & Maintenance Manuals................231
		4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest exiting point from the boom. Make sure that all debris is removed before operating the machine.......................................231
		5. If pressurized air cannot dislodge the debris, then water with mild solvents applied via a pressure washer can be used. Again the method is to wash the debris toward the nearest exiting point from the boom. Make sure that all debris is removed, th...............231
		6. If neither pressurized air nor washing of the boom dislodges and removes the debris, then disassemble the boom in accordance to the instructions outlined in the JLG Service & Maintenance Manual to remove the debris................................................231
	4.9 Boom Shimming Procedure..................................................................................................................................................................................................................................................232
		1. Measure and take note of the inside width and inside height of the base boom opening for reference later in this procedure............................................................................................................................................232
		2. Install the side wear pads on the fly boom and shim as required to match the corresponding dimension recorded in Step 1 within +0/-1.2 mm. Shims should be divided as evenly as possible between the sides of the boom. The number of shims installed a...............232
		3. Install the top wear pads and shims on the fly boom...................................................................................................................................................................................................................232
		4. Install the bottom wear pads on the fly boom and shim as required to obtain the total base boom dimension within +0/-1.2 mm of the corresponding dimension from Step 1................................................................................................232
		5. Slide the fly boom into the base boom, leaving 1 to 2 meters exposed..................................................................................................................................................................................................232
		6. Install the bottom wear pads and shims into the end of the base boom..................................................................................................................................................................................................232
		7. Install the side pads and shims into the base boom. Distribute shims to each side to match the distribution noted in Step 2. Positions #5/6 must match positions #1/ 2. Positions #7/8 must match positions #3/4 (See Figure 4-12. and Figure 4-13.). V...............232
		8. Install the top wear pads and shims into the base boom leaving a gap of 0mm to 1.2mm between the top of the fly boom and the inside of the base boom..................................................................................................................232
	4.10 Boom Assembly...........................................................................................................................................................................................................................................................241
		Upper Boom Removal.......................................................................................................................................................................................................................................................241
			1. Remove the platform assembly and jib. Refer to Section 4.2, Platform and Section 4.4, Jib.........................................................................................................................................................................241
			2. Remove the hardware securing boom end cover to the upper boom. Remove the boom end cover..........................................................................................................................................................................241
			3. Using a suitable lifting device, adequately support upper boom assembly weight along entire length................................................................................................................................................................241
			4. Tag and disconnect hydraulic lines from telescope cylinder, main lift cylinder and master cylinder. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports.........................................241
			5. Attach an adequate supporting device to the main lift cylinder and master cylinder to support their weight........................................................................................................................................................241
			6. Remove bolt and keeper pin from main lift cylinder pin #1. Using a suitable brass drift and hammer, remove the cylinder pin #1 securing main lift cylinder to upper boom..........................................................................................241
			7. Remove bolt and keeper pin from master cylinder pin #2. Using a suitable brass drift and hammer, remove the cylinder pin #2 securing master cylinder to upper boom................................................................................................241
			8. Remove Engine side hood to gain access to keeper pins on upper upright, if necessary..............................................................................................................................................................................241
			9. Remove bolt and keeper pin #3 securing the upper boom to the upper upright. Using a suitable brass drift and hammer, remove the pin #3 from upper boom............................................................................................................241
			10. Using all applicable safety precautions, carefully lift upper boom assembly clear of upper upright and lower to ground or suitably supported work surface........................................................................................................241
			11. If necessary remove bolt and keeper pin from main lift cylinder pin #4. Using a suitable brass drift and hammer, remove the cylinder pin #4 from upper upright. Carefully remove the main lift cylinder..........................................................242
			12. If necessary remove bolt and keeper pin #5 from master cylinder pin. Using a suitable brass drift and hammer, remove the cylinder pin #5 from upper upright. Carefully remove the master cylinder................................................................242
		Mid Boom Removal.........................................................................................................................................................................................................................................................242
			1. Using a suitable lifting equipment, adequately support mid boom assembly weight...................................................................................................................................................................................242
			2. Tag and disconnect hydraulic lines from tower lift cylinder. Use suitable container to retain any residual hydraulic fluid. Cap and plug all openings of hydraulic lines and ports................................................................................242
			3. Remove Hydraulic tank side hood to gain access to keeper pins on upper upright, if necessary......................................................................................................................................................................242
			4. Attach an adequate supporting device to the upper upright to support its weight...................................................................................................................................................................................242
			5. Remove mounting hardware from pins. Using a suitable brass drift and hammer, remove the pins from upper upright...................................................................................................................................................242
			6. Using all applicable safety precautions, carefully lift upper upright and lower to ground or suitably supported work surface......................................................................................................................................242
			7. Using a suitable lifting equipment, adequately support tower lift cylinder to supper its weight...................................................................................................................................................................242
			8. Remove mounting hardware from pins securing tower lift cylinder to the mid boom. Using a suitable brass drift and hammer, remove the pin from tower lift cylinder securing to mid boom............................................................................243
			9. If necessary remove bolt and keeper pin from tower lift cylinder pin. Using a suitable brass drift and hammer, remove the cylinder pin from lower boom. Carefully remove the tower lift cylinder..................................................................243
			10. Attach an adequate supporting device to the lower upright to support its weight..................................................................................................................................................................................243
			11. Remove mounting hardware from pins. Using a suitable brass drift and hammer, remove the pins from lower upright..................................................................................................................................................243
			12. Using all applicable safety precautions, carefully lift lower upright and lower to ground or suitably supported work surface.....................................................................................................................................243
			13. Attach an adequate supporting device to the timing link to support its weight....................................................................................................................................................................................243
			14. Remove mounting hardware from pin. Using a suitable brass drift and hammer, remove the pin from timing link......................................................................................................................................................243
			15. Using all applicable safety precautions, carefully lift mid boom assembly and lower to ground or suitably supported work surface.................................................................................................................................243
		Lower Boom Removal.......................................................................................................................................................................................................................................................244
			1. Using a suitable lifting device, adequately support lower boom assembly weight....................................................................................................................................................................................244
			2. Remove mounting hardware from pin. Using a suitable brass drift and hammer, remove the pin from timing link.......................................................................................................................................................244
			3. Using all applicable safety precautions, carefully lift lower timing link to ground or suitably supported work surface............................................................................................................................................244
			4. Remove front hood and counterweight to gain access to keeper pins on turntable, if necessary......................................................................................................................................................................244
			5. Remove mounting hardware from pins. Using a suitable brass drift and hammer, remove the pins from lower boom securing to turntable................................................................................................................................244
			6. Using all applicable safety precautions, carefully lift lower boom assembly and lower to ground or suitably supported work surface................................................................................................................................244
		Upper Boom Disassembly...................................................................................................................................................................................................................................................244
			1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments.................................................................................................................................................................................244
			2. Loosen the wear pad retaining bolts at the rear of fly boom section and remove the shims and wear pads noting the location and number of shims to aid in reassembly...............................................................................................244
			3. If necessary, using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down the portable ...........244
			4. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port. Cap...........244
			5. Remove the retaining ring and pin securing the telescope cylinder rod end to the fly boom section.................................................................................................................................................................245
			6. Remove the bolts and washers securing telescope cylinder to the rear of the base boom section.....................................................................................................................................................................245
			7. Using a suitable lifting device, remove telescope cylinder from the rear of the boom sections.....................................................................................................................................................................245
			8. Remove hardware securing the front wear pads on base boom section, remove wear pads and shims, noting the location and number of shims to aid in reassembly.......................................................................................................245
			9. Using a suitable lifting device, remove fly boom from boom section................................................................................................................................................................................................245
		Inspection...............................................................................................................................................................................................................................................................246
			1. Inspect all boom pivot pins for wear, scoring or other damage, and for tapering or ovality. Replace pins as necessary.............................................................................................................................................246
			2. Inspect lift cylinder pins for wear, scoring or other damage, and for tapering or ovality. Ensure pin surfaces are protected prior to installation. Replace pins as necessary.....................................................................................246
			3. Inspect telescope cylinder rod attach pin for wear, scoring or other damage. Replace pin as necessary.............................................................................................................................................................246
			4. Inspect inner diameter of boom pivot bushings for scoring, distortion, wear or other damage. Replace bushings as necessary........................................................................................................................................246
			5. Inspect wear pads for wear........................................................................................................................................................................................................................................246
			6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary..............................................................................................................................................246
			7. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.........................................................................................................................246
		Upper Boom Assembly......................................................................................................................................................................................................................................................246
			1. Using JLG threadlocker P/N 0100011 or equivalent, install the bottom wear pads and shims as noted during disassembly on the rear of the fly section. Torque the retaining bolts to 40 ft. lbs. (55 Nm). Install the rest of the wear pads on the rear o...........246
			2. Using an adequate lifting device, slide the fly boom section into the base boom section. Install the remaining shims on the rear of the fly section as noted during disassembly and torque the retaining bolts to 40 ft. lbs. (55 Nm). Pull the fly sec...........246
			3. Using JLG threadlocker P/N 0100011 compound or equivalent, install the front wear pads and shims as noted during disassembly on the base boom section. Torque the retaining bolts to 40 ft. lbs. (55 Nm)..........................................................246
			4. Using an adequate lifting device, install the telescope cylinder into the boom assembly. It will aid assembly if the cylinder is extended to enable connection to the fly boom section............................................................................246
			5. Align the telescope cylinder rod end with the corresponding hole in the fly boom section. If necessary, attach a portable power supply to the cylinder to extend or retract the cylinder for alignment. Install the retaining pin and secure it in plac...........247
			6. Using JLG threadlocker P/N 0100011 or equivalent, secure the rear of the telescope cylinder to the base boom section with the attaching bolts and washers. Torque the bolts 85 ft. lbs. (115 Nm)..................................................................247
			7. Retract boom section fully. Using shims, adjust wear pads at aft end of boom section to zero clearance. Adjust pads alternately side to side, so fly boom section is centered in base boom section................................................................247
		Lower Boom Installation..................................................................................................................................................................................................................................................247
			1. Remove front hood and counterweight to gain access to keeper pins on turntable, if necessary......................................................................................................................................................................247
			2. Using all applicable safety precautions, carefully lift lower boom assembly to align the pivot holes in the lower boom with those of the turntable................................................................................................................247
			3. Using a soft head mallet, install pins into turntable and secure with mounting hardware...........................................................................................................................................................................247
			4. Using all applicable safety precautions, carefully lift and align timing link with lower boom assembly. Using a soft head mallet, install pins into timing link and secure with mounting hardware.................................................................247
		Mid Boom Installation....................................................................................................................................................................................................................................................248
			1. Attach an adequate supporting device to the Mid Boom to support its weight........................................................................................................................................................................................248
			2. Using all applicable safety precautions, carefully lift timing link and mid boom to align the pivot hole in the timing link with holes of the Mid boom............................................................................................................248
			3. Using a soft head mallet, install pin into lower boom and secure with mounting hardware...........................................................................................................................................................................248
			4. Attach an adequate supporting device to the lower upright to support its weight...................................................................................................................................................................................248
			5. Using all applicable safety precautions, carefully lift and align lower upright with lower boom and mid boom. Using a soft head mallet, install pins into lower upright and secure with mounting hardware.........................................................248
			6. Using a suitable lifting equipment, adequately support tower lift cylinder to supper its weight...................................................................................................................................................................248
			7. Using all applicable safety precautions, carefully lift and align tower lift cylinder assembly with lower boom and mid boom. Using a soft head mallet, install pins into tower lift cylinder and secure with mounting hardware....................................248
			8. Attach an adequate supporting device to the upper upright to support its weight...................................................................................................................................................................................249
			9. Using all applicable safety precautions, carefully lift and align upper upright with mid boom. Using a soft head mallet, install pins into lower upright and secure with mounting hardware........................................................................249
			10. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines to the tower lift cylinder as tagged during removal.............................................................................................................................249
		Upper Boom Installation..................................................................................................................................................................................................................................................249
			1. Using a suitable lifting device, align the master cylinder with the upper upright. Using a soft head mallet install pin #5 in the upper upright. Install the hardware for pin #5..................................................................................249
			2. Using a suitable lifting device, align the main lift cylinder with the upper upright. Using a soft head mallet install pin #4 in the upper upright. Install the hardware for pin #4...............................................................................249
			3. Attach an adequate lifting device to support the entire length of the upper boom..................................................................................................................................................................................249
			4. Using all applicable safety precautions, carefully lift and align upper boom with upper upright. Using a soft head mallet, install pin3 into upper upright and secure with mounting hardware......................................................................249
			5. Using all applicable safety precautions, carefully lift and align master cylinder with upper boom. Using a soft head mallet, install pin #2 into master cylinder and secure with mounting hardware................................................................250
			6. Using all applicable safety precautions, carefully lift and align main lift cylinder with upper boom. Using a soft head mallet, install pin #1 into main lift cylinder and secure with mounting hardware..........................................................250
			7. Remove cap or plugs from openings of hydraulic lines and connect hydraulic lines to the master cylinder, main lift cylinder and telescope cylinder as tagged during removal.......................................................................................250
			8. Install boom end cover on the upper boom..........................................................................................................................................................................................................................250
			9. Install the jib and platform assembly. Refer to Section 4.4, Jib and Section 4.2, Platform........................................................................................................................................................................250
			10. Start machine and check all hydraulic functions for proper operation. Check for any hydraulic oil leaks..........................................................................................................................................................250
	4.11 Rotary Actuator.........................................................................................................................................................................................................................................................251
		Theory of Operation......................................................................................................................................................................................................................................................251
		Required Tools...........................................................................................................................................................................................................................................................252
			1. PIPE VISE.........................................................................................................................................................................................................................................................252
			2. HEX WRENCH - Removal and replacement of port plugs and setscrews..................................................................................................................................................................................................252
			3. ASSORTED SCREWS...................................................................................................................................................................................................................................................252
			4. SAFETY GLASSES....................................................................................................................................................................................................................................................252
			5. END CAP REMOVAL TOOLS (provided with Helac seal kit)..............................................................................................................................................................................................................252
			6. DRILL.............................................................................................................................................................................................................................................................252
			7. FLASHLIGHT - Helps to locate and examine timing marks, component failure and overall condition....................................................................................................................................................................252
			8. RUBBER MALLET - Removal and installation of shaft and piston sleeve assembly......................................................................................................................................................................................252
			9. PLASTIC MANDREL...................................................................................................................................................................................................................................................252
			10. PRY BAR - Removal of end cap and manual rotation of shaft........................................................................................................................................................................................................252
			11. FELT MARKER - Highlights the timing marks and outline troubled areas.............................................................................................................................................................................................252
			12. T-HANDLE SCREW EXTRACTOR.........................................................................................................................................................................................................................................252
			13. HEX WRENCH SET - Removal and replacement of port plugs and setscrews (106 &110)..................................................................................................................................................................................252
			14. SEAL TOOLS - Removal and installation of seals and wear guides. Directions to make a seal tool are provided below making a Seal Tool.............................................................................................................................252
			15. PUNCH............................................................................................................................................................................................................................................................252
			16. DOWEL PINS - Removal and installation of end cap.................................................................................................................................................................................................................252
		Making a Seal Tool.......................................................................................................................................................................................................................................................252
			1. Heat the flat end with a torch until it glows.....................................................................................................................................................................................................................252
			2. Secure the heated end of the screwdriver in a vise and bend the heated end to a slight radius.....................................................................................................................................................................252
			3. Round off all sharp edges of the heated to a polished finish. The tool may be modified slightly to your own personal preference. To avoid injury be careful while handling the hot screwdriver....................................................................252
		Before Disassembly.......................................................................................................................................................................................................................................................252
		Disassembly..............................................................................................................................................................................................................................................................255
			1. Remove the cap screws (113) over end cap lock pins (109)..........................................................................................................................................................................................................255
			2. Using a 1/8 in. (3.18 mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16 in. (4.76 mm)...................................................................................................................................255
			3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 5/16 in. drill bit to a depth of 1/2 in. (12.7 mm) to drill out the entire pin...............................................................255
			4. Install the end cap (4) removal tools provided with the Helac seal kit............................................................................................................................................................................................255
			5. Using a metal bar, or similar tool, unscrew the end cap (4) by turning it counter clockwise.......................................................................................................................................................................255
			6. Remove the end cap (4) and set aside for later inspection.........................................................................................................................................................................................................256
			7. Remove the stop tube if equipped. The stop tube is an available option to limit the rotation of the actuator......................................................................................................................................................256
			8. Every actuator has timing marks for proper engagement.............................................................................................................................................................................................................256
			9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assembly..............................................................................................256
			10. Remove the shaft (2). It may be necessary to strike the threaded end of the shaft with a rubber mallet...........................................................................................................................................................257
			11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O.D. gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2)..............................................................257
			12. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston is not damaged..................................................................................................................................................................257
			13. At the point when the piston gear teeth come out of engagement with the housing gear teeth, mark the piston and housing with a marker as shown...................................................................................................................257
			14. Remove the o-ring (204) and backup ring (207) from end cap (4) and set aside for inspection......................................................................................................................................................................257
			15. Remove the wear guides (302) from the end cap (4) and shaft (2)..................................................................................................................................................................................................257
			16. To remove the main pressure seals (205), it is easiest to cut them using a sharp razor blade being careful not to damage the seal groove.........................................................................................................................258
			17. Remove the thrust washers (304), from the end cap (4) and shaft (2)..............................................................................................................................................................................................258
			18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2)...................................................................................................................................................................................258
			19. Remove the piston O.D. seal (202) from the piston................................................................................................................................................................................................................258
			20. Remove the piston I.D. seal (200). You may now proceed to the inspection process.................................................................................................................................................................................258
		Inspection...............................................................................................................................................................................................................................................................259
			1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore and gear teeth............259
			2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092 in. or 2.34 mm).......................................................................................259
			3. Inspect the wear guide condition and measure thickness (not less than 0.123 in. or 3.12 mm).......................................................................................................................................................................259
		Assembly.................................................................................................................................................................................................................................................................259
			1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal orientations...........................................................................................................................259
			2. Install the thrust washer (304) onto shaft (2) and end cap (4)....................................................................................................................................................................................................260
			3. Install the wiper seal (304.1/green o-ring) into the groove on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304)...................................................................................................................260
			4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion.....................................................................................................................................260
			5. Install the wear guide (302) on the end cap (4) and shaft (2).....................................................................................................................................................................................................260
			6. Install the O-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4).....................................................................................................................................................................261
			7. Install the inner T-seal (200) into the piston (3) using a circular motion........................................................................................................................................................................................261
			8. Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion. Make sure the wedged ends overlap correctly......................................................................................261
			9. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) is touching inside the housing bore........................................................................................................................................261
			10. Looking from the angle shown, rotate the piston (3) until the marks you put on the piston and the housing (1) during disassembly line up as shown. Using a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet..............262
			11. Looking from the opposite end of the housing (1) you can see if your timing marks are lining up. When they do, tap the piston (3) in until the gear teeth mesh together. Tap the piston into the housing the rest of the way until it bottoms out................262
			12. Install the shaft (2) into the piston (3). Be careful not to damage the seals. Do not engage the piston gear teeth yet...........................................................................................................................................262
			13. Looking from the view shown, use the existing timing marks to line up the gear teeth on the shaft (2) with the gear teeth on the inside of the piston (3). Now tap the flange end of the shaft with a rubber mallet until the gear teeth engage..................262
			14. Install 2 bolts in the threaded holes in the flange. Using a bar, rotate the shaft in a clockwise direction until the wear guides are seated inside the housing bore.............................................................................................263
			15. Install the stop tube onto the shaft end, if equipped. Stop tube is an available option to limit the rotation of an actuator.....................................................................................................................................263
			16. Coat the threads on the end of the shaft with anti-seize grease to prevent galling...............................................................................................................................................................................263
			17. Install the 0-ring (204) and back-up ring (207) into the inner seal groove on the end cap (4)....................................................................................................................................................................263
			18. Thread the end cap (4) onto the shaft (2) end. Make sure the wear guide remains in place on the end cap as it is threaded into the housing (1)...................................................................................................................263
			19. Tighten the end cap (4). In most cases the original holes for the lock pins will line up.........................................................................................................................................................................264
			20. Place the lock pins (109) provided in the Helac seal kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole..................................................................................................264
			21. Insert the set screws (113) over the lock pins. Tighten them to 25 in. lbs. (2.825 Nm)...........................................................................................................................................................................264
		Installing Counterbalance Valve..........................................................................................................................................................................................................................................265
			1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old JLG Threadlocker P/N 0100011...........................................................................................................................265
			2. Make sure the new valve has the o-rings in the counterbores of the valve to seal it to the actuator housing.......................................................................................................................................................265
			3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. JLG Threadlocker P/N 0100011 should be applied to the shank of the three bolts at the time of installation..................................................265
			4. Torque the 1/4 in. bolts 110 to 120 in. lbs. (12.4 to 13.5 Nm). Do not torque over 125 in. lbs. (14.1 Nm). Torque the 5/16 in. bolts 140 in. lbs. (15.8 Nm). Do not torque over 145 in. lbs. (16.3 Nm)............................................................265
			5. Make sure the valve is seated against the housing valve flat. If it is raised up on any side or corner, remove the valve to determine what the obstruction is. If possible, test this using a hydraulic hand pump or electric test. bench.........................265
		Greasing Thrust Washers..................................................................................................................................................................................................................................................266
			1. After the actuator is assembled but before it is put into service, the thrust washer area must be packed with Lithium grease......................................................................................................................................266
			2. There are two grease ports located on both the shaft flange and the end cap. They are plugged with cap screws (113) or set screws. Remove the grease port screws from the shaft flange and end cap. (See exploded view)...........................................266
			3. Insert the tip of a grease gun into one port and apply grease to the shaft flange. Continue applying until grease flows from the opposite port. Cycle the actuator five times and apply grease again. Repeat this process on the end cap. Insert the ca...........266
		Testing the Actuator.....................................................................................................................................................................................................................................................266
			Testing the Actuator for Internal Leakage............................................................................................................................................................................................................................266
		Installation and Bleeding................................................................................................................................................................................................................................................267
			1. Connect a 3/16 in. inside diameter x 5/16 in. outside diameter x 5 foot clear, vinyl drain tube to each of the two bleed nipples. Secure them with hose clamps. Place the vinyl tubes in a clean 5-gallon container to collect the purged oil. The oil ...........267
			2. With an operator in the platform, open both bleed nipples 1/4 turn. Hydraulically rotate the platform to the end of rotation (either clockwise or counterclockwise), and maintain hydraulic pressure. Oil with small air bubbles will be seen flowing t...........267
			3. Keep the fittings open and rotate the platform in the opposite direction to the end position. Maintain hydraulic pressure until an additional 1/4 gallon of fluid is pumped into the container....................................................................267
			4. Repeat steps 2 & 3. After the last 1/2 gallon is purged, close both bleed nipples before rotating away from the end position......................................................................................................................................267
	4.12 Foot Switch Adjustment..................................................................................................................................................................................................................................................267
		Troubleshooting..........................................................................................................................................................................................................................................................268
			1. Shaft rotates slowly or not at all................................................................................................................................................................................................................................268
			2. Operation is erratic or not responsive............................................................................................................................................................................................................................268
			3. Shaft will not fully rotate.......................................................................................................................................................................................................................................268
			4. Selected position cannot be maintained............................................................................................................................................................................................................................268
	4.13 Skyguard................................................................................................................................................................................................................................................................269
		Operation................................................................................................................................................................................................................................................................269
		Function Test............................................................................................................................................................................................................................................................269
			SkyGuard Only........................................................................................................................................................................................................................................................269
				1. Operate the telescope out function, then activate SkyGuard sensor.............................................................................................................................................................................................269
				2. Once sensor has been activated, ensure telescope out function stops then telescope in function operates for a short duration. Additionally, verify Soft Touch/SkyGuard indicator light flashes and horn sounds. If machine is equipped with SkyGuard be.......269
				3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify operation can be resumed..........................................................................................................269
				4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure normal operation available........................................................................................................................................................269
				1. Operation is allowed regardless of SkyGuard activation........................................................................................................................................................................................................269
			Soft touch only......................................................................................................................................................................................................................................................269
			SkyGuard not selected in machine setup...............................................................................................................................................................................................................................269
		Diagnostics & Troubleshooting............................................................................................................................................................................................................................................270
			Fault Codes..........................................................................................................................................................................................................................................................270
Section 5. Basic Hydraulics Information & Schematics.............................................................................................................................................................................................................................271
	5.1 Lubricating O-rings In The Hydraulic System..............................................................................................................................................................................................................................271
		Cup and Brush............................................................................................................................................................................................................................................................271
			1. Hold the fitting in one hand while using the brush with the other hand to dip into the container. Remove excess hydraulic oil from the brush so an even film of oil is applied on the o-ring......................................................................271
			2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated....................................................................................271
			3. Turn the o-ring on the other side of the fitting and repeat the previous step, ensuring the entire o-ring is coated with hydraulic oil............................................................................................................................271
		Dip Method...............................................................................................................................................................................................................................................................272
			1. Place the sponge inside the container and add hydraulic oil to the sponge until it is fully saturated.............................................................................................................................................................272
			2. Dip the fitting into the sponge using firm pressure. Upon lifting the fitting, a small droplet will form and drip from the bottom of the fitting. This should signify an even coating of oil on the fitting.......................................................272
			3. O-ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated sponge. This will also cause more oil to be dispersed from the sponge..............................................................................272
		Spray Method.............................................................................................................................................................................................................................................................272
			1. Fill the spray bottle with hydraulic oil..........................................................................................................................................................................................................................272
			2. Hold the fitting over a suitable catch can........................................................................................................................................................................................................................272
			3. Spray the entire o-ring surface with a medium coat of oil.........................................................................................................................................................................................................272
		Brush-on Method..........................................................................................................................................................................................................................................................272
			1. Fill the bottle with hydraulic oil................................................................................................................................................................................................................................272
			2. Using slight pressure to the body of the spray bottle, invert the bottle so the brush end is in the downward position.............................................................................................................................................272
			3. Brush hydraulic oil on the entire o-ring, applying an even coat of oil............................................................................................................................................................................................272
	5.2 Hydraulic Connection Assembly And Torque Specification...................................................................................................................................................................................................................273
		Tapered Thread Types.....................................................................................................................................................................................................................................................273
		Straight Thread Types, Tube and Hose Connections.........................................................................................................................................................................................................................273
		Straight Thread Types, Port Connections..................................................................................................................................................................................................................................274
		Flange Connection Types..................................................................................................................................................................................................................................................274
		Tightening Methods.......................................................................................................................................................................................................................................................274
		Assembly And Torque Specifications.......................................................................................................................................................................................................................................275
			GENERAL TUBE TYPE FITTING ASSEMBLY INSTRUCTIONS......................................................................................................................................................................................................................275
				1. Take precautions to ensure that fittings and mating components are not damaged during storage, handling or assembly. Nicks and scratches in sealing surfaces can create a path for leaks which could lead to component contamination and/or failure...........275
				2. When making a connection to tubing, compression or flare, inspect the tube in the area of the fitting attachment to ensure that the tube has not been damaged.................................................................................................275
				3. The assembly process is one of the leading causes for contamination in air and hydraulic systems. Contamination can prevent proper tightening of fittings and adapters from occurring.........................................................................275
					a. Avoid using dirty or oily rags when handling fittings.....................................................................................................................................................................................................275
					b. If fittings are disassembled, they should be cleaned and inspected for damage. Replace fittings as necessary before re-installing.........................................................................................................................275
					c. Sealing compounds should be applied where specified; however, care should be taken not to introduce sealant into the system...............................................................................................................................275
					d. Avoid applying sealant to the area of the threads where the sealant will be forced into the system. This is generally the first two threads of a fitting..................................................................................................275
					e. Sealant should only be applied to the male threads........................................................................................................................................................................................................275
					f. Straight thread fittings do not require sealants. O- rings or washers are provided for sealing............................................................................................................................................................275
					g. When replacing or installing an O-ring, care is to be taken while transferring the O-ring over the threads as it may become nicked or torn. When replacing an O-ring on a fitting, the use of a thread protector is recommended...........................275
					h. When installing fittings with O-rings, lubrication shall be used to prevent scuffing or tearing of the O- ring. See O-ring Installation (Replacement) in this section.....................................................................................275
				4. Take care to identify the material of parts to apply the correct torque values................................................................................................................................................................................275
					a. Verify the material designation in the table headings.....................................................................................................................................................................................................275
					b. If specifications are given only for steel fittings and components, the values for alternate materials shall be as follows: Aluminum and Brass- reduce steel values by 35%; Stainless Steel- Use the upper limit for steel................................275
				5. To achieve the specified torque, the torque wrench is to be held perpendicular to the axis of rotation........................................................................................................................................................275
				6. Refer to the appropriate section in this manual for more specific instructions and procedures for each type of fitting connection.............................................................................................................................275
		Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.......................................................................................................................................................................................276
			1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs................................................................................................................................................276
			2. Apply a suitable thread sealant, such as Loctite 567, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads are uncovered to prevent system contamination..............................................................................276
			3. Assemble connection hand tight....................................................................................................................................................................................................................................276
			4. Mark fittings, male and female....................................................................................................................................................................................................................................276
			5. Rotate male fitting the number of turns per Table 5-1, NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT procedure requirements................................................................................................................................276
		Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections........................................................................................................................................................................................277
			1. Inspect components to ensure male and female port threads are free of rust, splits, dirt, foreign matter, or burrs................................................................................................................................................277
			2. Apply a suitable thread sealant, such as Loctite 567, to the male pipe threads if not already applied. Ensure the first 1 to 2 threads are uncovered to prevent system contamination..............................................................................277
			3. Assemble connection hand tight....................................................................................................................................................................................................................................277
			4. Mark fittings, male and female....................................................................................................................................................................................................................................277
			5. Rotate male fitting the number of turns per Table 5-2, BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT procedure requirements................................................................................................................................277
		Assembly Instructions for 37° (JIC) Flare Fittings.......................................................................................................................................................................................................................278
			1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.....................278
			2. Align tube to fitting and start threads by hand...................................................................................................................................................................................................................278
			3. Torque assembly to value listed in Table 5-3, 37° Flare (JIC)Thread - Steel or Table 5-4, 37° Flare (JIC)Thread - Aluminum/Brass while using the Double Wrench Method per Double Wrench Method. Refer to FFWR and TFFT Methods for procedure requirem.............278
		Assembly Instructions for 45° SAE Flare Fittings.........................................................................................................................................................................................................................281
			1. Inspect the flare for obvious visual squareness and concentricity issues with the tube OD. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter.....................281
			2. Align tube to fitting.............................................................................................................................................................................................................................................281
			3. Tighten fitting by hand until hand tight..........................................................................................................................................................................................................................281
		Assembly Instructions for O-Ring Face Seal (ORFS) Fittings...............................................................................................................................................................................................................283
			1. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement).............................................................................................................................................................283
			2. Ensure surface is smooth, free of rust, weld and brazing splatter, splits, dirt, foreign matter, or burrs. If necessary replace fitting or adapter................................................................................................................283
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................283
			4. Place the tube assembly against the fitting body so that the flat face comes in contact with the O-ring. Hand thread the nut onto the fitting body................................................................................................................283
			5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Aluminum/Brass while using the Double Wrench Method. Refer to FFWR and TFFT Methods for procedure requirements if using the FFWR method..........283
		Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)...............................................................................................................................................................................................285
			1. Inspect the components to ensure free of contamination, external damage, rust, splits, dirt, foreign matter, or burrs. Ensure tube end is visibly square. If necessary replace fitting or tube....................................................................285
			2. Lubricate thread and cone of fitting body or hardened pre-assembly tool, as well as the progressive ring and nut threads..........................................................................................................................................285
			3. Slip nut and progressive ring over tube, assuring that they are in the proper orientation.........................................................................................................................................................................285
			4. Push the tube end into the coupling body..........................................................................................................................................................................................................................285
			5. Slide collet into position and tighten until finger tight. Mark nut and tube in the finger-tight position. Tighten nut to the number of flats listed in Table 5-9, DIN 24°Cone (MBTL & MBTS) while using the Double Wrench Method. The tube must not t............285
		Assembly Instructions for Bulkhead (BH) Fittings.........................................................................................................................................................................................................................287
			1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter..........................................................................................................287
			2. Remove the locknut from the bulkhead assembly.....................................................................................................................................................................................................................287
			3. Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening................................................................................................................................................................................287
			4. Hand thread the locknut onto the bulkhead end of the fitting body.................................................................................................................................................................................................287
			5. Torque nut onto fitting per Table 5-10 and Table 5-11 while using the Double Wrench Method........................................................................................................................................................................287
		Assembly Instructions for O-Ring Boss (ORB) Fittings.....................................................................................................................................................................................................................290
			1. Inspect components to ensure that male and female port threads are free of rust, splits, dirt, foreign matter, or burrs...........................................................................................................................................290
			2. Ensure proper O-ring is installed. If O-ring is missing install per O-ring Installation (Replacement).............................................................................................................................................................290
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................290
			4. For Non-Adjustable and Plugs, thread the fitting by hand until contact............................................................................................................................................................................................290
			5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly................................................................................................................................................................................290
			6. Torque the fitting or nut to value listed in Table 5-12 through Table 5-17 while using the Double Wrench Method...................................................................................................................................................290
				a. The table headings identify the straight thread O- ring port and the type on the other side of the fitting. The torque will be applied to the straight thread O-ring port.....................................................................................290
				b. Torque values provided in Table 5-12 through Table 5-17 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate either the following material configurations:............290
			7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port..........................................................................................................................................................290
		Assembly Instructions for Adjustable Port End Metric (MFF) Fittings......................................................................................................................................................................................................297
			1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter or burrs....................................................................................................................................297
			2. If O-ring is not pre-installed, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions.........................................................................................................................297
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................297
			4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact...................................................................................................................................................................................297
			5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly................................................................................................................................................................................297
			6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5- 23 while using the Double Wrench Method......................................................................................................297
				a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the Metric port......................................................................................................................297
				b. Torque values provided in Table 5-18, Table 5-19, Table 5-20, Table 5-21, Table 5-22, and Table 5-23 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate e...........297
			7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port..........................................................................................................................................................297
		Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends..................................................................................................................................................................................................304
			1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter or burrs....................................................................................................................................304
			2. If O-ring is not pre-installed, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions.........................................................................................................................304
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................304
			4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact...................................................................................................................................................................................304
			5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly................................................................................................................................................................................304
			6. Torque the fitting or nut to value listed in Table 5-24 while using the Double Wrench Method......................................................................................................................................................................304
				a. The table headings identify the Metric port and the type on the other side of the fitting. The torque will be applied to the Metric port......................................................................................................................304
				b. Torque values provided in Table 5-24 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/ BRASS MATING COMPONENTS’ indicate either the following material configurations:..............................304
			7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port..........................................................................................................................................................304
		Assembly instructions for Adjustable Port End (BSPP) Fittings............................................................................................................................................................................................................307
			1. Inspect components to ensure that male and female threads and surfaces are free of rust, splits, dirt, foreign matter or burrs....................................................................................................................................307
			2. If O-ring is not pre-installed, install proper size, taking care not to damage it. See O-ring Installation (Replacement) for instructions.........................................................................................................................307
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................307
			4. For Non-Adjustable Fittings and Plugs, thread the fitting by hand until contact...................................................................................................................................................................................307
			5. For Adjustable fittings, refer to Adjustable Stud End Assembly for proper assembly................................................................................................................................................................................307
			6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5- 30 while using the Double Wrench Method......................................................................................................307
				a. The table headings identify the BSPP port and the type on the other side of the fitting. The torque will be applied to the BSPP port..........................................................................................................................307
				b. Torque values provided in Table 5-25, Table 5-26, Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are segregated based on the material configuration of the connection. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING COMPONENTS’ indicate e...........307
			7. Inspect to ensure the O-ring is not pinched and the washer is seated flat on the counterbore of the port..........................................................................................................................................................307
		Assembly Instructions for Flange Connections: (FL61 and FL62)............................................................................................................................................................................................................314
			1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter or burrs.....................................................................................................................................................................314
			2. Install O-ring as per “O-ring Installation (Replacement)” ........................................................................................................................................................................................................314
			3. Pre-lubricate the O-ring with Hydraulic Oil.......................................................................................................................................................................................................................314
			4. Position flange and clamp halves..................................................................................................................................................................................................................................314
			5. Place lock washers on bolt and bolt through clamp halves..........................................................................................................................................................................................................314
			6. Tighten all bolts by hand.........................................................................................................................................................................................................................................314
			7. Torque bolts in diagonal sequence in two or more increments to the torque listed on Table 5-31and Table 5-32......................................................................................................................................................314
		Double Wrench Method.....................................................................................................................................................................................................................................................317
		FFWR and TFFT Methods....................................................................................................................................................................................................................................................318
			FFWR (Flats from Wrench Resistance Method)...........................................................................................................................................................................................................................318
				1. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight condition..............................................................................................................................318
				2. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter. See Figure 5-12.........................................................................................................................................318
				3. Use the double wrench method per Appendix A, turn the swivel nut to tighten as shown in Figure 5-11. The nut is to be rotated clockwise the number of hex flats as defined by the applicable Table in Section 5.0.............................................318
				4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to indicate the connection has been properly tightened. See Figure 5-12............................................................318
			TFFT (Turns from Finger Tight Method)................................................................................................................................................................................................................................318
				1. Tighten the swivel nut to the mating fitting until no lateral movement of the swivel nut can be detected; finger tight condition..............................................................................................................................318
				2. Mark a dot on one of the swivel hex nut flats and another dot in line on the connecting tube adapter..........................................................................................................................................................318
				3. Use the double wrench method per Appendix A, turn the swivel nut to tighten. The nut is to be rotated clockwise the number of turns as defined by the applicable Table in Section 5.0.........................................................................318
				4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to indicate the connection has been properly tightened.............................................................................318
		Adjustable Stud End Assembly.............................................................................................................................................................................................................................................318
			1. Lubricate the o-ring with a light coat of hydraulic oil...........................................................................................................................................................................................................318
			2. Position #1 – The o-ring should be located in the groove adjacent to the face of the backup washer. The washer and o-ring should be positioned at the extreme top end of the groove as shown......................................................................318
			3. Position #2 – Position the locknut to just touch the backup washer as shown. The locknut in this position will eliminate potential backup washer damage during the next step......................................................................................318
			4. Position #3 – Install the connector into the straight thread box port until the metal backup washer contacts the face of the port as shown........................................................................................................................318
			5. Position #4 – Adjust the connector to the proper position by turning out (counterclockwise) up to a maximum of one turn as shown to provide proper alignment with the mating connector, tube assembly, or hose assembly...........................................318
			6. Position #5 – Using two wrenches, use the backup wrench to hold the connector in the desired position and then use the torque wrench to tighten the locknut to the appropriate torque.............................................................................318
			7. Visually inspect, where possible, the joint to ensure the o-ring is not pinched or bulging out from under the washer and that the backup washer is properly seated flat against the face of the port..............................................................318
		O-ring Installation (Replacement)........................................................................................................................................................................................................................................319
			1. Inspect O-ring for tears or nicks. If any are found replace O-ring................................................................................................................................................................................................319
			2. Ensure proper O-ring to be installed. Many O-rings look the same but are of different material, different hardness, or are slightly different diameters or widths.................................................................................................319
			3. Use a thread protector when replacing O-rings on fittings.........................................................................................................................................................................................................319
			4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation...............................................................................................................319
			5. Inspect O-ring for any visible nicks or tears. Replace if found...................................................................................................................................................................................................319
	5.3 Hydraulic Cylinders......................................................................................................................................................................................................................................................320
		Axle Lockout Cylinder....................................................................................................................................................................................................................................................320
			DISASSEMBLY..........................................................................................................................................................................................................................................................320
				1. Open bleeder valve. Rotate rod and remove from barrel.........................................................................................................................................................................................................320
				2. Remove two wear rings, wiper seal and rod seal from grooves of barrel bore. Do not scratch barrel bore........................................................................................................................................................320
				3. Remove counterbalance valve and plugs.........................................................................................................................................................................................................................320
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................320
				1. Inspect bore and rod for scoring, pitting, or excessive wear..................................................................................................................................................................................................320
				2. Remove minor surface blemishes with wet sandpaper.............................................................................................................................................................................................................320
				3. Pitting requires replacement of barrel and rod................................................................................................................................................................................................................320
			ASSEMBLY.............................................................................................................................................................................................................................................................320
				1. Install two new wear rings, wiper seal and rod seal in barrel bore grooves. Make sure they are not twisted....................................................................................................................................................320
				2. Lubricate rod bore with clean hydraulic fluid.................................................................................................................................................................................................................320
				3. Insert and push the rod into top of barrel bore, rotate to install the rod into barrel bore...................................................................................................................................................................320
				4. Install plugs and counterbalance valve. Torque the plugs to 22-24 ft. lbs. (30-33 Nm) and counterbalance valve to 22 ft. lbs. (30 Nm).........................................................................................................................320
				5. Bleed system..................................................................................................................................................................................................................................................320
				1. Rod...........................................................................................................................................................................................................................................................321
				2. Plug..........................................................................................................................................................................................................................................................321
				3. Bleeder Valve.................................................................................................................................................................................................................................................321
				4. Counterbalance Valve..........................................................................................................................................................................................................................................321
				5. Barrel........................................................................................................................................................................................................................................................321
				6. Wear Ring.....................................................................................................................................................................................................................................................321
				7. Rod Seal......................................................................................................................................................................................................................................................321
				8. Wiper Seal....................................................................................................................................................................................................................................................321
		Platform Level Cylinder..................................................................................................................................................................................................................................................322
			DISASSEMBLY..........................................................................................................................................................................................................................................................322
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................322
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................322
				3. Remove the counterbalance valves and plugs from the cylinder port block. Discard o-rings......................................................................................................................................................................322
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................322
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel............................................................................................................322
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................322
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................322
				1. Barrel........................................................................................................................................................................................................................................................323
				2. Rod...........................................................................................................................................................................................................................................................323
				3. Piston........................................................................................................................................................................................................................................................323
				4. Head..........................................................................................................................................................................................................................................................323
				5. Setscrew......................................................................................................................................................................................................................................................323
				6. Ball..........................................................................................................................................................................................................................................................323
				7. Wear Ring.....................................................................................................................................................................................................................................................323
				8. Seal..........................................................................................................................................................................................................................................................323
				9. Counterbalance Valve..........................................................................................................................................................................................................................................323
				10. Counterbalance Valve.........................................................................................................................................................................................................................................323
				11. O-Ring.......................................................................................................................................................................................................................................................323
				12. Backup Ring..................................................................................................................................................................................................................................................323
				13. Rod Seal.....................................................................................................................................................................................................................................................323
				14. O-Ring.......................................................................................................................................................................................................................................................323
				15. Wiper Seal...................................................................................................................................................................................................................................................323
				16. O-Ring.......................................................................................................................................................................................................................................................323
				17. Retaining Ring...............................................................................................................................................................................................................................................323
				18. Bushing......................................................................................................................................................................................................................................................323
				19. Plug.........................................................................................................................................................................................................................................................323
				20. Plug.........................................................................................................................................................................................................................................................323
				21. Plug.........................................................................................................................................................................................................................................................323
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................324
					9. Loosen and remove the setscrew and ball which attaches the piston to the rod..............................................................................................................................................................................324
					10. Screw the piston counterclockwise by hand and remove the piston from cylinder rod........................................................................................................................................................................324
					11. Remove and discard the piston wear rings and seal........................................................................................................................................................................................................324
					12. Remove the rod from the holding fixture. Remove the cylinder head. Discard the o-rings, seal, rod seal, retaining ring and wiper seal....................................................................................................................324
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................324
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................324
				2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Briteor equivalent. Replace rod if necessary....................................................................................................324
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................324
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................324
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................324
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................324
				7. Inspect threaded portion of piston for damage. Dress threads as necessary.....................................................................................................................................................................................324
				8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................324
				9. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................324
				10. Inspect threaded portion of head for damage. Dress threads as necessary......................................................................................................................................................................................324
				11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................324
				12. Inspect cylinder head outside diameter for scoring, tapering, ovality or other damage. Replace if necessary..................................................................................................................................................324
				13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary...........................................................................................................................................324
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................324
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................324
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................324
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................324
				14. Inspect port block fittings and holding valve. Replace if necessary..........................................................................................................................................................................................325
				15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair if necessary....................................................................................................................................................325
				16. Inspect piston rings for cracks or other damage. Replace if necessary........................................................................................................................................................................................325
			ASSEMBLY.............................................................................................................................................................................................................................................................325
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................325
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new retaining ring and o-ring into the applicable inside diameter of the cylinder head groove...................................................................326
				3. Place a new o-ring and seal in the applicable outside diameter groove of the cylinder head....................................................................................................................................................................326
				4. Carefully install the cylinder head on the rod, ensuring that the wiper seal, retaining ring and rod seals are not damaged or dislodged. Push the head along the rod to the rod end...........................................................................326
				5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................326
				6. Carefully thread the piston on the cylinder rod hand tight. Secure using ball and setscrew....................................................................................................................................................................326
				7. Remove the cylinder rod from the holding fixture. Place new seal and bearing rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)..............................326
				8. Position the cylinder barrel in a suitable holding fixture....................................................................................................................................................................................................326
				9. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading bearing rings and seals are not damaged or dislodged....................................................326
				10. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................326
				11. Screw the cylinder head into the barrel using a pin-face spanner wrench and torque to 443 ft. lbs. (600 Nm)..................................................................................................................................................326
				12. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves................................................................................................326
				13. Install the counterbalance valves in the rod port block. Torque to 37 ft. lbs. (50 Nm).......................................................................................................................................................................326
				14. Install the new o-rings and plugs into the cylinder port block and torque plugs as shown in Figure 5-18......................................................................................................................................................326
		Jib Lift Cylinder........................................................................................................................................................................................................................................................327
			DISASSEMBLY..........................................................................................................................................................................................................................................................327
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................327
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................327
				3. Remove the counterbalance valves and plugs from the cylinder port block. Discard o-rings......................................................................................................................................................................327
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................327
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a spanner wrench, unscrew the cylinder head from the barrel. (It is easier to do this with rod pulled out 5cm from the cylinder head)...........................................327
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................327
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................327
				1. Barrel........................................................................................................................................................................................................................................................328
				2. Rod...........................................................................................................................................................................................................................................................328
				3. Head..........................................................................................................................................................................................................................................................328
				4. Wiper Seal....................................................................................................................................................................................................................................................328
				5. Retaining Ring................................................................................................................................................................................................................................................328
				6. Rod Seal......................................................................................................................................................................................................................................................328
				7. Backup Ring...................................................................................................................................................................................................................................................328
				8. Bearing.......................................................................................................................................................................................................................................................328
				9. O-Ring........................................................................................................................................................................................................................................................328
				10. Backup Ring..................................................................................................................................................................................................................................................328
				11. O-Ring.......................................................................................................................................................................................................................................................328
				12. Piston.......................................................................................................................................................................................................................................................328
				13. O-Ring.......................................................................................................................................................................................................................................................328
				14. Piston Seal..................................................................................................................................................................................................................................................328
				15. Piston Ring..................................................................................................................................................................................................................................................328
				16. Nut..........................................................................................................................................................................................................................................................328
				17. Bushing......................................................................................................................................................................................................................................................328
				18. Bushing......................................................................................................................................................................................................................................................328
				19. Counterbalance Valve.........................................................................................................................................................................................................................................328
				20. Plug.........................................................................................................................................................................................................................................................328
				21. Plug.........................................................................................................................................................................................................................................................328
				22. Plug.........................................................................................................................................................................................................................................................328
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................329
					9. Remove locknut from the piston rod........................................................................................................................................................................................................................329
					10. Screw the piston counterclockwise by hand and remove the piston from cylinder rod........................................................................................................................................................................329
					11. Remove and discard the piston ring and piston seals......................................................................................................................................................................................................329
					12. Remove the rod from the holding fixture. Remove the cylinder head. Discard the o-rings, backup rings, rod seal, retainer ring, bearing and wiper seal....................................................................................................329
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................329
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................329
				2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary....................................................................................................329
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................329
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................329
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................329
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................329
				7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................329
				8. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................329
				9. Inspect threaded portion of head for damage. Dress threads as necessary.......................................................................................................................................................................................329
				10. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................329
				11. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary...................................................................................................................................................329
				12. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary...........................................................................................................................................329
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................329
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................329
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................329
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................329
				13. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary....................................................................................................................................................330
				14. Inspect piston rings for cracks or other damage. Replace if necessary........................................................................................................................................................................................330
			ASSEMBLY.............................................................................................................................................................................................................................................................330
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................330
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new retaining ring, backup ring and dry bearing into the applicable inside diameter of the cylinder head groove.................................................331
				3. Place new o-rings and backup ring in the applicable outside diameter groove of the cylinder head..............................................................................................................................................................331
				4. Carefully install the cylinder head on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.................................................................................331
				5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................331
				6. Place a new o-ring in the applicable inner piston diameter....................................................................................................................................................................................................331
				7. Carefully thread the piston on the cylinder rod and hand tight................................................................................................................................................................................................331
				8. Install locknut onto the piston rod...........................................................................................................................................................................................................................331
				9. Remove the cylinder rod from the holding fixture..............................................................................................................................................................................................................331
				10. Place new piston rings and piston seal in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)........................................................................331
				11. Position the cylinder barrel in a suitable holding fixture...................................................................................................................................................................................................331
				12. With barrel clamped secured and adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading piston rings and piston seal are not damaged or dislodged......................................................331
				13. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................331
				14. Screw the cylinder head into the barrel using a spanner wrench and torque to 369 ft. lbs. (500 Nm)...........................................................................................................................................................331
				15. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves................................................................................................331
				16. Install the counterbalance valves in the rod port block. Torque to 52 ft. lbs. (70 Nm).......................................................................................................................................................................331
				17. Install the new o-rings and plugs into the cylinder port block and torque plug as shown in Figure 5-28.......................................................................................................................................................331
		Main Lift Cylinder.......................................................................................................................................................................................................................................................332
			DISASSEMBLY..........................................................................................................................................................................................................................................................332
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................332
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................332
				3. Remove the check valve, cartridge valves, pressure compensator valve, orifice plug and plugs from the cylinder port block. Discard o-rings....................................................................................................................332
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................332
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a hook wrench, unscrew the cylinder head from the barrel........................................................................................................................332
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................332
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................332
				1. Rod...........................................................................................................................................................................................................................................................333
				2. Head..........................................................................................................................................................................................................................................................333
				3. Barrel........................................................................................................................................................................................................................................................333
				4. Piston........................................................................................................................................................................................................................................................333
				5. Orifice Plug..................................................................................................................................................................................................................................................333
				6. Plug..........................................................................................................................................................................................................................................................333
				7. Check Valve...................................................................................................................................................................................................................................................333
				8. Plug..........................................................................................................................................................................................................................................................333
				9. Cartridge Valve...............................................................................................................................................................................................................................................333
				10. Cartridge Valve..............................................................................................................................................................................................................................................333
				11. Pressure Compensator Valve...................................................................................................................................................................................................................................333
				12. Radial Screw.................................................................................................................................................................................................................................................333
				13. Wear Ring....................................................................................................................................................................................................................................................333
				14. Piston Seal..................................................................................................................................................................................................................................................333
				15. Backup Ring..................................................................................................................................................................................................................................................333
				16. O-ring.......................................................................................................................................................................................................................................................333
				17. Wear Ring....................................................................................................................................................................................................................................................333
				18. O-ring.......................................................................................................................................................................................................................................................333
				19. Backup Ring..................................................................................................................................................................................................................................................333
				20. Rod Seal.....................................................................................................................................................................................................................................................333
				21. O-ring.......................................................................................................................................................................................................................................................333
				22. Wiper Seal...................................................................................................................................................................................................................................................333
				1. Rod...........................................................................................................................................................................................................................................................334
				2. Head..........................................................................................................................................................................................................................................................334
				3. Barrel........................................................................................................................................................................................................................................................334
				4. Piston........................................................................................................................................................................................................................................................334
				5. Orifice Plug..................................................................................................................................................................................................................................................334
				6. Plug..........................................................................................................................................................................................................................................................334
				7. Check Valve...................................................................................................................................................................................................................................................334
				8. Plug..........................................................................................................................................................................................................................................................334
				9. Cartridge Valve...............................................................................................................................................................................................................................................334
				10. Pressure Compensated Flow Control Valve......................................................................................................................................................................................................................334
				11. Radial Screw.................................................................................................................................................................................................................................................334
				12. Wear Ring....................................................................................................................................................................................................................................................334
				13. Piston Seal..................................................................................................................................................................................................................................................334
				14. Backup Ring..................................................................................................................................................................................................................................................334
				15. O-ring.......................................................................................................................................................................................................................................................334
				16. Wear Ring....................................................................................................................................................................................................................................................334
				17. O-ring.......................................................................................................................................................................................................................................................334
				18. Backup Ring..................................................................................................................................................................................................................................................334
				19. Rod Seal.....................................................................................................................................................................................................................................................334
				20. O-ring.......................................................................................................................................................................................................................................................334
				21. Wiper Seal...................................................................................................................................................................................................................................................334
				22. O-ring.......................................................................................................................................................................................................................................................334
				23. Bushing......................................................................................................................................................................................................................................................334
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................335
					9. Loosen and remove the radial screw which attaches the piston to the rod...................................................................................................................................................................................335
					10. Screw the piston counterclockwise by hand and remove the piston from cylinder rod........................................................................................................................................................................335
					11. Remove and discard the piston o-ring, wear rings, backup rings and piston seal...........................................................................................................................................................................335
					12. Remove the rod from the holding fixture. Remove the cylinder head. Discard the o-rings, backup rings, rod seal, wear ring, and wiper seal................................................................................................................335
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................335
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................335
				2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary....................................................................................................335
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................335
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................335
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................335
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................335
				7. Inspect threaded portion of piston for damage. Dress threads as necessary.....................................................................................................................................................................................335
				8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................335
				9. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................335
				10. Inspect threaded portion of head for damage. Dress threads as necessary......................................................................................................................................................................................335
				11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................335
				12. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary...................................................................................................................................................335
				13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary...........................................................................................................................................335
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................335
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................335
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................335
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................335
				14. Inspect port block fittings and valves. Replace if necessary.................................................................................................................................................................................................336
				15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary....................................................................................................................................................336
				16. Inspect piston rings for cracks or other damage. Replace if necessary........................................................................................................................................................................................336
			ASSEMBLY.............................................................................................................................................................................................................................................................336
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................336
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new wear rings into the applicable inside diameter of the cylinder head groove..................................................................................337
				3. Place new o-rings and backup ring in the applicable outside diameter groove of the cylinder head..............................................................................................................................................................337
				4. Carefully install the cylinder head on the rod, ensuring that the wiper seal, wear rings and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable................................................................337
				5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................337
				6. Place a new o-ring and backup rings in the inner piston diameter groove.......................................................................................................................................................................................337
				7. Carefully thread the piston on the cylinder rod, hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged...........................................................................................................................337
				8. Apply locking glue on the threads of radial screw and install on the piston...................................................................................................................................................................................337
				9. Put needle shock on piston to prevent the radial screw from loosening.........................................................................................................................................................................................337
				10. Remove the cylinder rod from the holding fixture.............................................................................................................................................................................................................337
				11. Place new wear rings and piston seal in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)..........................................................................337
				12. Position the cylinder barrel in a suitable holding fixture...................................................................................................................................................................................................337
				13. With barrel clamped secured and adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading piston rings and piston seal are not damaged or dislodged......................................................337
				14. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................337
				15. Screw the cylinder head into the barrel using a hook wrench and torque the cylinder head.....................................................................................................................................................................337
				16. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves................................................................................................337
				17. Install the new o-rings, plugs, check valve, cartridge valves, pressure compensator valve and orifice plug in the cylinder port block. Torque as shown Figure 5-38. and Figure 5-39. as per the applicable cylinder..........................................337
		Tower Boom Lift Cylinder.................................................................................................................................................................................................................................................338
			DISASSEMBLY..........................................................................................................................................................................................................................................................338
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................338
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................338
				3. Remove the cartridge valve, orifice plugs check valve, and plugs from the cylinder port block. Discard o-rings................................................................................................................................................338
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................338
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a hook wrench, unscrew the cylinder head from the barrel........................................................................................................................338
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................338
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................338
				1. Rod...........................................................................................................................................................................................................................................................339
				2. Head..........................................................................................................................................................................................................................................................339
				3. Barrel........................................................................................................................................................................................................................................................339
				4. Piston........................................................................................................................................................................................................................................................339
				5. Orifice Plug..................................................................................................................................................................................................................................................339
				6. Plug..........................................................................................................................................................................................................................................................339
				7. Check Valve...................................................................................................................................................................................................................................................339
				8. Plug..........................................................................................................................................................................................................................................................339
				9. Plug..........................................................................................................................................................................................................................................................339
				10. Cartridge Valve..............................................................................................................................................................................................................................................339
				11. Cartridge Valve..............................................................................................................................................................................................................................................339
				12. Orifice Plug.................................................................................................................................................................................................................................................339
				13. Radial Screw.................................................................................................................................................................................................................................................339
				14. Wear Ring....................................................................................................................................................................................................................................................339
				15. Piston Seal..................................................................................................................................................................................................................................................339
				16. Backup Ring..................................................................................................................................................................................................................................................339
				17. O-ring.......................................................................................................................................................................................................................................................339
				18. Wear Ring....................................................................................................................................................................................................................................................339
				19. O-ring.......................................................................................................................................................................................................................................................339
				20. Backup Ring..................................................................................................................................................................................................................................................339
				21. Rod Seal.....................................................................................................................................................................................................................................................339
				22. O-ring.......................................................................................................................................................................................................................................................339
				23. Wiper Seal...................................................................................................................................................................................................................................................339
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................340
					9. Loosen and remove the radial screw which attaches the piston to the rod...................................................................................................................................................................................340
					10. Screw the piston counterclockwise, by hand, and remove the piston from cylinder rod......................................................................................................................................................................340
					11. Remove and discard the piston o-ring, wear rings, backup rings and piston seal...........................................................................................................................................................................340
					12. Remove the rod from the holding fixture. Remove the cylinder head. Discard the o-rings, backup rings, rod seal, wear ring, and wiper seal................................................................................................................340
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................340
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................340
				2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary....................................................................................................340
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................340
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................340
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................340
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................340
				7. Inspect threaded portion of piston for damage. Dress threads as necessary.....................................................................................................................................................................................340
				8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................340
				9. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................340
				10. Inspect threaded portion of head for damage. Dress threads as necessary......................................................................................................................................................................................340
				11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................340
				12. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary...................................................................................................................................................340
				13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary...........................................................................................................................................340
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................340
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................340
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................340
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................340
				14. Inspect port block fittings and valves. Replace if necessary.................................................................................................................................................................................................341
				15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary....................................................................................................................................................341
				16. Inspect piston rings for cracks or other damage. Replace if necessary........................................................................................................................................................................................341
			ASSEMBLY.............................................................................................................................................................................................................................................................341
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................341
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install new wear rings into the applicable inside diameter of the cylinder head groove....................................................................................342
				3. Place new o-rings and backup ring in the applicable outside diameter groove of the cylinder head..............................................................................................................................................................342
				4. Carefully install the cylinder head on the rod, ensuring that the wiper seal, wear rings and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable................................................................342
				5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................342
				6. Place a new o-ring and backup rings in the inner piston diameter groove.......................................................................................................................................................................................342
				7. Carefully thread the piston on the cylinder rod, hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged...........................................................................................................................342
				8. Apply locking glue on the threads of radial screw and install on the piston...................................................................................................................................................................................342
				9. Put needle shock on piston to prevent the radial screw from loosening.........................................................................................................................................................................................342
				10. Remove the cylinder rod from the holding fixture.............................................................................................................................................................................................................342
				11. Place new wear rings and piston seal in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)..........................................................................342
				12. Position the cylinder barrel in a suitable holding fixture...................................................................................................................................................................................................342
				13. With barrel clamped secured and adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading piston rings and piston seal are not damaged or dislodged......................................................342
				14. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................342
				15. Screw the cylinder head into the barrel using a hook wrench and torque cylinder head.........................................................................................................................................................................342
				16. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves................................................................................................342
				17. Install the check valve, orifice plugs and cartridge valve. Torque as shown in Figure 5-49...................................................................................................................................................................342
				18. Install the new o-rings and plugs into the cylinder port block...............................................................................................................................................................................................342
		Master Cylinder..........................................................................................................................................................................................................................................................343
			DISASSEMBLY..........................................................................................................................................................................................................................................................343
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................343
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................343
				3. Remove the plugs from the cylinder ports......................................................................................................................................................................................................................343
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................343
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a pin-face spanner wrench, unscrew the cylinder head from the barrel............................................................................................................343
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................343
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................343
				1. Barrel........................................................................................................................................................................................................................................................344
				2. Rod...........................................................................................................................................................................................................................................................344
				3. Piston........................................................................................................................................................................................................................................................344
				4. Head..........................................................................................................................................................................................................................................................344
				5. Setscrew......................................................................................................................................................................................................................................................344
				6. Ball..........................................................................................................................................................................................................................................................344
				7. Plug..........................................................................................................................................................................................................................................................344
				8. Piston Ring...................................................................................................................................................................................................................................................344
				9. Seal..........................................................................................................................................................................................................................................................344
				10. O-ring.......................................................................................................................................................................................................................................................344
				11. Backup Ring..................................................................................................................................................................................................................................................344
				12. Rod Seal.....................................................................................................................................................................................................................................................344
				13. O-ring.......................................................................................................................................................................................................................................................344
				14. Wiper Seal...................................................................................................................................................................................................................................................344
				15. Retainer Ring................................................................................................................................................................................................................................................344
				16. Bushing......................................................................................................................................................................................................................................................344
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................345
					9. Loosen and remove the setscrew and ball which attaches the piston to the rod..............................................................................................................................................................................345
					10. Screw the piston counterclockwise by hand and remove the piston from cylinder rod........................................................................................................................................................................345
					11. Remove and discard the piston rings and seal.............................................................................................................................................................................................................345
					12. Remove the rod from the holding fixture. Remove the cylinder head. Discard the o-rings, backup rings, rod seal, retaining ring, and wiper seal...........................................................................................................345
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................345
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................345
				2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary....................................................................................................345
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................345
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................345
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................345
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................345
				7. Inspect threaded portion of piston for damage. Dress threads as necessary.....................................................................................................................................................................................345
				8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................345
				9. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................345
				10. Inspect threaded portion of head for damage. Dress threads as necessary......................................................................................................................................................................................345
				11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................345
				12. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary...................................................................................................................................................345
				13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary...........................................................................................................................................345
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................345
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................345
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................345
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................345
				14. Inspect port block fittings and valves. Replace if necessary.................................................................................................................................................................................................346
				15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary....................................................................................................................................................346
				16. Inspect piston rings for cracks or other damage. Replace if necessary........................................................................................................................................................................................346
			ASSEMBLY.............................................................................................................................................................................................................................................................346
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................346
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new retainer ring into the applicable inside diameter of the cylinder head groove...............................................................................347
				3. Place new o-rings and backup ring in the applicable outside diameter groove of the cylinder head..............................................................................................................................................................347
				4. Carefully install the cylinder head on the rod, ensuring that the wiper seal, retaining ring and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable............................................................347
				5. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................347
				6. Carefully thread the piston on the cylinder rod, hand tight, ensuring that the o-ring and backup rings are not damaged or dislodged...........................................................................................................................347
				7. Install the setscrew and ball on the piston and attach the piston on the rod..................................................................................................................................................................................347
				8. Remove the cylinder rod from the holding fixture..............................................................................................................................................................................................................347
				9. Place new seal and piston ring in the outer piston diameter grooves. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal).................................................................................347
				10. Position the cylinder barrel in a suitable holding fixture...................................................................................................................................................................................................347
				11. With barrel clamped secured and adequately support ng the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading piston rings and piston seal are not damaged or dislodged......................................................347
				12. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................347
				13. Screw the cylinder head into the barrel using a pin-face spanner wrench and torque cylinder head to 443 ft. lbs. (600 Nm)....................................................................................................................................347
				14. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any plugs..................................................................................................................347
				15. Install the plugs in the cylinder ports and torque to 22 ft. lbs. (30 Nm)....................................................................................................................................................................................347
		Steer Cylinder...........................................................................................................................................................................................................................................................348
			DISASSEMBLY..........................................................................................................................................................................................................................................................348
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................348
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................348
				3. Remove the plugs from the cylinder ports. Discard o-rings.....................................................................................................................................................................................................348
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................348
				5. Using a hook spanner wrench, loosen the cylinder head on both ends of the rod. Remove the cylinder head from the barrel and the rod...........................................................................................................................348
				6. Remove and discard the wiper seal, rod seal, backup ring, bearing, and o-ring from both the cylinder head.....................................................................................................................................................348
				7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................348
				8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................348
				9. Remove and discard the piston seal form the rod...............................................................................................................................................................................................................348
				1. Barrel........................................................................................................................................................................................................................................................349
				2. Rod...........................................................................................................................................................................................................................................................349
				3. Head..........................................................................................................................................................................................................................................................349
				4. Wiper Seal....................................................................................................................................................................................................................................................349
				5. Rod Seal......................................................................................................................................................................................................................................................349
				6. Backup Ring...................................................................................................................................................................................................................................................349
				7. Bearing.......................................................................................................................................................................................................................................................349
				8. O-ring........................................................................................................................................................................................................................................................349
				9. O-ring........................................................................................................................................................................................................................................................349
				10. Piston Seal..................................................................................................................................................................................................................................................349
				11. Plug.........................................................................................................................................................................................................................................................349
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................350
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................350
				2. Inspect the cylinder rod for scoring, tapering, ovality or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary....................................................................................................350
				3. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................350
				4. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................350
				5. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................350
				6. Inspect threaded portion of head for damage. Dress threads as necessary.......................................................................................................................................................................................350
				7. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.....................................................................................................................................................350
				8. Inspect cylinder head outside diameter for scoring, tapering or ovality other damage. Replace if necessary....................................................................................................................................................350
				9. Inspect port block fittings and valves. Replace if necessary..................................................................................................................................................................................................350
				10. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary....................................................................................................................................................350
			ASSEMBLY.............................................................................................................................................................................................................................................................350
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................350
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new bearing and backup ring into the applicable inside diameter of the cylinder head groove.....................................................................350
				3. Place new o-rings, backup ring, and bearing in the applicable outside diameter groove of both the cylinder head...............................................................................................................................................350
				4. Place new piston seal in the applicable groove of the rod.....................................................................................................................................................................................................350
				5. With barrel clamped secured and adequately supporting the rod, insert the rod into the barrel cylinder........................................................................................................................................................350
				6. Carefully install the cylinder head on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the barrel, as applicable..................................................................................350
				7. Install new plugs into the cylinder port block................................................................................................................................................................................................................350
		Telescope Cylinder.......................................................................................................................................................................................................................................................351
			DISASSEMBLY..........................................................................................................................................................................................................................................................351
				1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting........................................................................................................................................................................351
				2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.....................................................................................................351
				3. Remove the motor control valves and plugs from the cylinder port block. Discard o-rings.......................................................................................................................................................................351
				4. Place the cylinder barrel into a suitable holding fixture.....................................................................................................................................................................................................351
				5. Mark cylinder head and barrel with a center punch for easy realignment. Using a hook spanner wrench, unscrew the cylinder head from the barrel................................................................................................................351
				6. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable........................................................................................................................................................351
				7. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel..........................................................................................................351
				1. Barrel........................................................................................................................................................................................................................................................352
				2. Rod...........................................................................................................................................................................................................................................................352
				3. Piston........................................................................................................................................................................................................................................................352
				4. Head..........................................................................................................................................................................................................................................................352
				5. Plug..........................................................................................................................................................................................................................................................352
				6. Plug..........................................................................................................................................................................................................................................................352
				7. Motor Control Valve...........................................................................................................................................................................................................................................352
				8. Washer........................................................................................................................................................................................................................................................352
				9. Bolt..........................................................................................................................................................................................................................................................352
				10. Wear Ring....................................................................................................................................................................................................................................................352
				11. Piston Seal..................................................................................................................................................................................................................................................352
				12. O-ring.......................................................................................................................................................................................................................................................352
				13. Spacer.......................................................................................................................................................................................................................................................352
				14. O-ring.......................................................................................................................................................................................................................................................352
				15. Wear Ring....................................................................................................................................................................................................................................................352
				16. Rod Seal.....................................................................................................................................................................................................................................................352
				17. O-ring.......................................................................................................................................................................................................................................................352
				18. Wiper Seal...................................................................................................................................................................................................................................................352
				19. Bushing......................................................................................................................................................................................................................................................352
					8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.................................................................................................................................353
					9. Remove bolt and washer attaching the piston to the rod....................................................................................................................................................................................................353
					10. Screw the piston counterclockwise, by hand and remove the piston from cylinder rod.......................................................................................................................................................................353
					11. Remove and discard the piston o-ring, piston seal and wear rings.........................................................................................................................................................................................353
					12. Remove piston spacer from the rod........................................................................................................................................................................................................................353
					13. Remove the rod from the holding fixture. Remove the cap and the cylinder head. Discard the o-rings, wear rings, rod seal and wiper seal..................................................................................................................353
			CLEANING AND INSPECTION..............................................................................................................................................................................................................................................353
				1. Clean all parts thoroughly in an approved cleaning solvent....................................................................................................................................................................................................353
				2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary...................................................................................................353
				3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary..............................................................................................................................................................................353
				4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary................................................................................................................353
				5. Inspect threaded portion of barrel for damage. Dress threads as necessary.....................................................................................................................................................................................353
				6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.........................................................................................................................................353
				7. Inspect threaded portion of rod for damage. Dress threads as necessary........................................................................................................................................................................................353
				8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary...................................................................................................................................................353
				9. Inspect cylinder head inside diameter for scoring, tapering, ovality or other damage. Replace if necessary....................................................................................................................................................353
				10. Inspect threaded portion of head for damage. Dress threads as necessary......................................................................................................................................................................................353
				11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary....................................................................................................................................................353
				12. Inspect cylinder head outside diameter for scoring, tapering, ovality or other damage. Replace if necessary..................................................................................................................................................353
				13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace if necessary...........................................................................................................................................353
					a. Thoroughly clean hole (steel bushing) of burrs, dirt etc. to facilitate bearing installation..............................................................................................................................................................353
					b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/barrel must be replaced..........................................................................................................................................353
					c. Lubricate inner side of steel bushing prior to bearing installation.......................................................................................................................................................................................353
					d. Using an arbor of the correct size, carefully press the bearing into steel bushing........................................................................................................................................................................353
				14. Inspect spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent........................................................................................................................................354
				15. Inspect port block fittings and holding valve. Replace if necessary..........................................................................................................................................................................................354
				16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair if necessary....................................................................................................................................................354
			ASSEMBLY.............................................................................................................................................................................................................................................................354
				1. A special tool is used to install a new rod seal into the applicable cylinder head groove.....................................................................................................................................................................354
				2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head groove. Install a new wear ring into the applicable inside diameter of the cylinder head groove...................................................................................355
				3. Place a new o-rings in the applicable outside diameter groove of the cylinder head............................................................................................................................................................................355
				4. Carefully install the cylinder head on the rod, ensuring that the wear ring, rod seal and wiper seal are not damaged or dislodged. Push the head along the rod to the rod end.................................................................................355
				5. Install the spacer tube onto the cylinder rod.................................................................................................................................................................................................................355
				6. Place a new o-ring in the inner piston diameter groove........................................................................................................................................................................................................355
				7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.........................................................................................................................................355
				8. Carefully install the piston on the cylinder rod till it abuts the spacer, ensuring that the o-ring is not damaged or dislodged...............................................................................................................................355
				9. Secure the piston onto the rod using bolt and washer..........................................................................................................................................................................................................355
				10. Remove the cylinder rod from the holding fixture.............................................................................................................................................................................................................355
				11. Position the cylinder barrel in a suitable holding fixture...................................................................................................................................................................................................355
				12. Place new piston seal and wear rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal)...........................................................................355
				13. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged......................................................355
				14. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder....................................................................................................................................................355
				15. Screw the cylinder head into the barrel using a hook spanner wrench and torque the cylinder head.............................................................................................................................................................355
				16. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves................................................................................................355
				17. Install the motor control valves in the rod port block. Torque to 30-35 ft. lbs. (41-47 Nm)..................................................................................................................................................................355
				18. Install the new o-rings and plugs into the cylinder port block...............................................................................................................................................................................................355
	5.4 Pressure Setting Procedure...............................................................................................................................................................................................................................................384
		Main System Relief.......................................................................................................................................................................................................................................................384
			1. Install a pressure gauge at port MP1 of the Main Control Valve capable of reading pressures up to 4000 psi (275 Bar)..............................................................................................................................................384
			2. Activate telescope in function continuously at end of stroke. Pressure that is observed should be 3000 ± 75 psi (207 ± 6 Bar).....................................................................................................................................384
			3. If necessary, loosen jam nut and adjust the Main System Relief valve clockwise to increase and counterclockwise to decrease.......................................................................................................................................384
		Steer Left Relief........................................................................................................................................................................................................................................................384
			1. Install a pressure gauge at port MP1 of the Main Control Valve capable of reading pressures up to 4000 psi (275 Bar)..............................................................................................................................................384
			2. Activate Steer Left function continuously at end of stroke. Pressure that is observed should be 2750 ± 75 psi (190 ± 6 Bar).......................................................................................................................................384
			3. If necessary, loosen jam nut and adjust the Steer Left Relief valve clockwise to increase and counterclockwise to decrease........................................................................................................................................384
		Steer Right Relief.......................................................................................................................................................................................................................................................384
			1. Install a pressure gauge at port MP1 of the Main Control Valve capable of reading pressures up to 4000 psi (275 Bar)..............................................................................................................................................384
			2. Activate Steer Right function continuously at end of stroke. Pressure that is observed should be 2750 ± 75 psi (190 ± 6 Bar)......................................................................................................................................384
			3. If necessary, loosen jam nut and adjust the Steer Right Relief valve clockwise to increase and counterclockwise to decrease.......................................................................................................................................385
		Boom Swing Relief........................................................................................................................................................................................................................................................385
			1. Install a pressure gauge at port MP1 of the Main Control Valve capable of reading pressures up to 3000 psi (207 Bar)..............................................................................................................................................385
			2. Activate Boom Swing Right or Left function continuously against the stop or lock. Pressure that is observed should be 1800 ± 50 psi (125 ± 4 Bar).................................................................................................................385
			3. If necessary, loosen jam nut and adjust the Boom Swing Relief valve clockwise to increase and counterclockwise to decrease........................................................................................................................................385
		Jib Lift Down Relief.....................................................................................................................................................................................................................................................385
			1. Install a pressure gauge at port M34 of the Fly Boom Control Valve capable of reading pressures up to 3000 psi (207 Bar)..........................................................................................................................................385
			2. Activate Jib Lift Down function continuously at end of stroke.....................................................................................................................................................................................................385
			3. Pressure that is observed should be 1500 ± 50 psi (104 ± 4 Bar)...................................................................................................................................................................................................385
			4. If necessary, loosen jam nut and adjust the Jib Lift Down Relief valve clockwise to increase and counterclockwise to decrease.....................................................................................................................................385
		Platform Level Up Relief.................................................................................................................................................................................................................................................385
			1. With the tower boom fully lowered, lift the main boom up several degrees from the fully lowered position. Ensure that there is still access to the level cylinder.................................................................................................385
			2. Remove the hose from the Level Up port of the Level Cylinder (V1 Port) - Install a pressure gauge capable of reading pressures up to 4000 psi (275 Bar) onto this hose and cap or plug the port in the Level Cylinder.............................................385
			3. Activate Main Boom Lift Down function using Axillary Mode continuously until fully lowered........................................................................................................................................................................386
			4. Pressure that is observed should be 3400 ± 85 psi (234 ± 6 Bar)...................................................................................................................................................................................................386
			5. If necessary, loosen jam nut and adjust the Platform Level Up Relief valve clockwise to increase and counterclockwise to decrease.................................................................................................................................386
			6. Remove the gauge and reinstall the hose...........................................................................................................................................................................................................................386
		Platform Level Down Relief...............................................................................................................................................................................................................................................386
			1. With the tower boom fully lowered, lift the main boom down until fully lowered....................................................................................................................................................................................386
			2. Remove the hose from the Level Down port of the Level Cylinder (V2 Port) - Install a pressure gauge capable of reading pressures up to 3000 psi (207 Bar) onto this hose and cap or plug the port in the Level Cylinder...........................................386
			3. Activate Platform Level Down function continuously................................................................................................................................................................................................................386
			4. Pressure that is observed should be 2000 ± 50 psi (138 ± 4 Bar). If necessary, loosen jam nut and adjust the Platform Level Down Relief valve clockwise to increase and counterclockwise to decrease..............................................................386
			5. Remove the gauge and reinstall the hose...........................................................................................................................................................................................................................386
	5.5 Drive Pump Pre-Fill Procedure............................................................................................................................................................................................................................................386
		1. Fill the hydraulic reservoir..........................................................................................................................................................................................................................................386
		2. Determine if the hydraulic oil tank sight level gauge is higher than other hydraulic components.......................................................................................................................................................................386
			a. Determine if the hydraulic oil tank sight level gauge is higher than the hydraulic drive pump assembly............................................................................................................................................................386
			b. Determine if the hydraulic oil tank sight level gauge is higher than all hydraulic hose loops or routings between the hydraulic tank and the drive pump assembly..................................................................................................386
			c. If sight level gauge is the highest hydraulic oil level point, proceed to step 3..................................................................................................................................................................................386
			d. If sight level gauge is NOT the highest hydraulic oil level point, low pressure air may need to be applied to the hydraulic oil tank (fill cap via air regulator) in conjunction with step 4 to get hydraulic oil to move over the air locks created by...........386
		3. If the machine is be equipped with a hydraulic oil cooler option:.....................................................................................................................................................................................................386
			a. Determine if there is a hydraulic ‘tee’ fitting installed at the hydraulic drive pump that has a ‘cap’ fitting attached to it. (this will generally be at or near the top of the hydraulic drive pump body). This ‘cap’ fitting is to be us.......................386
			b. Remove ‘cap’ fitting..............................................................................................................................................................................................................................................386
			c. Fill hydraulic drive pump case with hydraulic oil.................................................................................................................................................................................................................386
			d. Reattach and torque ‘cap’ fitting.................................................................................................................................................................................................................................386
			e. Prefilling of the hydraulic drive pump w/oil cooler option is complete (Step 4 can be omitted at this point.).....................................................................................................................................................386
		4. If machine is NOT equipped with a hydraulic oil cooler option,........................................................................................................................................................................................................386
			a. Locate a case access port on the hydraulic drive pump. Preferably one located at or near the top or upper sides of the pump.......................................................................................................................................386
			b. Using the proper wrench, remove the O-ring plug to allow air to escape from the hydraulic drive pump case.........................................................................................................................................................386
			c. Hydraulic oil will flow by gravity from the hydraulic tank to the drive pump......................................................................................................................................................................................386
			d. When hydraulic oil starts to flow out this port, the pump is full.................................................................................................................................................................................................386
			e. Re-install the o-ring plug and torque.............................................................................................................................................................................................................................386
		5. Pre-filling of the hydraulic drive pump is complete...................................................................................................................................................................................................................386
		1. Main Dump Valve.......................................................................................................................................................................................................................................................387
		2. Steer Valve...........................................................................................................................................................................................................................................................387
		3. Main Lift Up Valve....................................................................................................................................................................................................................................................387
		4. Tower Lift Up Valve...................................................................................................................................................................................................................................................387
		5. Flow Control Valve....................................................................................................................................................................................................................................................387
		6. Swing Valve...........................................................................................................................................................................................................................................................387
		7. Cartridge Valve.......................................................................................................................................................................................................................................................387
		8. Relief Valve..........................................................................................................................................................................................................................................................387
		9. Check Valve...........................................................................................................................................................................................................................................................387
		10. Plug.................................................................................................................................................................................................................................................................387
		11. Steer Right Relief...................................................................................................................................................................................................................................................387
		12. Steer Left Relief....................................................................................................................................................................................................................................................387
		13. Main System Relief...................................................................................................................................................................................................................................................387
		14. Boom Swing Relief....................................................................................................................................................................................................................................................387
		1. Cartridge Valve.......................................................................................................................................................................................................................................................389
		2. Platform Level Down Relief............................................................................................................................................................................................................................................389
		3. Relief Valve..........................................................................................................................................................................................................................................................389
		4. Cartridge Valve Without Coil..........................................................................................................................................................................................................................................389
		5. Cartridge Valve Without Coil..........................................................................................................................................................................................................................................389
		6. Platform Level Down Relief............................................................................................................................................................................................................................................389
		1. Cartridge Valve Without Coil..........................................................................................................................................................................................................................................391
		2. Cartridge Valve.......................................................................................................................................................................................................................................................391
		3. Jib Down Relief Valve.................................................................................................................................................................................................................................................391
		4. Test Fitting..........................................................................................................................................................................................................................................................391
	5.6 Hydraulic Schematics.....................................................................................................................................................................................................................................................394
Section 6. JLG Control System....................................................................................................................................................................................................................................................399
	6.1 JLG Control System Analyzer Kit Instructions.............................................................................................................................................................................................................................399
		Introduction.............................................................................................................................................................................................................................................................399
		To Connect the JLG Control System Analyzer...............................................................................................................................................................................................................................400
			1. Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer....................................................400
			2. Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on................................................................................................................................400
		Using the Analyzer.......................................................................................................................................................................................................................................................400
		Changing the Access Level of the Hand Held Analyzer......................................................................................................................................................................................................................401
		Adjusting Parameters Using the Hand Held Analyzer........................................................................................................................................................................................................................402
		Machine Setup............................................................................................................................................................................................................................................................403
		Level Vehicle Description................................................................................................................................................................................................................................................403
		Tilt Sensor Calibration..................................................................................................................................................................................................................................................404
			1. Place the machine on a firm, level surface........................................................................................................................................................................................................................404
			2. Using the analyzer, go to Service Access level. Refer to Changing the Access Level of the Hand Held Analyzer in this section......................................................................................................................................404
			3. Using the arrow keys, navigate to Calibrations Menu as shown below and press ENTER ...............................................................................................................................................................................404
			4. Using the arrow keys, navigate to the Tilt Sensor calibration as shown below and press ENTER . the screen will then read:.........................................................................................................................................404
			5. When the sensor is calibrated in that position, the screen will read:.............................................................................................................................................................................................405
			6. Swing the machine 180 degrees, making sure the boom is centered and in the transport position, and ENTER . The screen will read:..................................................................................................................................405
			7. When the calibration is complete the screen will read as shown below. Return the machine to the travel position...................................................................................................................................................405
		Ground Control Keyswitch System..........................................................................................................................................................................................................................................407
		Diagnostics/Controller Programming.......................................................................................................................................................................................................................................407
		Ground Control Console Display Gauge.....................................................................................................................................................................................................................................407
	6.2 LSS System...............................................................................................................................................................................................................................................................433
		1. The Overload Visual Warning Indicator will flash at the selected control position (platform or ground)................................................................................................................................................................433
		2. The Platform and Ground Alarms will sound 5 seconds On, and 2 seconds Off.............................................................................................................................................................................................433
		3. All normal movement will be prevented from the platform control position (optional - ground control functions may be prevented).......................................................................................................................................433
		4. Further movement is permitted by:.....................................................................................................................................................................................................................................433
			a. Removing the excess platform load until actual platform load is less than Rated Load..............................................................................................................................................................................433
			b. Operation of the overriding emergency system (Auxiliary Power Unit)...............................................................................................................................................................................................433
			c. By an authorized person at the ground control position (optional - ground control functions may be prevented).....................................................................................................................................................433
			a. LSS Sensor removal or replacement.................................................................................................................................................................................................................................433
			b. Addition or removal of certain platform mounted accessories. (Refer to Calibration)...............................................................................................................................................................................433
			c. Platform is removed, replaced, repaired or shows evidence of impact...............................................................................................................................................................................................433
		Diagnostic Menu..........................................................................................................................................................................................................................................................434
		Calibration Procedure....................................................................................................................................................................................................................................................435
			1. Remove everything from the platform, except permanently fixed JLG Accessories, to allow the Load Sensing System to record its’ weight during calibration. This includes all tools, debris, and customer-installed devices.........................................435
			2. Plug the JLG Analyzer into the Machine at the Ground Station and enter Service Access Password 33271..............................................................................................................................................................435
			3. The platform should be approximately level for calibration. Level the platform from ground control (if necessary) to within +/- 5°................................................................................................................................435
			4. To access the Calibration Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. The screen will read:............................................................................................................................435
			5. Press the ENTER key to view the menu. Upon entry to the Calibration Menu, the JLG Control System will link to the Analyzer and the screen will read:..............................................................................................................435
			6. Press Enter . The Screen will read:...............................................................................................................................................................................................................................435
			7. Press ENTER . The analyzer screen will read:......................................................................................................................................................................................................................436
			8. If the platform is empty, press ENTER . The screen will read:.....................................................................................................................................................................................................436
			9. The control system will calculate the load cell readings and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg)...........................................................................................................................437
			10. Press ENTER . The control system will ask for installed accessories. The screen will show the following:.........................................................................................................................................................437
			11. Use the analyzer keys to select N for no or Y for yes. Press ENTER . The screen will read:.......................................................................................................................................................................437
			12. Use the analyzer keys to select N for no or Y for yes. Press ENTER . The control system will default to an estimate of unrestricted capacity, which can be adjusted if necessary. Refer to Table 6-6, SkyGlazier Capacity Reductions and Table 6-7, Pi...........438
			13. Press ENTER . The following screen will be displayed for restricted capacity, which can be adjusted if necessary. Refer to Table 6-6, SkyGlazier Capacity Reductions and Table 6-7, Pipe Rack Capacity Reductions................................................438
			14. Press ENTER . If calibration is successful, the screen will read:................................................................................................................................................................................................439
		Testing & Evaluation.....................................................................................................................................................................................................................................................439
			1. Connect the JLG Analyzer..........................................................................................................................................................................................................................................439
			2. Level the Platform. The platform should be approximately level for analysis, or the guidelines below will not be applicable. Level the platform from Ground Control (if necessary) to within ±5 degrees...........................................................439
			3. Observe the Empty Platform Weight. Proceed to the DIAGNOSTICS, PLTLOAD sub-menu and observe the measured platform load. All tools, debris, and customer- installed devices shall be removed during evaluation. Ideally, the PLTLOAD should be zero but ...........439
			4. Use the Technician’s Weight to Evaluate. The technician should enter the platform and record the PLTLOAD reading while standing in the center of the platform.....................................................................................................439
			5. Confirm Control System Warnings and Interlocks. Using the keyswitch, select Platform Mode and power-up. Start the vehicle’s engine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible Warnings a...............439
			6. Confirm Control System Capacity Indication (optional for vehicles with Dual Capacity Ratings). For vehicles equipped with a Capacity Select switch on the Platform Console Box, it is necessary to examine an additional interface between the Load Sen...........439
			7. Confirm Load Sensing System Performance with Calibrated Weights. Operate the vehicle from Ground Control and place the boom in the transport position (fully stowed) for safety. Plug the JLG Analyzer into the control system connection and proceed t...........439
		Troubleshooting..........................................................................................................................................................................................................................................................440
	6.3 Resetting the MSSO System................................................................................................................................................................................................................................................441
		1. Use the following procedure to reset the MSSO system..................................................................................................................................................................................................................441
		2. Position the Platform/Ground select switch to the desired position....................................................................................................................................................................................................441
		3. Plug the analyzer into the connector coming from the ground control module or from the platform console...............................................................................................................................................................441
		4. Pull out the Emergency Stop switch....................................................................................................................................................................................................................................441
		5. The analyzer screen should read:......................................................................................................................................................................................................................................441
		6. Use the arrow button to reach OPERATOR ACCESS. Press Enter ...........................................................................................................................................................................................................441
		7. Enter the Access Code, 33271..........................................................................................................................................................................................................................................441
		8. Use the right Arrow key to reach MENU: CALIBRATIONS. Press Enter .....................................................................................................................................................................................................441
		9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read:............................................................................................................................................................................................441
		10. Press ENTER .........................................................................................................................................................................................................................................................441
		11. Use the Down arrow to reach MSSO RESET...............................................................................................................................................................................................................................441
		12. Press Enter . The screen will read:..................................................................................................................................................................................................................................442
		13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu.................................................................................................................442
	6.4 Machine Model Adjustment.................................................................................................................................................................................................................................................443
		Adjustment Notes.........................................................................................................................................................................................................................................................443
			1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.........................................................................................................................................443
			2. Stop watch should be started with the function movement, not with actuation of the joystick or switch.............................................................................................................................................................443
			3. Drive speeds should be set to the values below regardless of the tire size........................................................................................................................................................................................443
			4. All speed tests are run from the platform, these speeds do not reflect the ground control operation...............................................................................................................................................................443
			5. The Function Speed Control knob must be at full speed (turned clockwise completely) unless noted..................................................................................................................................................................443
			6. Some flow control functions may not work with the Function Speed Control knob clicked into the creep position.....................................................................................................................................................443
			7. Functional speeds may vary due to cold thick hydraulic oil. Test should be run with the oil temperature above 38° C (100° F)......................................................................................................................................443
		Machine Orientation When Performing Test.................................................................................................................................................................................................................................443
			Drive (Below Elevation)..............................................................................................................................................................................................................................................443
				1. Test should be done on a smooth, level surface. The Drive Select Switch should be in the "Max Speed" position.................................................................................................................................................443
				2. Start approximately 7.6m (25 ft) from starting point so the unit is at a maximum speed when starting the test.................................................................................................................................................443
				3. Results should be recorded for a 61m (200ft) course...........................................................................................................................................................................................................443
				4. Drive forward, "High Speed", record time......................................................................................................................................................................................................................443
				5. Drive Reverse, "High Speed", record time......................................................................................................................................................................................................................443
			Drive (Above Elevation)..............................................................................................................................................................................................................................................443
				1. Test should be done on a smooth, level surface. The Drive Select Switch should be in the "Max Speed" position.................................................................................................................................................443
				2. The boom should be > 10° above horizontal to ensure the drive is operating in Max Torque mode.................................................................................................................................................................443
				3. Results should be recorded for a 15.2m (50ft) course..........................................................................................................................................................................................................443
				4. Drive forward, record time....................................................................................................................................................................................................................................443
				5. Drive Reverse, record time....................................................................................................................................................................................................................................443
				6. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................443
				7. Creep light on Panel must be energized........................................................................................................................................................................................................................443
				8. Verify that machine will Drive Forward and Reverse............................................................................................................................................................................................................443
				9. Return Knob to fully clockwise................................................................................................................................................................................................................................443
			Swing................................................................................................................................................................................................................................................................444
				1. Boom at full elevation, Telescope retracted. Swing Right until over rear axle or end stop (if equipped).......................................................................................................................................................444
				2. Swing Left 360° or end stop (if equipped), record time........................................................................................................................................................................................................444
				3. Swing Right 360° or end stop (if equipped), record time.......................................................................................................................................................................................................444
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................444
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................444
				6. Verify that machine will swing left and right.................................................................................................................................................................................................................444
				7. Return Function Speed Knob to fully clockwise.................................................................................................................................................................................................................444
			Tower Lift...........................................................................................................................................................................................................................................................444
				1. Tower Lift in stowed position, Telescope Retracted............................................................................................................................................................................................................444
				2. Tower Lift Up, record time....................................................................................................................................................................................................................................444
				3. Tower Lift Down, record time..................................................................................................................................................................................................................................444
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................444
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................444
				6. Verify that machine will Tower Up and Down. Return Knob to fully clockwise....................................................................................................................................................................................444
			Main Lift............................................................................................................................................................................................................................................................444
				1. Main Lift in stowed position, Telescope Retracted.............................................................................................................................................................................................................444
				2. Main Lift Up, record time.....................................................................................................................................................................................................................................444
				3. Main Lift Down, record time...................................................................................................................................................................................................................................444
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................444
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................444
				6. Verify that machine will Lift Up and Down.....................................................................................................................................................................................................................444
				7. Return Knob to fully clockwise................................................................................................................................................................................................................................444
			Telescope............................................................................................................................................................................................................................................................444
				1. Main Lift at full elevation, Telescope Retracted..............................................................................................................................................................................................................444
				2. Telescope Out, record time....................................................................................................................................................................................................................................444
				3. Telescope In, record time.....................................................................................................................................................................................................................................444
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................444
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................444
				6. Verify that machine will Telescope In and Out.................................................................................................................................................................................................................444
				7. Return Knob to fully clockwise................................................................................................................................................................................................................................444
			JIB LIFT.............................................................................................................................................................................................................................................................445
				1. Platform level and centered with the boom. Jib Lift Down until stop...........................................................................................................................................................................................445
				2. Jib Lift Up, record time......................................................................................................................................................................................................................................445
				3. Jib Lift Down, record time....................................................................................................................................................................................................................................445
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................445
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................445
				6. Verify that machine will Jib Lift Up and Down.................................................................................................................................................................................................................445
				7. Return Knob to fully clockwise................................................................................................................................................................................................................................445
			Platform Rotate......................................................................................................................................................................................................................................................445
				1. Platform level, Rotate Platform Right until stop..............................................................................................................................................................................................................445
				2. Platform Left, record time....................................................................................................................................................................................................................................445
				3. Platform Right, record time...................................................................................................................................................................................................................................445
				4. Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode...................................................................................................................................................................................445
				5. Creep light on Panel must be energized........................................................................................................................................................................................................................445
				6. Verify that machine will Platform Rotate Left and Right.......................................................................................................................................................................................................445
				7. Return Knob to fully clockwise................................................................................................................................................................................................................................445
Section 7. Basic Electrical Information & Electrical Schematics..................................................................................................................................................................................................................477
	7.1 General..................................................................................................................................................................................................................................................................477
	7.2 Multimeter Basics........................................................................................................................................................................................................................................................477
		Grounding................................................................................................................................................................................................................................................................477
		Backprobing..............................................................................................................................................................................................................................................................477
		Min/Max..................................................................................................................................................................................................................................................................477
		Polarity.................................................................................................................................................................................................................................................................477
		Scale....................................................................................................................................................................................................................................................................477
		Voltage Measurement......................................................................................................................................................................................................................................................477
		Resistance Measurement...................................................................................................................................................................................................................................................478
		Continuity Measurement...................................................................................................................................................................................................................................................478
		Current Measurement......................................................................................................................................................................................................................................................479
	7.3 Applying Silicone Dielectric Compound to Electrical Connections..........................................................................................................................................................................................................479
		1. To prevent oxidation, silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly. This is most easily achieved by using a syringe.........................................................................479
		2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing. Also, silicone grease must be applied at the joint where the male and female connectors come together. Any other joints (ar...............479
		3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only...............................................................................................................................................480
		Installation of Dielectric Grease........................................................................................................................................................................................................................................480
			1. Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors.........................................................................................................................................................480
			2. Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals (fill it approximately ½ full; see example below)................................................................................................480
			3. Leave a thin layer of dielectric grease on the face of the connector..............................................................................................................................................................................................480
			4. Assemble the connector system immediately to prevent moisture ingress or dust contamination.......................................................................................................................................................................480
			5. Pierce one of the unused wire seals prior to assembly if the connector system tends to trap air (i.e. AMP Seal) and then install a seal plug......................................................................................................................480
		Deutsch HD, DT, DTM, DRC Series..........................................................................................................................................................................................................................................480
		AMP Seal.................................................................................................................................................................................................................................................................480
		AMP Mate-N-Lok...........................................................................................................................................................................................................................................................481
		DIN Connectors...........................................................................................................................................................................................................................................................481
		Exclusions...............................................................................................................................................................................................................................................................482
			Brad Harrison / Phoenix Contact M12..................................................................................................................................................................................................................................482
			ENGINE CONTROL UNIT CONNECTORS.......................................................................................................................................................................................................................................482
			SEALED ENCLOSURES....................................................................................................................................................................................................................................................482
			MIL-C-5015 SPEC CONNECTOR’S..........................................................................................................................................................................................................................................483
			MOLEX CMC SERIES CONNECTORS..........................................................................................................................................................................................................................................483
	7.4 AMP Connector............................................................................................................................................................................................................................................................484
		Applying Silicone Dielectric Compound to AMP Connectors..................................................................................................................................................................................................................484
			1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by using a syri...........484
			2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.........................................................................................................................................................................484
			3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it..................................................................................................................................................484
		Assembly.................................................................................................................................................................................................................................................................484
			1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-11.).................................................................................................................................................484
			2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-11.).............................................................................................................................484
			3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-12.).....................................................................................485
			4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-13.).......................................................................................................................................................................485
		Disassembly..............................................................................................................................................................................................................................................................486
			1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs.........................................................................................................................................................486
			2. Pry open the wedge lock to the open position......................................................................................................................................................................................................................486
			3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed...........................................................................................................................486
		Wedge Lock...............................................................................................................................................................................................................................................................486
		Service - Voltage Reading................................................................................................................................................................................................................................................486
	7.5 Deutsch Connectors.......................................................................................................................................................................................................................................................488
		DT/DTP Series Assembly...................................................................................................................................................................................................................................................488
			1. Grasp crimped contact about 25mm behind the contact barrel........................................................................................................................................................................................................488
			2. Hold connector with rear grommet facing you.......................................................................................................................................................................................................................488
			3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.................................................................................................................................488
			4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.........................................................488
		DT/DTP Series Disassembly................................................................................................................................................................................................................................................488
			5. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.........................................................................................................................................................................488
			6. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.....................................................................................................488
			7. Hold the rear seal in place, as removing the contact may displace the seal........................................................................................................................................................................................488
		HD30/HDP20 Series Assembly...............................................................................................................................................................................................................................................489
			8. Grasp contact about 25mm behind the contact crimp barrel..........................................................................................................................................................................................................489
			9. Hold connector with rear grommet facing you.......................................................................................................................................................................................................................489
			10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place........................................................................................................................489
		HD30/HDP20 Series Disassembly............................................................................................................................................................................................................................................489
			11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.........................................................................................................................................................489
			12. Slide tool along into the insert cavity until it engages contact and resistance is felt..........................................................................................................................................................................489
			13. Pull contact-wire assembly out of connector......................................................................................................................................................................................................................489
	7.6 Telematics Gateway.......................................................................................................................................................................................................................................................490
		Telematics-Ready (TCU) Plug..............................................................................................................................................................................................................................................490
	7.7 Wiring Harness Connector Labels..........................................................................................................................................................................................................................................494
		Connector Labels.........................................................................................................................................................................................................................................................494
		Component Labels.........................................................................................................................................................................................................................................................494
	7.8 Wiring Harness...........................................................................................................................................................................................................................................................506
	7.9 Electrical Schematics....................................................................................................................................................................................................................................................591

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